Carrier Flotronic Ii 30Gn040 420 Users Manual

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30GN040-420
Flotronic™ II Reciprocating Liquid Chillers
50/60 Hz

Controls, Operation, and
Troubleshooting
with Microprocessor Controls and Electronic Expansion Valves
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . 2-5
Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low-Voltage Relay Module . . . . . . . . . . . . . . . . . . . 4
Electronic Expansion Valve Module . . . . . . . . . . . 4
Options Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Keypad and Display Module
(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . . 4
Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electronic Expansion Valve (EXV) . . . . . . . . . . . . 4
Thermostatic Expansion Valves (TXV) . . . . . . . . 4
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compressor Protection Control
Module (CPCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 24
• EXV UNITS
• TXV UNITS
Pumpout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
• EXV UNITS
• TXV UNITS
Keypad and Display Module
(Also Called HSIO or LID) . . . . . . . . . . . . . . . . . 24
• ACCESSING FUNCTIONS AND SUBFUNCTIONS
• AUTOMATIC DEFAULT DISPLAY
• AUTOMATIC DISPLAY OPERATION/DEFAULT
DISPLAY
• KEYPAD OPERATING INSTRUCTIONS
• STATUS FUNCTION
• TEST FUNCTION
• HISTORY FUNCTION
• SET POINT FUNCTION
• SERVICE FUNCTION
• SCHEDULE FUNCTION
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 47-64
Checking Display Codes . . . . . . . . . . . . . . . . . . . . 47

Page
Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . 48
Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . 48
Lag Compressor Stoppage . . . . . . . . . . . . . . . . . . 48
Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• POWER FAILURE EXTERNAL TO THE UNIT
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Compressor Alarm/Alert Circuit . . . . . . . . . . . . . 50
Electronic Expansion Valve (EXV) . . . . . . . . . . . 55
• EXV OPERATION
• CHECKOUT PROCEDURE
Thermostatic Expansion Valve (TXV) . . . . . . . . . 57
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• LOCATION
• THERMISTOR REPLACEMENT (T1, T2, T7, T8)
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . 60
• TROUBLESHOOTING
• TRANSDUCER REPLACEMENT
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• PROCESSOR MODULE (PSIO), 4IN/4OUT
MODULE (SIO), LOW-VOLTAGE RELAY
MODULE (DSIO-LV), AND EXV DRIVER
MODULE (DSIO-EXV)
• RED LED
• GREEN LED
• PROCESSOR MODULE (PSIO)
• LOW-VOLTAGE RELAY MODULE (DSIO)
• 4IN/4OUT MODULE (SIO)
ACCESSORY UNLOADER INSTALLATION . . . 64-68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• 040-110, 130 (60 Hz) UNITS
(And Associated Modular Units)
• 130 (50 Hz), 150-210 UNITS
(And Associated Modular Units)
FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,70
REPLACING DEFECTIVE PROCESSOR
MODULE (PSIO) . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Catalog No. 563-079
Printed in U.S.A.
Form 30GN-3T
Pg 1
7-95
Replaces: 30G-1T
Tab 5c

Table 1 — Unit Sizes and Modular Combinations

SAFETY CONSIDERATIONS

UNIT MODEL
30GN
040
045
050
060
070
080
090
100
110
130
150
170
190
210
230
245
255
270
290
315
330
360
390
420

Installing, starting up, and servicing this equipment can
be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start up, and service this equipment.
When working on this equipment, observe precautions in
the literature, and on tags, stickers, and labels attached to the
equipment, and any other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting this equipment,
and in handling all electrical components.

Electrical shock can cause personal injury and death.
Shut off all power to this equipment during installation
and service. There may be more than one disconnect
switch. Tag all disconnect locations to alert others not
to restore power until work is completed.

This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short
out components, or to bypass or otherwise depart from
recommended procedures. Any short-to-ground of the
control board or accompanying wiring may destroy the
electronic modules or electrical components.

NOMINAL
TONS
40
45
50
60
70
80
90
100
110
125
145
160
180
200
220
230
240
260
280
300
325
350
380
400

SECTION A
UNIT 30GN
—
—
—
—
—
—
—
—
—
—
—
—
—
—
150
150
150
170
190
210
170
190
210
210

SECTION B
UNIT 30GN
—
—
—
—
—
—
—
—
—
—
—
—
—
—
080
090
100
100
110
110
170
190/170*
190
210

*60 Hz units/50 Hz units.

The Flotronic II control system cycles compressor unloaders and/or compressors to maintain the selected leaving
fluid temperature set point. It automatically positions the EXV
to maintain the specified refrigerant superheat entering the
compressor cylinders. It also cycles condenser fans on and
off to maintain suitable head pressure for each circuit. Safeties are continuously monitored to prevent the unit from operating under unsafe conditions. A scheduling function, programmed by the user, controls the unit occupied/unoccupied
schedule. The control also operates a test program that allows the operator to check output signals and ensure components are operable.
The control system consists of a processor module (PSIO),
a low-voltage relay module (DSIO-LV), 2 EXVs, an EXV
driver module (DSIO-EXV), a 6-pack relay board, a keypad
and display module (also called HSIO or LID), thermistors,
and transducers to provide inputs to the microprocessor. A
standard options module (SIO) is used to provide additional
functions. See Fig. 1 for a typical 30GN Control Panel.

GENERAL
IMPORTANT: This publication contains controls, operation and troubleshooting data for 30GN040-420
Flotronic™ II chillers.
Circuits are identified as circuits A and B, and compressors are identified as A1, A2, etc. in circuit A, and
B1, B2, etc. in circuit B.
Use this guide in conjunction with separate Installation Instructions booklet packaged with the unit.
The 30G Series standard Flotronic II chillers feature
microprocessor-based electronic controls and an electronic
expansion valve (EXV) in each refrigeration circuit.
NOTE: The 30GN040 and 045 chillers with a factoryinstalled brine option have thermal expansion valves (TXV)
instead of the EXV.
Unit sizes 230-420 are modular units which are shipped
as separate sections (modules A and B). Installation instructions specific to these units are shipped inside the individual
modules. See Table 1 for a listing of unit sizes and modular
combinations. For modules 230B-315B, follow all general
instructions as noted for unit sizes 080-110. For all remaining modules, follow instructions for unit sizes 130-210.

MAJOR SYSTEM COMPONENTS
Processor Module — This module contains the operating software and controls the operation of the machine. It
continuously monitors information received from the various transducers and thermistors and communicates with the
relay modules and 6-pack relay board to increase or decrease the active stages of capacity. The processor module

2

COMM 3

PWR

POINT NUMBER
OF
FIRST CHANNEL

X X

EXV

LV

STATUS

STATUS

COMM

COMM

5VDC

1

Potter & Brumfield
CZ770

HK35AA002

2

COMM 1
COMM 3

4- 3+

J5

PWR

S1

J4

J4

X X

S2

EQUIP GND
99NA505322 D

FUSE 1

LO C A L /
ENABLE

SW1

STOP
CCN
FUSE 3
F

U SE

9

5

6

1

2

3

TEST

ENTR

–

0

•

HIST

CLR

F

8

4

SET

EXPN

E

U

SE

FU S

7
SCHD

SRVC

STAT

FUSE 2
GFI - CO
( 5 AMP MAX )

CB5

CB6
30GT510568

–

LEGEND
CCN — Carrier Comfort Network
TB
— Terminal Block

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

3

Table 2 — LOCAL/ENABLE-STOP-CCN
Switch Positions and Operation

also controls the EXV driver module (as appropriate), commanding it to open or close each EXV in order to maintain
the proper superheat entering the cylinders of each lead compressor. Information is transmitted between the processor module and relay module, the EXV driver module, and the keypad and display module through a 3-wire communications
bus. The options module is also connected to the communications bus.
For the Flotronic™ II chillers, the processor monitors system pressure by means of 6 transducers, 3 in each lead compressor. Compressor suction pressure, discharge pressure, and
oil pressure are sensed. If the processor senses high discharge pressure or low suction pressure, it immediately shuts
down all compressors in the affected circuit. During operation, if low oil pressure is sensed for longer than one minute,
all compressors in the affected circuit are shut down. At startup, the oil pressure signal is ignored for 2 minutes. If shutdown occurs due to any of these pressure faults, the circuit
is locked out and the appropriate fault code is displayed.

SWITCH
POSITION
STOP
LOCAL/ENABLE
CCN Stop —
Run —

UNIT
OPERATION
Unit
Unit
Unit
Unit

Cannot Run
Can Run
Cannot Run
Can Run

CONFIGURATION AND
SET POINT CONTROL
Keypad Control
CCN Control
Read/Write
Read Only
Read/Limited Write Read Only
Read Only
Read/Write
Read/Limited
Read Only
Write

In the CCN position, the chiller is under remote control
and responds only to CCN network commands. The occupied/
unoccupied conditions are defined by the network. All keypad and display functions can be read at the chiller regardless of position of the switch.
CCN run or stop condition is established by a command
from the CCN network. It is not possible to force outputs
from the CCN network, except that an emergency stop command shuts down the chiller immediately and causes ‘‘ALARM
52’’ to be displayed.

Low-Voltage Relay Module — This module closes
contacts to energize compressor unloaders and/or compressors. It also senses the status of the safeties for all compressors and transmits this information to the processor.

Electronic Expansion Valve (EXV) — The microprocessor controls the EXV (if so equipped) through the EXV
driver module. Inside the expansion valve is a linear actuator stepper motor.
The lead compressor in each circuit has a thermistor and
a pressure transducer located in the suction manifold after
the compressor motor. The thermistor measures the temperature of the superheated gas entering the compressor cylinders. The pressure transducer measures the refrigerant pressure
in the suction manifold. The microprocessor converts the pressure reading to a saturated temperature. The difference between the temperature of the superheated gas and the saturation temperature is the superheat. The microprocessor controls
the position of the electronic expansion valve stepper motor
to maintain 30 F (17 C) superheat.
At initial unit start-up, the EXV position is at zero. After
that, the microprocessor keeps accurate track of the valve
position in order to use this information as input for the other
control functions. The control monitors the superheat and
the rate of change of superheat to control the position of the
valve. The valve stroke is very large, which results in very
accurate control of the superheat.

Electronic Expansion Valve Module (If So
Equipped) — This module receives signals from the processor and operates the electronic expansion valves.

Options Module — This module allows the use of Flotronic II features such as dual set point, remote reset, demand limit, hot gas bypass, and accessory unloaders. The
options module also allows for reset and demand limit to be
activated from a remote 4-20 mA signal. The options module is installed at the factory.
Keypad and Display Module (Also Called HSIO
or LID) — This device consists of a keypad with 6 function keys, 5 operative keys, 12 numeric keys, and an alphanumeric 8-character LCD (liquid crystal display). Key usage is explained in Accessing Functions and Subfunctions
section on page 24.

Control Switch — Control of the chiller is defined by
the position of the LOCAL/ENABLE-STOP-CCN switch.
This is a 3-position manual switch that allows the chiller to
be put under the control of its own Flotronic II controls, manually stopped, or put under the control of a Carrier Comfort
Network (CCN). Switch allows unit operation as shown in
Table 2.
In the LOCAL/ENABLE position, the chiller is under local control and responds to the scheduling configuration and
set point data input at its own local interface device (keypad
and display module).

Thermostatic Expansion Valves (TXV) — Model
30GN040 and 045 units with factory-installed brine option
are equipped with conventional thermostatic expansion valves
with liquid line solenoids. The liquid line solenoid valves
are not intended to be a mechanical shut-off. When service
is required, use the liquid line service valve to pump down
the system.

4

The TXV is set at the factory to maintain approximately
8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler
by monitoring the proper amount of refrigerant into the cooler.
All TXVs are adjustable, but should not be adjusted unless
absolutely necessary. When TXV is used, thermistors T7 and
T8 are not required.
The TXV is designed to limit the cooler saturated suction
temperature to 55 F (12.8 C). This makes it possible for unit
to start at high cooler fluid temperatures without overloading the compressor.

Sensors — The Flotronic™ II chiller control system gathers information from sensors to control the operation of the
chiller. The units use 6 standard pressure transducers and
4 standard thermistors to monitor system pressures and temperatures at various points within the chiller. Sensors are listed
in Table 3.

Fig. 2 — Compressor Protection Control Module

Table 3 — Thermistor and Transducer Locations
Sensor
T1
T2
T7
T8
T10
Sensor
DPT-A
SPT-A
OPT-A
DPT-B
SPT-B
OPT-B

THERMISTORS
Location
Cooler Leaving Fluid Temp
Cooler Entering Fluid Temp
Compressor Suction Gas Temp Circuit A
Compressor Suction Gas Temp Circuit B
Remote Temperature Sensor (Accessory)
PRESSURE TRANSDUCERS
Location
Compressor A1 Discharge Pressure
Compressor A1 Suction Pressure
Compressor A1 Oil Pressure
Compressor B1 Discharge Pressure
Compressor B1 Suction Pressure
Compressor B1 Oil Pressure

Fig. 3 — Compressor Ground Fault Module

Compressor Protection Control Module (CPCS)
— Each compressor on models 30GN070 (50 Hz), 080-

ground of any compressor winding exceeds 2.5 amps. If this
condition occurs, the CPCS module shuts down the
compressor.
A high-pressure switch with a trip pressure of 426
± 7 psig (2936 ± 48 kPa), is wired in series with the CPCS.
If this switch opens during operation, the compressor stops
and the failure is detected by the processor when the signal
contacts open. The compressor is locked off. If the lead compressor in either circuit is shut down by the high-pressure
switch or ground current protector, all compressors in the
circuit are locked off.

110, and 230B-315B, has its own CPCS as standard equipment. See Fig. 2. All 30GN040-060 and 070 (60 Hz) units
feature the CPCS as an accessory, and CR (control relay) as
standard equipment. The 30GN130-210 and associated modular units have a CR as standard equipment. The CPCS or CR
is used to control and protect the compressors and crankcase
heaters. The CPCS provides the following functions:
• compressor contactor control
• crankcase heater control
• compressor ground current protection
• status communication to processor board
• high-pressure protection
The CR provides all of the same functions as the CPCS
with the exception of compressor ground current protection.
Ground current protection is accomplished by using a CGF
(compressor ground fault module) in conjunction with the
CR. The CGF (See Fig. 3) provides the same ground fault
function as the CPCS for units where the CPCS is not
utilized.
One large relay is located on the CPCS board. This relay
(or CR) controls the crankcase heater and compressor
contactor. The CPCS also provides a set of signal contacts
that the microprocessor monitors to determine the operating
status of the compressor. If the processor board determines
that the compressor is not operating properly through the signal contacts, it will lock the compressor off by deenergizing
the proper 24-v control relay on the relay board. The
CPCS board contains logic that can detect if the current-to-

OPERATION DATA
Capacity Control — The control system cycles
compressor to give capacity control steps as shown in
Tables 4A-4C. The unit controls leaving chilled fluid temperature. Entering fluid temperature is used by the microprocessor in determining the optimum time to add or subtract steps of capacity, but is not a control set point.
The chilled fluid temperature set point can be automatically reset by the return temperature reset or space and
outdoor-air temperature reset features. It can also be reset
from an external 4 to 20 mA signal, or from a network
signal.
The operating sequences shown are some of many possible loading sequences for the control of the leaving fluid
temperature. If a circuit has more unloaders than another,
that circuit will always be the lead circuit.

5

Table 4A — Capacity Control Steps, 040-070
UNIT
30GN

040 (60 Hz)
A1†,B1
040 (60 Hz)
A1†,B1**
040 (50 Hz)
045 (60 Hz)
A1†,B1
040 (50 Hz)
045 (60 Hz)
A1†,B1**

040 (50 Hz)
045 (60 Hz)
A1†,B1**
045 (50 Hz)
050 (60 Hz)
A1†,B1
045 (50 Hz)
050 (60 Hz)
A1†,B1**
045 (50 Hz)
050 (60 Hz)
A1†**,B1

045 (50 Hz)
050 (60 Hz)
A1†**,B1**

045 (50 Hz)
050 (60 Hz)
A1†,B1**

CONTROL
STEPS
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
5
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
6
7
1
2
3
4
5
6
7

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
25
A1*
50
A1
75
A1*, B1
100
A1,B1
25
A1*
50
A1
75
A1*,B1
100
A1,B1
24
A1*
47
A1
76
A1*,B1
100
A1,B1
24
A1*
47
A1
61
A1*,B1*
76
A1*,B1
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
31
A1*
44
A1
87
A1*,B1
100
A1,B1
31
A1*
44
A1
69
A1*,B1*
87
A1*,B1
100
A1,B1
18
A1††
31
A1*
73
A1††,B1
87
A1*,B1
100
A1,B1
18
A1††
31
A1*
44
A1
56
A1††,B1*
73
A1††,B1
87
A1*,B1
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader(s), accessory.
††Two unloaders, both unloaded.

6

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
25
B1*
50
B1
75
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
37
B1*
53
B1
61
A1*,B1*
84
A1,B1*
100
A1,B1
21
B1††
37
B1*
53
B1
68
A1,B1††
84
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
38
B1*
56
B1
69
A1*,B1*
82
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
20
B1††
38
B1*
56
B1
51
A1*,B1††
64
A1,B1††
82
A1,B1*
100
A1,B1

Table 4A — Capacity Control Steps, 040-070 (cont)
UNIT
30GN

045 (50 Hz)
050 (60 Hz)
A1†**,B1**

050 (50 Hz)
060 (60 Hz)
A1†,B1
050 (50 Hz)
060 (60 Hz)
A1†,B1**
050 (50 Hz)
060 (60 Hz)
A1†**,B1

050 (50 Hz)
060 (60 Hz)
A1†**,B1**

050 (50 Hz)
060 (60 Hz)
A1†,B1**

050 (50 Hz)
060 (60 Hz)
A1†**,B1**

060 (50 Hz)
070 (60 Hz)
A1†,B1
060 (50 Hz)
070 (60 Hz)
A1†,B1**
060 (50 Hz)
070 (60 Hz)
A1†**,B1

060 (50 Hz)
070 (60 Hz)
A1†**,B1**

060 (50 Hz)
070 (60 Hz)
A1†,B1**

CONTROL
STEPS
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
6
7
1
2
3
4
5
6
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
6
1
2
3
4
5
6

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
18
A1††
31
A1*
44
A1
56
A1††,B1*
73
A1††,B1
87
A1*,B1
100
A1,B1
28
A1*
42
A1
87
A1*,B1
100
A1,B1
28
A1*
42
A1
67
A1*,B1*
87
A1*,B1
100
A1,B1
15
A1††
28
A1*
73
A1††,B1
87
A1*,B1
100
A1,B1
15
A1††
28
A1*
42
A1
53
A1,B1*
73
A1††,B1
87
A1*,B1
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
15
A1††
28
A1*
42
A1
53
A1††,B1*
73
A1††,B1
87
A1*,B1
100
A1,B1
33
A1*
50
A1
83
A1*,B1
100
A1,B1
33
A1*
50
A1
67
A1*,B1*
83
A1*,B1
100
A1,B1
16
A1††
33
A1*
66
A1††,B1
83
A1*
100
A1,B1
16
A1††
33
A1*
50
A1
66
A1††,B1
83
A1*,B1
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader(s), accessory.
††Two unloaders, both unloaded.

7

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
20
B1††
38
B1*
56
B1
64
A1,B1††
82
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
—
—
38
B1*
58
B1
67
A1*,B1*
80
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
18
B1††
38
B1*
58
B1
60
A1,B1††
80
A1,B1*
100
A1,B1
18
B1††
38
B1*
58
B1
60
A1,B1††
80
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
—
—
33
B1*
50
B1
66
A1*,B1*
83
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
16
B1††
33
B1*
50
B1
66
A1,B1††
83
A1,B1*
100
A1,B1

Table 4A — Capacity Control Steps, 040-070 (cont)
UNIT
30GN

060 (50 Hz)
070 (60 Hz)
A1†**,B1|

070 (50 Hz)
A1†,B1

070 (50 Hz)
A1†,B1**

070 (50 Hz)
A1†**,B1

070 (50 Hz)
A1†**,B1**

070 (50 Hz)
A1†,B1|

070 (50 Hz)
A1†**,B1|

CONTROL
STEPS
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
10

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
16
A1††
33
A1*
50
A1
66
A1††,B1
83
A1*,B1
100
A1,B1
19
A1*
27
A1
65
A1*,B1
73
A1,B1
92
A1*,A2,B1
100
A1,A2,B1
19
A1*
27
A1
49
A1*,B1*
65
A1*,B1
73
A1,B1
76
A1*,A2,B1*
92
A1*,A2,B1
100
A1,A2,B1
11
A1††
19
A1*
57
A1††,B1
65
A1*,B1
73
A1,B1
84
A1††,A2,B1
92
A1*,A2,B1
100
A1,A2,B1
11
A1††
19
A1*
27
A1
41
A1††,B1*
57
A1††,B1
65
A1*,B1
73
A1,B1
84
A1††,A2,B1
92
A1*,A2,B1
100
A1,A2,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
11
A1††
19
A1*
27
A1
41
A1††,B1*
57
A1††,B1
65
A1*,B1
73
A1,B1
84
A1††,A2,B1
92
A1*,A2,B1
100
A1,A2,B1

*Unloaded compressor.
†Compressor unloader, standard.
**One compressor unloader, accessory.
††Two unloaders, both unloaded.
\ Two compressor unloaders, accessory.

8

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
16
B1††
33
B1*
50
B1
66
A1,B1††
83
A1,B1*
100
A1,B1
—
—
—
—
—
—
—
—
—
—
—
—
31
B1*
47
B1
49
A1*,B1*
57
A1,B1*
73
A1,B1
76
A1*,A2,B1*
84
A1,A2,B1*
100
A1,A2,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
15
B1††
31
B1*
47
B1
57
A1*,B1*
73
A1,B1
84
A1,A2,B1*
100
A1,A2,B1
15
B1††
31
B1*
47
B1
54
A1*,B1*
73
A1,B1
84
A1,A2,B1*
100
A1,A2,B1
—
—
—
—
—
—

Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units
UNIT
30GN

CONTROL
STEPS

080, 230B (60 Hz)
A1†,B1†

080, 230B (60 Hz)
A1†**, B1†

080, 230B (60 Hz)
A1†,B1†**

080, 230B (60 Hz)
A1†**,B1†**

080, 230B (50 Hz)
A1†,B1†

080, 230B (50 Hz)
A1†**,B1†

080, 230B (50 Hz)
A1†,B1†**

080, 230B (50 Hz)
A1†**,B1†**

1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
22
A1*
34
A1
52
A1*,B1*
67
A1*,B1
78
A1,B1
89
A1*,A2,B1
100
A1,A2,B1
11
A1††
22
A1*
34
A1
41
A1††,B1*
55
A1††,B1
67
A1*,B1
78
A1,B1
89
A1*,A2,B1
100
A1,A2,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
11
A1††
22
A1*
34
A1
41
A1††,B1*
55
A1††,B1
67
A1*,B1
78
A1,B1
89
A1*,A2,B1
100
A1,A2,B1
17
A1*
25
A1
42
A1*,B1*
54
A1*,B1
62
A1,B1
79
A1*,A2,B1*
92
A1*,A2,B1
100
A1,A2,B1
8
A1††
17
A1*
25
A1
33
A1††,B1*
46
A1††,B1
54
A1*,B1
62
A1,B1
71
A1††,A2,B1*
84
A1††,A2,B1
92
A1*,A2,B1
100
A1,A2,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
A1††
17
A1*
25
A1
33
A1††,B1*
46
A1††,B1
54
A1*,B1
62
A1,B1
71
A1††,A2,B1*
84
A1††,A2,B1
92
A1*,A2,B1
100
A1,A2,B1

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
30
B1*
44
B1
52
A1*,B1*
63
A1,B1*
78
A1,B1
85
A1,A2,B1*
100
A1,A2,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
15
B1††
30
B1*
44
B1
48
A1,B1††
63
A1,B1*
78
A1,B1
85
A1,A2,B1*
100
A1,A2,B1
15
B1††
30
B1*
44
B1
48
A1,B1††
63
A1,B1*
78
A1,B1
85
A1,A2,B1*
100
A1,A2,B1
—
—
25
B1*
38
B1
42
A1*,B1*
50
A1, B1*
62
A1,B1
79
A1*,A2,B1*
88
A1,A2,B1*
100
A1,A2,B1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
13
B1††
25
B1*
38
B1
50
A1,B1*
62
A1,B1
67
A1*,A2,B1††
75
A1,A2,B1††
88
A1,A2,B1*
100
A1,A2,B1
13
B1††
25
B1*
38
B1
50
A1,B1*
62
A1,B1
67
A1*,A2,B1††
75
A1,A2,B1††
88
A1,A2,B1*
100
A1,A2,B1
—
—
—
—

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

9

Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)
UNIT
30GN

CONTROL
STEPS

090, 245B (60 Hz)
A1†,B1†

090, 245B (60 Hz)
A1†**,B1†

090, 245B (60 Hz)
A1†,B1†**

090, 245B (60 Hz)
A1†**,B1†**

090, 245B (50 Hz)
A1†,B1†

090, 245B (50 Hz)
A1†**,B1†

1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
18
A1*
27
A1
35
A1*,B1*
44
A1*,B1
53
A1,B1
56
A1*,A2,B1*
65
A1*,A2,B1
74
A1,A2,B1
82
A1*,A2,B1*,B2
91
A1*,A2,B1,B2
100
A1,A2,B1,B2
9
A1††
18
A1*
27
A1
35
A1††,B1
44
A1*,B1
53
A1,B1
56
A1††,A2,B1
65
A1*,A2,B1
74
A1,A2,B1
82
A1††,A2,B1,B2
91
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
9
A1††
18
A1*
27
A1
35
A1††,B1
44
A1*,B1
53
A1,B1
56
A1††,A2,B1
65
A1*,A2,B1
74
A1,A2,B1
82
A1††,A2,B1,B2
91
A1*,A2,B1,B2
100
A1,A2,B1,B2
14
A1*
21
A1
29
A1*,B1*
36
A1*,B1
43
A1,B1
61
A1*,A2,B1*
68
A1*,A2,B1
75
A1,A2,B1
86
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
7
A1††
14
A1*
21
A1
29
A1††,B1
36
A1*,B1
43
A1,B1
54
A1††,A2,B1*
61
A1††,A2,B1
68
A1*,A2,B1
75
A1,A2,B1
79
A1††,A2,B1*,B2
86
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
18
B1*
27
B1
35
A1*,B1*
44
A1,B1*
53
A1,B1
62
A1*,B1*,B2
71
A1,B1*,B2
80
A1,B1,B2
82
A1*,A2,B1*,B2
91
A1,A2,B1*,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
9
B1††
18
B1*
27
B1
35
A1,B1††
44
A1,B1*
53
A1,B1
62
A1,B1††,B2
71
A1,B1*,B2
80
A1,B1,B2
82
A1,A2,B1††,B2
91
A1,A2,B1*,B2
100
A1,A2,B1,B2
9
B1††
18
B1*
27
B1
35
A1,B1††
44
A1,B1*
53
A1,B1
62
A1,B1††,B2
71
A1,B1*,B2
80
A1,B1,B2
82
A1,A2,B1††,B2
91
A1,A2,B1*,B2
100
A1,A2,B1,B2
14
B1*
21
B1
29
A1*,B1*
36
A1,B1*
43
A1,B1
53
A1*,B1*,B2
60
A1,B1*,B2
67
A1,B1,B2
86
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—

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

10

Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)
UNIT
30GN

090, 245B (50 Hz)
A1†,B1†**

090, 245B (50 Hz)
A1†**,B1†**

100, 255B,
270B (60 Hz)
A1†,B1†

100, 255B,
270B (60 Hz)
A1†**,B1†

100, 255B,
270B (60 Hz)
A1†,B1†**

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
A1††
14
A1*
21
A1
29
A1††,B1
36
A1*,B1
43
A1,B1
49
A1††,A2,B1††
54
A1††,A2,B1*
61
A1††,A2,B1
68
A1*,A2,B1
75
A1,A2,B1
79
A1††,A2,B1*,B2
86
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
16
A1*
23
A1
31
A1*,B1*
39
A1*,B1
46
A1,B1
58
A1*,A2,B1*
66
A1*,A2,B1
73
A1,A2,B1
85
A1*,A2,B1*,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
8
A1††
16
A1*
23
A1
31
A1††,B1
39
A1*,B1
46
A1,B1
50
A1††,A2,B1*
58
A1††,A2,B1
66
A1*,A2,B1
73
A1,A2,B1
77
A1††,A2,B1*,B2
85
A1††,A2,B1,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
7
B1††
14
B1*
21
B1
29
A1,B1††
36
A1,B1*
43
A1,B1
46
A1*,B1††,B2
53
A1,B1††,B2
60
A1,B1*,B2
67
A1,B1,B2
79
A1*,A2,B1††,B1
86
A1,A2,B1††,B1
93
A1,A2,B1*,B2
100
A1,2,B1,B2
7
B1††
14
B1*
21
B1
29
A1,B1††
36
A1,B1*
43
A1,B1
46
A1*,B1††,B2
53
A1,B1††,B2
60
A1,B1*,B2
67
A1,B1,B2
72
A1††,A2,B1††,B2
79
A1*,A2,B1††,B2
86
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
16
A1*
23
A1
31
A1*,B1*
39
A1*,B1
46
A1,B1
58
A1*,A2,B1*
66
A1*,A2,B1
73
A1,A2,B1
85
A1*,A2,B1*,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
B1††
16
B1*
23
B1
31
A1,B1††
39
A1,B1*
46
A1,B1
50
A1*,B1††,B2
58
A1,B1††,B2
66
A1,B1*,B2
73
A1,B1,B2
77
A1*,A2,B1††,B2
85
A1,A2,B1††,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2

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

11

Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)
UNIT
30GN

100, 255B,
270B (60 Hz)
A1†**,B1†**

100, 255B,
270B (50 Hz)
A1†,B1†

100, 255B,
270B (50 Hz)
A1†**,B1†

100, 255B,
270B (50 Hz)
A1†,B1†**

100, 255B,
270B (50 Hz)
A1†**,B1†**

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
8
A1††
16
A1*
23
A1
31
A1††,B1
39
A1*,B1
46
A1,B1
50
A1††,A2,B1*
58
A1††,A2,B1
66
A1*,A2,B1
73
A1,A2,B1
77
A1††,A2,B1*,B2
85
A1††,A2,B1,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
13
A1*
20
A1
26
A1*,B1*
33
A1,B1
40
A1,B1
57
A1*,A2,B1*
63
A1*,A2,B1
70
A1,A2,B1
87
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
7
A1††
13
A1*
20
A1
26
A1††,B1
33
A1*,B1
40
A1,B1
50
A1††,A2,B1*
57
A1††,A2,B1
63
A1*,A2,B1
70
A1,A2,B1
80
A1††,A2,B1*,B2
87
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
A1††
13
A1*
20
A1
26
A1††,B1
33
A1*,B1
40
A1,B1
43
A1††,A2,B1††
50
A1††,A2,B1*
57
A1††,A2,B1
63
A1*,A2,B1
70
A1,A2,B1
74
A1††,A2,B1††,B2
80
A1††,A2,B1*,B2
89
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
8
B1††
16
B1*
23
B1
31
A1,B1††
39
A1,B1*
46
A1,B1
50
A1*,B1††,B2
58
A1,B1††,B2
66
A1,B1*,B2
73
A1,B1,B2
77
A1*,A2,B1††,B2
85
A1,A2,B1††,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2
13
B1*
20
B1
26
A1*,B1*
33
A1,B1*
40
A1,B1
57
A1*,B1*,B2
63
A1,B1*,B2
70
A1,B1,B2
87
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
B1††
13
B1*
20
B1
26
A1,B1††
33
A1,B1*
40
A1,B1
50
A1*,B1††,B2
57
A1,B1††,B2
63
A1,B1*,B2
70
A1,B1,B2
80
A1*,A2,B1††,B2
87
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
7
B1††
13
B1*
20
B1
26
A1,B1††
33
A1,B1*
40
A1,B1
43
A1††,B1††,B2
50
A1*,B1††,B2
57
A1,B1††,B2
63
A1,B1*,B2
70
A1,B1,B2
74
A1††,A2,B1††,B2
80
A1*,A2,B1††,B2
87
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2

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

12

Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)
UNIT
30GN

110, 290B,
315B (60 Hz)
A1†,B1†

110, 290B,
315B (60 Hz)
A1†**,B1†

110, 290B,
315B (60 Hz)
A1†,B1†**

110, 290B,
315B (60 Hz)
A1†**,B1†**

110, 290B,
315B (50 Hz)
A1†,B1†

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
14
A1*
21
A1
29
A1*,B1*
36
A1*,B1
43
A1,B1
61
A1*,A2,B1*
68
A1*,A2,B1
75
A1,A2,B1
86
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
7
A1††
14
A1*
21
A1
29
A1††,B1
36
A1*,B1
43
A1,B1
54
A1††,A2,B1*
61
A1††,A2,B1
68
A1*,A2,B1
75
A1,A2,B1
79
A1††,A2,B1*,B2
86
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
A1††
14
A1*
21
A1
29
A1††,B1
36
A1*,B1
43
A1,B1
47
A1††,A2,B1††
54
A1††,A2,B1*
61
A1††,A2,B1
68
A1*,A2,B1
75
A1,A2,B1
79
A1††,A2,B1*,B2
86
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
17
A1*
25
A1
33
A1*,B1*
42
A1*,B1
50
A1,B1
58
A1*,A2,B1*
67
A1*,A2,B1
75
A1,A2,B1
83
A1*,A2,B1*,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
14
B1*
21
B1
29
A1*,B1*
36
A1,B1*
43
A1,B1
53
A1*,B1*,B2
60
A1,B1*,B2
67
A1,B1,B2
86
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
B1††
14
B1*
21
B1
29
A1,B1††
36
A1,B1*
43
A1,B1
46
A1*,B1††,B2
53
A1,B1††,B2
60
A1,B1*,B2
67
A1,B1,B2
79
A1*,A2,B1††,B2
86
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
7
B1††
14
B1*
21
B1
29
A1,B1††
36
A1,B1*
43
A1,B1
46
A1*,B1††,B2
53
A1,B1††,B2
60
A1,B1*,B2
67
A1,B1,B2
72
A1††,A2,B1††,B2
79
A1*,A2,B1††,B2
86
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
17
B1*
25
B1
33
A1*,B1*
42
A1,B1*
50
A1,B1
58
A1*,B1*,B2
67
A1,B1*,B2
75
A1,B1,B2
83
A1*,A2,B1*,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2

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

13

Table 4B — Capacity Control Steps, 080-110 and Associated Modular Units (cont)
UNIT
30GN

110, 290B,
315B (50 Hz)
A1†**,B1†

110, 290B,
315B (50 Hz)
A1†,B1†**

110, 290B,
315B (50 Hz)
A1†**,B1†**

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
8
A1††
17
A1*
25
A1
33
A1††,B1
42
A1*,B1
50
A1,B1
58
A1††,A2,B1
67
A1*,A2,B1
75
A1,A2,B1
83
A1††,A2,B1,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
A1††
17
A1*
25
A1
33
A1††,B1
42
A1*,B1
50
A1,B1
58
A1††,A2,B1
67
A1*,A2,B1
75
A1,A2,B1
83
A1††,A2,B1,B2
92
A1*,A2,B1,B2
100
A1,A2,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
B1††
17
B1*
25
B1
33
A1,B1††
42
A1,B1*
50
A1,B1
58
A1,B1††,B2
67
A1,B1*,B2
75
A1,B1,B2
83
A1,A2,B1††,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2
8
B1††
17
B1*
25
B1
33
A1,B1††
42
A1,B1*
50
A1,B1
58
A1,B1††,B2
67
A1,B1*,B2
75
A1,B1,B2
83
A1,A2,B1††,B2
92
A1,A2,B1*,B2
100
A1,A2,B1,B2

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

14

Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units
UNIT
30GN

130 (60 Hz)
A1†,B1†

130 (60 Hz)
A1†**,B1†

130 (60 Hz)
A1†,B1†**

130 (60 Hz)
A1†**,B1†**

130 (50 Hz)
A1†,B1†

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
14
A1*
21
A1
28
A1*,B1*
35
A1*,B1
42
A1,B1
58
A1*,A2,B1*
64
A1*,A2,B1
71
A1,A2,B1
87
A1*,A2,B1*,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
8
A1††
14
A1*
21
A1
22
A1††,B1*
28
A1††,B1
35
A1*,B1
42
A1,B1
51
A1††,A2,B1*
58
A1††,A2,B1
64
A1*,A2,B1
71
A1,A2,B1
80
A1††,A2,B1*,B2
87
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
A1††
14
A1*
21
A1
22
A1††,B1*
28
A1††,B1
35
A1*,B1
42
A1,B1
44
A1††,A2,B1††
51
A1††,A2,B1*
58
A1††,A2,B1
64
A1*,A2,B1
71
A1,A2,B1
73
A1††,A2,B1††,B2
80
A1††,A2,B1*,B2
87
A1††,A2,B1,B2
93
A1*,A2,B1,B2
100
A1,A2,B1,B2
10
A1*
14
A1
26
A1*,B1*
35
A1*,B1
39
A1,B1
44
A1*,A2,B1*
53
A1*,A2,B1
57
A1,A2,B1
69
A1*,A2,B1*,B2
78
A1*,A2,B1,B2
82
A1,A2,B1,B2
87
A1*,A2,A3,B1*,B2
96
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
14
B1*
21
B1
28
A1*,B1*
35
A1,B1*
42
A1,B1
58
A1*,B1*,B2
64
A1,B1*,B2
71
A1,B1,B2
87
A1*,A2,B1*,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
B1††
14
B1*
21
B1
22
A1*,B1††
28
A1,B1††
35
A1,B1*
42
A1,B1
51
A1*,B1††,B2
58
A1,B1††,B2
64
A1,B1*,B2
71
A1,B1,B2
80
A1*,A2,B1††,B2
87
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
8
B1††
14
B1*
21
B1
22
A1*,B1††
28
A1,B1††
35
A1,B1*
42
A1,B1
44
A1††,B1††,B2
51
A1*,B1††,B2
58
A1,B1††,B2
64
A1,B1*,B2
71
A1,B1,B2
73
A1††,A2,B1††,B2
80
A1*,A2,B1††,B2
87
A1,A2,B1††,B2
93
A1,A2,B1*,B2
100
A1,A2,B1,B2
16
B1*
25
B1
26
A1*,B1*
31
A1,B1*
39
A1,B1
51
A1*,B1*,B2
56
A1,B1*,B2
64
A1,B1,B2
69
A1*,A2,B1*,B2
74
A1,A2,B1*,B2
82
A1,A2,B1,B2
87
A1*,A2,A3,B1*,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2

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

15

Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)
UNIT
30GN

130 (50 Hz)
A1†**,B1†

130 (50 Hz)
A1†,B1†**

130 (50 Hz)
A1†**,B1†**

150, 230A, 245A,
255A (60 Hz)
A1†,B1†

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
6
A1††
10
A1*
14
A1
22
A1††,B1*
31
A1††,B1
35
A1*,B1
39
A1,B1
40
A1††,A2,B1*
49
A1††,A2,B1
53
A1*,A2,B1
57
A1,A2,B1
65
A1††,A2,B1*,B2
74
A1††,A2,B1,B2
78
A1*,A2,B1,B2
82
A1,A2,B1,B2
83
A1††,A2,A3,B1*,B2
91
A1††,A2,A3,B1,B2
96
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6
A1††
10
A1*
14
A1
22
A1††,B1*
31
A1††,B1
35
A1*,B1
39
A1,B1
40
A1††,A2,B1*
49
A1††,A2,B1
53
A1*,A2,B1
57
A1,A2,B1
65
A1††,A2,B1*,B2
74
A1††,A2,B1,B2
78
A1*,A2,B1,B2
82
A1,A2,B1,B2
83
A1††,A2,A3,B1*,B2
91
A1††,A2,A3,B1,B2
96
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
11
A1*
15
A1
29
A1*,B1*
38
A1*,B1
42
A1,B1
44
A1*,A2,B1*
53
A1*,A2,B1
58
A1,A2,B1
71
A1*,A2,B1*,B2
80
A1*,A2,B1,B2
85
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
95
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
8
B1††
16
B1*
25
B1
31
A1,B1*
39
A1,B1
43
A1*,B1††,B2
47
A1,B1††,B2
56
A1,B1*,B2
64
A1,B1,B2
65
A1,A2,B1††,B2
74
A1,A2,B1*,B2
82
A1,A2,B1,B2
83
A1,A2,A3,B1††,B2,B3
91
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
8
B1††
16
B1*
25
B1
31
A1,B1*
39
A1,B1
43
A1*,B1††,B2
47
A1,B1††,B2
56
A1,B1*,B2
64
A1,B1,B2
65
A1,A2,B1††,B2
74
A1,A2,B1*,B2
82
A1,A2,B1,B2
83
A1,A2,A3,B1††,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
18
B1*
27
B1
29
A1*,B1*
33
A1,B1*
42
A1,B1
55
A1*,B1*,B2
60
A1,B1*,B2
69
A1,B1,B2
71
A1*,A2,B1*,B2
75
A1,A2,B1*,B2
85
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2

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

16

Table 4C — Capacity Control Steps, 130-210 and Associated Modular Units (cont)
UNIT
30GN

150, 230A, 245A,
255A (60 Hz)
A1†**,B1†

150, 230A, 245A,
255A (60 Hz)
A1†,B1†**

150, 230A, 245A,
255A (60 Hz)
A1†**,B1†**

150, 230A, 245A,
255A (50 Hz)
A1†,B1†

150, 230A, 245A,
255A (50 Hz)
A1†**,B1†

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
6
A1††
11
A1*
15
A1
24
A1††,B1*
33
A1††,B1
38
A1*,B1
42
A1,B1
49
A1††,A2,B1
53
A1*,A2,B1
58
A1,A2,B1
66
A1††,A2,B1*,B2
75
A1††,A2,B1,B2
80
A1*,A2,B1,B2
85
A1,A2,B1,B2
91
A1††,A2,A3,B1,B2
95
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6
A1††
11
A1*
15
A1
24
A1††,B1*
33
A1††,B1
38
A1*,B1
42
A1,B1
49
A1††,A2,B1
53
A1*,A2,B1
58
A1,A2,B1
66
A1††,A2,B1*,B2
75
A1††,A2,B1,B2
80
A1*,A2,B1,B2
85
A1,A2,B1,B2
91
A1††,A2,A3,B1,B2
95
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
13
A1*
20
A1
26
A1*,B1*
33
A1*,B1
40
A1,B1
46
A1*,A2,B1*
53
A1*,A2,B1
60
A1,A2,B1
66
A1*,A2,B1*,B2
73
A1*,A2,B1,B2
80
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
93
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
6
A1††
13
A1*
20
A1
26
A1††,B1
33
A1*,B1
40
A1,B1
46
A1††,A2,B1
53
A1*,A2,B1
60
A1,A2,B1
66
A1††,A2,B1,B2
73
A1*,A2,B1,B2
80
A1,A2,B1,B2
86
A1††,A2,A3,B1,B2
93
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
9
B1††
18
B1*
27
B1
33
A1,B1*
42
A1,B1
46
A1*,B1††,B2
51
A1,B1††,B2
60
A1,B1*,B2
69
A1,B1,B2
75
A1,A2,B1*,B2
85
A1,A2,B1,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
9
B1††
18
B1*
27
B1
33
A1,B1*
42
A1,kB1
46
A1*,B1††,B2
51
A1,B1††,B2
60
A1,B1*,B2
69
A1,B1,B2
75
A1,A2,B1*,B2
86
A1,A2,B1,B2
91
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
13
B1*
20
B1
26
A1*,B1*
33
A1,B1*
40
A1,B1
46
A1*,B1*,B2
53
A1,B1*,B2
60
A1,B1,B2
66
A1*,A2,B1*,B2
73
A1,A2,B1*,B2
80
A1,A2,B1,B2
86
A1*,A2,A3,B1*,B2
93
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—

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

17

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

150, 230A, 245A,
255A (50 Hz)
A1†,B1†**

150, 230A, 245A,
255A (50 Hz)
A1†**,B1†**

170, 270A,
330A/B (60 Hz)
A1†,B1†

170, 270A,
330A/B (60 Hz)
A1†**,B1†

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6
A1††
13
A1*
20
A1
26
A1††,B1
33
A1*,B1
40
A1,B1
46
A1††,A2,B1
53
A1*,A2,B1
60
A1,A2,B1
66
A1††,A2,B1,B2
73
A1*,A2,B1,B2
80
A1,A2,B1,B2
86
A1††,A2,A3,B1,B2
93
A1*,A2,A3,B1,B2
100
A1,A2,A3,B1,B2
11
A1*
17
A1
23
A1*,B1*
28
A1*,B1
33
A1,B1
39
A1*,A2,B1*
45
A1*,A2,B1
50
A1,A2,B1
56
A1*,A2,B1*,B2
61
A1*,A2,B1,B2
67
A1,A2,B1,B2
73
A1*,A2,A3,B1*,B2
78
A1*,A2,A3,B1,B2
83
A1,A2,A3,B1,B2
89
A1*,A2,A3,B1*,B2,B3
95
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
6
A1††
11
A1*
17
A1
17
A1††,B1*
23
A1††,B1
28
A1*,B1
33
A1,B1
34
A1††,A2,B1*
39
A1††,A2,B1
45
A1*,A2,B1
50
A1,A2,B1
51
A1††,A2,B1*,B2
56
A1††,A2,B1,B2
61
A1*,A2,B1,B2
67
A1,A2,B1,B2
67
A1††,A2,A3,B1*,B2
73
A1††,A2,A3,B1,B2
78
A1*,A2,A3,B1,B2
83
A1,A2,A3,B1,B2
84
A1††,A2,A3,B1*,B2,B3
89
A1††,A2,A3,B1,B2,B3
95
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
6
B1††
13
B1*
20
B1
26
A1,B1††
33
A1,B1*
40
A1,B1
46
A1,B1††,B2
53
A1,B1*,B2
60
A1,B1,B2
66
A1,A2,B1††,B2
73
A1,A2,B1*,B2
80
A1,A2,B1,B2
86
A1,A2,A3,B1††,B2
93
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
6
B1††
13
B1*
20
B1
26
A1,B1††
33
A1,B1*
40
A1,B1
46
A1,B1††,B2
53
A1,B1*,B2
60
A1,B1,B2
66
A1,A2,B1††,B2
73
A1,A2,B1*,B2
80
A1,A2,B1,B2
86
A1,A2,A3,B1††,B2
93
A1,A2,A3,B1*,B2
100
A1,A2,A3,B1,B2
11
B1*
17
B1
23
A1*,B1*
28
A1,B1*
33
A1,B1
39
A1*,B1*,B2
45
A1,B1*,B2
50
A1,B1,B2
56
A1*,A2,B1*,B2
61
A1,A2,B1*,B2
67
A1,A2,B1,B2
73
A1*,A2,B1*,B2,B3
78
A1,A2,B1*,B2,B3
83
A1,A2,B1,B2,B3
89
A1*,A2,A3,B1*,B2,B3
95
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—

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

18

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

170, 270A,
330A/B (60 Hz)
A1†,B1†**

170, 270A,
330A/B (60 Hz)
A1†**,B1†**

170, 270A,
330A/B,360B (50 Hz)
A1†,B1†

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6
A1††
11
A1*
17
A1
17
A1††,B1*
23
A1††,B1
28
A1*,B1
33
A1,B1
34
A1††,A2,B1*
39
A1††,A2,B1
45
A1*,A2,B1
50
A1,A2,B1
51
A1††,A2,B1*,B2
56
A1††,A2,B1,B2
61
A1*,A2,B1,B2
67
A1,A2,B1,B2
67
A1††,A2,A3,B1*,B2
73
A1††,A2,A3,B1,B2
78
A1*,A2,A3,B1,B2
83
A1,A2,A3,B1,B2
84
A1††,A2,A3,B1*,B2,B3
89
A1††,A2,A3,B1,B2,B3
95
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
9
A1*
14
A1
19
A1*,B1*
23
A1*,B1
28
A1,B1
33
A1*,A2,B1*
37
A1*,A2,B1
42
A1,A2,B1
52
A1*,A2,B1*,B2
57
A1*,A2,B1,B2
61
A1,A2,B1,B2
72
A1*,A2,A3,B1*,B2
76
A1*,A2,A3,B1,B2
81
A1,A2,A3,B1,B2
91
A1*,A2,A3,B1*,B2,B3
96
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING
%
Displacement
(Approx)
6
11
17
17
23
28
33
34
39
45
50
51
56
61
67
67
73
78
83
84
89
95
100
6
11
17
17
23
28
33
34
39
45
50
51
56
61
67
67
73
78
83
84
89
95
100
9
14
19
23
28
38
43
47
52
57
61
72
76
81
91
96
100

SEQUENCE B
Compressors
B1††
B1*
B1
A1*,B1††
A1,B1††
A1,B1*
A1,B1
A1*,B1††,B2
A1,B1††,B2
A1,B1*,B2
A1,B1,B2
A1*,A2,B1††,B2
A1,A2,B1††,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1*,A2,B1††,B2,B3
A1,A2,B1††,B2,B3
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1*,A2,A3,B1††,B2,B3
A1,A2,A3,B1††,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
B1††
B1*
B1
A1*,B1††
A1,B1††
A1,B1*
A1,B1
A1*,B1††,B2
A1,B1††,B2
A1,B1*,B2
A1,B1,B2
A1*,A2,B1††,B2
A1,A2,B1††,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1*,A2,B1††,B2,B3
A1,A2,B1††,B2,B3
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1*,A2,A3,B1††,B2,B3
A1,A2,A3,B1††,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
B1*
B1
A1*,B1*
A1,B1*
A1,B1
A1*,B1*,B2
A1,B1*,B2
A1,B1,B2
A1*,A2,B1*,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1*,A2,B1*,B2,B3
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1*,A2,A3,B1*,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3

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

19

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

170, 270A,
330A/B, 360B (50 Hz)
A1†**,B1†

170, 270A,
330A/B, 360B (50 Hz)
A1†,B1†**

170, 270A,
330A/B, 360B (50 Hz)
A1†**,B1†**

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
5
A1††
9
A1*
14
A1
14
A1††,B1*
19
A1††,B1
23
A1*,B1
28
A1,B1
28
A1††,A2,B1*
33
A1††,A2,B1
37
A1*,A2,B1
42
A1,A2,B1
48
A1††,A2,B1*,B2
52
A1††,A2,B1,B2
57
A1*,A2,B1,B2
61
A1,A2,B1,B2
67
A1††,A2,A3,B1*,B2
72
A1††,A2,A3,B1,B2
76
A1*,A2,A3,B1,B2
81
A1,A2,A3,B1,B2
87
A1††,A2,A3,B1*,B2,B3
91
A1††,A2,A3,B1,B2,B3
96
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
5
A1††
9
A1*
14
A1
14
A1††,B1*
19
A1††,B1
23
A1*,B1
28
A1,B1
28
A1††,A2,B1*
33
A1††,A2,B1
37
A1*,A2,B1
42
A1,A2,B1
43
A1††,A2,B1††,B2
48
A1††,A2,B1*,B2
52
A1††,A2,B1,B2
57
A1*,A2,B1,B2
61
A1,A2,B1,B2
63
A1††,A2,A3,B1††,B2
67
A1††,A2,A3,B1*,B2
72
A1††,A2,A3,B1,B2
76
A1*,A2,A3,B1,B2
81
A1,A2,A3,B1,B2
82
A1††,A2,A3,B1††,B2,B3
87
A1††,A2,A3,B1*,B2,B3
91
A1††,A2,A3,B1,B2,B3
96
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
5
B1††
9
B1*
14
B1
14
A1*,B1††
19
A1,B1††
23
A1,B1*
28
A1,B1
34
A1*,B1††,B2
38
A1,B1††,B2
43
A1,B1*,B2
47
A1,B1,B2
48
A1*,A2,B1††,B2
52
A1,A2,B1††,B2
57
A1,A2,B1*,B2
61
A1,A2,B1,B2
67
A1*,A2,B1††,B2,B3
72
A1,A2,B1††,B2,B3
76
A1,A2,B1*,B2,B3
81
A1,A2,B1,B2,B3
87
A1*,A2,A3,B1††,B2,B3
91
A1,A2,A3,B1††,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
5
B1††
9
B1*
14
B1
14
A1*,B1††
19
A1,B1††
23
A1,B1*
28
A1,B1
29
A1††,B1††,B2
34
A1*,B1††,B2
38
A1,B1††,B2
43
A1,B1*,B2
47
A1,B1,B2
48
A1*,A2,B1††,B2
52
A1,A2,B1††,B2
57
A1,A2,B1*,B2
61
A1,A2,B1,B2
63
A1††,A2,B1††,B2,B3
67
A1*,A2,B1††,B2,B3
72
A1,A2,B1††,B2,B3
76
A1,A2,B1*,B2,B3
81
A1,A2,B1,B2,B3
82
A1††,A2,A3,B1††,B2,B3
87
A1*,A2,A3,B1††,B2,B3
91
A1,A2,A3,B1††,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B3,B3

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

20

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

190, 290A, 360A/B,
390B (60 Hz)
A1,B1

190, 290A, 360A/B,
390B (60 Hz)
A1**,B1

190, 290A, 360A/B,
390B (60 Hz)
A1,B1**

190, 290A, 360A/B,
390B (60 Hz)
A1**,B1**

190, 290A, 360A,
390B (50 Hz)
A1,B1

190, 290A, 360A,
390B (50 Hz)
A1**,B1

CONTROL
STEPS
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12

LOADING SEQUENCE A
%
Displacement
Compressors
(Approx)
13
A1
25
A1,B1
41
A1,A2,B1
56
A1,A2,B1,B2
78
A1,A2,A3,B1,B2
100
A1,A2,A3,B1,B2,B3
9
A1*
13
A1
21
A1*,B1
25
A1,B1
37
A1*,A2,B1
41
A1,A2,B1
53
A1*,A2,B1,B2
56
A1,A2,B1,B2
74
A1*,A2,A3,B1,B2
78
A1,A2,A3,B1,B2
96
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
9
A1*
13
A1
18
A1*,B1*
21
A1*,B1
25
A1,B1
33
A1*,A2,B1*
37
A1*,A2,B1
41
A1,A2,B1
49
A1*,A2,B1*,B2
53
A1*,A2,B1,B2
56
A1,A2,B1,B2
71
A1*,A2,A3,B1*,B2
74
A1*,A2,A3,B1,B2
78
A1,A2,A3,B1,B2
93
A1*,A2,A3,B1*,B2,B3
96
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
17
A1
33
A1,B1
50
A1,A2,B1
67
A1,A2,B1,B2
83
A1,A2,A3,B1,B2
100
A1,A2,A3,B1,B2,B3
11
A1*
17
A1
28
A1*,B1
33
A1,B1
44
A1*,A2,B1
50
A1,A2,B1
61
A1*,A2,B1,B2
67
A1,A2,B1,B2
78
A1*,A2,A3,B1,B2
83
A1,A2,A3,B1,B2
94
A1*,A2,A3,B1,B2,B3
100
A1,A2,A3,B1,B2,B3

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING SEQUENCE B
%
Displacement
Compressors
(Approx)
13
B1
25
A1,B1
41
A1,B1,B2
56
A1,A2,B1,B2
78
A1,A2,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
9
B1*
13
B1
21
A1,B1*
25
A1,B1
37
A1,B1*,B2
41
A1,B1,B2
53
A1,A2,B1*,B2
56
A1,A2,B1,B2
74
A1,A2,B1*,B2,B3
78
A1,A2,B1,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
9
B1*
13
B1
18
A1*,B1*
21
A1,B1*
25
A1,B1
33
A1*,B1*,B2
37
A1,B1*,B2
41
A1,B1,B2
49
A1*,A2,B1*,B2
53
A1,A2,B1*,B2
56
A1,A2,B1,B2
71
A1*,A2,B1*,B2,B3
74
A1,A2,B1*,B2,B3
78
A1,A2,B1,B2,B3
93
A1*,A2,A3,B1*,B2,B3
96
A1,A2,A3,B1*,B2,B3
100
A1,A2,A3,B1,B2,B3
17
B1
33
A1,B1
50
A1,B1,B2
67
A1,A2,B1,B2
83
A1,A2,B1,B2,B3
100
A1,A2,A3,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—

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

21

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

190, 290A, 360A,
390B (50 Hz)
A1,B1**

190, 290A, 360A,
390B (50 Hz)
A1**,B1**

210, 315A, 390A,
420A/B (60 Hz)
A1,B1

210, 315A, 390A,
420A/B (60 Hz)
A1**,B1

210, 315A, 390A,
420A/B (60 Hz)
A1,B1**

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14

LOADING
%
Displacement
(Approx)
—
—
—
—
—
—
—
—
—
—
—
—
11
17
22
28
33
39
44
50
55
61
67
72
78
83
89
94
100
11
25
36
56
67
86
100
8
11
22
25
33
36
52
56
63
67
83
86
97
100
—
—
—
—
—
—
—
—
—
—
—
—
—
—

SEQUENCE A
Compressors
—
—
—
—
—
—
—
—
—
—
—
—
A1*
A1
A1*,B1*
A1*,B1
A1,B1
A1*,A2,B1*
A1*,A2,B1
A1,A2,B1
A1*,A2,B1*,B2
A1*,A2,B1,B2
A1,A2,B1,B2
A1*,A2,A3,B1*,B2
A1*,A2,A3,B1,B2
A1,A2,A3,B1,B2
A1*,A2,A3,B1*,B2,B3
A1*,A2,A3,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1
A1,B1
A1,A2,B1
A1,A2,B1,B2
A1,A2,A3,B1,B2
A1,A2,A3,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
A1*
A1
A1*,B1
A1,B1
A1*,A2,B1
A1,A2,B1
A1*,A2,B1,B2
A1,A2,B1,B2
A1*,A2,A3,B1,B2
A1,A2,A3,B1,B2
A1*,A2,A3,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1*,A2,A3,A4,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING
%
Displacement
(Approx)
11
17
28
33
44
50
61
67
78
83
94
100
11
17
22
28
33
39
44
50
55
61
67
72
78
83
89
94
100
14
25
44
56
75
86
100
—
—
—
—
—
—
—
—
—
—
—
—
—
—
9
14
21
25
40
44
51
56
71
75
82
86
96
100

SEQUENCE B
Compressors
B1*
B1
A1,B1*
A1,B1
A1,B1*,B2
A1,B1,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
B1*
B1
A1*,B1*
A1,B1*
A1,B1
A1*,B1*,B2
A1,B1*,B2
A1,B1,B2
A1*,A2,B1*,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1*,A2,B1*,B2,B3
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1*,A2,A3,B1*,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
B1
A1,B1
A1,B1,B2
A1,A2,B1,B2
A1,A2,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
B1*
B1
A1,B1*
A1,B1
A1,B1*,B2
A1,B1,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
A1,A2,A3,A4,B1*,B2,B3
A1,A2,A3,A4,B1,B2,B3

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

22

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

210, 315A, 390A,
420A/B (60 Hz)
A1**,B1**

210, 315A, 390A,
420A/B (50 Hz)
A1,B1

210, 315A, 390A,
420A/B (50 Hz)
A1**,B1

210, 315A, 390A,
420A/B (50 Hz)
A1,B1**

210, 315A, 390A,
420A/B (50 Hz)
A1**,B1**

CONTROL
STEPS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

LOADING
%
Displacement
(Approx)
8
11
17
22
25
28
33
36
48
52
56
59
63
67
78
83
86
92
97
100
9
26
35
51
67
84
100
6
9
23
26
32
35
48
51
65
67
81
84
97
100
—
—
—
—
—
—
—
—
—
—
—
—
—
—
7
9
17
23
26
27
32
35
43
48
51
59
65
67
75
81
84
92
97
100

SEQUENCE A
Compressors
A1*
A1
A1*,B1*
A1*,B1
A1,B1
A1*,A2,B1*
A1*,A2,B1
A1,A2,B1
A1*,A2,B1*,B2
A1*,A2,B1,B2
A1,A2,B1,B2
A1*,A2,A3,B1*,B2
A1*,A2,A3,B1,B2
A1,A2,A3,B1,B2
A1*,A2,A3,B1*,B2,B3
A1*,A2,A3,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1*,A2,A3,A4,B1*,B2,B3
A1*,A2,A3,A4,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
A1
A1,B1
A1,A2,B1
A1,A2,B1,B2
A1,A2,A3,B1,B2
A1,A2,A3,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
A1*
A1
A1*,B1
A1,B1
A1*,A2,B1
A1,A2,B1
A1*,A2,B1,B2
A1,A2,B1,B2
A1*,A2,A3,B1,B2
A1,A2,A3,B1,B2
A1*,A2,A3,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1*,A2,A3,A4,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
A1*
A1
A1*,B1*
A1*,B1
A1,B1
A1*,A2,B1*
A1*,A2,B1
A1,A2,B1
A1*,A2,B1*,B2
A1*,A2,B1,B2
A1,A2,B1,B2
A1*,A2,A3,B1*,B2
A1*,A2,A3,B1,B2
A1,A2,A3,B1,B2
A1*,A2,A3,B1*,B2,B3
A1*,A2,A3,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1*,A2,A3,A4,B1*,B2,B3
A1*,A2,A3,A4,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3

*Unloaded compressor.
†Compressor unloader, standard.
**Compressor unloader, accessory.
††Two unloaders, both unloaded.

LOADING
%
Displacement
(Approx)
9
14
17
21
25
37
40
44
48
51
56
67
71
75
78
82
86
92
96
100
16
26
42
51
67
84
100
—
—
—
—
—
—
—
—
—
—
—
—
—
—
11
16
20
26
36
42
46
51
62
67
78
84
94
100
11
16
17
20
26
34
36
42
43
46
51
59
62
67
75
78
84
92
94
100

SEQUENCE B
Compressors
B1*
B1
A1*,B1*
A1,B1*
A1,B1
A1*,B1*,B2
A1,B1*,B2
A1,B1,B2
A1*,A2,B1*,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1*,A2,B1*,B2,B3
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1*,A2,A3,B1*,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
A1*,A2,A3,A4,B1*,B2,B3
A1,A2,A3,A4,B1*,B2,B3
A1,A2,A3,A4,B1,B2,B3
B1
A1,B1
A1,B1,B2
A1,A2,B1,B2
A1,A2,B1,B2,B3
A1,A2,A3,B1,B2,B3
A1,A2,A3,A4,B1,B2,B3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
B1*
B1
A1,B1*
A1,B1
A1,B1*,B2
A1,B1,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
A1,A2,A3,A4,B1*,B2,B3
A1,A2,A3,A4,B1,B2,B3
B1*
B1
A1*,B1*
A1,B1*
A1,B1
A1*,B1*,B2
A1,B1*,B2
A1,B1,B2
A1*,A2,B1*,B2
A1,A2,B1*,B2
A1,A2,B1,B2
A1*,A2,B1*,B2,B3
A1,A2,B1*,B2,B3
A1,A2,B1,B2,B3
A1*,A2,A3,B1*,B2,B3
A1,A2,A3,B1*,B2,B3
A1,A2,A3,B1,B2,B3
A1*,A2,A3,A4,B1*,B2,B3
A1,A2,A3,A4,B1*,B2,B3
A1,A2,A3,A4,B1,B2,B3

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

23

Head Pressure Control

Keypad and Display Module (Also Called HSIO
or LID) — The only function of this module is to allow

EXV UNITS (All 30GN units except 040 and 045 with optional brine) — The microprocessor controls the condenser
fans in order to maintain the lowest condensing temperature
possible, thus the highest unit efficiency. Instead of using the
conventional head pressure control methods, the fans are controlled by the position of the EXV and suction superheat.
As the condensing temperature drops, the EXV opens to
maintain the proper suction superheat. Once the EXV is fully
open, if the condensing temperature continues to drop, the
suction superheat begins to rise. Once the suction superheat
is greater than 40 F (22.2 C), a fan stage is removed after
2 minutes.
As the condensing temperature rises, the EXV closes to
maintain the proper suction superheat. Once the EXV has
closed to 39.5% open (600 steps open), a fan stage is added
after 2 minutes.
During start-up, all the condenser fans are started when
the condensing temperature reaches 95 F (35 C) to prevent
excessive discharge pressure during pulldown. See Table 5
for condenser fan sequence of operation.
For low-ambient operation, the lead fan in each circuit can
be equipped with the optional or accessory Motormastert
III head pressure controller. This control has its own sensor
which is mounted on a return bend in the liquid portion of
the condenser. It will vary the fan speed to maintain a saturated condensing temperature of 100 F. The controls automatically default to condensing temperature control during
this first stage of condenser-fan operation. When subsequent
fan stages start, the controls revert to EXV fan control.
TXV UNITS (30GN040,045 with optional brine only) —
Head pressure control is based on set point control. The microprocessor stages the condenser fans to maintain the set point
temperature specified by the controller.

the operator to communicate with the processor. It is used to
enter configurations and set points and to read data, perform
tests, and set schedules. This device consists of a keypad
with 6 function keys, 5 operative keys, 12 numeric keys
(0 to 9, •, and -), and an alphanumeric, 8-character LCD. See
Fig. 4. See Table 6 for key usage.
IMPORTANT: When entering multiple character inputs beginning with a zero, a decimal point must be
entered in place of the first zero. When entering an input of zero, only the decimal point need be entered.
ACCESSING FUNCTIONS AND SUBFUNCTIONS — See
Tables 6 - 8. Table 7 shows the 6 functions (identified by
name) and the subfunctions (identified by number).
AUTOMATIC DEFAULT DISPLAY — When keypad has
not been used for 10 minutes, display automatically switches
to the rotating automatic default display. This display has
7 parts, listed below, which appear in continuous rotating
sequence.
DISPLAY
TUE 15:45
LOCAL ON
CLOCK ON
8 MODE
COOL 1
2 ALARMS
3 MINS

EXPANSION
TODAY IS TUE, TIME IS 15:45 (3:45 PM)
UNIT IN LOCAL MODE
UNIT IS ON VIA CLOCK SCHEDULE
TEMPERATURE RESET IN EFFECT
NUMBER OF STAGES IS 1
THERE ARE 2 ALARMS
3 MINUTES REMAINING IN THE OFF-TO-ON
TIME DELAY

Pumpout
EXV UNITS — When the lead compressor in each circuit
is started or stopped, that circuit goes through a pumpout
cycle to purge the cooler and refrigerant suction lines of
refrigerant.
The pumpout cycle starts immediately upon starting the
lead compressor and continues until the saturated suction temperature is 10° F (5.6° C) below the saturated suction temperature at start-up, is 10° F (5.6° C) below the cooler leaving fluid temperature, or reaches a saturated suction temperature
of –15 F (–26 C). No pumpout is necessary if the saturated
suction temperature is below –15 F (–26 C). At this point,
the EXV starts to open and continues to open gradually to
provide a controlled start-up to prevent liquid flood-back to
the compressor.
At shutdown, the pumpout cycle continues until the saturated suction temperature for that circuit is 10° F (5.5° C)
below the saturated suction temperature when pumpout is
initiated, or saturated suction temperature reaches –15 F
(–26 C). At that point, the compressor shuts down and the
EXV continues to move until fully closed.
TXV UNITS — Pumpout is based on timed pumpout. On a
command for start-up, the lead compressor starts. After
10 seconds, the liquid line solenoid opens. At shutdown, the
liquid line solenoid closes, and the lead compressor continues to run for 10 seconds before stopping.

Fig. 4 — Keypad and Display Module

24

Table 5 — Condenser Fan Sequence
FAN ARRANGEMENT
30GN

FAN NUMBER(S)

FAN CONTACTOR
(FC)

CONTROLLED BY

1

FC-A1

Compressor A1

2

FC-B1

Compressor B1

3

FC-A2

First Stage
Microprocessor

4

FC-B2

Second Stage
Microprocessor

1

FC-A1

Compressor A1

2

FC-B1

Compressor B1

3, 4

FC-A2

First Stage
Microprocessor

5, 6

FC-B2

Second Stage
Microprocessor

1

FC-A1

Compressor A1

2

FC-B1

Compressor B1

3

FC-A2

4

FC-B2

First Stage
Microprocessor

3, 4, 5, 6

FC-A2, FC-B2,
FC-A3, FC-B3

Second Stage
Microprocessor

1

FC-A1

Compressor A1

2

FC-B1

Compressor B1

3

FC-A2

4

FC-B2

First Stage
Microprocessor

5, 7, 6, 8

FC-A3, FC-B3

Second Stage
Microprocessor

3, 4, 5, 6, 7, 8

FC-A2, FC-A3,
FC-B2, FC-B3

Third Stage
Microprocessor

5, 7

FC-A1

Compressor A1

6, 8

FC-B1

Compressor B1
First Stage
Microprocessor

040-050

060,070

080,090 (and associated modular units*)

100,110 (and associated modular units*)

130-170 (and associated modular units*)

190,210 (and associated modular units*)

3, 9

FC-A2

4, 10

FC-B2

1, 3, 9

FC-A2, FC-A3

2, 4, 10

FC-B2, FC-B3

5, 7

FC-A1

Compressor A1

6, 8

FC-B1

Compressor B1

3, 9

FC-A2

4, 10

FC-B2

First Stage
Microprocessor

1, 3, 9, 11

FC-A2, FC-A3

2, 4, 10, 12

FC-B2, FC-B3

Second Stage
Microprocessor

Second Stage
Microprocessor

*See Table 1.
†Control box.

KEYPAD OPERATING INSTRUCTIONS (Refer to
Table 9.)
1. White keys on left side of keypad are shown and operated in these instructions according to the following ex-

AUTOMATIC DISPLAY OPERATION/DEFAULT DISPLAY — This display automatically rotates as follows:

ample: keypad entry

, then

the white key marked
.
2. The standard display uses abbreviations. Expanded in-

DOW — Day of Week
HH
— Hour(s)
MM
— Minute(s)

formation scrolls through the display whenever
is pressed.

The default rotating display is displayed every 2 seconds
if there has been no manual input from the keypad for
10 minutes.
To return to automatic display, enter

means press the

at any time.
25

key

Table 6 — Keypad and Display Module Usage
FUNCTION
KEYS

3. All functions are made up of a group of subfunctions. To
enter a subfunction, first press subfunction number desired. Then press the function key in which the subfunction resides. To move within that subfunction, press

USE
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.
TEST — For checking inputs and outputs for
proper operation.
SCHEDULE — For entering occupied/unoccupied
schedules for unit operation.
SET POINT — For entering operating set points
and day/time information.

OPERATIVE
KEYS

the
or
arrow. For example, a
enters
the Temperature Information subfunction.
4. At any time, another subfunction may be entered by pressing the subfunction number, then the function key.
5. Prior to starting unit, check leaving fluid set point for correct setting. Refer to Set Point Function section on
page 38.
6. Depending on system configuration, all displays may not
be shown. All displays are shown unless marked with the
following symbol:
†Must be configured.
For additional unit start-up procedures, see separate
Installation, Start-Up, and Service Instructions supplied
with unit.

USE
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.

Table 7 — Functions and Subfunctions
SUBFUNCTION
NO.

Status

1

Automatic
Display
Alarm
Display
Mode (Operating)
Display
Capacity
Stages
Set Points
(Current Operating)
Temperatures
Pressures
Analog Inputs
Discrete Inputs
Outputs
—

2
3
4
5
6
7
8
9
10
11

Test

FUNCTIONS
Schedule

Outputs

Override

Compressors
and Unloaders
Calibrate
Transducers
—

Clock Select

—

Period 3

—
—
—
—
—
—

Period 4
Period 5
Period 6
Period 7
Period 8
HOLIDAYS

Period 1
Period 2

26

Service

History

Set Point

Log On and
Log Off
Version
(Software)
Factory
Configuration
Field
Configuration
Service
Configuration
—
—
—
—
—
—

Run Time

Set Points
(Chiller Fluid)
Reset
Set Points
Demand Limit
Set Points
Date and
Time
Leaving Chiller
Fluid Alert Limit
—
—
—
—
—
—

Starts
Alarm
History
—
—
—
—
—
—
—
—

Table 8 — Accessing Functions and Subfunctions
KEYPAD
ENTRY

OPERATION

DISPLAY
RESPONSE

To access a function, press
subfunction no. and function
name key. Display shows subfunction group.
To move to other elements,
scroll up or down using arrow
keys. NOTE: These
displays do not show if
control is not configured
for reset.
When the last element in a
subfunction has been displayed,
the first element is repeated.
To move to next subfunction
it is not necessary to use
subfunction number. Press
function name key to advance display through all
subfunctions within a
function and then back
to the first.
To move to another function,
either depress function name
key for desired function
(display shows the first
subfunction),
or
Access a specific subfunction by using the subfunction number and the
function name key.

EXPANSION

RESET

RESET SETPOINTS

CRT1 x

COOL RESET AT 20 MA

CRT2N x

COOL RTEMP (NO RESET)

CRT2F x

COOL RTEMP (FULL RESET)

CRT2D x

COOL DEGREES RESET

RESET

RESET SETPOINTS

CRT1 x

COOL RESET AT 20 MA

DEMAND

DEMAND LIMIT SETPOINTS

TIME

CURRENT TIME AND DAY OF
WEEK

SETPOINT

UNIT SETPOINTS

X ALARMS

THERE ARE n ALARMS

STAGE

CAPACITY STAGING
INFORMATION

Table 9 — Keypad Directory
STATUS
SUBFUNCTION

KEYPAD ENTRY

1 AUTOMATIC DISPLAY
2 ALARMS/ALERTS

DISPLAY

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

Number of Tripped Alarms/Alerts

R S AL

Reset all Alarms/Alerts

ALARM* X

}

ALARM* X
ALARM* X
ALARM* X
ALARM* X
To toggle between inputs (Yes/No) Press:
3 MODES

COMMENT

(no) or

Displays Tripped Alarms/Alerts

(yes)

X MODES

Number of Modes in Effect

X MODE

}

X MODE
X MODE
X MODE

27

Displays Mode in Effect

Table 9 — Keypad Directory (cont)
STATUS (cont)
SUBFUNCTION

KEYPAD ENTRY

4 STAGE

5 SET POINT

6 TEMPERATURE

DISPLAY

COMMENT

STAGE

Capacity Staging Information

COOL X

Number of Requested Stages

CAPT X

Percent of Total Capacity

CAPA X

Percent Circuit A Total Capacity

CAPB X

Percent Circuit B Total Capacity

AVAIL X

Percent Available Capacity

AV A X

Percent Circuit A Available Capacity

AV B X

Percent Circuit B Available Capacity

LMT X†

Demand Limit Set Point (percent)

CIRA X

Circuit A Compressor Relay Status

CIRB X

Circuit B Compressor Relay Status

SMZ X

Load/Unload Factor for Compressors
Factor = 1 Unloader Factor = 0.6

SETPOINT

Fluid Set Point Information

SET X

Set Point (F)

MSP X

Modified Set Point = Set Point + Reset (F)

TW X

Actual Control Temperature (F)

TEMPS

Temperature Information (F)

EWT X

Cooler Entering Fluid Temperature (F)

LWT X

Cooler Leaving Fluid Temperature (F)

SCTA X

Circuit A Saturated Condenser Temperature (F)

SSTA X

Circuit A Saturated Suction Temperature (F)

CTA X

Compressor A1 Suction Temperature (F)

SHA X

Circuit A Suction Superheat (F)

SCTB X

Circuit B Saturated Condenser Temperature (F)

SSTB X

Circuit B Saturated Suction Temperature (F)

CTB X

Compressor B1 Suction Temperature (F)

SHB X

Circuit B Suction Superheat (F)

SPC X

Space Temperature (F)

OAT X

Outdoor-Air Temperature (F)

LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve
MOP — Maximum Operating Pressure

*Will read ALARM or ALERT as appropriate.
†Must be configured.
**If applicable.
††Not manually resettable.
NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

28

Table 9 — Keypad Directory (cont)
STATUS (cont)
SUBFUNCTION

KEYPAD ENTRY

7 PRESSURE

8 ANALOG

9 INPUTS

10 OUTPUTS

DISPLAY

COMMENT

PRESSURE

Refrigerant System Pressure (psig)

MM DD YY

Date of Last Calibration

DPA X

Circuit A Discharge Pressure (psig)

SPA X

Circuit A Suction Pressure (psig)

XXXX XXX

Circuit A Discharge/Suction (psig)

OPA X

Circuit A Oil Pressure Differential (psig)

DPB X

Circuit B Discharge Pressure (psig)

SPB X

Circuit B Suction Pressure (psig)

XXXX XXX

Circuit B Discharge/Suction (psig)

OPB X

Circuit B Oil Pressure Differential (psig)

ANALOG

Status of Analog Inputs

REF X

Transducer Supply Voltage (volts)

LMT X†

Demand 4-20 mA Signal (mA)

RST X†

Reset 4-20 mA Signal (mA)

SW INPUT

Status of Switch Inputs

SPW X†

Dual Set Point Switch (open/closed)

DL1 X†

Demand Limit Switch 1 (open/closed)

DL2 X†

Demand Limit Switch 2 (open/closed)

OUTPUTS

Status of Outputs

ALMR X

Alarm Relay K3 (on/off)

FRA1 X

Fan Relay K1 (on/off)

FRA2 X

Fan Relay K2 (on/off)

FRB1 X

Fan Relay K4 (on/off)

FRB2 X

Fan Relay K5 (on/off)

CHWP X†

Cooler Water Pump Relay K6 (on/off)

ULA1 X

Unloader A1 (on/off)**

ULA2 X†

Unloader A2 (on/off)**

ULB1 X

Unloader B1 (on/off)**

ULB2 X†

Unloader B2 (on/off)**

LLSA X

Liquid Line Solenoid A

LLSB X

Liquid Line Solenoid B

EXVA X

EXVA Percent Open†

LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve
MOP — Maximum Operating Pressure

*Will read ALARM or ALERT as appropriate.
†Must be configured.
**If applicable.
††Not manually resettable.
NOTE: If metric option is selected under

, temperature

expressed as Celsius and pressure will be expressed as kPa.

29

Table 9 — Keypad Directory (cont)
STATUS (cont)
SUBFUNCTION

KEYPAD ENTRY

10 OUTPUTS (cont)

DISPLAY

COMMENT

EXVB X

EXVB Percent Open**

HGBA X†

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

HGBB X†

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

MMA X†

MotormasterT A Output Percent**

MMB X†

Motormaster B Output Percent**

TEST
To use Test function, LOCAL/ENABLE-STOP-CCN switch must be in STOP position. To operate a test, scroll to desired test.
Then, press
to start test. Press
to stop test.
SUBFUNCTION

KEYPAD ENTRY

DISPLAY

1 OUTPUTS

To toggle between inputs (Yes/No) Press:

COMMENT

OUTPUTS

Test Outputs

8.8.8.8.8.8.8.8

Display Check

ALMR X

Energize Alarm Relay K3 (on/off)

FRA1 X

Energize Fan Relay A1 K1 (on/off)

FRA2 X

Energize Fan Relay A2 K2 (on/off)

FRB1 X

Energize Fan Relay B1 K4 (on/off)

FRB2 X

Energize Fan Relay B2 K5 (on/off)

CHWP X†

Energize Cooler Water Pump K6 (on/off)

LSVA X

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

LSVB X

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

EXVA X

Enter Desired EXVA Position (percent)**

EXVB X

Enter Desired EXVB Position (percent)**

HGBA X†

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

HGBB X†

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

MMA X†

Enter Desired Motormaster A Output Signal (percent)**

MMB X†

Enter Desired Motormaster B Output Signal (percent)**

(no) or

(yes)

During compressor test, compressors start and run for
10 seconds. Compressor service valves and liquid line
valves must be open. Energize crankcase heaters 24 hours
prior to performing compressor tests.
SUBFUNCTION

KEYPAD ENTRY

DISPLAY

2 COMPRESSORS AND
UNLOADERS

30

COMMENT

COMP

Compressor and Unloader Test

CPA1 X

Test Compressor A1 (on/off)

CPA2 X†

Test Compressor A2 (on/off)**

Table 9 — Keypad Directory (cont)
TEST (cont)
SUBFUNCTION

KEYPAD ENTRY

DISPLAY

2 COMPRESSORS AND
UNLOADERS (cont)

3 CALIBRATE
TRANSDUCERS

COMMENT

CPA3 X†

Test Compressor A3 (on/off)**

CPA4 X†

Test Compressor A4 (on/off)**

CPB1 X

Test Compressor B1 (on/off)

CPB2 X†

Test Compressor B2 (on/off)**

CPB3 X†

Test Compressor B3 (on/off)**

CPB4 X†

Test Compressor B4 (on/off)**

UNA1 X

Energize Unloader A1 (on/off)**

UNA2 X†

Energize Unloader A2 (on/off)**

UNB1 X

Energize Unloader B1 (on/off)**

UNB2 X†

Energize Unloader B2 (on/off)**

XDR CAL

Transducer Calibration

CDPA X

Circuit A Discharge Pressure (psig)

CSPA X

Circuit A Suction Pressure (psig)

COPA X

Circuit A Oil Pressure (psig)

CDPB X

Circuit B Discharge Pressure (psig)

CSPB X

Circuit B Suction Pressure (psig)

COPB X

Circuit B Oil Pressure (psig)

SCHEDULE
The Schedule function key

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

unoccupied shutdown or unoccupied setback depending on the cooling set point control configuration. The Schedule function
described is for clock 1, which is the internal clock. Password required for all subfunctions except override.
SUBFUNCTION

KEYPAD ENTRY

DISPLAY

1 OVERRIDE

COMMENT

OVRD X

Number of Override Hrs (0 - 4 Hrs)

OVRD 3

Extended Occupied Time

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

2 CLOCK SELECT

CLOCK XX

Type of Clock Control
0 = No Clock, 1 = Clock 1 (Internal)

3 PERIOD 1

PERIOD 1

Period 1 Time Schedule

Yes = Schedule Operational for that day

OCC HH.MM

Occupied Time

UNO HH.MM

Unoccupied Time

MON X

Monday Flag (yes/no)

TUE X

Tuesday Flag (yes/no)

WED X

Wednesday Flag (yes/no)

THU X

Thursday Flag (yes/no)

LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve
MOP — Maximum Operating Pressure
*Will read ALARM or ALERT as appropriate.
†Must be configured.
**If applicable.

††Not manually resettable.
NOTE: If metric option is selected under
, temperature
expressed as Celsius and pressure will be expressed as kPa.

31

Table 9 — Keypad Directory (cont)
SCHEDULE (cont)
SUBFUNCTION

KEYPAD ENTRY

3 PERIOD 1 (cont)

To toggle between inputs (Yes/No) Press:

(no) or

DISPLAY

COMMENT

FRI X

Friday Flag (yes/no)

SAT X

Saturday Flag (yes/no)

SUN X

Sunday Flag (yes/no)

HOL X

Holiday Flag (yes/no)

(yes)

4 PERIOD 2

PERIOD 2

Period 2 Time Schedule

PERIOD 3 ...
PERIOD 7

Period 3 ... Period 7 Time Schedule

10 PERIOD 8

PERIOD 8

Period 8 Time Schedule

11 HOLIDAYS

HOLIDAYS

Define Calendar Holidays

DAT MM.DD

Holiday Date 1

DAT MM.DD.NN

Holiday Date 30

5 PERIOD 3 ... 9 PERIOD 7

...

New = Unassigned Holiday Date

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

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

operation, refer to Schedule Function section on page 44.

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

KEYPAD ENTRY

DISPLAY

1 LOG ON AND LOG OFF

COMMENT

PASSWORD

Enter Password/Disable Password Protection

LOGGEDON

Logged On

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

2 VERSION

LOGGEDON

—

LOG OFF

Disable Password Protection

EXIT LOG

Logged Off/Enable Password Protection

VERSION

Software Information

XXXXXXXX

Version No. of Software (CESRXX)

The next 3 subfunctions provide the ability to modify configurations. Refer to separate Installation, Start-Up, and Service Instructions
supplied with unit for further information on changing configurations.
To change a configuration, enter the new configuration and press

while on the correct configuration.

3 FACTORY
CONFIGURATION

32

FACT CFG

Factory Configuration Codes

XXXXXXXX

Configuration Code 1

XXXXXXXX

Configuration Code 2

XXXXXXXX

Configuration Code 3

XXXXXXXX

Configuration Code 4

Table 9 — Keypad Directory (cont)
SERVICE (cont)
SUBFUNCTION

KEYPAD ENTRY

DISPLAY

3 FACTORY
CONFIGURATION (cont)

4 FIELD
CONFIGURATION

COMMENT

XXXXXXXX

Configuration Code 5

XXXXXXXX

Configuration Code 6

XXXXXXXX

Configuration Code 7

FLD CFG

Adjustable Field Configuration

ENO X

CCN Element Address

BUS X

CCN Bus Number

BAUD X

CCN Baud Rate

FLUID X

Cooler Fluid Select (water/medium brine)

UNITS X

Display Unit Select (English/Metric)

DELAY X

Delay at Power Up (minutes)

NULA X

No. Circuit A Unloaders

NULB X

No. Circuit B Unloaders

HGB X

Hot Gas Bypass Select (used, not used)

SEQT X

Loading Sequence Select (equal circuit, staged circuit)

LEADT X

Lead/Lag Sequence Type

OPS X

MM X

Oil Pressure Switch Select (enable/disable)
Head Pressure Control Type
(none, air cooled, water cooled)
MotormasterT Select

CSPTYP X

Cooling Set Point Control Select

CRTYP X

Cooling Reset Control Select

ERTYP X

External Reset Sensor Select

OATSEL X

Outdoor-Air Sensor Select

LSTYP X

Demand Limit Control Select

RAMP X

Ramp Load Select (enable, disable)

LOCK X

Cooler Pump Interlock Select

CPC X

Cooler Pump Control Select

REMA X

Remote Alarm Option Select (yes/no)

ALRST X

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

HEADT X

To toggle between inputs (Yes/No) Press:
5 SERVICE
CONFIGURATION

(no) or

(yes)
SRV CFG

Service Configurations

XXXXXXXX

Configuration Code 8

XXXXXXXX

Configuration Code 9

REFRIG X

Refrigerant

TDTYP X

Pressure Transducer Select

OPS X

Oil Transducer Set Point (psig)

LPS X

Low Pressure Set Point (psig)

FANTYP X

Fan Staging Select

SH X

EXV Superheat Set Point (F)

MOP X

EXV MOP Set Point (F)

ZM X

Z Multiplier

LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve
MOP — Maximum Operating Pressure
*Will read ALARM or ALERT as appropriate.
†Must be configured.

**If applicable.
††Not manually resettable.

NOTE: If metric option is selected under
, temperature
expressed as Celsius and pressure will be expressed as kPa.

33

Table 9 — Keypad Directory (cont)
HISTORY
SUBFUNCTION

KEYPAD ENTRY

1 RUN TIME

2 STARTS

3 ALARM/ALERT
HISTORY††

DISPLAY

COMMENT

RUN TIME

Run Time Information

HR X

Total Hrs Unit Has a Comp Operating

HRA X

Circuit A Run Time

HRB X

Circuit B Run Time

HA1 X

Circuit A, Comp A1 Operating Hours

HA2 X

Circuit A, Comp A2 Operating Hours**

HA3 X

Circuit A, Comp A3 Operating Hours**

HA4 X

Circuit A, Comp A4 Operating Hours**

HB1 X

Circuit B, Comp B1 Operating Hours

HB2 X

Circuit B, Comp B2 Operating Hours**

HB3 X

Circuit B, Comp B3 Operating Hours**

HB4 X

Circuit B, Comp B4 Operating Hours**

STARTS

Starts Information

CY X

Cycles from Stage 0 to Stage 1

CYA X

Circuit A Starts

CYB X

Circuit B Starts

CA1 X

Circuit A, Comp A1 Starts

CA2 X

Circuit A, Comp A2 Starts**

CA3 X

Circuit A, Comp A3 Starts**

CA4 X

Circuit A, Comp A4 Starts**

CB1 X

Circuit B, Comp B1 Starts

CB2 X

Circuit B, Comp B2 Starts**

CB3 X

Circuit B, Comp B3 Starts**

CB4 X

Circuit B, Comp B4 Starts**

ALRMHIST

Last 10 Alarms/Alerts

ALARM X
ALARM X
ALARM X
ALARM X
ALARM X

}

Alarm/Alert Description

ALARM X
ALARM X
ALARM X
ALARM X
ALARM X
LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve
MOP — Maximum Operating Pressure

*Will read ALARM or ALERT as appropriate.
†Must be configured.
**If applicable.
††Not manually resettable.
NOTE: If metric option is selected under
, temperature
expressed as Celsius and pressure will be expressed as kPa.

34

Table 9 — Keypad Directory (cont)
SET POINT
To read a set point, go to proper subfunction and read desired set point. To change a set point, enter new set point value, then press
LOCAL/ENABLE-STOP-CCN switch must be in LOCAL/ENABLE or STOP position.
SUBFUNCTION

KEYPAD ENTRY

1 SET POINTS

2 RESET SET POINTS

3 DEMAND SET POINTS

4 DATE AND TIME

DISPLAY

.

COMMENT

SET POINT

Unit Set Point

CSP1 X

Chiller Fluid Set Point 1 (F)

CSP2 X

Chiller Fluid Set Point 2 (F)

HSPA X

Head Pressure Set Point Circuit A (F)

HSPB X

Head Pressure Set Point Circuit B (F)

CRAMP X

Cooling Ramp Loading Rate (F)

RESET

Reset Set Points

CRT1 X

Cooling reset at 20 mA (F)

CRT2N X

Reference Temperature at No Reset (F)

CRT2F X

Reference Temperature at Full Reset (F)

CRT2D X

Total Degrees of Reset (F)

CRT3N X

Chiller Fluid DT at No Reset (F)

CRT3F X

Chiller Fluid DT at Full Reset (F)

CRT3D X

Total Degrees of Reset (F)

DEMAND

Demand Set Points

DLS1 X†

Demand Switch 1 Set Point (percent)

DLS2 X†

Demand Switch 2 Set Point (percent)

DL20 X

Demand Limit at 20 mA (percent)

DLGN X

Loadshed Group Number

LSDD X

Loadshed Demand (percent)

TIME X

Minimum Loadshed Time (minutes)

DATE.TIME

Date, Time and Day of Week

DOW.HR.MIN

Day 1 = Mon, 2 = Tues. . .7 = Sun
Hours are displayed in 24-hr time. Decimal point serves as colon.

MM.DD.YR

Month.Day.Year. When entering date, enter a decimal
point between entries. Each entry must be two numbers.

5 LEAVING CHILLER
FLUID ALERT LIMIT

LMT X

Leaving Chiller Fluid Alert Limit (F)

LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve
MOP — Maximum Operating Pressure

*Will read ALARM or ALERT as appropriate.
†Must be configured.
**If applicable.
††Not manually resettable.
NOTE: If metric option is selected under
, temperature
expressed as Celsius and pressure will be expressed as kPa.

35

To reset alarms/alerts using keypad and display module:

STATUS FUNCTION — This function shows the rotating
display, current status of alarm and alert (diagnostic) codes,
capacity stages, operating modes, chilled water set point, all
measured system temperatures and pressures, superheat values, pressure switch positions, analog inputs, and switch inputs. These subfunctions are defined on pages 36 and 37.

KEYPAD
ENTRY

(Rotating Display)

plays and then press

KEYPAD
ENTRY

to move to the individual dis-

Example 1 — Reading Alarm Codes
DISPLAY
RESPONSE

RSAL DSB

Reset all alarms/alerts
function disabled

RSAL ENB

Reset all alarms/alerts
function enabled

Example 2 — Reading Current Operating Modes

to enter the alarm/alert dis-

plays. Press
after a code has been displayed. The meaning of the code scrolls across the screen. See Example 1.

KEYPAD
ENTRY

COMMENTS

(Modes) — The operating mode codes are displayed to indicate the operating status of the unit at a given
time. See Table 10.
To enter the MODES subfunction, press
and
press the
key to determine if more than one mode applies. See Example 2 to read current mode with expansion.

(Alarms/Alerts) — Alarms and alerts are messages
that one or more faults have been detected. Each fault is assigned a code number which is reported with the alarm or
alert. See Table 10 for code definitions. The codes indicate
failures that cause the unit to shut down, terminate an option
(such as reset) or result in the use of a default value as set
point.
Up to 10 codes can be stored at once. To view them
in sequence, press

DISPLAY
RESPONSE

COMMENTS

DISPLAY
RESPONSE

COMMENTS

TUE 15:45
LOCAL ON
CLOCK ON
8 MODE
COOL 1
0 ALARMS
3 MINS

Keypad has not been used for at
least 10 minutes. Rotating summary
display appears on screen

2 MODES

There are 2 modes currently in effect

LOCAL ON

Unit is on by chiller on/off switch

8 MODE

Temperature reset is in effect

TUE 12:45
LOCAL ON
CLOCK ON
13 MODE
8 MODE
COOL 1
2 ALARMS
3 MINS

Keypad has not been used for
at least 10 minutes. Alternating
summary display appears on
screen

2 ALARMS

2 alarms/alerts detected

RSAL DSB

Reset all alarms/alerts

(Stage) — This subfunction displays the capacity stage number. See Tables 4A-4C for compressor loading
sequence. To enter the STAGE subfunction, press
and press the
to display the stage number.

ALARM 9

First alarm/alert code

Continue pressing
•
•
•
•
•
•

for the following information:

Number of requested stages.
Percent of total unit capacity being utilized.
Percent of each circuit capacity being utilized.
Percent of total capacity available.
Percent of capacity available in each circuit.
Demand limit set point in effect (can be any value between 0% and 100%).
• Status of each compressor relay. When a compressor is
on, the number of that compressor is displayed. If a compressor is off, a 0 is displayed. For example: In a given
circuit, if compressors 1 and 3 are running, and 2 and 4 are
not running, 0301 is displayed for that circuit.
• Load/Unload factor for compressors. This factor is an indication of when a step of capacity is added or subtracted.
Its value can range from slightly less than –1.0 to slightly
more than +1.0. When load/unload factor reaches +1.0, a
compressor is added. When the load/unload factor reaches
–1.0, a compressor is subtracted. If compressor unloaders
are used, at –.6 a compressor is unloaded and at +.6, a
compressor is loaded up.

COOLER LEAVING
FLUID THERMISTOR Explanation of alarm/alert code
FAILURE
Second alarm/alert code.
ALARM 42
Cooler freeze protection
COOLER FREEZE
Explanation of alarm/alert code
PROTECTION

When a diagnostic (alarm or alert) code is stored in the
display and the machine automatically resets, the code is deleted. Codes for safeties which do not automatically reset
are not deleted until the problem is corrected and either the
machine is switched to STOP position, then back to LOCAL/
ENABLE or CCN position, or by using the keypad and display module.

36

Table 10 — Operational and Mode Display Codes
The operating modes are displayed by name or code number, to indicate the operating status of the unit at a given
time. The modes are:

(Set Point) — This subfunction displays leaving
fluid temperature and leaving chilled fluid set point. If unit
is programmed for dual set point, the chilled fluid set point
currently in effect (either occupied or unoccupied) is
displayed. If reset is in effect, the unit operates to the modified chilled fluid set point. This means the leaving fluid temperature may not equal the chilled fluid set point. The
modified chilled fluid set point can also be displayed in the
Status function. To enter the set point subfunction,
press
and press
to display the set point followed by the modified leaving chilled fluid set point and actual control temperature.

CODE

DESCRIPTION
Unit is off. LOCAL/ENABLE-STOP-CCN switch is in
position, or LOCAL/ENABLE-STOP-CCN switch
LOCAL OFF OFF
may be in LOCAL position with external ON/OFF
switch in OFF position.
Unit is off due to CCN network command. LOCAL/
CCN OFF
ENABLE-STOP-CCN switch is in CCN position.
is off due to internal clock schedule. LOCAL/
CLOCK OFF Unit
ENABLE-STOP-CCN switch is in LOCAL position.
Unit is on. LOCAL/ENABLE-STOP-CCN switch is in
LOCAL ON LOCAL position. If external ON/OFF switch is used,
it will be in ON position.
Unit is on due to CCN command. LOCAL/ENABLECCN ON
STOP-CCN switch is in CCN position.
Unit is on due to internal clock schedule or occuCLOCK ON pied override function. LOCAL/ENABLE-STOPCCN switch is in LOCAL/ENABLE position.
Dual set point is in effect. In this mode, unit continues to run in unoccupied condition, but leaving fluid
MODE 7
set point is automatically increased to a higher level
(CSP2 set point is in SET function).
Temperature reset is in effect. In this mode, unit is
using temperature reset to adjust leaving fluid set
point upward, and unit is currently controlling to the
MODE 8
modified set point. The set point can be modified based
on return fluid, outdoor-air temperature, or space temperature.
Demand limit is in effect. This indicates that capacity of unit is being limited by demand limit control
MODE 9
option. Because of this limitation, unit may not
be able to produce the desired leaving fluid
temperature.
Flotronic™ System Manager (FSM) is controlling the
MODE 10
chiller.
MODE 11
Not applicable.
Ramp load (pulldown) limiting is in effect. In this mode,
the rate at which leaving fluid temperature is dropped
is limited to a predetermined value to prevent comMODE 12
pressor overloading. See CRAMP set point in the
SET function in Table 9. The pulldown limit can be
modified, if desired, to any rate from .2 F to 2 F
(.1° to 1° C)/minute.
Timed override is in effect. This is a 1 to 4 hour temporary override of the programmed schedule, forcMODE 13
ing unit to occupied mode. Override can be implemented with unit under LOCAL/ENABLE or CCN
control. Override expires after each use.
Low cooler suction protection is in effect. In this mode,
circuit capacity is not allowed to increase if cooler
saturated suction temperature is 20° F (11° C) for
fluid or 30° F (16° C) for brine or more below leaving
MODE 14
fluid temperature, and saturated suction temperature is less than 32 F (0° C). If these conditions persist beyond 10 minutes, circuit is shut down and fault
code 44 or 45 is displayed.
MODE 15
Water System Manager is controlling the chiller.
MODE 16
Slow change override is in effect.
MODE 17
X minute off-to-on delay is in effect.
MODE 18
Low suction superheat protection is in effect.

(Temperature) — The temperature subfunction displays the readings at temperature sensing thermistors.
To read a temperature, enter
, then scroll to desired temperature using the
key. See Table 9 for the
order of readouts. This subfunction also displays the saturated refrigerant temperatures corresponding to the suction
and discharge pressures measured by the compressor
transducers.
(Pressure) — This subfunction displays suction,
discharge, and net oil pressure at lead compressor of each
circuit of unit.
(Analog Inputs) — This subfunction displays
analog inputs, if any. Press
, then press
. The
transducer supply voltage, 4-20 mA reset signal can be displayed. This is useful for problem diagnosis prior to using
the test function.
(Discrete Inputs) — This subfunction displays status (open/closed) of discrete input switch where applicable.
Status of dual set point switch and demand limit switches 1
and 2 can be displayed. This is useful for problem diagnosis
prior to using the test function.
(Outputs) — This function displays on/off status of alarm relay, all fan relays, and chilled water pump
relay. It also displays on/off status of compressor unloaders
(if used). The position of each EXV (in percent open) can be
displayed.
TEST FUNCTION — The test function operates the diagnostic program. To initiate test function, the LOCAL/
ENABLE-STOP-CCN switch must be in STOP position.
To reach a particular test, press its subfunction number,
then scroll to desired test by pressing
. Press
to
start a test. Press

or

or

to terminate or exit a

test. Pressing the
key after a test has started advances
system to next test, whether current test is operating or has
timed out. Once in the next step, you may start
test by pressing
or advance past it by pressing
.
While the unit is in test, you may leave test function and
access another display or function by pressing appropriate
keys. However, a component that is operating when another function is accessed remains operating. You must
re-enter test function and press
to shut down the component. Components with a timed operating limit time out
normally even if another function is accessed.

CCN — Carrier Comfort Network

37

Keypad entry

SET POINT FUNCTION — Set points are entered through
the keypad. Set points can be changed within the upper and
lower limits, which are fixed. The ranges are listed below.

allows the operator to make the

following checks by using
:
• LID display check. Proper display is 8.8.8.8.8.8.8.8.
• Operation of alarm relay.
• Operation of condenser fans.
• Operation of chilled fluid pump.
• Operation of liquid line solenoids.
• Operation of the hot gas bypass relays.
• Operation of EXVs. To drive EXV fully open, enter

Chilled Fluid Set Point
Water:
38 to 86 F (3.3 to 30 C)
Medium Brine:
14 to 86 F (–10 to 30 C)
Pulldown Set Point
0.2 to 2.0 F (0.11 to 1.1 C)/min.

(100% open). To drive EXV fully closed, enter
(0% open).
• Operation of each remote alarm.
• Operation of Motormastert signals.

Reset Set Points
Maximum Reset Range:
–30° to 30° F (–17° to 17° C)
External Temperature Reset –40 to 240 F
(–40 to 118 C)
Chiller Fluid DT: 0° to 15° F
(0° to 8° C)
External Signal Reset 4 to 20 mA

Keypad entry
accesses the compressor and
compressor unloader operational tests.

During compressor operational tests, compressor starts
and runs for 10 seconds. Compressor service valves must
be open. Energize crankcase heaters 24 hours prior to
performing compressor tests.

Demand Limit Set Points
Switch Input:
Step 1 — 0 to 100% Capacity Reduction
Step 2 — 0 to 100% Capacity Reduction
External Signal:
Maximum Demand Limit 4 to 20 mA
Minimum Demand Limit 4 to 20 mA
Loadshed Demand Delta: 0 to 60%
Maximum Loadshed Time: 0 to 120 min.

Since test function checks only certain outputs, it is good
practice to also check all inputs and outputs accessible
through the status function. These are located at
,
, and
(see Table 9). If keypad is not used
for 10 minutes, unit automatically leaves test function and
resumes rotating display. See Example 3.

Set points are grouped in subfunctions as follows:

Example 3 — Using Test Function
KEYPAD DISPLAY
ENTRY RESPONSE

Subfunction displays chiller fluid set points.

COMP

Factory/field test of compressors
subfunction of test function

CPA 1 OFF

Circuit A, Compressor 1A test

CPA 1 ON

Pressing ENTR starts the test:
when the compressor should be running
the display shows CPA1 on
If the test is allowed to time out (10 seconds) the display will show CPA1 off
Pressing the down arrow key advances the
system to Circuit A, compressor 2 test

CPA 1 OFF
CPA 2 OFF

a. The first value shown is the occupied chilled fluid set
point.
b. The next value displayed depends on how the schedule function has been programmed. (See pages 4447.) If dual set point has been selected, the next set
point after
has been pressed is the second chilled
fluid set point. If single set point or inactive schedule has been selected in the schedule function,
then when
is pressed, the display shows the
head pressure set points, one for each circuit. These
are utilized only if the set point controlled method of
head pressure control is selected in
.

COMMENTS

NOTE: Once a compressor has been run using the
it is not allowed to run again for 30 seconds.

function,

c. The final value displayed when the
is pressed
is the cooling ramp loading rate. This is the maximum
rate at which the leaving chilled fluid is allowed to
drop, and can be field set from 0.2 to 2.0 F (.11° to
1.1° C)/minute. This value is not displayed unless the
function is enabled (see Adjustable Field Configurations on page 44).

accesses the transducer calibration subfunction.
All transducers must be calibrated in order for the unit to
operate. Refer to Pressure Transducers section on page 60
for calibration procedure.
HISTORY FUNCTION — Pressing
and
displays total unit run time, total run time for each circuit, and
total run time for each compressor.

Reading and Changing Set Points — Example 4 shows how
to read and change the chilled fluid set point. Other set points
can be changed by following the same procedure. Refer to
Table 9 for the sequence of display of set points in each subfunction.

Pressing
and
displays total unit starts, the
total starts for each circuit, and total starts for each compressor. Pressing
and
displays the last 10 alarms
along with a description of each alarm.

38

Example 4 — Reading and Changing
Chilled Fluid Set Point
KEYPAD
ENTRY

DISPLAY
RESPONSE

COMMENTS

SET POINT

System set points

CSP1 44.0

Present occupied chilled fluid
set point is 44.0 F

CSP1 42.0

Press the
.
Display shows new occupied
chilled fluid set point is 42.0 F
Present unoccupied chilled fluid
set point is 44.0 F

CSP2 44.0
CSP2 50.0

RESET

configuration. Select one of the 4 choices for type of reset:
Return Fluid Reset, External Temperature Reset, 4-20 mA
External Signal Reset, or 4-20 mA Internal Signal Reset.
If dual set point control is enabled (see Field Wiring section on page 69), the amount of reset is applied to whichever
set point is in effect at the time.
Examples 5A-5C demonstrate how to activate reset. Example 6 demonstrates how to change the type of reset. Assume that reset is to be based on return fluid temperature,
the desired reset range is to be 0° to 10° F (0° to 5.5° C) and
full load is a 10° F (5.5° C) drop across the cooler. See
Fig. 5.
Activating reset based on external temperature or
4-20 mA signal is done the same way, except the reference
set point range is –40° to 240° F (–40° to 115° C), or 4 to
20 mA depending on which method was selected at the field
configuration step.

Press the
. Display
shows new unoccupied chilled
fluid set point is 50.0 F
Displays the maximum reset
set point. The minimum and
maximum reference reset
set points can also be displayed.
These set points are not
accessible when reset type has
been configured for NONE in
the service function.

Example 5A — External Reset
In this example, the unit set point is reset from full load
at 90 F (32 C) to a maximum reset value of 10 F (5.5 C) at
20 F (–6.7 C) outdoor ambient.
NOTE: All temperatures given in this example are in F.

Subfunction displays temperature reset set points.

KEYPAD
ENTRY

Temperature Reset Based on Return Fluid Temperature —
The control system is capable of providing leaving fluid temperature reset based on return fluid temperature. Because the
temperature difference between leaving and return temperature is a measure of the building load, return fluid temperature reset is essentially an average building load reset method.
Under normal operation, the chiller maintains a constant
leaving fluid temperature approximately equal to chilled fluid
set point. As building load drops from 100% down to 0%,
entering cooler fluid temperature drops in proportion to load.
Thus, temperature drop across the cooler drops from a typical 10 F (5.5 C) at full load to a theoretical 0° F (0° C) at no
load. See Fig. 5.
At partial load, leaving chilled fluid temperature may be
lower than required. If this is allowed to increase (reset), the
efficiency of the chiller increases. Amount of reset can be
defined as a function of cooler temperature drop, as shown
in Fig. 5. This is a simple linear function that requires
3 pieces of input data for the set function that will vary depending on measurement method used as follows (see
Table 11):
NOTE: Reset set points are not accessible unless the reset
function is enabled first. This is done as a field

DISPLAY
RESPONSE

COMMENTS

FLD CFG
CRTYP 0

Scroll past to reset type

CRTYP 2

External reset selected

ERTYP 0

Scroll past to space
thermistor sensor selected

ERTYP 1

OAT selected

RESET

CRT2F 20

Temperature
reset is 0
Temperature
reset is 90
Temperature
reset is 0
Temperature
reset is 20

CRT2D 0

Maximum reset is 0

CRT2D 10

Maximum reset is 10

CRT2N 0
CRT2N 90
CRT2F 0

for no
for no
for maximum
for maximum

Table 11 — Reset Amounts
INPUT DATA DESCRIPTION
Maximum Reset Amount — Allowable range for
maximum amount which LWT is to be reset.
Maximum Reset Reference — Temperature at
which maximum reset occurs.
Minimum Reset Reference — Temperature at
which no reset occurs.

4-20 mA

MEASUREMENT METHOD
OAT/Occupied Space
or Internal/External
Variable
Limits (F)

Variable

Limits (F)

CRT1

–30 to 30

CRT2D

—

—

—

—

LEGEND
OAT — Outdoor-Air Temperature
LWT — Leaving Fluid Temperature

39

Return Water
Variable

Limits (F)

–30 to 30

CRT3D

–30 to 30

CRT2F

–40 to 240

CRT3F

0 to 15

CRT2N

–40 to 240

CRT3N

0 to 15

Example 5B — 4 to 20 mA and Internally or
Externally Powered Reset
In this example, the unit set point is reset from full load
at 4 mA to a maximum reset value of 10 F (5.5 C) at
20 mA. Internally powered 4 to 20 mA option is used in this
example.
NOTE: To use externally powered reset, when CRTYP

Temperature Reset Based on External Temperature — If desired, temperature reset can be based on an external temperature, such as space or outdoor-air temperature. This requires a thermistor (T10, Part No. 30GB660002) located in
the space or outdoor air and wired to terminals as follows
(also see Field Wiring section on page 69 and Fig. 6):

appears, press
so CRTYP 4 appears in the
display. The remainder of the information in the following example applies to either type of reset.

At the field configuration step, enter set points as described in Examples 5A-5C on pages 39 and 40. Then

KEYPAD
ENTRY

DISPLAY
RESPONSE

4 in/4 out Module — J7-15 and J7-16.

select external temperature reset by entering
when
CRTYP 0 appears. See Fig. 7.
Temperature Reset Based on 4-20 mA Signal— If desired,
temperature reset can be based on a 4-20 mA signal. For
proper connections, refer to Field Wiring section on
page 69 and Fig. 8.
At the field configuration step, select 4-20 mA reset by
entering
(internally powered) or
(externally powered) when CRTYP 0 appears. Then enter set points as described previously in Examples 5A-C. See Fig. 8.

COMMENTS

FLD CFG
CRTYP 0

Scroll past to reset type

CRTYP 1

Internally powered reset
selected

RESET
CRT1 0

Reset at 20 mA is 0

CRT1 10

Reset at 20 mA is 10

Subfunction displays demand limit set points.

Example 5C — Using Return Fluid
Temperature Reset
KEYPAD
ENTRY

DISPLAY
RESPONSE

COMMENTS

FLD CFG

Field configuration
subfunction of
service function

CSPTYP X

Scroll past single/dual

CRTYP 0
CRTYP 3
RESET

Demand Limit, 2-Stage Switch Control — This control has
been designed to accept demand limit signals from a building load shedding control. The demand limit function provides for 2 capacity steps. The keypad is used to set the 2
demand limit set points, which range from 100 to 0% of capacity. Capacity steps are controlled by 2 field-supplied relay contacts connected to the designated chiller terminals.
(See Field Wiring section on page 69 and Fig. 7.)

Display shows no reset
type has been selected
Return fluid temperature
is selected and activated
Reset set points

Fig. 5 — Cooling Return Fluid Reset
40

Fig. 6 — Cooling External Temperature Reset

LEGEND
COMM — Communications Bus
PWR
— Power
SW
— Switch
NOTE: For specific connection points,
see Fig. 25 - 29.

Fig. 7 — 4 IN/4 OUT Options Module Wiring for Reset, Demand Limit, and Dual Set Point
41

Fig. 8 — 4-20 mA Cooling Temperature Reset
Table 12 — Service Functions
To view and modify configurations, the password must be
entered under the log on subfunction.

Example 6 — Changing Reset Type
To change type of reset, first log on as shown in
Table 12. Also refer to Set Point Function section, page 38,
for information on entering reset set points using reset
feature.
KEYPAD
ENTRY

DISPLAY
RESPONSE
FLD CFG
CSPTYP 0
CRTYP 0
CRTYP 1
CRTYP 2
CRTYP 3
CRTYP 4
CRTYP 0

SUBFUNCTION
1 Log On

COMMENTS

KEYPAD
ENTRY

DISPLAY

COMMENT

Password/
PASSWORD Enter
Disable Password
LOGGEDON Logged On

Field configuration
subfunction of
service function
Scroll past single cooling
set point
No reset has been
selected
Internally powered 4-20 mA
signal reset is selected
Space or outdoor-air
temperature reset is
selected
Return fluid temperature
reset is selected
Externally powered 4-20 mA
signal reset is selected

NOTE: Configurations may be modified at this time. When
finished viewing and/or modifying configurations, log out as
follows:
LOGGEDON —

2 Version

LOG OFF

Disable Password
Protection

EXIT LOG

Logged Off/
Enable Password
Protection

VERSION

Software
Information

XXXXXXXX

Version No.
of Software

Reset is deactivated

Demand Limit, 4 to 20 mA Signal — The controls can also
accept a 4 to 20 mA signal for load shedding. Input for the
signal are terminals shown below:
Externally powered
Positive lead to J7-5 - 4 In/4 Out Module
Negative lead to J7-6 - 4 In/4 Out Module
Internally powered
Positive lead to J7-6 - 4 In/4 Out Module
Negative lead to J7-7 - 4 In/4 Out Module
See Field Wiring section on page 69 and Fig. 7.

To use Demand Limit, first enable loadshed, then enter
demand limit set points. See Example 7A. Closing the first
stage demand limit contact puts unit on the first demand limit
level, that is, the unit does not exceed the percentage of capacity entered as demand limit stage 1. Closing contacts on
second-stage demand limit relay prevents unit from exceeding capacity entered as demand limit stage 2. The demand
limit stage that is set to the lowest demand takes priority if
both demand limit inputs are closed.
The demand limit function must be enabled in order to
function and may be turned off when its operation is not desired. The demand limit relays can, in off condition, remain
connected without affecting machine operation.
42

the loadshed demand delta, which defines the percent of the
load to be removed when a loadshed command is in effect.
The third set point is maximum loadshed time, which defines the maximum length of time that a loadshed condition
is allowed to exist. The allowable range for this entry is zero
to 120 minutes.
Subfunction displays date, time, and day of the week.

At field configuration step, select 4 to 20 mA loadshed
by entering
(internally powered) or
(externally powered) when the LSTYP 0 display appears. See Example 7B.
Then enter set points as follows. In this example, set points
are coordinates of the demand limit curve shown in Fig. 9.
Example 7A — Using Demand Limit
(First Log On as Shown in Table 12)
KEYPAD
ENTRY

DISPLAY
RESPONSE

COMMENTS

FLD CFG

Field configuration subfunction of service function

LSTYP 0

Loadshed is not enabled

LSTYP 1

DLS1 80

Loadshed is now enabled
for 2-stage switch control
Demand Limit set points
subfunction of set point
function
Loadshed 1 currently set
at 80%

DLS1 60

Loadshed reset to 60%

DLS2 50

Loadshed 2 currently set
at 50%

DLS2 40

Loadshed 2 reset to 40%

DEMAND

Reading and Changing Time Display — Time is entered and
displayed in 24-hour time. The day of the week is entered as
a number.
1 = Mon, 2 = Tue, 7 = Sun, etc.
Key is used as the colon when entering time. See
Example 8.
subfunction accesses the leaving chiller fluid alert
limit (LMT) option. The value to be entered here is the number of degrees above the control set point at which an alert
should be generated. For example, if the control set point is
44 F, and an alert is desired (alert 70) if the fluid temperature
reaches 50 F, then enter 6 for this set point. The allowable
range for this entry is between 2 and 30 (F).
SERVICE FUNCTION — This function allows the technician to view and input configuration data. Factory configuration data, field configuration data, and service configuration data may be viewed or entered through the keypad and
display module. See Table 9 for a complete listing of configurable items. Whenever a processor module is replaced in
the field, the complete list of configuration codes must be
entered.
Logging On/Logging Off — The service function is password protected. Therefore, to gain entry to this function,

To Disable Demand Limit:
KEYPAD
ENTRY

DISPLAY
RESPONSE

COMMENTS

LSTYP 1

Field configuration subfunction of service function
Scroll past other elements
in the subfunction
Loadshed is enabled for
2-stage switch control

LSTYP 0

Loadshed is now disabled

FLD CFG
ERTYP 0

this password must be entered. Pressing
allows the technician to view, change, or enter configuration
codes. To log off, perform the following keystrokes:
. The service function is once again password
protected.

NOTES:
1. Select 2 for internally powered 4 to 20 mA signal load limiting.
2. Select 3 for Carrier Comfort Network loadshed.
3. Select 4 for externally powered 4 to 20 mA signal load limiting.

Software Information —
displays the version
number of the software that resides in the processor
module. The
rized in Table 12.

Example 7B — Using Demand Limit (4-20 mA)
(First Log On As Shown in Table 12)
KEYPAD
ENTRY

DISPLAY
RESPONSE

and

subfunctions are summa-

Example 8 — Setting Time of Day and
Day of Week

COMMENTS

ERTYP 0

Field configuration subfunction
of service function
Scroll past other elements in
the subfunction

LSTYP 0

Loadshed is not enabled

TIME

LSTYP 2

Loadshed is now enabled
for 4-20 mA internally-powered
signal control

MON 16.00

DEMAND

Demand Limit set points

TUE 13.05

DL20 100

Maximum demand limit is 100%

DL20 90

Maximum demand limit is 90%

FLD CFG

KEYPAD
ENTRY

DISPLAY
RESPONSE

JAN 01 90
APR 15 90

Scrolling past the 4 to 20 mA demand limit set point brings
up the loadshed set points. The loadshed feature is activated
by a redline alert and loadshed commands from the CCN
loadshed option. The first set point is the group number, established by the CCN system designer. The second option is
43

COMMENTS
Time display subfunction of set point
function
Current setting is
Monday, 4:00 p.m.
New setting of
Tuesday, 1:05 p.m.
is entered
and displayed
Current date is
Jan. 1, 1990
New setting
April 15, 1990
is entered
and displayed

Fig. 9 — 4-20 mA Demand Limiting
replaced in the field, the 2 groups of configuration codes must
be entered through the keypad and display module. The
2 groups of configuration codes (groups 8 and 9) that apply
to the unit being serviced can be found on a label diagram
inside the control box cover. See Table 13 for keystroke information to enter configuration codes 8 and 9. The remaining items in this subfunction are read-only data provided to
assist in service evaluations.
SCHEDULE FUNCTION — This function provides a means
to automatically switch chiller from an occupied mode to an
unoccupied mode. When using schedule function, chilled fluid
pump relay must be used to switch chilled fluid pump on
and off. Connections for chilled fluid pump relay are: TB3-3
and TB3-4. The chilled fluid pump relay starts chilled fluid
pump but compressors do not run until remote chilled fluid
pump interlock contacts are between TB6-1 and TB6-2 are
closed and leaving chilled fluid temperature is above set point.
If a remote chilled fluid pump interlock is not used, the first
compressor starts (upon a call for cooling) approximately
one minute after chilled fluid pump is turned on.
The unit can be programmed for inactive, single set point,
or dual set point operation.
When unit is configured for inactive, chilled fluid pump
relay remains energized continuously but is not used since
chiller is usually controlled by remote chilled fluid pump interlock contacts.
When unit is configured for single set point operation, chilled
fluid pump relay is energized whenever chiller is in occupied mode regardless of whether chiller is running. When
chiller is in unoccupied mode, chilled fluid pump relay is
not energized.

Factory Configuration Codes —
allows entry into
the factory configuration subfunction. Under this subfunction, there are 7 groups of configuration codes that are downloaded at the factory. Each group is made up of 8 digits. If
processor module is replaced in the field, these 7 groups of
configuration codes must be entered through the keypad
and display module. Factory configuration codes (groups 1
through 7) that apply to the particular Flotronic™ II chiller
being serviced are found on a label diagram located inside
the control box cover. See Table 13 for a summary of factory
configuration subfunction keystrokes.
Adjustable Field Configurations — After logging on, press
to enter subfunction. The subfunction allows operation of the chiller to be customized to meet the particular
needs of the application. The chiller comes from the factory
preconfigured to meet the needs of most applications. Each
item should be checked to determine which configuration
alternative best meets the needs of a particular application.
See Table 14 for factory loaded configuration codes and alternative configurations.
If processor module is replaced, the replacement module
is preloaded with factory default configuration codes. Each
configuration code must be checked and, if necessary, reconfigured to meet needs of the application. See Table 14 for
pre-loaded service replacement configuration codes.
Service Configuration Codes — Press
to enter the
service configuration subfunction. The first 2 items under this
subfunction are 2 groups (8 digits each) of configuration codes
that are downloaded at the factory. If processor module is

44

Table 13 — Factory Configuration Keystrokes
To change a configuration enter the new configuration
and press
SUBFUNCTION
3 FACTORY
CFG

5 SERVICE
CFG

Table 14 — Adjustable Field Configurations
FIELD CONFIGURATION
ITEM AND CODES

while on the correct configuration.
KEYPAD
ENTRY

DISPLAY

COMMENTS

FACT CFG

FACTORY
CONFIGURATION
CODES

XXXXXXXX

Configuration
Code 1

XXXXXXXX

Configuration
Code 2

XXXXXXXX

Configuration
Code 3

XXXXXXXX

Configuration
Code 4

XXXXXXXX

Configuration
Code 5

XXXXXXXX

Configuration
Code 6

XXXXXXXX

Configuration
Code 7

SRV CFG

CCN element address
(Entered by CCN Technician)
CCN Bus Number
(Entered by CCN Technician)
CCN Baud Rate
(Entered by CCN Technician)
Cooler Fluid Select
1 = Water (38 to 70 F
[3.3 to 21 C] Set Point)
2 = Medium Brine (15 to 70 F
[–9 to 21 C] Set Point)
Display Unit Select
0 = English
1 = Metric SI
Delay at Power Up
No. Circuit A Unloaders
0 = No Unloaders
1 = One Unloader
2 = Two Unloaders
No. Circuit B Unloaders
0 = No Unloaders
1 = One Unloader
2 = Two Unloaders
Hot Gas Bypass Select
0 = No Valve
Loading Sequence Select
1 = Equal Circuit Loading
2 = Staged Circuit Loading
Lead/Lag Sequence Select
1 = Automatic
2 = Manual, Circuit A Leads
3 = Manual, Circuit B Leads
Oil Pressure Switch Select
0 = Not Used
1 = Air Cooled
Head Pressure Control Type
0 = Not Used
1 = Air Cooled
Head Pressure Control Method
1 = EXV Controlled
2 = Set Point Control for
Both Circuits
3 = Set Point Control for
Circuit A; EXV Control
for Circuit B
4 = Set Point Control for
Circuit B; EXV Control
for Circuit A
MotormasterT Select
0 = None
2 = Indirect Control
Cooling Set Point
Control Select
0 = Single Set Point Control
1 = External Switch
Controlled Set Point
2 = Clock Controlled
Set Point
Cooling Reset Control Select
0 = No Reset
1 = 4-20 mA, Internally Powered
2 = External Temperature
Reset
3 = Return Fluid Reset
4 = 4-20 mA, Externally Powered

SERVICE
CONFIGURATION
CODES

XXXXXXXX

Configuration
Code 8

XXXXXXXX

Configuration
Code 9

REFRIG X

Refrigerant Type

TDTYPE X

Pressure Transducer Select

OPS X

Oil Pressure Set Point

LPS X

Low Pressure Set Point

FANTYP X

Fan Staging Select

SH X

EXV Superheat Set Point

MOP X

EXV MOP Superheat

ZM X

Z Multiplier

LEGEND
MOP — Maximum Operating Pressure
EXV — Electronic Expansion Valve

FACTORY
CONFIGURATION
CODE

SERVICE
REPLACEMENT
CODE

001

001

000

000

9600

9600

1 = Standard Models

clock for the scheduling function.
are used
to program schedules for specific occupied and unoccupied
periods.
The schedule consists of from one to 8 occupied time periods, set by the operator. These time periods can be flagged
to be in effect or not in effect on each day of the week. The
day begins at 00.00 and ends at 24.00. The machine is in
unoccupied mode unless a scheduled time period is in effect.
If an occupied period is to extend past midnight, it must be
programmed in the following manner: occupied period must
end at 24:00 hours (midnight); a new occupied period must
be programmed to begin at 00:00 hours.

0

0

0
0

0 = 30GN040-070,
190-210*
1 = 30GN080-170*

0

LEGEND
CCN — Carrier Comfort Network
EXV — Electronic Expansion Valve

45

0

0 = 30GN190-210*
1 = 30GN040-170*

External Reset Sensor Select
0 = Thermistor Connected to
Options Module
1 = Obtained Through CCN
Outdoor-Air Sensor Select
0 = Not Selected
1 = Selected
Demand Limit Control Select
0 = No Demand Limiting
1 = Two External Switch Inputs
2 = Internal 4-20 mA Input
3 = CCN Loadshed
4 = External 4-20 mA Input
Ramp Load Select
(Pulldown Control)
0 = Disabled
1 = Enabled
Cooler Pump Interlock Select
0 = No Interlock
1 = With Interlock
Cooler Pump Control Select
0 = Not Controlled
1 = ON/OFF Controlled
Remote Alarm Option Select
0 = Not Selected
1 = Selected
Local/Enable-Stop-CCN
Switch Usage†
0 = Not Allowed
1 = Allowed

When unit is configured for dual set point, chilled liquid
pump relay is energized continuously, in both occupied and
unoccupied modes. Occupied mode places occupied chilled
water set point into effect; unoccupied mode places unoccupied chilled water set point into effect.
Scheduling —
is used to override any current schedule in effect (for 0-4 hours).
is used to activate a

1

2 = Brine Models

0

0

1

1

1

1

0

0

1

0

1
2 = 040,045
Brine Units

1

0

0

0

0

0

0

0

0

0

0

0

0

1

0

1

0

1

0

0

0

1

1

*And associated modular units.
†For reset of alarms.

Example 9 — Using the Schedule Function (cont)

NOTE: This is true only if the occupied period starts at 00:00
(midnight). If the occupied period starts at a time other than
midnight, then the occupied period must end at 00:00 hours
(midnight) and new occupied period must be programmed
to start at 00:00 in order for the chiller to stay in the occupied mode past midnight.
The time schedule can be overridden to keep unit in occupied mode for one, 2, 3, or 4 hours on a one-time basis.
See Example 9.
All subfunctions of schedule function are password
protected except the override subfunction,

KEYPAD
ENTRY

DISPLAY

PERIOD 2

Occupied time will start
at 7:00 a.m.
Start of unoccupied time
of period). For this
UNO 00.00 (end
example, period 2 should
end at 18:00 (6:00 p.m.)
OCC 7.00

. Pass-

2 ends at 18:00
UNO 18.00 Period
(6:00 p.m.)
MON NO
MON YES

TUE NO

TUE YES

Example 9 — Using the Schedule Function
WED YES
DISPLAY

COMMENT

OVRD 0

No scheduled override
in effect

OVRD 3

3 hours override in effect

OVRD 0

Override cancelled

CLOCK 0

Schedule function is inactive

CLOCK 1

Schedule function is enabled
through local unit clock

WED NO
PERIOD 3

OCC 00.00

UNO 00.00

UNO 3.00

MON NO

MON YES

TUE YES

TUE NO

Monday is now flagged no
for period 2. To put period 2
into effect on Monday,
Monday must be flagged yes
Monday is now flagged for
period 2 to be in effect
Tuesay is now flagged no
for period 2. To put period 2
into effect on Tuesday,
Tuesday must be flagged
yes
Tuesday is now flagged for
period 2 to be in effect
For this example, period 2
is to be in effect only on
Monday and Tuesday.
All other days must be
checked to be sure that
they are flagged no. If
a day is flagged yes,
change to no
Wednesday is now flagged
no for period 2
Define schedule
period 3

of occupied
OCC 00.00 Start
time
Occupied time will start
at 7:00 a.m.
Start of unoccupied time
of period 3). For this
UNO 00.00 (end
example, period 3 should
end at 21:30 (9:30 p.m.)
3 ends at 21:30
UNO 21.30 Period
(9:30 p.m.)
Check to be sure that
MON NO
Monday and Tuesday are
flagged no for period 3
OCC 7.00

PROGRAMMING PERIOD 1:
PERIOD 1

Define schedule period 2

OCC 00.00 Start of occupied time

word entry into subfunctions
through
,
is done through service function. See page 43, logging on/
logging off.
Figure 10 shows a schedule for an office building with the
chiller operating on a single set point schedule. The schedule is based on building occupancy with a 3-hour off-peak
cool-down period from midnight to 3 a.m. following the weekend shutdown. To learn how this sample schedule would be
programmed, see Example 9.
NOTE: This schedule was designed to illustrate the programming of the schedule function and is not intended as a
recommended schedule for chiller operation.

KEYPAD
ENTRY

COMMENT

PROGRAMMING PERIOD 2:

Define schedule period 1.
Start of occupied time
For this example, first
period should start here
(at midnight) so no entry
is needed
Start of unoccupied time
(end of period). For this
example, period 1 should
end at 3:00 a.m.

TUE NO
WED NO

Wednesday is flagged
no, change to yes

WED YES

Wednesday is now
flagged yes for period 3

THUR NO

Check to be sure that all
other days are flagged no

Period 1 ends at 3:00 a.m.
Monday is now flagged no
for period 1. To put period 1
into effect on Monday,
Monday must be flagged
yes
Monday is now flagged for
period 1 to be in effect
For this example, period 1
is to be in effect on Monday
only. All other days must be
checked to be sure that they
are flagged no. If any day is
flagged yes, change to no
Tuesday is now flagged
no for period 1

FRI NO
SAT NO
SUN NO

CCN — Carrier Comfort Network

46

Periods 4 and 5 can be programmed in the same manner,
flagging Thursday and Friday yes for period 4 and Saturday
yes for period 5. For this example, periods 6, 7, and 8
are not used: they should be programmed OCC 00.00,
UNO 00.00.
NOTE: When a day is flagged yes for 2 overlapping periods,
occupied time will take precedence over unoccupied time.
Occupied times can overlap in the schedule with no
consequence.
To extend an occupied mode beyond its normal termination for a one-time schedule override, program as shown
below:
OVRD 0

OVRD 3

Override is set for 0. Enter
the number of hours of
override desired
Unit will now remain in
occupied mode for
an additional 3 hours

Holiday Schedule — Press
to schedule up to
30 holiday periods. All holidays are entered with numerical
values. First, the month (01 to 12), then the day (01 to 31),
then the duration of the holiday period in days.
Examples: July 04 is 07.04.01.
Dec 25 - 26 is 12.25.02
If any of the 30 holiday periods are not used, the display
shows NEW.
See Example 10.

Fig. 10 — Sample Time Schedule

TROUBLESHOOTING

Example 10 — Holiday Schedule Function
ENTER

The Flotronic™ II control has many features to aid the
technicians in troubleshooting a Flotronic II Chiller. By using the keypad and display module and the status function,
actual operating conditions of the chiller are displayed while
unit is running. Test function allows proper operation of compressors, compressor unloaders, fans, EXVs and other components to be checked while chiller is stopped. Service function displays how configurable items are configured. If an
operating fault is detected, an alarm is generated and an
alarm code(s) is displayed under the subfunction
,
along with an explanation of the fault. Up to 10 current alarm
codes are stored under this subfunction. For checking specific items, see Table 9.

DISPLAY
HOLIDAY
JAN01 02 (Includes Jan 1st
and 2nd)
APR17 01 (Includes April 17th)
MAY21 01(Includes May 21st)
JUL03 01 (Includes July 3rd)
JUL04 01 (Includes July 4th)

Checking Display Codes — To determine how ma-

SEP07 01 (Includes Sep. 7th)

chine has been programmed to operate, check diagnostic
information (
) and operating mode displays (
).
If no display appears, follow procedures in Control Modules
section on page 63. If display is working, continue as
follows:
1. Note all alarm codes displayed,
.

NOV26 02 (Includes Nov. 26th
and 27th)
DEC24 02 (Includes Dec. 24th
and 25th)
DEC30 02 (Includes Dec. 30th
and 31st)

2. Note all operating mode codes displayed,
.
3. Note leaving chilled water temperature set point in effect and current leaving water temperature,
.
If machine is running, compare the ‘‘in effect’’ leaving
water temperature set point with current water temperature. Remember, if reset is in effect, the values may be
different because machine is operating to the modified chilled
water set point. If current temperature is equal to set point,
but set point is not the one desired, remember that if dual
set point has been selected in the schedule function, there
are 2 set points to which the machine can be operating.
Check the programming of schedule function to see if occupied or unoccupied set point should be in effect.

NEW
MAY25 01 (Includes May 25th)
NEW
NEW
NEW
NEW
NEW (30TH HOLIDAY)

NEW indicates a holiday that has not been assigned yet.

47

Unit Shutoff — To shut unit off, move LOCAL/ENABLESTOP-CCN switch to STOP position. Any refrigeration circuit operating at this time continues to complete the pumpout cycle. Lag compressors stop immediately, and lead
compressors run to complete pumpout.

If stoppage occurs more than once as a result of any of
the above safety devices, determine and correct the cause
before attempting another restart.

Complete Unit Stoppage — Complete unit stoppage
can
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

13.
14.
15.
16.
17.

Restart Procedure — After cause for stoppage has been
corrected, restart is either automatic or manual, depending
on fault. Manual reset requires that LOCAL/ENABLESTOP-CCN switch be moved to STOP position, then back
to original operating position. Some typical fault conditions
are described in Table 15. For a complete list of fault conditions, codes, and reset type, see Table 16.

be caused by any of the following conditions:
Cooling load satisfied
Remote on/off contacts open
Programmed schedule
Emergency stop command from CCN
General power failure
Blown fuse in control power feed disconnect
Open control circuit fuse
LOCAL/ENABLE-STOP-CCN switch moved to STOP
position
Freeze protection trip
Low flow protection trip
Open contacts in chilled water flow switch (optional)
Open contacts in any auxiliary interlock. Terminals that
are jumpered from factory are in series with control switch.
Opening the circuit between these terminals places unit
in stop mode, similar to moving the control switch to
STOP position. Unit cannot start if these contacts are
open. If they open while unit is running, unit pumps down
and stops.
Cooler entering or leaving fluid thermistor failure
Low transducer supply voltage
Loss of communications between processor module and
other control modules
Low refrigerant pressure
Off-to-on delay is in effect.

Table 15 — Typical Stoppage Faults and Reset Types
Chilled Fluid, Low Flow
Chilled Fluid, Low Temperature

Manual reset
Auto reset first time, manual
if repeated in same day
Chilled Fluid Pump Interlock
Manual reset
Unit
restarts automatically when
Control Circuit Fuse Blown
power is restored
High-Pressure Switch Open
Manual reset
Auto reset first time, then
Low Refrigerant Pressure
manual if within same day
Low Oil Pressure
Manual reset
Discharge Gas Thermostat Open Manual reset

POWER FAILURE EXTERNAL TO THE UNIT — Unit
restarts automatically when power is restored.

Alarms and Alerts — These are warnings of abnormal
or fault conditions, and may cause either one circuit or the
whole unit to shut down. They are assigned code numbers as
described below. These code numbers are displayed
on the HSIO when the
subfunction is entered. A
fault that affects one one circuit of the chiller will generate
an alert, and a fault that affects the entire unit will generate
an alarm.
Following is a detailed description of each alarm and alert
code error and possible cause. Manual reset is accomplished
by moving LOCAL/ENABLE-STOP-CCN Switch to STOP
position, then back to LOCAL or CCN position. See
Table 16 for listing of each alarm and alert code.
Code 0
No alarms or alerts exist
Codes 1 - 8 Compressor failure
If DSIO-LV or -EXV relay module control relay feedback
switch or signal is sensed as open during operation of a compressor, microprocessor detects this and stops compressor,
energizes alert light, and displays a code of 1, 2, 3, 4, 5, 6,
7, or 8 depending on the compressor. Compressor locks off;
to reset, use manual reset method.
If lead compressor in a circuit shuts down, the other compressors in the circuit stop and lock off. Only the alert mode
for lead compressor is displayed.
The microprocessor is also programmed to indicate compressor failure if feedback terminal on DSIO-LV or -EXV J3
terminal strip receives voltage when compressor is not supposed to be on.

Single Circuit Stoppage — Single circuit stoppage
can
1.
2.
3.
4.
5.
6.
7.
8.
9.

10.

be caused by the following:
Low oil pressure in lead compressor
Open contacts in lead compressor high-pressure switch
Low refrigerant pressure
Thermistor failure
Transducer failure
Ground fault in lead compressor indicator (indicator is
field-supplied on 040-060, 070 [60 Hz], and 080-110 and
associated modular units)
High suction superheat
Low suction superheat
Lead compressor circuit breaker trip. Stoppage of one
circuit by a safety device action does not affect other
circuit. When a safety device trips on a lead compressor, circuit is shut down immediately and EXV closes.
Ground fault for any circuit compressor (130-210 and
associated modular units).

Lag Compressor Stoppage — Lag compressor stoppage can be caused by the following:
1. Open contacts in high-pressure switch
2. Compressor ground fault (indicator is field-supplied on
040-060, 070 [60 Hz], and 080-110 and associated modular units)
3. Compressor circuit breaker trip
4. Not required to run to meet cooling load requirement

NOTE: It takes 5 seconds for the control to generate the alarm
code and lock out the compressor(s) on compressor failure
code(s) 1 through 8.

48

Table 16 — Alarm and Alert Codes

0

ALARM
OR
DESCRIPTION
ALERT
—
No Alarms or Alerts Exist

—

—

1

Compressor A1 failure

Circuit A shut down

No

Manual

Compressor A2, A3, A4 failure
Compressor B1 failure
Compressor B2, B3, B4 failure

Compressor shut down
Circuit B shut down
Compressor shut down

Yes
No
Yes

Manual
Manual
Manual

Leaving fluid thermistor failure
Entering fluid thermistor failure
Compressor A1 sensor failure
Compressor B1 sensor failure
Reset thermistor failure

Unit shut down
Unit shut down
Circuit A shut down
Circuit B shut down
Normal set point used

Yes
Yes
Yes
Yes
No

Auto.
Auto.
Auto.
Auto.
Auto.

Thermistor or transducer failure
or wiring error.

Circuit A shut down
Circuit B shut down
Circuit A shut down
Circuit B shut down
Circuit A shut down
Circuit B shut down

Yes
Yes
No
No
No
No

Auto.
Auto.
Auto.
Auto.
Auto.
Auto.

Transducer failure or wiring error.

DISPLAY

2, 3, 4
5
6, 7, 8
9
10
19
20
21

Alert

Alarm

Alert

ACTION TAKEN
BY CONTROL
—

CIRCUIT
RESET
PUMPDOWN METHOD

22
23
24
25
26
27

Alert

Discharge pressure transducer failure, circuit A
Discharge pressure transducer failure, circuit B
Suction pressure transducer failure, circuit A
Suction pressure transducer failure, circuit B
Oil pressure transducer failure, circuit A
Oil pressure transducer failure, circuit B

28
29

Alarm

Transducer supply voltage low
LOCAL/ENABLE-STOP-CCN

Unit shut down
Unit shut down

No
No

Auto.
Manual

4-20 mA reset input failure
4-20 mA demand limit failure
Loss of communication with DSIO-LV

Normal set point used
Demand limit ignored
Unit shut down

No
No
No

Auto.
Auto.
Auto.

Loss of communication with DSIO-EXV
Loss of communication with 4 In/4 Out module

Unit shut down
Unit shut down

No
Yes

Auto.
Auto.

30
31
32
33
34
35

Alert

Alarm

—

36
37

Alert

38
39

Alert

40

41

42
43

Alert

Alarm

44
45

Alert

46
47

Alert

Not used

—

PROBABLE CAUSE
—
High-pressure switch trip, or wiring
error.
CPCS Ground Fault Protection

Unit voltage low or PS1 faulty.
Switch failure or wiring error.

Wiring error or faulty module
or improper address code.

—

—

Low refrigerant pressure circuit A

Circuit A shut down

No

*

Low refrigerant pressure circuit B

Circuit B shut down

No

*

Failure to pump out circuit A

Circuit A shut down

No

Manual

Failure to pump out circuit B

Circuit B shut down

No

Manual

Low oil pressure circuit A

Circuit A shut down

No

Manual

Low oil pressure circuit B

Circuit B shut down

No

Manual

Cooler freeze protection
Low cooler fluid flow

Unit shut down
Unit shut down

No
No

*
Manual

Low suction temperature circuit A

Circuit A shut down
after 10 minutes
Circuit B shut down
after 10 minutes

No

Manual

Low fluid flow or faulty thermistor.
Chilled fluid pump failure
or faulty thermistor.
Faulty expansion valve or thermistor.

No

Manual

Faulty expansion valve or thermistor.

High suction superheat circuit A

Circuit A shut down

Yes

Manual

High suction superheat circuit B

Circuit B shut down

Yes

Manual

Low charge, faulty expansion valve or
thermistor, or plugged filter drier.
Low charge, faulty expansion valve or
thermistor, or plugged filter drier.

Low suction temperature circuit B

—
Low refrigerant charge, plugged filter
drier, faulty expansion valve.
Low refrigerant charge, plugged filter
drier, faulty expansion valve.
Faulty expansion valve, transducer,
or thermistor.
Faulty expansion valve, transducer,
or thermistor.
Low oil level, circuit breaker trip,
faulty expansion valve, crankcase
heater, or pressure transducer.
Low oil level, circuit breaker trip,
faulty expansion valve, crankcase
heater, or pressure transducer.

48
49

Alert

Low suction superheat circuit A
Low suction superheat circuit B

Circuit A shut down
Circuit B shut down

Yes
Yes

Manual
Manual

Faulty EXV or thermistor.
Faulty EXV or thermistor.

50
51
52

Alarm

Illegal configuration
Initial configuration required
Emergency stop by CCN command

Unit cannot start
Unit cannot start
Unit shut down

—
—
Yes

Manual
Manual
CCN

Configuration error.
Configuration omitted.
Network command.

53
54
55

Alarm

Cooler pump interlock failure
Cooler pump interlock failure
Cooler pump interlock failure

Unit shut down
Unit shut down
Cooler pump shut down

No
No
—

Manual
Manual
Manual

Failure of cooler pump or controls
Failure of cooler pump or controls
Failure of cooler pump relay or interlock

56

Alert

WSM communication failure

WSM forces removed

—

Auto.

discharge pressure

Circuit cannot start

—

Auto.

discharge pressure

Circuit cannot start

—

Auto.

suction pressure

Circuit cannot start

—

Auto.

Alert

Calibration required for
transducer, circuit A
Calibration required for
transducer, circuit B
Calibration required for
transducer, circuit A
Calibration required for
transducer, circuit B
Calibration required for
transducer, circuit A
Calibration required for
transducer, circuit B

suction pressure

Circuit cannot start

—

Auto.

oil pressure

Circuit cannot start

—

Auto.

oil pressure

Circuit cannot start

—

Auto.

57
58
59
60
61
62

49

Wiring fault or module failure

Transducer not calibrated

Table 16 — Alarm and Alert Codes (cont)
DISPLAY

ALARM
OR
ALERT

63

DESCRIPTION

ACTION TAKEN
BY CONTROL

CIRCUIT
PUMPDOWN

RESET
METHOD

PROBABLE CAUSE

Alarm

Complete unit shutdown

Alarm only

—

Auto.

Check individual alarms

64
65

Alert

Loss of charge, circuit A
Loss of charge, circuit B

Circuit cannot start
Circuit cannot start

—
—

Auto.
Auto.

Refrigerant leak or transducer
failure

66

Alarm

FSM communication loss

FSM forces removed

—

Auto.

Wiring faulty or module failure

67

Alarm

Transducer calibration date code failure

Unit cannot start

—

Auto.

68,69

—

Not used

—

—

—

70

Alert

High leaving chilled fluid temperature

Alarm only

—

Auto.

CPCS
FSM
PS
WSM

—
—
—
—

Incorrect date code entered
—
Building load greater than unit capacity,
low water/brine flow, or compressor
fault. Check for other alarms or alerts.

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

LEGEND
Compressor Protection Control Module
Flotronic™ System Manager
Power Supply
Water System Manager

Possible causes of failure:
1. High-Pressure Switch Open — High-pressure switch for
each compressor is wired in series with 24-v power that
energizes compressor control relay. If high-pressure switch
opens during operation, compressor stops. This is
detected by microprocessor through the feedback
terminals.
2. DSIO-LV or DSIO-EXV Module Failure — If a DSIO-LV
relay module relay fails open or closed, microprocessor
detects this, locks compressor off, and indicates an
error.
3. Wiring Errors — If a wiring error exists causing CPCS,
CR, or feedback switch to not function properly, microprocessor indicates an error.
4. Processor (PSIO) Failure — If hardware that monitors
feedback switch fails, or processor fails to energize relay
module relay to on, an error may be indicated.
NOTE: The control does not detect circuit breaker failures. If a circuit breaker trips on lead compressor in a
circuit, a low oil pressure failure is indicated. On the other
compressors, no failure is indicated.
5. Ground Fault Module on 130-210 and associated modular units (CGFA or CGFB) Open — Module contacts are
in lead compressor circuits, but ground fault could be in
any compressor in affected circuit.
Ground fault of any 040-110 and associated modular unit
compressor (field-supplied accessory on 040-060 and 070,
60 Hz units; standard on 070, 50 Hz and 80-110 and associated modular units) will cause a trip.
6. Checkout Procedure — Shut off main power to unit. Turn
on control power, then step through subfunction
to proper compressor number (i.e., failure
code 5 is compressor B1). Next, energize the step. If step
works correctly, then failure code is caused by:
• HPS (high-pressure switch) open
• Misplaced feedback wire from J4 and J5 terminals
• Ground wire and 24-v feeds reversed on one or more
points on J3

Compressor Alarm/Alert Circuit — For compressor A1 circuit, processor closes contacts between J4 terminals 2 and 3 to start compressor. See Fig. 11A-11C. Safeties
shown to left of J4 must be closed in order for power to
reach compressor control relay, and the feedback input terminals on J3.
Failure of power to terminal 1 on J3, when contacts between 2 and 3 on J4 should be closed, causes a code 1 alert.
Terminal 2 on J3 is the other leg of the compressor A1
feedback channel. It is connected to the 24-v common.
NOTE: Similar connections for each compressor can be followed on the unit wiring diagrams located on the unit.
Code 9
Leaving fluid thermistor failure (alarm)
Code 10 Entering fluid thermistor failure (alarm)
If temperature measured by these thermistors is outside
range of –40 to 240 F (–40 to 116 C), unit shuts down after
going through a normal pumpout. Reset is automatic if temperature returns to the acceptable range, and unit start-up follows normal sequence. The cause of the fault is usually a
bad thermistor, wiring error, or loose connection.
Code 19
Compressor A1 suction sensor failure (alert)
Code 20
Compressor B1 suction sensor failure (alert)
On units with thermistors, if temperature measured by these
thermistors is outside the range of –40 to 240 F (–40 to
116 C), affected circuit shuts down after going through a normal pumpout. Other circuit continues to run. Reset is automatic if temperature returns to the acceptable range, and circuit start-up follows normal sequence. The cause of this fault
is usually a bad thermistor, wiring error, or loose
connection.
On units with transducers, if the saturated suction temperature is greater than the leaving fluid temperature plus
10° F (5.5 C) for more than 5 minutes, the affected circuit
shuts down (after going through normal pumpout). The reset
is automatic if the saturated suction temperature returns to
the acceptable range and start-up follows the normal sequence. The cause of this fault is usually a bad transducer,
a wiring error, or a loose connection.

50

C
CB
COM, COMM
CPCS

—
—
—
—

CR
DGT
DSIO
HPS
LV
NC
NO
PL
PWR
SNB
TB
TRAN
U

—
—
—
—
—
—
—
—
—
—
—
—
—

LEGEND
Contactor
Circuit Breaker
Communications Bus
Compressor Protection
Control Module
Compressor Contactor Relay
Discharge Gas Thermostat (Optional)
Relay Module (Low Voltage)
High-Pressure Switch
Low Voltage
Normally Closed
Normally Open
Plug
Power
Snubber
Terminal Block
Transformer
Unloader

Fig. 11A — 24-V Safety Circuit Wiring (040-070)
Code 21 Reset thermistor failure (applies only to installations having external temperature reset) (alert)
If temperature measured by this thermistor is outside range
of –40 to 240 F (–40 to 116 C), reset function is disabled and
unit controls to normal set point. If temperature returns to
the acceptable range, reset function is automatically enabled. The cause of this fault is usually a bad thermistor,
wiring error, or loose connection.
Code 22 Compressor A1 discharge pressure
transducer failure (alert)
Code 23 Compressor B1 discharge pressure
transducer failure (alert)
Code 24 Compressor A1 suction pressure transducer
failure (alert)
Code 25 Compressor B1 suction pressure transducer
failure (alert)
Code 26 Compressor A1 oil pressure transducer failure (alert)

Code 27 Compressor B1 oil pressure transducer failure (alert)
If output voltage of any of these transducers is greater than
5 v, affected circuit shuts down without going through pumpout process (Alerts 24-27). Other circuit continues to run.
Reset is automatic if output voltage returns to the acceptable
range, and circuit start-up follows normal sequence. The cause
of this fault is usually a bad transducer or a wiring error.
Code 28
Low transducer supply voltage (alarm)
If transducer supply voltage is less than 4.5 v or greater
than 5.5 v, unit shuts down without going through pumpout
process. Reset is automatic if supply voltage returns to the
acceptable range, and circuit start-up follows normal sequence. The cause of this fault is usually a faulty transformer or primary voltage is out of range.

51

C
CB
COMM
CPCS
DGT
DSIO
HPS
LV
PL
PWR
TB
TRAN
U

—
—
—
—
—
—
—
—
—
—
—
—
—

LEGEND
Contactor
Circuit Breaker
Communications Bus
Compressor Protection Control Module
Discharge Gas Thermostat (Optional)
Relay Module (Low Voltage)
High-Pressure Switch
Low Voltage
Plug
Power
Terminal Block
Transformer
Unloader

*And associated modular units.

Fig. 11B — 24-V Safety Circuit Wiring (080-110 and Associated Modular Units)
The voltage supplied to the processor is polarized. When
checking for proper voltage supply, be sure to consider this
polarity. If voltage appears to be within acceptable tolerance, check to be sure the transformer supplying PS1 is not
grounded. Grounding the supply transformer can result in
serious damage to the control system.
Code 29 LOCAL/ENABLE-STOP-CCN Switch Failure
(switch resistances out of range) (alarm)
This fault occurs due to the failure of the switch or due to
a wiring error.
Code 30 Reset input failure (4 to 20 mA) (alert)
Code 31 Demand limit input failure (4 to 20 mA) (alert)
These codes apply only if unit is configured for these functions. If 4 to 20 mA signal is less than 4 or more than
20 mA, reset or demand limit function is disabled and unit
functions normally. If mA signal returns to the acceptable
range, function is automatically enabled.
Code 32 Loss of communication with compressor
relay module (DISO-LV) (alarm)
Code 33 Loss of communication with EXV relay
module (DSIO-EXV) (alarm)
If communication is lost with either of these modules, unit
shuts down without pumpout. This alarm resets automatically when communication is restored. The unit starts up normally after alarm condition is reset. Probable cause of condition is a faulty or improperly connected plug, wiring error,
or faulty module.

Loss of communication can be attributed to a grounded
transformer with a secondary voltage of 21 vac supplying
the PSIO, DSIO-LV, or 4 IN/4 OUT modules; the 12.5-vac
transformer supplying the DSIO-EXV module; or the
24-vac transformer supplying PS1 for the transformers. These
transformers should not be grounded, or serious damage to
controls can result. Check to be sure the transformers are
not grounded.
NOTE: If a blank PSIO module is downloaded without being connected to the modules DSIO, this alarm is
energized.
Code 34 Loss of communication with 4 In/4 Out module
(alarm)
This applies only if one or more of the following options
are used:
• external temperature reset
• 4 to 20 mA temperature reset
• external switch controlled dual set point
• switch controlled demand limit
• 4 to 20 mA demand limit
• hot gas bypass
If communication is lost with 4 IN/4 OUT module, the
unit shuts off automatically, after finishing pumpout. Reset
of alarm is automatic when communication is restored. Start-up
after alarm is remedied follows a normal sequence. Probable
cause of condition is a faulty or improperly connected plug,
wiring error, or faulty module.
52

CB
CGF
COMM
CR
DSIO
HPS
LV
PL
SNB
TB
TRAN
U

LEGEND
— Circuit Breaker
— Ground Fault Module
— Communications Bus
— Compressor Contactor Relay
— Relay Module (Low Voltage)
— High-Pressure Switch
— Low Voltage
— Plug
— Snubber
— Terminal Block
— Transformer
— Unloader

*And associated modular units.

Fig. 11C — 24-V Safety Circuit Wiring (130-210 and Associated Modular Units)
Loss of communication can be attributed to a grounded
transformer with a secondary voltage of 21 vac supplying
the PSIO, DSIO-LV, or 4 IN/4 OUT; the 12.5-vac transformer supplying the DSIO-EXV module, or the 24-vac transformer supplying PS1 for the transformers. These transformers
should not be grounded, or serious damage to controls can
result. Check to be sure the transformers are not grounded.
Code 36 Low refrigerant pressure, Circuit A (alert)
Code 37 Low refrigerant pressure, Circuit B (alert)
If suction pressure transducer senses a pressure below set
point for more than 5 minutes at start-up or more than
2 minutes during normal operation, affected circuit shuts down
without going through the pumpout process. Reset is automatic when pressure reaches 10 psig above set point if there
have been no previous occurrences of this fault on the same
day. If this is a repeat occurrence on same day, then reset is
manual, with LOCAL/ENABLE-STOP-CCN switch. Factory configured set point is 27 psig for standard chillers and
12 psig for brine chillers.

Possible causes of fault are low refrigerant charge, faulty
EXV, plugged filter drier, or faulty transducer.
Code 38 Failure to pump out, Circuit A (alert)
Code 39 Failure to pump out, Circuit B (alert)
The pumpout process is terminated when saturated suction temperature is 10° F (5.6° C) below temperature at beginning of pumpout, or 10° F (5.6° C) below leaving water
temperature or reaches a saturated suction temperature of
–15 F (–26 C). If appropriate saturated suction temperature
is not met within 3 minutes (on 2 consecutive tries), circuit
shuts down without pumpout. Reset is manual with LOCAL/
ENABLE-STOP-CCN switch, and start-up follows normal
sequence.
Possible causes for this alarm are a bad thermistor or transducer or a faulty expansion valve.
Code 40 Low oil pressure, Circuit A (alert)
Code 41 Low oil pressure, Circuit B (alert)

53

Code 50 Illegal configuration (alarm)
This fault indicates a configuration error. Unit is not allowed to start. Check all configuration data and set points
and correct any errors.
Code 51 Initial configuration required (alarm)
This fault indicates factory configuration has not been done,
and unit is not allowed to start. Refer to unit wiring
label diagrams for factory configuration codes. There are
9 groups of 8-digit numbers that must be entered. The first
7 groups must be entered under
subfunction. Groups

If oil pressure differential is less than set point for more
than 2 minutes at start-up, or more than one minute during
normal operation, affected circuit shuts down without going
through pumpout process. Reset is manual with LOCAL/
ENABLE-STOP-CCN switch, and start-up follows normal
sequence. Factory configured differential oil pressure is
6 psig.
Possible causes of fault are faulty compressor, expansion
valve, crankcase heater or transducer, refrigerant overcharge, insufficient oil charge, or tripped circuit breaker.
Code 42 Cooler freeze protection (alarm)
If cooler entering or leaving water temperature is below
34° F (1.1° C) for water or more than 8° F (4.4° C) below
set point for brine, unit shuts down without pumpout. Chilled
water pump continues to run if controlled by chiller controls. Reset is automatic when leaving fluid temperature reaches
6° F (3° C) above set point, providing there has been no prior
occurrence of this fault the same day. If fault has occurred
previously the same day, reset is manual with LOCAL/
ENABLE-STOP-CCN switch.
Possible causes of fault are low fluid flow or faulty
thermistor.
Code 43 Low fluid flow (alarm)
If any compressors are operating and entering fluid temperature is 3° F (1.7° C) or more below leaving fluid temperature for more than one minute, unit shuts down without
pumpout. Chilled fluid pump also shuts down. Reset is manual
with LOCAL/ENABLE-STOP-CCN switch, and start-up follows normal sequence.
This is a suitable method for sensing low fluid flow because entering fluid thermistor is in the cooler shell and responds more quickly to compressor operation than the leaving fluid thermistor in the leaving water nozzle. Possible causes
of fault are faulty chilled fluid pump, control or thermistor.
Code 44 Low cooler suction temperature, Circuit A (alert)
Code 45 Low cooler suction temperature, Circuit B (alert)
If saturated suction temperature is less than 32 F (0°C)
and is 20° F (11° C) for water or 30° F (16° C) for brine or
more below leaving fluid temperature, mode 14 is displayed. Unit continues to run, but additional compressors are
not allowed to start. If condition persists for more than
10 minutes, fault code is displayed, and unit shuts down without pumpout. Reset is manual with LOCAL/ENABLE-STOPCCN switch, and start-up follows normal sequence.
Possible causes of fault are low refrigerant charge, plugged
filter drier, or a faulty expansion valve or thermistor.
Code 46 High suction superheat, Circuit A (alert)
Code 47 High suction superheat, Circuit B (alert)
If expansion valve is fully open, suction superheat is greater
than 75 F (42 C), and saturated evaporator temperature is
less than MOP (maximum operating pressure) for more than
5 minutes, unit shuts down after normal pumpout process.
Reset is manual with LOCAL/ENABLE-STOP-CCN switch,
and start-up follows normal sequence.
Possible causes of fault are low refrigerant charge, plugged
filter drier, or a faulty expansion valve or thermistor.
Code 48 Low suction superheat, Circuit A (alert)
Code 49 Low suction superheat, Circuit B (alert)
If EXV is at minimum position, suction superheat is less
than 10° F (5.5° C) or saturated evaporator temperature is
greater than MOP (maximum operating pressure) for more
than 5 minutes, affected circuit shuts down after going through
pumpout process. Reset is manual with LOCAL/ENABLESTOP-CCN switch, and start-up follows normal sequence.
Possible causes of fault are faulty expansion valve or
thermistor.

8 and 9 must be entered under

subfunction.

Enter each group, then press the
key. Press the
down arrow
after each group to bring up the next
empty screen. Unit should start after factory and field configurations are correctly entered.
The usual cause of this fault is replacement of the processor module. Refer to instructions accompanying the replacement module.
Code 52 Emergency stop by CCN command (alarm).
Unit shuts down immediately without pumpout when this
command is received, and goes through normal start-up when
command is cancelled.
Code 53 Cooler pump interlock failure — Contacts fail to
close at start-up (alarm)
If the unit is configured for cooler pump control and cooler
pump interlock, and the interlock fails to close within one
minute of starting the cooler pump, the unit is shut down
without pumpout. The cooler pump is also shut down. Reset
is manual with the LOCAL/ENABLE-STOP-CCN switch,
and start-up follows the normal sequence.
Possible causes are:
1. Interlock switch fails to close within one minute after chilled
water pump starts
2. Interlock switch opens during unit operation
3. Interlock voltage is detected, but unit is not configured
for interlock
4. Interlock voltage is outside its valid range
If any of these conditions occur, all compressors are disabled and, if running, shutdown occurs without pumpout.
Chilled fluid pump also shuts down. Reset is manual, with
LOCAL/ENABLE-STOP-CCN switch. Most probable cause
of this fault is shutdown or failure of chilled fluid pump to
start. Other possibilities are improper configuration or wiring errors.
Code 54 Cooler pump interlock failure — Contacts open
during normal operation (alarm)
If the unit is configured for cooler pump control and cooler
pump interlock, and the interlock opens during normal operation, the unit is shut down without pumpout. The cooler
pump is also shut down. Reset is manual with the LOCAL/
ENABLE-STOP-CCN switch, and startup follows the normal sequence.
Possible causes are:
1. Interlock switch fails to close within one minute after chilled
water pump starts
2. Interlock switch opens during unit operation
3. Interlock voltage is detected, but unit is not configured
for interlock
4. Interlock voltage is outside its valid range
If any of these conditions occur, all compressors are disabled and, if running, shutdown occurs without pumpout.
Chilled fluid pump also shuts down. Reset is manual, with
54

15 psig. This alarm does not function in units using different
part number transducers for suction and discharge pressure,
since the discharge transducer in that application does not
function below 20 psig.
Code 66 Flotronic™ System Manager loss of communications (alarm)
If the FSM has established communication with the control, and the communication is subsequently lost for more
than 20 seconds, the control will remove all forces on the
chiller variables. Control of the unit will revert to standalone basis, and reset is automatic upon re-establishment of
communication.
Code 67 Transducer calibration failure due to incorrect date
code (alarm)
This applies to units having pressure transducers with the
same part number for both suction and discharge pressures.
If the transducer calibration is attempted and the factory default date code (Jan. 1, 1980) is in the date variable, then the
unit will not start. Reset is automatic when the proper date
code is entered upon calibration.
Code 70 High leaving chilled fluid temperature (alert)
If the leaving chilled fluid temperature is rising and is
higher than the limit established in the
subfunction
and the unit is at full capacity then alert 70 will be activated.
The unit will continue to function normally, and reset will
be automatic upon leaving chilled fluid temperature dropping to 5° F below the limit or less than control
set point.

LOCAL/ENABLE-STOP-CCN switch. Most probable cause
of this fault is shutdown or failure of chilled fluid pump to
start. Other possibilities are improper configuration or wiring errors.
Code 55 Cooler pump interlock failure — Contacts closed
when pump is off (alarm)
If the unit is configured for cooler pump control and cooler
pump interlock, and the interlock is closed when the cooler
pump relay is off, the cooler pump shall be shut down and
the unit prevented from starting. Reset is manual with the
LOCAL/ENABLE-STOP-CCN switch.
Possible causes are:
1. Interlock switch fails to close within one minute after chilled
water pump starts
2. Interlock switch opens during unit operation
3. Interlock voltage is detected, but unit is not configured
for interlock
4. Interlock voltage is outside its valid range
If any of these conditions occur, all compressors are disabled and, if running, shutdown occurs without pumpout.
Chilled fluid pump also shuts down. Reset is manual, with
LOCAL/ENABLE-STOP-CCN switch. Most probable cause
of this fault is shutdown or failure of chilled fluid pump to
start. Other possibilities are improper configuration or wiring errors.
Code 56 Water System Manager (WSM) communication
failure (alert)
If the WSM has previously established communications
with the control and the WSM is not disabled and has not
communicated with the control within the last 5 minutes, the
control will remove all WSM forces from the chillers variables. The chiller will continue to operate on a stand-alone
basis. Reset is automatic when the WSM re-establishes communication with the unit.
Code 57 Calibration required for discharge pressure transducer, circuit A (alert)
Code 58 Calibration required for discharge pressure transducer, circuit B (alert)
If the discharge pressure transducer has not been successfully calibrated, the circuit will not start. Reset is automatic
upon successful calibration of the transducer.
Code 59 Calibration required for suction pressure transducer, circuit A (alert)
Code 60 Calibration required for suction pressure transducer, circuit B (alert
If the suction pressure transducer has not been successfully calibrated, the circuit will not start. Reset is automatic
upon successful calibration of the transducer.
Code 61 Calibration required for oil pressure transducer,
circuit A (alert)
Code 62 Calibration required for oil pressure transducer,
circuit B (alert)
If the oil pressure transducer has not been successfully
calibrated, the circuit will not start. Reset is automatic upon
successful calibration of the transducer.
Code 63 Complete unit shutdown due to failure (alarm)
This alarm alerts the user that the unit is totally shut down
due to one or more fault conditions. Reset is automatic when
all alarms causing complete unit shutdown are reset.
Code 64 Loss of charge, circuit A (alert)
Code 65 Loss of charge, circuit B (alert)
If the unit uses suction and discharge transducers with the
same part number, and the discharge pressure is below
10 psig when the unit is shut down, the circuit will not start.
Reset is automatic when the discharge pressure rises above

Electronic Expansion Valve (EXV)
NOTE: This applies to all units except 30GN040 and 045
with optional brine. The 040 and 045 units with optional brine
have TXVs.
EXV OPERATION — These valves control the flow of liquid refrigerant into the cooler. They are operated by the processor to maintain a specified superheat at lead compressor
entering gas thermistor (located between compressor motor
and cylinders). There is one EXV per circuit. See
Fig. 12.
High-pressure liquid refrigerant enters valve through bottom. A series of calibrated slots are located in side of orifice
assembly. As refrigerant passes through orifice, pressure drops
and refrigerant changes to a 2-phase condition (liquid and

Fig. 12 — Electronic Expansion Valve (EXV)

55

vapor). To control refrigerant flow for different operating conditions, sleeve moves up and down over orifice, thereby changing orifice size. Sleeve is moved by a linear stepper motor.
Stepper motor moves in increments and is controlled directly by the processor module. As stepper motor rotates,
motion is transferred into linear movement by lead screw.
Through stepper motor and lead screws, 1500 discrete steps
of motion are obtained. The large number of steps and long
stroke result in very accurate control of refrigerant flow.
The
subfunction shows EXV valve position as
a percent of full open. Position should change constantly while
unit operates. If a valve stops moving for any reason (mechanical or electrical) other than a processor or thermistor
failure, the processor continues to attempt to open or close
the valve to correct the superheat. Once the calculated valve
position reaches 120 (fully closed) or 1500 (fully open), it
remains there. If EXV position reading remains at 120 or
1500, and the thermistors and pressure transducers are reading correctly, the EXV is not moving. Follow EXV checkout
procedure below to determine cause.
The EXV is also used to limit cooler suction temperature
to 50 F (10 C). This makes it possible for chiller to start at
higher cooler fluid temperatures without overloading compressor. This is commonly referred to as MOP (maximum
operating pressure), and serves as a load limiting device to
prevent compressor motor overloading. This MOP or load
limiting feature enables the 30G Flotronic™ II chillers to
operate with up to 95 F (35 C) entering fluid temperatures
during start-up and subsequent pull-down.
CHECKOUT PROCEDURE — Follow steps below to diagnose and correct EXV problems.
1. Check EXV driver outputs. Check EXV output signals at
appropriate terminals on EXV driver module (see
Fig. 13) as follows:
Connect positive test lead to terminal 1 on EXV driver.
Set meter for approximately 20 vdc. Enter outputs
subfunction of test function by pressing

EXV — Electronic Expansion Valve

Fig. 13 — EXV Cable Connections to EXV Driver
Module, DSIO (EXV)
Control of valve is by microprocessor. A thermistor and
a pressure transducer located in lead compressor are used
to determine superheat. The thermistor measures temperature of the superheated gas entering the compressor
cylinders. The pressure transducer measures refrigerant
pressure in the suction manifold. The microprocessor converts pressure reading to a saturation temperature. The
difference between temperature of superheated gas and
saturation temperature is the superheat.
Because the EXVs are controlled by the processor module, it is possible to track valve position. During initial
start-up, EXV is fully closed. After start-up, valve position is tracked by processor by constantly observing amount
of valve movement.
The processor keeps track of EXV position by counting
the number of open and closed steps it has sent to each
valve. It has no direct physical feedback of valve position. Whenever unit is switched from STOP to RUN position, both valves are initialized, allowing the processor
to send enough closing pulses to the valve to move it from
fully open to fully closed, then reset the position counter
to zero.
4. The EXV test can be used to drive EXV to any desired
position. When EXV opens, the metering slots begin to
provide enough refrigerant for operation at step 120. This
is fully closed position when circuit is operating. The fully
open position is 1500 steps.
5. Check thermistors and pressure transducers that control
EXV. Check thermistors and pressure transducers that control processor output voltage pulses to EXVs. See Fig. 14
for locations.
Circuit A — Thermistor T7, Suction Pressure Transducer
SPTA
Circuit B — Thermistor T8, Suction Pressure Transducer
SPTB
a. Use temperature subfunction of the status function
(
) to determine if thermistors are reading
correctly.
b. Check thermistor calibration at known temperature by
measuring actual resistance and comparing value measured with values listed in Tables 17 and 18.
c. Make sure thermistor leads are connected to proper
pin terminals at J7 terminal strip on processor module
and that thermistor probes are located in proper position in refrigerant circuit. See Fig. 15 and 16.
d. Use the pressure subfunction of the Status function
(
) to determine if pressure transducers are

, then

advance to EXVA test by pressing
10 times. Press
. The driver should drive the circuit A
EXV fully open. During next several seconds connect negative test lead to pins 2, 3, 4, and 5 in succession. Voltage
should rise and fall at each pin. If it remains constant at
a voltage or at zero v, remove connector to valve and
recheck.
Press
to close circuit A EXV. If a problem still
exists, replace EXV driver module. If voltage reading is
correct, expansion valve should be checked. Next, test
EXVB. Connect positive test lead to pin 7 and the negative test lead to pin 8, 9, 10, and 11 in succession during
EXVB test.
2. Check EXV wiring. Check wiring to electronic expansion valves from terminal strip on EXV driver. See
Fig. 13.
a. Check color coding and wire connections. Make sure
they are connected to correct terminals at driver and
EXV plug connections.
b. Check for continuity and tight connection at all pin
terminals.
c. Check plug connections at driver and at EXVs to be
sure EXV cables are not crossed.
3. Check resistance of EXV motor windings. Remove plug
at J4 terminal strip and check resistance between common lead (red wire, terminal D) and remaining leads, A,
B, C, and E (see Fig. 13). Resistance should be
25 ohms 6 2 ohms.
56

Other possible causes of improper refrigerant flow control could be restrictions in liquid line. Check for plugged
filter drier(s) or restricted metering slots in the EXV. Formation of ice or frost on lower body of electronic expansion valve is one symptom of restricted metering slots.
However, frost or ice formation is normally expected when
leaving fluid temperature from the cooler is below 40 F.
Clean or replace valve if necessary.
NOTE: Frosting of valve is normal during compressor
test steps and at initial start-up. Frost should dissipate after 5 to 10 minutes operation in a system that is operating
properly. If valve is to be replaced, wrap valve with a wet
cloth to prevent excessive heat from damaging internal
components.

reading correctly. Connect a calibrated gage to lead
compressor suction or discharge pressure connection
to check transducer reading.
e. Make sure transducer leads are properly connected in
junction box and at processor board. Check transformer 5 output. Check voltage transducer 5 vdc
6 .2 v.
When above checks have been completed, check actual operation of EXV by using procedures outlined in
this step.
6. Check operation of EXV.
a. Close liquid line service valve of circuit to be checked,
and run through the test step (
) for lead compressor in that circuit to pump down low side of system. Repeat test step 3 times to ensure all refrigerant
has been pumped from low side.
NOTE: Be sure to allow compressors to run for the
full pumpout period.
b. Turn off compressor circuit breaker(s). Close compressor discharge service valves and remove any remaining refrigerant from low side of system.
c. Remove screws holding top cover of EXV. Carefully
remove top cover. If EXV plug was disconnected during this process, reconnect it after cover is removed.

Thermostatic Expansion Valve (TXV) — Refer to
base unit Installation Instructions for TXV information
(30GN040,045 with optional brine only).
Thermistors — All thermistors are identical in their temperature vs. resistance performance. Resistance at various temperatures are listed in Tables 17 and 18.
LOCATION — General location of thermistor sensors are
shown in Fig. 14.
Cooler Leaving Fluid Thermistor (T1) — T1 is located in
leaving fluid nozzle. The probe is immersed directly in the
fluid. All thermistor connections are made through a 1⁄4-in.
coupling. See Fig. 16. Actual location is shown in Fig. 14
and 15.
Cooler Entering Fluid Thermistor (T2) — T2 is located in
cooler shell in first baffle space near tube bundle. Thermistor
connection is made through a 1⁄4-in. coupling. See Fig. 16.
Actual location is shown in Fig. 14 and 15.
Compressor Suction Gas Temperature Thermistors (T7 and
T8) — T7 and T8 are located in lead compressor in each
circuit in suction passage between motor and cylinders, above
oil pump. They are well-type thermistors. See Fig. 14
and 15.

When removing top cover, be careful to avoid damaging motor leads.
d. Enter appropriate EXV test step for EXVA or
EXVB in the outputs subfunction of the test function
(
). Press
to initiate test. With
cover lifted off EXV valve body, observe operation of
valve motor and lead screw. The motor should turn
counterclockwise, and the lead screw should move up
out of motor hub until valve is fully open. Lead screw
movement should be smooth and uniform from
fully closed to fully open position. Press
to
check open to closed operation.
If valve is properly connected to processor and receiving correct signals, yet does not operate as described
above, valve should be replaced.
Operation of EXV valve can also be checked without
removing top cover. This method depends on operator’s skill in determining whether or not valve is moving. To use this method, initiate EXV test and open
valve. Immediately grasp EXV valve body. As valve
drives open, a soft, smooth pulse is felt for approximately 26 seconds as valve travels from fully closed
to fully open. When valve reaches end of its opening
stroke, a hard pulse is felt momentarily. Drive valve
closed and a soft, smooth pulse is felt for the 52 seconds necessary for valve to travel from fully open to
fully closed. When valve reaches end of its stroke, a
hard pulse is again felt as valve overdrives by 50 steps.
Valve should be driven through at least 2 complete cycles
to be sure it is operating properly. If a hard pulse is
felt for the 26-second duration, valve is not moving
and should be replaced.
The EXV test can be repeated as required by entering any percentage from 0 (
) to 100 to initiate
movement.
If operating problems persist after reassembly, they may
be due to out-of-calibration thermistor(s) or intermittent
connections between processor board terminals and EXV
plug. Recheck all wiring connections and voltage signals.

THERMISTOR REPLACEMENT (T1, T2, T7, T8)

Thermistors are installed directly in fluid Relieve all pressure using standard practices or drain fluid before removing.
Proceed as follows (see Fig. 16):
To replace thermistor sensor T2:
1. Remove and discard original thermistor and coupling.
IMPORTANT: Do not disassemble new coupling.
Install as received.
2. Apply pipe sealant to 1⁄4-in. NPT threads on replacement
coupling and install in place of original. Do not use packing nut to tighten coupling. This damages ferrules (see
Fig. 16).
3. Insert new thermistor in coupling body to its full depth.
If thermistor bottoms out before full depth is reached, pull
thermistor back out 1⁄8 in. before tightening packing nut.
Hand tighten packing nut to position ferrules, then finish
tightening 11⁄4 turns with a suitable tool. Ferrules are now
attached to thermistor which can be withdrawn from coupling for unit servicing.
To replace thermistors T1, T7, and T8:
Add a small amount of thermal conductive grease to thermistor well. Thermistors are friction-fit thermistors, which
must be slipped into well located in the compressor pump
end.
57

Table 17 — Thermistor Temperature (°F) vs Resistance/Voltage Drop; Flotronic™ II
TEMPERATURE
(F)
−25.0
−24.0
−23.0
−22.0
−21.0
−20.0
−19.0
−18.0
−17.0
−16.0
−15.0
−14.0
−13.0
−12.0
−11.0
−10.0
−9.0
−8.0
−7.0
−6.0
−5.0
−4.0
−3.0
−2.0
−1.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
51.0
52.0
53.0
54.0
55.0
56.0
57.0
58.0
59.0
60.0
61.0
62.0
63.0
64.0
65.0
66.0
67.0
68.0
69.0
70.0

VOLTAGE
DROP (V)
4.821
4.818
4.814
4.806
4.800
4.793
4.786
4.779
4.772
4.764
4.757
4.749
4.740
4.734
4.724
4.715
4.705
4.696
4.688
4.676
4.666
4.657
4.648
4.636
4.624
4.613
4.602
4.592
4.579
4.567
4.554
4.540
4.527
4.514
4.501
4.487
4.472
4.457
4.442
4.427
4.413
4.397
4.381
4.366
4.348
4.330
4.313
4.295
4.278
4.258
4.241
4.223
4.202
4.184
4.165
4.145
4.125
4.103
4.082
4.059
4.037
4.017
3.994
3.968
3.948
3.927
3.902
3.878
3.854
3.828
3.805
3.781
3.757
3.729
3.705
3.679
3.653
3.627
3.600
3.575
3.547
3.520
3.493
3.464
3.437
3.409
3.382
3.353
3.323
3.295
3.267
3.238
3.210
3.181
3.152
3.123

RESISTANCE
(OHMS)
98010
94707
91522
88449
85486
82627
79871
77212
74648
72175
69790
67490
65272
63133
61070
59081
57162
55311
53526
51804
50143
48541
46996
45505
44066
42679
41339
40047
38800
37596
36435
35313
34231
33185
32176
31202
30260
29351
28473
27624
26804
26011
25245
24505
23789
23096
22427
21779
21153
20547
19960
19393
18843
18311
17796
17297
16814
16346
15892
15453
15027
14614
14214
13826
13449
13084
12730
12387
12053
11730
11416
11112
10816
10529
10250
9979
9717
9461
9213
8973
8739
8511
8291
8076
7868
7665
7468
7277
7091
6911
6735
6564
6399
6238
6081
5929

TEMPERATURE
(F)
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166

VOLTAGE
DROP (V)
3.093
3.064
3.034
3.005
2.977
2.947
2.917
2.884
2.857
2.827
2.797
2.766
2.738
2.708
2.679
2.650
2.622
2.593
2.563
2.533
2.505
2.476
2.447
2.417
2.388
2.360
2.332
2.305
2.277
2.251
2.217
2.189
2.162
2.136
2.107
2.080
2.053
2.028
2.001
1.973
1.946
1.919
1.897
1.870
1.846
1.822
1.792
1.771
1.748
1.724
1.702
1.676
1.653
1.630
1.607
1.585
1.562
1.538
1.517
1.496
1.474
1.453
1.431
1.408
1.389
1.369
1.348
1.327
1.308
1.291
1.289
1.269
1.250
1.230
1.211
1.192
1.173
1.155
1.136
1.118
1.100
1.082
1.064
1.047
1.029
1.012
0.995
0.978
0.962
0.945
0.929
0.914
0.898
0.883
0.868
0.853

58

RESISTANCE
(OHMS)
5781
5637
5497
5361
5229
5101
4976
4855
4737
4622
4511
4403
4298
4196
4096
4000
3906
3814
3726
3640
3556
3474
3395
3318
3243
3170
3099
3031
2964
2898
2835
2773
2713
2655
2597
2542
2488
2436
2385
2335
2286
2239
2192
2147
2103
2060
2018
1977
1937
1898
1860
1822
1786
1750
1715
1680
1647
1614
1582
1550
1519
1489
1459
1430
1401
1373
1345
1318
1291
1265
1240
1214
1190
1165
1141
1118
1095
1072
1050
1029
1007
986
965
945
925
906
887
868
850
832
815
798
782
765
750
734

TEMPERATURE
(F)
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225

VOLTAGE
DROP (V)
0.838
0.824
0.810
0.797
0.783
0.770
0.758
0.745
0.734
0.722
0.710
0.700
0.689
0.678
0.668
0.659
0.649
0.640
0.632
0.623
0.615
0.607
0.600
0.592
0.585
0.579
0.572
0.566
0.560
0.554
0.548
0.542
0.537
0.531
0.526
0.520
0.515
0.510
0.505
0.499
0.494
0.488
0.483
0.477
0.471
0.465
0.459
0.453
0.446
0.439
0.432
0.425
0.417
0.409
0.401
0.393
0.384
0.375
0.366

RESISTANCE
(OHMS)
719
705
690
677
663
650
638
626
614
602
591
581
570
561
551
542
533
524
516
508
501
494
487
480
473
467
461
456
450
445
439
434
429
424
419
415
410
405
401
396
391
386
382
377
372
367
361
356
350
344
338
332
325
318
311
304
297
289
282

Table 18 — Thermistor Temperature (°C) vs Resistance/Voltage Drop; Flotronic™ II
TEMPERATURE
(C)
−40
−39
−38
−37
−36
−35
−34
−33
−32
−31
−30
−29
−28
−27
−26
−25
−24
−23
−22
−21
−20
−19
−18
−17
−16
−15
−14
−13
−12
−11
−10
−9
−8
−7
−6
−5
−4
−3
−2
−1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

VOLTAGE
DROP (V)
4.896
4.889
4.882
4.874
4.866
4.857
4.848
4.838
4.828
4.817
4.806
4.794
4.782
4.769
4.755
4.740
4.725
4.710
4.693
4.676
4.657
4.639
4.619
4.598
4.577
4.554
4.531
4.507
4.482
4.456
4.428
4.400
4.371
4.341
4.310
4.278
4.245
4.211
4.176
4.140
4.103
4.065
4.026
3.986
3.945
3.903
3.860
3.816
3.771
3.726
3.680
3.633
3.585
3.537
3.487
3.438
3.387
3.337
3.285
3.234
3.181
3.129
3.076
3.023
2.970
2.917
2.864
2.810
2.757
2.704
2.651
2.598
2.545
2.493
2.441
2.389
2.337
2.286
2.236
2.186
2.137
2.087
2.039
1.991

RESISTANCE
(Ohms)
168 230
157 440
147 410
138 090
129 410
121 330
113 810
106 880
100 260
94 165
88 480
83 170
78 125
73 580
69 250
65 205
61 420
57 875
54 555
51 450
48 536
45 807
43 247
40 845
38 592
38 476
34 489
32 621
30 866
29 216
27 633
26 202
24 827
23 532
22 313
21 163
20 079
19 058
18 094
17 184
16 325
15 515
14 749
14 026
13 342
12 696
12 085
11 506
10 959
10 441
9 949
9 485
9 044
8 627
8 231
7 855
7 499
7 161
6 840
6 536
6 246
5 971
5 710
5 461
5 225
5 000
4 786
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008
2 888
2 773
2 663
2 559
2 459
2 363

TEMPERATURE
(C)
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107

59

VOLTAGE
DROP (V)
1.944
1.898
1.852
1.807
1.763
1.719
1.677
1.635
1.594
1.553
1.513
1.474
1.436
1.399
1.363
1.327
1.291
1.258
1.225
1.192
1.160
1.129
1.099
1.069
1.040
1.012
0.984
0.949
0.920
0.892
0.865
0.838
0.813
0.789
0.765
0.743
0.722
0.702
0.683
0.665
0.648
0.632
0.617
0.603
0.590
0.577
0.566
0.555
0.545
0.535
0.525
0.515
0.506
0.496
0.486
0.476
0.466
0.454
0.442
0.429
0.416
0.401
0.386
0.370

RESISTANCE
(Ohms)
2 272
2 184
2 101
2 021
1 944
1 871
1 801
1 734
1 670
1 609
1 550
1 493
1 439
1 387
1 337
1 290
1 244
1 200
1 158
1 118
1 079
1 041
1 006
971
938
906
876
836
805
775
747
719
693
669
645
623
602
583
564
547
531
516
502
489
477
466
456
446
436
427
419
410
402
393
385
376
367
357
346
335
324
312
299
285

DPT
EXV
OPT
SPT
T

—
—
—
—
—

LEGEND
Discharge Pressure Transducer
Electronic Expansion Valve
Oil Pressure Transducer
Suction Pressure Transducer
Thermistor Number

Fig. 14 — Thermistor and Pressure Transducer Locations

Pressure Transducers — A single style of pressure
transducer is used for both high- and low-pressure sensing
on Flotronic™ II chillers. However, this transducer must be
calibrated before the unit will operate. On new units, this
will have been done at the factory in order to test run the
unit. If a transducer or PSIO is replaced in the field, however, the transducer will have to be field calibrated as
follows:
1. Disconnect transducer from the system.
2. Hang the transducer in the atmosphere.
3. Press
on the HSIO keypad, and Read the pressure. Pressures before calibration must be within the
range of 6 5 psig. If the pressure is outside the range of
6 5 psig, the HSIO display will read ---. If this is the
case, replace the transducer or PSIO or check for a wiring error. If the value of the atmospheric pressure is greater
than 5 psig or less than –5 psig, the transducer will be
considered out of range and will not calibrate.

4. Press
on the HSIO keypad. This automatically applies the proper correction factor to all future inputs from
the transducer.
Three pressure transducers are mounted on each lead compressor: 2 low-pressure transducers to monitor compressor
suction pressure and oil pressure, and a high-pressure transducer to monitor compressor discharge pressure (see
Fig. 17 for exact locations on compressor). Each transducer
is supplied with 5 vdc power from a rectifier which changes
24 vac to 5 vdc.
TROUBLESHOOTING — If transducer is suspected of being faulty, first check supply voltage to transducer. Supply
voltage should be 5 vdc ± .2 v. If supply voltage is correct,
compare pressure reading displayed on keypad and display
module against pressure shown on a calibrated pressure gage.
If the 2 pressure readings are not reasonably close, replace
pressure transducer.

60

Fig. 15 — Thermistor Locations
(Circuits A and B, Lead Compressor Only)

COMPRESSOR SUCTION GAS TEMPERATURE
THERMISTORS T7 AND T8
(ALL UNITS) AND FLUID-SIDE TEMPERATURE
THERMISTOR T1 (ALL UNITS)

FLUID-SIDE TEMPERATURE THERMISTOR T2
(ALL UNITS)

Fig. 16 — Thermistors

61

Fig. 17 — Lead Compressor Transducer and Thermistor Locations
3. Unscrew transducer from 1⁄4-in. male flare fitting. When
installing new pressure transducer, do not use thread
sealer. Thread sealer can plug transducer and render it
inoperative.
4. Insert weathertight wiring plug into end of transducer until locking tab snaps in place.
5. Check for refrigerant leaks.

TRANSDUCER REPLACEMENT

Transducers are installed directly in the refrigerant circuit. Relieve all refrigerant pressure using standard refrigeration practices before removing.
1. Relieve refrigerant pressure using standard refrigeration
practices.
2. Disconnect transducer wiring at transducer by pulling up
on locking tab while pulling weathertight connection plug
from end of transducer. Do not pull on transducer wires.

62

Control Modules
Turn controller power off before servicing controls. This
ensures safety and prevents damage to controller.
PROCESSOR MODULE (PSIO), 4 IN/4 OUT MODULE
(SIO), LOW-VOLTAGE RELAY MODULE (DSIO-LV),
AND EXV DRIVER MODULE (DSIO-EXV) — The PSIO,
DSIO and SIO modules all perform continuous diagnostic
evaluations of the condition of the hardware. Proper operation of these modules is indicated by LEDs (light-emitting
diodes) on the front surface of the DSIOs, and on the top
horizontal surface of the PSIO and SIO.
RED LED — Blinking continuously at a 3- to 5-second rate
indicates proper operation. Lighted continuously indicates a
problem requiring replacement of module. Off continuously
indicates power should be checked. If there is no input power,
check fuses. If fuse is bad, check for shorted secondary of
transformer or for bad module. On the PSIO module, if the
light is blinking at a rate of twice per second, the module
should be replaced.
GREEN LED — On a PSIO and an SIO, this is the green
LED closest to COMM connectors. The other green LED on
module indicates external communications, when used. Green
LED should always be blinking when power is on. It indicates modules are communicating properly. If green LED is
not blinking, check red LED. If red LED is normal, check
module address switches. See Fig. 18. Proper addresses are:
PSIO (Processor Module) — 01 (different when CCN
connected)
DSIO (Relay Module) — 19
DSIO (EXV Driver Module) — 31
SIO
(4 In/4 Out Module) — 59
If all modules indicate communication failure, check COMM
plug on PSIO module for proper seating. If a good connection is assured and condition persists, replace PSIO module.
If only DSIO or SIO module indicates communication failure, check COMM plug on that mode for proper seating. If
a good connection is assured and condition persists, replace
DSIO or SIO module.
All system operating intelligence rests in PSIO module,
the module that controls unit. This module monitors conditions through input and output ports and through DSIO modules (low-voltage relay module and EXV driver module).
The machine operator communicates with microprocessor through keypad and display module. Communication between PSIO and other modules is accomplished by a 3-wire
sensor bus. These 3 wires run in parallel from module to
module.
On sensor bus terminal strips, terminal 1 of PSIO module
is connected to terminal 1 of each of the other modules.
Terminals 2 and 3 are connected in the same manner. See
Fig. 19. If a terminal 2 wire is connected to terminal 1, system does not work.
In Flotronic™ II chillers, processor module, low-voltage
relay module, and keypad and display module are all powered from a common 21-vac power source which connects
to terminals 1 and 2 of power input strip on each module. A
separate source of 21-vac power is used to power options
module through terminals 1 and 2 on power input strip. A
separate source of 12.5 vac power is used to power EXV
driver module through terminals 1 and 2 on power input strip.

Fig. 18 — Module Address
Selector Switch Locations

63

Fig. 19 — Sensor Bus Wiring
(Communications)
PROCESSOR MODULE (PSIO) (Fig. 20)
Inputs — Each input channel has 3 terminals; only 2 of the
terminals are used. Application of machine determines which
terminals are used. Always refer to individual unit wiring
for terminal numbers.
Outputs — Output is 24 vdc. There are 3 terminals, only 2
of which are used, depending on application. Refer to unit
wiring diagram.
NOTE: Address switches (see Fig. 20) must be set at 01 (different when CCN connected).
LOW VOLTAGE RELAY MODULE (DSIO-LV) (Fig. 21)
Inputs — Inputs on strip J3 are discrete inputs (ON/OFF).
When 24-vac power is applied across the 2 terminals in a
channel it reads as on signal. Zero v reads as an off signal.
Outputs — Terminal strips J4 and J5 are internal relays whose
coils are powered-up and powered-off by a signal from
microprocessor. The relays switch the circuit to which they
are connected. No power is supplied to these connections by
DSIO module.
4 IN/4 OUT MODULE (SIO) (Fig. 22) — 4 In/4 Out module allows the following features to be utilized:
1. Temperature Reset by outdoor air or space temperature.
A remote thermistor (Part No. 30GB660002) is also required.
NOTE: This accessory is not required for return water
temperature reset.
2. Temperature Reset by remote 4 to 20 mA signal.
3. Demand Limit by remote 2-stage switch.
4. Demand Limit by remote 4 to 20 mA signal
5. Dual Set Point by remote switch.
The options module is standard. Remember to reconfigure the chiller for each feature selected (see Table 14). For
temperature reset, demand limit, and dual set point, desired
set points must be entered through keypad and display module (see Set Point Function section on page 38).
See Table 19 for overall troubleshooting information.

PWR — Power

Fig. 20 — Processor Module (PSIO)

ACCESSORY UNLOADER INSTALLATION
Some of the 30G Flotronic™ II units come standard with
unloader(s), and many permit additional unloader(s) to be
added if desired. See Table 20.
IMPORTANT: The following combinations ARE NOT
permitted (combinations are per circuit):
1. Two unloaders and hot gas bypass
2. Four compressors and 2 unloaders.
3. Four compressors, 1 unloader, and hot gas
bypass.

LEGEND
COMM — Communications Bus
NC
— Normally Closed

NO
— Normally Open
PWR — Power

Fig. 21 — Low-Voltage Relay Module (DSIO)
64

3. Install the additional unloader cylinder head on the lead
compressor, A1 or B1, according to instructions provided
by the compressor manufacturer in the accessory
package.
4. Continue installation per either 040-110, 130 (60 Hz) units
or 130 (50 Hz), 150-210 units section as appropriate.
040-110, 130 (60 Hz) UNITS (And Associated Modular Units)
1. Wire the solenoid before any field wiring begins. Wiring
between components and control box must be enclosed
in conduit. All local electrical codes and National Electrical Code (NEC) must be followed. Factory wires are
provided in the compressor harness to connect the solenoid. These wires are in the compressor control box.
2. Wire the control side. Open the left side control box door
and remove inner panel. Using the holes provided and
field-supplied screws, install field-supplied transformer above
the DSIO-LV on the control panel.
Wire the primary side of the transformer in parallel with
TRAN4. See Fig. 23. This supplies transformer with proper
line voltage. Be sure to connect proper tap of the transformer to ensure supply of proper secondary voltage.
Wire the secondary side of transformer to DSIO-LV - J5-9,
and a jumper from DSIO-LV - J5-9 to DSIO-LV - J4-9.
Wire the secondary common to TB7-2. Connect the transformer ground to ground hole supplied near the transformer. These connections provide DSIO with necessary
power to energize the solenoid coils.
3. When all connections are made, check for proper wiring
and tight connections. Replace and secure inner panel.
Restore power to unit.
4. Configure the processor. With the addition of extra unloaders, the unit configuration has changed. To change
the configuration of the processor, enter the service function using the keypad and display module. Before any
changes can be made, the LOCAL/ENABLE-STOPCCN switch must be in the STOP position, and the servicer must log on to the processor.

LEGEND
COMM — Communications Bus
PWR
— Power

a. Press
. Keypad LCD displays the word
PASSWORD.
b. Enter
. Keypad LCD displays
LOGGEDON.
c. To change configuration, press
. Keypad LCD
displays FLD CFG.
d. If an additional unloader was added to compressor
A1, press
until NULA 1 appears in keypad dis-

Fig. 22 — 4 In/4 Out Module (SIO)
If accessory unloaders are desired, an accessory unloader
package is used. Package includes a suction cutoff unloader
head package. The 24-v coil in the package can be used
for 040-110, 130 (60 Hz), and associated modular units
(Table 1). A 115 v or 230 v coil must be used for 130
(50 Hz), 150-210, and associated modular units (Table 1).
Coil voltage depends on control circuit voltage. Consult current Carrier price pages for appropriate part numbers.
NOTE: The accessory package will include all necessary components and wiring with the following exceptions: The field
must provide screws, and on the 130-210, and associated modular units, the field must also supply a 20 vdc (part number
HK35AB001) unloader relay and wire (90° C or
equivalent).

play. Press
for the number of unloaders on
circuit A. Keypad display now reads NULA 2.
e. If an additional unloader was added to compressor
B1, press
until NULB 1 appears in keypad display. Press
for the number of unloaders on
circuit B. Keypad display now reads NULB 2.
f. When configuration is complete, press
. Key-

Installation
1. Be sure all electrical disconnects are open and tagged before any work begins. Inspect the package contents for
any damage during shipping. File a claim with the shipper if damage has occurred.
2. For ease of installation, factory-supplied wiring for the
additional unloader is provided in the compressor
harness.

pad display reads LOGGEDON. Press
pad display reads LOG OFF. Press
play reads EXIT LOG.

65

until key. Keypad dis-

Table 19 — Troubleshooting
SYMPTOMS
COMPRESSOR DOES
NOT RUN

CAUSE
Power line open
Control fuse open
High-Pressure Switch (HPS)
tripped
Tripped power breaker
Loose terminal connection
Improperly wired controls
Low line voltage
Compressor motor defective

COMPRESSOR CYCLES OFF
ON LOW PRESSURE
COMPRESSOR SHUTS DOWN
ON HIGH PRESSURE
CONTROL

UNIT OPERATES LONG OR
CONTINUOUSLY

SYSTEM NOISES

Seized compressor
Loss of charge
Bad transducer
Low refrigerant charge
High-pressure control erratic in action
Compressor discharge valve partially closed
Condenser fan(s) not operating
Condenser coil plugged or dirty
Low refrigerant charge
Control contacts fused
Partially plugged or plugged expansion
valve or filter driver
Defective insulation
Service load
Inefficient compressor
Piping vibration
Expansion valve hissing
Compressor noisy

COMPRESSOR LOSES OIL

FROSTED SUCTION LINE
HOT LIQUID LINE
FROSTED LIQUID LINE
COMPRESSOR DOES NOT
UNLOAD

COMPRESSOR DOES NOT
LOAD

Leak in system
Mechanical damage (blown piston or
broken discharge valve)
Crankcase heaters not energized
during shutdown
Expansion valve admitting either too
much or too little refrigerant
Shortage of refrigerant due to leak
Shutoff valve partially closed or restricted
Burned out coil
Defective capacity control valve
Miswired solenoid
Weak, broken, or wrong valve body spring
Miswired solenoid
Defective capacity control valve
Plugged strainer (high side)
Stuck or damaged unloader piston or
piston ring(s)

REMEDY
Reset circuit breaker.
Check control circuit for ground or short.
Replace fuse.
Move LOCAL/ENABLE-STOP-CCN switch to STOP
position then back to RUN or CCN position.
Check the controls. Find cause of trip
and reset breaker.
Check connections.
Check wiring and rewire.
Check line voltage. Determine location
of voltage drop and remedy deficiency.
Check motor winding for open or short.
Replace compressor if necessary.
Replace compressor.
Repair leak and recharge.
Replace transducer.
Add refrigerant.
Replace control.
Open valve or replace if defective.
Check wiring. Repair or replace motor(s)
if defective.
Clean coil.
Add refrigerant.
Replace control.
Clean or replace.
Replace or repair.
Keep doors and windows closed.
Check valves. Replace if necessary.
Support piping as required.
Add refrigerant.
Check for plugged liquid line filter drier.
Check valve plates for valve noise.
Replace compressor (worn bearings).
Check for loose compressor holddown bolts.
Repair leak.
Repair damage or replace compressor.
Replace heaters, check wiring and
crankcase heater relay contacts.
Check cooler and compressor thermistors.
Test EXV.
Repair leak and recharge.
Open valve or remove restriction.
Replace coil.
Replace valve.
Rewire correctly.
Replace spring
Rewire correctly.
Replace valve.
Clean or replace strainer.
Clean or replace the necessary parts.

EXV — Electronic Expansion Valve

Table 20 — Standard and Accessory Unloaders

UNIT

NO. OF STANDARD
UNLOADER(s)

30GN040-070
30GN080-170*
30GN190-210*

1
2
0

*And associated modular units.

66

NO. OF ACCESSORY
UNLOADERS
PERMITTED
Circuit A
Circuit B
1
1 or 2
1
1
1
1

5. Using test function, check unloaders. Press
pad display reads OUTPUTS. Press
reads UNA2 OFF. Press

b. Log into the processor and enter the service function using the keypad and display module.

. Keyuntil display

Press

. Relay energizes. Press

and relay deenergizes. Press

. The keypad LCD will display

‘‘PASSWORD.’’ Enter
, and the
keypad LCD will display ‘‘LOGGEDON.’’
c. To change the configuration, press
, and the
keypad LCD will display ‘‘FLD CFG.’’ Press
until either ‘‘NULA 0’’ or ‘‘NULA 1’’ is displayed
(depending on the number of unloaders provided as

until display reads

UNB2 OFF. Press
. Relay energizes. Press
and relay deenergizes.
6. When unloader check has been performed, return LOCAL/
ENABLE-STOP-CCN to proper position. Close and secure control box door.
130 (50 Hz), 150-210 UNITS (And Associated Modular Units)
1. Install control wiring. The minimum wire size for installation is 16 AWG (American Wire Gage). Refer to
Fig. 23 and 24 for proper wiring. Open the control box
door. Locate unloader relays A and B (UA, UB) in place
of the hot gas bypass relays as shown on the component
arrangement diagram on the unit. Mount the relays with
the field-supplied screws. Be careful not to damage the
components and wiring in the area when mounting the
relays.
2. Wire the control side. Wire the UA coil in series between
J6-18 and J6-19 of the 4 IN/4 OUT module with the wires
provided. Wire the UB coil in series between J6-21 and
J6-22 of the same module with the wires provided.
Locate the black wire in the control harness originating
from TRAN5 labeled HGBPR-A-COM. Connect this wire
to the UA terminal COM. Connect the wire labeled HGBPRA-NO to UA-NO. Connect the wire from UA-NO to
TB3-5. For an extra unloader on circuit B, connect the
wire labeled HGBPR-B-COM to UR-B-COM, and the wire
labeled HGBPR-B-NO to UB-NO. Connect the wire from
UB-NO to TB3-6.
3. Wire in the solenoid valves.
NOTE: Wires external to the control box must be run in
conduit.
Terminal blocks are provided for easy field wiring. Use
one of the isolated 7⁄8-in. (22-mm) holes in the side of the
compressor electrical box with a strain relief to run the
wires to the solenoid coil. Connect UA between TB3-5
and TB3-8. Connect UB between TB3-6 and TB3-8. Check
all of the electrical connections for proper location and
tightness, and replace and secure the electrical box of the
compressor.
4. Configure the microprocessor. Once the relays are mounted
in the control box, the microprocessor must be configured for the unloader option. To do so:
a. Be sure the LOCAL/ENABLE-STOP-CCN switch is
in the STOP position.

standard). Then press

(for 1 unloader on A1)

or
(for 2 unloaders on compressor A1). The
display will now read either ‘‘NULA 1’’ or
‘‘NULA 2,’’ as appropriate. Press
to get to the
NULB display, and change this setting in the same manner as with circuit A.
d. Once the configuration is complete, press
,
and the keypad LCD will display ‘‘LOGGEDON,’’
Press

until the keypad LCD display reads ‘‘LOG

OFF.’’ Press
and the keypad LCD will display
‘‘EXIT LOG.’’
5. Once the unloader heads are installed, the unit is checked
for leaks, and the system is prepared for operation per the
instructions for the compressor unloader head installation, check the output of the relays using the test function
as follows:
a. Press
, and the display will read ‘‘COMP.’’
b. Press the
to scroll down until the display reads
‘‘CPA1 OFF.’’
c. Press
, and the compressor should start.
d. Press

, and the compressor should stop.

e. Press
f. Press

until the display reads ‘‘UNA1 OFF.’’
, and the solenoid should energize.

g. Press

and the solenoid should deenergize.

h. Use the
and
keys to check the remainder of
the unloader coils.
6. Once the check has been performed, return the LOCAL/
ENABLE-STOP-CCN switch to the proper position.
7. Close and secure the control box door.
8. Start the unit and confirm that the chiller operates
properly.

67

*Or HGBPR-A.
†Or HGBPR-B.

LEGEND
C
CB
COMM
HGBPR

—
—
—
—

Contactor
Circuit Breaker
Communications Bus
Hot Gas Bypass Relay

PWR
SW
TRAN
U

—
—
—
—

Power
Switch
Transformer
Unloader

Fig. 23 — Accessory Unloader Control Wiring, All Units

COM
HGBPR
NO
SNB

—
—
—
—

LEGEND
Communications Bus
TB
— Terminal Block
Hot Gas Bypass Relay
TRAN — Transformer
Normally Open
U
— Unloader
Snubber

Fig. 24 — Flotronic™ II 115/230-V (Unloader Wiring, 130 (50 Hz), 150-210 and Associated Modular Units
(See Table 1)

68

FIELD WIRING
Refer to Fig. 25-35 for field wiring.

NOTE: Contacts must be rated for dry circuit application, capable of
reliably switching a 5 vdc, 1 mA to 20 mA load.

Fig. 25 — Demand Limit — Two External
Switch Inputs

Fig. 26 − Demand Limit — 4-20 mA Signal
(Externally Powered)

Fig. 30 — Remote Reset from 4-20 mA Signal
(Internally Powered)

TB — Terminal Block
NOTE: Contacts must be rated for dry circuit application, capable of
reliably switching a 5 vdc, 1 mA to 20 mA load.

Fig. 27 — Demand Limit — 4-20 mA Signal
(Internally Powered)

Fig. 31 — Remote On/Off

Fig. 28 — Remote Reset from Space or
Outdoor-Air Temperature

Fig. 32 — Remote Dual Set Point Control

Fig. 29 — Remote Reset from 4-20 mA Signal
(Externally Powered)

CWP — Chilled Water (Fluid) Pump
TB
— Terminal Block

Fig. 33 — Chilled Fluid Pump

69

TB — Terminal Block

Fig. 34 — Remote Alarm

CWP1 — Chilled Water (Fluid) Pump Interlock
CWFS — Chilled Water (Fluid) Flow Switch (not required — low flow
protection is provided by Flotronic™ II controls)
TB
— Terminal Block

Fig. 35 — Interlocks

REPLACING DEFECTIVE
PROCESSOR MODULE
The replacement part number is printed on a small label
on the front of the PSIO module. The model and serial numbers are printed on the unit nameplate located on an exterior
corner post. The proper software and unit configuration data
is factory installed by Carrier in the replacement module.
Therefore, when ordering a replacement processor module
(PSIO), specify complete replacement part number, full unit
model number, and serial number. If these numbers are not
provided, the replacement module order is configured instead as a generic Flotronic II replacement module. This requires reconfiguration of the module by the installer.

4. Remove defective PSIO by removing its mounting screws
with a Phillips screwdriver, and removing the module
from the control box. Save the screws for later use.
5. Use a small screwdriver to set address switches S1 and
S2 on the new PSIO module to exactly match the settings on the defective module.
6. Package the defective module in the carton of the new
module for return to Carrier.
7. Mount the new module in the unit control box using a
Phillips screwdriver and the screws saved in Step 4 above.
8. Reinstall all 6 wire connectors and the green ground wire.
9. Carefully check all wiring connections before restoring
power.
10. Verify the LOCAL/ENABLE-STOP-CCN switch is in
STOP position.
11. Restore control power. Verify the red and green lights
on top of PSIO and front of each DSIO module respond
as described in Control Modules section on page 63. The
keypad and display module should also begin its rotating display.
12. Using the keypad and display module, press
to verify that the software version number matches the
ER (engineering requirement) number shown on the PSIO
label.
13. Press
to verify that the 7 factory configuration
codes (CODE 1 through CODE 7) exactly match the codes
listed for this unit model on the component arrangement
label diagram on the control box door. If they are different or are all zeros, reenter the 7 codes. If any changes
are required, the PSIO display becomes blank and
reconfigures itself after pressing the
key while displaying CODE 7. The display returns in approximately
15 seconds.
NOTE: Codes with leading zeros in the configuration
will be displayed starting with the first number greater
than zero.
14. Press
to verify each item is configured as needed

Electrical shock can cause personal injury. Disconnect
all electrical power before servicing.

for this particular installation. Table 14 shows the factory configuration code default settings. Table 14 also
shows the service replacement code default settings which
are used if no model number was specified when ordering the replacement PSIO module. It is strongly suggested that the Start-Up Checklist for Flotronic II Chiller
Systems (completed at time of original start-up) be used
at this time to verify and/or reprogram the various options and configurations required for this job.
15. Press
to verify that the 2 field configuration
codes (codes 8 and 9) match exactly the codes listed on
the label diagram on the control box door. If they are
different, or are all zeros, reenter the 2 codes.
16. After completing the configuration steps outlined above,
restore main power and perform a unit test as described in
and
sections on page 38.
17. Complete this procedure and restore chiller to normal
operation by returning the LOCAL/ENABLE-STOPCCN switch to desired position.

Installation
1. Verify the existing PSIO module is defective by using
the procedure described in the Control Modules section
on page 63.
2. Refer to Start-Up Checklist for Flotronic II Chiller Systems (completed at time of original start-up) found in
job folder. This information is needed later in this
procedure. If checklist does not exist, fill out the
and
configuration code sections on a new checklist. Tailor the various options and configurations as needed
for this particular installation.
3. Check that all power to unit is off. Carefully disconnect
all wires from defective module by unplugging the 6 connectors. It is not necessary to remove any of the individual wires from the connectors. Remove the green ground
wire.

70

Copyright 1995 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Catalog No. 563-079
Printed in U.S.A.
Form 30GN-3T
Pg 72
7-95
Replaces: 30G-1T
Tab 5c



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