COPY N°

ECG-UG-00-001 ECG CARRIER S.A.

SPECIFICATION
N°

06/12/00
DATE

USER'S GUIDE

TITLE: PRO-DIALOG CONTROL 4 FOR AIR & WATER COOLED

CHILLERS SERIES 30 GX & HXC

SYNOPTIQUE CARRIER - AIR-COOLED BI CIRCUIT - ABC PARTNERS 08/06/98

REV: Original

Property of CARRIER S.A. Montluel.

Not to be disclosed to persons outside the organization without Written authorization
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: /89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

ORIGINATOR Ba-Tung PHAM

COPY # NAME COMPANY

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

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page:2 /89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

CONTENTS

1 - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 - About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4.2.4.7 - Service 4 configuration from Service
1.2 - Manual Structure and contents . . . . . . . . . . . . . . . . . 4 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.4.8 - Service 4 configuration from Main
2 - GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 4 Interface, runtime sub menu . . . . . 31
2.1 - Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 - Software Reference Number . . . . . . . . . . . . . . . . . . 7
2.3 - Abbreviations Used . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.2.5 - User Configuration . . . . . . . . . . . . . . . . . . . . 32

3 - HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 7 4.2.6 - Network Configuration . . . . . . . . . . . . . . . . . 32

3.1 - Produc Component . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.2.6.1 - General . . . . . . . . . . . . . . . . . . . . . 32
3.1.1 - Basic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.2.6.2 - Configuring a Control as a
3.1.2 - CCN/Clock Option Board . . . . . . . . . . . . . . . . 10 Broadcast Acknowledger . . . . . . . 32
3.1.3 - Screw Compressor Protection Module . . . . . 11 4.2.6.3 - Setting Time and Date . . . . . . . . . 32
3.1.3.1 - Screw Compressor Module Layout 11 4.2.6.4 - Alarm Configuration Table . . . . . . 33
3.1.3.2 - Compressor Part Number/MTA Header 4.2.6.5 - Master/Slave Configuration . . . . . 35
Configuration . . . . . . . . . . . . . . . . . . 12
4.3 - Cooler Interlock Contact . . . . . . . . . . . . . . . . . . . . . . 36
3.1.4 - 4 xDO Board . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.4 - Cooler heater control . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.4.1 - General . . . . . . . . . . . . . . . . . . . . . . 13
4.5 - Oil heater control . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.4..2 - Terminal J4 Description . . . . . . . . 14
3.1.5 - EXV Driver Board . . . . . . . . . . . . . . . . . . . . . . 15 4.6 - Motor cooling control without plate exchanger economizer
3.1.6 - 4 x AI - 2 x AO Board . . . . . . . . . . . . . . . . . . . 16 36
3.1.7 - Aquasnap Basic Board . . . . . . . . . . . . . . . . . 18 4.7 - Motor cooling control without sub cooling plate exchanger
economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 - Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.8 - Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.1 - High Pressure Side Sensors . . . . . . . . . . . . 19 4.8.1 - Logic Description . . . . . . . . . . . . . . . . . . . . . . 37
3.2.2 - Large Band Pressure Sensors . . . . . . . . . . 19 4.8.1.1 - Basic Logic . . . . . . . . . . . . . . . . . 37
3.2.3 - Suction and economizer Pressure Sensors 20 4.8.1.2 - Z Multiplier Calculation . . . . . . . . 38
3.3 - Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.8.1.3 - Overrides . . . . . . . . . . . . . . . . . . . 38
3.3.1 - Discharge Gas temperature . . . . . . . . . . . . . 20 4.9 - Compressors & loaders loading sequence . . . . . . . 38
3.3.2 - 5K Resistor : Resistance vs Temperature 4.9.1 - General Description . . . . . . . . . . . . . . . . . . . 38
Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.9.2 - Compressor capacity determination . . . . . . 39
4.9.3 - Staged Loading Increasing Capacity Logic 40
4 - CONTROL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 22 4.9.4 - Equal Loading Increasing Capacity Logic
with close control = NO . . . . . . . . . . . . . . . 40
4.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.9.5 - Equal Loading Increasing Capacity Logic
4.2 - Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
with close control = YES . . . . . . . . . . . . . . 41
4.2.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9.6 - Equal Loading Decreasing Capacity Logic
4.2.2 - Main Interface Configuration sub menu
structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 with close control = YES . . . . . . . . . . . . . . 41
4.2.3 - Factory Configuration . . . . . . . . . . . . . . . . . . 23 4.9.7 - Equal Loading Decreasing Capacity Logic
4.2.3.1 - Factory configuration from Service with close control = NO . . . . . . . . . . . . . . . 42
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.9.8 - Staged Loading Decreasing Capacity Logic
4.2.3.2 - Factory configuration from Main
with close control = NO . . . . . . . . . . . . . . . 42
Interface . . . . . . . . . . . . . . . . . . . . . . 24
4.9.9 - Staged Loading Decreasing Capacity Logic
4.2.4 - Service Configuration . . . . . . . . . . . . . . . . . . 25
4.2.4.1 - Service 1 configuration from Service with close control = YES . . . . . . . . . . . . . . 43
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.10 - EXV Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.4.2 - Service 1 configuration from Main 4.10.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Interface . . . . . . . . . . . . . . . . . . . . . . 27 4.10.2 - Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.4.3 - Service 2 configuration from Service 4.11 - Air Cooled Condensing Pressure Control . . . . . . . 45
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4.12 - Air Cooled Condensing Pressure Control -
4.2.4.4 - Service 2 configuration from Main Fan staging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Interface . . . . . . . . . . . . . . . . . . . . . . 29 4.13 - Water Cooled Condensing Pressure Control . . . . 46
4.2.4.5 - Service 3 configuration from Service
4.14 - High Pressure Override . . . . . . . . . . . . . . . . . . . . . . 46
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.4.6 - Service 3 configuration from Main 4.15 - High Current Override . . . . . . . . . . . . . . . . . . . . . . . 46
Interface . . . . . . . . . . . . . . . . . . . . . . 31

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page:3 /89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

CONTENTS

4.16 - Stopping Function . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.16.1 - Stopping a compressor by capacity
unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.16.2 - Stopping the unit by manual command
(OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.16.3 - Stopping a circuit by failure . . . . . . . . . . . . 47
4.17 - Oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.17.1 - Oil pressure setpoint determination . . . . . 48
4.17.2 - Oil pump control . . . . . . . . . . . . . . . . . . . . . 48
4.17.3 - Low oil pressure alarm determination . . . . 48
4.17.4 - Differential Oil Pressure Setpoint 1
alarm condition summary . . . . . . . . . . . . . . 49
4.18 - Reclaim Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.18.1 - General Description . . . . . . . . . . . . . . . . . . 50
4.18.2 - Reclaim to Air Cooled Changeover
Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.18.3 - Air Cooled To Reclaim Changeover
Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.18.4 - Reclaim Operation hr_status
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.18.5 - Reclaim Operation Using Air Cooled
Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.18.6 - Reclaim Condenser Water Valve Control 51
4.18.7 - Reclaim Condenser Heater Control . . . . . 51
4.19 - Two Units Master/Slave Control . . . . . . . . . . . . . . . 52
4.19.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.19.2 - Abnormal Conditions . . . . . . . . . . . . . . . . . 54

5 - CCN ALARM MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . 56

6 - CCN COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7 - PRO_DIALOG 4 DOWNLOADER ADDENDUM

INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Appendix A - CCN DIPSLAY, SETPOINT, MAINTENANCE,

CONFIGURATION TABLE SCREENS . . . . . . 60
Appendix B - CCN Variables . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Appendix C - Wiring Schemes . . . . . . . . . . . . . . . . . . . . . . . . . 82
Appendix D - JBUS memory with GX& HX
default configuration . . . . . . . . . . . . . . . . . . . . . . . 87
Appendix E - SAM Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Appendix F - CCN Network Example . . . . . . . . . . . . . . . . . . . 89

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 4/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

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:

Y Introduction
Y Product general description
Y Hardware description
Y Control description
Y Appendixes
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:

Z Dual circuits
Z Air cooled and water cooled chillers
Z Non 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 S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 5/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

Standard features:
Z Local control

Z Remote control (external contacts)

Z CCN control

Z Compressor & loader sequence control (up to 4 compressors - two loaders per compressor)

Z Cooler leaving or entering fluid temperature control

Z Ramp loading

Z Delay at startup

Z Circuit & Compressors loading sequence optimization

Z Heat machine condenser entering or leaving fluid control

Z Head pressure control

Z Cooling dual setpoints control

Z Temperature reset

Z Outdoor temperature monitoring

Z Demand limit control

Z High pressure and high current override

Z Cooler and Condenser pump control

Z Oil temperature control

Z Motor temperature control

Z Safety lock control

Z Quick test function

Z Diagnostics function

Z Local Interface Display with Metric units

Z Digital pressure gauges through the main interface

Z Display of all I/O and other data

Z CCN Network compatibility

Z Occupancy and dual setpoint schedules

Z SAM (LID 1B) compatibility

Z Alarm POC

Z System Manager compatibility

Z Integrated two chillers master/slave control

Available options With optional board:

Z Varifan control

Z Condenser water valve control

Z Reclaim sensors

Z Cooler heater control

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 6/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

FUNCTIONS HARDWARE FACTORY SERVICE USER

OPTION CONFIG CONFIG CONFIG
Chiller Type x
Air Cooled
Water Cooled
Heat Machine
Refrigerant R134 No configuration required
Heat Reclaim Option x x x
Cooler Fluid Type x
Water
Medium Brine
Low Temperature Brine
Economizer Select x
Large Band Oil Transducer Select x
Compressor Number (1 to 4) & Capacity x
Loader ( 2 per compressor) No configuration required
EXV No configuration required
Fans x x
2 Separate Circuits with 1 to 8 fans per circuit

Cooler Heater Select x x x

Compressor Number (1 to 4) & Capacity x
Unit on/off schedule control x** x
Night head pressure control mode x** x
Night capacity limitation mode x** x
Time and OAT broadcast capability x** x
Water pump periodical quick start sequence x** x
Cooler pump #1 and # 2 control sequence x
Entering Fluid Control X
Condenser Pump Control Select X
Loading Sequence x
Equal
Staged
Demand Limit Type Select x
Reset Type Select (Heat & Cool) x
Setpoint Control (single or dual) No configuration required
Ramp Loading (Heat & Cool) x
Cooling and heating Capacity Adjustment x
(z_multiplier)
Delay at startup x
Condenser Sensors x x
Heat Reclaim Sensors x x
Reclaim Condenser Water Valve x x
Oil Transducers On all compressors No configuration required
Condenser Varifan or Water Valve x x
0-10 Vdc
10-0 Vdc
4-20 mA
20-4 mA
Maximum Condensing Temperature Override x
Maximum Current Override x
Close Control Select x

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 7/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

FUNCTIONS HARDWARE FACTORY SERVICE USER

OPTION CONFIG CONFIG CONFIG
FSM & CSM II Control x
Two units Master/Slave Control x

** : 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. 1.0).

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.

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
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
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 8/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

High Pressure Transducer OP12DA039 EE

Large Band Oil transducer OP12DA057 (for unit operating in low ambient)

COMPONENT USAGE

UNIT TYPE : WATER COOLED

NUMBER OF
COMPONENTS COMPRESSORS
2 3 4
PD4 - BASIC BOARD 1 1 1
PD4 - SCPM BOARD 2 3 4
PD4 - EXV BOARD 1 1 1
4 x AI-2xAO BOARD 1* 1* 1*

UNIT TYPE : AIR COOLED - 2 FAN STAGES PER CIRCUIT MAX

NUMBER OF
COMPONENTS COMPRESSORS
2 3 4
PD4 - BASIC BOARD 1 1 1
PD4 - SCPM BOARD 2 3 4
PD4 - EXV BOARD 1 1 1
4x DO BOARD 1 1 1
NRCP BASIC BOARD 1 ** 1 ** 1 **
4 x AI-2xAO BOARD 1* 1* 1*

UNIT TYPE : AIR COOLED - MORE THAN 2 FAN STAGES PER CIRCUIT
NUMBER OF
COMPONENTS COMPRESSORS
2 3 4
PD4 - BASIC BOARD 1 1 1
PD4 - SCPM BOARD 2 3 4
PD4 - EXV BOARD 1 1 1
4x DO BOARD 2 2 2
NRCP BASIC BOARD 1 ** 1 ** 1 **
4 x AI-2xAO BOARD 1* 1* 1*

* - additional 4 x AI - 2 x AO board is required for varifan or reclaim sensors or water valve option or
split system
** additional NRCP board is required for reclaim option or cooler heater option.

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 9/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

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).

main interface SIO BUS

plug ccn/clock board
plug

analog inputs

24VAC DO's 0-10vdc customer interlock discrete inputs

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 10/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

TERMINAL CHANNEL FUNCTION UNIT TYPE

J6 1 Cooling leaving water temperature All

J6 2 Cooling entering water temperature All

J6 3 Master/Slave common piping fluid temperature Master/Slave

J6 4 Outside Temperature Air cooled

J6 4 Condenser leaving water temperature Water cooled and heat pump

J6 5 Condenser entering water temperature Water cooled and heat pump

J7A 6 Circuit A discharge pressure All

J7B 7 Circuit A suction pressure All

J7C 8 Circuit B discharge pressure All

J7D 9 Circuit B suction pressure All

J8 10 0-10 VDC setpoint reset signal or demand limit signal All

J4 11 Remote Control switch status All

J4 12 Dual setpoint switch All

J4 13 Heat Cool switch Heat machine

J4 13 Heat Reclaim switch All excepted heat machine

J4 14 Demand limit switch All

J4 & J5 15 a & 15 b Cooler flow switch & customer interlock (lock_1) All

J5 16 a & 16 b Electrical box thermostat & network power reverse phase All
detection

J5 17 Condenser flow switch All excepted air cooled without

reclaim option

J5 18 Cooler pump default All

J2 19 Cooler Pump #1 All

J2 20 Cooler Pump #2 All

J2 21 Condenser Pump All excepted air cooled without

reclaim option

J2 22 Oil Heater Circuit A Air cooled

J2 23 Oil Heater Circuit B Air cooled

J3 24 Alarm Circuit A All

J3 25 Alarm Circuit B All

J3 26 Unused All

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.

3.3 - Screw Compressor Protection Module

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 11/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

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

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 12/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

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.

Connector AI #* Channel# Type Usual Functions

J9 1 1 5K thermistor Compressor temperature
J9 2 2 5K thermistor Discharge Gas Temperature
J10A 3 3 0-5V pressure transducer Economizer pressure
J10B 4 4 0-5V pressure transducer Oil pressure

Connector CT #* Channel# Type Usual Functions

J8 1 - Current sensor 1 Current Phase #1
J8 2 - Current sensor 2 Current Phase #2
J8 3 - Current sensor 3 Current Phase #3

Connector DI #* Channel# Type Main Functions

J7 1 5 Dry contact High Pressure
J6 2 6 Dry contact Oil level

Connector DO #* Channel# Type Load max Main Functions

(Voltage,power)
J3 1 7 Relay/Triac 115VAC, 250VA Compressor output “D”
J3 2 8 Relay/TRiac 115VAC, 70VA, Compressor output “Y”
J4 3 9 Triac 115VAC,145VA,- Oil pump
J2 4 12 Triac 24VAC ,10VA Oil solenoid
J2 5 13 Triac 24VAC, 26 VA Motor cooling #1
J2 6 14 Triac 24VAC, 10VA Motor cooling #2 or economizer
valve for circuit which has 2
compressors
J2 7 10 Triac 24VAC, 10VA Loader #1
J2 8 11 Triac 24VAC, 10VA Loader #2

3.3.2- Compressor Part Number / MTA header configuration

Compressor phase 3 Part Tons MTA Compressor MTA Header Config
Number (for 400V) MSB(8 . . . . . . . 1) LSB
06NA2300S5E 80 298 01111100
06NA2300S5N 80 240 01011111
06NA2250S7N 66 204 01001101
06NW2300S5E 80 218 01010100
06NA2209S7N 56 170 00111100
06NA2174S7N 46 142 00101110
06NW2250S7N 66 164 00111001
06NA2146S7N 39 114 00100000
06NW2300S7N 80 198 01001010
06NW2209S7N 56 136 00101011
06NW2174S7N 46 112 00011111
06NW2146S7N 39 92 00010101

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 13/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

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 shall support 1 fan
D0 #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. SIO Bus

Control LEDs

Address Selector

Digital Outputs 24 Vac Power Supply

4xDO BOARD

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 14/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

3.1.4.2 - Terminal J4 Description

DO #1 TO CONTACTOR # 1

DO #2 TO CONTACTOR # 2

DO #3 TO CONTACTOR #3 (or and #4)

DO #4 TO OTHER CONTACTORS

11 12 12 4 3 2 1 TERMINAL J4

24 VAC DO
POWER SUPPLY

TRIAC
pins 12 are connected together
TRIAC

TRIAC

TRIAC

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 15/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

3.1.5 - EXV BOARD

The EXV board shall be able to control 2 EXV’s and 2 thermistors.

Analog inputs requirements

Connect AI Type Usual Functions

or #*
J3 1 5/10 K thermistor not used
J3 2 5/10 K not used
thermistor

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].

Connector J2A & J2B - Pins description

1 2 3 4 5
Coil 1 Coil 2 Coil 3 Coil 4 12VDC (for unipolar stepper motor)

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 16/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

3.1.6 - 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:
Z Optional reclaim thermistors when reclaim option is not used
Z Remote discharge transducer on remote condenser on split units.
Z Optional 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.
J2

ANALOG BRIDGE FUNCTION PINS REMARKS

INPUT POSITION

T,C unused 1-R unused

V Pressure transducer V-1-R V: Transducers 5 Volts power supply

(remote discharge 1: Signal
AI #1
pressure circuit A) R: -

T,C unused 1-R Carrier thermistor: HH 79NZ 047, 5K@ 25°C

V Pressure transducer V-1-R V: Transducers 5 Volts power supply

(remote discharge 1: Signal
AI #2
pressure circuit B) R: -

T Reclaim leaving 1-R Carrier thermistor: HH 79NZ 047, 5K@ 25°C

thermistor

V not used V-1-R V: Transducers 5 Volts power supply

AI #3
1: Signal
R: -

C unused 1-R 1: +
R: -

T Reclaim entering 1-R Carrier thermistor: HH 79NZ 047, 5K@ 25°C

thermistor

V not used V-1-R V: Transducers 5 Volts power supply

AI #4
1: Signal
R: -

C unused 1-R 1: +
R: -

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 17/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

Each output can be independently configured with a bridge allowing to close 2 pair of pins named C or V.

J1
ANALOG BRIDGE FUNCTION PINS REMARKS
OUTPUT POSITION

V 0- 10 Vdc Varifan circuit 5-R 5: +

A or water valve R: -
AO #1
C 4 - 20 mA Varifan circuit 5-R 5: +
A or water valve R: -

V 0-10 Vdc Varifan circuit 6-R 6: +

B R: -
AO #2
C 4 - 20 mA Varifan circuit 6-R 6: +
B R: -

24 Vac Power Supply

Analog Inputs Analog Outputs

Address Selector

Control LEDs

SIO Bus
4xAI-2xAO BOARD

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 18/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

3.1.7 - 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).

Channel Number I/O Type FUNCTION

01 AI_1 Thermistor 5K or 10K Reclaim option leaving temperature
02 AI_2 Thermistor 5K or 10K Reclaim option entering temperature
03, 04 AI_3 Thermistor 5K or 10K unused
05 AI_5 Pressure transducer 0 - 5 Vdc Reclaim option pumpdown pressure circuit A
06 AI_6 Pressure transducer 0 - 5 Vdc Reclaim option pumpdown pressure circuit B
07 AO_1 0 - 10 Vdc Reclaim option, condenser water valve
08 to 15 DI’s Relay input unused
0 DO_13 Triac reclaim option or cooler heater option, circuit A,
refrigerant condenser entering solenoid
17 DO_24 Triac reclaim option or cooler heater option, circuit B,
refrigerant condenser entering solenoid
18 DO_3 Triac unused
19 DO_4 Triac Reclaim option, condenser heater
20 DO_5 Triac Reclaim option, pumpdown solenoids circuit A
21 DO_6 Triac Reclaim option, pumpdown solenoids circuit B
22 DO_7 Triac unused
23 DO_8 Triac Cooler heater output
24 DO_9 Relay output Cooler heater option, condenser and cooler refrigerant
isolation solenoid circuit A
25 DO_10 Relay output Cooler heater option, condenser and cooler refrigerant
isolation solenoid circuit B

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 19/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

3.2 - Pressure sensors

They are used to measure in each circuit :

Z Discharge gas pressure

Z Suction pressure

Z Economizer pressure

and in each compressor :

Z Oil pressure

Z Economizer 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

4
Voltage (VDC)

0 50 100 150 200 250 300 350 400 450 500 PSI
345 689 1034 1379 1724 2068 2414 2758 3103 3447 kPa
Pressure

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

4
Voltage (VDC)

-6.6 50 100 155 215 276 327 387 420 500 PSI
-45 345 689 1068 1484 1904 2252 2670 2895 3447 kPa
Pressure

Large band oil pressure transducer curve

© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION
 USER'S GUIDE FOR
CARRIER SA ECG-UG-00-001 Page: 20/89
30GX & 30 HX PRO_DIALOG 4 Rev: Original

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

4
Voltage (VDC)

0 20 40 60 80 100 120 140 160 180 200 PSI

138 276 414 552 689 828 965 1103 1241 1379 kPa
Pressure

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 S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER
ORGANIZATION