Carrier Pro-Dialog CONTROL 4 User manual

USER'S GUIDE
TITLE: PRO-DIALOG CONTROL 4 FOR AIR & WATER COOLED
CHILLERS SERIES 30 GX & HXC VERSION 2
REV: original
Property of CARRIER S.A. Montluel.
Not to be disclosed to persons outside the organization without Written authorization
SYNOPTIQUE CARRIER - AIR-COOLED BI CIRCUIT - ABC PARTNERS 08/06/98
DATE SPECIFICATION
N° COPY N°
ECG CARRIER S.A.
ECG-UG-00-001
06/12/00

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CarrierCarrier Service1COMPANYNAMECOPY #
Ba-Tung PHAM
ORIGINATOR
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: /98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

1 - INTRODUCTION ...................................4
1.1 - About This Manual .............................4
1.2 - Manual Structure and contents ..................4
2 - GENERAL DESCRIPTION ...........................4
2.1 - Generalities ...................................4
2.1 - Software Reference Number ....................7
2.3 - Abbreviations Used ............................7
3 - HARDWARE DESCRIPTION ........................8
3.1 - Produc Component ............................8
3.1.1 - Basic Board .............................10
3.1.2 - CCN/Clock Option Board .................10
3.1.3 - Screw Compressor Protection Module .....11
3.1.3.1 - Screw Compressor Module Layout 11
3.1.3.2 - Compressor Part Number/MTA Header
Configuration ....................12
3.1.4 - 4 xDO Board ............................12
3.1.4.1 - General ........................12
3.1.4..2 - Terminal J4 Description ........12
3.1.5 - AUX Boards .............................13
3.1.5.1 - General ........................13
3.1.6 - EXV Driver Board ........................14
3.1.7 - 4 x AI - 2 x AO Board ....................14
3.1.8 - Aquasnap Basic Board ..................16
3.2 - Pressure Sensors ..............................17
3.2.1 - High Pressure Side Sensors .............17
3.2.2 - Large Band Pressure Sensors ...........17
3.2.3 - Suction and economizer Pressure Sensors 18
3.3 - Thermistors ...................................18
3.3.1 - Discharge Gas temperature ..............18
3.3.2 - 5K Resistor : Resistance vs Temperature
Curve .................................19
4 - CONTROL DESCRIPTION ..........................20
4.1 - General ......................................20
4.2 - Configuration .................................20
4.2.1 - General ................................20
4.2.2 - Main Interface Configuration sub menu
structure ...............................20
4.2.3 - Factory Configuration ...................21
4.2.3.1 - Factory configuration from Service
Tool ............................21
4.2.3.2 - Factory configuration from Main
Interface ........................23
4.2.3.3 - Economizer TQ valve Feedback
Signal Wiring ....................24
4.2.4 - Service Configuration ...................25
4.2.4.1 - Service 1 configuration from Service
Tool ............................25
4.2.4.2 - Service 1 configuration from Main
Interface ........................27
4.2.4.3 - Service 2 configuration from Service
Tool ............................28
4.2.4.4 - Service 2 configuration from Main
Interface ........................29
4.2.4.5 - Service 3 configuration from Service
Tool ............................30
4.2.4.6 - Service 3 configuration from Main
Interface ........................31
4.2.4.7 - Service 4 configuration from Service
Tool ............................31
4.2.4.8 - Service 4 configuration from Main
Interface,runtimesubmenu ......31
4.2.5 - User Configuration ......................32
4.2.6 - Network Configuration ..................32
4.2.6.1 - General .......................32
4.2.6.2 - Configuring a Control as a
Broadcast Acknowledger ........32
4.2.6.3 - Setting Time and Date ..........32
4.2.6.4 - Alarm Configuration Table ......33
4.2.6.5 - Master/Slave Configuration .....35
4.3 - Cooler Interlock Contact ........................36
4.4 - Cooler heater control ...........................36
4.5 - Oil heater control ..........................36
4.6 - Motor cooling control without plate exchanger
economizer ....................................36
4.7 - Motor cooling control without sub cooling plate
exchanger economizer ..........................37
4.7.1 - Motor cooling with TQ feedback Signal Control 37
4.8 - Capacity Control ...............................38
4.8.1 - Logic Description .......................38
4.8.1.1 - Basic Logic ...................38
4.8.1.2 - Z Multiplier Calculation ........38
4.8.1.3 - Overrides ....................39
4.9 - Compressors & loaders loading sequence .......40
4.9.1 - General Description .....................40
4.9.2 - Compressor capacity determination ......41
4.9.3 - Staged Loading Increasing Capacity Logic 41
4.9.4 - Equal Loading Increasing Capacity Logic
with close control = NO .................41
4.9.5 - Equal Loading Increasing Capacity Logic
with close control = YES ................42
4.9.6 - Equal Loading Decreasing Capacity Logic
with close control = YES ................42
4.9.7 - Equal Loading Decreasing Capacity Logic
with close control = NO .................43
4.9.8 - Staged Loading Decreasing Capacity Logic
with close control = NO .................43
4.9.9 - Staged Loading Decreasing Capacity Logic
with close control = YES ................44
4.10 - EXV Control ..................................45
4.10.1 - General ...............................45
4.10.2 - Overrides .............................45
4.11 - Air Cooled Condensing Pressure Control .......46
4.12.1 - Air Cooled Condensing Pressure Control -
Fan staging with AUX board .................46
4.12.2 - Air Cooled Condensing Pressure Control -
Fan staging ................................46
4.13 - Water Cooled Condensing Pressure Control ....47
4.14 - High Pressure Override .......................48
4.15 - High Current Override .........................48
CONTENTS
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page:2 /98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

4.16 - Stopping Function ............................48
4.16.1 - Stopping a compressor by capacity
unloading .............................48
4.16.2 - Stopping the unit by manual command
(OFF) .................................48
4.16.3 - Stopping a circuit by failure .............48
4.17 - Oil pressure control ...........................49
4.17.1 - Oil pressure setpoint determination .....49
4.17.2 - Oil pump control .......................49
4.17.3 - Low oil pressure alarm determination ....49
4.17.4 - Differential Oil Pressure Setpoint 1
alarm condition summary ...............50
4.18 - Reclaim Operation ............................51
4.18.1 - General Description ...................51
4.18.2 - Reclaim to Air Cooled Changeover
Initiation ...............................51
4.18.3 - Air Cooled To Reclaim Changeover
Initiation ...............................52
4.18.4 - Reclaim Operation hr_status
Description ............................52
4.18.5 - Reclaim Operation Using Air Cooled
Exchanger ............................52
4.18.6 - Reclaim Condenser Water Valve Control 52
4.18.7 - Reclaim Condenser Heater Control .....52
4.19 - Two Units Master/Slave Control ................53
4.19.1 - General ...............................53
4.19.2 - Abnormal Conditions ..................55
5 - CCN ALARM MESSAGES ...........................57
6 - CCN COMPATIBILITY ..............................60
7 - PRO_DIALOG 4 DOWNLOADER ADDENDUM
INFORMATION ....................................60
Appendix A - CCN DIPSLAY, SETPOINT, MAINTENANCE,
CONFIGURATION TABLE SCREENS .......61
Appendix B - CCN Variables ............................76
Appendix C - Wiring Schemes ..........................83
Appendix D - JBUS memory with GX& HX
default configuration ........................96
Appendix E - SAM Screen ..............................97
Appendix F - CCN Network Example .....................98
CONTENTS
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page:3 /98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

1 - INTRODUCTION
1.1 - ABOUT THIS MANUAL
This manual is intended to be used as an additional guide for using and configuring the Pro-Dialog control for
the 30GX & HX chillers. The use of this document does not substitute the IOM.
This manual is intended for use by Service organizations inside the Carrier corporation. It is delivered on
the express condition that it is not to be disclosed, reproduced in whole or in part, or used for
manufacture by anyone other than Carrier Corporation.
1.2 - MANUAL STRUCTURE AND CONTENTS
This manual includes the following sections:
vIntroduction
vProduct general description
vHardware description
vControl description
vAppendixes
The introduction and product general description sections contain information about this manual as an overview
of the 30GX&HX Pro-Dialog Plus controls.
The hardware section provides complete information on boards, devices and connections used by the product.
The control description section is divided in several subsections. First provides a main description of hardware
configuration. This subsection provides sufficient information to runs the control in the most operating cases. For
more complete information, use the remaining sections and also IOM. Second subsection describes all the unit
configuration and the methods to modify it. The last subsections describe the unit control logic’s.
2 - GENERAL DESCRIPTION
2.1 - GENERALITIES
PRO-DIALOG is a system for controlling units which use screw compressors:
wDual circuits
wAir cooled and water cooled chillers
wNon reversible heat machines
PRO-DIALOG controls compressors and loaders needed to maintain the desired leaving or entering water
control point. It automatically sets the position of the electronic expansion valve to maintain a correct refrigerant
flow in the cooler. For air cooled units it controls the operation of the fans to maintain the correct condensing
pressure in each circuit.
Safety circuits in the unit are constantly monitored by PRO-DIALOG to ensure its safe operation. PRO-DIALOG
also gives access to a Quick Test program covering all inputs and outputs excepted compressors outputs.
The control features of the 30GX&HX Pro-Dialog Plus are divided into standard features and options
(additional board needed):
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 4/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

Standard features:
wLocal control
wRemote control (external contacts)
wCCN control
wCompressor & loader sequence control (up to 4 compressors - two loaders per compressor)
wCooler leaving or entering fluid temperature control
wRamp loading
wDelay at startup
wCircuit & Compressors loading sequence optimization
wHeat machine condenser entering or leaving fluid control
wHead pressure control
wCooling dual setpoints control
wTemperature reset
wOutdoor temperature monitoring
wDemand limit control
wHigh pressure and high current override
wCooler and Condenser pump control
wOil temperature control
wMotor temperature control
wSafety lock control
wQuick test function
wDiagnostics function
wLocal Interface Display with Metric units
wDigital pressure gauges through the main interface
wDisplay of all I/O and other data
wCCN Network compatibility
wOccupancy and dual setpoint schedules
wSAM (LID 1B) compatibility
wAlarm POC
wSystem Manager compatibility
wIntegrated two chillers master/slave control
Available options With optional board:
wVarifan control
wCondenser water valve control
wReclaim sensors
wCooler heater control
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 5/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

xxCondenser Varifan or Water Valve
0-10 Vdc
10-0 Vdc
4-20 mA
20-4 mA
No confi
g
uration re
q
uiredOil Transducers On all com
p
ressors
xxReclaim Condenser Water Valve
xxHeat Reclaim Sensors
xxCondenser Sensors
xDela
y
at startu
p
xCooling and heating Capacity Adjustment
(
z multi
p
lier
)
xRam
p
Loadin
g
(
Heat & Cool
)
No confi
g
uration re
q
uiredSet
p
oint Control
(
sin
g
le or dual
)
xReset T
yp
e Select
(
Heat & Cool
)
xDemand Limit T
yp
e Select
xLoading Sequence
Equal
Sta
g
ed
XCondenser Pum
p
Control Select
XEnterin
g
Fluid Control
xCooler
p
um
p
#1 and # 2 control se
q
uence
xx**Water
p
um
p
p
eriodical
q
uick start se
q
uence
xx**Time and OAT broadcast ca
p
abilit
y
xx**Ni
g
ht ca
p
acit
y
limitation mode
xx**Ni
g
ht head
p
ressure control mode
xx**Unit on/off schedule control
xCom
p
ressor Number
(
1 to 4
)
& Ca
p
acit
y
xEconomizer Motor cooling TQ valve feedback
si
g
nal
xxxCooler Heater Select
xxFans
2 Separate Circuits with 1 to 8 fans per circuit
x
EXV
1500 steps = Mueller, unipolar, 33 steps/s
No confi
g
uration re
q
uiredLoader
(
2
p
er com
p
ressor
)
xCom
p
ressor Number
(
1 to 4
)
& Ca
p
acit
y
xLar
g
e Band Oil Transducer Select
xEconomizer Select
xCooler Fluid Type
Water
Medium Brine
Low Tem
p
erature Brine
xx
xHeat Reclaim Option
No confi
g
uration re
q
uiredRefri
g
erant R134
xChiller Type
Air Cooled
Water Cooled
Heat Machine
USER
CONFIG
SERVICE
CONFIG
FACTORY
CONFIG
HARDWARE
OPTION
FUNCTIONS
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 6/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

xTwo units Master/Slave Control
xFSM & CSM II Control
xClose Control Select
xMaximum Current Override
xMaximum Condensin
g
Tem
p
erature Override
USER
CONFIG
SERVICE
CONFIG
FACTORY
CONFIG
HARDWARE
OPTION
FUNCTIONS
** : require a CCN/Clock board
All Pro-Dialog controls can work either autonomously or they can be interfaced with the Carrier Comfort Network
(CCN). In the later case a communication data cable is used to connect the unit to the CCN communication bus.
When Pro-Dialog system operates autonomously it retains all of its own control capabilities but does not offer
the functionality of the CCN network.
2.2 - SOFTWARE REFERENCE NUMBER
This software is referenced under the 15 digits software reference number:
CSA-SR-208410XX
The two last digits (XX) provides the software version (e.g. 2.0).
15 digits reference number can be displayed in the CCN configuration Ctrl_ID table through the Building
Supervisor, the Network Service Tool or the 30GX&HX Downloader.
Unit Main Interface Configuration Menu allows to display the software version: item #13, user 1 menu.
2.2 - Abbreviations Used
In this manual, the refrigeration circuits are called circuit A and circuit B. The compressors in circuit A are
labeled A1, and A2. Those in circuit B are B1 and B2.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 7/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3 - HARDWARE DESCRIPTION
3.1 - PRODUCT COMPONENT
This control shall employ the following electronic modules:
Basic Board 32 GB 500 182 EE
NRCP Board 32 GB 500 052 EE
CCN and RTC Board 32 GB 500 062 EE
4 x DO Board (087) OP 12AS 004 EE
4xAI - 2xAO Board OP 12AS 005 EE
8 x DO Board (Auxiliary 2) 32 GB 500 312 EE
8xDO - 4xAI - 2xAO Board (Auxiliary 1) 32 GB 500 322 EE
EXV Board 32 GB 500 192 EE
Screw Compressor Protection Module 32 GB 500 232 EE
Local Interface Device 30GX dual circuits 32 GB 500 092 EE
Local Interface Device 30HX dual circuits 32 GB 500 112 EE
Local Interface Device 30GX single circuit 32 GB 500 082 EE
Local Interface Device 30HX single circuit 32 GB 500 102 EE
This control shall employ the following sensors modules:
Thermistors HH79NZ047C (small size)
HH79NZ059C (large size)
Low Pressure Transducer OP12DA040 EE
High Pressure Transducer OP12DA039 EE
Large Band Oil transducer OP12DA057 (for unit operating in low ambient)
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 8/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

COMPONENT USAGE
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
AUX 1 BOARD
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
4 x AI-2xAO BOARD
2
[
2
]
2
[
2
]
2
[
2
]
1PD4 - EXV BOARD
4321PD4 - SCPM BOARD
1111PD4 - BASIC BOARD
4321
NUMBER OF COMPRESSORS
COMPONENTS
UNIT TYPE : WATER COOLED
2
[
1
]
2
[
1
]
2
[
1
]
1
[
1
]
AUX 1 BOARD
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
4 x AI-2xAO BOARD
1
[
4
]
1
[
4
]
1
[
4
]
1
[
4
]
NRCP BASIC BOARD
1
[
3
]
1
[
3
]
1
[
3
]
1
[
3
]
AUX 2 BOARD
(
8xDO
)
1
[
3
]
1
[
3
]
1
[
3
]
2
[
3
]
4x DO BOARD
2
[
2
]
2
[
2
]
2
[
2
]
1PD4 - EXV BOARD
4321PD4 - SCPM BOARD
1111PD4 - BASIC BOARD
4321
NUMBER OF COMPRESSORS
COMPONENTS
UNIT TYPE : AIR COOLED - 2 FAN STAGES PER CIRCUIT MAX
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
AUX 1 BOARD
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
4 x AI-2xAO BOARD
1
[
4
]
1
[
4
]
1
[
4
]
0NRCP BASIC BOARD
1
[
3
]
1
[
3
]
1
[
3
]
1
[
3
]
AUX 2 BOARD
(
8xDO
)
2
[
3
]
2
[
3
]
2
[
3
]
2
[
3
]
4x DO BOARD
2
[
2
]
2
[
2
]
2
[
2
]
1PD4 - EXV BOARD
4321PD4 - SCPM BOARD
1111PD4 - BASIC BOARD
4321
NUMBER OF COMPRESSORS
COMPONENTS
UNIT TYPE : AIR COOLED - MORE THAN 2 FAN STAGES (if no AUX board) or MORE
THAN 4 FAN STAGES
(
AUX BOARD
)
PER CIRCUIT
1 - additional 4 x AI - 2 x AO board or 8xD0-4xAI-2xAO board required for varifan or reclaim sensors or
water valve option
2 - Second EXV board is required for motor cooling using EXV valve on economizer units
3- 4xDO board or 8xDO board is required to control fans. 4xDO is also used to control hot gas bypass
valve on units with single compressor.
4-additional NRCP board is required for reclaim option or cooler heater option.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 9/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.2 - Basic Board
The PD4 - Basic board is 24VAC power supplied. It contains 8 Discrete Inputs (Switch type), 8 Digital Outputs (5
triacs and 3 relays), 10 Analog Inputs (five thermistors and four pressure transducers) and 1 analog input (0-10
Vdc) . See the schemes in Appendix E. The software is contained in a Flash EPROM (downloadable only with
Downloader). All the setpoints, runtime and configuration parameters are contained in an EEPROM (data
storage at power down).
AllSafety Critical Signal (for Contactor Failure)26J3
AllAlarm Circuit B25J3
AllAlarm Circuit A24J3
Air cooledOil Heater Circuit B23J2
Air cooledOil Heater Circuit A22J2
All excepted air cooled without
reclaim option
Condenser Pump21J2
AllCooler Pump #220J2
AllCooler Pump #119J2
AllCooler pump default18J5
All excepted air cooled without
reclaim option
Condenser flow switch17J5
AllElectrical box thermostat & network power reverse
phase detection
16 a & 16 bJ5
AllCooler flow switch & customer interlock (lock_1)15 a & 15 bJ4 & J5
AllDemand limit switch14J4
All excepted heat machineHeat Reclaim switch13J4
Heat machineHeat Cool switch13J4
AllDual setpoint switch12J4
AllRemote Control switch status11J4
All0-10 VDC setpoint reset signal or demand limit signal10J8
AllCircuit B suction pressure9J7D
AllCircuit B discharge pressure8J7C
AllCircuit A suction pressure7J7B
AllCircuit A discharge pressure6J7A
Water cooled and heat pumpCondenser entering water temperature
5
J6
Water cooled and heat pumpCondenser leaving water temperature
4
J6
Ai
r coo
l
e
d
Outside Temperature4J6
Master/SlaveMaster/Slave common piping fluid temperature3J6
AllCooling entering water temperature2J6
AllCooling leaving water temperature1J6
UNIT TYPEFUNCTIONCHANNELTERMINAL
3.2 - CCN/Clock Option Board (factory installed)
The PD4 - Global chiller controller has a small option board that can be connected to the Basic Board via a
single 10 pin header and 4 metal standoff. This option board contains one RS-485 driver for CCN
communication, a real time clock and super cap for two weeks backup. There are two connectors for CCN. One
is a 3 pin screw connector ( 1= + signal, 2 = ground signal, 3 = - signal) and the other is a 6 pins phone jack.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 10/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.3 - Screw Compressor Protection Module
This board shall monitor compressor pressure transducer, temperature sensors, oil level, high pressure switch,
motor cooling solenoids, oil pumps, motor current, compressor wye-delta startup and compressor protection.
3.3.1 Screw Compressor Module Layout
N.B :Only Y✁
✁✁
✁dip switch of the 4 is used to configure start-delta startup procedure (when in ON
position), the 3 others shall remain OFF ! If not, MTA header configuration alarm will occur.
Oil
p
ressure0-5V
p
ressure transducer44J10B Economizer
p
ressure0-5V
p
ressure transducer33J10A Dischar
g
e Gas Tem
p
erature5K thermistor22J9 Com
p
ressor tem
p
erature5K thermistor11J9 Usual FunctionsT
yp
eChannel#AI #*Connector
Current Phase #3Current sensor 3-3J8 Current Phase #2Current sensor 2-2J8 Current Phase #1Current sensor 1-1J8 Usual FunctionsT
yp
eChannel#CT #*Connector
Oil levelDr
y
contact62J6 Hi
g
h PressureDr
y
contact51J7 Main FunctionsT
yp
eChannel#DI #*Connector
Loader #2
24VAC, 10VA
Triac118J2 Loader #1
24VAC, 10VA
Triac107J2
Motor cooling #2 or economizer valve for
circuit which has 2 com
p
ressors
24VAC, 10VA
Triac146J2 Motor coolin
g
#1
24VAC, 26 VA
Triac135J2 Oil solenoid
24VAC ,10VA
Triac124J2 Oil
p
um
p
115VAC,145VA,-
Triac93J4 Com
p
ressor out
p
ut “Y”
115VAC, 70VA,
Rela
y
/TRiac82J3 Com
p
ressor out
p
ut “D”
115VAC, 250VA
Rela
y
/Triac71J3
Main FunctionsLoad max
(
Volta
g
e
,p
ower
)
TypeChannel#DO #*Connector
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 11/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.3.2- Compressor Part Number / MTA header configuration
0
0
0
1
0
1
0
1
92
39
06NW2146S7N
0
0
0
1
1
1
1
1
112
46
06NW2174S7N
0
0
1
0
1
0
1
1
136
56
06NW2209S7N
0
1
0
0
1
0
1
0
198
80
06NW2300S7N
0
0
1
0
0
0
0
0
114
39
06NA2146S7N
0
0
1
1
1
0
0
1
164
66
06NW2250S7N
0
0
1
0
1
1
1
0
142
46
06NA2174S7N
0
0
1
1
1
1
0
0
170
56
06NA2209S7N
0
1
0
1
0
1
0
0
218
80
06NW2300S5E
0
1
0
0
1
1
0
1
204
66
06NA2250S7N
0
1
0
1
1
1
1
1
240
80
06NA2300S5N
0
1
1
1
1
1
0
0
298
80
06NA2300S5E
Compressor MTA Header Config
MSB(8 . . . . . . . 1) LSB
MTA
(for 400V)
TonsCompressor phase 3 Part Number
3.1.4 - 4xDO BOARD
The 4xDO board has 4 digital outputs capable of switching 24 VAC at 1 amp numbered from 1 to 4 on connector
J4. They have a common point numbered 12 on connector J4.
D0 #1 and Do # 2 shall support 1 fan
D0 #3 shall support 1 fan if circuit has less than 5 fans. It shall support 2 fans if circuit has more than 4 fans.
D0 #4 shall support 1 fan if circuit has less than 6 fans. It shall support
2 fans if circuit has 6 fans.
3 fans if circuit has 7 fans.
4 fans if circuit has 8 fans.
3.1.4.2 - Terminal J4 Description
12
1212
12 12
1212
1211
1111
11
DO #4
DO #4DO #4
DO #4
DO #3
DO #3DO #3
DO #3
DO #2
DO #2DO #2
DO #2
DO #1
DO #1DO #1
DO #1
24 VAC DO
24 VAC DO24 VAC DO
24 VAC DO
POWER SUPPLY
POWER SUPPLYPOWER SUPPLY
POWER SUPPLY
TRIAC
TRIACTRIAC
TRIAC
TRIAC
TRIACTRIAC
TRIAC
TRIAC
TRIACTRIAC
TRIAC
TRIAC
TRIACTRIAC
TRIAC
TO CONTACTOR # 1
TO CONTACTOR # 1TO CONTACTOR # 1
TO CONTACTOR # 1
TO CONTACTOR # 2
TO CONTACTOR # 2TO CONTACTOR # 2
TO CONTACTOR # 2
TO CONTACTOR #3 (or and #4)
TO CONTACTOR #3 (or and #4)TO CONTACTOR #3 (or and #4)
TO CONTACTOR #3 (or and #4)
TO OTHER CONTACTORS
TO OTHER CONTACTORSTO OTHER CONTACTORS
TO OTHER CONTACTORS
pins 12 are connected together
pins 12 are connected togetherpins 12 are connected together
pins 12 are connected together
4
44
43
33
32
22
21
11
1TERMINAL J4
TERMINAL J4TERMINAL J4
TERMINAL J4
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 12/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.1.5 - AUX Boards
3.1.5.1 - General
R S V
CH
4
J7
CH
1
--
R S V
--
J2
--
CH13
75 mm
(2.95
in)
CH
3
J4
CH
2
PD4-AUX1
--
------
32GB 500 322 EE
-- G +
12
STATUS
--
T
P
V
CH13
CEPL130487-01
J3
CH
12
J1
24VAC
--
------
SIO
J9
143 mm ( 5.60 in )
SIO
CH
11
--
11
CH
10
--
J5
T
P
V
CH14
l
3 2 1
--
3 2 1
CH
8
--
-- G +
CH
7
--
J6
CH14
CH
6
l
--
J8
CH
5 CH
9
The AUX1 board shall allow:
wthe control of 1 to 8 fan stages;
wthe monitoring of 4 temperatures or 2 temperatures and 2 pressures.
wthe control of 2 Varifan or two water valves
The AUX2 board shall allow:
wthe control of 1 to 8 fan stages.
Discrete outputs requirements: AUX1 and AUX2
Fan 8 - circuit A
,
4 or 8 circuit B88
Fan 7 - circuit A , 3 or 7 circuit B/Reclaim option,
condenser heater
77
Fan 6 - circuit A
,
2 or 6 circuit B66
Fan 5 - circuit A
,
1 or 5 circuit B/ Reclaim valve B55
J3
Fan 4 - circuit A or circuit B/ Pum
p
down valve B44
Fan 3 - circuit A or circuit B33
Fan 2 - circuit A or circuit B/ Reclaim valve A22
Fan 1 - circuit A or circuit B/ Pum
p
down valve A11
J2
AUX1
&
AUX2
Main FunctionsChannel#DO #ConnectorBoard
All are standard 24 VAC/±10%. All 24Vac common ground must be connected together on board and to 24Vac
ground pin of J1. All DO’s total consomption = 115VA
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 13/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.1.6 - EXV BOARD
The EXV board shall be able to control 2 EXV’s and 2 thermistors.
Analog inputs requirements
Economizer Motor Coolin
g
T
Q
Valve Feedback Si
g
nal Circuit B5/10 K thermistor2J3
(
TH B
)
Economizer Motor Coolin
g
T
Q
Valve Feedback Si
g
nal Circuit A5/10 K thermistor1J3
(
TH A
)
Usual FunctionsTypeAI
#*
Connector
Discrete output requirements
The EXV board shall be able to drive both unipolar and bipolar stepper motors via a common connector. The
default configuration shall be unipolar, 30 steps/s step rates and 1500 steps range such as to allow easy retrofit
with Pro-Dialog phase 1, 2 and 3 units fitted with Mueller Brass EXV’s. It shall be able to handle 12V @ 0.5 A per
coil and maintain a step rate of at least 200 steps per second (unipolar or bipolar).
Note: board shall be able to handle a total coil load of 1 Amp for unipolar and 2 Amps for bipolar.
Connection to the EXV shall be done through two Molex, 5 pin, 3.91 pitch (one per EXV) [J2A & J2B].
12VDC (for unipolar stepper motor)Coil 4Coil 3Coil 2Coil 1 54321 Connector J2A & J2B - Pins description
3.1.7 - 4xAI-2xAO BOARD
This board provides 4 analog inputs (labeled AI #1, AI #2, AI #3, and AI #4 on the terminal J2) and 2 analog
outputs (labeled AO #1 and AO #2 on the terminal J1). It allows to use the following features:
wOptional reclaim thermistors when reclaim option is not used
wRemote discharge transducer on remote condenser on split units.
wOptional varifan on air cooled units or water valve on water cooled units
Each input can be independently configured with a bridge allowing to close 3 pair of pins named T,C or V.
V: Transducers 5 Volts power supply
1: Signal
R: -
V - 1 - RPressure transducer
(remote discharge
pressure circuit B)
V
Carrier thermistor: HH 79NZ 047, 5K@ 25°C1 - RunusedT,C
AI #2
V: Transducers 5 Volts power supply
1: Signal
R: -
V - 1 - RPressure transducer
(remote discharge
pressure circuit A)
V
unused1 - RunusedT,C
AI #1
REMARKSPINSFUNCTIONBRIDGE
POSITION
ANALOG
INPUT
J2
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 14/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

1: +
R: -
1 - RunusedC
V: Transducers 5 Volts power supply
1: Signal
R: -
V - 1 - Rnot usedV
Carrier thermistor: HH 79NZ 047, 5K@ 25°C1 - RReclaim entering
thermistor
T
AI #4
1: +
R: -
1 - RunusedC
V: Transducers 5 Volts power supply
1: Signal
R: -
V - 1 - Rnot usedV
Carrier thermistor: HH 79NZ 047, 5K@ 25°C1 - RReclaim leaving
thermistor
T
AI #3
REMARKSPINSFUNCTIONBRIDGE
POSITION
ANALOG
INPUT
J2
Each output can be independently configured with a bridge allowing to close 2 pair of pins named C or V.
6: +
R: -
6 - R4 - 20 mA Varifan
circuit B
C
6: +
R: -
6 - R0-10 Vdc Varifan circuit
B
V
AO #2
5: +
R: -
5 - R4 - 20 mA Varifan
circuit A or water valve
C
5: +
R: -
5 - R0- 10 Vdc Varifan circuit
A or water valve
V
AO #1
REMARKSPINSFUNCTIONBRIDGE
POSITION
ANALOG
OUTPUT
J1
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 15/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.1.8 - Aquasnap Basic Board
This board is used on global chiller as slave board for air cooled units with reclaim option or cooler heater option.
It contains 8 Discrete Inputs (switch type), 10 Digital Outputs (8 triacs and 2 relays), 6 Analog Inputs (four 5K or
10K thermistors and two active pressure transducer types) and 1 analog output (0-10 Vdc).
Cooler heater option, condenser and cooler
refri
g
erant isolation solenoid circuit B
Relay outputDO_1025
Cooler heater option, condenser and cooler
refri
g
erant isolation solenoid circuit A
Relay outputDO_924
Cooler heater out
p
utTriacDO 823
unusedTriacDO
_
722
Reclaim o
p
tion
,
p
um
p
down solenoids circuit BTriacDO 621
Reclaim o
p
tion,
p
um
p
down solenoids circuit ATriacDO
_
520
Reclaim o
p
tion
,
condenser heaterTriacDO 419
unusedTriacDO 318
reclaim option or cooler heater option, circuit B,
refrigerant condenser entering solenoid
TriacDO_24
17
reclaim option or cooler heater option, circuit A,
refri
g
erant condenser enterin
g
solenoid
TriacDO_13
0
unusedRela
y
in
p
utDI’s08 to 15
Reclaim o
p
tion, condenser water valve0 - 10 VdcAO
_
107
Reclaim o
p
tion
p
um
p
down
p
ressure circuit BPressure transducer 0 - 5 VdcAI 606
Reclaim o
p
tion
p
um
p
down
p
ressure circuit APressure transducer 0 - 5 VdcAI
_
505
unusedThermistor 5K or 10KAI 303
,
04
Reclaim o
p
tion enterin
g
tem
p
eratureThermistor 5K or 10KAI 202
Reclaim o
p
tion leavin
g
tem
p
eratureThermistor 5K or 10KAI
_
101
FUNCTIONT
yp
eI/OChannel Number
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 16/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3.2 - Pressure sensors
They are used to measure in each circuit :
wDischarge gas pressure
wSuction pressure
wEconomizer pressure
and in each compressor :
wOil pressure
wEconomizer pressure on first compressor and also in the second compressor if unit is not equipped
with economizer
They are electronic sensors which linearise the output signal and deliver a 0 to 5 Vdc to either the basic board or
to an analog board. Three types of sensors are used.
3.2.1 - High pressure side sensors
They are used to measure discharge pressure and oil pressures when large band oil pressure transducer is not
selected. Carrier part: OP12DA039
High pressure side transducer curve
3.2.2 - Large band pressure sensors
They are used to measure oil pressures for unit operating with low ambient (when large band oil pressure
transducer is selected). Carrier part: OP12DA057
Large band oil pressure transducer curve
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 17/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION
50 100 150 200 250 450 500
689 2068 2414 3103
2758
4
2
0
Voltage (VDC)
Voltage (VDC)Voltage (VDC) Voltage (VDC)
kPa
PSI
3
1
5
3447
1724
345 1034 Pressure
PressurePressure
Pressure
1379 350
300 400
-6.6 100 155 420 500
1904 2252 2895
2670
4
2
Voltage (VDC)
Voltage (VDC)Voltage (VDC) Voltage (VDC)
kPa
PSI
3
1
5
3447
1484
-45 689 Pressure
PressurePressure
Pressure
1068 327
276 387
50
345
215

3.2.3 - Suction Pressure and Economizer Pressure sensors
These are in the low pressure side. Suction pressure transducer takes the place of the low pressure switches,
low pressure gauges and the low pressure safety switch (where these are usually fitted). Economizer pressure is
used to measure the intermediary pressure between low and high pressure. The oil pressure is subtracted from
this pressure to determine the oil differential pressure for oil pressure safety purpose.
Carrier part: OP12DA040
Low pressure transducer curve
3.3 - THERMISTORS
All thermistor, excepted the reset sensor, have similar characteristics (see next page).
They have Carrier Part No. HH 79 NZ 047
3.3.1 - Discharge gas temperature
This is installed on the discharge pipe of each compressor. It is used to control the discharge superheat. The
discharge gas temperature (lowest discharge compressor temperature or average discharge temperature of both
compressors) is subtracted to the saturated condensing temperature to determine the discharge superheat.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 18/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION
20 40 60 80 100 180 200
276 828 965 1241
1103
4
2
0
Voltage (VDC)
Voltage (VDC)Voltage (VDC) Voltage (VDC)
kPa
PSI
3
1
5
1379
689
138 414 Pressure
PressurePressure
Pressure
552 140
120 160

5K Resistor: Resistance vs Temperature Curve
60
2
,
4
80,0
1
69
4
,0
5
2
,0
5
2
03,
224
,0
2
0
0
7
5,9
-4
,0
612
,
679
,
51 725
,
151
,
55 321
,
223
,
520 606
,
4-4
,
52
85,
21
0
7
,0
6
2
3,
27
9,0
1 7
56,8
5
1
,0
5
442
,
22
3,0
21 1
5
2
,6
-
5,0
292
,
1106
,
5634
,
078
,
51 789
,
150
,
55 566
,
422
,
521 715
,
7-5
,
52
98,6
1
06,0
6
4
5,
27
8,0
1
8
22
,
1
50,0
5
693,9
22
,0
22 2
95,6
-
6,0
305
,
3105
,
5656
,
877
,
51 855
,
749
,
55 824
,
621
,
522 893
,
2-6
,
5
3
11
,6
1
05,0
668,6
77
,0
1
890,
14
9,0
5
958,
721
,0
2
3
509,0
-7
,0
317
,
9104
,
5680
,
876
,
51 925
,
148
,
56 096
,
320
,
524 143
,
6-7
,
5
3
2
3,8
1
0
4
,0
693,3
7
6,0
1
960,9
4
8,0
6
2
3
7
,5
2
0,0
24 7
9
7
,8
-
8,0
329
,
7103
,
5706
,
175
,
51 997
,
447
,
56 382
,
319
,
525 472
,
2-8
,
5
335,3
1
03,0
71
9,
27
5,0
2
03
4
,
747
,0
6
530,9
1
9,0
2
6
1
6
7
,5
-
9,0
341
,
1102
,
5732
,
674
,
52 072
,
846
,
56 683
,
418
,
526 884
,
4-9
,
5
3
4
6,3
1
0
2
,0
74
6,5
74
,0
2 111
,
74
6,0
6
839,8
1
8,0
27
6
2
3,8
-1
0,0
351
,
5101
,
5760
,
673
,
52 151
,
545
,
57 000
,
317
,
528 386
,
3-10
,
5
356,
71
0
1
,0
77
5,0
7
3,0
2 1
9
2
,
24
5,0
7164.917
,0
2
9
172
,
7-11
,0
361
,
6100
,
5789
,
872
,
52 233
,
844
,
57 333
,
916
,
529 984
,
0-11
,
5
366,5
1
00,0
80
4
,8
72
,0
2 27
6,3
44
,0
7
50
7
,
21
6,0
30
8
21
,0
-12
,0
371
,
199
,
5820
,
271
,
52 319
,
943
,
57 685
,
115
,
531 684
,
6-12
,
5
3
7
5,8
99,0
836,0
71
,0
2
36
4
,
44
3,0
7
86
7
,
71
5,0
3
2
5
7
5,6
-1
3,0
380
,
398
,
5952
,
070
,
52 410
,
042
,
58 055
,
014
,
533 495
,
2-13
,
5
38
4
,
7
98,0
868,
47
0,0
2 4
56,6
42
,0
8
247
,
214
,0
3
4 444
,
2-14
,0
389
,
097
,
5885
,
169
,
52 504
,
441
,
58 444
,
513
,
535 423
,
7-14
,
5
393,3
9
7
,0
90
2
,
1
69,0
2
553,3
41
,0
8
4
69,9
1
3,0
36
4
3
4
,
7-1
5,0
397
,
696
,
5919
,
468
,
52 603
,
440
,
58854.712
,
537 478
,
4-15
,
54
0
1
,8
96,0
93
7
,
1
68,0
2
65
4
,
74
0,0
9068.012
,0
38
555,9
-1
6,0
406
,
095
,
5955
,
167
,
52 707
,
239
,
59287.011
,
539 668
,
3-16
,
541
0,3
95,0
9
7
3,
4
6
7
,0
2 7
6
1
,
1
39,0
9
5
11
,
711
,0
4
0
8
1
6,9
-17
,0
414
,
594
,
5992
,
166
,
52 816
,
238
,
59742.510
,
542 002
,
9-17
,
541
8,8
9
4
,0
1
0
11
,0
66,0
2
8
72
,8
38,0
9979.31
0,0
4
3
227
,6
-1
8,0
423
,
093
,
51 030
,
365
,
52 930
,
737
,
510 222
,
69.544 492
,
4-18
,
5427
,
4
93,0
1
050,0
65,0
2
990,
1
3
7
,0
1
0
472
,3
9.04
5
7
98,6
-1
9,0
431
,
892
,
51 069
,
964
,
53 051
,
036
,
510 728
,
88
,
547 147
,
7-19
,
54
36,3
9
2
,0
1
090,
2
6
4
,0
3
11
3,
4
36,0
1
0
99
2
,
1
8,0
4
8
5
41
,
1-2
0,0
440
,
991
,
51 110
,
963
,
53 177
,
535
,
511 262
,
77
,
549 980
,
4-20
,
544
5,
7
9
1
,0
1 1
3
1
,8
63,0
3
24
3,
1
35,0
11
5
4
0,5
7.0
5
1 4
6
7
,0
-21
,0
450
,
690
,
51 153
,
262
,
53 310
,
434
,
511 826
,
06.553 002
,
7-21
,
54
55,6
90,0
1 174
,8
6
2
,0
3
3
7
9,
4
3
4
,0
12 11
9,
2
6,0
5
4
589,
1-22
,0
460
,
889
,
51 196
,
961
,
53 450
,
233
,
512 420
,
55
,
556 227
,
9-22
,
54
66,
1
89,0
1 21
9,3
6
1
,0
3
5
22
,9
33,0
12 7
30,
1
5,0
5
7
9
2
0,9
-2
3,0
571
,
688
,
51 242
,
160
,
53 597
,
332
,
513 048
,
34.559 670
,
0-23
,
5477
,
4
88,0
1 2
65,
2
60,0
3
6
7
3,
7
3
2
,0
1
3
3
7
5,3
4
,0
6
1 47
6,9
-24
,0
483
,
287
,
51 288
,
759
,
53 752
,
131
,
513 711
,
43
,
563 343
,
7-24
,
54
89,
4
8
7
,0
1
3
12
,6
59,0
3
83
2
,5
3
1
,0
14
056,9
3
.
0
65
272
,
4-2
5,0
495
,
786
,
51 336
,
958
,
53 915
,
030
,
514 412
,
22.567 265
,
0-25
,
5
50
2
,3
86,0
1
36
1
,6
58,0
3
999,6
30,0
14 777
,5
2
,0
69
3
2
3,
7-2
6,0
509
,
285
,
51 386
,
857
,
54 086
,
329
,
515 153
,
11.571 450
,
6-26
,
5
5
1
6,
2
85,0
1 412
,3
5
7
,0
4 17
5,
42
9,0
1
5
539,5
1
,0
7
3
6
4
8,0
-27
,0
523
,
684
,
51 438
,
356
,
54 266
,
728
,
515 936
,
90
,
575 918
,
3-27
,
5
53
1
,
2
8
4
,0
1 4
6
4
,
7
56,0
4
630,
42
8,0
1
6
3
4
5,
7
0,0
7
8
2
63,9
-2
8,0
539
,
183
,
51 491
,
655
,
54 456
,
627
,
516 766
,
3-0
,
580 687
,
1-28
,
5
5
47
,
2
83,0
1
5
1
9,0
55,0
4
555,
227
,0
17 1
99,
1-1
,0
83
1
90,
7-2
9,0
555
,
782
,
51 546
,
954
,
54 656
,
426
,
517 644
,
5-1
,
585 777
,
0-29
,
5
56
4
,
4
8
2
,0
1
5
7
5,
2
5
4
,0
4 7
60,
22
6,0
1
8
1
0
2
,9
-2
,0
88
44
9,0
-
30,0
573
,
481
,
51 604
,
153
,
54 866
,
825
,
518 574
,
8-2
,
591 209
,
3-30
,
5
58
2
,8
8
1
,0
1
633,5
53,0
4
9
7
6,0
2
5,0
1
9
060,6
-
3,0
9
4
060,8
-
3
1
,0
592
,
480
,
51 663
,
552
,
55 088
,
124
,
519 560
,
8-3
,
597 006
,
4-31
,
5
60
2
,
4
80,0
1
69
4
,0
5
2
,0
5
2
03,
224
,0
2
0
0
7
5,9
-
3,5
1
00
0
4
9,0
-
3
2
,0
(
OHMS
)
(
°C
)
(
OHMS
)
(
°C
)
(
OHMS
)
(
°C
)
(
OHMS
)
(
°C
)
(
OHMS
)
(
°C
)
Resistanc
e
Temp.Resistanc
e
Temp.Resistanc
e
Temp.Resistanc
e
Temp.Resistanc
e
Temp.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 19/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION