Instruction/ maintenance manual of the product 30GN040-420 Carrier
Go to page of 72
Controls, Operation, and T roubleshooting with Microprocessor Controls and Electronic Expansion V alves CONTENTS Page SAFETY CONSIDERA TIONS ..................2 GENERAL ...................................2 MAJOR SYSTEM COMPONENTS ............2 - 5 Processor Module .
SAFETY CONSIDERA TIONS Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical compo- nents, and equipment location (roof, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment.
789 456 123 – 0• STAT EXPN HIST CLR SCHD SRVC SET TEST ENTR FUSE 1 LOC AL/ ENABLE SW1 STOP CCN FUSE 3 FUSE 2 F U S E F U S E F U S E CB5 CB6 EQUIP GND 99NA505322 D COMM 1 COMM 3 PWR XX S1 S2 XX PO.
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 .
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 .
T able 4A — Capacity Control Steps, 040-070 UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (Approx) (Approx) 040 (60 Hz) A1†,B1.
T able 4A — Capacity Control Steps, 040-070 (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (Approx) (Approx) 045 (50 Hz) 0.
T able 4A — Capacity Control Steps, 040-070 (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (Approx) (Approx) 060 (50 Hz) 0.
T able 4B — Capacity Control Steps, 080-1 10 and Associated Modular Units UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (Approx).
T able 4B — Capacity Control Steps, 080-1 10 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (.
T able 4B — Capacity Control Steps, 080-1 10 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (.
T able 4B — Capacity Control Steps, 080-1 10 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (.
T able 4B — Capacity Control Steps, 080-1 10 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (.
T able 4B — Capacity Control Steps, 080-1 10 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (Approx) .
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT 30GN CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
T able 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont) UNIT SIZE CONTROL STEPS LOADING SEQUENCE A LOADING SEQUENCE B % Compressors % Compressors Displacement Displacement (A.
Head Pressure Control 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 ef f iciency .
T able 5 — Condenser Fan Sequence F AN ARRANGEMENT 30GN F AN NUMBER(S) F AN CONT ACTOR (FC) CONTROLLED BY 040-050 1 FC-A1 Compressor A1 2 FC-B1 Compressor B1 3 FC-A2 First Stage Microprocessor 4 FC-.
T able 6 — Keypad and Display Module Usage FUNCTION KEYS USE ST A TUS — For displaying diagnostic codes and current operating information about the machine. HISTOR Y — For displaying run time, cycles and previous alarms. SERVICE — For entering specific unit configura- tion information.
T able 8 — Accessing Functions and Subfunctions OPERA TION KEYP AD DISPLA Y EXP ANSION ENTR Y RESPONSE T o access a function, press RESET RESET SETPOINTS subfunction no. and function name key . Display shows sub- function group. T o move to other elements, scroll up or down using arrow keys.
T able 9 — Keypad Directory (cont) ST A TUS (cont) SUBFUNCTION KEYP AD ENTR Y DISPLA Y COMMENT 4 ST AGE ST AGE Capacity Staging Information COOL X Number of Requested Stages CAPT X Percent of T otal.
T able 9 — Keypad Directory (cont) ST A TUS (cont) SUBFUNCTION KEYP AD ENTRY DISPLA Y COMMENT 7 PRESSURE PRESSURE Refrigerant System Pressure (psig) MM DD YY Date of Last Calibration DP A X Circuit .
T able 9 — Keypad Directory (cont) ST A TUS (cont) SUBFUNCTION KEYP AD ENTR Y DISPLA Y COMMENT 10 OUTPUTS (cont) EXVB X EXVB Percent Open** HGBA X† Hot Gas Bypass Relay Circuit A (on/off)** HGBB X.
T able 9 — Keypad Directory (cont) TEST (cont) SUBFUNCTION KEYP AD ENTR Y DISPLA Y COMMENT 2 COMPRESSORS AND UNLOADERS (cont) CP A3 X† T est Compressor A3 (on/off)** CP A4 X† T est Compressor A4.
T able 9 — Keypad Directory (cont) SCHEDULE (cont) SUBFUNCTION KEYP AD ENTRY DISPLA Y COMMENT 3 PERIOD 1 (cont) FRI X Friday Flag (yes/no) SA T X Saturday Flag (yes/no) SUN X Sunday Flag (yes/no) HOL X Holiday Flag (yes/no) T o toggle between inputs (Y es/No) Press: (no) or (yes) 4 PERIOD 2 PERIOD 2 Period 2 T ime Schedule 5 PERIOD 3 .
T able 9 — Keypad Directory (cont) SERVICE (cont) SUBFUNCTION KEYP AD ENTR Y DISPLA Y COMMENT 3 F ACTOR Y CONFIGURA TION (cont) XXXXXXXX Configuration Code 5 XXXXXXXX Configuration Code 6 XXXXXXXX.
T able 9 — Keypad Directory (cont) HISTOR Y SUBFUNCTION KEYP AD ENTRY DISPLA Y COMMENT 1 RUN TIME RUN TIME Run Time Information HR X T otal Hrs Unit Has a Comp Operating HRA X Circuit A Run Time HRB.
T able 9 — Keypad Directory (cont) SET POINT T o read a set point, go to proper subfunction and read desired set point. T o change a set point, enter new set point value, then press . LOCAL/ENABLE-STOP-CCN switch must be in LOCAL/ENABLE or ST OP position.
ST A TUS 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.
T able 10 — Operational and Mode Display Codes The operating modes are displayed by name or code num- ber , to indicate the operating status of the unit at a given time.
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 . • Operation of condenser fans. • Operation of chilled fluid pump. • Operation of liquid line solenoids.
Example 4 — Reading and Changing Chilled Fluid Set Point KEYP AD DISPLA Y COMMENTS ENTR Y RESPONSE SET POINT System set points CSP1 44.0 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.
Example 5 B—4t o2 0m Aa n d 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.
Fig. 6 — Cooling External T emperature Reset LEGEND COMM — Communications Bus PWR — Power SW — Switch NOTE: For specific connection points, see Fig.
Example 6 — Changing Reset T ype T o change type of reset, first log on as shown in T able 12. Also refer to Set Point Function section, page 38, for information on entering reset set points using reset feature.
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.
Factory Configuration Codes — allows entry into the factory configuration subfunction. Under this subfunc- tion, there are 7 groups of configuration codes that are down- loaded at the factory .
T able 13 — Factory Configuration Keystrokes T o change a configuration enter the new configuration and press while on the correct configuration.
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.
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.
Unit Shutoff — T o shut unit of f, move LOCAL/ENABLE- STOP-CCN switch to ST OP 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.
T able 16 — Alarm and Alert Codes DISPLA Y ALARM DESCRIPTION ACTION T AKEN CIRCUIT RESET PROBABLE CAUSE OR ALERT BY CONTROL PUMPDOWN METHOD 0 — No Alarms or Alerts Exist — — — — 1 Alert Compressor A1 failure Circuit A shut down No Manual High-pressure switch trip, or wiring error .
T able 16 — Alarm and Alert Codes (cont) DISPLA Y ALARM DESCRIPTION ACTION T AKEN CIRCUIT RESET PROBABLE CAUSE OR ALERT BY CONTROL PUMPDOWN METHOD 63 Alarm Complete unit shutdown Alarm only — Auto. Check individual alarms 64 Alert Loss of charge, circuit A Circuit cannot start — Auto.
Code 21 Reset thermistor failure (applies only to installa- tions having external temperature reset) (alert) If temperature measured by this thermistor is outside range of –40 to 240 F (–40 to 1 16 C), reset function is disabled and unit controls to normal set point.
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. Gr ounding the supply transformer can result in serious damage to the contr ol system.
Loss of communication can be attributed to a grounded transformer with a secondary voltage of 21 vac supplying the PSIO, DSIO-L V , 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.
If oil pressure dif ferential is less than set point for more than 2 minutes at start-up, or more than one minute during normal operation, af fected circuit shuts down without going through pumpout process. Reset is manual with LOCAL/ ENABLE-STOP-CCN switch, and start-up follows normal sequence.
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.
vapor). T o control refrigerant flow for dif ferent 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.
reading correctly . Connect a calibrated gage to lead compressor suction or discharge pressure connection to check transducer reading. e. Make sure transducer leads are properly connected in junction box and at processor board. Check trans- former 5 output.
T able 17 — Thermistor T emperature (°F) vs Resistance/V oltage Drop; Flotronic™ II TEMPERA TURE VOL T AGE RESIST ANCE (F) DROP (V) (OHMS) −25.0 4.821 98010 −24.0 4.818 94707 −23.0 4.814 91522 −22.0 4.806 88449 −21.0 4.800 85486 −20.0 4.
T able 18 — Thermistor T emperature (°C) vs Resistance/V oltage Drop; Flotronic™ II TEMPERA TURE VOL T AGE RESIST ANCE (C) DROP (V) (Ohms) −40 4.896 168 230 −39 4.889 157 440 −38 4.882 147 410 −37 4.874 138 090 −36 4.866 129 410 −35 4.
Pressure T ransducers — 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.
Fig. 15 — Thermistor Locations (Circuits A and B, Lead Compressor Only) FLUID-SIDE TEMPERA TURE THERMISTOR T2 (ALL UNITS) COMPRESSOR SUCTION GAS TEMPERA TURE THERMISTORS T7 AND T8 (ALL UNITS) AND FLUID-SIDE TEMPERA TURE THERMISTOR T1 (ALL UNITS) Fig.
TRANSDUCER REPLACEMENT Transducers are installed directly in the refrigerant cir- cuit. Relieve all refrigerant pressure using standard re- frigeration practices before removing. 1. Relieve refrigerant pressure using standard refrigeration practices. 2.
Control Modules Turn controller power of f before servicing controls. This ensures safety and prevents damage to controller. PROCESSOR MODULE (PSIO), 4 IN/4 OUT MODULE (SIO), LOW -VOL T AGE RELA Y MOD.
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.
If accessory unloaders are desired, an accessory unloader package is used. Package includes a suction cutof f unloader head package. The 24-v coil in the package can be used for 040-1 10, 130 (60 Hz), and associated modular units (T able 1). A 115 v or 230 v coil must be used for 130 (50 Hz), 150-210, and associated modular units (T able 1).
T able 19 — T roubleshooting SYMPTOMS CAUSE REMEDY COMPRESSOR DOES NOT RUN Power line open Reset circuit breaker . Control fuse open Check control circuit for ground or short. Replace fuse. High-Pressure Switch (HPS) tripped Move LOCAL/ENABLE-STOP-CCN switch to ST OP position then back to RUN or CCN position.
5. Using test function, check unloaders. Press . Key- pad display reads OUTPUTS. Press until display reads UNA2 OFF . Press . Relay energizes. Press and relay deenergizes. Press until display reads UNB2 OFF . Press . Relay energizes. Press and relay deenergizes.
LEGEND C— Contactor PWR — Power CB — Circuit Breaker SW — Switch COMM — Communications Bus TRAN — Transformer HGBPR — Hot Gas Bypass Relay U— Unloader *Or HGBPR-A.
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 — T wo External Switch Inputs Fig. 26 − Demand Limit — 4-20 mA Signal (Externally Powered) Fig.
REPLACING DEFECTIVE PROCESSOR MODULE 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.
.
Copyright 1995 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
An important point after buying a device Carrier 30GN040-420 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Carrier 30GN040-420 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Carrier 30GN040-420 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Carrier 30GN040-420 you will learn all the available features of the product, as well as information on its operation. The information that you get Carrier 30GN040-420 will certainly help you make a decision on the purchase.
If you already are a holder of Carrier 30GN040-420, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Carrier 30GN040-420.
However, one of the most important roles played by the user manual is to help in solving problems with Carrier 30GN040-420. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Carrier 30GN040-420 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
