Ecologic 30gx080265 PDF

30GX080-265
30HXA,HXC076-271
ECOLOGIC™ Air-Cooled and Fluid Cooled Chillers
50/60 Hz
Series 0,1,2
Controls, Start-Up, Operation,

Service, and Troubleshooting
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can DO NOT attempt to unbraze factory joints when ser-
be hazardous due to system pressures, electrical compo- vicing this equipment. Compressor oil is flammable and
nents, and equipment location (roof, elevated structures, etc.). there is no way to detect how much oil may be in any
Only trained, qualified installers and service mechanics should of the refrigerant lines. Cut lines with a tubing cutter as
install, start up, and service this equipment. required when performing service. Use a pan to catch
When working on this equipment, observe precautions in any oil that may come out of the lines and as a gage for
the literature, and on tags, stickers, and labels attached to the how much oil to add to system. DO NOT re-use com-
equipment, and any other safety precautions that apply. Fol- pressor oil.
low all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting this equipment, CONTENTS
and in handling all electrical components. Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical shock can cause personal injury and death.
Shut off all power to this equipment during installation MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . . . 3
and service. There may be more than one disconnect Processor Module (PSIO-1) . . . . . . . . . . . . . . . . . . . 3
switch. Tag all disconnect locations to alert others not DSIO-HV Relay Module . . . . . . . . . . . . . . . . . . . . . . . 3
to restore power until work is completed. Electronic Expansion Device Module . . . . . . . . . 3
Compressor Protection Module (CPM) . . . . . . . . . 3
PSIO-2 (8052) Module . . . . . . . . . . . . . . . . . . . . . . . . 3
Keypad and Display Module
This unit uses a microprocessor-based electronic con- (Also Called HSIO-II) . . . . . . . . . . . . . . . . . . . . . . . 3
trol system. Do not use jumpers or other tools to short Control (LOR) Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3
out components, or to bypass or otherwise depart from OPERATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
recommended procedures. Any short-to-ground of the Electronic Expansion Device (EXD) . . . . . . . . . . . 3
control board or accompanying wiring may destroy the • EXV OPERATION
electronic modules or electrical components. • ECONOMIZER OPERATION
Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Back Pressure Valve (30GX and 30HXA only) . . 4
To prevent potential damage to heat exchanger tubes al- Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ways run fluid through heat exchangers when adding or Compressor Protection Module (CPM) . . . . . . . . . 4
removing refrigerant charge. • OUTPUTS
DO NOT VENT refrigerant relief valves within a build- • INPUTS
ing. Outlet from relief valves must be vented outdoors Wye-Delta vs Across-the-Line (XL)
in accordance with the latest edition of ANSI/ASHRAE Starting Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(American National Standards Institute/American Soci- Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ety of Heating, Refrigeration and Air Conditioning En- • MINUTES LEFT FOR START
gineers) 15 (Safety Code for Mechanical Refrigeration). • MINUTES OFF TIME
The accumulation of refrigerant in an enclosed space • LOADING SEQUENCE
can displace oxygen and cause asphyxiation. Provide ad- • CLOSE CONTROL
equate ventilation in enclosed or low overhead areas. • LEAD/LAG DETERMINATION
Inhalation of high concentrations of vapor is harmful • CAPACITY SEQUENCE DETERMINATION
and may cause heart irregularities, unconsciousness or • MINIMUM LOAD VALVE
death. Misuse can be fatal. Vapor is heavier than air and • CAPACITY CONTROL OVERRIDES
reduces the amount of oxygen available for breathing. Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . 8
Product causes eye and skin irritation. Decomposition • GENERAL
products are hazardous. • AIR COOLED UNITS (30GX)
• WATER COOLED UNITS (30HX)
• ADJUSTING PID ROUTINES
Cooler and Condenser (30HXC)
Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg 1 1-98 Replaces: 30G,H-2T
Tab 5c
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CONTENTS (cont) Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Page • PRESSURE RELIEF VALVES
• COOLER PUMP CONTROL Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
• CONDENSER PUMP CONTROL • PROCESSOR MODULE (PSIO-1), HIGH VOLTAGE
Cooler Heater Control . . . . . . . . . . . . . . . . . . . . . . . 13 RELAY MODULE (DSIO-HV), AND EXV DRIVER
Keypad and Display Module MODULE (DSIO-EXV), 12/6 MODULE (PSIO-2)
(Also Called HSIO-II) . . . . . . . . . . . . . . . . . . . . . . 13 • RED LED
• ACCESSING FUNCTIONS • GREEN LED
AND SUBFUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . 13 Carrier Comfort Network (CCN) Interface . . . . . 64
• AUTOMATIC DEFAULT DISPLAY . . . . . . . . . . . . . 13 • PROCESSOR MODULE (PSIO-1)
• STATUS FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 • HIGH VOLTAGE RELAY MODULE (DSIO-HV)
• TEST FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Replacing Defective Processor Module . . . . . . . 66
• HISTORY FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . 25 Winter Shutdown Preparation . . . . . . . . . . . . . . . . 66
• SET POINT FUNCTION . . . . . . . . . . . . . . . . . . . . . . 25 PRE-START-UP PROCEDURE . . . . . . . . . . . . . . . . 67
• SERVICE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 30 START-UP AND OPERATION . . . . . . . . . . . . . . . . . 67
• SCHEDULE FUNCTION. . . . . . . . . . . . . . . . . . . . . . 37
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 39 FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-73
• EXTERNAL TEMPERATURE RESET APPENDIX A
• EXTERNALLY POWERED RESET (Compressor Must Trip Amps) . . . . . . . . . . . 74-76
• RETURN FLUID TEMPERATURE RESET APPENDIX B
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 (Capacity Loading Sequence) . . . . . . . . . . . . 77-79
• DEMAND LIMIT
• EXTERNALLY POWERED DEMAND LIMIT APPENDIX C (Available Accessories) . . . . . . . . . 80
• DEMAND LIMIT (CCN Loadshed Controlled) APPENDIX D (CPM Configurations) . . . . . . . . . 81-85
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 43-52 APPENDIX E (Cooler and
Checking Display Codes . . . . . . . . . . . . . . . . . . . . 43 Condenser Pressure Drop) . . . . . . . . . . . . . . . 86-88
Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . . 43 APPENDIX F
Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . 43 (Typical System Components) . . . . . . . . . . . . 89,90
Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
• POWER FAILURE EXTERNAL TO THE UNIT START-UP CHECKLIST . . . . . . . . . . . . . . CL-1 to CL-8
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Compressor Alarm/Alert Circuit . . . . . . . . . . . . . . 43
EXD Troubleshooting Procedure . . . . . . . . . . . . . 50 GENERAL
• INSPECTING/OPENING ELECTRONIC
EXPANSION VALVES IMPORTANT: The 30GX/HX units use refrigerant
• INSPECTING/OPENING ECONOMIZERS R-134a. Compressor oil used with R-134a is Polyo-
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-66 lester oil.
Servicing Coolers and Condensers . . . . . . . . . . 52
• TUBE PLUGGING This publication contains Start-Up, Service, Controls,
• RETUBING Operation and Troubleshooting data for the 30GX080-265
• TIGHTENING COOLER/CONDENSER and 30HXA,C076-271 screw chillers.
HEAD BOLTS Circuits are identified as circuits A and B, and compres-
Inspecting/Cleaning Heat Exchangers . . . . . . . . 53 sors are identified as A1 or A2 in circuit A, and B1 in
• COOLERS circuit B.
• CONDENSERS (30HX Only) The 30GX/HX Series chillers feature microprocessor-
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 based electronic controls and electronic expansion devices
Condenser Coils (30GX Only) . . . . . . . . . . . . . . . . 53 (EXD) in each refrigeration circuit.
• COIL CLEANING
Condenser Fans (30GX Only) . . . . . . . . . . . . . . . . 54 The control system cycles compressor loaders and/or com-
Refrigerant Charging/Adding Charge . . . . . . . . . 54 pressors to maintain the selected leaving fluid temperature
Oil Charging/Low Oil Recharging . . . . . . . . . . . . 55 set point. The system automatically positions the EXD to
Oil Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . 56 maintain the specified refrigerant level in the cooler. The sys-
• REPLACING THE EXTERNAL OIL FILTER tem also has capabilities to control a condenser water valve
• REPLACING THE INTERNAL OIL FILTER to maintain suitable leaving-water temperature for the 30HXC
Compressor Changeout Sequence . . . . . . . . . . . 56 unit. Safeties are continuously monitored to prevent the unit
• BURNOUT CLEAN-UP PROCEDURE from operating under unsafe conditions. A scheduling func-
Moisture-Liquid Indicator . . . . . . . . . . . . . . . . . . . . 58 tion can be programmed by the user to control the unit’s oc-
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 cupied and unoccupied schedules. The control also operates
Liquid Line Service Valve . . . . . . . . . . . . . . . . . . . . 58 a test function and a manual control function that allows the
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 operator to check output signals and ensure components are
• LOCATION operable.
• THERMISTOR REPLACEMENT The control system consists of a processor module
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . 59 (PSIO-1), an EXD driver module (DSIO-EXV), a high volt-
• PRESSURE TRANSDUCER CALIBRATION age relay module on 30GX units (DSIO-HV), 2 six-pack re-
• TROUBLESHOOTING lay boards, a keypad and display module (also called HSIO-
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 II), 2 electronic expansion devices (EXDs), 1 compressor
• COMPRESSOR PROTECTION protection module (CPM) per compressor, a PSIO-2 mod-
• OIL SEPARATOR HEATERS (30GX) ule, 6 thermistors, and 8 transducers. A remote enhanced dis-
• COOLER PROTECTION play is available as an accessory.
2
MAJOR SYSTEM COMPONENTS Table 1 — Unit Mode from LOR Switch
and CCN State
Processor Module (PSIO-1) — This module is an
upgrade to the original PSIO (8088) module, with superior SWITCH REMOTE CCN CCN UNIT
electrical noise immunity capability. It contains the operat- POSITION CONTACTS CONFIGURATION STATE MODE
ing software and controls the operation of the machine. It OFF NR NR NR LOCAL OFF
has 12 input channels and 6 output channels. DISABLE NR LOCAL ON
The PSIO-1 continuously monitors input/output channel LOCAL NR
ENABLE
RUN CCN ON
information received from all the modules and controls all STOP CCN OFF
output signals for all output channels. It also controls the OPEN NR NR LOCAL OFF
relays on the six-pack relay board. The processor module DISABLE NR LOCAL ON
also controls the EXD driver module (as required), com- REMOTE
CLOSED RUN CCN ON
manding it to open or close each EXD in order to maintain ENABLE
STOP CCN OFF
the proper cooler level. Information is transmitted between
the processor module, CPM modules, the EXD driver mod- LEGEND
ule, and the HSIO-II standard display module through a 3-wire CCN — Carrier Comfort Network
communications bus called COMM3. The remote enhanced NR — Input Not Read by Processor
display (accessory) is connected to the PSIO-1 module through NOTE: If the unit is configured for a clock, then the unit is under clock
a 3-wire communications bus, but uses a different commu- control if it is in an ON mode.
nication bus called COMM1. The COMM1 bus is also used
to communicate to other CCN (Carrier Comfort Network)
devices when the unit is installed in a network application. OPERATION DATA
DSIO-HV Relay Module — The DSIO-HV module has Electronic Expansion Device (EXD) — The micro-
4 inputs and 8 outputs and is installed on 30GX units only. processor controls the EXD through the EXD driver mod-
The module communicates the status of the inputs with the ule. The EXD will either be an EXV (electronic expansion
PSIO-1 module and operates the oil heater, outdoor fan, and valve) or an economizer. Inside both these devices is a linear
minimum load control outputs. actuator stepper motor.
Electronic Expansion Device Module — The elec- EXV OPERATION — High-pressure liquid refrigerant en-
tronic expansion device module has 4 inputs and 2 outputs. ters the valve through the bottom. A series of calibrated slots
It receives signals from the PSIO-1 module and operates the are located inside the orifice assembly. As refrigerant passes
electronic expansion devices. The electronic expansion de- through the orifice, the pressure drops and the refrigerant
vice module also sends the PSIO-1 module the status of its changes to a 2-phase condition (liquid and vapor). To con-
4 input channels. trol refrigerant flow for different operating conditions, the
sleeve moves up and down over the orifice, thereby chang-
Compressor Protection Module (CPM) — The coming orifice size. The sleeve is moved by a linear stepper mo-
pressor protection module monitors several of the compres- tor. The stepper motor moves in increments and is controlled
sor safeties and controls 4 of the outputs used to control each directly by the processor module. As the stepper motor ro-
compressor. The CPM monitors compressor current, com- tates, motion is transferred into linear movement by the lead
pressor voltage, high pressure switch status, and compressor screw. Through the stepper motor and lead screw, 1500 dis-
motor temperature. The CPM controls the compressor con- crete steps of motion are obtained. The large number of steps
tactors, oil solenoid, and motor cooling solenoid. Each CPM and long stroke result in very accurate control of refrigerant
sends the PSIO-1 its circuit’s motor temperature, alarm sta- flow.
tus of the module, and the compressor relay status. Each circuit has a liquid level sensor mounted vertically
PSIO-2 (8052) Module — This module is used as an in the top of the cooler shell. The level sensor consists of a
input/output module only, as there is no unit software loaded small electric resistance heater and 3 thermistors wired in
in the module. This module has 12 input channels and 6 out- series, positioned at different heights inside the body of the
put channels. well. The heater is designed so that the thermistors read ap-
proximately 200 F (93.3 C) in dry air. As the refrigerant level
Keypad and Display Module (Also Called rises (falls) in the cooler, the resistance of the closest ther-
mistor(s) will increase (decrease) as it is cooled by the rising
HSIO-II) — This device consists of a keypad with 8 func- liquid refrigerant (heated by the heater). This large resis-
tion keys, 4 operative keys, 12 numeric keys, and a 2-line
24-character alphanumeric LCD (liquid crystal display). Key tance difference allows the control to accurately maintain a
usage is explained in the Accessing Functions and Subfunc- specified level.
tions section on page 13. The level sensor monitors the refrigerant liquid level in
the cooler and sends this information to the PSIO-1. At ini-
Control (LOR) Switch — Control of the chiller is de- tial start-up, the EXV position is at zero. After that, the micro-
fined by the position of the LOCAL/OFF/REMOTE (LOR) processor keeps accurate track of the valve position in order
switch. This is a 3-position manual switch that allows the to use this information as input for the other control func-
chiller to be put under the control of its own controls (LO- tions. The processor does this by initializing the EXVs at
CAL), manually stopped (OFF), or controlled through a set start-up. The processor sends out enough closing pulses to
of remote contacts (REMOTE). This switch is different than the valve to move it from fully open to fully closed, then
the switch that is used in the Flotronic™ II controls con- resets the position counter to zero. From this point on, until
figuration. The CCN control is enabled through the HSIO-II. the next initialization, the processor counts the total number
The switch allows unit operation as shown in Table 1. of open and closed steps it has sent to each valve.
In the LOCAL position, the chiller is allowed to operate
and respond to the scheduling configuration, CCN configu-
ration, and set point data. In the remote position, the unit
operates similarly to the LOCAL position, except the remote
contacts must be closed for the unit to operate.
3
ECONOMIZER OPERATION — Economizers are factory Back Pressure Valve (30GX and 30HXA only)
installed on 30GX105-265 units and 30HXA,C161-271 units. — This valve is located on the oil separator outlet on 30GX
All other sizes use standard EXVs. The economizer im- units and mounted on the oil separator shell of 30HXA units.
proves both the chiller capacity and efficiency as well as pro- The valve’s function is to ensure that there is sufficient sys-
viding compressor motor cooling. Inside the economizer are tem differential pressure to allow for oil to be driven back to
both a linear stepper motor (same as standard EXV motor) the compressor. A small copper line (economizer pressure)
and a float valve. The stepper motor is controlled by the pro- is connected to the top of the valve, which contains an in-
cessor to maintain the desired liquid level in the cooler (as ternal spring that closes a piston if the pressure in the oil
is done for chillers without economizers). The float valve separator is not at least 15 psig greater than the economizer
maintains a liquid level in the bottom of the economizer. pressure.
Liquid refrigerant is supplied from the condenser through
the end to the bottom of the economizer. A bubbler tube sup- Sensors — The 30GX,HX control system (based on the
plies a small amount of discharge gas to ensure that the float Flotronic™ II chiller control system) gathers information from
will be able to work properly. As the refrigerant passes through sensors to control the operation of the chiller. The units use
the EXD, its pressure is reduced to an intermediate level of up to 9 standard pressure transducers, 7 standard thermistors
about 75 psig (517 kPag). This pressure is maintained inside (including 3 motor temperature thermistors), and 2 liquid level
the economizer shell. Next, the refrigerant flows through the thermistors to monitor and control system operation. The sen-
float valve where its pressure is further reduced to slightly sors are listed in Table 2.
above the pressure in the cooler.
Compressor Protection Module (CPM) — Each
The increase in performance is achieved when some of compressor has its own CPM. The CPM provides the fol-
the refrigerant passing through the EXD flashes to vapor, lowing functions:
further subcooling the liquid that is maintained at the bottom • compressor main contactor control
of the economizer. This increase in subcooling provides ad- • Wye-Delta contactor transition
ditional capacity. Also, since the additional power required • compressor ground current protection
to accomplish this is minimal, the efficiency of the machine • motor temperature reading
improves. The vapor that flashes rises to the top of the econo- • high-pressure protection
mizer where it passes to the compressor and is used to pro- • reverse rotation protection
vide motor cooling. After passing over the motor windings, • voltage imbalance protection
the refrigerant reenters the cycle at an intermediate port in • current imbalance protection
the compression cycle. • compressor oil solenoid control
Oil Pumps — The 30GX/HX screw chillers use one ex- • motor cooling solenoid control
ternally mounted prelubricating oil pump per circuit. This • sensor bus communications
pump is operated as part of the start-up sequence. On 30GX • starting and running overcurrent protection
units, the pumps are mounted to the base rails on the oil sepa- The CPM has the following 4 output relays and 4 inputs:
rator side of the unit. The pumps are mounted to a bracket OUTPUTS:
on the condensers of 30HXC units and to the oil separator • compressor contactor
on 30HXA units. • compressor oil solenoid
When a circuit is required to start, the controls energize • compressor motor cooling solenoid
the oil pump first and read the oil pressure transducer read- • Wye-Delta transition relay
ing. The pump is operated for a period of 20 seconds, after INPUTS:
which the oil solenoid is energized to open the oil inlet valve • motor temperature
at the compressor. The control again reads the pressure from • three-phase voltage
the oil pressure transducer. If the pump has built up suffi- • three-phase current
cient oil pressure, the compressor is allowed to start. • high-pressure switch
Once the compressor has started, the oil pump is turned A diagram of the CPM board is shown in Fig. 1. There are
off within 10 seconds and is not used again until the next line voltage inputs at L1, L2, and L3. Below these inputs are
start-up. If the pump is not able to build up enough oil pres- the current toroid inputs at Plug 1. Below Plug 1 are the 3
sure, the pump is turned off. Within 3 seconds, the pump is COMM3 communication terminals. In the lower left corner
re-energized and makes one additional attempt to build oil of the board are the inputs for motor winding temperature.
pressure. The control generates an alarm if the second at- The address DIP (dual-in-line package) switch and com-
tempt fails. pressor must-trip amps header are factory set. For compres-
Motor Cooling — Compressor motor winding tempera- sor A1, switches 2 and 4 should be set. For compressor A2
tures are controlled to a set point of 200 F (93.3 C). (30HXA,C206-271 AND 30GX205-265), switches 2, 3, and
The control accomplishes this by cycling the motor cooling 4 should be set. For compressor B1, switches 1 and 4 should
olenoid valve to allow liquid refrigerant to flow across the be set.
motor windings as needed. On units equipped with econo- To verify proper must trip amps header configuration, press
mizers, flash gas leaves the top of the economizer and con- and use the up arrow key on the HSIO to locate the
tinually flows to the motor windings. All refrigerant used for must trip amp values. Press the reset button on the HSIO/
motor cooling re-enters the rotors through a port located mid- fuse panel to update these values. See Appendix A. If the
way along the compression cycle and is compressed to dis- values do not match those in Appendix A, verify with Ap-
charge pressure. pendix D that the configuration headers have been properly
punched out.
4
Table 2 — Thermistor and Transducer Locations
THERMISTORS
Sensor Description Location Connection Terminals
T1 Cooler Leaving Fluid Temp Cooler Head Leaving Fluid Side PSIO-2, J7 pins 2,3
T2 Cooler Entering Fluid Temp Cooler Head Entering Fluid Side PSIO-2, J7 pins 5,6
Motor Temp A1 Motor Temperature A1 Compressor A1 Junction Box CPM-A1, T terminals
Motor Temp A2* Motor Temperature A2 Compressor A2 Junction Box CPM-A2, T terminals
Motor Temp B1 Motor Temperature B1 Compressor B1 Junction Box CPM-B1, T terminals
T5 Discharge Gas Temp A Top of Condenser Circuit A (30HXC Only) PSIO-2, J7 pins 8,9
Top of Oil Separator Circuit A (All Other Units)
T6 Discharge Gas Temp B Top of Condenser Circuit B (30HXC Only) PSIO-2, J7 pins 11,12
Top of Oil Separator Circuit B (All Other Units)
LL-A (T3) Liquid Level Circuit A Top of Cooler Circuit A PSIO-1, J7 pins 5,6
LL-B (T4) Liquid Level Circuit B Top of Cooler Circuit B PSIO-1, J7 pins 8,9
T7 (optional)† Outdoor Air Thermistor Outside Air Stream PSIO-2, J7 pins 20,21
STP (optional)† Space Temperature Conditioned Space PSIO-2, J7 pins 23,24
T8 (optional)† Condenser Entering Water Temp Condenser Entering Fluid Line PSIO-2, J7 pins 14,15
T9 (optional)† Condenser Leaving Water Temp Condenser Leaving Fluid Line PSIO-2, J7 pins 17,18
PRESSURE TRANSDUCERS
Sensor Description Location Connection Terminals
DPT-A Discharge Pressure Circuit A Top of Condenser Circuit A (30HXC Only) PSIO-1, J7 pin 22
Top of Oil Separator Circuit A (All Other Units)
SPT-A Suction Pressure Circuit A Top of Cooler Circuit A PSIO-1, J7 pin 19
EPT-A Economizer Pressure Circuit A Economizer Line Entering Comp A PSIO-1, J7 pin 10
OPT-A1 Oil Pressure Compressor A1 Compressor A1 Oil Connection PSIO-1, J7 pin 25
OPT-A2* Oil Pressure Compressor A2 Compressor A2 Oil Connection PSIO-1, J7 Pin 1
DPT-B Discharge Pressure Circuit B Top of Condenser Circuit B (30HXC Only) PSIO-1, J7 pin 16
Top of Oil Separator Circuit B (All Other Units)
SPT-B Suction Pressure Circuit B Top of Cooler Circuit B PSIO-1, J7 pin 31
EPT-B Economizer Pressure Circuit B Economizer Line Entering Comp B PSIO-1, J7 pin 13
OPT-B Oil Pressure Compressor B Compressor B1 Oil Connection PSIO-1, J7 pin 28
*30HX206-271 only.
†Sensors are available as accessories for field installation.
The CPM communicates on the COMM3 communication operation, all relays on the CPM are deenergized and the
bus to the PSIO-1 module. Proper operation of the CPM board compressor is stopped. The failure is reported to the PSIO-1
can be verified by observing the 3 LEDs (light-emitting di- and the processor module locks off the compressor from re-
odes) located on the board. The top LED is red and blinks starting until the alarm is manually reset.
at a rate of once every 1 to 2 seconds. This indicates that the
module is powered and operating correctly. The middle LED Table 3 — Compressor Protection Module
is yellow and blinks when there is an automatic reset alarm Feedback Codes
condition. The yellow LED remains on and does not blink
ALARM CONDITION VALUE
for manual reset alarm conditions. The bottom LED is green
and blinks when the module is satisfactorily communicating High Pressure Switch Trip 1.0
No Motor Current 2.0
with the PSIO-1 module. The CPM communicates the status Current Imbalance Alarm 10% 2.5
of its inputs and outputs, and reports 18 different alarm con- Current Imbalance Warning 10% 2.7
ditions to the PSIO-1. The alarms are listed in Table 3. Current Imbalance 18% 3.0
Single Phase Current Loss 3.5
High Motor Current 4.0
Ground Fault 5.0
Voltage Imbalance Alarm 3% 5.5
The CPM module has many features that are specifi- Voltage Imbalance Warning 3% 5.7
cally designed to protect the compressor, including re- Voltage Imbalance 7% 6.0
Voltage Phase Reversal 7.0
verse rotation protection. Do not attempt to bypass or Contactor Failure 7.5
alter any of the factory wiring. Any compressor opera- Current Phase Reversal 8.0
tion in the reverse direction will result in a compressor Motor Overtemperature 8.5
failure that will require compressor replacement. Open Thermistor 9.0
Configuration Header Fault 9.5
Shorted Thermistor 10.0
The PSIO-1 will generate an alert when it receives an alarm No Error 0
input from the CPM. The alert will be generated in a y.xx
format, where ‘‘y’’ refers to the compressor and ‘‘xx’’ to the Wye-Delta vs Across-the-line (XL) Starting
alarm value in Table 3 (decimal point removed). For ex- Option — All 30GX,HX chillers operating at voltages of
ample, the HSIO might display Alarm 1.70 for a voltage phase 208/230-3-60 or 230-3-50 (5 or 8 at Position 12 in model
reversal occurring on compressor A1. Similarly, the display number) are supplied with factory installed Wye-Delta start-
would read 5.85 for a motor overtemperature condition on ers. All other voltage options can be ordered with either
compressor B1. Alerts for compressors A2 and B2 (if present) Wye-Delta or XL starting options. The XL starting method
would be generated as ‘‘2.xx’’ and ‘‘6.xx,’’ respectively. Alarm is the most cost effective and simply starts the compressor
codes 3 and 4 would not be used. Ending zeros are not motor in a Delta configuration (the motors are designed for
displayed. continuous operation in this configuration) using a single con-
The high-pressure switch is wired in series with the relay tactor. See Fig. 2. This is the simplest starting method to use
coils of the 4 relays on the CPM. If this switch opens during and is ideal where starting current does not require limiting.
5
COMPRESSOR PROTECTION MODULE (CPM) PUSH THIS SIDE OF SWITCH
DOWN TO SET ADDRESS
L1
24/115/230 VAC
L2 INPUTS/OUTPUTS
1
ROCKER DOWN
L3
CURRENT TOROID
INPUT PLUG
1
4 3 2 1
0
2 2 3 4 5
COMM3
3
LED — Light-Emitting Diode
1 ADDRESS DIP NOTES:
SWITCH RED LED 1. The red LED blinks continuously when the module
2
is operating properly.
MOTOR INPUT YELLOW LED 2. The yellow LED blinks during automatic reset alarm,
TEMPERATURE T COMPRESSOR and is continuously lit when the manual reset alarm
MUST TRIP
AMPS HEADER
GREEN LED is active.
T 3. The green LID blinks continuously when communi-
cating properly with PSIO-1.
Fig. 1 — Compressor Protection Module
Where current limitations exist, the Wye-Delta option may control starts (stops) a compressor when the ratio reaches
be used. See Fig. 3. This option uses a factory-installed starter + 100% (− 100%). If the next stage of capacity is a loader,
assembly for each compressor, which consists of 3 contac- the control energizes (deenergizes) a loader when the ratio
tors labelled 1M, 2M, and S. As the compressor is started, reaches + 60% (− 60%). Loaders are allowed to cycle faster
the CPM module energizes contactors 1M and S, which con- than compressors, to minimize the number of starts and stops
nects and energizes the motor windings in a Wye configu- on each compressor. A delay of 90 seconds occurs after each
ration. The starting current required will be approximately capacity step change.
60% less than that required for an XL start due to the higher MINUTES LEFT FOR START — This value is displayed in
impedance of the motor windings when Wye connected. The the Status subfunction and represents the amount of time to
compressor will attain about 100% of its normal operating elapse before the unit is started. This value can be zero with-
speed (approximately 3 to 6 seconds) before the CPM mod- out the machine running in many situations. This can in-
ule deenergizes the S contactor and energizes the 2M con- clude being unoccupied, LOR switch in the OFF position,
tactor, switching the compressor windings to a Delta wiring CCN not allowing unit to start, Demand Limit in effect, no
configuration. The S and 2M contactors in the starter assem- call for cooling due to no load, and alarm or alert conditions
bly are both mechanically and electrically interlocked so that present. If the machine should be running and none of the
they will not both be energized at the same time. above are true, a minimum off time may be in effect. The
Do not alter the factory-installed power wiring from the machine should start normally once the time limit has
control box terminal block to the compressor junction block. expired.
Doing so will cause permanent damage to the compressor
and will require that the compressor be replaced. MINUTES OFF TIME ( ) — This user config-
urable time period is used by the control to determine how
Capacity Control — The control system cycles com- long unit operation is delayed after power is applied/
pressors, loaders, and minimum load control valves to main- restored to the unit. It is also used to delay compressor re-
tain the user-configured leaving chilled fluid temperature set starts after the unit has shut off its lowest stage of capacity.
point. Entering fluid temperature is used by the microproces- Typically, this time period is configured when multiple ma-
sor to determine the temperature drop across the cooler and chines are located on a single site. For example, this gives
is used in determining the optimum time to add or subtract the user the ability to prevent all the units from restarting at
capacity stages. The chilled fluid temperature set point can once after a power failure. A value of zero for this variable
be automatically reset by the return temperature reset or space does not mean that the unit should be running.
and outdoor-air temperature reset features. It can also be re-
set from an external 4 to 20 mA signal (requires field- LOADING SEQUENCE — The 30GX,HX chiller effi-
supplied 500-ohm, 1⁄2 watt resistor), or from a network signal. ciency is greatest at full load. Therefore, the following se-
quence list applies to capacity control.
The capacity routine runs every 30 seconds. The routine
attempts to maintain the Control Point at the desired set point. 1. The next compressor is not started until all others are run-
Each time it runs, the control reads the entering and leaving ning at 100%.
fluid temperatures. The control determines the rate at which 2. The second unloading stage is only used during initial
conditions are changing and calculates 2 variables based on capacity staging of the unit at start-up.
these conditions. Next, a capacity ratio (Load/Unload Fac- 3. Whenever a compressor is started in a circuit, the loaders
in the circuit are deenergized for 15 seconds before the
tor under ) is calculated using the 2 variables to compressor is started. The loaders are energized 90 sec-
determine whether or not to make any changes to the current onds after the compressor is started.
stages of capacity. This ratio value ranges from − 100 to
+ 100%. If the next stage of capacity is a compressor, the
6
TERMINAL BLOCK COMPRESSOR CONTACTOR COMPRESSOR JUNCTION BOX
1 1
L1 T1 1 6
21
2 2
22 L2 T1 2 4
3 3
T3 3 5
23 L3
JUMPER BARS
Fig. 2 — Across-the-Line (XL) Compressor Wiring
TERMINAL BLOCK COMPRESSOR STARTER ASSEMBLY COMPRESSOR JUNCTION BOX
1 1 6
21 L1 T1 4
2
22
2
L2
1M T2
3 3 1 6
23 L3 T3
21
L1 T1 2 4
22
L2 T2
2M
23
L3 T3
3 5
L1 T1
L2 S T2 5
L3 T3
Fig. 3 — Wye-Delta Compressor Wiring
CLOSE CONTROL ( ) — When configured for Close MINIMUM LOAD VALVE ( ) — When this option
Control, the control is allowed to use any loading/capacity is installed and configured, the first stage of capacity is ini-
control devices required to maintain better leaving fluid tem- tiated by energizing the Minimum Load valve relay. The con-
perature regulation. All stages of unloading are available. See trol energizes loaders as needed thereafter. Similarly, the
Appendix B for an example. Minimum Load valve relay will be energized for the last stage
of capacity to be used before the circuit is shut down.
LEAD/LAG DETERMINATION ( ) — This is a con-
CAPACITY CONTROL OVERRIDES — The following over-
figurable choice and is factory set to be automatic. The value rides will modify the normal operation of the routine.
can be changed to Circuit A or Circuit B leading, as desired.
Set at automatic, the control will sum the current number of Deadband Multiplier — The user configurable Deadband Mul-
logged circuit starts and one-quarter (Version 3.0 and later) tiplier ( ) has a default value of 1.0. The range is from
of the current operating hours for each circuit. The circuit 1.0 to 4.0. When set to other than 1.0, this factor is applied
with the lowest sum is started first. Changes to which circuit to the capacity Load/Unload Factor. The larger this value is
is the lead circuit and which is the lag are made when shut- set, the longer the control will delay between adding or re-
ting off compressors. moving stages of capacity. Figure 4 shows how compressor
On 30HX206-271 and 30GX205-265 units set for staged starts can be reduced over time if the leaving water tempera-
loading, the control fully loads the lead circuit before start- ture is allowed to drift a larger amount above and below the
ing the lag circuit and unloads the lag circuit first. When these set point. This value should be set in the range of 3.0 to 4.0
units are set for equal loading, the control maintains nearly for systems with small loop volumes.
equal capacities in each circuit when the chiller is loading First Stage Override — If the current capacity stage is zero,
and unloading.
the control will modify the routine with a 1.2 factor on add-
CAPACITY SEQUENCE DETERMINATION ( )— ing the first stage to reduce cycling. This factor is also ap-
This is configurable as equal circuit loading or staged circuit plied when the control is attempting to remove the last stage
loading with the default set at staged. The control deter- of capacity.
mines the order in which the steps of capacity for each cir-
cuit are changed. This control choice does NOT have any
impact on machines with only 2 compressors.
7
2 STARTS
DEADBAND EXAMPLE
47
8
46
45
7
LWT (C)
LWT (F)
44
6 43
42
5 41
0 200 400 600 800 1000
TIME (SECONDS) 3 STARTS
STANDARD
LEGEND DEADBAND
MODIFIED
LWT — Leaving Water DEADBAND
Temperature
Fig. 4 — Deadband Multiplier
Slow Change Override — The control prevents the capacity water (brine) circuits, if the Saturated Suction temperature
stages from being changed when the leaving fluid tempera- falls below 34 F (1.1 C) (the Brine Freeze Point), the unit
ture is close to the set point (within an adjustable deadband) capacity will not increase. If the Saturated Suction tempera-
and moving towards the set point. ture falls below 28 F (−2.2 C), the Brine Freeze Point minus
Ramp Loading ( ) — Limits the rate of change of leav- 6° F (3.3° C), for 90 seconds, all loaders in the circuit are
turned off. If this condition continues for a total of 3 min-
ing fluid temperature. If the unit is in a cooling mode and utes, the circuit will shut down.
configured for Ramp Loading, the control makes 2 compari-
sons before deciding to change stages of capacity. The con- High Condensing Temperature Unloading — Every 10 sec-
trol calculates a temperature difference between the control onds the control checks for the conditions below. Loaders
point and leaving fluid temperature. If the difference is greater will be cycled as needed to control the saturated condensing
than 4° F (2.2° C) and the rate of change (°F or °C per minute) temperature below the configured maximum condensing tem-
is less than the configured Cooling Ramp Loading value perature. Configured maximums are 154 F (67.8 C) for 30GX,
152 F (66.7 C) for 30HXA, and 122 F (50 C) for 30HXC
( ), the control does not allow any changes to the units. If a circuit’s saturated condensing temperature is more
current stage of capacity. than 12° F (6.7 C) below the maximum condensing tem-
Low Entering Fluid Temperature Unloading — When the perature, the circuit capacity is not allowed to increase. If
entering fluid temperature is below the control point, the con- the saturated condensing temperature is more than 2° F
trol will attempt to remove 25% of the current stages being (1.1° C) above the maximum condensing temperature for
used. If exactly 25% cannot be removed, the control re- 60 seconds, a loader is turned off. If the saturated condensing
moves an amount greater than 25%, but no more than nec- temperature rises to more than 5° F (2.8° C) above the maxi-
essary. The lowest stage will not be removed. mum condensing temperature during the 60 seconds, a loader
Low Discharge Superheat — If a circuit’s discharge super- is turned off immediately. If all the loaders were already off,
the compressor is shut down and an alarm is generated.
heat is less than 15° F (8.3° C), the control does not increase
the current capacity stage and the EXD is not opened any MOP (Maximum Operating Pressure) Override — The con-
further. If the discharge superheat is less than 10° F trol monitors saturated condensing and suction temperature
(5.6° C) and decreasing, the EXD is closed 50 steps every for each circuit as well as differential oil pressure. Based
10 seconds. If the discharge superheat is less than on a configurable maximum operating set point (saturated
5° F (2.8° C) and decreasing, the circuit is unloaded every suction temperature), set maximum condensing tempera-
30 seconds until the superheat is greater than 5° F ture, and minimum differential oil pressure, the control may
(2.8° C). The final capacity stage is not unloaded unless an reduce the number of capacity stages being used and/or may
alarm condition exists. This override is ignored for the first lower the EXD position when system pressures approach the
3 minutes after a compressor is started. set parameters.
Low Saturated Suction Temperature — To avoid freezing Head Pressure Control
the cooler, the control will compare the circuit Saturated Suc-
tion temperature with a predetermined freeze point. For wa- GENERAL — The microprocessor controls the condenser
ter circuits, the freeze point is 28 F (−2.2 C). For brine cir- fans (30GX) or analog water valve (30HXC) to maintain the
cuits, the freeze point is 8° F (4.4° C) below the cooling set saturated condensing temperature to a configurable set point.
point (lower of 2 cooling set points for dual configuration). The fans are staged or speed varied (30GX) or water valve
If the saturated suction temperature is below the freeze point, controlled (30HX) based on each circuit’s saturated con-
the unit capacity is not allowed to increase. For brine cir- densing temperature and compressor status. Water cooled units
(30HXC) operating at less than 70 F (21.1 C) for entering
cuits, the freeze point can be entered by pressing condenser water require the use of head pressure control.
and scrolling 12 items down. The control will use the Brine The chiller must be field configured for the options shown
Freeze Point value less 6°F (3.3°C) as the freeze point to in Table 4. Fan stage settings are shown in Table 5.
compare with the Saturated Suction temperature. The de-
fault for the Brine Freeze Point is 34 F (1.1 C) which means AIR COOLED UNITS (30GX) — See Fig. 5 for condenser
the control will use 28 F (−2.2 C) as the freeze point. This fan locations.
value is adjustable from −15 F to 34 F (−26.1 to 1.1 C). For
8
No Motormastert Control — The fans are controlled based 20 mA output is driven through the PSIO-2 module. To ob-
on Saturated Condensing Temperature. The first fan stage tain this accessory for field installation, order by part num-
for each circuit is turned on whenever the compressor is turned ber 30GX-900---012 for a single controller package (30GX080-
on. A fan stage is added when the Saturated Condensing Tem- 150 and 160). Order part number 30GX-900---014 for a
perature (SCT) exceeds the Head Pressure Set Point. The dual controller package (30GX151 and 161-265). These
Head Pressure Set Point is configurable in the Set Point sub- packages contain all the hardware required to install the
function. The default is 113 F (45 C). Once a fan stage has accessory. See Fig. 6B.
been added, the software temporarily modifies the head pres- The control will use the higher of the 2 Saturated Con-
sure set point by adding 15° F (8.3° C) for 35 seconds. A densing Temperature values for 30GX080-150 and 160 units.
fan stage will be removed when the Saturated Condensing For the 30GX151 and 161-265 units, each circuit’s fan stages
Temperature has been less than the Head Pressure Set Point are independently controlled based on the circuit Saturated
minus 35 F (19.4 C) for 2 minutes. The control uses the higher Condensing Temperature. Refer to Table 6 for condenser fan
of the 2 Saturated Condensing Temperature values for staging information.
30GX080-150 and 160 units. For the 30GX151 and 161-265
units, each circuit’s fan stages are independently controlled WATER-COOLED UNITS (30HX) — The 30HX chillers
based on the circuit Saturated Condensing Temperature. can be configured to control direct or reverse-acting water
Refer to Table 6 for condenser fan control information. See valves that are controlled by a 4 to 20 mA signal. A 2 to
Fig. 6A. 10 VDC signal can be used by installing a 500-ohm resistor
across the 2 output terminals of the 4 to 20 mA signal. This
With Motormaster Control — For low-ambient operation, control scheme reads the saturated condensing temperature
the lead fan in each circuit can be equipped with the optional and uses a PID (proportional integral deriative) loop to
or accessory Motormaster III head pressure controller. This control the head pressure. Proportional, Integral and Deriva-
controller can be used in one of 2 ways. If factory installed, tive gain parameters for both the water and air cooled con-
the controller will be configured for 4 to 20 mA control. With trols are adjustable and can be found in the Service subfunc-
the Motormaster III option enabled, the PSIO-1 module cal- tion. Checkout and adjustment of the PID loop should
culates the required output based on Saturated Condensing only be performed by certified Carrier Comfort Network
temperature, Head Pressure set point, and a PID (propor- technicians.
tional integral derivative) loop calculation. This 4 to
Table 4 — Field Configured Chiller Options

CONFIGURATION OPTION DESCRIPTION HSIO LOCATION FACTORY CONFIGURED?
Fan Staging Select Air cooled staging method Yes. See Table 5
Yes. 0 = None
Motormaster Control Select Applies to air cooled units only Set to 1 to enable (Motormaster only)
Yes. 0 = None
Water Valve Type Applies to water cooled unit only Set to 1 = 4 − 20 mA, 2 = 0 − 10 V,
3 = 20 − 4 mA, 4 = 10 − 0 V
Table 5 — Fan Staging Settings for Air Cooled (30GX) Units

UNIT 30GX DESCRIPTION OPTION NUMBER
080-105 1st stage compressor status 12
2nd stage common control based on highest SCT
106-125 1st stage compressor status 14
2nd and 3rd stage common control based on highest SCT
136, 150, 160 1st stage compressor status 16
2nd through 4th stage common control based on highest SCT
151, 161, 175, 1st stage each circuit, compressor status
205, 225 2nd stage Circuit B independent 7
2nd and 3rd stage Circuit A independent
1st stage each circuit, compressor status
176 3
2nd and 3rd stage each circuit independent
1st stage each circuit, compressor status
206, 226, 250 2nd stage Circuit B independent 9
2nd, 3rd and 4th stage Circuit A independent
251, 265 1st stage each circuit, compressor status 5
2nd, 3rd and 4th stage each circuit independent
LEGEND
SCT — Saturated Condensing Temperature
9
30GX080-105 30GX106-125 30GX136, 150, 160
4 2 4 6
2 4 6 8
2
CONTROL CONTROL CONTROL

BOX BOX BOX
END END END
1 3 1 3 5
1 3 5 7
30GX151, 161, 175, 205, 225 30GX176

10 8 6 4 2 12 10 8 6 4 2
CONTROL
BOX CONTROL
END BOX
END
9 7 5 3 1 11 9 7 5 3 1
30GX206, 226, 250 30GX251, 265

1 3 5 7 9 11 14 12 10 8 6 4 2
CONTROL
CONTROL
BOX
BOX
END
END
2 4 6 8 10 12 13 11 9 7 5 3 1
Fig. 5 — 30GX Condenser Fan Locations
ADJUSTING PID ROUTINES — The 30GX and 30HXC COOLER PUMP CONTROL ( ) — The factory de-
head pressure control routines use PID (proportional inte- fault setting for cooler pump control is ‘‘Not Controlled.’’
gral derivative) loops to maintain a user-configurable head All chillers are enabled at the factory for cooler pump in-
pressure set point. Gain default values are located in the Serv- terlock. See page 71 of Field Wiring section for wiring of
ice function. See page 30. The current values can be read cooler flow switch and/or cooler pump interlock contacts.
under from the HSIO. The control calculates a new Whether cooler pump control is enabled or not, the control
fan speed (30GX) or water valve position (30HXC) every generates an alarm if this input does not close within one
5 seconds based on these gain values and an error term equal minute after the unit switches to an occupied mode or the
to saturated condensing temperature minus head pressure set cooler pump is turned on. See Alarms and Alerts section,
point. If the control routine is not responding fast enough to page 43 for a description of Alarms 53-55. If cooler pump
large changes (circuit starting, for example), increase the pro- control is enabled, the control waits one minute and checks
portional term. the interlock or switch input before starting to determine if
cooling is needed. The cooler pump is turned on when the
When the routine is making too great a change to valve chiller is in the occupied mode and turned off otherwise. The
position or fan speed, decrease the proportional term. To mini- cooler pump is turned on in either of two override condi-
mize hunting, keep the integral term positive and as low as tions: If the cooler freeze protection alarm has been gener-
possible. The default for the derivative term is zero. This ated, the cooler pump is turned on if not already running. If
valve is used to control ‘‘droop,’’ which is common in master/ a cooler heater is being used and has been on for more than
submaster control schemes. The value should not need to be 15 minutes during saturated suction freeze protection, the
changed. cooler pump is turned on.
Cooler and Condenser (30HXC) Pump Control
— The 30GX and 30HX chillers can be configured for cooler
and condenser (30HXC) pump control. Inputs for a cooler
flow switch or interlock and condenser flow switch are also
provided.
10
Table 6 — 30GX080-265 Condenser Fan Staging (PSIO-1 Controlled)
30GX UNIT SIZE FAN TYPE FAN CONTACTOR FANS CONTROLLED FAN RELAY NO.*
FC-1 1, 2 5
Standard
FC-2 3, 4 1
080-105
FC-1, 1A 1, 2 5
High Static
FC-2, 2A 3, 4 1
FC-1 1, 2 5
Standard FC-2 3, 4 1
FC-3 5, 6 2
106-125
FC-1, 1A 1, 2 5
High Static FC-2, 2A 3, 4 1
FC-3, 3A 5, 6 2
FC-1 1, 2 5
FC-2 3, 4 1
Standard
FC-3 5, 6 2
136, 150, FC-4 7, 8 2
160 FC-1, 1A 1, 2 5
FC-2, 2A 3, 4 1
High Static
FC-3, 3A 5, 6 2
FC-4, 4A 7, 8 2
FC-1 1, 2 Comp. B1 contactor†
FC-2 3, 4 3
Standard FC-3 5, 6 2
FC-4 7, 8 Comp. A1/A2 contactor†
151, 161, 175 FC-5 9, 10 1
205, 225 FC-1, 1A 1, 2 Comp. B1 contactor†
FC-2, 2A 3, 4 3
High Static FC-3, 3A 5, 6 2
FC-4, 4A 7, 8 Comp. A1/A2 contactor†
FC-5, 5A 9, 10 1
FC-2 3, 4 3
FC-3 5, 6 4
Standard
FC-4 7, 8 Comp. A1 contactor†
FC-5 9, 10 1
FC-6 11, 12 2
176
FC-1, 1A 1, 2 Comp. B1 contactor†
FC-2, 2A 3, 4 3
FC-3, 3A 5, 6 4
High Static
FC-4, 4A 7, 8 Comp. A1 contactor†
FC-5, 5A 9, 10 1
FC-6, 6A 11, 12 2
FC-2 3, 4 3
FC-3 5, 6 1
Standard
FC-5 9, 10 2
FC-6 11, 12 2
206, 226, 250
FC-1, 1A 1, 2 Comp. B1 contactor†
FC-2, 2A 3, 4 3
FC-3, 3A 5, 6 1
High Static
FC-5, 5A 9, 10 2
FC-6, 6A 11, 12 2
FC-1 2, 4 1
FC-2 6, 8 2
FC-3 1 Comp B1 contactor†
FC-4 3 3
Standard
FC-5 5, 7 4
FC-7 11, 12 2
FC-8 13, 14 2
251, 265
FC-1, 1A 2, 4 1
FC-2, 2A 6, 8 2
FC-3 1 Comp. B1 contactor†
FC-4 3 3
High Static
FC-5, 5A 5, 7 4
FC-7, 7A 11, 12 2
FC-8, 8A 13, 14 2
LEGEND
*Fan Relay number displayed when using to test fans.
Comp. — Compressor
FC — Fan Contactor †Proper rotation of these fans to be checked when compressor(s) is running. See Fig. 5 for condenser fan locations when viewing
from the control box end.
11
30GX UNITS — MOTORMASTER III CONTROL NOT INSTALLED
IS SCT GREATER HAS SCT BEEN 35° F

READ CIRCUIT THAN HEAD NO LESS THAN HEAD
SATURATED PRESSURE SET POINT NO
PRESSURE
CONDENSING SET POINT? 2 MINUTES?
TEMPERATURE
AND CURRENT
FAN STAGE
YES
YES
INCREASE DECREASE
CURRENT FAN CURRENT FAN
STAGE BY ONE STAGE BY ONE
ADD 15° F TO
HEAD PRESSURE
SET POINT FOR
NEXT 35 SECONDS
LEGEND
Fig. 6A — 30GX Head Pressure Control Without MotormasterT III Control
30GX UNITS — MOTORMASTER III CONTROL INSTALLED
IS SCT GREATER CALCULATE NEW DOES PID OUTPUT

READ CIRCUIT THAN HEAD NO PID VALUE. DOSE NO
SATURATED REQUIRE LESS NO
PRESSURE SET OUTPUT REQUIRE FANS?
CONDENSING POINT PLUS 15F? MORE FANS?
TEMPERATURE
AND CURRENT
FAN STAGE
YES YES
YES
INCREASE INCREASE DECREASE

CURRENT FAN CURRENT FAN CURRENT FAN
STAGE BY ONE STAGE BY ONE STAGE BY ONE
OUTPUT NEW mA
SIGNAL TO
CONTROLLER
LEGEND
PID — Proportional Integral Derivative
Fig. 6B — 30GX Head Pressure Control With Motormaster III Control
CONDENSER PUMP CONTROL ( ) — Factory de- the Service function). The second method of control is to
faults for both condenser pump control and condenser flow turn the pump on when the first compressor is started and off
switch are set to ‘‘Not Controlled’’ and ‘‘Disabled,’’ respec- when the last compressor is turned off (set to Type 2 using
tively. The condenser pump can be controlled in one of two the Service function). With the flow switched enabled, the
ways: In the first method, the pump can be controlled like control checks the status of the input one minute after start-
the cooler pump — it is turned on whenever the machine is ing the pump. An alarm is generated if the flow switch input
in the on state and turned off otherwise (set to Type 1 using is not closed.
12
Cooler Heater Control — Accessory cooler heaters Leaving Fluid Temp
can be ordered for the 30GX chillers. If installed and en- xx.x° F
abled, these heaters are turned on only when the machine is Percent Total Capacity
in the off state and the chiller is in a saturated suction tem- xxx.x%
perature freeze condition. Total Number of Alarms
Keypad and Display Module (Also Called xx
HSIO-II) — This module allows the operator to commu- MODES : MODE_TBL
nicate with the processor. It is used to enter configurations Current active modes
and set points and to read data, perform tests, and set sched- All functions are made up of a group of subfunctions. To
ules. The device consists of a keypad with 7 function keys, enter a subfunction, first press the subfunction number de-
5 operative keys, 12 numeric keys (0 to 9, •, and -), and a sired. Then press the function key in which the subfunction
2-line, 24-character alphanumeric liquid crystal display. See resides. To move within that subfunction, press the up or
Fig. 7. down arrow keys. Another subfunction may be entered at
ACCESSING FUNCTIONS AND SUBFUNCTIONS — any time by pressing the subfunction number, then the func-
Table 7 shows a brief description of the keypad buttons. tion key. Depending on system type and configuration, all
Table 8A shows the 6 functions (identified by name) and the displays may not be shown.
subfunctions (identified by number). Table 8B shows the 6
functions (identified by name) and the subfunctions (iden-
tified by number) when using the optional LID-2B control-
ler. Table 9 shows a brief example on how to access
subfunctions. TWENTY-FOUR CHARACTER
NOTE: It is not necessary to use the through every TWO-LINE LCD DISPLAY
item in a subfunction. For example, if you wanted to read
the oil pressure for the A1 compressor, press , then STAT EXPN 1 2 3 SRVC
TEST
EDIT ALRM
press to go directly to A1 Oil Pressure. Use a simi-
lar procedure to view an item near the bottom of a subfunc- SET SCHD 4 5 6 HIST ALGO
tion. To view the Circuit A Oil Switch status, press
and . Use a similar procedure to view an item near 7 8 9 CLEAR
the bottom of a subfunction. To view Condenser Pump Flow
Switch status, press , , and . This proce- ENTER
- 0 .
dure is available in all functions except the TEST function.
AUTOMATIC DEFAULT DISPLAY — When the keypad
has not been used for 10 minutes, the display automatically
switches to the rotating automatic default display. This dis-
LEGEND
play contains the 5 parts shown below.
LCD — Liquid Crystal Display
Entering Fluid Temp
xx.x° F Fig. 7 — Keypad and Display Module
Table 7 — Keypad and Display Module Usage

FUNCTION
USE
KEYS
STATUS — For displaying diagnostic codes and
current operating information about the machine.
HISTORY — For displaying run time, cycles, and
previous alarms.
SERVICE — For entering specific unit configuration
information and enabling manual control function.
SCHEDULE — For entering occupied/unoccupied
schedules for unit operation.
ALGORITHM — Not used.
SET POINT — For entering operating set points
and day/time information.
TEST — For testing operating of the analog and
discrete outputs.
OPERATIVE USE
KEYS
EXPAND — For displaying a non-abbreviated
expansion of the display.
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.
13
Table 8A — HSIO Functions and Subfunctions
FUNCTIONS
SUBFUNCTION Status Test Schedule Service History Set Point
NO.
Alarm Circuit A Ice Build Factory Operating Hours Set Points

1 Display Discrete Outputs Occupancy Configuration
Schedule
General Parameters Circuit B Local/Normal Options Alarm History English/Metric
2 Display Discrete Outputs Occupancy Configuration 1
Schedule
Circuit A Unit Remote CCN Options — Bus Address
3 Analog Values Discrete Outputs Occupancy Configuration 2
Schedule
Circuit A Valves and Holiday 01 Reset/Demand Limit — Time/Date
4 Discrete Inputs/ MotormasterT Configuration Configuration Configuration
Outputs Table Control
Circuit B — Holiday 02 Machine — CCN
5 Analog Values Configuration Configuration Enable/Disable
Codes
Circuit B — Holiday 03 — — —
6 Discrete Inputs/ Configuration
Outputs Table
7 Unit Analog — Holiday 04 Transducer — —
Parameters Configuration Calibration
Miscellaneous — Holiday 05 Manual Control — —
8 Inputs/Outputs Configuration
Operating Modes — Holiday 06 Master/Slave — —
9
Configuration Configuration
Capacity Control — Holiday 07 — — —
10
Configuration
Dual Chiller — Holiday 08 — — —
11
Configuration*
*Subfunctions through are for configuring Holidays 09 through 30.
14
Table 8B — Functions and Subfunctions Cross-Reference for the Optional LID-2B Controller
The optional LID-2B controller cross reference table be- reference table lists the menu item from the LID-2B which
low can be used as a guide to access the same information contains the alarm history information. In another example,
outlined in the HSIO functions and subfunctions table (see from Table 8A, pressing 3 and the Status button on the HSIO
Table 8A). For example, in Table 8A, the alarm history is keypad will access the circuit A analog values. In the table
accessed through the HSIO by pressing 2 and the History below, the circuit A analog values are accessed by selecting
button on the keypad (see Table 7). The LID-2B cross STATUS CIRCA_AN from the appropriate LID-2B menu.
HSIO FUNCTION KEY

HSIO
SUBFUNCTION Status Test Schedule Service History Set Point
NO.
STATUS SERVICE SCHEDULE SERVICE SERVICE SETPOINT

1 A_UNIT_1 CONTROL TEST OCCPC012 EQUIPMENT EQUIPMENT
CONFIGURATION CONFIGURATION
STRTHOUR
STATUS SERVICE SCHEDULE SERVICE SERVICE SERVICE
2 A_UNIT_1 CONTROL TEST OCCPC02S EQUIPMENT ALARM HISTORY LID
OPTIONS1
STATUS SERVICE SCHEDULE SERVICE SERVICE
3 CIRCA_AN CONTROL TEST OCCPC65S EQUIPMENT — CONTROLLER
CONFIGURATION IDENTIFICATION
OPTIONS2
STATUS SERVICE SERVICE SERVICE SERVICE
CIRA_DIO CONTROL TEST EQUIPMENT EQUIPMENT TIME AND DATE
4 CONFIGURATION CONFIGURATION —
HOLIDAY,HOLDY_01 RESETCON
STATUS SERVICE SERVICE STATUS
5 CIRCB_AN — EQUIPMENT EQUIPMENT — A_UNIT_1
HOLIDAY,HOLDY_02 CONCODES
STATUS SERVICE
CIRB_DIO EQUIPMENT
6 — — — —
CONFIGURATION
HOLIDAY,HOLDY_03
STATUS SERVICE SERVICE
UNIT_2 EQUIPMENT EQUIPMENT SERVICE
7 — CONFIGURATION CALIBRTE — —
HOLIDAY,HOLDY_04
8 UNIT_3 — EQUIPMENT EQUIPMENT SERVICE — —
CONFIGURATION MAN_CTRL
HOLIDAY,HOLDY_05
MODE_TBL EQUIPMENT EQUIPMENT
9 — — —
HOLIDAY,HOLDY_06 MSTR_SLV
SERVICE SERVICE
CONTROL EQUIPMENT
10 ALGORITHM — CONFIGURATION — — —
STATUS HOLIDAY,HOLDY_07
LOADFACT
SERVICE SERVICE
CONTROL EQUIPMENT —
11 ALGORITHM — CONFIGURATION — —
STATUS HOLIDAY,HOLDY_08*
LEADLAG
*Subfunctions through are for configuring Holidays 09 through 30, and are also found under Service, Equipment
Configuration.
NOTE: The optional LID-2B controller uses the same password (1111) as the HSIO.
15
Table 9 — Accessing Functions and Subfunctions
OPERATION KEYPAD ENTRY DISPLAY RESPONSE

To access a function, press Circuit A Discrete Outputs
subfunction no. and function
name key. Display shows sub- Loader A1
function group. Relay is OFF
To move to other elements, Loader A2
scroll up or down using arrow keys. Relay is OFF
Minimum Load Valve A
Relay is OFF
Circuit A Oil Heater
Relay is OFF
A1 Mtr. Cooling Solenoid
Relay is OFF
Relay is OFF
Circuit A Oil Pump
Relay is OFF
Oil Solenoid A1
Relay is OFF
Oil Solenoid A2
Relay is OFF
When the last element in a Loader A1
subfunction has been displayed, Relay is OFF
the first element is repeated.
To move to next subfunction Circuit B Discrete Outputs
it is not necessary to use
subfunction number. Press
function name key to Loader B1
advance display through all Relay is OFF
subfunctions within a
function and then back Unit Discrete Outputs
to the first. Valves and Motor Master
Circuit A Discrete Outputs
To move to another function, Alarms : xx

either depress function name Reset Alarms : 1 <ENTER>
key for desired function
(display shows the first CIR. A DISCRETE OUTPUTS
subfunction),
or
Access a specific sub-
function by using the sub-
function number and the
function name key.
STATUS FUNCTION — This function shows the rotating for safeties which do not automatically reset are not deleted
display, current status of alarm and alert (diagnostic) codes, until the problem is corrected and the machine is reset. To
capacity stages, operating modes, chilled water set point, all clear manual reset alarms from the CPM modules, the reset
measured system temperatures and pressures, analog inputs, button on the HSIO bracket must be pressed. Next, switch
and switch inputs. Refer to Table 10 for a complete descrip- the LOR switch to OFF and back to Local or Remote
tion of the function. position (default alarm clearing method). Press
Alarms/Alerts — Alarms and alerts are messages that one and then to clear the alarm from the PSIO
or more faults have been detected. The alarms and alerts in- if the default LOR reset function has been disabled.
dicate failures that cause the unit to shut down, terminate an
option (such as reset) or result in the use of a default value General Parameters — General operating parameters are
such as a set point. Refer to the Troubleshooting section for displayed including control mode, run status, CCN status,
more information. and the 5 most current alarms. Press to display these
Up to 10 alarms/alerts can be stored at once. To view them, and the other values as shown in Table 10.
press . The control will display the current total Circuit A and B Analog and Discrete Information — Circuit
number of alarms/alerts. Use the arrow keys to scroll through A Analog Values can be viewed by pressing and scroll-
the list. Press the key when needed to view the full ing down to see current system operating conditions such as
description of an alarm or alert. Press to clear pressures and temperatures. Pressing will bring up
all the alarms. See Table 11. Circuit A Discrete Inputs and Outputs. Scroll down to view
the On/Off status of the compressor(s), loaders, solenoids,
IMPORTANT: Do not clear the alarms without first and pumps. Oil switch and feedback inputs are also dis-
reviewing the full list and investigating and correcting
the cause of the alarms. played. Press and to view the identical ana-
log values and discrete inputs and outputs for Circuit B. See
Table 10 for a complete display.
When an alarm or alert is stored in the display and the
machine automatically resets, the alarm/alert is deleted. Codes
16
Unit Analog Parameters and Temperature Reset — Press
To enter the MODES subfunction, press and use
and scroll down to display the unit entering and leav-
the key to view all current modes of operation. See
ing fluid temperatures as well as the temperature reset signal Table 13.
and calculated values.
Capacity Control — Pressing , this subfunc-
Miscellaneous Inputs and Outputs — Pressing and
tion displays the load/unload factor, control point, and leav-
scrolling down will reveal the On/Off status of the con- ing water temperature. Scrolling down will also reveal the
denser fans (30GX only). Also found here are the Demand liquid level sensor values in degrees format.
Limit settings, pump relay and switch status, and miscella-
neous items such as Heat/Cool and Dual Set Point switch Dual Chiller — Pressing will access the dual
positions. See Table 10 for a complete list. chiller control status. This subfunction will display whether
Modes — The operating modes are displayed to indicate the or not the chiller is operating as a Master or Slave, any alarm
operating status of the unit at a given time. See Table 12 for conditions present for dual chiller control, and lead/lag in-
a complete list of all modes. formation for changeover. Dual chiller control is configured
under .
17
Table 10 — Status Function and Subfunction Directory
SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

1 Alarms Alarm : xx
Reset Alarms: 1 <ENTER>
All current alarms are displayed Use as needed
2 General Parameters GENERAL PARAMETERS
Control Mode Displays LOCAL ON/OFF or CCN ON/OFF
Run Status
Off/On
Occupied ?
Yes/No
CCN Enable Force/clear value with HSIO or CCN device.
Off/On Must be ON for CCN clock control.
CCN Chiller Start/Stop
Start/Stop
Alarm State
Normal/Alarm
Current Alarm 1
x.xx
Current Alarm 2
x.xx
Current Alarm 3
x.xx
Current Alarm 4
x.xx
Current Alarm 5
x.xx
Active Demand Limit
xxx.x%
Percent Total Capacity
xxx.x%
Water/Brine Setpoint
xx.x dF
Control Point
xx.x dF
Entering Fluid Temperature
xx.x dF
Leaving Fluid Temperature
xx.x dF
Emergency Stop
Emstop
Minutes Left for Start
xx min
Heat-Cool Status
Heat/Cool
3 Circuit A Analog Values CIRCUIT A ANALOG VALUES
Total Capacity Percentage of total circuit capacity

xxx.x% currently in use.
Available Capacity Percentage of Total Capacity value not in
xxx.x% an alarm or fault condition.
Discharge Pressure
xxx.x PSI
Suction Pressure
xxx.x PSI
A1 Oil Pressure Diff.
xxx.x PSI
A2 Oil Pressure Diff.
xxx.x PSI
A1 Oil Pressure
xxx.x PSI
A2 Oil Pressure
xxx.x PSI
Discharge Gas Temperature
xxx.x dF
A1 Motor Temperature
xxx.x dF
A2 Motor Temperature
xxx.x dF
See Legend on page 23.
18
Table 10 — Status Function and Subfunction Directory (cont)

3 Circuit A Analog Valves (cont) SAT Condensing Temp
xxx.x dF
Saturated Suction Temp
xxx.x dF
EXV Percent Open
xxx.x%
Motormaster Speed
xxx.x%
Water Valve Position
xxx.x%
Cooler Level Indicator
x.xx
CPM A1 Feedback See Table 3.
x.x Volts
CPM A2 Feedback See Table 3.
x.x Volts
Circuit A Econ Pressure
xxx.x PSI
4 Circuit A Discrete Inputs/Outputs CIR. A DISCRETE OUTPUTS
Compressor A1
Off/On
Compressor A2
Off/On
Loader A1
Off/On
Loader A2
Off/On
Off/On
Off/On
A1 Mtr Cooling Solenoid
Off/On
A2 Mtr Cooling Solenoid
Off/On
Circuit A Oil Pump
Off/On
Oil Solenoid A1
Off/On
Oil Solenoid A2
Off/On
CIR. A DISCRETE INPUTS
Circuit A Oil Switch

Open/Close
Compressor A1 Feedback
Off/On
Compressor A2 Feedback
Off/On
5 Circuit B Analog Values CIRCUIT B ANALOG VALUES
Total Capacity Percentage of total circuit capacity

xxx.x% currently in use.
Available Capacity Percentage of Total Capacity value
xxx.x% not in an alarm or fault condition.
Discharge Pressure
xxx.x PSI
Suction Pressure
xxx.x PSI
B1 Oil Pressure Diff.
xxx.x PSI
B2 Oil Pressure Diff.
xxx.x PSI
B1 Oil Pressure
xxx.x PSI
B2 Oil Pressure
xxx.x PSI
Discharge Gas Temperature
xxx.x dF
19

5 Circut B Analog Valves (cont) B1 Motor Temperature
xxx.x dF
B2 Motor Temperature
xxx.x dF
SAT Condensing Temp
xxx.x dF
Saturated Suction Temp
xxx.x dF
EXV Percent Open
xxx.x%
Motormaster Speed
xxx.x%
Water Valve Position
xxx.x%
Cooler Level Indicator
x.xx
CPM B1 Feedback See Table 3.
x.x Volts
CPM B2 Feedback See Table 3.
x.x Volts
Circuit B Econ Pressure
xxx.x PSI
6 Circuit B Discrete Inputs/Outputs CIR. B DISCRETE OUTPUTS
Compressor B1
Off/On
Compressor B2
Off/On
Loader B1
Off/On
Loader B2
Off/On
Minimum Load Valve B
Off/On
Circuit B Oil Heater
Off/On
B1 Mtr Cooling Solenoid
Off/On
B2 Mtr Cooling Solenoid
Off/On
Circuit B Oil Pump
Off/On
Oil Solenoid B1
Off/On
Oil Solenoid B2
Off/On
CIR. B DISCRETE INPUTS
Circuit B Oil Switch

Open/Close
Compressor B1 Feedback
Off/On
Compressor B2 Feedback
Off/On
7 Unit Analog Parameters UNIT ANALOG PARAMETERS
Cooler Entering Fluid

xx.x dF
Cooler Leaving Fluid
xx.x dF
Condenser Entering Fluid
xx.x dF
Condenser Leaving Fluid
xx.x dF
Reclaim Entering Fluid
xx.x dF
Reclaim Leaving Fluid
xx.x dF
5 Volt Supply
x.x Volts
20

7 Unit Analog Parameters (cont) TEMPERATURE RESET
4-20 mA Reset Signal

xx.x mA
Return Reset Signal
xx.x dF
External Reset Signal
xx.x dF
Outdoor Air Temp
xx.x dF
Calculated Reset
xx.x dF
8 Misc. Inputs/Outputs MISC INPUTS/OUTPUTS
FAN_1
Off/On
FAN_2
Off/On
FAN_3
Off/On
FAN_4
Off/On
FAN_5
Off/On
FAN_6
Off/On
DEMAND LIMIT
4-20 mA Demand Signal

xx.x mA
Demand Switch 1
Off/On
Demand Switch 2
Off/On
CCN Loadshed Signal
Normal/Alarm
Max Allowable CAP
xxx.x%
PUMPS
Cooler Pump Relay

Off/On
Cooler Pump Flow Switch
Off/On
Condenser Pump Relay
Off/On
Condenser Pump Flow Switch
Off/On
MISCELLANEOUS
Ice Valve
Off/On
Ice Build Complete
Yes/No
Heat/Cool Switch
Heat/Cool
Dual Set point Switch
Off/On
Cooler Heater
Off/On
Options Temperature 1 Not Used
xx.x dF
Options Temperature 2 Not Used
xx.x dF
9 Operating Modes MODES :MODE_TBL Only active modes displayed
mode name ON/OFF
LOCAL OFF Scroll with down arrow key to display
CCN OFF
21

9 Operating Modes (cont) CLOCK OFF
LOCAL ON
CCN ON
CLOCK ON
DUAL SP ACTIVE (1st SP)
DUAL SP ACTIVE (2nd SP)
TEMPERATURE RESET
ACTIVE
DEMAND LIMIT ACTIVE
LOAD LIMIT ACTIVE
LOW SOURCE TEMP PROTECT
RAMP LOADING ACTIVE
TIMED OVERRIDE ACTIVE
LOW COOLER SUCTION TEMP
WSM CONTROLLING
SLOW CHANGE OVERRIDE
OFF TO ON DELAY ACTIVE
FSM CONTROLLING
2 CHILLR LEAD LAG ACTIVE
2 CHILLR LL COMM FAILURE
CIR A LOW DISCHG SUPERHT
CIR B LOW DISCHG SUPERHT
CIR A HIGH SDT
CIR B HIGH SDT
10 Capacity Control CAPACITY CONTROL
Load/Unload Factor
xxx.x%
Control Point
xx.x dF
Leaving Water Temp
xx.x dF
MISC. INDICATORS
Liquid Lvl Sensor Cir. A

xx.x dF
Liquid Lvl Sensor Cir. B
xx.x dF
22

11 Dual Chiller DUAL CHILLER
Unit Master / Slave 0 = Neither

0/1/2 1 = Slave
2 = Slave
Master / Slave Ctrl Active
Yes / No
Lead Chiller 1 = Master
1/2 2 = Slave
Slave Chiller State 0 = Chiller OFF

0/1/3/5/6 1 = Valid Run State in CCN Mode
3 = Chiller in Local Mode
5 = Shutdown on Alarm
6 = Communications Failure
Slave Chiller Total Cap
xxx.x%
Lead / Lag Changeover Yes if Lead / Lag Balance Enabled
Master / Slave Error 1 = Master / Slave Have Same Address

1/2/3/4/5/6 2 = Master / Slave Communication Failure
3 = Chiller in Local Mode
4 = Slave Shutdown on Alarm(s)
5 = Master Configured for Heating
6 = No Slave Configured
LEGEND
CCN — Carrier Comfort Network
CPM — Compressor Protection Module
dF — Degrees Fahrenheit
EXV — Electronic Expansion Valve
FSM — Flotronic™ System Manager
LL — Lead/Lag
SAT — Saturated
SDT — Saturated Discharge Temperature
SP — Set Point
WSM — Water System Manager
Table 11 — Reading and Clearing Alarms
KEYPAD ENTRY DISPLAY COMMENT

Alarm: 02
Reset Alarms: 1 <ENTER>
Comp A1 Fail - 1.70 Volt
Alarm : 15:12 04/15/96
Comp A1 Fail - 1.70 Volts Phase Reversal
Alarm : 15:12 04/15/96
Compressor A1 Low Oil Pr
Alarm : 10:34 04/15/96
Compressor A1 Low Oil Pressure
Alarm : 10:34 04/15/96
Alarm: 02 Press Reset
Reset Alarms: 1 <ENTER> button first
Alarm: 00 Alarms reset
Reset Alarms: 1 <ENTER> and cleared
Entering Fluid Temp Returns to rotating
xx.x dF default display
Leaving Fluid Temp
xx.x dF
Percent Total Capacity
xxx.x%
Total Number of Alarms
xx
MODES: MODE TBL
List of All Current Modes
23
Table 12 — Operational and Mode Display Codes
CODE DESCRIPTION CODE DESCRIPTION
LOCAL OFF Unit is off. LOCAL/OFF/REMOTE switch is OFF TO ON Chiller is being held off by Minutes Off Time
in OFF position or LOCAL/OFF/REMOTE DELAY ACTIVE found by keying . Also, normal
switch is in REMOTE position and remote
contacts are open. operation of the chiller includes a minimum
CCN OFF Unit is off. LOCAL/OFF/REMOTE switch is 1.5 minute delay after a capacity stage
in LOCAL position and CCN control is change has been made. This delay is
enabled (Stop state) or CCN is enabled adjustable from 1.5 to 6 minutes.
(Stop state) with LOR switch in REMOTE LOAD LIMIT This function determines the maximum
position and remote contacts closed. ACTIVE allowable capacity that can be running and
CLOCK OFF Unit is off due to internal clock schedule. is accomplished through the Flotronic
LOR switch is in LOCAL position. System Manager. The unit may not be able
to produce the desired leaving fluid
LOCAL ON Unit is on. LOR switch is in LOCAL position temperature.
and CCN is disabled or LOR switch is in
REMOTE position with contacts closed and 2 CHILLR LEAD Future Use.
CCN is disabled. LAG ACTIVE
CCN ON Unit is on due to CCN command. LOR 2 CHILLR LL Future Use.
switch is in LOCAL position and CCN is COMM FAILURE
enabled (Run state) or LOR switch is in CIRCUIT A LOW If the circuit discharge superheat is less
REMOTE position with contacts closed and DISCHARGE than 15° F (8.3° C), the capacity control
CCN is enabled (Run state) SUPERHT routine will not add any stages (to either
CLOCK ON Unit is on due to internal clock schedule or circuit).
occupied override function. LOR switch is If the compressor has been running for at
in LOCAL position. least 3 minutes, the EXV will not be
DUAL SP ACTIVE Dual set point is in effect. In this mode, unit opened any further. If the circuit
(1st SP) continues to run in an occupied condition, discharge superheat is less than 10° F
and leaving fluid set point is automatically (5.6° C) and falling, the circuit EXV will
controlled to the CSP1 set point in the SET be closed 50 steps every 10 seconds.
POINT function. If the discharge superheat is less than
DUAL SP ACTIVE Dual set point is in effect. In this mode, unit 5° F (2.8° C) and falling, a circuit loader
(2nd SP) continues to run in unoccupied condition, will be deenergized every 30 seconds.
but leaving fluid set point is automatically The final stage will not be unloaded
increased to a higher level (CSP2 set point unless an alarm condition is present.
is in SET POINT function). CIRCUIT B LOW See description for Circuit A above.
TEMPERATURE Temperature reset is in effect. In this mode, DISCHARGE
RESET ACTIVE unit is using temperature reset to adjust SUPERHT
leaving fluid set point upward, and unit is CIRCUIT A If the circuit is running and the Saturated
currently controlling to the modified set HIGH SCT Condensing Temperature (SCT) is greater
point. The set point can be modified based than the Maximum Condensing
on return fluid, outdoor-air temperature, Temperature Set point (MCT_SP) minus
space temperature, or 4 to 20 mA signal.* 12° F (6.7° C), the control will not add
DEMAND LIMIT Demand limit is in effect. This indicates that any stages.
ACTIVE capacity of unit is being limited by demand If the SCT is greater than the MCT_SP
limit control option. Because of this plus 5° F (2.8° C), the circuit will be
limitation, the unit may not be able to unloaded and shut down if necessary. If
produce the desired leaving fluid the SCT is greater than the MCT_SP plus
temperature. Demand limit can be controlled 2° F (1.1° C) for one minute, a loader will
by a switch or 4 to 20 mA signal.* be deenergized.
FSM Flotronic™ System Manager (FSM) is If the SCT is greater than the MCT_SP
CONTROLLING controlling the chiller. minus 4° F (2.2° C), the control will
RAMP LOADING Ramp load (pulldown) limiting is in effect. compare the maximum operating
ACTIVE In this mode, the rate at which leaving fluid pressure set point (MOP_SP) with the
temperature is dropped is limited to a modified MOP_SP (MOP_CTRL).
predetermined value to prevent compressor If the MOP_CTRL is greater than the
overloading. See CRAMP set point in the MOP_SP, the mode will be cleared.
SET function in (page 25). The pulldown limit Otherwise the control will display the
can be modified, if desired, to any rate from high SCT override mode. The capacity
0.2° F to 2° F (0.1° to 1° C)/minute. control routine will not add any stages. If
TIMED OVERRIDE Timed override is in effect. This is a 1 to the circuit is at its lowest capacity, this
ACTIVE 4 hour temporary override of the pro- mode will be ignored.
grammed schedule, forcing unit to occupied CIRCUIT B See description for Circuit A above.
mode. Override can be implemented with HIGH SCT
unit under LOCAL/REMOTE or CCN control.
Override expires after each use. LEGEND
WSM Water System Manager is controlling the CCN — Carrier Comfort Network
CONTROLLING chiller. CSP — Cooling Set Point
CRAMP — Cooling Ramp Loading
SLOW CHANGE Slow change override is in effect. The EXV — Electronic Expansion Valve
OVERRIDE leaving fluid temperature is close to and LOR — Local/Off/Remote
moving towards the control point. SP — Set Point
WSM — Water System Manager
*A field-supplied 500 Ohm 1⁄2 W resistor must be installed across the
input terminals when using a 4 to 20 mA signal.
Table 13 — Reading Current Operating Modes
KEYPAD ENTRY DISPLAY

MODES :MODE_TBL
CCN ON
DEMAND LIMIT
ACTIVE
24
TEST FUNCTION — The test function operates the diag- SET POINT FUNCTION — Set points are entered through
nostic program. To initiate the test function, the LOCAL/ the keypad. Set points can be changed within the upper and
OFF/REMOTE switch must be in the OFF position. lower limits, which are fixed. The ranges are listed below.
To reach a particular test, press its subfunction number Refer to Table 17 for a complete description of the function.
followed by the key then scroll to the desired test by Cooling Set Point 1,2
pressing the down arrow key. Refer to Table 14 for a com- Medium Low
Water:
plete description of the test function. Temperature Brine: Temperature Brine:
38 to 70 F 14 to 70 F −13 to 70 F
To start a test of discrete outputs, press . To end (3.3 to 21.1 C) (−10 to 21.1 C) (−25 to 21.1 C)
the test, simply press the key or press . Pressing Reset Set Points
the key after a test has started advances the system to Maximum External Temperature
Reset Range: Reset: Chiller Fluid D:
the next test, whether the current test is operating or has timed 0° to 15 F
−30 to 30 F −40 to 240 F
out. Circuit A discrete outputs can be tested in and (−17 to 17 C) (−40 to 118 C) (0° to 8 C)
include loaders, minimum load valve, oil heater (if equipped), External Signal Reset: 4 to 20 mA (2-10 vdc with
motor cooling solenoids, oil pump, and oil solenoids. Simi- 500 Ohm resistor)
larly, Circuit B discrete outputs can be tested in
Demand Limit Set Points
. Additional discrete outputs, including condenser fans, Switch Input: Step 1 — 0 to 100% Capacity Reduction
cooler heater, water pumps, and remote alarms can be tested Step 2 — 0 to 100% Capacity Reduction
in . External Signal: Maximum Demand Limit 4 to 20 mA
(2-10 vdc with 500 Ohm resistor)
Press to access Valves and Motormastert device Minimum Demand Limit 4 to 20 mA
analog outputs. Scroll down to display Circuit A EXV Valve (2-10 vdc with 500 Ohm resistor)
with a target percent of 0%. Press to step the EXV Loadshed Demand Delta: 0 to 60%
Maximum Loadshed Time: 0 to 120 min.
to 25%. Pressing three additional times will move
Head Pressure Set Points
the EXV to 50%, 75%, and 100%. The EXV may be closed
Air cooled chillers (30GX): 80 to 135 F (26.7 to 57.2 C)
in 25% steps by pressing for each desired step. Wait
30 seconds between each step when opening and closing for Water cooled chillers (30HX): 80 to 128 F (26.7 to 53.3 C)
the valve to stop moving. Pressing the down arrow will dis- Set Point Table — The unit operating set points can be found
play Circuit B EXV Valve and it is tested in the same man- under . Use the down arrow key to scroll through
ner as Circuit A. Also available for test are Circuit A water the set points. The first set point is Cool Set Point 1. This is
valve (if equipped) and the Circuit A and B Fan speed % the occupied chilled fluid set point. Scroll down to Cool Set
(direct control Motormaster device) outputs for 30GX chill- Point 2 and then to the Cooling Ramp load multiplier which
ers. These are tested in the same manner as the EXV valves. is configurable from 0.2 to 2.0° F/min. (0.11 to 1.1° C/min.).
Note that condenser fan motors are NOT started during fan This value is the maximum rate at which the leaving fluid
speed quick tests. Measure 4 to 20 mA dc output using meter temperature is allowed to drop without adding a stage. Cool-
in series with violet wire to controller. See page 72 of Field ing Set Point 2 is used in conjunction with the dual set point
Wiring section. switch function. This is used as the low temperature set point
While the unit is in test, you can leave the test function for ice duty or as the unoccupied set point. Press the down
and access another display or function by pressing the ap- arrow key to display the Circuit A and B head pressure set
propriate keys. However, a component that is operating when points. The remaining set points in this subfunction include
another function is accessed remains operating. You must demand limit, LCW (leaving chilled water) delta alarm limit,
re-enter the test function and press to shut down the minutes off time, and motor temperature set point.
component. Components with a timed operating limit time Display Units — Press to display the units of mea-
out normally even if another function is accessed. sure being used. Type 0 is for English and type 1 is for
Since the Test function checks only certain outputs, it is Metric.
a good practice to also check all inputs and outputs acces- Address — For CCN configurations, press and
sible through the status function. These can be located by scroll down to display the address and bus number of the
pressing through . If keypad is not used for chiller.
10 minutes, the unit automatically leaves the test function Time — Press and scroll down to read and change
and resumes the normal rotating display. See Table 15. the unit day of week, time, day of month, month of year and
year of century. See the examples in Table 17 for making
HISTORY FUNCTION — Pressing displays total changes to these values.
machine operating hours. Scroll down to display machine CCN Enable/Disable — Press to disable the CCN
run time and starts, and total run time and starts for each control of the chiller. This function will override CCN con-
compressor. Refer to Table 16 for a complete description of
the function. When the PSIO-1 module is replaced or down- trol commands. The CCN Enable value under must
loaded with Version 4.0 or later software, the number of starts be ON to activate this function. With CCN Enable set to ON
and run hours may be changed one time. Record the current and Disable CCN Control set to ‘‘0,’’ the chiller will func-
values from the PSIO before removing the module or down- tion normally under CCN control. With Disable CCN Con-
loading new software. The number of starts and hours may trol set to ‘‘1,’’ the chiller will operate in a local mode under
be changed by entering the desired value at the HSIO and its own control.
pressing the key. Reading and Changing Set Points — Table 18 shows how
to read and change the chilled fluid set point. Other set points
Pressing displays the last 10 alarms along with a can be changed by following the same procedure. Refer to
description and time and date of occurrence of each alarm. Table 17 for the sequence of display of set points in each
subfunction.
25
Table 14 —Test Function and Subfunction Directory

1 Circuit A Discrete Output Circuit A Discrete Output
Loader A1
Relay is OFF
Loader A1
Relay is ON
Loader A2 Similarly, use to test remaining outputs. Press the
down arrow key or to turn an output off.
Circuit A Oil Pump
Oil Solenoid A1
Oil Solenoid A2
NOTE: Output will display Relay is ABSENT when

not configured
2 Circuit B Discrete Outputs Circuit B Discrete Outputs
Loader B1
Relay is OFF
Loader B1
Relay is ON
Loader B2 Similarly, use to test remaining outputs. Press the
down arrow key or to turn the output off.
Minimum Load Valve B
Circuit B Oil Heater
B1 Mtr. Cooling Solenoid
B2 Mtr. Cooling Solenoid
Circuit B Oil Pump
Oil Solenoid B1
Oil Solenoid B2
NOTE: Output will display Relay is ABSENT when

not configured
3 Unit Discrete Output Unit Discrete Output
Fan 1
Relay is OFF
Fan 1
Relay is ON
Fan 2 Similarly use to test remaining outputs. Press the
down arrow key or to turn output off.
Fan 3
Fan 4
Fan 5 Energizes Circuit A fans for 30HXA units.
Fan 6 Energizes Circuit B fans for 30HXA units.
Cooler Pump
Condenser Pump
Cooler Heater
Alarm
Remote Alarm 1 Currently not supported.
26
Table 14 —Test Function and Subfunction Directory (cont)

3 Unit Discrete Output (cont) Remote Alarm 2 Currently not supported.
4 Valves and Motormaster Valves and Motor Master

Circuit A EXV Valve
Target Percent = 0%
Circuit A EXV Valve Step in 25% increments.
Target Percent = 25%
Circuit A EXV Valve Wait 30 seconds between each step for valve to stop moving.
Circuit A EXV Valve Valve may be closed in 25% increments by keying in .
Target Percent = 75% Wait 30 seconds between each step for valve to stop moving.
Circuit A EXV Valve
Circuit B EXV Valve Test same method as for Circuit A
Target Percent = 0%
Circuit A Water Valve Test same method as for EXV valves
Target Percent = 0%
Circuit A% Fan Speed Test same method as for EXV valves
Circuit B% Fan Speed Test same method as for EXV valves
LEGEND
Table 15 — Using Test Function

KEYPAD ENTRY DISPLAY RESPONSE COMMENTS
Circuit A Discrete Output Appears on screen momentarily, then will switch to Loader A1.
Loader A1
Relay is OFF
Loader A1 Compressor Loader A1 solenoid energized
Relay is ON
Loader A1 Compressor Loader A1 solenoid deenergized
Relay is OFF
Valves and Motor Master
Circuit A EXV Valve
Target Percent = 0%
Circuit A EXV Valve Continue pressing to step to 50%, 75%, and 100%.
Circuit A EXV Valve Continue pressing to step closed.

Target Percent = 0
LEGEND
27
Table 16 — History Function and Subfunction Directory

1 Operating Hours Machine Operating Hours Number of hours unit has at least
xxx.x hours 1 compressor running
Machine Starts Number of unit starts from
xxx zero capacity
Circuit A
Operating Hours These values may be changed once, when new software is down-
xxx.x hours loaded or when the PSIO-1 module is replaced (Version 4.0 and later).
Compressor A1 Hours
xxx.x hours
Compressor A2 Hours
xxx.x hours
Starts
Compressor A1 Starts
xxx
Compressor A2 Starts
xxx
Circuit B
Operating Hours
xxx.x hours
Compressor B1 Hours
xxx.x hours
Compressor B2 Hours
xxx.x hours
Starts
Compressor B1 Starts
xxx
Compressor B2 Starts
xxx
2 Alarm History Previous Alarm 1 - description Lists 10 most recent alarms. Use key when necessary
Alarm description, time/day
of occurrence
Previous Alarm 2 - description
of occurrence
of occurrence
of occurrence
of occurrence
of occurrence
of occurrence
of occurrence
of occurrence
Previous Alarm 10- description
of occurrence
28
Table 17 — Set Point Function and Subfunction Directory

1 Set Point Table COOLING
Cool Setpoint 1 Default: 44.0

xx.x dF
Cool Setpoint 2 Default: 44.0
xx.x dF
Cooling Ramp Loading Default: 0.5
xx.x dF
HEATING NOT SUPPORTED
Heat Setpoint 1 NOT SUPPORTED

xx.x dF Default: 98.0
Heat Setpoint 2 NOT SUPPORTED
Heating Ramp Loading NOT SUPPORTED
HEAD PRESSURE
Head Pressure Setpoint A Default: 113.0 (GX)

xxx.x dF 100.0 (HXA) 85.0 (HXC)
Head Pressure Setpoint B Default: 113.0 (GX)
xxx.x dF 100.0 (HXA) 85.0 (HXC)
DEMAND LIMIT
Demand Switch 1 Setpoint Default: 80.0%

xxx.x%
Demand Switch 2 Setpoint Default: 50.0%
xxx.x%
LCW Delta Alarm Limit Default: 50.0 dF
xxx.x dF
Minutes Off Time Default: 0 min
xxx min
Motor Temp Set Point Default: 200.0 dF
xxx.x dF
2 Units US IMPERIAL/METRIC 0 = English (Default)
0 1 = Metric
3 Address TARGET ADDRESS Default: 1
x
TARGET BUS NUMBER Default: 0
x
4 Time Day of Week Mon=1, Tues=2, etc.
Monday
Day of Week Day of week set
Wednsday
TIME (HOUR:MIN) Enter military format
00:00
TIME (HOUR:MIN) Time of day set
10:30
DAY OF MONTH
xx
DAY OF MONTH Day of month set
20
MONTH OF YEAR
xx
MONTH OF YEAR Month of year set
05
YEAR OF CENTURY
xx
YEAR OF CENTURY Year of century set
96
5 CCN Disable Disable CCN Control 0=no, 1=yes
x Default: 0
LEGEND
LCW — Leaving Chilled Water
NOTE: If metric option is selected under , temperatures are expressed
in degrees Celsius and pressures are expressed in kPa.
29
Table 18 — Reading and Changing
Chilled Fluid Set Point Transducer Calibration — Press and scroll down to
view the transducer calibration information. See Table 19
KEYPAD ENTRY DISPLAY RESPONSE COMMENTS for a complete list, and the Pressure Transducers section on
COOLING Change set point from page 59 for a description of this subfunction.
default to 48 F.
Cool Set point 1 Manual Control Mode — This control allows the user to
44.0 F default have full control over the compressors, loaders, and the mini-
Cool Set point 1 Set point change mum load valve (if installed) of the machine. Normal safe-
48.0 F complete ties such as high pressure, oil level and pressure, and CPM
related alarms are NOT bypassed in this control mode. The
SERVICE FUNCTION — This function allows the techni- capacity control function and overrides ARE bypassed when
cian to view and input configuration data. Factory configu- using the manual control mode. To enter this mode, switch
ration data, field configuration data, and service configura- the LOR switch to OFF. Press at the HSIO. The dis-
tion data may be viewed or entered through the keypad and
display module. See Table 19 for a complete listing of con- play will read Manual Control Enable - Disable. Press
figurable items. Whenever a processor module is replaced in and switch the LOR switch to Local. The display will change
the field, the complete list of configuration codes should be to Manual Control Enable - Enable. The Disable and Enable
checked for correct settings. The current software version will appear on the second line of the display. See Table 19
can be displayed. See Table 20. for a complete list of this function.
Scroll down in this function to display configuration in- Scroll down and press to start the desired com-
formation including number of compressors, tonnage, and pressor. The control will start the compressor if the pre-lube
compressor must-trip amps. cycle is passed, just as in normal operation. Press to
Password Protection of HSIO Configurable Service Points
add loaders as desired and press to turn off loaders
— To modify configurations and values and to use the manual
control subfunction, the password must be entered before the and compressors. The Minimum Load Valve can be ener-
first change can be made. The default password is set to gized using the same procedure.
. See Table 21 for an example of how to Dual Chiller Configuration — Press to enter the Dual
enter the password to change the Lead/Lag configuration. Chiller control configuration. This method of control is for
a stand-alone Master/Slave combination of chillers and will
Options Configuration Tables 1 and 2 — These subfunc- NOT work with the Flotronic™ System Manager (FSM).
tions can be accessed by pressing or and scroll- The Minus One Pass Cooler option is required for this
ing down to display the configuration options. See Table 19 configuration.
for a complete list of these options. The chillers should be piped for series flow through the
coolers. The Master chiller must be downstream from the
Temperature Reset, Demand Limit and Head Pressure PID Slave chiller leaving water. Both the Master and Slave chiller
Configurations — Press and scroll down to view the must be connected to the same CCN Level II communica-
configuration information. See Table 19 for a complete list. tions bus with different addresses. To enable the dual chiller
Factory Configuration Codes — Pressing allows configuration the CCN Enable function must be set
entry into the factory and service configuration codes to Enable for each chiller, otherwise each chiller will oper-
subfunction. Under this subfunction, there are 5 configura- ate independently. This value can be activated through the
tion codes that are downloaded at the factory. Each code is HSIO or through a CCN device. Both chillers should be con-
made up of 8 digits. If the processor module is replaced in figured for Close Control and require flow switches
the field, these 5 configuration codes should be checked us- to be installed. For cooler pump control, wire both Master
ing the keypad and HSIO display module. See Table 22 for and Slave chiller outputs to the cooler pump starter. All sys-
a description of the factory configuration codes (codes 1 through tem inputs (temperature reset, demand limit, dual set point,
3) and service configuration codes (codes 4 and 5). etc.) should be connected to the Master chiller. If Lead/Lag
The factory and service configuration codes are found by Balance is disabled, the Master chiller will always be the
lead chiller. If Lead/Lag Balance is enabled, the control will
pressing . These are preset from the factory. They can alternate between the Master and Slave chillers to keep their
be verified by following the description in Table 22. These respective run hours balanced within the value configured
codes MUST be checked and corrected in the field if the for Lead/Lag Balance Delta. The desired leaving fluid set
PSIO-1 module is replaced.
point for the Duplex chiller must be configured in
NOTE: The LOCAL/OFF/REMOTE switch must be in the
OFF position to change configuration codes. the Master chiller. CCN Control of the chillers can be dis-
A label is applied to a control box panel with a list of abled locally through the HSIO by entering and en-
factory and service codes for particular units. Table 23 shows abling the Disable CCN Control value. This value must be
how to configure a new PSIO-1 module for use in a 30HXC- disabled before the chiller will return to Duplex control.
106---501CA water cooled chiller.
30
Table 19 — Service Function and Subfunction Directory
1 Service Configuration Software CESR_500100 Ver
xxx
Unit Type 1 = Air-cooled, 2 = Water-cooled
x 3 = Split system
Number of Cir A Comp
x
Compressor A1 Tonnage
xx
Compressor A2 Tonnage
xx
Oil Switch Configuration
x
Number of Cir B Comp
x
Compressor B1 Tonnage
xx
Compressor B2 Tonnage
xx
Max. Cond. Temp Setpoint 30GX = 154 F (68 C)
xxx.x dF 30HXA = 152 F (67 C)
30HXC = 122 F (50 C)
MOP Set point Default = 52 F (11.1 C)
xx.x dF
Fan Staging Select Displays ‘‘Not Used’’ or a
x number. See Table 5
CPM Board Used?
Yes
Compr. A1 Must Trip Amps Value from CPM module. See Appendix A.
xxx.x
Compr. A2 Must Trip Amps Value from CPM module. See Appendix A.
xxx.x
Compr. B1 Must Trip Amps Value from CPM module. See Appendix A.
xxx.x
Compr. B2 Must Trip Amps CURRENTLY NOT USED
xxx.x
2 Options Configuration 1 Cooler Fluid Select 1 = Water (Default), 2 = Medium Temp Brine
x 3 = Low Temp Brine (HX only)
Min. Load Valve Select Displays Enable/Dsable
x Default: Dsable
Loading Sequence Select 1 = Equal circuit, 2 = Staged circuit
x Default: 2. See page 6
Lead/Lag Sequence Select 1 = Automatic (Default), 2 = Circuit A leads,
x 3 = Circuit B leads
Head Press. Control Type 0 = None (Default, HX), 1 = Air cooled
x (Default, GX), 2 = Water cooled
Motormaster Select 0 = None (Default), 1 = Direct control
x
Water Valve Type 0 = None (Default), 1 = 4-20 mA, 2 = 0-10 V,
x 3 = 20-4 mA, 4 = 10-0 V
Ext. Reset Sensor Select 0 = Space Temp Thermistor (Default)
x 1 = Outside Air Thermistor
Cooler Pump Interlock 0 = No interlock
x 1 = Interlock enabled (Default)
Cooler Pump Control 0 = Not controlled (Default)
x 1 = On/Off Control
Condenser Pump Control 0 = Not controlled (Default)
x 1 = On/Off Control
2 = Off when stages equal 0 (unit off)
Condenser Flow Switch Displays Enable/Dsable
x Default: Dsable
Condenser Water Sensors 0 = Not used (Default), 1 = Used
x
Heat Reclaim Sensors CURRENTLY NOT SUPPORTED
x
3 Options Configuration 2 Cooling Setpoint Select 0 = Single set point (Default), 1 = Dual
x set point (switch controlled), 2 = Dual
set point (clock controlled)
Heating Setpoint Select 0 = Single set point (Default), 1 = Dual
x set point (switch controlled), 2 = Dual
set point (clock controlled)
CURRENTLY NOT SUPPORTED
31
Table 19 — Service Function and Subfunction Directory (cont)
3 Options Configuration 2 (cont) Ramp Load Select 0 = Disabled, 1 = Enabled (Default)
x See page 8
Clock Control Select 0 = No clock control (Default)
x 1 = Local clock control
65 = CCN Clock Control
Ice Configuration Select 0 = Disabled (Default)
x 1 = Clock Control
2 = Demand Limit Control
OAT Sensor Select 0 = Disabled, 1 = Enabled
x Default: 0
Remote Alarm Select 0 = Disabled, 1 = Enabled
x Default: 0
Alarm Reset Select 0 = Not selected, 1 = Selected
x (Default, allows use of LOR
switch to reset alarms)
Close Control Select 0 = Disabled, 1 = Enabled
x Default: 0. See page 7
Deadband Multiplier Default: 1.0
x.x
Current Unbalance Alarm Alarm at 10% imbalance; 0 = Disabled, 1 = Enabled
x Default: 1
Voltage Unbalance Alarm Alarm at 3% imbalance; 0 = Disabled, 1 = Enabled
x Default: 1
4 Reset Configuration Table COOLING RESET TYPE See Demand Limit section, page 39
1
Degrees Reset at 20 mA Default: 0
xx.x dF
COOLING RESET TYPE
2
Remote temp=No Reset Default: 20
xx.x dF
Remote temp=Full Reset Default: 125
xx.x dF
Degrees Reset Default: 0
xx.x dF
COOLING RESET TYPE
3
CHW Delta T=No Reset Default: 15
xx.x dF
CHW Delta T=Full Reset Default: 0
xx.x dF
xx.x dF
COOLING RESET
Select/Enable Reset Type 0 = No Reset (Default) , 1 = 4-20 mA Reset,

x 2 = External Reset, 3 = Return Fluid Reset
HEATING RESET TYPE CURRENTLY NOT SUPPORTED
1
Degrees Reset at 20 mA Default: 0
xx.x dF
2
Remote temp=No Reset Default: 125
xx.x dF
Remote temp=Full Reset Default: 20
xx.x dF
xx.x dF
3
HTW Delta T=No Reset Default: 15
xx.x dF
HTW Delta T=Full Reset Default: 0
xx.x dF
xx.x dF
HEATING RESET
Select/Enable Reset Type 0 = No Reset (Default), 1 = 4-20 mA reset,

x 2 = External reset, 3 = Return Fluid reset
DEMAND LIMIT See Demand Limit section, page 39
Demand Limit at 20 mA Enter 0-100, Default: 0%

xxx.x%
32

4 Reset Configuration Table (cont) Demand Limit Select 0 = None (Default), 1 = Two step switch,
x 2 = 4-20 mA, 3 = CCN Loadshed
Loadshed Group Number 0-99, Default: 0
x
Loadshed Demand Delta 0-60%,Default: 0
xxx%
Maximum Loadshed Time 0-120 min, Default: 60 min
xx min
WATER VALVE PID
Proportional PID Gain Default = 1.0

x.x Adjustable from -20.0 to 20.0
Integral PID Gain Default = 0.1
Derivative PID Gain Default = 0.0
AIR MOTOR MASTER
PID
Proportional PID Gain Default = 1.0
Integral PID Gain Default = 0.1
Derivative PID Gain Default = 0.0
5 Factory Configuration Codes FACTORY CODES
Configuration Code 1 Factory set. See Table 22.

xxxxxxxx
xxxxxxxx
xxxxxxxx
SERVICE CODES

xxxxxxxx
xxxxxxxx
6 NOT USED
7 Transducer Calibration CALIBRATION OFFSET See Pressure Transducer Calibration, page 59
CIRCUIT A PRESSURE
Discharge Pressure
xxx.x PSI
Suction Pressure
xxx.x PSI
A1 Oil Pressure
xxx.x PSI
A2 Oil Pressure
xxx.x PSI
Economizer Pressure
xxx.x PSI
CALIBRATION OFFSET
CIRCUIT B PRESSURE
Discharge Pressure
xxx.x PSI
Suction Pressure
xxx.x PSI
B1 Oil Pressure
xxx.x PSI
B2 Oil Pressure
xxx.x PSI
Economizer Pressure
xxx.x PSI
Calibrate All at 0 PSIG
No
Last Calibration Date
mmm dd - yy
33

8 Manual Control Table Manual Control Enable LOR switch should be in
Dsable OFF position
Password Protected Will be displayed if not entered
Enter: earlier in current HSIO use
Manual Control Enable
Dsable
Manual Control Enable Switch LOR switch to Local
Enable before proceeding
Circuit A Compressor 1
Off
Circuit A Compressor 1 Provided no alarms exist,
On control will attempt circuit
start within 2 minutes.
Press to stop circuit.
Circuit A Compressor 2 to enable,
Off
to stop
Circuit A Loader 1
Off to enable,
to stop
Circuit A Loader 2
to enable,
Off
to stop
Circuit A Min Load Valve
to enable,
Off
to stop
Circuit B Compressor 1
to enable,
Off
to stop
Circuit B Compressor 2 to enable,
Off
to stop
Circuit B Loader 1
Off to enable,
to stop
Circuit B Loader 2
Off to enable,
to stop
Circuit B Min Load Valve
Off to enable,
to stop
9 Dual Chiller Configuration MST SLV
Master/Slave Select 0 = Disabled

0/1/2 1 = Master
2 = Slave
Slave Address Default = 0
0 Adjustable from 0-236
Lead/Lag Balance 0 = Disabled
0/1 1 = Enabled
Lead/Lag Balance Delta Default = 168
xxx hours Adjustable from 40-400
LEGEND
CHW — Chilled Water
CPM — Compressor Protection Module
HSIO — Standard Keypad
HTW — Hot Water
LOR — Local/Off/Remote
MOP — Maximum Operating Pressure
OAT — Outdoor-Air Temperature
PID — Proportional Integral Derivative
34
Table 20 — Displaying Current Software Version
KEYPAD
FUNCTION ENTRY DISPLAY COMMENT
Software Software CESR_500100 Ver Carrier Software Part

Version XXX Number, where XXX is
the revision number.
Table 21 — Compressor Lead/Lag Configuration

SUB-FUNCTION KEYPAD DISPLAY
ENTRY
Options Cooler Fluid Select
Configuration 1 1
Min. Load Valve Select
Dsable
Loading Sequence Select
1
Lead/Lag Sequence Select
1
PASSWD PROTECTED FUNC
Enter Password:
0
2
NOTE: Configurations may be modified after entering the password. The password is only
required to be entered once. After a period of 10 minutes of no HSIO activity, the user is
automatically logged out and the control requires that the password be entered on the
next use.
35
Table 22 — Factory and Service Configuration Code Values
UNIT MODEL NUMBER CONF. CODE 1* CONF. CODE 2 CONF. CODE 3 CONF. CODE 4 CONF. CODE 5
30GX080 11460010 13900000 00000170 15400521 12000093
30GX090,105 11560010 13900000 00000180 15400521 12000093
30GX106 11560010 13900000 00000180 15400521 14000095
30GX115 11660010 13900000 00000190 15400521 14000095
30GX125 11660010 14600000 00000161 15400521 14000095
30GX136 11660010 15600000 00000162 15400521 14000095
30GX150 11560010 18000000 00000095 15400521 16000097
30GX151 11800010 15600000 00000176 15400521 07000088
30GX160 11660010 18000000 00000105 15400521 16000097
30GX161 11800010 16600000 00000177 15400521 07000088
30GX175 11800010 18000000 00000119 15400521 07000088
30GX176 11800010 18000000 00000119 15400521 03000084
30GX205 12663910 18000000 00000145 15400521 07000088
30GX206 12803910 16600000 00000217 15400521 09000090
30GX225 12804610 18000000 00000166 15400521 07000088
30GX226 12804610 18000000 00000166 15400521 09000090
30GX250 12806610 18000000 00000186 15400521 09000090
30GX251 12808010 16600000 00000258 15400521 05000086
30GX265 12808010 18000000 00000200 15400521 05000086
30HXA076 31390010 13900000 00000183 15200521 02000063
30HXA086 31460010 13900000 00000190 15200521 02000063
30HXA096 31560010 13900000 00000200 15200521 02000063
30HXA106 31660010 13900000 00000210 15200521 02000063
30HXA116 31660010 14600000 00000181 15200521 02000063
30HXA126 31660010 15600000 00000182 15200521 02000063
30HXA136 31800010 15600000 00000196 15200521 02000063
30HXA146 31800010 16600000 00000197 15200521 02000063
30HXA161 31800010 15600000 00000196 15200521 02000063
30HXA171 31660010 18000000 00000125 15200521 02000063
30HXA186 31800010 18000000 00000139 15200521 02000063
30HXA206 32663910 18000000 00000165 15200521 02000063
30HXA246 32805610 18000000 00000196 15200521 02000063
30HXA261 32806610 18000000 00000206 15200521 02000063
30HXA271 32808010 18000000 00000220 15200521 02000063
30HXC076 21390010 13900000 00000173 12200521 00000058
30HXC086 21460010 13900000 00000180 12200521 00000058
30HXC096 21560010 13900000 00000190 12200521 00000058
30HXC106 21660010 13900000 00000200 12200521 00000058
30HXC116 21660010 14600000 00000171 12200521 00000058
30HXC126 21660010 15600000 00000172 12200521 00000058
30HXC136 21800010 15600000 00000186 12200521 00000058
30HXC146 21800010 16600000 00000187 12200521 00000058
30HXC161 21800010 15600000 00000186 12200521 00000058
30HXC171 21660010 18000000 00000115 12200521 00000058
30HXC186 21800010 18000000 00000129 12200521 00000058
30HXC206 22663910 18000000 00000155 12200521 00000058
30HXC246 22805610 18000000 00000186 12200521 00000058
30HXC261 22806610 18000000 00000196 12200521 00000058
30HXC271 22808010 18000000 00000210 12200521 00000058
*Unit Type will be listed as air cooled, water cooled, or remote split system. Unit type is first digit in
Configuration Code 1 and is 1 for 30GX units, 2 for 30HXC units, and 3 for 30HXA cooling only chillers.
For other options, see Table 19 under the Service subfunction. A label listing configuration codes is
located on the control box door or panel.
36
Table 23 — Entering Configuration Codes
KEYPAD ENTRY DISPLAY RESPONSE

FACTORY CODES
Configuration Code 1
00000000
21660010
00000000
13900000
00000000
00000200
SERVICE CODES
00000000
12200521
00000000
00000058
SCHEDULE FUNCTION — This function provides a means Dual Set Point Control — This feature can be enabled to
to automatically switch the chiller from an occupied mode allow the use of a second or unoccupied cooling set point.
to an unoccupied mode. Refer to Table 24 for a complete The function can be either switch controlled or clock con-
description of the function. trolled. To enable switch control, set the Cooling Setpoint
The schedules consist of 8 user-configurable occupied time selection under to 1. See page 72 or 73 of Field
periods. The control supports time schedules for local con- Wiring section, depending on unit type, for switch input wir-
trol, remote control and ice building. These time periods can ing to the PSIO-2 module. Configure Cool Setpoint 2 under
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 ma- to the desired value. The unit will then control leav-
chine is in unoccupied mode unless a scheduled time period ing water temperature to Cool Setpoint 2 when the switch
is in effect. If an occupied period is to extend past midnight, input is closed. To enable clock control, set the Cooling
it must be programmed in the following manner: occupied
period must end at 24:00 hours (midnight); a new occupied Setpoint selection under to 2. Set Cool Setpoint 2 to
period must be programmed to begin at 00:00 hours. the desired unoccupied value. Using , configure lo-
NOTE: This is true only if the occupied period starts at 00:00 cal operating schedules for the desired occupied and unoc-
(midnight). If the occupied period starts at a time other than cupied time periods. The unit will then control leaving water
midnight, then the occupied period must end at 24:00 hours temperature to Cool Setpoint 2 during unoccupied time
(midnight) and new occupied period must be programmed periods.
to start at 00:00 in order for the chiller to stay in the occu-
pied mode past midnight. Each time schedule can be over-
ridden to keep the chiller in an Occupied mode for 1, 2, 3 or
4 hours on a one-time basis.
37
Table 24 — Schedule Function and Subfunction Directory

1 Ice Build Schedule* SCHEDULES: OCCPC01S Extended Occupied Time
Timed Override: 00
SCHEDULES: OCCPC01S Two hour override entered
Timed Override: 02
MTWTFSSH OCC UNOCC Displays current stored schedule
01- 00000000 00:00 00:00 (First 2 numbers are schedule, 01-08)
MTWTFSSH OCC UNOCC Monday-Friday now occupied
01- 11111000 00:00 00:00
MTWTFSSH OCC UNOCC Occupied time now set
01- 11111000 21:00 00:00
MTWTFSSH OCC UNOCC Unoccupied time now set
01- 11111000 21:00 06:30 Ice Build schedule completed
MTWTFSSH OCC UNOCC Can enter up to 7
02- 00000000 00:00 00:00 additional ice build schedules
2 Local Schedule† SCHEDULES: OCCPC02S Extended Occupied Time
Timed Override: 00
MTWTFSSH OCC UNOCC Displays current stored schedule
01- 11111000 00:00 00:00
01- 11111000 06:30 00:00
01- 11111000 06:30 21:00 Local schedule completed
02- 00000000 00:00 00:00 additional local schedules
3 Remote Schedule SCHEDULES: OCCPC65S Extended Occupied Time
(Currently Not Timed Override: 00
Used) MTWTFSSH OCC UNOCC Displays current stored schedule
01- 11111000 00:00 00:00
01- 11111000 06:30 00:00
01- 11111000 06:30 21:00 Remote schedule completed
02- 00000000 00:00 00:00 additional remote schedules
4 Holiday Configuration** HOLIDAYS : HOLDY_01 Can configure holiday start day
Starts on 00/00 00 days and duration
HOLIDAYS : HOLDY_01 Start of holiday set
Starts on 12/23 00 days
HOLIDAYS : HOLDY_01 Holiday duration set
Starts on 12/23 10 days
5-33 Holiday Configuration HOLIDAYS : HOLDY_02 Allows configuration of 29
through
Starts on 00/00 00 days additional holiday periods
*Ice configuration select must be set to 1 for clock control. The ice configuration can be accessed by pressing and scrolling down.
†Clock control select must be set to 1 for clock control. The clock control can be accessed by pressing and scrolling down.
**The BROADCAST function (BRODEFS table) must be activated (change to 9YES9 and download) when using the LID-2B controller, Building
Supervisor or ComfortWorks™ software for the control to recognize holidays.
38
Temperature Reset — The control system is capable RETURN FLUID TEMPERATURE RESET — In this ex-
of providing leaving fluid temperature reset based on return ample, the unit set point is reset from full load based on the
fluid temperature. Because the temperature difference be- chilled fluid return temperature. The example uses a reset
tween leaving and return temperature is a measure of the value of 10 degrees at full reset. Full reset is at a 2-degree
building load, return fluid temperature reset is essentially an temperature difference across the cooler and no reset would
average building load reset method. be at a 10° F difference across the cooler. See Fig. 10 and
Under normal operation, the chiller maintains a constant Table 28.
leaving fluid temperature approximately equal to the chilled Demand Limit — Demand Limit is a feature that allows
fluid set point. As building load drops from 100% down to the unit capacity to be limited during periods of peak energy
0%, entering cooler fluid temperature drops in proportion to usage. There are 3 types of demand limiting which can be
load. Thus, the temperature drop across the cooler drops from configured. The first type is through 2 switch inputs, which
a typical 10° F (5.5° C) at full load to a theoretical 0° F will reduce the maximum capacity to 2 user-configurable per-
(0° C) at no load. See Fig. 8. centages. The second type is by a 4 to 20 mA signal input
At partial load, leaving chilled fluid temperature may be which will reduce the maximum capacity linearly between
lower than required. If this is allowed to increase (reset), the 100% at a 4 mA input signal (no reduction) down to the user-
efficiency of the chiller increases. Amount of reset can be configurable level at a 20 mA input signal. The third type
defined as a function of cooler temperature drop. This is a uses the CCN Loadshed module and has the ability to limit
simple linear function that requires 3 pieces of input data for the current operating capacity to maximum and further re-
the set function that will vary depending on measurement duce the capacity if required.
method used. See the following sections and Table 25. To use Demand Limit, select the type of demand limiting
NOTE: Reset set points are not accessible unless the reset to use. Then configure the Demand Limit set points based on
function is enabled first. The Control Point will be recalcu- the type selected.
lated taking into account the set point plus the amount of
reset. This is done as a field configuration. Select one of the DEMAND LIMIT (Switch Controlled, 30GX only) — In this
3 choices for type of reset: Return Fluid Reset, External Tem- example, demand limit by switch control will be configured
perature Reset, or 4 to 20 mA Signal Reset. See Table 25. and the switch set points will be set at 75% and 40%. Ca-
pacity steps are controlled by 2 relay switch inputs field wired
If dual set point control is enabled, the amount of reset is to PSIO-2, terminal 28 for switch 1 and terminal 25 for switch
applied to whichever set point is in effect at the time. 2. See Table 29.
Tables 26-28 demonstrate how to activate reset. For Demand Limit by switch control, closing the first stage
EXTERNAL TEMPERATURE RESET — In this example, demand limit contact will put the unit on the first demand
the unit set point is reset from full load at 90 F (32 C) to a limit level. The unit will not exceed the percentage of ca-
maximum reset value of 10° F (5.5° C) at 25 F (−6.7 C) pacity entered as Demand Switch 1 set point. Closing con-
outdoor ambient. This means that if the chilled fluid set point tacts on the second demand limit switch prevents the unit
is 44 F (6.7 C), there is no reset if the temperature is 90 F from exceeding the capacity entered as Demand Switch 2
(32 C). At a temperature of 25 F (−6.7 C), the chilled fluid set point. The demand limit stage that is set to the lowest
set point would be reset to 54 F (12.2 C). See Fig. 8 and demand takes priority if both demand limit inputs are closed.
Table 26. A field-supplied outdoor air thermistor must be con- If the demand limit percentage does not match unit staging,
nected to PSIO-2 as shown in Fig. 37. the unit will limit capacity to the closest capacity stage.
To activate this function for space temperature reset leave To Disable Demand Limit: Enter as shown
both the External Reset Sensor Select and the OAT Sensor in Table 29. Scroll down to Demand Limit Select and press
Select at 0, and change the Select/Enable Reset Type to 2,
following the procedure in Table 26. to select no Demand Limit control.
EXTERNALLY POWERED RESET (4 to 20 mA) — 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. See
Fig. 9 and Table 27.
Table 25 — Temperature Reset Set Point Limits
MEASUREMENT METHOD
Type 1 — 4-20 mA Type 2 — OAT/Occupied Space
INPUT DATA DESCRIPTION (With 500-Ohm Resistor) (External Sensor) Type 3 — Return Fluid
Variable Limits Variable Limits Variable Limits
Maximum Reset Amount — Degrees Reset (−30 to 30 F) Degrees Reset (−30 to 30 F) Degrees Reset (−30 to 30 F)
Allowable range for maximum at 20 mA −34 to −1 C −34 to −1 C −34 to −1 C
amount which LWT set point
is reset.
Maximum Reset Reference — — — Remote temp = (20 to 125 F) CHW Delta T = (0 to 15 degrees F)
Temperature at which Full Reset −7 to 52 C Full Reset 0 to 8° C
maximum reset occurs. cooler temperature rise
Minimum Reset Reference — — — Remote temp = (20 to 125 F) CHW Delta T = (0 to 15 degrees F)
Temperature at which No Reset −7 to 52 C No Reset 0 to 8° C
no reset occurs. cooler temperature rise
LEGEND
CHW — Chilled Water
OAT — Outdoor-Air Temperature
LWT — Leaving Fluid Temperature
39
6.7 (12)
RESET AMOUNT
5.5 (10) 100
RESET AMOUNT C (F)
4.4 (8) 80
PERCENT BUILDING LOAD

3.3 (6) 60
2.2 (4) 40
1.1 (2) 20
BUILDING LOAD
0
0.0 (0)
-18 (0) -12 (10) -7 (20) -1 (30) 4 (40) 10 (50) 16 (60) 21 (70) 27 (80) 32 (90) 38(100)
RESET REFERENCE TEMPERATURE-OUTDOOR AIR OR SPACE TEMPERATURE THERMISTOR C (F)
Fig. 8 — Cooling External Temperature Reset
6.7 (12)
5.5 (10)
RESET AMOUNT C (F)
4.4 (8)
3.3 (6)
2.2 (4)
1.1 (2)
0 (0)
0 (0) 2 (1) 4 (2) 6 (3) 8 (4) 10 (5) 12 (6) 14 (7) 16 (8) 18 (9) 20 (10)
RESET REFERENCE – 4-20 mA SIGNAL INPUT (VOLTS DC)
Fig. 9 — 4 to 20 mA Cooling Temperature Reset
Fig. 10 — Cooling Return Water Reset
40
Table 26 — Setting External Temperature Reset Table 27 — Setting Externally Powered Reset
KEYPAD DISPLAY KEYPAD DISPLAY COMMENTS

COMMENTS ENTRY RESPONSE
ENTRY RESPONSE
Cooler Fluid Select COOLING RESET TYPE
1 1
Min. Load Valve Select Degrees Reset at 20 mA
Disable 0.0 dF
Loading Sequence Select
1 Degrees Reset at 20 mA
Lead/Lag Sequence Select 10.0 dF
1
COOLING RESET Scroll down to
Head Press. Control Type this point
0
Motormaster Select Select/Enable Reset Type
0 0
Water Valve Type Select/Enable Reset Type 4-20 mA reset
0
1 selected
Ext. Reset Sensor Select
0
Ext. Reset Sensor Select Outdoor Ambient
1 sensor selected
for reset
Table 28 — Setting Return Fluid
Cooling Setpoint Select Temperature Reset
0
Heating Setpoint Select KEYPAD DISPLAY
0 COMMENTS
ENTRY RESPONSE
Ramp Load Select COOLING RESET TYPE
0 1
Clock Control Select
1 COOLING RESET TYPE Scroll down
3 to this point.
Ice Configuration Select
0
CHW Delta T = No Reset
OAT Sensor Select 15.0 dF
0
OAT Sensor Select OAT sensor CHW Delta T = No Reset
1 enabled 10.0 dF
COOLING RESET TYPE CHW Delta T = Full Reset
1 0.0 dF
Degrees Reset at 20 mA
0.0 dF CHW Delta T = Full Reset
COOLING RESET TYPE 2.0 dF
2
Degrees Reset
Remote temp = No Reset 0.0 dF
20.0 dF
Remote temp = No Reset Degrees Reset
25.0 dF 10.0 dF
Remote temp = Full Reset
COOLING RESET
125.0 dF
Remote temp = Full Reset
90.0 dF Select/Enable Reset Type
Degrees Reset 0
0.0 dF
Select/Enable Reset Type Return Fluid reset
Degrees Reset 3 selected
10.0 dF
COOLING RESET Scroll down
to this point.
Select/Enable Reset Type
0
Select/Enable Reset Type External reset
2 selected
41
EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Table 30 — Setting Demand Limit
Controlled) — In this example, the 4 to 20 mA Demand Limit (4 to 20 mA Controlled;
will be configured and the 20 mA demand limit percentage 2 to 10 vdc With 500-Ohm Resistor)
will be set to 50%. See Table 30 and Fig. 11.
KEYPAD DISPLAY
DEMAND LIMIT (CCN Loadshed Controlled) — In this ENTRY RESPONSE
COMMENTS
example, the CCN Loadshed Demand Limit will be config- COOLING RESET
ured. The loadshed group will be set to 1, demand delta will TYPE 1
be set to 40% and the maximum loadshed time will be set to
90 minutes. See Table 31. DEMAND LIMIT Scroll down to this
point
The Loadshed Group number is established by the CCN
system designer. The PIC (product integrated control) will Demand Limit at 20 mA
respond to a Redline command from the Loadshed control. 0.0%
When the Redline command is received, the current stage of Demand Limit at 20 mA
capacity is set to the maximum stages available. Should the 50.0%
loadshed control send a Loadshed command, the PIC will
reduce the current stages by the value entered for Loadshed Demand Limit Select
0
Demand delta. For the above example the Loadshed De-
mand delta is 40%. If the chiller is operating at 80% of total Demand Limit Select 4-20 mA control
capacity when a Redline command is received, the maxi- 2 configured
mum available capacity is set to 80%. When a Loadshed com-
mand is received, the chiller capacity will be reduced by 40%. Table 31 — Setting Demand Limit
The chiller can now operate at a total capacity of no more (CCN Loadshed Controlled)
than 48% [80% − (80% x 40%)] until a Cancel Redline or
Cancel Loadshed command is received. The control will dis- KEYPAD DISPLAY
COMMENTS
able the Redline/Loadshed command if no Cancel command ENTRY RESPONSE
has been received within the configured maximum loadshed COOLING RESET TYPE
time limit. 1
DEMAND LIMIT Scroll down to

Table 29 — Setting Switch-Controlled Demand Limit this point
KEYPAD DISPLAY Demand Limit at 20 mA
COMMENTS
ENTRY RESPONSE 0.0%
COOLING RESET
TYPE 1 Demand Limit Select
0
DEMAND LIMIT Scroll down to this
point Demand Limit Select CCN Loadshed
Demand Limit at 20 mA 3 control configured
0.0%
Loadshed Group Number
Demand Limit Select 0
0
Demand Limit Select Two step switch Loadshed Group Number
1 configured 1
COOLING
Loadshed Demand Delta
0
DEMAND LIMIT Scroll down to this
point Loadshed Demand Delta
Demand Switch 1 Setpoint 40%
80.0%
Demand Switch 1 Setpoint Maximum Loadshed Time
75.0 60 min
Demand Switch 2 Setpoint Maximum Loadshed Time Configuration
50.0% 90 min complete
Demand Switch 2 Setpoint Configuration
40.0% complete
100
50% CAPACITY AT 20 mA
MAX. ALLOWABLE LOAD (%)
80
60
40 100% CAPACITY AT 4 mA
75% CAPACITY AT 12 mA
20
0
0 (0) 2 (1) 4 (2) 6 (3) 8 (4) 10 (5) 12 (6) 14 (7) 16 (8) 18 (9) 20 (10)
DEMAND LIMIT SIGNAL – 4 - 20 mA INPUT (VOLTS DC)
Fig. 11 — 4 to 20 mA Demand Limiting

42
TROUBLESHOOTING
The 30GX,HX screw chiller control has many features to If a stoppage occurs more than once as a result of any
aid in troubleshooting. By using the keypad and display mod- of the preceding safety devices, determine and correct
ule and the Status function, operating conditions of the chiller the cause before attempting another restart.
are displayed while the unit is running. The Test function
allows for operational checkout of compressor loaders, fans,
EXVs, solenoids, and other components while the chiller is Restart Procedure — After the cause for stoppage has
stopped. The Service function displays how configurable items been corrected, restart is either automatic or manual, de-
are configured and provides a manual control mode where pending on the fault. Manual reset requires that the alarm(s)
the compressors can be started and loaded. If an operating be reset via the HSIO. Press and then to
fault is detected, an alarm is generated and an alarm code clear manual reset alarms. If the Alarm Reset Select feature
is displayed under the subfunction along with an is selected ( ), a manual reset alarm can also be reset
explanation of the fault. Up to 10 current alarm codes are by switching the LOR switch from LOCAL/REMOTE to OFF
stored under this subfunction. For checking specific items, and back to LOCAL/REMOTE again. If an alarm was from
see Table 10. the CPM module, depress the reset button located on the HSIO
Checking Display Codes — To determine how the or fuse bracket before clearing the alarm through the HSIO.
machine has been programmed to operate, check the diag- Some typical fault conditions are described in Table 32. For
nostic information displayed in the Status function and the a complete list of fault conditions, codes, and reset type, see
configuration information displayed in the Service function. Table 33.
POWER FAILURE EXTERNAL TO THE UNIT — Unit
Unit Shutoff — To shut the unit off, move the LOCAL/ restarts automatically when power is restored.
OFF/REMOTE switch to OFF position. All compressors and
solenoids stop immediately. Table 32 — Typical Stoppage Faults
and Reset Types
Complete Unit Stoppage — Complete unit stoppage
STOPPAGE FAULT RESET TYPE
can be caused by any of the following conditions:
Loss of Condenser Flow (30HXC) Manual reset
• cooling load satisfied Cooler Freeze Protection Auto reset first time, manual if
• remote on/off contacts open (Chilled Fluid, Low repeated in same day
• programmed schedule Temperature)
• emergency stop command from CCN Chilled Fluid Pump Interlock Automatic reset (Manual for
closed contacts when pump is off)
• general power failure Control Circuit Fuse Blown Unit restarts automatically when
• blown fuse in control power feed disconnect power is restored
• open control circuit fuse(s) High-Pressure Switch Open Manual reset
• LOCAL/OFF/REMOTE switch moved to OFF position Low Sat. Suction Temperature Manual reset
• freeze protection trip Low Oil Pressure Manual reset
• low flow protection trip Loss of Communications with Automatic reset
• open contacts in chilled water flow switch (optional) WSM or FSM controller
• Open contacts in any auxiliary interlock. Terminals that LEGEND
are jumpered from factory are in series with control switch. FSM — Flotronic™ System Manager
Opening the circuit between these terminals places unit in WSM — Water System Manager
Stop mode, similar to moving the control switch to OFF
position. Unit cannot start if these contacts are open. If Alarms and Alerts — These are warnings of abnormal
they open while unit is running, the unit stops or fault conditions, and may cause either one circuit or the
• cooler entering or leaving fluid thermistor failure whole unit to shut down. They are assigned code numbers as
• low/high transducer supply voltage described in Table 33. The alarm descriptions are displayed
• loss of communications between processor module and other on the HSIO when the subfunction is entered. When
control modules a communication loss occurs to a hardware point, an alert or
• low refrigerant pressure alarm may be generated. Refer to Table 34. The PSIO also
• off-to-on delay is in effect recognizes illegal configurations. Illegal configurations are
shown in Table 35.
Table 33 contains a detailed description of each alarm and
alert code error and possible cause. Manual reset is
If a stoppage occurs more than once as a result of any
of the above safety devices, determine and correct the accomplished by entering from the HSIO and press-
cause before attempting another restart. ing or moving the LOCAL/OFF/REMOTE Switch
to the OFF position, then back to LOCAL or REMOTE po-
sition (If Alarm Reset Select is enabled).
Single Circuit Stoppage — Single circuit stoppage
can be caused by the following: Compressor Alarm/Alert Circuit — Each compres-
• low oil pressure sor is controlled by its own CPM processor, which closes
• open contacts in high pressure switch contacts between plug terminals PL2-3 and PL2-6 to start
• low refrigerant pressure the compressor. Power is supplied to the CPM logic circuit
• thermistor failure through each compressor high-pressure switch and into plug
• transducer failure terminal PL2-2. If the high-pressure switch opens, the CPM
• alarm condition from CPM module generates an alarm.
• Overload relay trip. Stoppage of one circuit by a safety NOTE: Similar connections for each compressor can be fol-
device action does not affect other circuit. When a safety lowed on the unit wiring diagrams located on the unit.
device trips, the circuit is shut down immediately and EXV
closes
43
Table 33 — Alarm and Alert Codes
ALARM/ALERT ALARM OR DESCRIPTION WHY WAS THIS ACTION TAKEN RESET PROBABLE
CODE ALERT ALARM GENERATED? BY CONTROL METHOD CAUSE
0 — No Alarms or Alerts — — — —
Exist
1.xx See CPM subcodes Compressor A1 Failure See CPM subcodes See CPM subcodes Manual See CPM subcodes
below below below below
2.xx See CPM subcodes Compressor A2 Failure See CPM subcodes See CPM subcodes Manual See CPM subcodes
5.xx See CPM subcodes Compressor B1 Failure See CPM subcodes See CPM subcodes Manual See CPM subcodes
6.xx See CPM subcodes Compressor B2 Failure See CPM subcodes See CPM subcodes Manual See CPM subcodes
CPM SUBCODES
(xx)
x.0 — No Error — — — —
x.1 Alarm High Pressure Switch HPS input to CPM Comp. shut down Manual/Button Loss of condenser air/
Trip module open water flow. Operation
beyond chiller capability.
Liquid valve not open.
x.2 Alarm No Motor Current CPM reads less than Comp. shut down Manual/Button Power supply discon-
10% of MTA on all legs nected, blown fuse(s),
for >3 seconds wiring error, contactor
not energized, faulty
current toroid, motor
overload tripped
x.25* Alarm Current Imbalance CPM measures current Circuit shut down Manual/Button Loose terminals on
>10% (Alarm) balance between power wires. Poor
phases greater than power supply. Disabled
10% for 25 minutes only if alarm feature is
enabled in
x.27* Alert Current Imbalance CPM measures current None — Loose terminals on
>10% (Warning) balance between power wires. Poor
phases greater than power supply. Displayed
10% for 25 minutes only if alarm feature is
disabled in
x.3 Alarm Current Imbalance CPM measures current Circuit shut down Manual/Button Loose terminals on
>18% balance between power wires.
phases greater than Poor power supply.
18% for 25 minutes
x.35 Alarm Single Phase Current CPM measures current Circuit shut down Manual/Button Blown fuse, wiring error,
Loss imbalance between loose terminals.
phases greater than
20%
x.4 Alarm High Motor Current CPM detects high cur- Comp. shut down Manual/Button Operation beyond chiller
rent compared to MTA capability, improperly
setting punched configuration
header, blown fuse
x.5 Alarm Ground Fault CPM detects ground Comp. shut down Manual/Button Motor winding(s) gone
current (2.5 ± 2.0 amps) to ground, wiring error,
loose plug connector,
current toroid plugs not
facing same direction.
x.55* Alarm Voltage Imbalance >3% CPM measures voltage Circuit shut down Manual/Button Compressor fault, local
(Alarm) imbalance between utility supply imbalance,
phases greater than 3% Poor power supply. Dis-
for 25 minutes played only if alarm fea-
ture is enabled in
x.57* Alert Voltage Imbalance >3% CPM measures voltage None — Compressor fault, local
(Warning) imbalance between utility supply imbalance.
phases greater than 3% Displayed only if alarm
for 25 minutes feature is disabled in
x.6 Alarm Voltage Imbalance >7% CPM measures voltage Circuit shut down Manual/Button Compressor fault, local
imbalance between utility supply imbalance
phases greater than 7%
for 25 minutes
x.7 Alarm Volt Phase Reversal CPM detects incoming Chiller shut down and Manual/Button Leads at CPM board
power supply out of not allowed to start not connected. Supply
phase power not in phase;
interchange any 2
incoming leads.
x.75 Alarm Contactor Failure CPM detects min. 10% All remaining compres- Manual/Button Faulty contactor, con-
of MTA for 10 seconds sors shut down. All tactor welded, wiring
after shutting off com- loaders deenergized. error.
pressor contactor. Oil Min. load valve of af-
solenoid is energized. fected circuit energized
(if equipped)
x.8 Alarm Current Phase Reversal CPM detects phase re- Circuit shut down Manual/Button Multiple terminal block
versal from toroid power supply leads not
reading in phase. Toroid wire
harness crossed, toroid
not all facing same
direction
44
Table 33 — Alarm and Alert Codes (cont)
CPM SUBCODES
(xx)
x.85 Alarm Motor Over Temperature CPM detects high motor Comp. shut down Manual/Button Motor cooling (all) or
temperature Economizer (2 comp.
circuits) solenoid failure,
low refrigerant charge.
x.9 Alarm Open Thermistor CPM detects open Comp. shut down Manual/Button Wiring error or faulty
circuit in motor temp thermistor.†
thermistor
x.95 Alarm Config. Header Fault CPM finds error with Comp. shut down Manual/Button Header pins on CPM
MTA value punched out board either all or none
in header punched out, header not
fully seated in CPM
board.
x.10 Alarm Shorted Thermistor CPM detects short Comp. shut down Manual/Button Wiring error or faulty
circuit in motor tempt thermistor.†
thermistor
ALARM/ALERT
CODE
7 Alert Cir. A Discharge Gas Thermistor outside Circuit A shut down Manual Thermistor failure, motor
Thermistor Failure range of −40 to 245 F cooling solenoid failure
(−40 to 118 C) or DGT or wiring error.
>210 F (98.9 C)
8 Alert Cir. B Discharge Gas Thermistor outside Circuit B shut down Manual Thermistor failure, motor
Thermistor Failure range of −40 to 245 F cooling solenoid failure
(−40 to 118 C) or DGT or wiring error.
>210 F (98.9 C)
9 Alarm Cooler Leaving Fluid Thermistor outside Chiller shut down. Automatic Thermistor failure, dam-
Thermistor Failure range of −40 to 245 F aged cable/wire or wir-
(−40 to 118 C) ing error.
10 Alarm Cooler Entering Fluid Thermistor outside Uses 0.1° F/% Total Ca- Automatic Thermistor failure, dam-
Thermistor Failure range of −40 to 245 F pacity as rise/ton. aged cable/wire or wir-
(−40 to 118 C). ing error.
11 Alert Condenser Leaving Thermistor outside None. Chiller continues Automatic Thermistor failure, dam-
Fluid Thermistor Failure range of −40 to 245 F to run. aged cable/wire or wir-
12 Alert Condenser Entering Thermistor outside None. Chiller continues Automatic Thermistor failure, dam-
Fluid Thermistor Failure range of −40 to 245 F to run. aged cable/wire or wir-
15 Alert Compressor A1 High Thermistor outside Compressor A1 shut Manual Thermistor failure, motor
Motor Temperature range of −39.9 to 245 F down cooling (all) or Econo-
(−39.9 to 118 C) for 5 mizer (2 comp. circuits)
consecutive readings solenoid failure.
16 Alert Compressor A2 High Thermistor outside Compressor A2 shut Manual Thermistor failure, motor
17 Alert Compressor B1 High Thermistor outside Compressor B1 shut Manual Thermistor failure, motor
18 Alert Compressor B2 High Thermistor outside Compressor B2 shut Manual Thermistor failure, motor
21 Alert External Reset Tem- Thermistor outside Reset disabled. Runs Automatic Thermistor failure or
perature Thermistor range of −40 to 245 F under normal control/ wiring error.
Failure (−40 to 118 C) set points.
22 Alert Circuit A Discharge Calibration offset more Circuit A shut down Automatic Transducer failure,
Pressure Transducer than 6 PSIG or Voltage power supply failure or
Failure ratio (volts read/ref. volt- wiring damage/error.
age) more than 99.9%
or less than 0.5%.
23 Alert Circuit B Discharge Calibration offset more Circuit B shut down Automatic Transducer failure,
Pressure Transducer than 6 PSIG or Voltage power supply failure or
Failure ratio (volts read/ref. volt- wiring damage/error.
or less than 0.5%.
24 Alert Circuit A Suction Pres- Calibration offset more Circuit A shut down Automatic Transducer failure,
sure Transducer Failure than 6 PSIG or Voltage power supply failure or
ratio (volts read/ref. volt- wiring damage/error.
or less than 0.5%.
25 Alert Circuit B Suction Pres- Calibration offset more Circuit B shut down Automatic Transducer failure,
sure Transducer Failure than 6 PSIG or Voltage power supply failure or
or less than 0.5%.
26 Alert Comp A1 Oil Pressure Calibration offset more Comp A1 shut down Automatic Transducer failure,
Transducer Failure than 6 PSIG or Voltage power supply failure or
or less than 0.5%.
27 Alert Comp A2 Oil Pressure Calibration offset more Comp A2 shut down Automatic Transducer failure,
or less than 0.5%.
45
28 Alert Comp B1 Oil Pressure Calibration offset more Comp B1 shut down Automatic Transducer failure,
or less than 0.5%.
29 Alert Comp B2 Oil Pressure Calibration offset more Comp B2 shut down Automatic Transducer failure,
or less than 0.5%.
30 Alert Circuit A Economizer Calibration offset more Circuit A shut down Automatic Transducer failure,
or less than 0.5%.
31 Alert Circuit B Economizer Calibration offset more Circuit B shut down Automatic Transducer failure,
or less than 0.5%.
32 Alarm Transducer Supply Out- Reference voltage mea- Chiller shut down Automatic Power supply failure or
side 4.5 to 5.5 Volts sured at PSIO-1, wiring error. Low trans-
J7-34,35 less than 4.5 V former voltage.
or greater than 5.5 V.
34 Alert 4-20 mA Reset Input If configured and input Reset function disabled. Automatic Faulty signal generator,
Out of Range signal to PSIO-2, Normal set point used wiring error, 500 ohm
J7-19,20(HX), resistor missing or not
J7-22,23(GX) less than properly installed.
2 mA or greater than
20 mA
35 Alert 4-20 mA Demand Limit If configured and input Demand limit ignored. Automatic Faulty signal generator,
Input Out of Range signal to PSIO-2, Runs under normal con- wiring error, 500 ohm
J7-22,23(HX), trol based on 100% de- resistor missing or not
J7-13,14(GX) less than mand limit. properly installed.
2 mA or greater than
20 mA
36 Alarm Loss of Communication PSIO-1 has lost com- See Table 34. Automatic Failed module, wiring
with ‘‘Hardware Point’’ munication with one of error, failed transformer,
the points in Table 34. loose connection plug,
wrong address
37 Alert Circuit A Low Saturated SST reads 6 F (3.3 C) Circuit A shut down Manual Low refrigerant charge,
Suction Temperature or more below the plugged strainer, faulty
freeze point for 3 min- expansion valve. Low
utes. Point is 28 F water flow.
(−2.2 C) for water, set
point minus 8 F (4.4 C)
for brines.
38 Alert Circuit B Low Saturated SST reads 6 F (3.3 C) Circuit B shut down Manual Low refrigerant charge,
Suction Temperature or more below the plugged strainer, faulty
freeze point for 3 min- expansion valve. Low
utes. Point is 30 F water flow.
(−1.1 C) for water, cool-
ing set point minus 8 F
(4.4 C) for brines.
40 Alert Compressor A1 Low Oil See Note 1. Comp A1 shut down Manual Low Water Temperature,
Pressure low refrigerant charge,
plugged oil filter, closed
oil valve, bad oil sole-
noid, compressor oil
check valve stuck, oil
line check valve stuck,
plugged oil strainer.
41 Alert Compressor A2 Low Oil See Note 1. Comp A2 shut down Manual Low Water Temperature,
plugged oil strainer
42 Alert Compressor B1 Low Oil See Note 1. Comp B1 shut down Manual Low Water Temperature,
43 Alert Compressor B2 Low Oil See Note 1. Comp B2 shut down Manual Low Water Temperature,
44 Alarm Circuit A Condenser For W/C chillers only, if Chiller shut down. Turn Automatic Failed/bad discharge
Freeze Protection SCT <34 F (1.1 C) Cond pump On if Chiller pressure transducer,
(alarm ignored for brine is Off refrigerant leak,
chillers) configured for water-
cooled condenser
46
45 Alarm Circuit B Condenser For W/C chillers only , if Chiller shut down. Turn Automatic Failed/bad discharge
Freeze Protection SCT <34 F (1.1 C) Cond pump On if Chiller pressure transducer,
(alarm ignored for brine is Off refrigerant leak,
chillers) configured for water-
cooled condenser
46 Alarm Cooler Freeze Protec- Cooler EWT or LWT Chiller shut down. Automatic** Faulty thermistor, low
tion less than freeze point. Leave Cooler pump on. water flow
Freeze point is 34 F Turn Cooler pump On if
(1.1 C) for water, cool- Chiller is Off.
ing set point minus 8 F
(4.4 C) for brines.
47 Alert Circuit A High Saturated After first 90 seconds, Circuit A shut down Manual Faulty expansion valve,
Suction Temperature SST > 55 F (12.8 C) liquid level sensor or
and EXV < 1% for transducer.
5 minutes
48 Alert Circuit B High Saturated After first 90 seconds, Circuit B shut down Manual Faulty expansion valve,
Suction Temperature SST > 55 F (12.8 C) liquid level sensor or
and EXV < 1% for transducer.
5 minutes
49 Alarm Loss of Condenser Flow Flow switch not closed Chiller shut down Manual Low condenser water
within 1 minute after flow, failed condenser
pump is started or if pump
flow switch opens dur-
ing normal operation for
>10 seconds
50 Alarm Illegal Configuration x Illegal Configuration has Chiller cannot start. See Manual Configuration error.
been entered. Correc- Table 35.
tion needed.
51 Alarm Initial Configuration No configuration has Chiller cannot start Manual Configuration omitted.
Required been entered.
52 Alarm Unit is in Emergency CCN command received Chiller shut down CCN/ Network command.
Stop to shut unit down. Automatic
53 Alarm Cooler Pump Interlock Interlock did not close Chiller shut down. Pump Automatic Failure of cooler pump
Failed at Start-Up within 1 minute after turned off. or controls
transition
54 Alarm Cooler Pump Interlock Interlock opened for at Chiller shut down. Pump Automatic Failure of cooler pump
Opened Unexpectedly least 5 seconds during turned off. or controls
operation
55 Alarm Cooler Pump Interlock Interlock closed when Cooler pump remains Manual Failure of cooler pump
Closed When Pump pump relay is off off. Unit prevented from relay or interlock,
OFF starting. welded contacts
56 Alert Loss of Communication No communications WSM forces removed. Automatic Failed module, wiring
with WSM have been received by Runs under own control error, failed transformer,
PSIO-1 within 5 minutes loose connection plug,
of last transmission. wrong address
57 Alert Circuit A Liquid Level Sensor reads 245 F Runs, but controls EXV Automatic Thermistor circuit open,
Sensor Failure (118 C) or −40 F based on Disch. Super- faulty liquid level sensor,
(−40 C) with SST > 9 F heat wiring error
(−12.8 C)
58 Alert Circuit B Liquid Level Sensor reads 245 F Runs, but controls EXV Automatic Thermistor circuit open,
Sensor Failure (118 C) or −40 F based on Disch. Super- faulty liquid level sensor,
(−40 C) with SST > 9 F heat wiring error
(−12.8 C)
59 Alarm Compressor A1 Oil Pump did not build Circuit cannot start Manual Low oil, oil pump failure,
Pre-Start Oil Pressure sufficient pressure dur- oil solenoid failure, oil
ing pre-lube cycle. transducer failure, check
valve failed open, oil
shutoff valve closed
60 Alarm Compressor A2 Oil Pump did not build Circuit cannot start Manual Low oil, oil pump failure,
61 Alarm Compressor B1 Oil Pump did not build Circuit cannot start Manual Low oil, oil pump failure,
62 Alarm Compressor B2 Oil Pump did not build Circuit cannot start Manual Low oil, oil pump failure,
63 Alarm Circuit A&B OFF for Control has shut down None Automatic Check individual alarms
Alerts. Unit down both circuits due to
alerts.
64 Alert Circuit A Loss of Charge Discharge pressure Circuit A shut down Manual Refrigerant leak or
reading <10 PSIG for transducer failure
30 seconds
65 Alert Circuit B Loss of Charge Discharge pressure Circuit B shut down Manual
reading <10 PSIG for
30 seconds
66 Alarm Loss of Communication No communications FSM forces removed Automatic Wiring faulty or module
with FSM have been received by Runs under own control failure
PSIO-1 within 5 minutes
of last transmission.
67 Alert Circuit A High Discharge SCT > MCT_SP + 5 F Circuit shut down Automatic** Faulty transducer/high
Pressure (2.8 C) pressure switch, low/
restricted condenser
air/water flow.††
47
68 Alert Circuit B High Dis- SCT > MCT_SP + 5 F Circuit shut down Automatic** Faulty transducer/high
charge Pressure (2.8 C) pressure switch, low/
restricted condenser
air/water flow.††
70 Alert High Leaving Chilled LCW read > LCW Delta Alert only. None Automatic Building load greater
Water Temperature Alarm limit and total ca- than unit capacity, low
pacity is 100% and cur- water/brine flow, or
rent LCW > LCW compressor fault. Check
reading 1 minute ago for other alarms or
alerts.
71 Alert Circuit A Low Oil Level Level switch input open Circuit A shut down Manual Low oil level, failed
for 4th time in same switch, wiring error,
day. failed DSIO module
72 Alert Circuit B Low Oil Level Level switch input open Circuit B shut down Manual Low oil level, failed
for 4th in same day. switch, wiring error,
failed DSIO module
73 Alert Circuit A Low Discharge Superheat <5 F (2.8 C) Circuit A shut down Manual Faulty thermistor,
Superheat for 10 minutes transducer or EXV or
Economizer. Motor cool-
ing solenoid stuck open.
74 Alert Circuit B Low Discharge Superheat <5 F (2.8 C) Circuit B shut down Manual Faulty thermistor,
Superheat for 10 minutes transducer or EXV or
Economizer. Motor cool-
ing solenoid stuck open.
75 Alarm Comp. A1 Max. Oil (Discharge press − Oil Comp. A1 shut down Manual Plugged oil filter, closed
Delta P, check oil line press) >100 PSI for oil valve, bad oil sole-
more than 5 seconds noid, compressor oil
76 Alarm Comp. A2 Max. Oil (Discharge press − Oil Comp. A2 shut down Manual Plugged oil filter, closed
77 Alarm Comp. B1 Max. Oil (Discharge press − Oil Comp. B1 shut down Manual Plugged oil filter, closed
78 Alarm Comp. B2 Max. Oil (Discharge press − Oil Comp. B2 shut down Manual Plugged oil filter, closed
79 Alarm Comp. A1 Failed Oil Diff. Oil pressure Comp. A1 not allowed Manual Faulty oil solenoid valve
Solenoid >2.5 PSI during period to start
after oil pump starts and
before oil solenoid opens
80 Alarm Comp. A2 Failed Oil Diff. Oil pressure Comp. A2 not allowed Manual Faulty oil solenoid valve
81 Alarm Comp. B1 Failed Oil Diff. Oil pressure Comp. B1 not allowed Manual Faulty oil solenoid valve
82 Alarm Comp. B2 Failed Oil Diff. Oil pressure Comp. B2 not allowed Manual Faulty oil solenoid valve
LEGEND NOTES:
CCN — Carrier Comfort Network 1. Low Oil Pressure Alert Criteria and Set Points
CPM — Compressor Protection Module Where: Pd = Discharge pressure, Ps = Suction pressure,
DGT — Discharge Gas Temperature Po = Oil pressure and Pe = Economizer pressure
EWT — Entering Water Temperature
EXV — Electronic Expansion Valve Two oil pressure set points are used. Oil Set point 1 is always 15 psig.
FSM — Flotronic™ System Manager a. If (Pd − Ps) <125, then Oil Set point 2 = 0.235 x (Pd − Ps) + 0.588
HPS — High-Pressure Switch b. If (Pd − Ps) > = 125 and <165, then Oil Set point 2 = 2.0 x (Pd − Ps)
LCW — Leaving Chilled Water − 220.0
LWT — Leaving Water Temperature c. If (Pd − Ps) > = 165, then Oil Set point 2 = 0.6364 x (Pd − Ps) + 5.0
MCT SP — Maximum Condensing Temperature Set Point
MTA — Compressor Must Trip Amps The 2 set points are used by the control for the Low Oil Pressure alert trip
SCT — Saturated Condensing Temperature criteria below:
SST — Saturated Suction Temperature a. Oil Pressure is ignored during the first 5 seconds after a compressor is
W/C — Water-Cooled started.
WSM — Water System Manager b. In period between 5 and 30 seconds after starting, the alert will be gen-
*Current and voltage imbalance alarms x.25 and x.55 may be changed to erated if (Po − Pe) < [(Oil Set point 1)/30] x (Compressor Run time in
warnings x.27 and x.57 after successful start-up of the chiller. seconds) for 3 consecutive readings
†Compressors are equipped with 2 motor winding temperature ther- c. After 30 seconds run time, the alert will be generated if:
mistors. Verify first that the problem is not a wiring error before using backup 1) (Po − Pe) < Oil Set point 1 for 15 seconds OR
thermistor. 2) (Po − Ps) < Oil Set point 2 for 25 seconds
**Reset automatic first time, manual if repeated on the same date.
††Note that the high-pressure switch should trip before this alert is generated. 2. (Po − Pe) is the Oil pressure differential displayed in for Circuit A
Check HPS operation if this alert is generated.
and for Circuit B.
48
Table 34 — Hardware Point Communications Loss/Action Taken
ACTION TAKEN UNTIL

HARDWARE POINT CONTROL POINT NAME COMMUNICATION RESTORED
ALARM Alarm Relay No Action
CFLOW_SW Cooler Flow Switch Chiller shut down
COND_ENT Condenser Entering Water Thermistor Same as Alert 12
COND_LWT Condenser Leaving Water Thermistor Same as Alert 11
COND_PMP Condenser Pump Relay Chiller shut down
COOL_EWT Cooler Entering Water Thermistor Same as Alarm 10
COOL_LWT Cooler Leaving Water Thermistor Chiller shut down
COOL_HTR Cooler Heater Turn ON Cooler Pump relay
COOL_PMP Cooler Pump Relay No Action
DFLOW_SW Condenser Flow Switch Chiller shut down
DISTMP_A Discharge Gas Temp Circuit A (Oil Temp) Circuit shut down
DISTMP_B Discharge Gas Temp Circuit A (Oil Temp) Circuit shut down
DISTMP_B Discharge Gas Temp Circuit B (Oil Temp) Circuit shut down
DMD_SW1 Demand Limit Switch 1 No Action
DMD_SW2 Demand Limit Switch 2 No Action
DPA Discharge Pressure Circuit A Circuit shut down
DPB Discharge Pressure Circuit B Circuit shut down
DUAL Dual Setpoint Switch Control to Setpoint 1
ECN_PR_A Circuit A Economizer Pressure Circuit shut down
ECN_PR_B Circuit B Economizer Pressure Circuit shut down
EXVA Expansion Valve, Circuit A Circuit shut down
EXVB Expansion Valve, Circuit B Circuit shut down
FAN_1 Fan Relay 1 No Action
HC_SW Heat/Cool Switch Chiller shut down
HR_EWT Heat Reclaim Entering Water Thermistor No Action
HR_LWT Heat Reclaim Leaving Water Thermistor No Action
ICE_DONE Ice Complete Indicator Disable function
ICE_VALV Ice Valve Disable function
K_A1_FBK Compressor A1 Feedback Compressor shut down
K_A1_RLY Compressor A1 Relay Compressor shut down
K_A2_FBK Compressor A2 Feedback Compressor shut down
K_A2_RLY Compressor A2 Relay Compressor shut down
K_B1_FBK Compressor B1 Feedback Compressor shut down
K_B1_RLY Compressor B1 Relay Compressor shut down
K_B2_FBK Compressor B2 Feedback Compressor shut down
K_B2_RLY Compressor B2 Relay Compressor shut down
LOADR_A1 Compressor A1 Loader No Action
LOADR_A2 Compressor A2 Loader No Action
LOADR_B1 Compressor B1 Loader No Action
LOADR_B2 Compressor B2 Loader No Action
LMT_MA Demand Limit 4-20 mA Input Disable function
LOR_SW Local/Off/Remote Switch Chiller shut down
MLV_A Min. Load Valve Relay Circuit A Disable function
MLV_B Min. Load Valve Relay Circuit B Disable function
MOTOR_A Circuit A MotormasterT Output Disable function
MOTOR_B Circuit B Motormaster Output Disable function
MTRCL_A1 Compressor A1 Motor Cooling Compressor shut down
MTRCL_A2 Compressor A2 Motor Cooling Compressor shut down
MTRCL_B1 Compressor B1 Motor Cooling Compressor shut down
MTRCL_B2 Compressor B2 Motor Cooling Compressor shut down
OAT Outside Air Temperature Disable function
OIL_A1 Compressor A1 Oil Pressure Transducer Compressor shut down
OIL_A2 Compressor A2 Oil Pressure Transducer Compressor shut down
OIL_B1 Compressor B1 Oil Pressure Transducer Compressor shut down
OIL_B2 Compressor B2 Oil Pressure Transducer Compressor shut down
OILA_HTR Circuit A Oil Heater Disable function
OILA_SW Circuit A Oil Level Circuit shut down
OILB_HTR Circuit B Oil Heater Disable function
OILB_SW Circuit B Oil Level Circuit shut down
OILPMP_A Circuit A Oil Pump No Action
OILPMP_B Circuit B Oil Pump No Action
OILSOL_A Circuit A Oil Solenoid Circuit shut down
OILSOL_B Circuit B Oil Solenoid Circuit shut down
P_REF 5 Volt Transducer Reference Chiller shut down
RALARMx Remote Alarm Relay x (1-16) Disable function
RST_MA Temp. Reset 4-20 mA signal Disable function
SPA Circuit A Suction Transducer Circuit shut down
SPB Circuit B Suction Transducer Circuit shut down
TLEV_A Circuit A Cooler Level Sensor Control EXV-A by discharge superheat
TLEV_B Circuit B Cooler Level Sensor Control EXV-B by discharge superheat
TMTR_A1 Compressor A1 Motor Thermistor Compressor shut down
TMTR_A2 Compressor A2 Motor Thermistor Compressor shut down
TMTR_B1 Compressor B1 Motor Thermistor Compressor shut down
TMTR_B2 Compressor B2 Motor Thermistor Compressor shut down
T_SPACE External Space Temp Thermistor Disable function
VALVE_A Circuit A Water Valve Control Circuit shut down
VALVE_B Circuit B Water Valve Control Circuit shut down
49
Table 35 — Illegal Configurations Recognized it reaches the top of its stroke (can be heard if
by PSIO-1 surroundings are relatively quiet). Press again if
CODE ILLEGAL CONFIGURATION necessary to confirm this. Press four times to step
NUMBER DESCRIPTION
the actuator closed in 25% increments, waiting again in be-
1 Incorrect Check Sum in configuration code tween each move. The actuator should knock when it reaches
(factory or service code)
the bottom of its stroke. If it is believed that the valve is not
2 Unit type outside range of (1-3)
working properly, continue with the checkout procedure
3 Number of compressors in a circuit outside the below:
range of 0-2
Air cooled chiller with a fan type outside the Check the EXV output signals at appropriate terminals
4 range of 1-16 on EXV driver module (see Fig. 12). Connect positive test
Air cooled chiller with Low Temperature Brine lead to terminal 1 on the EXV driver for Circuit A and to
5
fluid terminal 7 for Circuit B. Set meter for approximately 20 vdc.
6
Water cooled chiller configured for air cooled Enter Valves and Motor Master test subfunction by pressing
head pressure on the HSIO. The EXV for Circuit A will be dis-
7 Selecting both OAT and Space Temp sensors
for External Reset operation played; if desired, press the down arrow key for Circuit B.
8 Air cooled chiller with condenser water pump When at the desired valve, press . The display should
9 Air cooled chiller with condenser thermistors
MOP Set point is outside the range of
change to show a Target Percent of 25%. The driver should
10 40 - 55 F (4.4 - 12.8 C) drive the circuit EXV under test. During the next several sec-
Maximum Condensing Temperature Set point onds, connect negative test lead to pins 2, 3, 4, and 5 in suc-
11 (MCT_SP) is outside the range of 0 - 158 F cession (pins 8, 9, 10 and 11 for Circuit B). Voltage should
(-17.8 - 70 C) rise and fall at each pin. If it remains constant at a voltage
LEGEND
or shows 0 volts, remove the connector to the valve and
recheck.
MOP — Minimum Operating Temperature
OAT — Outdoor-Air Temperature Press to close the circuit EXV. Check the DSIO
address setting (the address should be 50). If a problem still
EXD Troubleshooting Procedure — Follow steps exists, replace the EXV driver module. If the voltage read-
below to diagnose and correct EXV/Economizer problems. ing is correct, the expansion valve and EXV wiring should
On 30HX units with economizers, verify that the valve be checked. Check the EXV terminal strip and interconnect-
for the bubbler tube (bottom of economizer) is open. Check ing wiring.
EXV motor operation first. Press on the HSIO II 1. Check color coding and wire connections. Make sure they
keypad and select the appropriate EXV. Press to are connected to the correct terminals at the EXV driver
and EXV plug and that the cables are not crossed.
move the valve to 25%. You should be able to feel the ac-
tuator moving by placing your hand on the EXV or econo- 2. Check for continuity and tight connection at all pin
mizer body (the actuator is located about one-half to two- terminals.
thirds of the way up from the bottom of the economizer shell). Check the resistance of the EXV motor windings.
Press three more times until the display reads 100% Remove the DSIO-EXV plug J4 terminal strip and check the
resistance between the common lead (red wire, terminal D)
for a Target Percent (waiting until actuator stops each time). and remaining leads, A, B, C, and E (see Fig. 12). The re-
A hard knocking should be felt from the actuator when sistance should be 25 ohms ± 2 ohms.
EXV DRIVER BOARD, J4
1 D
1 RED
C
2 GRN
E EXV-A
3 WHT
B
4 BLK
A
5 BRN
2 D
7 RED
C
8 GRN
E
EXV-B
9 WHT
B
10 BLK
A
EXV — Electronic Expansion 11 BRN
Valve
Fig. 12 — EXV Cable Connections to EXV Driver Module, DSIO-EXV

50
INSPECTING/OPENING ELECTRONIC EXPANSION 2. Remove any remaining refrigerant from the system low
VALVES side and discharge piping using proper reclaiming tech-
niques. For 30GX units, there is no shutoff valve in the
IMPORTANT: Obtain replacement O-ring before open- bubbler tube line. Drain oil from cooler using Schrader
ing EXV. Do not reuse O-rings. port in cooler inlet line. Turn off the line voltage power
supply to the compressors and control circuit power.
To check the physical operation of an EXV, the following 3. Remove the shell retaining bolts on the bottom of the econo-
steps must be performed: mizer and the bolts that secure the shell to the unit frame
1. Close the liquid line service valve of the circuit to be checked. or mounting bracket. Cut the motor cooling line leaving
Put the LOR switch in the OFF position. Using the the top of the economizer. Carefully remove the shell from
HSIO, enter the manual service mode by pressing the economizer. Make sure EXV plug is still connected.
. Enable the mode by pressing . Switch
IMPORTANT: When removing shell from econo-
the LOR switch to the Local position. Scroll down to the mizer, it must be lifted off as close to vertical as
desired compressor and press to turn it on. Let possible to prevent damage to any of the internal
compressor run until gage on suction pressure port reads parts. Use a catch pan beneath the economizer as
oil will come out when the shell is removed. Be
between 5 and 10 psig. Press to turn the com- careful to avoid damage to motor leads.
pressor off. Immediately after the compressor shuts off,
close the discharge valve.
4. Enter the appropriate EXV test step for EXV-A or EXV-B
2. Remove any remaining refrigerant from the system low
side using proper reclaiming techniques. Drain oil from by pressing on the HSIO. Scroll down to display
cooler using Schrader port in cooler inlet line. Turn off the desired EXV. Press and to initiate the test.
the line voltage power supply to the compressors and con- Observe the operation of the valve motor and lead screw.
trol circuit power. The motor should turn counterclockwise, and the lead screw
3. Remove screws holding top cover of EXV. Carefully re- should move up out of the motor hub until the valve is
move the top cover from the EXV making sure EXV plug fully open. Lead screw movement should be smooth and
is still connected. uniform from fully closed to fully open position. Press
as needed to reach 100% open. Wait 30 seconds
IMPORTANT: When removing top cover from
EXVs, be careful to avoid damage to motor leads. in between each step for motor to stop moving. Press
to check open to closed operation. If the valve is
4. Enter the appropriate EXV test step for EXV-A or EXV-B properly connected to the processor and receiving correct
signals, yet does not operate as described above, the econo-
by pressing on the HSIO. Scroll down to display mizer should be replaced.
the desired EXV. Press and to initiate the test. 5. Additional items to check for:
Observe the operation of the valve motor and lead screw. a. Verify that float assembly (see cross section view in
The motor should turn counterclockwise, and the lead screw Fig. 13) moves up and down freely. It should take only
should move up out of the motor hub until the valve is a minimal force (less than one pound) to move the float
fully open. Lead screw movement should be smooth and and there should be no binding.
uniform from fully closed to fully open position. Press
b. Check the bubbler tube (found by carefully lifting the
as needed to reach 100% open. Wait 30 seconds float) for crimps, etc. and verify that the end of the
in between each step for motor to stop moving. Press tube is open.
to check open to closed operation. If the valve is 6. Reassemble economizer; retorque shell retaining bolts to
35 ft-lb (48 N-m).
properly connected to the processor and receiving correct
signals, yet does not operate as described above, the valve If operating problems persist after reassembly, they may
should be replaced. be due to a bad liquid level sensor, suction pressure trans-
ducer or intermittent connections between the processor board
terminals and EXV plug. Recheck all wiring connections and
INSPECTING/OPENING ECONOMIZERS — To check the voltage signals.
physical operation of an economizer (see Fig. 13), the fol-
lowing steps must be performed: Other possible causes of improper refrigerant flow con-
trol could be restrictions in the liquid line. Check for plugged
1. Close the liquid line service valve of the circuit to be checked. strainer(s) or restricted metering slots in the EXV or econo-
Put the LOR switch in the OFF position. Using the mizer. Formation of ice or frost on lower body of electronic
HSIO, enter the manual service mode by pressing expansion valve is one symptom of restricted metering slots.
. Enable the mode by pressing . Switch However, frost or ice formation is normally expected when
the LOR switch to the Local position. Scroll down to the leaving fluid temperature from the cooler is below 40 F. Clean
desired compressor and press to turn it on. Let or replace valve if necessary.
compressor run until gage on suction pressure port reads NOTE (non-economizer units only): Frosting of valve is nor-
between 5 and 10 psig. Press to turn the com- mal during compressor test steps and at initial start-up. Frost
should dissipate after 5 to 10 minutes operation in a system
pressor off. Immediately after the compressor shuts off, that is operating properly. If valve is to be replaced, wrap
close the discharge valve and the bubbler valve on 30HX valve with a wet cloth to prevent excessive heat from dam-
units (located in elbow fitting on condenser shell). aging internal components.
51
STEPPER MOTOR OUTLET FOR
MOTOR COOLING
LINE CONNECTION
STEPPER MOTOR
HARNESS
PIN RING
TUBE SHEET
MOUNTING
FLOAT BRACKET
ASSEMBLY BOLTS
DISCHARGE GAS
BUBBLER TUBE
SHELL BOLTS
PIN
LIQUID INLET
OUTLET TO BOTTOM TUBE FROM
OF COOLER CONDENSER
Fig. 13 — 30GX,HX Cutaway View of

Economizer Assembly RING TUBE
SERVICE
PIN AND RING INSTALLED
Servicing Coolers and Condensers — When cooler Fig. 14 — Tube Plugging
heads and partition plates are removed, tube sheets are ex-
posed showing the ends of tubes. The 30GX,HX units use a
flooded cooler design. Water flows inside the tubes. Table 36 — Plugging Components
TUBE PLUGGING — A leaky tube can be plugged until
COMPONENTS FOR PLUGGING PART NUMBER
retubing can be done. The number of tubes plugged deter-
mines how soon the cooler must be retubed. All tubes in the For Tubes
Brass Pin 853103-1A*
30GX and 30HX coolers and 30HX condensers can be re- Brass Ring 853002-640*
moved. Loss of unit capacity and efficiency as well as in- For Holes without Tubes
creased pump power will result from plugging tubes. Failed Brass Pin 853103-1A*
tubes should be replaced as soon as possible. Up to 10% of Brass Ring 853002-738*
the total number of tubes can be plugged before retubing is Roller Extension S82-112/11
necessary. Figure 14 shows an Elliot tube plug and a cross- Loctite No. 675†
sectional view of a plug in place. The same components for Locquic ‘‘N’’†
plugging and rolling tubes can be used for all coolers and *Order directly from: Elliot Tube Company, Dayton, Ohio.
30HXC condensers. See Table 36. †Can be obtained locally.
Table 37 — Tube Diameters

Use extreme care when installing plugs to prevent dam- ITEM INCHES MILLIMETERS
age to the tube sheet section between the holes. Tube sheet hole diameter: 0.756 19.20
Tube OD 0.750 19.05
Tube ID after rolling: 0.704 17.88
RETUBING (See Table 37) — When retubing is to be done, (includes expansion to to
obtain service of qualified personnel experienced in boiler due to clearance) 0.710 18.03
maintenance and repair. Most standard procedures can be fol- NOTE: Tubes replaced along heat exchanger head partitions must
lowed when retubing the 30GX and 30HX heat exchangers. be flush with tube sheet.
A 7% crush is recommended when rolling replacement tubes TIGHTENING COOLER/CONDENSER HEAD BOLTS
into the tubesheet. A 7% crush can be achieved by setting
the torque on the gun at 48 to 50 in.-lb (5.4 to 5.6 N-m). O-Ring Preparation — When reassembling cooler and con-
The following Elliot Co. tube rolling tools are required: denser heads, always check the condition of the O-ring(s)
first. The O-ring should be replaced if there are any visible
B3400 Expander Assembly B3405 Mandrel signs of deterioration, cuts or damage. Apply a thin film of
B3401 Cage B3408 Rolls grease to the O-ring before installation. This will aid in hold-
Place one drop of Loctite No. 675 or equivalent on top of ing the O-ring into the groove while the head is installed.
tube prior to rolling. This material is intended to ‘‘wick’’ into Torque all bolts to the following specification and in the
the area of the tube that is not rolled into the tube sheet, and sequence shown in Fig. 15.
3⁄4-in. Diameter Perimeter and
prevent fluid from accumulating between the tube and the
tube sheet. New tubes must also be rolled into the center Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . 200 to 225 ft-lb.
tube sheet to prevent circuit-to-circuit refrigerant leakage. (271 to 305 N-m)
52
10 9 11 9
6 5 6 5
BLANK PLATE
3 2 3 10 12 2
1 4 1 4
8 7 8 7
12 11 14 13
10 9 11 9
6 5 6 5
3 2 3 10 12 2
BLANK PLATES
1 4 1 4
12 14 16 14
8 7 8 7
13 11 13 15
Fig. 15 — Cooler and Condenser Head Recommended Bolt Torque Sequence
1. Install all bolts finger tight. may be dirty, or water flow may be incorrect. Due to the
2. Follow numbered sequence shown for head type being pressure in the R-134a system, air usually will not enter the
installed. This will apply even pressure to the O-ring. machine; the refrigerant will leak out.
3. Apply torque in one-third steps until required torque is During the tube cleaning process, use brushes specially
reached. Load all bolts to each one-third step before pro- designed to avoid scraping and scratching the tube wall. Con-
ceeding to the next one-third step. tact your Carrier representative to obtain these brushes. Do
not use wire brushes.
4. No less than one hour later, retighten all bolts to required
torque values.
5. Restore water/brine flow and check for leaks. Fix leaks
as necessary. Replace insulation (on cooler heads only). Hard scale may require chemical treatment for its pre-
vention or removal. Consult a water treatment specialist
Inspecting/Cleaning Heat Exchangers for proper treatment procedures.
COOLERS — Inspect and clean the cooler tubes at the end
of the first operating season. Because these tubes have in- Water Treatment — Untreated or improperly treated
ternal ridges, a rotary-type tube cleaning system is neces- water may result in corrosion, scaling, erosion, or algae. The
sary to fully clean the tubes. Tube condition in the cooler services of a qualified water treatment specialist should be
will determine the scheduled frequency for cleaning, and will obtained to develop and monitor a treatment program.
indicate whether water treatment is adequate in the chilled
water/brine circuit. Inspect the entering and leaving ther-
mistors for signs of corrosion or scale. Replace the sensor if Water must be within design flow limits, clean and treated
corroded or remove any scale if found. to ensure proper machine performance and reduce the
CONDENSERS (30HX Only) — Since this water circuit is potential of tubing damage due to corrosion, scaling, ero-
usually an open-type system, the tubes may be subject to sion, and algae. Carrier assumes no responsibility for
contamination and scale. Clean the condenser tubes with a chiller or condenser damage resulting from untreated or
rotary tube cleaning system at regular intervals, and more improperly treated water.
often if the water is contaminated. Inspect the entering and
leaving condenser water thermistors (if installed) for signs
of corrosion or scale. Replace the sensor if corroded or re- Condenser Coils (30GX Only)
move any scale if found. COIL CLEANING — Clean coils with a vacuum cleaner,
Higher than normal condenser pressures, together with in- fresh water, compressed air, or a bristle brush (not wire). Units
ability to reach full refrigeration load, usually indicate dirty installed in corrosive environments should have coil clean-
tubes or air in the machine. If the refrigeration log indicates ing as part of a planned maintenance schedule. In this type
a rise above normal condenser pressures, check the con- of application, all accumulations of dirt should be cleaned
denser refrigerant temperature against the leaving condenser off the coil.
water temperature. If this reading is more than what the de-
sign difference is supposed to be, then the condenser tubes
53
PLASTIC FAN
PROPELLER
Do not use high-pressure water or air to clean coils as

fin damage may result.
Condenser Fans (30GX Only) — Each fan is sup- CLEARANCE OF 0.25 INCHES
(6.4 MM) FOR STANDARD
ported by a formed wire mount bolted to a fan deck and CONDENSER FANS
covered with a wire guard. The exposed end of the fan
motor shaft is protected from weather by grease. If the fan FAN DECK
SURFACE
motor must be removed for service or replacement, be sure
to regrease fan shaft and reinstall fan cover, retaining clips,
and fan guard. For proper performance, the fans should be
positioned as shown in Fig. 16 or 17. Tighten setscrews to FAN ORIFICE
14 ± 1 ft-lb (18 ± 1.3 N-m).
Fig. 16 — Condenser Fan Position (Standard Fan)
Check for proper rotation of the fan(s) once reinstalled
(clockwise for high static and counterclockwise for standard MOTOR FAN HUB
viewed from above). If necessary to reverse, switch leads at SHAFT STATIC FAN
PROPELLER
contactor(s) in control box.
Refrigerant Charging/Adding Charge

2.15 IN.
IMPORTANT: These units are designed for use with
R-134a only. DO NOT USE ANY OTHER REFRIG-
ERANT in these units without first consulting your
Carrier representative. FAN DECK
SURFACE
POSITION TOP OF HIGH STATIC FAN PROPELLER HUB
2.15 INCHES (54.6 mm) ABOVE FAN DECK SURFACE
Fig. 17 — Condenser Fan Position (High Static Fan)

When adding or removing charge, circulate water through
the condenser (30HXC) and cooler at all times to pre-
vent freezing. Freezing damage is considered abuse and 5. If the refrigerant appears to be flashing, the circuit is prob-
may void the Carrier warranty. ably low on charge. Verify this by checking the EXV
Percent Open. This information can be accessed by
entering on the HSIO keypad for Circuit A, or
for Circuit B. Scroll down using the down arrow
DO NOT OVERCHARGE system. Overcharging re- key on the keypad, until EXV Percent Open is displayed.
sults in higher discharge pressure with higher cooling
fluid consumption, possible compressor damage and higher 6. If the EXV Percent Open is greater than 60%, and the
power consumption. liquid-line sight glass is flashing, then the circuit is low
on charge. Follow the procedure for adding charge for
Indication of low charge on a 30HXC system: 30HXC units.
NOTE: To check for low refrigerant charge on a 30HXC, To add charge to the 30HXC systems:
several factors must be considered. A flashing liquid-line sight 1. Make sure that the unit is running at full load, and that
glass is not necessarily an indication of inadequate charge. the cooler leaving fluid temperature is in the range of 42
There are many system conditions where a flashing sight glass to 46 F (5.6 to 7.8 C).
occurs under normal operation. The 30HXC metering de- 2. At these operating conditions, check the liquid line sight
vice is designed to work properly under these conditions. glass. If there is a clear sight glass, then the unit has suf-
1. Make sure that the circuit is running at a full-load con- ficient charge. If the sight glass is flashing, then check the
dition. To check whether circuit A is fully loaded, enter EXV Percent Open. If this is greater than 60%, then be-
on the HSIO keypad. The display will read gin adding charge.
‘‘CIRCUIT A ANALOG VALUES.’’ Using the down ar- NOTE: A flashing liquid line sight glass at operating con-
row key on the keypad, scroll down once to ‘‘Total ditions other than those mentioned above is not neces-
Capacity.’’ If this value is 100%, the circuit is at full load. sarily an indication of low refrigerant charge.
To check circuit B, follow the same procedure, but enter 3. Add 5 lb of liquid charge into the cooler using the 1⁄4-in.
on the keypad. Schrader-type fitting located on the tube entering the bot-
tom of the cooler. This fitting is located between the Elec-
2. It may be necessary to use the Manual Control feature to tronic Expansion Valve (EXV) (size 076-146 units), or
force the circuit into a full-load condition. If this is the the economizer (size 161-271 units) and the cooler.
case, see the instructions for using the Manual Control
feature in Table 19 of this manual. 4. Observe the EXV Percent Open value. The EXV should
begin closing as charge is being added. Allow the unit to
3. With the circuit running at full load, verify that the cooler stabilize. If the EXV Percent Open remains above 60%,
leaving fluid temperature is in the range of 38 to 46 F and the sight glass continues flashing, add an additional
(3.3 to 7.8 C). Check pressure drop across liquid line strainer 5 lb of liquid charge.
and replace strainer if necessary.
5. Allow the unit to stabilize, and again check the EXV Per-
4. At this condition, observe the refrigerant in the liquid line cent Open. Continue adding 5 lb at a time of liquid re-
sight glass. If there is a clear sight glass, and no signs of frigerant charge, and allow the unit to stabilize before
flashing, then the circuit is adequately charged. Skip the checking the EXV position.
remaining steps.
54
6. When the EXV Percent Open is in the range of 40 to 60%, 3. After running the unit for 11⁄2 hours, allow the unit to
check the liquid line sight glass. Slowly add enough ad- restart and run normally. If the Low Oil Level alarms
ditional liquid charge to ensure a clear sight glass. This persist, continue following this procedure.
should be done slowly to avoid over-charging the unit. 4. Close the liquid line service valve, and place a pressure
7. Verify adequate charge by continuing to run at full load gage on top of the cooler. Enable the manual control
with 42 to 46 F (5.6 to 7.8 C) cooler leaving fluid tem- feature using the HSIO keypad, and turn the LOR switch
perature. Check that the refrigerant is not flashing in the to local. Start the desired compressor by pressing
liquid-line sight glass. The EXV Percent Open should be on the keypad, at the appropriate line on the
between 40 and 60%. The cooler level indicator should
be in the range of 1.5 to 2.2. display.
Indication of low charge on a 30HXA, GX systems: 5. Before starting the compressor, the unit will go through
its normal pre-lube pump routine. If there is an insuf-
1. Make sure that the circuit is running at a full load con- ficient level of oil in the oil separator, the compressor
dition and all condenser fans are energized and running will not start, and a pre-start oil pressure alarm will be
at full speed. To check whether circuit A is fully loaded, posted. Skip to Step 8.
enter on the HSIO keypad. The display will read 6. If the compressor starts successfully, observe the cooler
‘‘CIRCUIT A ANALOG VALUES.’’ Using the down ar- pressure gage. When this gage reads approximately
row key on the keypad, scroll down once to ‘‘Total 10 psig, press on the HSIO keypad, and move
Capacity.’’ If this value is 100%, the circuit is at full load.
To check circuit B, follow the same procedure, but enter the LOR switch to the off position.
on the keypad. 7. Open the liquid line service valve and allow the unit to
restart and run normally. If the Low Oil Level alarms
2. It may be necessary to use the Manual Control feature to persist, continue following this procedure.
force the circuit into a full-load condition. If this is the
case, see the instructions for using the Manual Control 8. If none of the previous steps were successful, the unit is
feature in Table 19 on page 31 of this manual. low on oil charge. Add oil to the oil separator using the
1⁄4-in. Schrader-type fitting on the discharge line enter-
3. With the circuit running at full-load, verify that the cooler ing the top of the oil separator (30HX units) or through
leaving fluid temperature is in the range of 38 to 48 F the Schrader fitting on the top of the oil separator (30GX
(5.6 to 7.8 C). units).
4. For 30HXA chillers, raise the compressor discharge to
approximately 125 F (51.7 C) saturated discharge tem-
perature (185 psig [1276 kPa]). For 30GX chillers, raise
the compressor discharge to approximately 130 F Do not add oil at any other location as improper
(54.4 C) saturated discharge temperature (198 psig unit operation may result.
[1366 kPa]). Measure the liquid temperature entering the 9. Make sure that the unit is not running when adding oil,
expansion device for 30HXA units. For 30GX units, mea- as this will make the oil charging process easier. Be-
sure the liquid temperature after the tee where all liquid cause the system is under pressure even when the unit
lines have joined. The liquid temperature should be ap- is not running, it will be necessary to use a suitable pump
proximately 107 F (41.7 C) for optimum charge. If the (hand pump or electric pump) to add oil to the system.
temperature is greater than 107 F (41.7 C) and the sight
glass is flashing, the circuit is undercharged. 10. Using a suitable pump, add 1⁄2 gal. (1.89 L) of Castrol
Icematict SW-220 Polyolester oil (Carrier Specifica-
5. Add 5 lb of liquid charge into the cooler using the 1⁄4-in. tion number is PP47-32; absolutely no substitutes are
Schrader-type fitting located on the tube entering the bot- approved) to the system. Make sure that the oil level
tom of the cooler. This fitting is located between the Elec- safety switch is NOT jumpered, and allow the unit to
tronic Expansion Valve (EXV) (30HXA076-146 units, restart and run normally. Do not exceed maximum oil
30GX080-090 units), or the economizer (30HXA161- change. See Table 38.
271 units, 30GX105-176 units) and the cooler.
11. If low oil level problems persist, add another 1.89 L
6. Allow the system to stabilize and then recheck the liquid (1⁄2 gal.) of oil. Continue adding oil in 1.89 L (1⁄2 gal.)
temperature. Repeat Step 5 as needed allowing the sys- increments until the problem is resolved. If it is neces-
tem to stabilize between each charge addition. Slowly add sary to add more than 5.75 L (1.5 gallons) of oil to the
charge as the sight glass begins to clear to avoid system, contact your Carrier distributor service
overcharging. department.
Oil Charging/Low Oil Recharging Table 38 — Maximum Oil Charges
Addition of oil charge to 30HX,GX systems:
UNIT CIRCUIT A CIRCUIT A CIRCUIT B CIRCUIT B
1. If the 30HX,GX unit shuts off repeatedly on Low Oil SIZE (gal) (L) (gal) (L)
Level (Alert number 71 or 72), this may be an indica- 30GX080-176 5.0 18.9 5.0 18.9
tion of inadequate oil charge. It could also mean simply 30GX205-265 7.0 26.5 5.0 18.9
that oil is in the process of being reclaimed from the 30HXA076-186 5.0 18.9 5.0 18.9
low-side of the system. 30HXC076-186 4.5 17.0 4.5 17.0
2. Begin by running the unit at full load for 11⁄2 hours. Use 30HXC206-271 7.5 28.4 5.0 18.9
the Manual Control feature of the software if the unit
does not normally run at full load.
55
Oil Filter Maintenance — Each compressor has its own 2. Close the discharge and liquid valve(s), suction valve,
internal oil filter and each circuit also has an in-line external and cooler inlet line service valve (if equipped), oil line
filter. The internal oil filter pressure drop should be checked shutoff valve, economizer bubble tube valve
and filter changed (if necessary) after the initial 200-300 hours (30HXA,C161-271 only) and minimum load shutoff valve
of compressor operation. It is recommended that oil line pres- (if equipped) for circuit to be changed. Disconnect the
sure loss checks be made on an annual basis thereafter to oil inlet line from the compressor. Disconnect oil filter
determine the need for filter changes. The need for filter main- with fitting at shutoff valve side and set filter and com-
tenance can be monitored through system pressure drop. Dis- pressor inlet line assembly aside.
charge pressure is read at the oil separator and oil pressure 3. Remove any remaining refrigerant in the compressor and
is read at the compressor. This pressure differential is typi- refrigerant lines using proper reclaiming techniques. All
cally 15 to 20 psi (103 to 138 kPa) for a system with clean of the refrigerant that is in the cooler must be removed
internal and external filters. See Pressure Transducers sec- if there is no suction service valve installed on the cooler.
tion, page 59 for information on removing discharge pres-
sure transducers to measure discharge pressure. Figure 18 IMPORTANT: Cooler and condenser pumps must
shows the location of the oil pressure bleed port on the com- be energized. Fluid must be flowing through heat
pressor. A gage can be attached to this point so that two pres- exchangers whenever adding or removing charge.
sure drops can be measured. The difference between discharge
pressure and the gage pressure will be the pressure loss due
mainly to the external oil filter. If this value exceeds 10 psi 4. Remove junction box cover of compressor to be changed.
(69 kPa), replace the external filter. The difference between Check main power leads for marked numbers. If no num-
the gage pressure and compressor oil pressure is the pres- bers are visible on leads, mark leads with appropriate
sure drop through the internal oil filter. Replace the internal numbers to match those printed on the ends of the ter-
oil filter if the pressure drop is greater than 30 psi (207 kPa). minal lugs. This is extremely important as power leads
MUST be installed on the exact terminals from which
REPLACING THE EXTERNAL OIL FILTER they were removed.
5. Disconnect main power leads from compressor terminal
lugs. Mark remaining control circuit wires (connected
together with wire nuts) for ease of reconnecting later.
Compressor oil is pressurized. Use proper safety pre- The following color scheme applies (verify with label
cautions when relieving pressure. diagram on panel):
Loader 1 2 Violet wires
Fully front seat (close) the angle valve on the filter. Connect Loader 2 2 Pink wires
a charging hose to the oil pressure bleed port and drain the Motor Cooling Solenoid 1 Blue wire, 1 Brown wire *
oil trapped between the filter and the internal check valve. Oil Solenoid 1 Orange wire, 1 Brown wire*
Use the function to cycle the oil solenoid a few times High-Pressure Switch 2 Red wires
to properly seat the internal check valve as the pressure is *One lead from the motor cooling and oil solenoids are con-
being relieved. If the oil pressure does not bleed off using nected together with a single brown wire.
this method it will be necessary to remove the entire circuit 6. Remove loader (mark solenoids no. 1 and 2 for replace-
charge. A pint of oil is typically what is removed during this ment) and oil solenoids and high-pressure switch from
process. Remove the charging hose. compressor. Using 2 wrenches, carefully remove the oil
Unscrew the nut from the other side of the filter and remove pressure transducer from the compressor. These will all
the old filter. Remove protective plastic caps from new filter be reconnected to the replacement compressor.
and install. Draw a vacuum at the bleed port. Remove charg- NOTE: Some oil will leak out of the transducer fitting
ing hose. Open angle valve enough to let oil flow. Check when the transducer is removed. See Fig. 18.
both fittings for leaks and repair if necessary. Backseat angle 7. Mark motor temperature leads (2 blue wires) and re-
valve. move from quick connect terminals in the junction box.
REPLACING THE INTERNAL OIL FILTER — Follow the
procedure above to the point that the oil has been drained
from the bleed port. Using a 3⁄4-in. allen wrench, remove the
internal filter access cover (see Fig. 18). Remove the old fil- The next steps involve compressor unbolting and
ter. Replacement filters (one for each compressor) are fac- removal. Compressor seals are made using O-rings.
tory supplied to cover the first changeout. After that, filters Use care when removing bolts and disconnecting
are field supplied. Remove the old O-ring from internal check flanges. The O-rings must NOT be re-used. New
valve. Lightly oil O-ring and install into groove. Install new O-rings are provided with the replacement com-
filter open end first into the housing. Replace access cover pressor. The 06N screw compressors weigh ap-
and retorque to 150 ft-lb (203 N-m). Follow procedure in proximately 900 pounds. Be sure that an appro-
previous section for opening angle valve and purging lines. priate lifting cart or hoist is used to avoid injury.
Check for leaks and repair if necessary. See Fig. 19 for lifting locations and center of grav-
ity dimensions. Make sure compressor is properly
Compressor Changeout Sequence rigged before unbolting.
NOTE: Replacement compressors can be ordered by calling
800-CARLYLE (800-227-5953). In most cases, replace- 8. Remove the 2 bolts securing the motor cooling/economizer
ment compressors can be shipped in 1 to 2 business days. line flange to the compressor.
Compressor service requires metric tools and hardware.
Change compressors according to the following procedure:
1. Turn off all main and control circuit power supplying
the machine.
56
9. Remove the four M14 bolts securing the discharge line OIL PRESSURE JUNCTION BOX
flange to the compressor. Two of the bolts also secure TRANSDUCER
OIL BLEED PORT
the mounting bracket for the external oil filter. Support INTERNAL OIL
OIL
the oil line to prevent damage to the line while the com- SOLENOID FILTER ACCESS
pressor is being changed. For 30GX units, place tem- (3/4 in.)
porary protection over coils to prevent fin and tube damage. LOADER
LOADER
SOLENOID
SOLENOID
10. Move lifting apparatus into place and attach to the 2 lift- NO. 2
NO. 1
ing rings on the compressor. Apply minimal tension to
hold the compressor while the remaining bolts are LOADER
removed. COVER HIGH
PLATE PRESSURE
11. Remove the 3⁄8-in. holddown bolt securing the foot at SWITCH
the discharge end of the compressor to the mounting bracket
on the cooler. A foot bracket will be mounted to the re- Fig. 18 — Transducer Removal
placement compressor.
12. Remove the 4 lockwashers and nuts securing the com- ONE LUG AT OUTSIDE EDGE, RING AT
pressor to the suction flange of the cooler. The compres- DISCHARGE CENTER
sor is held in place using four M14 x 2 studs through
the suction nozzle of the cooler. The studs have an E-12 COMPRESSOR LIFTING MECHANISM
external Torx drive head. If possible, remove studs; if
studs hit the cooler insulation, leave them in place — CENTER OF GRAVITY
OF COMPRESSOR
they will not interfere with compressor removal or in-
stallation. Save all the hardware as it will be needed to DISCHARGE END GEAR COVER END
install the replacement compressor.
13. After checking to ensure all lines, wires, conduits, etc.
are free and out of the way, remove compressor from
508 mm
cooler. Apply a light film of O-ring grease to new O-ring (20.0 in.)
and place back into groove in mounting flange of com-
pressor. If the new compressor is the A1 or A2 (30HX
units) compressor, remove the compressor junction box
and rotate it 180 degrees. Tighten screws to 6.8 to 178 mm
95 mm
9.5 N-m (5 to 7 ft-lb). The A1 and A2 compressors are (3.75 in.) (7.0 in.)
on the right side of the unit when facing the unit control
box. LIFTING LUGS BOTH OUTSIDE EDGES
14. Remove suction cover plate and bolts from new com-
pressor and set compressor on unit flange. Thread the COMPRESSOR LIFTING MECHANISM
studs all the way back into the compressor. Install CENTER OF GRAVITY
the 4 lockwashers and nuts finger-tight. Tighten bolts OF COMPRESSOR
in a crossing pattern to a range of 81.4 to 135.6 N-m
(60 to 100 ft-lb). Do NOT overtighten as damage may DISCHARGE END GEAR COVER END
result to O-ring. Install and tighten hold down bolt in MINIMUM MINIMUM
mounting foot. 381 mm 381 mm
(15 in.) (15 in.)
15. Remove motor cooling/economizer and discharge line
cover plates from new compressor.
16. Apply a light film of O-ring grease to motor cooling/
economizer and discharge line O-rings, place back into
grooves and install flange bolts. Tighten discharge line
NOTE: Locate strap from center of gravity lifting ring and support mo-
bolts in a crossing pattern to a range of 81.4 to tor casing to provide 3-point level rigging.
135.6 N-m (60 to 100 ft-lb). Tighten motor cooling/
economizer bolts to a range of 81.4 to 108.5 N-m (60 to Fig. 19 — Compressor Lifting Diagrams
80 ft-lb). Do NOT overtighten as damage may result to
O-rings.
RED HPS RRS RED
17. Reconnect the oil filter to the shutoff valve and oil line
to the compressor. Install oil line straight into fitting un- PL1-5 PL1-6
til ferrule seats against fitting. Thread packing nut onto LEGEND
fitting and tighten finger tight. Use a backup wrench to HPS — High-Pressure Switch
finish tightening the nut. Do not overtighten. PL — Plug
18. Reinstall the loader and oil solenoids, high-pressure switch, RRS — Reverse Rotation Switch
and oil pressure transducer. Make sure the loader sole- Fig. 20 — High-Pressure Switch Wiring
noids are installed on the correct number loader.
19. Reconnect conduits back into compressor junction box. 20. Leak check compressor and refrigerant lines with nitro-
Reconnect all wiring that was removed in Steps 4, 5, gen. Repair any leaks found. Remove nitrogen from sys-
and 7. The replacement compressor comes with a re- tem. Evacuate compressor and refrigerant lines. Refer
verse rotation switch. This switch must be wired in se- to the Refrigerant and Oil Charging sections on
ries with the high-pressure switch for compressor pro- pages 54 and 55 for recharging procedures.
tection. Reconnect these wires as shown in Fig. 20. 21. Open all shutoff valves and leak check the circuit and
all fittings and joints. Repair any leaks found.
57
22. Restore main and control power to the machine. Using Use the Carrier Standard Service Techniques Manual as
the HSIO, enter the quick test function by pressing a source of reference.
(for compressor A1 or A2 replacement) or
Moisture-Liquid Indicator — Clear flow of liquid
(for compressor B1 replacement). Test the op- refrigerant indicates sufficient charge in the system. Note,
eration of the solenoids. Press to test each loader however, that bubbles in the sight glass do not necessarily
indicate insufficient charge. Moisture in the system
solenoid, then use the key to find the motor cool- is measured in parts per million (ppm), changes of color of
ing and oil solenoids and test them in the same manner. indicator are:
Pressing the key after each output turns the
Green — moisture is below 80 ppm;
solenoid off (or press ). It is important that the Yellow-green (chartreuse) — 80 to 225 ppm (caution);
loaders are located properly (loader 1 on right hand side Yellow (wet) — above 225 ppm.
when viewed from side opposite control box on 30HX Change filter drier at the first sign of moisture in the
units, on left hand side when reaching over compressor system.
to far side on 30GX units).
23. Start the compressor using the Manual mode. Press IMPORTANT: Unit must in operation for at least
at the HSIO. Press to enable the Manual 12 hours before moisture indicator can give an accu-
mode. When display changes to ‘‘Enable,’’ switch the rate reading. With the unit running, the indicating el-
Local-Off-Remote switch to the Local position. Select ement must be in contact with liquid refrigerant to give
the desired compressor using the down arrow key. Press true reading.
to start the compressor. Use the down arrow
key and press to energize both loaders. Let the Filter Drier — Whenever moisture-liquid indicator shows
circuit stabilize with both loaders energized. Refer to the presence of moisture, replace filter drier. Refer to Carrier
Refrigerant and Oil Charging sections of this document Standards Service Technique Manual, Chapter 1, Refrig-
for recharging procedures and performance criteria. erants, for details on servicing filter driers.
BURNOUT CLEANUP PROCEDURE — If a screw com- Liquid Line Service Valve — This valve is located
pressor motor burns out on a 30GX,HX chiller, a simple cleanup ahead of the filter drier and provides a 1⁄4-in. Schrader con-
should be performed. The following procedure provides the nection (30GX only) for field charging. In combination with
minimum steps to be taken before restarting the circuit. compressor discharge service valve, each circuit can be pumped
down into the high side for servicing.
1. Remove the oil from the oil separator. This can be fa-
cilitated by connecting a hose to the port located on the Thermistors — To aid in verifying thermistor perfor-
service valve entering the external oil filter. Run the hose mance, resistances at various temperatures are listed for all
to a container(s) that can hold up to 5 to 6 gallons of oil. thermistors (except motor thermistors) in Tables 39A and 39B.
To force out most of the oil in the separator pressurize See Table 40 for motor thermistor values.
the circuit. To remove the remaining oil, the pre-lube
LOCATION — General location of thermistor sensors and
pump can be run in mode from the HSIO. To pre- terminal connections in the control box are listed in Table 2.
vent wear to the gears, do not allow the pre-lube pump
to operate ‘‘dry.’’ THERMISTOR REPLACEMENT
2. Remove the failed compressor following the Compres-
sor Changeout Sequence procedure above.
3. Once the compressor is removed access the oil catch pan
through the cooler-compressor mounting flange. Clean Liquid level thermistors are installed in the top of the
out any debris which may have collected in the oil catch cooler using compression fittings. All other thermistors
pan. are installed in wells and will slide out of the wells eas-
4. Install a new compressor. ily. The wells are under refrigerant pressure (cooler EWT
5. To dilute and remove any residual oil left in the sepa- and LWT are under waterside pressure) and do not need
rator, pump approximately 1⁄2 gallon of compressor oil to be removed to replace a faulty thermistor.
into the oil separator using the Schrader port located on To replace thermistors T1, T2, T5, or T6 (Entering,
top of the separator (30GX) or on the discharge line (30HX) Leaving Water; Discharge Gas Temperature):
and remove using the pre-lube pump described in
Step 1. Disconnect appropriate wires from PSIO-2 in unit control
box. Remove thermistor cable from harness. Remove and
6. Disconnect the hose from the external oil filter service discard original thermistor from well. Insert new thermistor
valve. in well body to its full depth. Add a small amount of thermal
7. Install a new filter drier and compressor external oil conductive grease to thermistor probe and well. Thermistors
filter. are friction-fit thermistors and will slip back into well lo-
8. Measure in the amount of Castrol SW 220 Polyolester cated at the cooler head (T1, T2) or at the top of the con-
oil as specified on the nameplate of the chiller. denser shell (T5, T6). Secure thermistor to well body with a
wire tie to prevent thermistor from working its way out of
9. Leak check, evacuate and recharge the machine as de- the well. See Fig. 21.
scribed in this manual with the amount of R-134a stated
on the chiller nameplate. To replace thermistors T3 or T4 (Liquid Level Sensors):
10. Perform periodic acid checks on the circuit and change See the Inspecting/Opening Economizers section on
the filter drier in the motor cooling line as necessary. page 51 for information on transferring the refrigerant charge
58
to the high side. Transfer refrigerant and reclaim any refrig- ambient temperature when calibrating. Calibrating a trans-
erant remaining in the low side. ducer when the system is under nitrogen charge will result
in an incorrect offset being applied to the reading (due to
NOTE: A new packing nut and ferrule will be required as temperature correction). Although these transducers are cali-
the old one is not removable from the old thermistor. brated at the factory, replacement transducers require cali-
For 30GX080-176 and all 30HX units cut wire nuts apart bration for accurate readings. Calibration is also required when
to appropriate blue leads at PSIO-1 (J7-5,6 for T3; J7-8,9 for replacing a PSIO. Access to the transducer calibration area
T4) and red leads connecting wires to TRAN-7. Remove old is through the Service function and the transducers can
leads from control box harness. For 30GX205-265 units, dis- be calibrated at the current system pressure using a pressure
connect plug assembly at liquid level sensor. Loosen the pack- gage at the same point or exposed to atmospheric pressure.
ing nut fully from the well threads. Remove and discard old In the example in Table 42, the Circuit A Discharge Pressure
thermistor and packing nut. Slide new packing nut then fer- transducer has been replaced and needs to be calibrated. A
rule up onto new thermistor probe from inserted end. Inser- pressure gage has been installed at the transducer and reads
tion depth is dependent on unit model number. See Fig. 22 85 psi (must be in the range of −5.0 to 185.0 psi). See
and Table 41. Table 42.
Hand tighten packing nut to position ferrule while hold-
ing thermistor in position. With wrench, tighten enough to
firmly secure thermistor in place in well. Run new harness Use care when removing the oil pressure transducers from
wires into main control box for 30GX080-176 and all 30HX the compressor fitting. The fitting that the transducers
units. Reconnect blue wires at PSIO-1 for thermistor read- mount in is sealed with an O-ring Schrader fitting into
ing and red wires to TRAN-7. Reconnect plug assembly to the compressor casting. Do NOT overtigthen the trans-
new liquid level sensor for 30GX205-265 units. Restore unit ducer when replacing after calibration. Hold both fit-
control power only and verify that level thermistor is read- tings with wrenches when removing and reinstalling.
ing correctly. Check system low side for leaks and repair as
necessary. Evacuate low side and open circuit discharge and
liquid valves. The control will apply the 0.8 psi offset from the calibra-
To service compressor motor thermistors: tion example in Table 42 to all future readings. The cali-
bration process for any of the other pressure transducers is
Two thermistors are factory installed in each compressor. done in a similar manner. A transducer can also be calibrated
Connections for the thermistors are located in the compres- at atmospheric pressure by removing the transducer from the
sor junction box. There are 3 terminals for the thermistors: system. To do this, carefully unplug the transducer connec-
S1, S2, and C. Motor temperature is measured by leads con- tor. Unscrew the transducer from its mounting location and
nected to one of the S terminals and the C terminal. If a com- reconnect the connector. Follow the steps in Table 42 to read
pressor motor thermistor failure occurs, verify that there is the current pressure and enter 0.0 psig as the gage pressure.
a true short or open circuit at these terminals. If one of the Remove the connector from the transducer, thread the trans-
thermistors fails, disconnect and relocate the wire on one of ducer back onto the fitting from which it was removed (do
the S terminals to the other S terminal (S1 to S2 or S2 to S1). NOT use thread sealant/compound), and reinstall the
The thermistors are not serviceable in the field. If both of the connector.
compressor motor thermistors fail, compressor replacement
is required. See Table 40 for motor thermistor temperature If it is necessary, all of the transducers may be calibrated
and resistance values. at 0.0 psig. All of the transducers must be removed from the
system and reconnected in atmosphere as described.
Pressure Transducers — A single style of pressure When complete, scroll down under to ‘‘Calibrate
transducer is used for both high- and low-pressure sensing
on the 30GX,HX chillers. The transducers operate on a All at 0 PSIG’’ and press . A ‘‘Yes’’ will be dis-
5 vdc supply. The power supply for this is a 24 vac to played at this step and will automatically change back to ‘‘No’’
5 vdc full wave rectified power supply, PS1. See unit com- once all transducers have been successfully calibrated. Re-
ponent arrangement label for mounting location and termi- connect the transducers and connectors as described above.
nal connections in the control box. Refer to Fig. 23A and All transducers are mounted on Schrader fittings. Therefore,
23B for pressure transducer locations. it is NOT necessary to remove system refrigerant charge.
Use a catch pan when removing the oil pressure transducer
PRESSURE TRANSDUCER CALIBRATION — Pressure for calibration as oil will leak out through the Schrader
transducers are factory installed on all models to read Dis- fitting.
charge, Suction, Economizer (reads leaving condenser pres- TROUBLESHOOTING — If transducer is suspected of be-
sure on models without economizer), and Oil pressure. DO ing faulty, first check supply voltage to transducer. Supply
NOT attempt to calibrate any of these transducers by the pres- voltage should be 5 vdc ± .2 v. If supply voltage is correct,
sure gage method unless the transducer is connected to a fully compare pressure reading displayed on keypad and display
charged refrigerant system. A more accurate method of cali- module against pressure shown on a calibrated pressure gage.
bration is used by the 30GX,HX software and corrects for If the 2 pressure readings are not reasonably close, replace
pressure transducer.
59
Table 39A — Thermistor Temperatures (°F) vs Resistance/Voltage Drop
(NOTE: These values do NOT Apply to the Motor Temperature Thermistors )
TEMP VOLTAGE RESISTANCE TEMP VOLTAGE RESISTANCE TEMP VOLTAGE RESISTANCE
(F) DROP (Ohms) (F) DROP (Ohms) (F) DROP (Ohms)
(V) (V) (V)
−25 4.821 98,010 59 3.437 7,868 143 1.250 1,190
−24 4.818 94,707 60 3.409 7,665 144 1.230 1,165
−23 4.814 91,522 61 3.382 7,468 145 1.211 1,141
−22 4.806 88,449 62 3.353 7,277 146 1.192 1,118
−21 4.800 85,486 63 3.323 7,091 147 1.173 1,095
−20 4.793 82,627 64 3.295 6,911 148 1.155 1,072
−19 4.786 79,871 65 3.267 6,735 149 1.136 1,050
−18 4.779 77,212 66 3.238 6,564 150 1.118 1,029
−17 4.772 74,648 67 3.210 6,399 151 1.100 1,007
−16 4.764 72,175 68 3.181 6,238 152 1.082 986
−15 4.757 69,790 69 3.152 6,081 153 1.064 965
−14 4.749 67,490 70 3.123 5,929 154 1.047 945
−13 4.740 65,272 71 3.093 5,781 155 1.029 925
−12 4.734 63,133 72 3.064 5,637 156 1.012 906
−11 4.724 61,070 73 3.034 5,497 157 0.995 887
−10 4.715 59,081 74 3.005 5,361 158 0.978 868
−9 4.705 57,162 75 2.977 5,229 159 0.962 850
−8 4.696 55,311 76 2.947 5,101 160 0.945 832
−7 4.688 53,526 77 2.917 4,976 161 0.929 815
−6 4.676 51,804 78 2.884 4,855 162 0.914 798
−5 4.666 50,143 79 2.857 4,737 163 0.898 782
−4 4.657 48,541 80 2.827 4,622 164 0.883 765
−3 4.648 46,996 81 2.797 4,511 165 0.868 750
−2 4.636 45,505 82 2.766 4,403 166 0.853 734
−1 4.624 44,066 83 2.738 4,298 167 0.838 719
0 4.613 42,679 84 2.708 4,196 168 0.824 705
1 4.602 41,339 85 2.679 4,096 169 0.810 690
2 4.592 40,047 86 2.650 4,000 170 0.797 677
3 4.579 38,800 87 2.622 3,906 171 0.783 663
4 4.567 37,596 88 2.593 3,814 172 0.770 650
5 4.554 36,435 89 2.563 3,726 173 0.758 638
6 4.540 35,313 90 2.533 3,640 174 0.745 626
7 4.527 34,231 91 2.505 3,556 175 0.734 614
8 4.514 33,185 92 2.476 3,474 176 0.722 602
9 4.501 32,176 93 2.447 3,395 177 0.710 591
10 4.487 31,202 94 2.417 3,318 178 0.700 581
11 4.472 30,260 95 2.388 3,243 179 0.689 570
12 4.457 29,351 96 2.360 3,170 180 0.678 561
13 4.442 28,473 97 2.332 3,099 181 0.668 551
14 4.427 27,624 98 2.305 3,031 182 0.659 542
15 4.413 26,804 99 2.277 2,964 183 0.649 533
16 4.397 26,011 100 2.251 2,898 184 0.640 524
17 4.381 25,245 101 2.217 2,835 185 0.632 516
18 4.366 24,505 102 2.189 2,773 186 0.623 508
19 4.348 23,789 103 2.162 2,713 187 0.615 501
20 4.330 23,096 104 2.136 2,655 188 0.607 494
21 4.313 22,427 105 2.107 2,597 189 0.600 487
22 4.295 21,779 106 2.080 2,542 190 0.592 480
23 4.278 21,153 107 2.053 2,488 191 0.585 473
24 4.258 20,547 108 2.028 2,436 192 0.579 467
25 4.241 19,960 109 2.001 2,385 193 0.572 461
26 4.223 19,393 110 1.973 2,335 194 0.566 456
27 4.202 18,843 111 1.946 2,286 195 0.560 450
28 4.184 18,311 112 1.919 2,239 196 0.554 445
29 4.165 17,796 113 1.897 2,192 197 0.548 439
30 4.145 17,297 114 1.870 2,147 198 0.542 434
31 4.125 16,814 115 1.846 2,103 199 0.537 429
32 4.103 16,346 116 1.822 2,060 200 0.531 424
33 4.082 15,892 117 1.792 2,018 201 0.526 419
34 4.059 15,453 118 1.771 1,977 202 0.520 415
35 4.037 15,027 119 1.748 1,937 203 0.515 410
36 4.017 14,614 120 1.724 1,898 204 0.510 405
37 3.994 14,214 121 1.702 1,860 205 0.505 401
38 3.968 13,826 122 1.676 1,822 206 0.499 396
39 3.948 13,449 123 1.653 1,786 207 0.494 391
40 3.927 13,084 124 1.630 1,750 208 0.488 386
41 3.902 12,730 125 1.607 1,715 209 0.483 382
42 3.878 12,387 126 1.585 1,680 210 0.477 377
43 3.854 12,053 127 1.562 1,647 211 0.471 372
44 3.828 11,730 128 1.538 1,614 212 0.465 367
45 3.805 11,416 129 1.517 1,582 213 0.459 361
46 3.781 11,112 130 1.496 1,550 214 0.453 356
47 3.757 10,816 131 1.474 1,519 215 0.446 350
48 3.729 10,529 132 1.453 1,489 216 9.439 344
49 3.705 10,250 133 1.431 1,459 217 0.432 338
50 3.679 9,979 134 1.408 1,430 218 0.425 332
51 3.653 9,717 135 1.389 1,401 219 0.417 325
52 3.627 9,461 136 1.369 1,373 220 0.409 318
53 3.600 9,213 137 1.348 1,345 221 0.401 311
54 3.575 8,973 138 1.327 1,318 222 0.393 304
55 3.547 8,739 139 1.308 1,291 223 0.384 297
56 3.520 8,511 140 1.291 1,265 224 0.375 289
57 3.493 8,291 141 1.289 1,240 225 0.366 282
58 3.464 8,076 142 1.269 1,214
60

Table 39B — Thermistor Temperatures (°C) vs Resistance/Voltage Drop
(NOTE: These Values do NOT Apply to the Motor Temperature Thermistors)
TEMP VOLTAGE RESISTANCE TEMP VOLTAGE RESISTANCE TEMP VOLTAGE RESISTANCE
DROP DROP DROP
(C) (V) (Ohms) (C) (V) (Ohms) (C) (V) (Ohms)
−40 4.896 168 230 10 3.680 9 949 60 1.291 1 244
−39 4.889 157 440 11 3.633 9 485 61 1.258 1 200
−38 4.882 147 410 12 3.585 9 044 62 1.225 1 158
−37 4.874 138 090 13 3.537 8 627 63 1.192 1 118
−36 4.866 129 410 14 3.487 8 231 64 1.160 1 079
−35 4.857 121 330 15 3.438 7 855 65 1.129 1 041
−34 4.848 113 810 16 3.387 7 499 66 1.099 1 006
−33 4.838 106 880 17 3.337 7 161 67 1.069 971
−32 4.828 100 260 18 3.285 6 840 68 1.040 938
−31 4.817 94 165 19 3.234 6 536 69 1.012 906
−30 4.806 88 480 20 3.181 6 246 70 0.984 876
−29 4.794 83 170 21 3.129 5 971 71 0.949 836
−28 4.782 78 125 22 3.076 5 710 72 0.920 805
−27 4.769 73 580 23 3.023 5 461 73 0.892 775
−26 4.755 69 250 24 2.970 5 225 74 0.865 747
−25 4.740 65 205 25 2.917 5 000 75 0.838 719
−24 4.725 61 420 26 2.864 4 786 76 0.813 693
−23 4.710 57 875 27 2.810 4 583 77 0.789 669
−22 4.693 54 555 28 2.757 4 389 78 0.765 645
−21 4.676 51 450 29 2.704 4 204 79 0.743 623
−20 4.657 48 536 30 2.651 4 028 80 0.722 602
−19 4.639 45 807 31 2.598 3 861 81 0.702 583
−18 4.619 43 247 32 2.545 3 701 82 0.683 564
−17 4.598 40 845 33 2.493 3 549 83 0.665 547
−16 4.577 38 592 34 2.441 3 404 84 0.648 531
−15 4.554 38 476 35 2.389 3 266 85 0.632 516
−14 4.531 34 489 36 2.337 3 134 86 0.617 502
−13 4.507 32 621 37 2.286 3 008 87 0.603 489
−12 4.482 30 866 38 2.236 2 888 88 0.590 477
−11 4.456 29 216 39 2.186 2 773 89 0.577 466
−10 4.428 27 633 40 2.137 2 663 90 0.566 456
−9 4.400 26 202 41 2.087 2 559 91 0.555 446
−8 4.371 24 827 42 2.039 2 459 92 0.545 436
−7 4.341 23 532 43 1.991 2 363 93 0.535 427
−6 4.310 22 313 44 1.944 2 272 94 0.525 419
−5 4.278 21 163 45 1.898 2 184 95 0.515 410
−4 4.245 20 079 46 1.852 2 101 96 0.506 402
−3 4.211 19 058 47 1.807 2 021 97 0.496 393
−2 4.176 18 094 48 1.763 1 944 98 0.486 385
−1 4.140 17 184 49 1.719 1 871 99 0.476 376
0 4.103 16 325 50 1.677 1 801 100 0.466 367
1 4.065 15 515 51 1.635 1 734 101 0.454 357
2 4.026 14 749 52 1.594 1 670 102 0.442 346
3 3.986 14 026 53 1.553 1 609 103 0.429 335
4 3.945 13 342 54 1.513 1 550 104 0.416 324
5 3.903 12 696 55 1.474 1 493 105 0.401 312
6 3.860 12 085 56 1.436 1 439 106 0.386 299
7 3.816 11 506 57 1.399 1 387 107 0.370 285
8 3.771 10 959 58 1.363 1 337
9 3.726 10 441 59 1.327 1 290
THERMISTOR JACKETED CABLE SENSOR TUBE BEND SLIGHTLY BEFORE WELL INSERTION THERMISTOR WELL
4 in. 3/16 in.
Fig. 21 — Thermistor Replacement (T1, T2, T5, or T6)
LEAD END (30GX080-176, ALL 30HX)

PLUG END (30GX205-265)
PACKING NUT MEASURE TO TOP

OF WELD COUPLING
FOR PROPER X
INSERTION
(SEE TABLE 41)
FERRULE
COOLER
Fig. 22 — Thermistor (Liquid Level Sensor) Replacement
61

Table 40 — Thermistor Temperatures vs Safety Devices — The 30GX/HX chillers contain many
Resistance, Motor Temperature Thermistors safety devices and protection logic built into the electronic
control. Following is a description of the major safeties.
TEMP TEMP RESISTANCE
(F) (C) (Ohms) COMPRESSOR PROTECTION
−22 −30 88,480.0 Motor Overload — One factory preset solid-state overload
−13 −25 65,205.0 protects each compressor against overcurrent. Do not by-
−4 −20 48,536.0
5 −15 36,476.0 pass the overload or make any changes to the overload
14 −10 27,663.0 setting. Determine the cause for trouble and correct the prob-
23 −5 21,163.0 lem before resetting a tripped overload. In addition to the
32 0 16,325.0 overload, each compressor is further protected by the
41 5 12,696.0
50 10 9,949.5 Compressor Protection Module. Each module has a factory
59 15 7,855.5 installed and configured 8-pin header. The configuration of
68 20 6,246.0 this header defines the must-trip amps at which the CPM
77 25 5,000.0 will turn the compressor off. See Appendix D for correct set-
86 30 4,028.4
95 35 3,265.7 ting of overload and configuration headers.
104 40 2,663.2 Each CPM board also reads the status of each compres-
113 45 2,184.2 sor’s high-pressure switch. All compressors have factory-
122 50 1,801.2
131 55 1,493.1 installed high-pressure switches. For 30GX units, the switch
140 60 1,243.9 is set to trip at 303 ± 7 psig (2089 ± 48 kPa). The setting
149 65 1,041.4 for 30HXA units is 275 ± 7 psig (1896 ± 48 kPa) and for
158 70 875.8 30HXC units the setting is 191 ± 7 psig (1317 ± 48 kPa).
167 75 739.7
176 80 627.6 If the switch opens during operation, the compressor will be
185 85 534.9 shut down. The CPM will reset automatically when the
194 90 457.7 switch closes, however, a manual reset is required to restart
203 95 393.3 the compressor.
212 100 339.3
221 105 293.8 OIL SEPARATOR HEATERS (30GX) — Each oil separator
230 110 255.3
239 115 222.6 circuit has a heater mounted on the underside of the vessel.
248 120 194.8 The heater is energized with control circuit power. After a
NOTE: Motor temperature thermistor values must be verified using
prolonged shutdown or service job, additional time may be
resistance. Voltage drop cannot be used. required before starting the unit. Oil heaters are energized
when the discharge gas temperature falls below 105 F
(40.6 C). The heaters are deenergized when the discharge
gas temperature rises above 110 F (43.3 C). The control will
Table 41 — Thermistor Depth allow the chiller to attempt to start with the heaters ener-
UNIT MODEL THERMISTOR DEPTH gized and will keep the heaters on, even when running, until
NUMBER ‘‘X’’-in. (mm) the discharge gas temperature reaches 110 F (43.3 C). Note
30GX080-090 6.00 (152.4) that the oil heaters are deenergized if the oil level switch is
30GX105-115 4.25 (108.0) open.
30GX125-136 5.56 (141.2)
30GX150,151 6.00 (152.4) COOLER PROTECTION
30GX160,161 4.25 (108.0) Low Water Temperature — Microprocessor is programmed
30GX175,176 4.25 (108.0)
30GX205-226 3.94 (100.0) to shut the chiller down if the leaving fluid temperature drops
30GX250-265 4.82 (122.4) below 34 F (1.1 C) for water or more than 8° F (4.4° C)
30HXA,C076-086 5.13 (130.3) below set point for brine units. When the fluid temperature
30HXA,C096 6.00 (152.4) rises 6° F (3.3° C) above the leaving fluid set point, the safety
30HXA,C106 4.25 (108.0)
30HXA,C116-126 5.13 (130.3) resets and the chiller restarts. Reset is automatic as long as
30HXA,C136-146 6.00 (152.4) this is the first occurrence of the day.
30HXA,C161-171 4.25 (108.0)
30HXA,C186 5.56 (141.2) IMPORTANT: If the unit is installed in an area where
30HXA,C206 3.94 (100.0) ambient temperatures fall below 32 F (0° C), inhibited
30HXA,C246-271 4.82 (122.4) ethylene glycol or other suitable solution must be used
in the chilled fluid circuit.
Table 42 — Calibrating Pressure Transducers Relief Devices — Fusible plugs are located in each cir-
(Pressure Gage Installed) cuit (30GX only) between the condenser and the liquid line
shutoff valve.
KEYPAD ENTRY DISPLAY RESPONSE COMMENTS
CALIBRATION
PRESSURE RELIEF VALVES — Valves are installed in each
OFFSET circuit and are located on all coolers. One relief valve is also
CIRCUIT A installed on each 30HXC condenser. Both circuits’ oil sepa-
PRESSURE rators on 30GX and 30HXA units have factory-installed
Discharge Pressure Current reading is relief valves as well. These valves are designed to relieve if
84.2 PSI displayed. an abnormal pressure condition arises. Relief valves on all
Discharge Pressure Enter gage pressure coolers and 30HXC condensers relieve at 220 psi (1517 kPa).
85.0 PSI reading to nearest Relief valves on 30GX and 30HXA oil separators relieve at
tenth. Control will
allow offset of up to 320 psi (2206 kPa). Units with factory-installed suction serv-
6 psig. Transducer ice valves also have a relief valve in each compressor dis-
calibration is now charge line. These valves are designed to relieve at 350 psig
complete.
(2413 kPa). These valves should not be capped. If a valve
relieves, it should be replaced. If the valve is not replaced,
it may relieve at a lower pressure, or leak due to trapped dirt
from the system which may prevent resealing.
62
COMPRESSOR A2 COMPRESSOR A1 COMPRESSOR B1
(206-271 ONLY)
4 4
3 3 3
COOLER
2 2
CONDENSER (30HXC MODEL)

1 1 OIL SEPARATOR (30HXA MODEL)
1 DISCHARGE PRESSURE 3 OIL PRESSURE
2 SUCTION PRESSURE 4 ECONOMIZER PRESSURE (LOCATED IN MOTOR COOLING LINE)
Fig. 23A — 30HX Pressure Transducer Locations
COMPRESSOR A2 COMPRESSOR A1 COMPRESSOR B1

(205-265 ONLY)
4 4
3 3 3
COOLER
2 2
OIL SEPARATORS
(ONE VESSEL ON
1 SMALL GX'S, TWO
1 SEPARATE ON LARGER
UNITS)
1 DISCHARGE PRESSURE 3 OIL PRESSURE
2 SUCTION PRESSURE 4 ECONOMIZER PRESSURE (LOCATED IN MOTOR COOLING LINE)
Fig. 23B — 30GX Pressure Transducer Locations
63
Pressure relief valves located on cooler and condenser shells On sensor bus terminal strips, terminal 1 of PSIO module
and 30HXA oil separator shells have 3⁄4-in. NPT connec- is connected to terminal 1 of each of the other modules.
tions for relief. The 30GX oil separators have 1⁄2-in. male Terminals 2 and 3 are connected in the same manner. See
flare connections. Some local building codes require that re- Fig. 24. If a terminal 2 wire is connected to terminal 1, sys-
lieved gases be removed. This connection allows conform- tem does not work.
ance to this requirement. In the 30GX,HX control box, the processor module
(PSIO-1), DSIO-HV, keypad and display module and 5 vdc
Control Modules power supply are all powered from a common 21 vac power
source (PSIO-1 and HSIO powered from 24 vac source on
30HX units) which connects to terminals 1 and 2 of the power
Turn controller power off before servicing controls. This connector on each module. A separate source of 21 vac power
ensures safety and prevents damage to controller. is used to power the PSIO-2 module and liquid level sensor
heaters. A separate 12.5 vdc power source is used for
PROCESSOR MODULE (PSIO-1), HIGH-VOLTAGE the DSIO-EXV module through terminals 1 and 2 on the
RELAY MODULE (DSIO-HV), AND EXV DRIVER power connector. The CPM modules are connected to 24 vac
MODULE (DSIO-EXV), 12/6 MODULE (PSIO-2) — The power sources. Refer to Table 43 for control troubleshooting
PSIO and DSIO modules all perform continuous diagnostic information.
evaluations of the condition of the hardware. Proper opera-
tion of these modules is indicated by LEDs on the front sur- Carrier Comfort Network (CCN) Interface — The
face of the DSIOs, and on the top horizontal surface of the 30GX,HX chiller units can be connected to the CCN if de-
PSIOs. sired. The communication bus wiring is a shielded, 3-conductor
cable with drain wire and is supplied and installed in the
RED LED — Blinking continuously at a 1 to 2 second rate field. The system elements are connected to the communi-
indicates proper operation. Lighted continuously indicates a cation bus in a daisy chain arrangement as shown in Fig. 24.
problem requiring replacement of module. Off continuously The positive pin of each system element communication con-
indicates power should be checked. If there is no input power, nector must be wired to the positive pins of the system el-
check fuses. If fuse is bad, check for shorted secondary of ements on either side of it. This is also required for the nega-
transformer, tripped circuit breaker or bad module. On the tive and signal ground pins of each system element. Wiring
PSIO module, if the light is blinking at a rate of twice per connections for CCN should be made at the COMM1 plug
second, the module should be replaced. on the PSIO-1 module. Consult the CCN Contractor’s Manual
GREEN LED — On a PSIO module, this is the green LED for further information.
closest to COMM connectors. The other green LED on mod- NOTE: Conductors and drain wire must be 20 AWG (Amer-
ule indicates external communications, when used. Green LED ican Wire Gage) minimum stranded, tinned copper. In-
should always be blinking when power is on. It indicates dividual conductors must be insulated with PVC, PVC/
modules are communicating properly. If green LED is not nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester
blinking, check red LED. If red LED is normal, check mod- 100% foil shield and an outer jacket of PVC, PVC/nylon,
ule address switches. Correct addresses are as follows: chrome vinyl, or Teflon with a minimum operating tem-
PSIO-1 (Processor Module) — 01 perature range of −20 C to 60 C is required. Wire manu-
CPM-A1 (Protection Module) — 21 factured by Alpha (2413 or 5463), American (A22503), Belden
CPM-A2 (Protection Module) — 29 (8772), or Columbia (02525) meets the above mentioned
CPM-B1 (Protection Module) — 37 requirements.
DSIO (EXV Driver Module) — 50 It is important when connecting to a CCN communication
DSIO-HV (Relay Module) — 62 bus that a color coding scheme be used for the entire net-
PSIO-2 (12/6 I/O Module) — 74 work to simplify the installation. It is recommended that red
be used for the signal positive, black for the signal negative,
The first number of the address for a DSIO module should and white for the signal ground. Use a similar scheme for
be set on the switch closest to the silver mounting plate. cables containing different colored wires.
If all modules indicate communication failure, check At each system element, the shields of its communication
COMM plug on PSIO-1 module for proper seating. If a good bus cables must be tied together. If the communication bus
connection is assured and condition persists, replace PSIO-1 is entirely within one building, the resulting continuous shield
module. must be connected to a ground at one point only. If the com-
If only a DSIO module indicates communication failure, munication bus cable exits from one building and enters an-
check COMM plug on that module for proper seating. If a other, the shields must be connected to grounds at the light-
good connection is assured and the condition persists, re- ning suppressor in each building where the cable enters or
place the DSIO module. exits the building (one point per building only). To connect
All system operating intelligence rests in the PSIO-1 mod- the unit to the network:
ule, the module that controls unit. This module monitors 1. Turn off power to the control box.
conditions through input and output ports and through 2. Cut the CCN wire and strip the ends of the red (+), white
DSIO modules (high-voltage relay module and EXV driver (ground), and black (−) conductors. (Substitute appropri-
module). ate colors for different colored cables.)
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.
64
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
PSIO-1-J8 DSIO-HV-J2 DSIO-EXV-J2 PSIO-2-J8 HSIO-II CPM-A1 CPM-B1

Fig. 24 — Sensor Bus Wiring (Communications)
Table 43 — Compressor Control Troubleshooting

SYMPTOMS CAUSE REMEDY
COMPRESSOR DOES NOT Power line open Check main disconnect.
RUN Control fuse open Check control circuit for ground or short. Replace fuse.
High-Pressure Switch (HPS) tripped Move LOCAL/OFF/REMOTE switch to OFF position
then back to LOCAL or REMOTE position.
Tripped motor overload Check the controls. Find cause of trip. Reset overload.
Loose terminal connection Check connections.
Improperly wired controls Check wiring and rewire.
Low line voltage Check line voltage. Determine location of voltage drop
and remedy deficiency.
Compressor motor defective Check motor winding for open or short. Replace com-
pressor if necessary.
Seized compressor Replace compressor.
Pre-lubrication not successful Check oil pump operation, oil pressure transducer, verify
oil level/flow switch operation.
COMPRESSOR CYCLES Loss of charge Repair leak and recharge.
OFF ON LOW PRESSURE Bad transducer Replace transducer.
Low refrigerant charge Add refrigerant.
Failed expansion device Repair/replace as needed.
COMPRESSOR SHUTS High-pressure switch erratic in action Replace switch.
DOWN ON HIGH PRES- Compressor discharge valve partially closed Open valve or replace if defective.
SURE CONTROL Condenser fan(s) not operating (air cooled units) Check wiring. Repair or replace motor(s) if defective.
Condenser coil plugged or dirty (air cooled units) Clean coil.
Condenser water valve not operating (water Check wiring. Repair or replace valve if defective
cooled units)
Circuit overcharged Clean condenser.
Liquid valve closed* Open valve or replace if defective.
UNIT OPERATES LONG OR Low refrigerant charge Add refrigerant.
CONTINUOUSLY Control contacts fused Replace control.
Partially plugged or plugged expansion valve or Clean or replace.
filter drier
Defective insulation Replace or repair.
Service load exceeding design capacity Keep doors and windows closed.
Inefficient compressor Check loader solenoid valves. Replace if necessary.
SYSTEM NOISES Piping vibration Support piping as required.
Expansion valve hissing Add refrigerant.
Check for plugged liquid line filter drier.
Compressor noisy Replace compressor (worn bearings).
Check for loose compressor bolts securing compressor
to cooler.
COMPRESSOR LOSES OIL Leak in system Find and repair leak.
Mechanical damage to rotors Replace compressor.
HOT LIQUID LINE Shortage of refrigerant due to leak Repair leak and recharge.
FROSTED LIQUID LINE Shutoff valve partially closed or restricted Open valve or remove restriction.
COMPRESSOR LOADERS Burned out coil Replace coil.
NOT WORKING PROPERLY Defective capacity control valve Replace valve.
Miswired solenoid Rewire correctly.
*30GX251, 265 sizes have two Circuit A discharge and liquid valves.
65
3. Remove the 4-pin female plug from the PSIO-1 COMM1 2. Remove the defective PSIO-1 module by removing its
plug and connect the red wire to terminal 1 of the plug, mounting screws with a Phillips screwdriver, and re-
the white wire to terminal 2, and the black wire to ter- moving the module from the control box. Save the screws
minal 3. for later use.
4. Insert the plug back into the COMM1 plug. 3. Use a small screwdriver to set the address switches S1
and S2 on the new PSIO module to exactly match the
IMPORTANT: A shorted CCN bus cable will prevent settings on the defective module.
some routines from running and may prevent the unit 4. Package the defective module in the carton of the new
from starting. If abnormal conditions occur, unplug the module for return to Carrier.
connector. If conditions return to normal, check the CCN 5. Mount the new module in the unit control box using a
connector and cable. Run new cable if necessary. A Phillips screwdriver and the screws saved in Step 2.
short in one section of the bus can cause problems with
all system elements on the bus. 6. Reinstall all 6 wire connectors, the green ground wire,
and the communications drain wire.
PROCESSOR MODULE (PSIO-1) 7. Carefully check all wiring connections before restoring
power.
Inputs — Each input channel has 3 terminals; only 2 of the 8. Verify the LOCAL/OFF/REMOTE switch is in the
terminals are used. Application of machine determines which OFF position.
terminals are used. Always refer to the individual unit wir-
ing for terminal numbers. 9. Restore control power. Verify the red and green lights
on top of the PSIO-1 and on front of each DSIO module
Outputs — Output is 20 vdc or 4 to 20 mA. There are 3 ter- respond as described in Control Modules section. The
minals, only 2 of which are used, depending on the appli- keypad and display module should also begin its rotat-
cation. Refer to unit the wiring diagram. ing display.
NOTE: The 12/6 Input/Output module (PSIO-2) has iden- Using the keypad and display module, press to
tical input and output configurations as the PSIO-1. There is verify that the software version number matches the
NO operating software in the PSIO-2 module. ER (engineering requirement) number shown on the
HIGH VOLTAGE RELAY MODULE (DSIO-HV) PSIO-1 label.
Inputs — Inputs on strip J3 are discrete inputs (ON/OFF). 10. Press , scroll down one level at a time, and check
When 24-vac power is applied across the 2 terminals in a the 3 factory and 2 service configuration codes as re-
channel it reads the input as an On signal. Zero volts input corded on checklist. These codes must exactly match the
is read as an Off signal. codes stored in the previous PSIO-1 module for proper
Outputs — Terminal strips J4 and J5 are internal relays whose unit operation. These should already be downloaded if
coils are signaled to be turned on and off by the micro- the proper information was supplied when ordering the
processor (PSIO-1). The relays switch the circuit to which replacement module. If the codes do not match, the codes
they are connected. No power is supplied to these connec- must be entered by the procedure described in the fac-
tions by DSIO-HV module. tory service code section of Table 22.
Replacing Defective Processor Module — The 11. Once all codes have been verified, and all configura-
PSIO-1 module replacement part number is 30GX500110. tions, set points, and schedules re-entered, return the
The unit model and serial numbers are printed on the unit LOCAL/OFF/REMOTE switch to its previous position.
nameplate located on an exterior corner post (30GX) or the
corner of the control box (30HX). The proper software and Winter Shutdown Preparation — At the end of each
unit configuration data is factory installed by Carrier in the cooling season the fluid should be drained from the system.
replacement module. Therefore, when ordering a replace- However, due to the cooler circuiting, some fluid will re-
ment processor module (PSIO-1), specify the replacement main in the cooler after draining. To prevent freeze-up dam-
part number, full unit model number, and serial number. If age to the cooler tubes perform the following procedure.
these numbers are not provided, the replacement module will 1. If accessory cooler heaters have been installed, deener-
be downloaded with the base software. The base software gize the heaters to prevent damage and possible safety
settings must be reconfigured by the installer in the field. hazards when draining, or when there is no liquid in the
Verify the existing PSIO-1 module is defective by using system. Remove Fuse 1 to deenergize the heaters. Drain
the procedure described in the Control Modules section. the fluid from the system.
Refer to Start-up Checklist for 30GX,HX Liquid Chillers 2. Isolate the cooler from the rest of the system with water
(completed at time of original start-up) found in the job folder. shut off valves.
This information is needed later in this procedure. If the 3. Fill the cooler with an appropriate amount of unhibited
checklist does not exist, fill out the current factory and ethylene glycol solution (or other suitable corrosion-
service configuration codes ( ) sections on a new check- inhibitive antifreeze) for 15° F (8.3° C) below the ex-
list. Tailor the various options and configurations as needed pected low ambient conditions.
for this particular installation. 4. Leave the cooler filled with the antifreeze solution for the
winter, or drain if desired. Be sure to deenergize heaters
(if installed) as explained in Step 1 to prevent damage.
Use an approved method of disposal when removing the
Electrical shock can cause personal injury. Disconnect antifreeze solution.
all electrical power before servicing.
1. 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 screws
securing the green ground wire and communication drain
wire. Save the screws.
66
PRE-START-UP PROCEDURE second terminal block, a current phase reversal alarm
will be generated when an attempt is made to start this
IMPORTANT: Before beginning Pre-Start-Up or Start- compressor. The compressor will be shut down within
Up, complete the Start-Up Checklist for the 30GX,HX 15 milliseconds. To correct this, interchange 2 power
Liquid Chillers on pages CL-1 to CL-8. This Check- leads at this terminal block only.
list assures proper start-up of the chiller, and provides
a record of unit condition, application requirements, 9. Check all field configuration data and set points.
system information and operation at initial start-up. The 10. Enter correct date, time, and operating schedule(s).
checklist should be removed from the manual and kept 11. Verify operation of solenoids, pumps, valves, compres-
with the job file for future reference. sors, fans, etc. as listed in the Checklist.
12. Open condenser water valves. Check condenser water
pump for proper operation (30HX).
IMPORTANT: DO NOT ATTEMPT TO START THE
CHILLER UNTIL THE FOLLOWING CHECKS HAVE
BEEN COMPLETED. START-UP AND OPERATION
Actual Start-Up — Actual start-up should be done only
System Check under supervision of a qualified refrigeration mechanic and
qualified Carrier Comfort Network personnel.
1. Check all auxiliary components such as the chilled fluid
circulating pump, air-handling equipment, or other equip- 1. Set leaving fluid temperature. No cooling range adjust-
ment to which the chiller supplies liquid. Consult the ment is necessary.
manufacturer’s instructions. If the unit has field-installed 2. Start chilled fluid pump and condenser pump (30HXC) if
accessories, be sure all are properly installed and wired not controlled by unit.
correctly. Refer to the unit wiring diagrams. 3. Switch LOCAL/OFF/REMOTE switch to LOCAL or
2. Check the cooler flow switch for proper configuration REMOTE.
and operation ( from HSIO). Ensure the switch 4. Provided there is a load on the chiller, allow the machine
closes when the pump is on and opens when the pump to operate and confirm that everything is functioning prop-
is turned off. A flow switch must be installed. erly. Verify that the leaving fluid temperature agrees with
3. Open the discharge and liquid valves in each circuit. The the cooling set point (1 or 2), or if reset is being used, the
discharge shutoff valves are in-line ball type and are open modified set point. Chiller is controlling to the Control
when parallel with the refrigerant flow. Point displayed under .
4. If factory-installed option is installed, open the suction
service valves in each circuit. Service valve is located Operating Sequence — The chiller is started by switch-
below the compressor in the cooler suction connection ing the LOCAL/OFF/REMOTE switch to either LOCAL or
flange. REMOTE. On a command for cooling, the oil pump is turned
on to start the pre-lubrication process. After 20 seconds, the
5. Open the oil shutoff valves located by the oil pre-filter. oil solenoid is opened and the control reads the oil pressure
Open bubbler tube valve on 30HX machines equipped from the transducer and determines if sufficient pressure has
with economizers. been built up. If there is not sufficient pressure, an alarm is
6. Check the tightness of all electrical connections. Check generated after the second attempt and the compressor is not
incoming power supply for proper nameplate voltage. started.
7. Check to ensure the unit is level per the installation Upon building pressure, the compressor is allowed to start.
instructions. For across-the-line (XL) start chillers, the compressor starts
8. Check the incoming power supply for proper phasing. and comes up to full speed within 1 to 3 seconds. For Wye-
This can be done by turning on both the line voltage and Delta start chillers, contactors 1M and S (starter contactor
control voltage power supplies. Leave the LOCAL/OFF/ assembly) are closed and the compressor is started in a Wye
REMOTE switch in the OFF position. If the incoming configuration. This method reduces the locked rotor current
power is not phased correctly, the CPM will generate requirements by approximately 60% while maintaining enough
an alarm for voltage phase reversal. Press for torque to bring the compressor up to full speed.
After 5 seconds, the CPM module switches out contactor
Circuit A and for Circuit B at the HSIO to check S and brings in contactor 2M, which runs the motor in a
for this alarm. Scroll up and locate the Feedback value Delta configuration (same configuration in which XL units
(displayed in units of volts). If a value of 7.0 appears, a run). The oil pump will shut off within 10 seconds after the
voltage phase reversal has been identified and requires compressor is started. Once the compressor is successfully
incoming power supply phase change. If this is the case, running, the control loads the compressor and adds addi-
shut down all power supplies and switch any 2 in- tional stages of capacity as needed to satisfy the leaving fluid
coming power leads at the control box terminal block. set point. Head pressure is controlled by fan cycling (30GX)
or can be controlled with a field installed accessory Motor-
mastert III controller (30GX) or field installed condenser
DO NOT make any changes to the factory installed water valves (30HX).
compressor power wiring in the control box or at If cooler pump control is enabled, the cooler pump is started.
the compressor junction box. Doing so will cause If condenser pump control (30HXC) is enabled, the con-
permanent damage to the compressor and will re- denser pump is started (Type 1).
quire compressor replacement. Proper phasing has
already been checked at the factory.
For those units with 2 incoming terminal blocks, the volt-
age sequence is sensed at one terminal block only. Check
the phasing to ensure that both circuits match.
If the incoming power is still phased incorrectly at the
67
FIELD WIRING LEGEND FOR FIG. 25-37
Field wiring is shown in Fig. 25-37. ALM — Alarm
C — Contactor
CFC — Condenser Fan Contactor
NEC FUSED DISCONNECT CPR — Condenser Pump Relay
CWP — Chilled Water Pump
DSIO — High Voltage Relay Module
EQUIP — Equipment
115 V CONTROL CIRCUITS EXV — Electronic Expansion Valve
USE 30 AMP MAXIMUM FROM FU — Fuse
SEPARATE POWER SUPPLY
GFI-CO — Ground Fault Interrupter Convenience Outlet
GND — Ground
NEC — National Electrical Code
FIELD CONTROL POWER SUPPLY PL — Plug
PSIO — Processor Sensor Input/Output Module
230 V CONTROL CIRCUITS RB — Relay Board
USE 15 AMP MAXIMUM FROM TB — Terminal Block
SEPARATE POWER SUPPLY
Field-Wired
2 1 Factory Wired
GND TB4
Fig. 25 — Power Supply Wiring
EQUIP GND
RELAY BOARD 1
TB2 SEPARATE
115 OR 230 V
FIELD POWER
T1 BLK 2 SUPPLY
K6
T2 BLK 3 ALM
TB2
MAX. LOAD ALLOWED FOR THE ALARM RELAY IS

125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT.
FIELD SUPPLIED
Fig. 26 — Remote Alarm Relay Accessory Wiring; 30HXA,C
EQUIP GND
RELAY BOARD 2
SEPARATE
115 OR 230 V
FIELD POWER
T4 SUPPLY
K3
T3 ALM
MAX. LOAD ALLOWED FOR THE ALARM RELAY IS

FIELD SUPPLIED
Fig. 27 — Remote Alarm Relay Accessory Wiring; 30GX
68
EQUIP GND
RELAY BOARD 1
TB2 SEPARATE
115 OR 230 V
FIELD POWER
T4 BLK 4 SUPPLY
K3
T3 BLK 5 C1 CWP C2
TB2
MAX. LOAD ALLOWED FOR THE CWP RELAY IS

ACCESSORY ONLY
Fig. 28 — Chilled Water Pump Relay Wiring; 30HXA,C
EQUIP GND
RELAY BOARD 1
SEPARATE
115 OR 230 V
FIELD POWER
T4 SUPPLY
K3
T3 C1 CWP C2
MAX. LOAD ALLOWED FOR THE CWP RELAY IS

ACCESSORY ONLY
Fig. 29 — Chilled Water Pump Relay Wiring; 30GX
69
ACCESSORY GFI-CO
GRN/YEL
TEST
TB4 15 AMPS RESET TB4
1 BLU FU1 BLK WHT 2
BRASS SCREWS SILVER SCREWS
Fig. 30 — Ground Fault Interrupter-Convenience Outlet Accessory Wiring
230V CONTROL CIRCUIT WIRING 115V CONTROL CIRCUIT WIRING
BRN VIO PNK ORN BLU RED BLK BRN VIO PNK ORN BLU RED BLK
BLU BLK BLU BLK
Fig. 31 — Oil Pump Motor Junction Box Wiring
RELAY BOARD 2 MINIMUM LOAD CONTROL CIRCUIT B

TB4
T3 GRA WHT 2
T1 PNK
MINIMUM LOAD CONTROL CIRCUIT A
NOTE: Gray, Pink, and White wires are included in the control box as part of the factory wire harness. Field supplied and installed wire is needed
from control box to solenoid valves.
Fig. 32 — Minimum Load Valve Accessory Wiring
70
RELAY BOARD 2
TB2 TB4
T6 BLK 1 C1 CFCA C2 2
K4
RB2PL2-5
TB2
CPR/
BLK 6 C1 CFCB C2
K5 RB2PL2-3
MAX. LOAD ALLOWED AT TB2-1 AND TB2-6 IS

125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLTS.
FIELD SUPPLIED
Fig. 33 — Condenser Pump Relay Wiring, 30HXC and Remote Condenser Fan On/Off Wiring, 30HXA
DSIO (EXV)-J3
TB2 COOLER FLOW SWITCH TB2
12 11 RED 3
CHILLED WATER
PUMP INTERLOCK
CONTACTS
Fig. 34 — Chilled Water Interlock and Flow Switch Input Wiring
DSIO (EXV)-J3
REMOTE
TB2 TB2
RED
13 14 RED 1
OFF
REMOTE ON/OFF
CONTACTS
TB2
12 RED
Fig. 35 — Remote On/Off Switch Input Wiring
71
PSIO-2, J7 PLUGS
CONDENSER ENTERING
WATER THERMISTOR
FIELD SUPPLIED 14
15
TOP
CONDENSER LEAVING 17
WATER THERMISTOR
FIELD SUPPLIED
18
+ 19
FIELD SUPPLIED 4-20 mA SIGNAL
AND POWERED GENERATOR 500 OHM, 1/2 WATT
4-20 mA SIGNAL TEMPERATURE FIELD SUPPLIED
RESET RESISTOR
- 20
BOTTOM
+ 22
FIELD SUPPLIED 4-20 mA SIGNAL 500 OHM, 1/2 WATT
AND POWERED GENERATOR FIELD SUPPLIED
4-20 mA SIGNAL DEMAND LIMIT RESISTOR
- 23
CONDENSER FLOW SWITCH

25
28
REMOTE DUAL SETPOINT
FIELD
SUPPLIED 31
24 VAC
ICE DONE
32
OUTDOOR AIR THERMISTOR 35

FIELD SUPPLIED
36
PSIO-2, J6 PLUG
FIELD SUPPLIED 4-20 mA + 46

WATER VALVE 4-20 mA
(30HXC ONLY) WATER
VALVE
- 47
Fig. 36 — PSIO-2 Wiring for Accessories and Field-Installed Options, 30HX Units
72
PSIO-2, J7 PLUGS
TOP
+ 13
4-20 mA SIGNAL DEMAND LIMIT RESISTOR
- 14
OUTDOOR AIR THERMISTOR

FIELD SUPPLIED 20
21
BOTTOM
+ 22
4-20 mA SIGNAL TEMPERATURE RESISTOR
RESET - 23
SPACE TEMPERATURE
SENSOR 24
FIELD SUPPLIED
STAGE 2
DEMAND LIMIT 25
EXTERNAL
SWITCH STAGE 1
28
REMOTE DUAL SETPOINT
31
FIELD ICE DONE
SUPPLIED
24 VAC 34
35
PSIO-2, J6 PLUG
VIO VIO 46
MOTORMASTER®
OPTION (080-150, 160)
CIRCUIT A (151, 161-265)
GRA GRA 47
MOTORMASTER VIO VIO 49

OPTION
CIRCUIT B (151, 161-265)
GRA GRA 50
Fig. 37 — PSIO-2 Wiring for Accessories and Field-Installed Options, 30GX Units
73
APPENDIX A
Compressor Must Trip Amps (Determined by CPM Modules)
COMPRESSOR MUST TRIP AMPS COMPRESSOR MUST TRIP AMPS
2-COMPRESSOR UNITS 2-COMPRESSOR UNITS
Unit Size Unit Voltage Compressor A1, B1 Unit Size Unit Voltage Compressor A1, B1
Must Trip Amps Must Trip Amps
575-3-60 98, 82 575-3-60 120, 82
380-3-60 148,124 380-3-60 180,124
30GX080 208/230-3-60 270,226 346-3-50 206,140
460-3-60 122,102 30HXA096 208/230-3-60 328,226
230-3-50 256,212 460-3-60 148,102
380/415-3-50 156,128 230-3-50 310,212
575-3-60 120, 82 380/415-3-50 188,128
380-3-60 180,124 575-3-60 144, 82
208/230-3-60 328,226 380-3-60 218,124
30GX090
460-3-60 148,102 346-3-50 250,140
230-3-50 310,212 30HXA106 208/230-3-60 400,226
380/415-3-50 188,128 460-3-60 180,102
230-3-50 344,238 230-3-50 376,212
30GX105 380/415-3-50 228,128
380/415-3-50 208,144
575-3-60 134, 92 575-3-60 144, 98
380-3-60 202,140 380-3-60 218,148
208/230-3-60 368,254 346-3-50 250,170
30GX106 460-3-60 168,114 30HXA116 208/230-3-60 400,270
230-3-50 344,238 460-3-60 180,122
380/415-3-50 208,144 230-3-50 376,256
380/415-3-50 228,156
575-3-60 162, 92
380-3-60 246,140 575-3-60 144,120
208/230-3-60 448,254 380-3-60 218,180
30GX115 346-3-50 250,206
460-3-60 204,114
230-3-50 418,238 30HXA126 208/230-3-60 400,328
380/415-3-50 254,144 460-3-60 180,148
230-3-50 376,310
575-3-60 162,110 380/415-3-50 228,188
380-3-60 246,168
208/230-3-60 448,306 575-3-60 176,120
30GX125 380-3-60 266,180
460-3-60 204,138
230-3-50 418,288 346-3-50 306,206
380/415-3-50 254,174 30HXA136 208/230-3-60 486,328
460-3-60 220,148
575-3-60 162,134 230-3-50 462,310
380-3-60 246,202 380/415-3-50 280,188
208/230-3-60 448,368
30GX136 575-3-60 176,144
460-3-60 204,168
230-3-50 418,344 380-3-60 266,218
380/415-3-50 254,208 346-3-50 306,250
30HXA146 208/230-3-60 486,400
230-3-50 344,520 460-3-60 220,180
30GX150
380/415-3-50 208,314 230-3-50 462,376
575-3-60 198,134 380/415-3-50 280,228
380-3-60 300,202 575-3-60 198,134
30GX151
208/230-3-60 546,368 380-3-60 300,202
460-3-60 240,168 346-3-50 344,228
230-3-50 418,520 30HXA161 208/230-3-60 546,368
30GX160 460-3-60 248,168
380/415-3-50 254,314
575-3-60 198,162 230-3-50 520,344
380/415-3-50 314,208
380-3-60 300,246
208/230-3-60 546,448 575-3-60 162,198
30GX161 380-3-60 246,300
460-3-60 248,204
230-3-50 520,418 346-3-50 278,344
380/415-3-50 314,254 30HXA171 208/230-3-60 448,546
230-3-50 520,520 460-3-60 204,248
30GX175 380/415-3-50 314,314 230-3-50 418,520
380/415-3-50 254,314
575-3-60 198,198 575-3-60 198,198
30GX176 380-3-60 300,300 380-3-60 300,300
208/230-3-60 546,546
460-3-60 248,248 346-3-50 344,344
30HXA186 208/230-3-60 546,546
575-3-60 82, 82 460-3-60 248,248
380-3-60 124,124 230-3-50 520,520
346-3-50 140,140 380/415-3-50 314,314
30HXA076 208/230-3-60 226,226
460-3-60 102,102
230-3-50 212,212
380/415-3-50 128,128
575-3-60 98, 82
380-3-60 148,124
346-3-50 170,140
30HXA086 208/230-3-60 270,226
460-3-60 122,102
230-3-50 256,212
380/415-3-50 156,128
74
APPENDIX A (cont)
Compressor Must Trip Amps (Determined by CPM Modules) (cont)
Unit Size Unit Voltage Compressor A1, B1 Unit Size Unit Voltage Compressor A1, B1
575-3-60 56, 56 575-3-60 120, 82
380-3-60 84, 84 380-3-60 180,124
346-3-50 96, 96 346-3-50 204,140
30HXC076 208/230-3-60 154,154 30HXC136 208/230-3-60 328,226
460-3-60 70, 70 460-3-60 148,104
230-3-50 144,144 230-3-50 308,212
380/415-3-50 88, 88 380/415-3-50 186,128
575-3-60 68, 56 575-3-60 120,100
380-3-60 102, 84 380-3-60 180,150
346-3-50 116, 96 346-3-50 204,168
30HXC086 208/230-3-60 186,154 30HXC146 208/230-3-60 328,274
460-3-60 84, 70 460-3-60 148,124
230-3-50 176,144 230-3-50 308,254
380/415-3-50 106, 88 380/415-3-50 186,154
575-3-60 82, 56 575-3-60 130, 90
380-3-60 124, 84 380-3-60 196,136
346-3-50 140, 96 346-3-50 220,152
30HXC096 208/230-3-60 226,154 30HXC161 208/230-3-60 358,246
460-3-60 104, 70 460-3-60 162,112
230-3-50 212,144 230-3-50 332,228
380/415-3-50 128, 88 380/415-3-50 202,138
575-3-60 100, 56 575-3-60 108,130
380-3-60 150, 84 380-3-60 164,196
346-3-50 168, 96 346-3-50 182,220
30HXC106 208/230-3-60 274,154 30HXC171 208/230-3-60 298,358
460-3-60 124, 70 460-3-60 136,162
230-3-50 254,144 230-3-50 274,332
380/415-3-50 154, 88 380/415-3-50 166,202
575-3-60 100, 68 575-3-60 130,130
380-3-60 150,102 380-3-60 196,196
346-3-50 168,116 346-3-50 220,220
30HXC116 208/230-3-60 274,186 30HXC186 208/230-3-60 358,358
460-3-60 124, 84 460-3-60 162,162
230-3-50 254,176 230-3-50 332,332
380/415-3-50 154,106 380/415-3-50 202,202
575-3-60 100, 82
380-3-60 150,124
346-3-50 168,140
30HXC126 208/230-3-60 274,226
460-3-60 124,104
230-3-50 254,212
380/415-3-50 154,128
75
APPENDIX A (cont)
Compressor Must Trip Amps (Determined by CPM Modules) (cont)
Unit Size Unit Voltage Compressor A1, A2, B1 Unit Size Unit Voltage Compressor A1, A2, B1
30GX205 230-3-50 418,238,520 575-3-60 198,162,198
380/415-3-50 254,144,314 380-3-60 300,246,300
575-3-60 198, 92,162 346-3-50 344,278,344
380-3-60 300,140,246 30HXA261 208/230-3-60 546,448,546
30GX206 208/230-3-60 546,254,448 460-3-60 248,204,248
460-3-60 248,114,204 230-3-50 520,418,520
380/415-3-50 314,254,314
30GX225 230-3-50 520,288,520
380/415-3-50 314,174,314 575-3-60 198,198,198
380-3-60 300,300,300
575-3-60 198,110,198 346-3-50 344,344,344
380-3-60 300,168,300 30HXA271 208/230-3-60 546,546,546
30GX226 208/230-3-60 546,306,546 460-3-60 248,248,248
460-3-60 248,138,248 230-3-50 520,520,520
230-3-50 520,288,520 380/415-3-50 314,314,314
380/415-3-50 314,174,314
575-3-60 108, 62,130
30GX250 230-3-50 520,418,520 380-3-60 164, 92,196
380/415-3-50 314,254,314 346-3-50 182,104,220
575-3-60 198,198,162 30HXC206 208/230-3-60 298,168,358
380-3-60 300,300,246 460-3-60 136, 76,162
30GX251 208/230-3-60 546,546,448 230-3-50 274,156,332
460-3-60 248,248,204 380/415-3-50 166, 94,202
575-3-60 198,198,198 575-3-60 130, 90,130
380-3-60 300,300,300 380-3-60 196,136,196
208/230-3-60 546,546,546 346-3-50 220,152,220
30GX265 30HXC246 208/230-3-60 358,246,358
460-3-60 248,248,248
230-3-50 520,520,520 460-3-60 162,112,162
380/415-3-50 314,314,314 230-3-50 332,228,332
575-3-60 162, 92,198 380/415-3-50 202,138,202
380-3-60 246,138,300 575-3-60 130,108,130
346-3-50 278,158,344 380-3-60 196,164,196
30HXA206 208/230-3-60 448,254,546 346-3-50 220,182,220
460-3-60 204,116,248 30HXC261 208/230-3-60 358,298,358
230-3-50 418,238,520 460-3-60 162,136,162
380/415-3-50 254,144,314 230-3-50 332,274,332
380/415-3-50 202,166,202
575-3-60 198,134,198
380-3-60 300,202,300 575-3-60 130,130,130
346-3-50 344,228,344 380-3-60 196,196,196
30HXA246 208/230-3-60 546,368,546 346-3-50 220,220,220
460-3-60 248,168,248 30HXC271 208/230-3-60 358,358,358
230-3-50 520,344,520 460-3-60 162,162,162
380/415-3-50 314,208,314 230-3-50 332,332,332
380/415-3-50 202,202,202
76
APPENDIX B
Capacity Loading Sequence Example — The fol- compressor has 2 loaders. There is no difference in opera-
lowing tables show the loading sequence for a 30HX186 tion between ‘‘Staged’’ and ‘‘Equal’’ circuit loading on 2 com-
(50/50 split) and a 30HX161 (59/41 split) chiller. Each pressor chillers.
STANDARD LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 2-COMPRESSOR UNIT)

COMP LOADER LOADER COMP LOADER LOADER % TOTAL % TOTAL
STAGE CAPACITY CAPACITY
A1 A1 A2 B1 B1 B2 (50/50 Split) (59/41 Split)
0 0 0 0 0 0 0 0.0 0.0
1 1 0 0 0 0 0 20.0 23.5
2 1 1 0 0 0 0 35.0 41.1
3 1 1 1 0 0 0 50.0 58.8
4 1 1 0 1 1 0 70.0 70.0
5 1 1 0 1 1 1 85.0 82.4
6 1 1 1 1 1 1 100.0 100.0
CLOSE CONTROL LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 2-COMPRESSOR UNIT)

% TOTAL % TOTAL
STAGE COMP LOADER LOADER COMP LOADER LOADER CAPACITY CAPACITY
A1 A1 A2 B1 B1 B2
(50/50 Split) (59/41 Split)
0 0 0 0 0 0 0 0.0 0.0
1 1 0 0 0 0 0 20.0 23.5
2 1 1 0 0 0 0 35.0 41.1
3 1 1 1 0 0 0 50.0 58.8
3A 1 0 0 1 0 0 40.0 40.0
3B 1 0 0 1 1 0 55.0 52.4
4 1 0 0 1 1 1 70.0 64.7
5 1 1 0 1 1 1 85.0 82.4
6 1 1 1 1 1 1 100.0 100.0
LEGEND Nominal Tons

0 — Off
1 — On COMPRESSOR 60 Hz NOM. 50 Hz NOM.
NOTES: PART NO. TONS TONS
1. Stage 3A (and 3B for 59/41 split) is not used by the algorithm when 06N_1123 39 —
increasing stages. Stage 3 (and 2 for 59/41 split) is not used when 06N_1146 46 39
decreasing stages.
2. The % Total Capacities above are calculated based on compres- 06N_1174 56 46
sor nominal tons. For the case of the 59/41 split above, the 30HX 06N_1209 66 56
uses compressors with flow rates of 250 and 174 cfm (from com-
pressor model numbers 06N_1250 and 06N_1174), which repre- 06N_1250 80 66
sent nominal tons of 80 and 56 (respectively) at 60 Hz. A factor of 06N_1300 — 80
40% is used when no loaders are energized and a factor of 70%
is used when Loader 1 is energized. The capacity shown for Stage
3B above is calculated as follows:
% Total Capacity = [(0.40 x 80 + 0.70 x 56)/(80 + 56)] x 100%
= 52.4%
77
APPENDIX B (cont)
The following tables show the loading sequence for 30HX206 compressors have two loaders and the chillers are config-
(57/43 split) and 30HX271 (67/33 split) chillers. All ured for equal circuit loading. See Note 2.

COMP LOADER LOADER COMP COMP LOADER LOADER % TOTAL % TOTAL
STAGE A1 A1 A2 A2 B1 B1 B2 CAPACITY CAPACITY
(57/43 Split) (67/33 Split)
0 0 0 0 0 0 0 0 0.0 0.0
1 1 0 0 0 0 0 0 14.3 13.3
2 1 1 0 0 0 0 0 25.0 23.3
3 1 1 1 0 0 0 0 35.7 33.3
4 1 1 0 0 1 1 0 55.2 46.7
5 1 1 0 0 1 1 1 68.2 56.7
6 1 1 1 0 1 1 1 78.9 66.7
7 1 1 0 1 1 1 1 83.0 80.0
8 1 1 1 1 1 1 1 100.0 100.0

STAGE CAPACITY CAPACITY
A1 A1 A2 A2 B1 B1 B2
(57/43 Split) (67/33 Split)
0 0 0 0 0 0 0 0 0.0 0.0
1 1 0 0 0 0 0 0 14.3 13.3
2 1 1 0 0 0 0 0 25.0 23.3
3 1 1 1 0 0 0 0 35.7 33.3
3A 1 0 0 0 1 0 0 31.6 26.7
4 1 0 0 0 1 1 0 44.5 36.7
5 1 0 0 0 1 1 1 57.5 46.7
6 1 1 0 0 1 1 1 68.2 56.7
7 1 1 1 0 1 1 1 78.9 66.7
7A 1 0 0 1 1 1 1 65.9 60.0
8 1 1 0 1 1 1 1 83.0 80.0
9 1 1 1 1 1 1 1 100.0 100.0
LEGEND
0 — Off
1 — On
NOTES:
1. Stages 3A and 7A are not used by the algorithm when increasing
stages. Stages 3 and 7 are not used by the algorithm when de-
creasing stages.
2. The loading sequence for 30GX205-265 units is the same as those
shown for the 30HZ206,271 above.
78
APPENDIX B (cont)
The following tables show the loading sequence for 30HX206 staged circuit loading. Loaders A1 on compressors A1 and
(57/43 split) and 30HX271 (67/33 split) chillers. All com- A2 are energized in parallel. The same is true for Loaders
pressors have two loaders and the chiller is configured for A2 on both compressors A1 and A2. See Note 3.

(57/43 Split) (67/33 Split)
0 0 0 0 0 0 0 0 0.0 0.0
1 1 0 0 0 0 0 0 14.3 13.3
2 1 1 0 0 0 0 0 25.0 23.3
3 1 1 1 0 0 0 0 35.7 33.3
4 1 1 0 1 0 0 0 39.7 46.7
5 1 1 1 1 0 0 0 56.8 66.7
6 1 1 1 1 1 1 0 87.0 90.0
7 1 1 1 1 1 1 1 100.0 100.0

(57/43 Split) (67/33 Split)
0 0 0 0 0 0 0 0 0.0 0.0
1 1 0 0 0 0 0 0 14.3 13.3
2 1 1 0 0 0 0 0 25.0 23.3
3 1 1 1 0 0 0 0 35.7 33.3
3A 1 0 0 1 0 0 0 22.7 26.7
4 1 1 0 1 0 0 0 39.7 46.7
5 1 1 1 1 0 0 0 56.8 66.7
6 1 1 1 1 1 0 0 74.1 80.0
7 1 1 1 1 1 1 0 87.0 90.0
8 1 1 1 1 1 1 1 100.0 100.0
LEGEND which represent nominal tons of 66, 39 and 80 (respectively) at
0 — Off 60 Hz. A factor of 40% is used when no loaders are energized and
1 — On a factor of 70% is used when Loader 1 is energized. The capacity
shown for Stage 4 above is calculated as follows:
NOTES:
1. Stage 3A is not used by the algorithm when increasing stages. % Total Capacity = [0.70 x 66 + 0.70 x 39 + 0.0 x 80)/(66 + 39 +
Stage 3 is not used by the algorithm when decreasing stages. 80)] x 100% = 39.7%
2. The % Total Capacities above are calculated based on compres- 3. The loading sequence for 30GX205-265 units is the same as those
sor nominal tons. For the case of the 57/43 split above, the 30HX shown for the 30HX206,271 above.
uses compressors with flow rates of 209, 123 and 250 cfm (from
compressor model numbers 06N_1209, 06N_123 and 06N_1250),
79
APPENDIX C
The following are the available accessories for 30GX/HXA/HXC units.
ACCESSORY USED ON DESCRIPTION OF ACCESSORY COMMENTS

PART NUMBER
30GX-900-001 30GX080-105 Condenser Grille Package
30GX-900-002 30GX106-125 Condenser Grille Package
30GX-900-003 30GX136, 150, 160 Condenser Grille Package
30GX-900-013 30GX151, 161, 175, 205, 225 Condenser Grille Package
30GX-900-024 30GX176 Condenser Grille Package
30GX-900-009 30GX206, 226, 250 Condenser Grille Package
30GX-900-010 30GX251, 265 Condenser Grille Package
30GX-900-004 30GX (115 V Control) Minimum Load Valve both circuits
30GX-900-005 30GX (230 V Control) Minimum Load Valve both circuits
30GX-900-006 30GX (460 V) Control Transformer
30GX-900-012 30GX080-150, 160 3-Phase MotormasterT Control single controller
30GX-900-014 30GX151, 161-265 3-Phase Motormaster Control two controllers
30GX-900-015 30GX080-265 Sound Enclosure/Hail Guard/Wind Baffle header end only
30GX-900-016 30GX080-105 Sound Enclosure/Hail Guard/Wind Baffle one side per package
30GX-900-017 30GX106-125 Sound Enclosure/Hail Guard/Wind Baffle one side per package
30GX-900-018 30GX136, 150, 160 Sound Enclosure/Hail Guard/Wind Baffle one side per package
one side per package (151, 161, 175)
30GX-900-019 30GX151, 161, 175, 205, 225 Sound Enclosure/Hail Guard/Wind Baffle cooler side only (205, 225)
one side per package (176)
30GX-900-020 30GX176, 206, 226, 250 Sound Enclosure/Hail Guard/Wind Baffle cooler side only (206, 226, 250)
30GX-900-028 30GX205, 225 Sound Enclosure/Hail Guard/Wind Baffle control box side only
30GX-900-029 30GX206, 226, 250 Sound Enclosure/Hail Guard/Wind Baffle control box side only
30GX-900-030 30GX251, 265 Sound Enclosure/Hail Guard/Wind Baffle cooler side only
30GX-900-031 30GX251, 265 Sound Enclosure/Hail Guard/Wind Baffle control box side only
30GX-900-021 30GX (230 V Control) Cooler Heater
30GX-900-022 30GX (115 V Control) Cooler Heater
30GX-900-023 30GX080-265 Vibration Isolation Pads
Insulation Kit
30GX-900-025 30GX105-136, 160-176 tubesheets/heads/economizer
(169, 3 Pass Cooler with Economizer)
30GX-900-026 30GX150, 151 Insulation Kit tubesheets/heads/economizer
30GX-900-027 30GX150, 151 Insulation Kit tubesheets/heads/economizer
30HX-900-001 30HX116-271 Sound Enclosure Panels
30HX-900-011 30HX076-106 Sound Enclosure Panels
30GX080-090, 150, 151
30HX-900-002 Victaulic Cooler Connections (14 in.)
30HX076-096, 116-146
30GX105-136, 160-176
30HX-900-003 Victaulic Cooler Connections (16 in.)
30HX106, 161-186
30GX205-265
30HX-900-014 30HX206-271 Victaulic Cooler Connections (18 in.)
30HX-900-015 30HX206-271 Victaulic Condenser Connection (22 in.)
30HX-900-004 30HX076-146 Victaulic Condenser (18 in.)
30HX-900-005 30HX161-186 Victaulic Condenser (20 in.)
30HX-900-006 30HX (230, 460 V) Control Transformer
30HX-900-013 30HX (575 V) Control Transformer
30HX-900-007 30GX,HX all LID 2B Enhanced Remote Controller
30HX-900-008 30HX (115 V Control) Minimum Load Valve single circuit
30HX-900-009 30HX (230 V Control) Minimum Load Valve single circuit
30HX-900-010 30HX076-271 Vibration Isolation Pad
30HX-900-016 30GX080,090 Insulation Kit tubesheets/heads
30HX076-096 (149, 3 Pass Cooler no Economizer)
30HX-900-017 30GX080,090 Insulation Kit tubesheets/heads
30HX076-096 (149, 2 Pass Cooler no Economizer)
30GX105-136,160-176 Insulation Kit
30HX-900-020 30HX161-186 (169, 2 Pass Cooler with Economizer) tubesheets/heads/economizer
30HX-900-021 30GX160-176 Insulation Kit tubesheets/heads/economizer

30HX161-186 (169, 1 Pass Cooler with Economizer)
30GX205-265 Insulation Kit
30HX-900-022 30GX206-271 (189, 2 Pass Cooler with Economizer) tubesheets/heads/economizer
30HX-900-023 30GX205-265 Insulation Kit tubesheets/heads/economizer

30HX206-271 (189, 1 Pass Cooler with Economizer)
80
APPENDIX D
Compressor Protection Module Configuration Header Punch-Outs and Overload Settings
2-Compressor Units
UNIT PUNCH OUTS PUNCH OUTS COMP A1 COMP B1

MODEL NUMBER FOR CPM-A FOR CPM-B OVERLOAD SETTING OVERLOAD SETTING
30GX-080---1 1,2,3,6,7,8 1,2,3,5,6,7,8 85 71
30GX-080---2 1,2,5,6,7 1,2,4,5,7 128 107
30GX-080---5 1,4,8 1,3,6,7,8 234 195
30GX-080---6 1,2,4,5,7,8 1,2,3,6,8 106 88
30GX-080---8 1,4,5 1,3,5,6,7 223 183
30GX-080---9 1,2,5,7 1,2,4,5 135 111
30GX-090---1 1,2,4,5,6 1,2,3,5,6,7,8 103 71
30GX-090---2 1,3,4,5,6,7 1,2,4,5,7 156 107
30GX-090---5 2,3,4,6 1,3,5,7,8 285 195
30GX-090---6 1,2,5,6,7 1,2,3,6,8 129 88
30GX-090---8 2,3,4,5,6,8 1,3,5,6,7 269 183
30GX-090---9 1,3,4,5,7 1,2,4,5 163 111
30GX-105---8 2,3,5,6 1,3,8 299 207
30GX-105---9 1,3,4 1,2,4 181 125
30GX-106---1 1,2,4,6,8 1,2,3,5,7 116 80
30GX-106---2 1,3,4,7,8 1,2,4,7 175 120
30GX-106---5 2,3 1,4,5,8 320 220
30GX-106---6 1,2,6 1,2,4,5,6,7,8 145 100
30GX-106---8 2,3,5,6 1,3,8 299 207
30GX-106---9 1,3,4 1,2,4 181 125
30GX-115---1 1,2,6,7,8 1,2,3,5,7 141 80
30GX-115---2 1,4,5,6,8 1,2,4,7 213 120
30GX-115---5 3,4,5 1,4,5,8 390 220
30GX-115---6 1,3,4,7 1,2,4,5,6,7,8 176 100
30GX-115---8 2,6,7,8 1,3,8 363 207
30GX-115---9 1,4,5,8 1,2,4 220 125
30GX-125---1 1,2,6,7,8 1,2,3,8 141 96
30GX-125---2 1,4,5,6,8 1,2,6 213 145
30GX-125---5 3,4,5 2,3,4,5,6,7,8 390 265
30GX-125---6 1,3,4,7 1,2,4,7,8 176 120
30GX-125---8 2,6,7,8 1,5 363 250
30GX-125---9 1,4,5,8 1,2,8 220 151
30GX-136---1 1,2,6,7,8 1,2,4,6,8 141 116
30GX-136---2 1,4,5,6,8 1,3,4,7,8 213 175
30GX-136---5 3,4,5 2,3 390 320
30GX-136---6 1,3,4,7 1,2,6 176 145
30GX-136---8 2,6,7,8 2,3,5,6 363 299
30GX-136---9 1,4,5,8 1,3,4 220 181
30GX-150---8 2,3,5,6 4,6 299 451
30GX-150---9 1,3,4 2,3,4,5,7,8 181 273
30GX-151---1 1,3,4,6,8 1,2,4,6,8 172 116
30GX-151---2 1,7 1,3,4,7,8 260 175
30GX-151---5 6,7,8 2,3 475 320
30GX-151---6 1,4,5,6 1,2,6 215 145
30GX-160---8 2,6,7,8 4,6 363 451
30GX-160---9 1,4,5,8 2,3,4,5,7,8 220 273
30GX-161---1 1,3,4,6,8 1,2,6,7,8 172 141
30GX-161---2 1,7 1,4,5,6,8 260 213
30GX-161---5 6,7,8 3,4,5 475 390
30GX-161---6 1,4,5,6 1,3,4,7 215 176
30GX-161---8 4,6 2,6,7,8 451 363
30GX-161---9 2,3,4,5,7,8 1,4,5,8 273 220
30GX-175---8 4,6 4,6 451 451
30GX-175---9 2,3,4,5,7,8 2,3,4,5,7,8 273 273
30GX-176---1 1,3,4,6,8 1,3,4,6,8 172 172
30GX-176---2 1,7 1,7 260 260
30GX-176---5 6,7,8 6,7,8 475 475
30GX-176---6 1,4,5,6 1,4,5,6 215 215
30HXA076---1 1,2,3,5,6,7,8 1,2,3,5,6,7,8 71 71
30HXA076---2 1,2,4,5,7 1,2,4,5,7 107 107
30HXA076---3 1,2,4,7 1,2,4,7 122 122
30HXA076---5 1,3,6,7,8 1,3,6,7,8 195 195
30HXA076---6 1,2,3,6,8 1,2,3,6,8 88 88
30HXA076---8 1,3,5,6,7 1,3,5,6,7 183 183
30HXA076---9 1,2,4,5 1,2,4,5 111 111
30HXA086---1 1,2,3,6,7,8 1,2,3,5,6,7,8 85 71
30HXA086---2 1,2,5,6,7 1,2,4,5,7 128 107
30HXA086---3 1,2,7,8 1,2,4,7 148 122
30HXA086---5 1,4,8 1,3,6,7,8 234 195
30HXA086---6 1,2,4,5,7,8 1,2,3,6,8 106 88
30HXA086---8 1,4,5 1,3,5,6,7 223 183
30HXA086---9 1,2,5,7 1,2,4,5 135 111
81
APPENDIX D (cont)
Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont)
2-Compressor Units
30HXA096---1 1,2,4,5,6 1,2,3,5,6,7,8 103 71
30HXA096---2 1,3,4,5,6,7 1,2,4,5,7 156 107
30HXA096---3 1,3,4,8 1,2,4,7 179 122
30HXA096---5 2,3,4,6 1,3,6,7,8 285 195
30HXA096---6 1,2,5,6,7 1,2,3,6,8 129 88
30HXA096---8 2,3,4,5,6,8 1,3,5,6,7 269 183
30HXA096---9 1,3,4,5,7 1,2,4,5 163 111
30HXA106---1 1,2,4 1,2,3,5,6,7,8 125 71
30HXA106---2 1,3,5,7,8 1,2,4,5,7 190 107
30HXA106---3 1,4,5,7,8 1,2,4,7 217 122
30HXA106---5 2,4 1,3,6,7,8 347 195
30HXA106---6 1,3,4,5,6,7 1,2,3,6,8 157 88
30HXA106---8 2,4,5,6 1,3,5,6,7 326 183
30HXA106---9 1,3,6,7 1,2,4,5 198 111
30HXA116---1 1,2,4 1,2,3,6,7,8 125 85
30HXA116---2 1,3,5,7,8 1,2,5,6,7 190 128
30HXA116---3 1,4,5,6,8 1,2,7,8 217 148
30HXA116---5 2,4 1,4,8 347 234
30HXA116---6 1,3,4,5,6,7 1,2,4,5,7,8 157 106
30HXA116---8 2,4,5,6 1,4,5 326 223
30HXA116---9 1,3,6,7 1,2,5,7 198 135
30HXA126---1 1,2,4 1,2,4,5,6 125 103
30HXA126---2 1,3,5,7,8 1,3,4,5,6,7 190 156
30HXA126---3 1,4,5,7,8 1,3,4,8 217 179
30HXA126---5 2,4 2,3,4,6 347 285
30HXA126---6 1,3,4,5,6,7 1,2,5,6,7 157 129
30HXA126---8 2,4,5,6 2,3,4,5,6,8 326 269
30HXA126---9 1,3,6,7 1,3,4,5,7 198 163
30HXA136---1 1,2 1,2,4,5,6 153 103
30HXA136---2 1,4,7,8 1,3,4,5,6,7 231 156
30HXA136---3 2,3,4,5,6,7,8 1,3,4,8 266 179
30HXA136---5 3,6,8 2,3,4,6 423 285
30HXA136---6 1,3,5,7 1,2,5,6,7 191 129
30HXA136---8 3,4,8 2,3,4,5,6,8 401 269
30HXA136---9 1,5,6 1,3,4,5,7 243 163
30HXA146---1 1,2 1,2,4 153 125
30HXA146---2 1,4,7,8 1,3,5,7,8 231 190
30HXA146---3 2,3,4,5,6,7,8 1,4,5,7,8 266 217
30HXA146---5 3,6,8 2,4 423 347
30HXA146---6 1,3,5,7 1,3,4,5,6,7 191 157
30HXA146---8 3,4,8 2,4,5,6 401 326
30HXA146---9 1,5,6 1,3,6,7 243 198
30HXA161---1 1,3,4,6,8 1,2,4,6,8 172 116
30HXA161---2 1,7 1,3,4,7,8 260 175
30HXA161---3 2,3,4,5 1,3,6,7 299 199
30HXA161---5 6,7,8 2,3 475 320
30HXA161---6 1,4,5,6 1,2,6 215 145
30HXA161---8 4,6 2,3,5,6 451 299
30HXA161---9 2,3,4,5,7,8 1,3,4 273 181
30HXA171---1 1,2,6,7,8 1,3,4,6,8 141 172
30HXA171---2 1,4,5,6,8 1,7 213 260
30HXA171---3 1,5,6,8 2,3,5,6 241 299
30HXA171---5 3,4,5 6,7,8 390 475
30HXA171---6 1,3,4,7 1,4,5,6 176 215
30HXA171---8 2,6,7,8 4,6 363 451
30HXA171---9 1,4,5,8 2,3,4,5,7,8 220 273
30HXA186---1 1,3,4,6,8 1,3,4,6,8 172 172
30HXA186---2 1,7 1,7 260 260
30HXA186---3 2,3,5,6 2,3,5,6 299 299
30HXA186---5 6,7,8 6,7,8 475 475
30HXA186---6 1,4,5,6 1,4,5,6 215 215
30HXA186---8 4,6 4,6 451 451
30HXA186---9 2,3,4,5,7,8 2,3,4,5,7,8 273 273
30HXC076---1 1,2,3,4,5,6 1,2,3,4,5,6 50 50
30HXC076---2 1,2,3,5,6,7 1,2,3,5,6,7 73 73
30HXC076---3 1,2,3,5 1,2,3,5 83 83
30HXC076---5 1,2,5,7,8 1,2,5,7,8 133 133
30HXC076---6 1,2,3,4,6,8 1,2,3,4,6,8 60 60
30HXC076---8 1,2,4 1,2,4 125 125
30HXC076---9 1,2,3,5,6 1,2,3,5,6 76 76
30HXC086---1 1,2,3,4,6,7 1,2,3,4,5,6 58 50
30HXC086---2 1,2,3,6,8 1,2,3,5,6,7 88 73
30HXC086---3 1,2,4,5,6,7 1,2,3,5 101 83
30HXC086---5 1,3,4,5,7,8 1,2,5,7,8 161 133
30HXC086---6 1,2,3,5,6,7 1,2,3,4,6,8 73 60
30HXC086---8 1,2 1,2,4 152 125
30HXC086---9 1,2,3,7,8 1,2,3,5,6 92 76
82
APPENDIX D (cont)
2-Compressor Units

30HXC096---1 1,2,3,5,6,7,8 1,2,3,4,5,6 71 50
30HXC096---2 1,2,4,5,7 1,2,3,5,6,7 108 73
30HXC096---3 1,2,4,7 1,2,3,5 122 83
30HXC096---5 1,3,6,7,8 1,2,5,7,8 197 133
30HXC096---6 1,2,3,6 1,2,3,4,6,8 89 60
30HXC096---8 1,3,5,6,7 1,2,4 183 125
30HXC096---9 1,2,4,5 1,2,3,5,6 111 76
30HXC106---1 1,2,3,6,7 1,2,3,4,5,6 86 50
30HXC106---2 1,2,5,6,8 1,2,3,5,6,7 130 73
30HXC106---3 1,2,6 1,2,3,5 146 83
30HXC106---5 1,5,6,7,8 1,2,5,7,8 238 133
30HXC106---6 1,2,4,5,7 1,2,3,4,6,8 108 60
30HXC106---8 1,4,5,8 1,2,4 220 125
30HXC106---9 1,2,5,7,8 1,2,3,5,6 133 76
30HXC116---1 1,2,3,6,7 1,2,3,4,6,7 86 58
30HXC116---2 1,2,5,6,8 1,2,3,6,8 130 88
30HXC116---3 1,2,6 1,2,4,5,6,7 146 101
30HXC116---5 1,5,6,7,8 1,3,4,5,7,8 238 161
30HXC116---6 1,2,4,5,7 1,2,3,5,6,7 108 73
30HXC116---8 1,4,5,8 1,2 220 152
30HXC116---9 1,2,5,7,8 1,2,3,7,8 133 92
30HXC126---1 1,2,3,6,7 1,2,3,5,6,7,8 86 71
30HXC126---2 1,2,5,6,8 1,2,4,5,7 130 108
30HXC126---3 1,2,6 1,2,4,7 146 122
30HXC126---5 1,5,6,7,8 1,3,6,7,8 238 197
30HXC126---6 1,2,4,5,7 1,2,3,6 108 89
30HXC126---8 1,4,5,8 1,3,5,6,7 220 183
30HXC126---9 1,2,5,7,8 1,2,4,5 133 111
30HXC136---1 1,2,4,5,6 1,2,3,5,6,7,8 103 71
30HXC136---2 1,3,4,5,6,7 1,2,4,5,7 156 108
30HXC136---3 1,3,4,7 1,2,4,7 177 122
30HXC136---5 2,3,4,6 1,3,6,7,8 285 197
30HXC136---6 1,2,5,6,7 1,2,3,6 129 89
30HXC136---8 2,3,4,5,6,7 1,3,5,6,7 267 183
30HXC136---9 1,3,4,5,7,8 1,2,4,5 162 111
30HXC146---1 1,2,4,5,6 1,2,3,6,7 103 86
30HXC146---2 1,3,4,5,6,7 1,2,5,6,8 156 130
30HXC146---3 1,3,4,7 1,2,6 177 146
30HXC146---5 2,3,4,6 1,5,6,7,8 285 238
30HXC146---6 1,2,5,6,7 1,2,4,5,7 129 108
30HXC146---8 2,3,4,5,6,7 1,4,5,8 267 220
30HXC146---9 1,3,4,5,7,8 1,2,5,7,8 162 133
30HXC161---1 1,2,4,6,7,8 1,2,3,5,7,8 112 78
30HXC161---2 1,3,4,6,7 1,2,4,6 170 117
30HXC161---3 1,3,5,7 1,2,5,6 192 132
30HXC161---5 2,3,6,8 1,4,5,6,8 310 214
30HXC161---6 1,2,6,7,8 1,2,3 140 97
30HXC161---8 2,4,5,7 1,3,6,7 289 198
30HXC161---9 1,3,4,7,8 1,2,4,7,8 175 120
30HXC171---1 1,2,3,7 1,2,4,6,7,8 94 112
30HXC171---2 1,2,6,7 1,3,4,6,7 142 170
30HXC171---3 1,3,4,5,6,8 1,3,5,7 158 192
30HXC171---5 1,7,8 2,3,6,8 259 310
30HXC171---6 1,2,4,6 1,2,6,7,8 117 140
30HXC171---8 1,5,6,7,8 2,3,4,7 237 289
30HXC171---9 1,2,6,8 1,3,4,7,8 144 175
30HXC186---1 1,2,4,6,7,8 1,2,4,6,7,8 112 112
30HXC186---2 1,3,4,6,7 1,3,4,6,7 170 170
30HXC186---3 1,3,5,7 1,3,5,7 192 192
30HXC186---5 2,3,6,8 2,3,6,8 310 310
30HXC186---6 1,2,6,7,8 1,2,6,7,8 140 140
30HXC186---8 2,3,4,7 2,3,4,7 289 289
30HXC186---9 1,3,4,7,8 1,3,4,7,8 175 175
83
APPENDIX D (cont)
3-Compressor Units
UNIT PUNCH OUTS PUNCH OUTS PUNCH OUTS COMP A1 COMP A2 COMP B1
OVERLOAD OVERLOAD OVERLOAD
MODEL NUMBER FOR CPM-A1 FOR CPM-A2 FOR CPM-B1 SETTING SETTING SETTING
30GX205---8 2,6,7,8 1,3,8 4,6 363 207 451
30GX205---9 1,4,5,8 1,2,4 2,3,4,5,7,8 220 125 273
30GX206---1 1,3,4,6,8 1,2,3,5,7 1,2,6,7,8 172 80 141
30GX206---2 1,7 1,2,4,7 1,4,5,6,8 260 120 213
30GX206---5 6,7,8 1,4,5,8 3,4,5 475 220 390
30GX206---6 1,4,5,6 1,2,4,5,6,7,8 1,3,4,7 215 100 176
30GX225---8 4,6 1,5 4,6 451 250 451
30GX225---9 2,3,4,5,7,8 1,2,8 2,3,4,5,7,8 273 151 273
30GX226---1 1,3,4,6,8 1,2,3,8 1,3,4,6,8 172 96 172
30GX226---2 1,7 1,2,6 1,7 260 145 260
30GX226---5 6,7,8 2,3,4,5,6,7,8 6,7,8 475 265 475
30GX226---6 1,4,5,6 1,2,4,7,8 1,4,5,6 215 120 215
30GX226---8 4,6 1,5 4,6 451 250 451
30GX226---9 2,3,4,5,7,8 1,2,8 2,3,4,5,7,8 273 151 273
30GX250---8 4,6 2,6,7,8 4,6 451 363 451
30GX250---9 2,3,4,5,7,8 1,4,5,6 2,3,4,5,7,8 273 220 273
30GX251---1 1,3,4,6,8 1,3,4,6,8 1,2,6,7,8 172 172 141
30GX251---2 1,7 1,7 1,4,5,6,8 260 260 213
30GX251---5 6,7,8 6,7,8 3,4,5 475 475 390
30GX251---6 1,4,5,6 1,4,5,6 1,3,4,7 215 215 176
30GX265---1 1,3,4,6,8 1,3,4,6,8 1,3,4,6,8 172 172 172
30GX265---2 1,7 1,7 1,7 260 260 260
30GX265---5 6,7,8 6,7,8 6,7,8 475 475 475
30GX265---6 1,4,5,6 1,4,5,6 1,4,5,6 215 215 215
30GX265---8 4,6 4,6 4,6 451 451 451
30GX265---9 2,3,4,5,7,8 2,3,4,5,7,8 2,3,4,5,7,8 273 273 273
30HXA206---1 1,2,6,7,8 1,2,3,5,7 1,3,4,6,8 141 80 172
30HXA206---2 1,4,5,6,8 1,2,4,7 1,7 213 120 260
30HXA206---3 1,5,6,8 1,2,5,8 2,3,5,6 241 137 299
30HXA206---5 3,4,5 1,4,5,8 6,7,8 390 220 475
30HXA206---6 1,3,4,7 1,2,4,5,6,7,8 1,4,5,6 176 100 215
30HXA206---8 2,6,7,8 1,3,8 4,6 363 207 451
30HXA206---9 1,4,5,8 1,2,4 2,3,4,5,7,8 220 125 273
30HXA246---1 1,3,4,6,8 1,2,4,6,8 1,3,4,6,8 172 116 172
30HXA246---2 1,7 1,3,4,7,8 1,7 260 175 260
30HXA246---3 2,3,5,6 1,3,6,7 2,3,5,6 299 199 299
30HXA246---5 6,7,8 2,3 6,7,8 475 320 475
30HXA246---6 1,4,5,6 1,2,6 1,4,5,6 215 145 215
30HXA246---8 4,6 2,3,5,6 4,6 451 299 451
30HXA246---9 2,3,4,5,7,8 1,3,4 2,3,4,5,7,8 273 181 273
84
APPENDIX D (cont)
3-Compressor Units
UNIT PUNCH OUTS PUNCH OUTS PUNCH OUTS COMP A1 COMP A2 COMP B1
OVERLOAD OVERLOAD OVERLOAD
MODEL NUMBER FOR CPM-A1 FOR CPM-A2 FOR CPM-B1 SETTING SETTING SETTING
30HXA261---1 1,3,4,6,8 1,2,6,7,8 1,3,4,6,8 172 141 172
30HXA261---2 1,7 1,4,5,6,8 1,7 260 213 260
30HXA261---3 2,3,5,6 1,5,6,8 2,3,5,6 299 241 299
30HXA261---5 6,7,8 3,4,5 6,7,8 475 390 475
30HXA261---6 1,4,5,6 1,3,4,7 1,4,5,6 215 176 215
30HXA261---8 4,6 2,6,7,8 4,6 451 363 451
30HXA261---9 2,3,4,5,7,8 1,4,5,8 2,3,4,5,7,8 273 220 273
30HXA271---1 1,3,4,6,8 1,3,4,6,8 1,3,4,6,8 172 172 172
30HXA271---2 1,7 1,7 1,7 260 260 260
30HXA271---3 2,3,5,6 2,3,5,6 2,3,5,6 299 299 299
30HXA271---5 6,7,8 6,7,8 6,7,8 475 475 475
30HXA271---6 1,4,5,6 1,4,5,6 1,4,5,6 215 215 215
30HXA271---8 4,6 4,6 4,6 451 451 451
30HXA271---9 2,3,4,5,7,8 2,3,4,5,7,8 2,3,4,5,7,8 273 273 273
30HXC206---1 1,2,3,7 1,2,3,4,5,8 1,2,4,6,7,8 94 53 112
30HXC206---2 1,2,6,7 1,2,3,5,7 1,3,4,6,7 142 80 170
30HXC206---3 1,3,4,5,6,8 1,2,3,6 1,3,5,7 158 90 192
30HXC206---5 1,7,8 1,2,6 2,3,6,8 259 145 310
30HXC206---6 1,2,4,6 1,2,3,4,7 1,2,6,7,8 117 66 140
30HXC206---8 1,5,6,7,8 1,2,5,7 2,3,4,7 237 135 289
30HXC206---9 1,2,6,8 1,2,3,5,8 1,3,4,7,8 144 82 175
30HXC246---1 1,2,4,6,7,8 1,2,3,5,7,8 1,2,4,6,7,8 112 78 112
30HXC246---2 1,3,4,6,7 1,2,4,6 1,3,4,6,7 170 117 170
30HXC246---3 1,3,5,7 1,2,5,6 1,3,5,7 192 132 192
30HXC246---5 2,3,6,8 1,4,5,6,8 2,3,6,8 310 214 310
30HXC246---6 1,2,6,7,8 1,2,3 1,2,6,7,8 140 97 140
30HXC246---8 2,3,4,7 1,3,6,7 2,3,4,7 289 198 289
30HXC246---9 1,3,4,7,8 1,2,4,7,8 1,3,4,7,8 175 120 175
30HXC261---1 1,2,4,6,7,8 1,2,3,7 1,2,4,6,7,8 112 94 112
30HXC261---2 1,3,4,6,7 1,2,6,7 1,3,4,6,7 170 142 170
30HXC261---3 1,3,5,7 1,3,4,5,6,8 1,3,5,7 192 158 192
30HXC261---5 2,3,6,8 1,7,8 2,3,6,8 310 259 310
30HXC261---6 1,2,6,7,8 1,2,4,6 1,2,6,7,8 140 117 140
30HXC261---8 2,3,4,7 1,5,6,7,8 2,3,4,7 289 237 289
30HXC261---9 1,3,4,7,8 1,2,6,8 1,3,4,7,8 175 144 175
30HXC271---1 1,2,4,6,7,8 1,2,4,6,7,8 1,2,4,6,7,8 112 112 112
30HXC271---2 1,3,4,6,7 1,3,4,6,7 1,3,4,6,7 170 170 170
30HXC271---3 1,3,5,7 1,3,5,7 1,3,5,7 192 192 192
30HXC271---5 2,3,6,8 2,3,6,8 2,3,6,8 310 310 310
30HXC271---6 1,2,6,7,8 1,2,6,7,8 1,2,6,7,8 140 140 140
30HXC271---8 2,3,4,7 2,3,4,7 2,3,4,7 289 289 289
30HXC271---9 1,3,4,7,8 1,3,4,7,8 1,3,4,7,8 175 175 175
85
APPENDIX E
The following charts list pressure drops for coolers and condensers.
100
136, 146
116, 126 161, 171
076, 086 106
186
096
206
246-271
PRESSURE DROP (FT WG)
10
1
100 1000
COOLER FLOW RATE (GPM)
Unit Size Range
NOTE: Ft of water = 2.31 x change in psig.
30HX COOLER PRESSURE DROP — ENGLISH

1000
136, 146
116, 126
106 161, 171
076, 086 096 186
100
PRESSURE DROP (KPA)
206
246-271
10
1
1 10 100
COOLER FLOW RATE (L/S)
Unit Size Range
30HX COOLER PRESSURE DROP — SI
86
APPENDIX E (cont)
Unit Size Range

30HX CONDENSER PRESSURE DROP — ENGLISH
Unit Size Range
30HX CONDENSER PRESSURE DROP — SI
87
APPENDIX E (cont)
30GX080-176 COOLER PRESSURE DROP — 30GX080-176 COOLER PRESSURE DROP —

ENGLISH SI
100
1000
PRESSURE DROP (kpa)
100
PRESSURE DROP (ft wg)
30GX205, 206
6
65
10 20 30GX250, 251, 265

26
,2
,
05 10
,2
51
X2
25
,2
G 30GX225, 226
X2
50
30
X2
G
30
G
30
1
10 100
COOLER FLOW RATE (L/s)
30GX205-265 COOLER PRESSURE DROP —

1 SI
100 1000
COOLER FLOW RATE (GPM)
30GX205-265 COOLER PRESSURE DROP —

ENGLISH
88
LEGEND
HPS — High Pressure Switch
89
APPENDIX F
Typical System Components, 30GX, With Economizer

LEGEND
HPS — High Pressure Switch

90
APPENDIX F (cont)
Typical System Components, 30HX, Without Economizer

INDEX
Accessing Functions and Subfunctions, 13 Loading Sequence, 6
Actual Start-Up, 67 Major System Components, 3
Adjusting PID Routines, 10 Minimum Load Valve, 7
Alarms and Alerts, 43 Minutes Left for Start, 6
Automatic Default Display, 13 Minutes Off Time, 6
Back Pressure Valve, 4 Moisture-Liquid Indicator, 58
Burnout Clean-Up Procedure, 58 Motor Cooling, 4
Capacity Control Overrides, 7 Oil Charging/Low Oil Recharging, 55
Capacity Control, 6 Oil Filter Maintenance, 56
Capacity Sequence Determination, 7 Oil Pumps, 4
Carrier Comfort Network (CCN) Interface, 64 Oil Separator Heaters (30GX), 62
Checking Display Codes, 43 Operating Sequence, 67
Close Control, 7 Operation Data, 3
Coil Cleaning, 53 Power Failure External to the Unit, 43
Complete Unit Stoppage, 43 Pre-Start-Up Procedure, 67
Compressor Alarm/Alert Circuit, 43 Pressure Relief Valves, 62
Compressor Changeout Sequence, 56 Pressure Transducer Calibration, 59
Compressor Protection Module (CPM), 3, 4 Pressure Transducers, 59
Compressor Protection, 62 Processor Module (PSIO-1), 3, 64, 66
Condenser Coils (30GX Only), 53 PSIO-2 (8052) Module, 3, 64
Condenser Fans (30GX Only), 54 Refrigerant Charging/Adding Charge, 54
Condenser Pump Control, 12 Relief Devices, 62
Control (LOR) Switch, 3 Replacing Defective Processor Module, 66
Control Modules, 64 Replacing the External Oil Filter, 56
Cooler and Condenser (30HXC) Pump Control, 10 Replacing the Internal Oil Filter, 56
Cooler Heater Control, 13 Restart Procedure, 43
Cooler Protection, 62 Retubing, 52
Cooler Pump Control, 10 Return Fluid Temperature Reset, 39
Demand Limit, 39 Safety Considerations, 1
Demand Limit, (CCN Loadshed Controlled), 42 Safety Devices, 62
DSIO-HV Relay Module, 3, 64 Schedule Function, 37
Economizer Operation, 4 Sensors, 4
Electronic Expansion Device (EXD), 3 Service Function, 30
Electronic Expansion Device Module, 3 Service, 52
EXD Troubleshooting Procedure, 50 Servicing Coolers and Condensers, 52
External Temperature Reset, 39 Set Point Function, 25
Externally Powered Demand Limit, 42 Single Circuit Stoppage, 43
Externally Powered Reset, 39 Start-Up and Operation, 67
EXV Driver Module (DSIO-EXV), 64 Start-Up Checklist, CL-1
EXV Operation, 3 Status Function, 16
Field Wiring, 68 System Check, 67
Filter Drier, 58 Temperature Reset, 39
Head Pressure Control, 8 Test Function, 25
High Voltage Relay Module (DSIO-HV), 64, 66 Thermistor Replacement, 58
History Function, 25 Thermistors, 58
Inspecting/Cleaning Heat Exchangers, 53 Tightening Cooler/Condenser Head Bolts, 52
Inspecting/Opening Economizers, 51 Troubleshooting, 43
Inspecting/Opening Electronic Expansion Valves, 51 Tube Plugging, 52
Keypad and Display Module (HSIO-II), 3, 13 Unit Shutoff, 43
Lead/Lag Determination, 7 Water Treatment, 53
Liquid Line Service Valve, 58 Winter Shutdown Preparation, 66
Wye-Delta vs. Across-the-Line (XL) Starting Option, 5
91
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your knowledge of the equip-
ment discussed in this manual, including:
• Unit Familiarization • Maintenance
• Installation Overview • Operating Sequence
A large selection of product, theory, and skills programs are available, using popular video-based for-
mats and materials. All include video and/or slides, plus companion book.
Classroom Service Training which includes ‘‘hands-on’’ experience with the products in our labs that
can mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks.
Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212

[ ] Packaged Service Training [ ] Classroom Service Training
Copyright 1998 Carrier Corporation
Book 2 PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg 92 1099 1-98 Replaces: 30G,H-2T
Tab 5
START-UP CHECKLIST FOR 30GX,HX LIQUID CHILLERS
(Remove and use for job file.)
A. Preliminary Information
JOB NAME
LOCATION
INSTALLING CONTRACTOR
DISTRIBUTOR
START-UP PERFORMED BY
EQUIPMENT:
MODEL S/N
COMPRESSORS:
CIRCUIT A CIRCUIT B
1) MODEL # 1) MODEL #
S/N S/N
2) MODEL # 2) MODEL #
S/N S/N
COOLER:
MODEL # S/N
CONDENSER: (30HX ONLY)
MODEL # S/N
AIR-HANDLING EQUIPMENT:
MANUFACTURER
MODEL # S/N
ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES
Book 2 PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg CL-1 1-98 Replaces: 30G,H-2T
Tab 5c
B. Preliminary Equipment Check
IS THERE ANY SHIPPING DAMAGE? IF SO, WHERE
WILL THIS DAMAGE PREVENT UNIT START-UP?
M UNIT IS LEVEL IN ITS INSTALLATION
M UNIT IS SUPPLIED WITH THE PROPER CONTROL VOLTAGE VAC
M ELECTRICAL CIRCUIT WIRING HAS BEEN SIZED AND INSTALLED PROPERLY
M UNIT GROUND WIRE HAS BEEN CONNECTED
M ELECTRICAL CIRCUIT PROTECTION HAS BEEN SIZED AND INSTALLED PROPERLY
M ALL TERMINALS ARE TIGHT
M ALL CABLES AND THERMISTORS HAVE BEEN INSPECTED FOR CROSSED WIRES
M ALL PLUG ASSEMBLIES ARE TIGHT
CHECK AIR-HANDLING SYSTEM
M ALL AIR HANDLERS ARE OPERATING
M ALL CHILLED WATER VALVES ARE OPEN
M ALL FLUID PIPING IS CONNECTED PROPERLY
M ALL AIR HAS BEEN VENTED FROM THE SYSTEM
M CHILLED WATER PUMP (CWP) IS OPERATING WITH THE CORRECT ROTATION
CWP AMPERAGE: RATED: ACTUAL:
PUMP PRESSURES: INLET: OUTLET:
CHECK CONDENSER SYSTEM (30HX ONLY):
M ALL CONDENSER WATER VALVES ARE OPEN
M ALL CONDENSER PIPING IS CONNECTED PROPERLY
ALL AIR HAS BEEN VENTED FROM THE SYSTEM
M CONDENSER WATER PUMP IS OPERATING WITH THE CORRECT ROTATION
CONDENSER WATER PUMP AMP: RATED: ACTUAL:
PUMP PRESSURES: INLET: OUTLET:
CHECK REMOTE CONDENSER SYSTEM (30HXA ONLY):
M ALL CONDENSER PIPING IS CONNECTED PROPERLY
M CONDENSER LINES/CONDENSER HAS BEEN EVACUATED, AS REQUIRED
CL-2
C. Unit Start-Up
M CWP STARTER HAS BEEN PROPERLY INTERLOCKED WITH THE CHILLER
M ALL LIQUID VALVES ARE BACKSEATED
M ALL DISCHARGE VALVES ARE OPEN
M ALL SUCTION VALVES ARE OPEN, IF EQUIPPED
M ALL OIL LINE VALVES ARE OPEN
M UNIT HAS BEEN LEAK CHECKED
LOCATE, REPAIR, AND REPORT ANY REFRIGERANT LEAKS
M CHECK VOLTAGE IMBALANCE: AB AC BC

AVERAGE VOLTAGE = (SEE INSTALLATION INSTRUCTIONS)
MAXIMUM DEVIATION = (SEE INSTALLATION INSTRUCTIONS)
VOLTAGE IMBALANCE = (SEE INSTALLATION INSTRUCTIONS)
M VOLTAGE IMBALANCE IS LESS THAN 2%

DO NOT START CHILLER IF VOLTAGE IMBALANCE IS GREATER THAN 2%. CONTACT LOCAL POWER
COMPANY FOR ASSISTANCE.
M ALL INCOMING POWER VOLTAGE IS WITHIN RATED VOLTAGE RANGE
CHECK COMPRESSOR RUNNING CURRENT:
COMPRESSOR NO LOADERS ONE LOADER FULL LOAD
COMP A1,L1 AMPS AMPS AMPS
COMP B1,L1 AMPS AMPS AMPS
CHECK COOLER WATER LOOP:
WATER LOOP DESIGN VOLUME: GALLONS (LITERS)

CALCULATED VOLUME GALLONS (LITERS)
3 GALLONS/NOMINAL TON (3.32 LITERS/kW) FOR AIR CONDITIONING
6 GALLONS/NOMINAL TON (6.65 LITERS/kW) FOR PROCESS COOLING
M PROPER LOOP VOLUME ESTABLISHED
M PROPER LOOP CORROSION INHIBITOR INCLUDED GALLONS (LITERS) OF
M PROPER LOOP FREEZE PROTECTION INCLUDED, IF REQUIRED
GALLONS (LITERS) OF
M PIPING INCLUDES ELECTRIC HEATER TAPE, IF EXPOSED TO THE OUTSIDE
M INLET PIPING TO COOLER INCLUDES A 40 MESH STRAINER
CL-3
CHECK PRESSURE DROP ACROSS THE COOLER:
ENTERING COOLER: PSIG (kPa)
LEAVING COOLER: PSIG (kPa)
(LEAVING − ENTERING) × 2.31 FT OF H2O/PSIG = FT OF H2O
(LEAVING − ENTERING) × 0.334 M OF H2O/kPa = M OF H2O
PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (IN PRODUCT DATA LITERATURE) TO
DETERMINE TOTAL GALLONS/MINUTE (GPM) OR LITERS PER SECOND (L/S) AND FIND UNIT’S MINIMUM
FLOW RATE.
TOTAL GPM (L/S):
GPM/NOMINAL TON (L/S PER TON) =
M TOTAL GPM (L/S) IS GREATER THAN UNIT’S MINIMUM FLOW RATE
M TOTAL GPM (L/S) MEETS JOB SPECIFIED REQUIREMENT OF GPM (L/S)
M COOLER HEATER FUSE INSTALLED, AND HEATERS ARE ACTIVE (IF USED)
CHECK CONDENSER WATER LOOP:
M PROPER LOOP CORROSION INHIBITOR INCLUDED
GALLONS (LITERS) OF
M INLET PIPING TO CONDENSER INCLUDES A 40 MESH STRAINER
CHECK PRESSURE DROP ACROSS THE CONDENSER (30HXC ONLY):
ENTERING CONDENSER: PSIG (kPa)
LEAVING CONDENSER: PSIG (kPa)
(LEAVING − ENTERING) × 2.31 FT OF H2O = FT OF H2O
(LEAVING − ENTERING) × 0.334 M OF H2O/kPa = M OF H2O
PLOT CONDENSER PRESSURE DROP ON PERFORMANCE DATA CHART (IN PRODUCT DATA LITERATURE) TO
DETERMINE TOTAL GALLONS/MINUTE (GPM) OR LITERS PER SECOND (L/S) AND FIND UNIT’S MINIMUM
FLOW RATE.
TOTAL GPM (L/S):
GPM/NOMINAL TON (L/S PER TON) =
M TOTAL CONDENSER GPM (L/S) IS GREATER THAN UNIT’S MINIMUM FLOW RATE
M TOTAL GPM MEETS JOB SPECIFIED REQUIREMENT OF GPM (L/S)
CL-4
PERFORM TEST FUNCTION (INDICATE POSITIVE RESULT):
ONCE POWER IS SUPPLIED TO THE UNIT, CHECK THE DISPLAY FOR ANY ALARMS, SUCH AS PHASE REVER-
SAL. FOLLOW THE TEST FUNCTION INSTRUCTIONS IN THE CONTROLS AND TROUBLESHOOTING LITERA-
TURE. BE SURE TO CHECK FOR PROPER FAN ROTATION WITH THE FAN TEST SECTIONS. BE SURE ALL SERV-
ICE VALVES ARE OPEN BEFORE BEGINNING THE COMPRESSOR TEST SECTION. ITEMS MARKED WITH ‘‘†’’
CAN BE TESTED ONLY IF THE UNIT IS CONFIGURED FOR THIS OPTION. DO NOT RUN OIL PUMPS FOR MORE
THAN 20 SECONDS.
M LOADER A1 M LOADER B1
M LOADER A2 M LOADER B2
M MINIMUM LOAD VALVE A† M MINIMUM LOAD VALVE B†
M CIRCUIT A OIL HEATER M CIRCUIT B OIL HEATER
M A1 MOTOR COOLING SOLENOID M B1 MOTOR COOLING SOLENOID
M A2 MOTOR COOLING SOLENOID† M B2 MOTOR COOLING SOLENOID†
M CIRCUIT A OIL PUMP M CIRCUIT B OIL PUMP
M OIL SOLENOID A1 M OIL SOLENOID B1
M OIL SOLENOID A2† M OIL SOLENOID B2†
M CIRCUIT A EXV M FAN 1 (30GX)†
M CIRCUIT B EXV M FAN 2 (30GX)†
M CIRCUIT A WATER VALVE† M FAN 3 (30GX)†
M CIRCUIT A% FAN SPEED (GX)† M FAN 4 (30GX)†
M CIRCUIT B% FAN SPEED (GX)† M FAN 5 (30GX)†
M FAN 6 (30GX)†
M COOLER PUMP†
M COMPRESSOR A1 M CONDENSER PUMP†
M COMPRESSOR A2† M COOLER HEATER†
M COMPRESSOR B1 M ALARM RELAY†
M COMPRESSOR B2†
M CHECK FOR COMMUNICATING MODULES (BLINKING RED AND GREED LEDs)
M CORRECT FLUID SET POINTS ARE ENTERED
COOL SET POINT 1

COOL SET POINT 2
M CORRECT DATE, TIME, AND OPERATING SCHEDULE(S) ARE SET
CL-5
M REVIEW AND RECORD FACTORY CONFIGURATION CODES,
CONFIGURATION CODE 1:
M REVIEW AND RECORD SOFTWARE VERSION,

SOFTWARE CESR500100 VERSION
M REVIEW AND RECORD FIELD CONFIGURATION,
COOLER FLUID SELECT COOLER PUMP CONTROL

MIN LOAD VALVE SELECT CONDENSER PUMP CONTROL
LOADING SEQ. SELECT CONDENSER FLOW SWITCH
LEAD/LAG SEQ. SELECT CONDENSER WATER SENSORS
HEAD PRESSURE CONTROL
MOTORMASTER SELECT
WATER VALVE TYPE
EXTERNAL RESET SENSOR
COOLER PUMP INTERLOCK
TO START THE CHILLER:

BE SURE THAT ALL SERVICE VALVES ARE OPEN, AND ALL PUMPS ARE ON BEFORE ATTEMPTING TO START
THIS MACHINE. ONCE ALL CHECKS HAVE BEEN MADE, MOVE THE SWITCH TO ‘‘LOCAL’’ OR ‘‘REMOTE’’
FROM ‘‘STOP.’’
M UNIT STARTS AND OPERATES PROPERLY.
TEMPERATURES AND PRESSURES:

ONCE THE MACHINE HAS BEEN OPERATING FOR A WHILE AND THE TEMPERATURES AND PRESSURES HAVE
STABLIZED, RECORD THE FOLLOWING:
COOLER EWT
COOLER LWT CIR. A DISCHARGE TEMP
AMBIENT TEMPERATURE CIR. A LIQUID LINE TEMP
CONDENSER EWT CIR. B OIL PRESS
(ENTERING WATER TEMP)
CIR. B SUCTION PRESS
CONDENSER LWT
(LEAVING WATER TEMP) CIR. B DISCHARGE PRESS
CIR. A OIL PRESS CIR. B DISCHARGE TEMP
CIR. A SUCTION PRESS CIR. B LIQUID LINE TEMP
CIR. A DISCHARGE PRESS
NOTE: OIL FILTER PRESSURE DROPS MUST BE CHECKED AFTER INITIAL 200-300 HOURS OF COMPRESSOR
OPERATION. SEE OIL FILTER MAINTENANCE SECTION, PAGE 56.
CL-6
NOTES:
CL-7
Copyright 1998 Carrier Corporation
Book 2 PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg CL-8 1099 1-98 Replaces: 30G,H-2T
Tab 5c

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Controls, Start-Up, Operation,

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Fig. 1 — Compressor Protection Module

Fig. 3 — Wye-Delta Compressor Wiring

Table 4 — Field Configured Chiller Options

Table 5 — Fan Staging Settings for Air Cooled (30GX) Units

CONTROL CONTROL CONTROL

30GX151, 161, 175, 205, 225 30GX176

30GX206, 226, 250 30GX251, 265

Fig. 5 — 30GX Condenser Fan Locations

IS SCT GREATER HAS SCT BEEN 35° F

30GX UNITS — MOTORMASTER III CONTROL INSTALLED

IS SCT GREATER CALCULATE NEW DOES PID OUTPUT

INCREASE INCREASE DECREASE

Table 7 — Keypad and Display Module Usage

Alarm Circuit A Ice Build Factory Operating Hours Set Points

*Subfunctions through are for configuring Holidays 09 through 30.

HSIO FUNCTION KEY

STATUS SERVICE SCHEDULE SERVICE SERVICE SETPOINT

OPERATION KEYPAD ENTRY DISPLAY RESPONSE

To move to another function, Alarms : xx

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

2 General Parameters GENERAL PARAMETERS

Control Mode Displays LOCAL ON/OFF or CCN ON/OFF

Total Capacity Percentage of total circuit capacity

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

Circuit A Oil Switch

Total Capacity Percentage of total circuit capacity

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

Circuit B Oil Switch

Cooler Entering Fluid

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

4-20 mA Reset Signal

4-20 mA Demand Signal

Cooler Pump Relay

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

DUAL SP ACTIVE (1st SP)

DUAL SP ACTIVE (2nd SP)

LOAD LIMIT ACTIVE

LOW SOURCE TEMP PROTECT

RAMP LOADING ACTIVE

TIMED OVERRIDE ACTIVE

LOW COOLER SUCTION TEMP

SLOW CHANGE OVERRIDE

OFF TO ON DELAY ACTIVE

2 CHILLR LEAD LAG ACTIVE

2 CHILLR LL COMM FAILURE

CIR A LOW DISCHG SUPERHT

CIR B LOW DISCHG SUPERHT

CIR A HIGH SDT

CIR B HIGH SDT

10 Capacity Control CAPACITY CONTROL

Liquid Lvl Sensor Cir. A

SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT

Unit Master / Slave 0 = Neither

Slave Chiller State 0 = Chiller OFF

Master / Slave Error 1 = Master / Slave Have Same Address

Table 11 — Reading and Clearing Alarms