Specifications

ManualsBrandsCarrier ManualsKitchen Appliances30GTR

Controls, Start-Up, Operation,

Service, and Troubleshooting

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can

be hazardous due to system pressures, electrical compo-

nents, and equipment location (roof, elevated structures, etc.).

Only trained, qualiﬁed installers and service mechanics should

install, start up, and service this equipment.

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. Fol-

low 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 con-

trol 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.

To prevent potential damage to heat exchanger tubes al-

ways run ﬂuid through heat exchangers when adding or

removing refrigerant charge. Use appropriate brine so-

lutions in cooler and condenser ﬂuid loops to prevent

the freezing of heat exchangers when the equipment is

exposed to temperatures below 32 F (0° C).

DO NOT VENT refrigerant relief valves within a build-

ing. Outlet from relief valves must be vented outdoors

in accordance with the latest edition of ANSI/ASHRAE

(American National Standards Institute/American Soci-

ety of Heating, Refrigeration and Air Conditioning En-

gineers) 15 (Safety Code for Mechanical Refrigeration).

The accumulation of refrigerant in an enclosed space

can displace oxygen and cause asphyxiation. Provide ad-

equate ventilation in enclosed or low overhead areas.

Inhalation of high concentrations of vapor is harmful

and may cause heart irregularities, unconsciousness or

death. Misuse can be fatal. Vapor is heavier than air and

reduces the amount of oxygen available for breathing.

Product causes eye and skin irritation. Decomposition

products are hazardous.

DO NOT attempt to unbraze factory joints when ser-

vicing this equipment. Compressor oil is ﬂammable and

there is no way to detect how much oil may be in any

of the refrigerant lines. Cut lines with a tubing cutter as

required when performing service. Use a pan to catch

any oil that may come out of the lines and as a gage for

how much oil to add to system. DO NOT re-use com-

pressor oil.

CONTENTS

Page

SAFETY CONSIDERATIONS ...................1

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

INTRODUCTION ..............................2

MAJOR SYSTEM COMPONENTS ............3-10

General ......................................3

Main Base Board (MBB) ......................3

Expansion Valve (EXV) Board .................3

Compressor Expansion Board (CXB) ..........3

Scrolling Marquee Display ....................3

Energy Management Module (EMM) ...........3

Enable/Off/Remote Contact Switch ............3

Emergency On/Off Switch ....................3

Reset Button ................................3

Board Address ...............................3

Control Module Communication ..............3

Carrier Comfort Network Interface ............3

OPERATING DATA .........................11-46

Sensors ....................................11

• T1 — COOLER LEAVING FLUID SENSOR

• T2 — COOLER ENTERING FLUID SENSOR

• T3,T4 — SATURATED CONDENSING

TEMPERATURE SENSORS

• T5,T6 — COOLER SUCTION TEMPERATURE

SENSORS

• T7,T8 — COMPRESSOR SUCTION GAS

TEMPERATURE SENSORS

• T9 — OUTDOOR-AIR TEMPERATURE SENSOR

• T10 — REMOTE SPACE TEMPERATURE SENSOR

Thermostatic Expansion Valves (TXV) ........15

Compressor Protection Control System

(CPCS) or Control Relay (CR) ..............15

Compressor Current Protection Board

(CGF) and Control Relay (CR) ..............15

Electronic Expansion Valve (EXV) ............16

Energy Management Module .................16

Capacity Control ............................16

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• LOADING SEQUENCE

• LEAD/LAG DETERMINATION

• CAPACITY SEQUENCE DETERMINATION

• CAPACITY CONTROL OVERRIDES

30GTN,GTR040-420

Air-Cooled Reciprocating Liquid Chillers

with

ComfortLink™

Controls

50/60 Hz

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

Book 2

Tab 5c

PC 903 Catalog No. 533-099 Printed in U.S.A. Form 30GTN-1T Pg 1 5-99 Replaces: New

Summary of content (84 pages)

PAGE 1
30GTN,GTR040-420 Air-Cooled Reciprocating Liquid Chillers with ComfortLink™ Controls 50/60 Hz Controls, Start-Up, Operation, Service, and Troubleshooting SAFETY CONSIDERATIONS 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.
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Page Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . 65 • TEMPERATURES • VOLTAGE • MINIMUM FLUID LOOP VOLUME • FLOW RATE REQUIREMENTS Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . 66 APPENDIX A — CCN TABLES . . . . . . . . . . . . . . 67-74 START-UP CHECKLIST . . . . . . . . . . . . . . CL-1 to CL-8 CONTENTS (cont) Page Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 27 • COMFORTLINK™ UNITS (With EXV) • UNITS WITH TXV Pumpout . . . . . . . . . . .
PAGE 3
MAJOR SYSTEM COMPONENTS Emergency On/Off Switch — The Emergency On/ Off switch should only be used when it is required to shut the chiller off immediately. Power to the MBB, EMM, CXB, and marquee display is interrupted when this switch is off and all outputs from these modules will be turned off. The EXV board is powered separately, but expansion valves will be closed as a result of the loss of communication with the MBB. There is no pumpout cycle when this switch is used. See Fig. 6.
PAGE 4
Table 2 — Thermistor Designations It is important when connecting to a CCN communication bus that a color coding scheme be used for the entire network to simplify the installation. It is recommended that red be used for the signal positive, black for the signal negative, and white for the signal ground. Use a similar scheme for cables containing different colored wires. At each system element, the shields of its communication bus cables must be tied together.
PAGE 5
Table 4 — Output Relay LEGEND FOR FIG.
PAGE 6
Fig.
PAGE 7
Fig.
PAGE 8
Fig.
PAGE 9
Fig.
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RED LED - STATUS GREEN LED LEN (LOCAL EQUIPMENT NETWORK) YELLOW LED CCN (CARRIER COMFORT NETWORK) CEPL130346-01 J1 J4 STATUS J2 J10 LEN J3 CCN J5 J6 J7 J9 J8 Fig. 5 — Main Base Board EMERGENCY ON/OFF SWITCH ENABLE/OFF/REMOTE CONTACT SWITCH RESET BUTTON (30GTN,R130-210 AND ASSOCIATED MODULES ONLY) GFI-CONVENIENCE OUTLET ACCESSORY ON 208/230V 460 AND 575V ONLY Fig.
PAGE 11
T5, T6 — COOLER SUCTION TEMPERATURE SENSORS — These thermistors are located next to the refrigerant inlet in the cooler head, and are inserted into a frictionfit well. The sensor well is located directly in the refrigerant path. These thermistors are not used on units with TXVs. T7, T8 — COMPRESSOR SUCTION GAS TEMPERATURE SENSORS — These thermistors are located in the lead compressor in each circuit in a suction passage after the refrigerant has passed over the motor and is about to enter the cylinders.
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040-070 080-110 AND ASSOCIATED MODULAR UNITS 130-210 AND ASSOCIATED MODULAR UNITS* *When thermistor is viewed from perspective where the compressor is on the left and the cooler is on the right. Fig.
PAGE 13
LEGEND EXV — Electronic Expansion Valve Fig. 9 — Compressor Thermistor Locations (T7 and T8) Fig.
PAGE 14
3. Insert and secure the white (ground) wire to terminal 4 of the space temperature sensor. 4. Insert and secure the black (−) wire to terminal 2 of the space temperature sensor. 5. Connect the other end of the communication bus cable to the remainder of the CCN communication bus. T10 — REMOTE SPACE TEMPERATURE SENSOR — Sensor T10 (part no. HH51BX006) is an accessory sensor that is remotely mounted in the controlled space and used for space temperature reset.
PAGE 15
will be detected through the signal contacts, and the compressor will be locked off. If the lead compressor in either circuit is shut down by the high-pressure switch, loss-ofcharge switch, ground current protector, or oil safety switch, all compressors in that circuit are shut down. NOTE: The CR operates the same as the CPCS, except the ground current circuit protection is not provided.
PAGE 16
Electronic Expansion Valve (EXV) (See Fig. 14) — Standard units are equipped with a bottom seal EXV. This device eliminates the use of the liquid line solenoid pumpdown at unit shutdown. An O-ring has been added to bottom of orifice assembly to complete a seal in the valve on shutdown. This is not a mechanical shut-off. When service is required, use the liquid line service valve to pump down the system.
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J2 LEN J3 TEST 1 PWR J4 J1 STATUS CEPL130351-01 CEBD430351-0396-01C J5 J7 J6 RED LED - STATUS TEST 2 GREEN LED LEN (LOCAL EQUIPMENT NETWORK) Fig. 15 — Energy Management Module The capacity routine runs every 30 seconds. The routine attempts to maintain the Control Point at the desired set point. Each time it runs, the control reads the entering and leaving fluid temperatures.
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Table 5A — Part Load Data Percent Displacement, Standard Units UNIT 30GTN,GTR 040 (60 Hz) 040 (50 Hz) 045 (60 Hz) 045 (50 Hz) 050 (60 Hz) 050 (50 Hz) 060 (60 Hz) 060 (50 Hz) 070 (60 Hz) 070 (50 Hz) 080, 230B (60 Hz) 080, 230B (50 Hz) 090, 245B (60 Hz) 090, 245B (50 Hz) 100, 255B, 270B (60 Hz) CONTROL STEPS 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 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 10 11 1 2 3 4 5 6 7 8 9 10 11 LOADING SEQUENCE A % Displacement Compre
PAGE 19
Table 5A — Part Load Data Percent Displacement, Standard Units (cont) UNIT 30GTN,GTR 100, 255B, 270B (50 Hz) 110, 290B, 315B (60 Hz) 110, 290B, 315B (50 Hz) 130 (60 Hz) 130 (50 Hz) 150, 230A, 245A, 255A (60 Hz) CONTROL STEPS 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 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) 13 A1* 20 A1 26 A1*,B1* 33 A1,B1 40 A1,B1 57 A1*,A2,B1* 63 A1*
PAGE 20
Table 5A — Part Load Data Percent Displacement, Standard Units (cont) UNIT 30GTN,GTR 150, 230A, 245A, 255A (50 Hz) 170, 270A, 330A/B (60 Hz) 170, 270A, 330A/B,360B (50 Hz) 190, 290A, 360A/B, 390B (60 Hz) 190, 290A, 360A, 390B (50 Hz) 210, 315A, 390A, 420A/B (60 Hz) 210, 315A, 390A, 420A/B (50 Hz) 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 16 17 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 1 2 3 4 5 6 7 1 2 3 4 5 6 7 LOADING SEQUENCE A % D
PAGE 21
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders UNIT 30GTN,GTR 040 (60 Hz) 040 (50 Hz) 045 (60 Hz) 045 (50 Hz) 050 (60 Hz) 050 (50 Hz) 060 (60 Hz) 060 (50 Hz) 070 (60 Hz) 070 (50 Hz) 080, 230B (60 Hz) 080, 230B (50 Hz) 090, 245B (60 Hz) CONTROL STEPS 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 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 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 LOADING SEQUENCE A % Displacement Compressors (Approx) 25 A1* 50 A1 75 A1*,B1 100 A1,B1 24 A
PAGE 22
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) UNIT 30GTN,GTR 090, 245B (50 Hz) 100, 255B, 270B (60 Hz) 100, 255B, 270B (50 Hz) 110, 290B, 315B (60 Hz) 110, 290B, 315B (50 Hz) 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 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 LOADING SEQUENCE A % Displacement Compressors (Approx) 7 A1† 14 A1* 21 A1 29 A1†,B1 36 A1*,B1 43 A1,B1 49 A1†,A
PAGE 23
Table 5B — Part Load Data Percent Displacement, with Accessory Unloaders (cont) UNIT 30GTN,GTR CONTROL STEPS 130 (60 Hz) 130 (50 Hz) 150, 230A, 245A, 255A (60 Hz) 150, 230A, 245A, 255A (50 Hz) 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 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 LOADING SEQUENCE A % Displacement Compressors (Approx) 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
PAGE 24
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) UNIT 30GTN,GTR CONTROL STEPS 170, 270A, 330A/B (60 Hz) 170, 270A, 330A/B, 360B (50 Hz) 190, 290A, 360A/B, 390B (60 Hz) 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 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 5 9 14 14 19 23 28 28 33 37 42 43 4
PAGE 25
Table 5B — Part Load Data Percent Displacement, With Accessory Unloaders (cont) UNIT 30GTN,GTR 190, 290A, 360A, 390B (50 Hz) 210, 315A, 390A, 420A/B (60 Hz) 210, 315A, 390A, 420A/B (50 Hz) 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 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LOADING % Displacement (Approx) 11 17 22 28 33 39 44 50 55 61 67 72 78 83 89 94 100 8 11 17 22 25 28 33 36 48 52 56 59 63 67 78 83 86 92 97 100 7 9 17 23 26 27
PAGE 26
capacity. Figure 16 shows how compressor starts can be reduced over time if the leaving water temperature is allowed to drift a larger amount above and below the set point. This value should be set in the range of 3.0 to 4.0 for systems with small loop volumes. First Stage Override — If the current capacity stage is zero, the control will modify the routine with a 1.2 factor on adding the first stage to reduce cycling.
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2 STARTS DEADBAND EXAMPLE 47 7 6 46 45 LWT (F) LWT (C) 8 44 43 42 5 41 0 200 400 600 TIME (SECONDS) 800 1000 3 STARTS STANDARD DEADBAND MODIFIED DEADBAND LEGEND LWT — Leaving Water Temperature Fig. 16 — Deadband Multiplier T4 is greater than 125 F (51.6 C), in which case all MBBcontrolled fans start immediately. If T3 and T4 are greater than 95 F (35.0 C) just prior to circuit start-up, all MBBcontrolled fan stages are turned on to prevent excessive discharge pressure during pull-down.
PAGE 28
FAN ARRANGEMENT 30GTN,R040-050 30GTN,R060-090, 230B, 245B 30GTN,R100,110, 255B-315B 30GTN,R130 (60 Hz) POWER 30GTN,R130 (50 Hz), 150-210, 230A-315A, 330A/B-420A/B† POWER FAN NO. FAN RELAY 1 — Compressor No. A1 2 — Compressor No. B1 3 A1 First Stage of Condenser Fans 4 B1 Second Stage of Condenser Fans 1 — Compressor No. A1 2 — Compressor No. B1 3, 4 A1 First Stage of Condenser Fans 5, 6 B1 Second Stage of Condenser Fans 1 — Compressor No. A1 2 — Compressor No.
PAGE 29
The Service Test function should be used to verify proper operation of compressors, unloaders, hot gas bypass (if installed), cooler pump and remote alarm relays, EXVs and condenser fans. To use the Service Test mode, the Enable/ Off/Remote Contact switch must be in the OFF position. Use the display keys and Table 8 to enter the mode and display TEST. Press ENTER twice so that OFF flashes, Enter the password if required. Use either arrow key to change the TEST value to the On position and press ENTER .
PAGE 30
RETURN FLUID LEAVING FLUID MASTER CHILLER SLAVE CHILLER INSTALL MASTER CHILLER LEAVING FLUID THERMISTOR (T1) HERE Fig.
PAGE 31
Table 7 — Run Status Mode and Sub-Mode Directory SUB-MODE VIEW RUN HOUR STRT KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION ENTER EWT XXX.X °F ENTERING FLUID TEMP LWT XXX.X °F LEAVING FLUID TEMP SETP XXX.X °F ACTIVE SETPOINT CTPT XXX.X °F CONTROL POINT MODE X CONTROL MODE OCC YES/NO OCCUPIED CAP XXX % PERCENT TOTAL CAPACITY STGE XX REQUESTED STAGE ALRM XX CURRENT ALARMS & ALERTS TIME XX.
PAGE 32
Table 8 — Service Test Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY TEST ENTER OUTS COMP ENTER ENTER ITEM DISPLAY ITEM EXPANSION ON/OFF SERVICE TEST MODE FR.A1 ON/OFF FAN A1 RELAY FR.A2 ON/OFF FAN A2 RELAY EXV.A 0-100% EXV % OPEN FR.B1 ON/OFF FAN B1 RELAY FR.B2 ON/OFF FAN B2 RELAY EXV.B 0-100% EXV % OPEN CLR.P ON/OFF COOLER PUMP RELAY RMT.A ON/OFF REMOTE ALARM RELAY CC.A1 ON/OFF COMPRESSOR A1 RELAY CC.A2 ON/OFF COMPRESSOR A2 RELAY CC.
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Table 9 — Temperature Mode and Sub-Mode Directory SUB-MODE UNIT CIR.A CIR.B KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION ENTER CEWT XXX.X °F COOLER ENTERING FLUID CLWT XXX.X °F COOLER LEAVING FLUID OAT XXX.X °F OUTSIDE AIR TEMPERATURE SPT XXX.X °F SPACE TEMPERATURE SCT.A XXX.X °F SATURATED CONDENSING TMP SST.A XXX.X °F SATURATED SUCTION TEMP SGT.A XXX.X °F COMPRESSOR SUCTION TEMP SUP.A XXX.X °F SUCTION SUPERHEAT TEMP SCT.B XXX.X °F SATURATED CONDENSING TMP SST.B XXX.
PAGE 34
Table 13 — Inputs Mode and Sub-Mode Directory SUB-MODE GEN.
PAGE 35
Table 14 — Outputs Mode and Sub-Mode Directory SUB-MODE GEN.O CIR.A CIR.B KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION ENTER C.PMP ON/OFF COOLER PUMP RELAY H.GAS ON/OFF HOT GAS BYPASS RELAY FR.A1 ON/OFF FAN A1 RELAY FR.A2 ON/OFF FAN A2 RELAY CC.A1 ON/OFF COMPRESSOR A1 RELAY CC.A2 ON/OFF COMPRESSOR A2 RELAY CC.A3 ON/OFF COMPRESSOR A3 RELAY CC.A4 ON/OFF COMPRESSOR A4 RELAY UL.A1 ON/OFF UNLOADER A1 RELAY UL.A2 ON/OFF UNLOADER A2 RELAY EXV.A XXX.X % EXV % OPEN FR.
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Table 15 — Configuration Mode and Sub-Mode Directory (cont) SUB-MODE KEYPAD ENTRY UNIT ENTER OPT1 ENTER ITEM TYPE DISPLAY X ITEM EXPANSION UNIT TYPE TONS XXX UNIT SIZE CAP.A XXX CIRCUIT A % CAPACITY CMP.A X NUMBER CIRC A COMPRESSOR CYL.A X COMPRESSOR A1 CYLINDERS CMP.B X NUMBER CIRC B COMPRESSOR CYL.B X COMPRESSOR B1 CYLINDERS EXV YES/NO EXV MODULE INSTALLED SH.SP DF EXV SUPERHEAT SETPOINT SH.OF DF EXV SUPERHEAT OFFSET REFG X REFRIGERANT FAN.
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Table 15 — Configuration Mode and Sub-Mode Directory (cont) SUB-MODE OPT2 RSET SLCT KEYPAD ENTRY ENTER ENTER ENTER ITEM CTRL DISPLAY X ITEM EXPANSION CONTROL METHOD CCNA XXX CCN ADDRESS CCNB XXX CCN BUS NUMBER BAUD X CCN BAUD RATE LOAD X LOADING SEQUENCE SELECT LLCS X LEAD/LAG CIRCUIT SELECT LCWT XX.X DF HIGH LCW ALERT LIMIT DELY XX MIN MINUTES OFF TIME CRST X COOLING RESET TYPE CRT1 XXX.X °F NO COOL RESET TEMP CRT2 XXX.X °F FULL COOL RESET TEMP DGRC XX.
PAGE 38
Table 16 — Example of Temperature Reset (Outdoor Air) Configuration SUB-MODE RSET KEYPAD ENTRY ENTER ITEM CRST DISPLAY 0 ITEM EXPANSION COOLING RESET TYPE 0 1 2 3 4 = = = = = COMMENT No reset 4 to 20 mA input Outdoor Air Temp Return Fluid Space Temperature ENTER 0 Scrolling stops ENTER 0 Value flashes 2 Select 2 2 Change accepted CRST 2 Item/Value/Units scrolls again CRT1 125 Range: 0 to 125 F ENTER 125 Scrolling stops ENTER 125 Value flashes 75 Select 75 75 Change accepted
PAGE 39
Table 17 — Example of Configuring Dual Chiller Control SUB-MODE KEYPAD ENTRY ITEM DISPLAY RSET ENTER CRST 0 LLDY 5 ITEM EXPANSION COMMENT LAG START DELAY ENTER 5 Scrolling stops ENTER 5 Value flashes 10 Select 10 10 Change accepted ENTER ESCAPE LLDY 10 LLBD 168 LEAD/LAG BALANCE DELTA LLBL DSBL LEAD/LAG BALANCE SELECT No change needed.
PAGE 40
Table 18 — Example of Compressor Lead/Lag Configuration SUB-MODE KEYPAD ENTRY ITEM DISPLAY OPT2 ENTER CTRL 0 CCNA 1 CCNB 0 BAUD 3 LOAD 1 LLCS 1 ITEM EXPANSION COMMENT CONTROL METHOD LEAD/LAG CIRCUIT SELECT DEFAULT: 2 (040-070); 1 (080-420) ENTER 1 Scrolling stops ENTER 1 Value flashes 3 Select 3 NOTE: Options 1 and/or 3 not valid for sizes 040-070 without Circuit B accessory unloader installed 3 Change accepted ENTER LLCS ESCAPE 3 LEAD/LAG CIRCUIT SELECT Item/Value/Units scrolls
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Table 20 — Setting an Occupied Time Schedule SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT ENTER MON.O 00.00 MONDAY OCCUPIED TIME TIME IN MILITARY FORMAT (HH.MM) ENTER 00.00 Scrolling stops ENTER 00.00 Hours flash 07.00 Select 7 AM 07.00 Change accepted, minutes flash 07.30 Select 30 07.30 Change accepted SCHD ENTER ENTER MON.O ESCAPE 07.
PAGE 42
Table 22 — Operating Modes MODE NO.
PAGE 43
Table 23 — Alarms Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY ITEM ITEM EXPANSION CRNT ENTER AXXX or TXXX CURRENTLY ACTIVE ALARMS RCRN ENTER YES/NO RESET ALL CURRENT ALARMS HIST ENTER AXXX or TXXX ALARM HISTORY RHIS ENTER YES/NO RESET ALARM HISTORY COMMENT Alarms are shown as AXXX. Alerts are shown as TXXX. Alarms are shown as AXXX. Alerts are shown as TXXX.
PAGE 44
Table 25 — Configuring Temperature Reset MODE KEYPAD SUB-MODE KEYPAD ITEM DISPLAY GREEN LED) ENTRY ENTRY CONFIGURATION ENTER ENTER DISP TEST ON/OFF TEST DISPLAY LEDs UNIT ENTER TYPE X UNIT TYPE OPT1 ENTER FLUD X COOLER FLUID OPT2 ENTER CTRL X CONTROL METHOD CRST X COOLING RESET TYPE RSET ENTER ITEM EXPANSION COMMENT 0 = No Reset 1 = 4 to 20 mA Input (EMM required) (Connect to EMM J6-2,5) 2 = Outdoor-Air Temperature (Connect to TB5-7,8) 3 = Return Fluid (Connect to TB5-5,6) 4 = Space
PAGE 45
lowest demand takes priority if both demand limit inputs are closed. If the demand limit percentage does not match unit staging, the unit will limit capacity to the closest capacity stage. To disable demand limit configure the DMDC to 0. See Table 25. Demand Limit — Demand Limit is a feature that allows the unit capacity to be limited during periods of peak energy usage. There are 3 types of demand limiting that can be configured.
PAGE 46
MAX. ALLOWABLE LOAD (%) 100 50% CAPACITY AT 20 mA 80 60 40 100% CAPACITY AT 4 mA 75% CAPACITY AT 12 mA 20 0 0 2 12 6 8 10 14 DEMAND LIMIT SIGNAL – 4 - 20 mA INPUT (VOLTS DC) 4 16 18 20 Fig. 21 — 4 to 20 mA Demand Limiting the quick test and initialization features built into the ComfortLink™ control. Follow the procedure below to diagnose and correct EXV problems.
PAGE 47
liquid line service valve. Turn the ENABLE/OFF/REMOTE contact switch and allow unit to operate. Verify proper operation of unit. This process of opening and closing the EXV (EXV.A/ EXV.B under OUTS) can be repeated by using these Service Test steps and recycling the control as described in the preceding steps. If the valve does not operate as described when properly connected to the processor and receiving the correct signals, it should be replaced.
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Table 27 — Alarm and Alert Codes ALARM/ ALERT CODE 51 ALARM OR ALERT Alert 52 Alert Circuit A, Compressor 2 Failure Compressor feedback signal does not match relay state 53 Alert Circuit A, Compressor 3 Failure Compressor feedback signal does not match relay state 54 Alert Circuit A, Compressor 4 Failure Compressor feedback signal does not match relay state 55 Alert Circuit B, Compressor 1 Failure Compressor feedback signal does not match relay state 56 Alert Circuit B, Compressor 2 Fail
PAGE 49
Table 27 — Alarm and Alert Codes (cont) ALARM/ ALARM ALERT OR DESCRIPTION CODE ALERT 112 Alert Circuit A High Suction Superheat WHY WAS THIS ACTION TAKEN ALARM BY CONTROL GENERAED? If EXV is greater than Circuit A shutdown 98%, suction superheat is after pumpdown greater than 75 F (41.7 C) complete.
PAGE 50
Table 27 — Alarm and Alert Codes (cont) ALARM/ ALARM ALEERT OR DESCRIPTION CODE ALERT 150 Alarm Emergency Stop WHY WAS THIS ALARm GENERATED? CCN emergency stop command received 151 Alarm Illegal Configuration 152 Alarm Unit Down Due to Failure One or more of the illegal configurations shown in the Note below exists. Both circuits are down due to alarms/alerts.
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Table 27 — Alarm and Alert Codes (cont) ALARM/ OR ALEERT ALARM DESCRIPTION ALERT CODE 203 Alert Loss of Communication with Slave Chiller 204 Alert 206 Alert 207 Alarm 208 Alarm 950 Alert 951 Alert CCN CPCS CXB EMM EXV FSM MBB MOP WSM — — — — — — — — — WHY WAS THIS ALARm GENERATED? Master MBB loses communication with Slave MBB ACTION TAKEN BY CONTROL RESET METHOD Dual chiller control disabled. Chiller runs as a stand-alone machine.
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Table 28 — Oil Charge SERVICE ELECTRIC SHOCK HAZARD. Turn off all power to unit before servicing. The ENABLE/OFF/REMOTE CONTACT switch on control panel does not shut off control power; use field disconnect. COMPRESSOR 06E250 06E265 06E275 06E299 OIL REQUIRED Pts L 14 6.6 19 9.0 19 9.0 19 9.0 Do not reuse drained oil or any oil that has been exposed to atmosphere. Electronic Components CONTROL COMPONENTS — Unit uses an advanced electronic control system that normally does not require service.
PAGE 53
c. Install thermistor T2 (entering fluid temperature) so that it is not touching an internal refrigerant tube, but so that it is close enough to sense a freeze condition. The recommended distance is 1⁄8 in. (3.2 mm) from the cooler tube. Tighten the packing nut finger tight, and then tighten 11⁄4 turns more using a back-up wrench. 6. Install the cooler heater and conduit (if equipped), connecting the wires as shown in the unit wiring schematic located on the unit. 7.
PAGE 54
Tube Plugging — A leaky tube can be plugged until retubing can be done. The number of tubes plugged determines how soon cooler must be retubed. Tubes plugged in the following locations will affect the performance of the unit: Any tube in the area, particularly the tube that thermistor T2 is adjacent to, will affect unit reliability and performance. Thermistor T2 is used in the freeze protection algorithm for the controller.
PAGE 55
installed in corrosive environments should have coil cleaning as part of a planned maintenance schedule. In this type of application, all accumulations of dirt should be cleaned off the coil. Tightening Cooler Head Bolts Gasket Preparation — When reassembling cooler heads, always use new gaskets. Gaskets are neoprene-based and are brushed with a light film of compressor oil. Do not soak gasket or gasket deterioration will result. Use new gaskets within 30 minutes to prevent deterioration.
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DIMENSION A B Standard 0.509 (13 mm) 0.889 (22 mm) High-pressure liquid refrigerant enters valve through bottom. A series of calibrated slots have been machined in side of orifice assembly. As refrigerant passes through orifice, pressure drops and refrigerant changes to a 2-phase condition (liquid and vapor). To control refrigerant flow for different operating conditions, a sleeve moves up and down over orifice and modulates orifice size. A sleeve is moved by a linear stepper motor.
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LIQUID LINE SOLENOID VALVE — All TXV units have a liquid line solenoid valve to prevent liquid refrigerant migration to low side of system during the off cycle. PL-EXVB 1 1 BRN 2 2 J7 3 4 5 3 4 5 WHT RED BLK GRN A E D LIQUID LINE SERVICE VALVE — This valve is located immediately ahead of filter drier, and has a 1⁄4-in. Schrader connection for field charging. In combination with compressor discharge service valve, each circuit can be pumped down into the high side for servicing.
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REPLACING THERMISTORS T1, T5, T6, T7, AND T8 — Add a small amount of thermal conductive grease to thermistor well. Thermistors are friction-fit thermistors, which must be slipped into receivers located in the cooler leaving fluid nozzle for T1, in the cooler head for T5 and T6 (EXV units only), and in the compressor pump end for T7 and T8 (EXV units only). MAIN BASE BOARD 1 1 2 2 3 3 THERMISTORS T3 AND T4 — These thermistors are located on header end of condenser coil.
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Table 30A — 5K Thermistor Temperatures (°F) vs Resistance/Voltage Drop (For Thermistors T1-T9) TEMP (F) −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 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 VOLTAGE DROP (V) 4.538 4.523 4.508 4.493 4.476 4.460 4.444 4.427 4.409 4.391 4.373 4.354 4.335 4.316 4.296 4.276 4.255 4.234 4.213 4.191 4.169 4.
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Table 30B — 5K Thermistor Temperatures (°C) vs Resistance/Voltage Drop (For Thermistors T1-T9) TEMP (C) −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 VOLTAGE DROP (V) 4.547 4.520 4.493 4.464 4.433 4.402 4.369 4.335 4.300 4.264 4.226 4.187 4.146 4.104 4.061 4.017 3.971 3.924 3.876 3.827 3.777 3.725 3.673 3.619 3.564 3.509 3.453 3.396 3.338 3.279 3.221 3.161 3.101 3.041 2.980 2.919 2.858 2.797 2.
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Table 31A — 10K Thermistor Temperatures (°F) vs Resistance/Voltage Drop (For Thermistor T10) TEMP (F) −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 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 VOLTAGE DROP (V) 4.758 4.750 4.741 4.733 4.724 4.715 4.705 4.696 4.686 4.676 4.665 4.655 4.644 4.633 4.621 4.609 4.597 4.585 4.572 4.560 4.546 4.
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Table 31B — 10K Thermistor Temperatures (°C) vs Resistance/Voltage Drop (For Thermistor T10) TEMP (F) −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 VOLTAGE DROP (V) 4.762 4.748 4.733 4.716 4.700 4.682 4.663 4.644 4.624 4.602 4.580 4.557 4.533 4.508 4.482 4.455 4.426 4.397 4.367 4.335 4.303 4.269 4.235 4.199 4.162 4.124 4.085 4.044 4.003 3.961 3.917 3.873 3.828 3.781 3.734 3.686 3.637 3.587 3.537 3.
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CRANKCASE HEATERS — Each compressor has a 180-w crankcase heater to prevent absorption of liquid refrigerant by oil in crankcase when compressor is not running. Heater power source is auxiliary control power, independent of main unit power. This assures compressor protection even when main unit power disconnect switch is off. Safety Devices — Chillers contain many safety devices and protection logic built into electronic control. Following is a brief summary of major safeties.
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Relief Devices — Fusible plugs are located in each circuit to protect against damage from excessive pressures. HIGH-SIDE PROTECTION — One device is located between condenser and filter drier; a second is on filter drier. These are both designed to relieve pressure on a temperature rise to approximately 210 F (99 C). LOW-SIDE PROTECTION — A device is located on suction line and is designed to relieve pressure on a temperature rise to approximately 170 F (77 C).
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NOTE: Refer to Start-Up Checklist on pages CL-1 to CL-8. Unbalanced 3-Phase Supply Voltage — Never operate a motor where a phase imbalance between phases is greater than 2%. To determine percent voltage imbalance: Actual Start-Up — Actual start-up should be done only under supervision of a qualified refrigeration mechanic. 1. Be sure all service valves are open. Units are shipped from factory with suction, discharge, and liquid line service valves closed. 2.
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control or CCN network command or remote contact closure), the unit stages up in capacity to maintain the cooler fluid set point. The first compressor starts 11⁄2 to 3 minutes after the call for cooling. The lead circuit can be specifically designated or randomly selected by the controls, depending on how the unit is field configured (for 040-070 sizes, Circuit A leads unless an accessory unloader is installed on Circuit B).
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APPENDIX A — CCN TABLES UNIT (Configuration Settings) DESCRIPTION Unit Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Unit Size Circuit A1% Capacity Number Circ A Compressor Compressor A1 Cylinders Number Circ B Compressor Compressor B1 Cylinders EXV Module Installed EXV Superheat Setpoint EXV MOP EXV Superheat Offset EXV Circ. A Min Position EXV Circ.
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CONFIGURATION SCREEN (TYPE 10) OPTIONS2 (Options Configuration) 1 DESCRIPTION Control Method 2 Loading Sequence Select 3 Lead/Lag Sequence Select 4 Cooling Setpoint Select 5 6 7 8 Ramp Load Select High LCW Alert Limit Minutes off time Deadband Multiplier STATUS 0 = Switch 1 = 7 day sched.
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RESETCON (Temperature Reset and Demand Limit) 1 2 DESCRIPTION COOLING RESET Cooling Reset Type 3 4 5 6 7 No Cool Reset Temp Full Cool Reset Temp Degrees Cool Reset DEMAND LIMIT Demand Limit Select 8 9 10 11 12 13 14 15 16 17 18 19 20 STATUS Demand Limit at 20mA Loadshed Group Number Loadshed Demand Delta Maximum Loadshed Time Demand Limit Switch 1 Demand Limit Switch 2 LEAD/LAG Lead/Lag Enable Master/Slave Select Slave Address Lead/Lag Balance Select Lead/Lag Balance Delta Lag Start Delay DEFAULT 0
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GENUNIT (General Unit Parameters) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION Control Mode STATUS 0 = Service Test 1 = OFF - local control 2 = OFF-CCN control 3 = OFF-timeclock 4 = Emergency stop 5 = ON-local control 6 = ON-CCN control 7 = ON-timeclock Yes/No Start/Stop Normal 0-100 0-100 nn snnn.n snnn.n snnn.n snnn.n snnn.
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CIRCB 1 2 3 4 5 6 7 8 9 10 DESCRIPTION Circuit B Analog Values Percent Total Capacity Percent Available Cap Discharge Pressure Suction Pressure Saturated Condensing Tmp Saturated Suction Temp Compressor Suction Temp Suction Superheat Temp EXV % Open CIRCB 1 2 3 4 5 6 7 8 9 10 11 AN (Circuit B Analog Parameters) DESCRIPTION Circuit B Discretes Fan B1 Relay Fan B2 Relay Oil Pressure Switch Compressor B1 Relay Compressor B2 Relay Compressor B3 Relay Compressor B4 Relay Unloader B1 Relay Unloader B2 Relay H
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STRTHOUR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 DESCRIPTION Machine Operating Hours Machine Starts STATUS nnnnn nnnnn UNITS hours POINT HR MACH CY MACH Circuit A Run Hours Compressor A1 Hours Compressor A2 Hours Compressor A3 Hours Compressor A4 Hours Circuit B Run Hours Compressor B1 Hours Compressor B2 Hours Compressor B3 Hours Compressor B4 Hours nnnnn nnnnn nnnnn nnnnn nnnnn nnnnn nnnnn nnnnn nnnnn nnnnn hours hours hours hours hours hours hours hours hours hours HR HR HR
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CURRMODS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 DESCRIPTION FSM controlling chiller WSM controlling chiller Master/Slave control Low source protection Ramp Load Limited Timed Override in effect Low Cooler Suction TempA Low Cooler Suction TempB Slow Change Override Minimum OFF Time Low Suction Superheat A Low Suction Superheat B Dual Setpoint Temperature Reset Demand Limit in effect Cooler Freeze Prevention Lo Tmp Cool/Hi Tmp Heat Hi Tmp Cool/Lo Tmp Heat STATUS ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/O
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CSM/FSM EQUIPMENT TABLE (Type 621H, Block 2) LINE 1 DESCRIPTION Chiller Status 0 = Chiller is off 1 = Valid run state in CCN mode 2 = Recycle active 3 = Chiller is in Local Mode 4 = Power Fail Restart in Progress 5 = Shutdown due to fault 6 = Communication Failure unused Percent Total Capacity Running Service Runtime unused unused unused Power Fail Auto Restart Percent Available Capacity On 2 3 4 5 6 7 8 9 POINT CHILSTAT CAP T HR MACH ASTART CAP A WSM EQUIPMENT PART COOL SOURCE MAINTENANCE TABLE SUPER
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Copyright 1999 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. 533-099 Printed in U.S.A.
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CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - START-UP CHECKLIST FOR COMFORTLINK™ CHILLER SYSTEMS (Remove and use for job file) A.
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B. Preliminary Equipment Check (YES or NO) IF SO, WHERE IS THERE ANY SHIPPING DAMAGE? WILL THIS DAMAGE PREVENT UNIT START-UP? HAVE COMPRESSOR BASE RAIL ISOLATORS ALL BEEN PROPERLY ADJUSTED? CHECK POWER SUPPLY.
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CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Unit Start-Up (cont) CHECK VOLTAGE IMBALANCE: AB AC AB + AC + BC (divided by 3) = AVERAGE VOLTAGE = MAXIMUM DEVIATION FROM AVERAGE VOLTAGE VOLTAGE IMBALANCE = (MAX.
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C. Unit Start-Up (cont) TO START THE CHILLER: (insert check mark as each item is completed) TURN THE EMERGENCY ON/OFF SWITCH (SW2) TO ON POSITION. LEAVE THE ENABLE/OFF/REMOTE CONTACT SWITCH (SW1) IN THE OFF POSITION. NOTE: USE ESCAPE KEY TO GO UP ONE LEVEL IN THE STRUCTURE. USE ARROW/ESCAPE KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER KEY AND ‘DISP’ WILL BE DISPLAYED. PRESS DOWN ARROW KEY TO DISPLAY ‘UNIT’. PRESS ENTER KEY.
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CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Unit Start-Up (cont) PRESS ESCAPE KEY TO DISPLAY ‘OPT1’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT2’. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW.
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C. Unit Start-Up (cont) PRESS ESCAPE KEY TO DISPLAY ‘RSET’. PRESS DOWN ARROW KEY TO DISPLAY ‘SLCT’. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW: SLCT (Cooling Setpoint Select) DESCRIPTION STATUS = = = = DEFAULT Cooling Setpoint Select 0 1 2 3 Single Dual Switch Dual Clock 4 to 20 mA Input Ramp Load Select Enable/Disable Enable Cooling Ramp Loading 0.2 to 2.0 1.0 Deadband Multiplier 1.0 to 4.0 1.
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CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Unit Start-Up (cont) USE ESCAPE/ARROW KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER TO DISPLAY ‘DISP’. PRESS ENTER AGAIN TO DISPLAY ‘TEST’ FOLLOWED BY ‘OFF’. PRESS ENTER TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ DISPLAY FLASHES.
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Copyright 1999 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. 533-099 Printed in U.S.A.