EXV problems on Carrier 30GT Chiller

[hvac-alan]

I am the third tech put on this chiller 30GT 130. Problem is that Circuit B shuts off on High Superheat, then sometimes Low Superheat, and occasionally low oil. All sensors are good. Their are two new compressors on Circuit B, New EXV, new chiller barrell. It seems as if the EXV does the opposite that it should. The previous tech told me that the EXV wire colors changed on the new EXV (brown and white??). Going back on Tuesday to run through the Carrier EXV troubleshooting guide. Any further suggestions. I am the junior guy in our shop, would like to find the solution to his growing headache.

[chilbrig]

Trace out your sensor wires and make sure the A's go to the A circuit, and the B's go to the B circuit.

[hvac-alan]

Thanks chillirig. I helped do that once, but that was before the chiller barrell was replaced--could have been swapped..

Note: I am able to see what the sensors are seeing with my DC volt meter and a chart. The unit will run for five minutes under high or low superheat conditions before shuting down. When it goes out on high superheat, the EXV actually closes completely and the compressor pulls into a vaccum.

This is a chore, but I have the software to plug into the board, just waiting on the Model 65 converter.

[double bubble]

First make sure the exv is the correct one , for some reason it's hard to get the right exv . There are two valves available a 700 step and a 1500 step valve don't quote me on exact # of steps . I have this info in my notes I'll look it up and post back .

[hvac-alan]

Thanks alot. I have read this in a previous post on this site. I am fairly certain that I need the 760 step EXV. The tech who changed the EXV told me that the wire colors in the new cable changed. He had to swap brown and white. I don't know what terminal that is but it is not common. Perhaps we do have the wrong exv. That could explain, I suppose why sometimes it locks out on High Superheat and then runs a while and then locks out on low superheat.

Another note: It was suggested that I change the board settings temporarily to allow for no unloading. The unit has 4 compressors and eight stages of cooling. With this change I have only 4 stages. All compressors come on loaded and stay that way. This appeared to help-it didn't lock out last night, but it did several times today.

[liscensed to chill]

i would have the exv board program flashed(a carrier distributor can do this). if that does not work then you can get a pressure transducer kit that replaces evap. and compressor thermistors and monitors pressure to control exv.
i have carrier part numbers if you need them.


had a30GT-150 where exv board steps did not match exv motor steps causing exv to open futher than exv percentage said (display said 20% after 4 minutes runtime but exv was actually opened at 30%

[hvac-alan]

I contacted Carrier on Friday. They gave me a software program (DOS) that could give me all the thermistor readings in real time and the position of the EXV. I need to get a Telebyte Model 65 Converter in order to hook the unit's board to the my laptop. Is this what you are referring to??? And have you done this before. Apparently I hook up to the no. 3 and 6 pins of the J8 plug on the board.

[hvac-alan]

Spoke to the tech who changed out the exv. He told me that the motor of the new exv burned out because of the water in refrigerant circuit. The chiller barrell had a crack. It was changed. Is it possible that Carrier gave him the wrong motor??? This unit needs a 760 step motor. Do all these motors look the same?? How do you distinguish between them??

[klrogers]

Originally posted by hvac-alan
I contacted Carrier on Friday. They gave me a software program (DOS) that could give me all the thermistor readings in real time and the position of the EXV. I need to get a Telebyte Model 65 Converter in order to hook the unit's board to the my laptop. Is this what you are referring to??? And have you done this before. Apparently I hook up to the no. 3 and 6 pins of the J8 plug on the board.

"Flashing" the board means that they rewrite the code onto the EPROM or whatever memory they use to store the code. The DOS program they gave you just allows you to read the sensors and EXV position directly.
Are you willing to share this DOS program with others on this site? If so my email is in the bottom left corner of my website.

Kevin

[hvac-alan]

krogers,

I sent you the attachment via email. I think that I sent it to the correct link. Let me know. According to Carrier it will let you look at all 8 thermistor temperatures without having to put a DC meter on the plug then converting it to a temp by a chart. It also lets you look at the position of the EXV. I will let you know how it works once I get the Model 65 converter. Has anyone done this before?????

[hvac-alan]

If I understand your post, it would be possible to repair the board if it is giving the wrong commands to the exv?? The board is EPROM. Not sure what that is, but I read it in the controls literature.

[ac eagle]

I just had this prblem with this chiller, !st sometimes the sensors right at one temperature and not at other temperatures, i didnt believe until I proved it it myself,then due the sensor probelm cause the Exv valve to get hung up, so we replaced the Exv powerhead,cable and board,fianlly due to the compressors running improperly due to senosrs,valve,board we change cores. After all said and the chiller has been operating fine.

[hvac-alan]

I am certain now that the sensors are working properly. Spent a good part of the day monitoring them. Saw what the board was seeing, ie a high superheat (the exv was closed completely). The valve should have opened, it didn't. The logic of the board indicates that it will allow the compressors to run with a SH of greater that 75 before shutting down on High superheat. Also saw the reverse happen several times where the board saw 0 superheat for 5minutes before shutting down on Low Superheat. The exv should have closed some to restrict the flow of refrigerant, it did not.

According to the controls manual, the board looks at 2 sensors to control the superheat with the exv. The sensors are cooler saturation temperature (located in the cooler) and the return gas (located in the compressor). It measures the temperature of the returning suction gas after it has cooled the windings to the compressor.

My thinking is that either the board or the exv are not working correctly or the cable. Would like to hold down cost for customer, they have already bought 2 compressors, exv, and chiller barrell. I am hoping that if it is the board it can be fixed (by flashing)instead of replacing.

Thanks for your input. Did you notice a change in wire colors on the new cable for the exv??????

[hvac-alan]

The original exv looks different than the replacement. Does anyone have a link to the differnet Carrier exv's????

[hvac-alan]

Would like those part numbers if you have them. Also do you have the part numbers for the different EXVs????

[klrogers]

Originally posted by hvac-alan
krogers,

I sent you the attachment via email. I think that I sent it to the correct link. Let me know. According to Carrier it will let you look at all 8 thermistor temperatures without having to put a DC meter on the plug then converting it to a temp by a chart. It also lets you look at the position of the EXV. I will let you know how it works once I get the Model 65 converter. Has anyone done this before?????

I did not receive it. email klrogers(at)ultimatehvac.com

[cool frog]

hey guys, i had the same problem with a smaller flowtronic and it was caused by the unit not configuered properly. my unit was configuered for txv's when it should have been for exv's. did you go through the service test for the exv's? hope this helped

[gyhooyabat]

hvac-alan,
what are the full model and serial numbers? Let's confirm that you have the correct controls and EXV's.

[hvac-alan]

You should have it now. It is a small DOS program. Looks like it will run on XP, though I have been told to use Windows95.

[hvac-alan]

Thanks Coolfrog:

If you are referring to going through the 42 step quick test and checking settings. I have and it gives me the code for having an EXV. I think it is step 5 and the code for EXV is 1.

The punch out settings I have not checked, but I would think that it would tell me that on the quick test.

[hvac-alan]

Hello John:

The Model and Serial number are:

30GT130610KA #4496F38497

I am going back Tuesday to go through the EXV troubleshooting guide that Carrier provides, but wanted to verify that I had the correct EXV----if not, then pumping the unit down and taking off the powerhead would be a waste of time until I got the correct Valve.

[ac eagle]

No,change in colors for the Exv cable same as old cable. As for your sensors I did the same and still could not believe bad sensors,but if your confindent then go with it..did you check for probalby restricted cores????

[hvac-alan]

Hey ac eagle:

I changed the core driers, I had a 4 degree drop across the drier plus we still had a little water in the system due to the cracked chiller barrell (the sight glass was yellow). I am going to change again on Tuesday. Sight glass is green, but not as green as the other circuit.

I certainly will not rule out the sensors, but like I say, as I was watching the sensors, ie the superheat went over 75 degrees, I would have expected the EXV to open up, but it was closed and the compressor was pulling the system into a vaccum. Same when I had 0 superheat, I would have expected the EXV to close some to raise the superheat, but it did not. The board will allow these conditions to exist for 5 minutes without locking compressor out. The exv did not react to the temperatures that I was seeing. My monitoring system was a little crude because I have to sit there and keep checking the two sensors with a DC volt meter then look at the chart that I photocopied to convert to temperature, so I might have missed some flucuations, but it is my thinking that the EXV should have reacted to the temperatures that I was seeing and it actually reacted the opposite that I would have expected.


Wire colors: I am going to check continuity of the cable and insure that white and brown were reversed, because that is what the last tech did when he changed the cable, he crossed white and brown???

[millerbug42]

Originally posted by hvac-alan
I am the third tech put on this chiller 30GT 130. Problem is that Circuit B shuts off on High Superheat, then sometimes Low Superheat, and occasionally low oil. All sensors are good. Their are two new compressors on Circuit B, New EXV, new chiller barrell. It seems as if the EXV does the opposite that it should. The previous tech told me that the EXV wire colors changed on the new EXV (brown and white??). Going back on Tuesday to run through the Carrier EXV troubleshooting guide. Any further suggestions. I am the junior guy in our shop, would like to find the solution to his growing headache.

I have had 3 differant parts go bad on this model chiller over a 5 year period. #1 driver board fuse #2 driver board and #3 processor board.. All three times the same diagnostics was just like your discription of problem.

Don Miller

[mmc]

I believe the name of the software you're talking about is Flotronic Manager. It's a DOS program that I run in WIN 98. The beauty is that you're able to see what the microprocessor sees. You may think the setpoint dial set at 45 but when you run FM, you see that the Micro is seeing the setpoint at 38 or 55 or whatever. Your voltage drop might tell you it's seeing 75 degree SH but when you run FM, you might see that it's only seeing 29.

It's a great program and it really helps troubleshoot the chiller. No more guessing. Get the ground loop converter and get connected.

[hvac-alan]

Thanks mmc

I havent got the converter yet, but I have the instructions to connect to the J8 plug. Do I hook the converter to my 9 pin serial port???? Where do you connect yours. Also, will this program work with XP, I have opened it in XP and manuvered to the temperature screen, but I am not connected to the microprocessor board.

[joeywpittman]

can you email me that program
Thanks
joeywpittman@hotmail.com

[hvac-alan]

You should have it. Let me know.

Alan

[hvac3901]

me too me too,

[Edited by hvac3901 on 09-05-2005 at 11:45 AM]

[hvac-alan]

I do not think that I have a driver board on this unit. The micro processor controls the exv directly. But just in case I am misinformed, what are you calling the driver board?? and where is the fuse??? It would be great if it was just a fuse.

Presently, I have 3 possible culprits:

1. The board or software that controls the exv
2. The exv or maybe the wrong exv
3. The wiring to the exv, --the cable

Of coarse, still could be the thermistors, but I haven't seen that. Some are new.

I think that the driver boards came with Flowtronic II, this unit is Flowtronic I. Any input on this assumption??

[hvac3901]

i sent you an email, had a little trouble on my end of it with outlook. could you please send one more time

[hvac-alan]

You should have it now. I sent the program to ultimatehvac.com. Hopefully he will be able to post in on the internet so I can link it in this post. I am no computer guru, but I think that it would be helpful since several people have indicated an interest in the program. Perhaps some that have actually used it can give some more detailed instructions on hooking it up. If the program works as I have been told, it will be very helpful and save a bunch of time.

[hvac3901]

to the best of my knowledge you do have to use the older windows version for alot of carrier stuff, i believe it has to do with com port settings and conflicts.

hooking it up is no problem, just use the designated connection and three wires out of a standard phone cable, rj-11. i dont remember the exact connection points / colors. i will look into it i think i might be able to find it, besides that i thought it was mentioned in the o&m

[mmc]

OK hvac-alan,

First contact Telebyte @ 800-835-3298. Order a M/N 65A or you can go to their website ( http://www.telebyteusa.com ) and order it. It is an external powered Ground Loop Converter. Power it up per the directions in the box.

When you start Flotronic Manager, on the first page on the right side it tells you how to connect. You're going to connect from plug J8 on the Flotronic to the Telebyte 4-20 GLC so follow that connection diagram. Connect two wires to your 6 pin plug at pin number 3 and 6 then connect the other end to your GLC at C+ and C-. Don't worry, everything is labeled. It sounds harder than it really is.

Once you get wired, just plug in your 6 pin connector onto plug J8 on the board and plug your GLC into your laptop. I use a 25 X 9 pin converter then a gender bender to get to my serial port.

Fill in M/N and S/N and your name for operator ID then make sure all your configurations are correct then press Enter. If you are communication correctly, the cursor will rotate every few seconds.

It shows Entering Water Temp, Leaving Water Temp, Leaving Water Setpoint, Cir A and B Ret Gas Tmp, Sat Sct Tmp,Superheat, EXV Calibration, EXV actual Position, Sat Cond Tmp, Liq Line Sol, and if your oil pressure switch is made. It shows which compressors are running: A1 A2 A3 A4 B1 B2 B3 B4.It also shows which fans are running on Cir A and Cir B. It also shows any alarms. Like I said, its a great little program. You see exactly what the microprocessor is seeing.

Good luck. Let me know if you have any other questions.

Mark Mc

[hvac-alan]

[QUOTE]Originally posted by mmc
[B]OK hvac-alan,

Once you get wired, just plug in your 6 pin connector onto plug J8 on the board and plug your GLC into your laptop. I use a 25 X 9 pin converter then a gender bender to get to my serial port.

MMC

That is great information. The above is the part that I am not clear on. I have a nine pin serial port adapter that I use for Comfortview. Can I use a phone cord to connect from this adapter to the Model 65A????? I suppose it may be clear once I get the converter, but wanted to ask while things were still fresh.

[hvac-alan]

Earlier I stated that the EXV motor I needed was a 760 step motor. Now I am not so sure since I have found some Carrier literature that indicates that the motor has 1500 steps. Does anyone have some info on this??? Both EXV's have been replaced. Circuit B's exv has been replaced recently, then the motor fried and that was replaced last week. Want to verify that I have the correct step motor.

[mmc]

The answer is NO. The Ground Loop Converter replaces the serial port adaptor that you use for Comfortview. And you cannot use a phone cord for Flotronic Manager. This is really OOOOOOOOOOOOOOld stuff.

Like you said, once you get the GLC, you'll see. You plug the GLC into your serial port with the help of a few adaptors that I mentioned. Then you connect your two conductor wire to the C+ and C- terminals on the GLC. At the other end of your two conductor wire, you connect your red and black wires to pin number 3 and 6 on a 6 pin female recepticle that will plug onto the J8 plug on the microprocessor. I know you can get the 6 pin female plug from Carrier. I just found an empty plastic bag in my bag of cables with Carrier Pt # HY 06AM 017 Then it says "Terminal" under the part number so I think that part number is correct. Once you get the plug on the end you are ready.

It goes like this: laptop serial port to the GLC. GLC to the two conductor wire. Two conductor wire to the six pin female plug. Six pin female plug plugs on to the plug J8 on the microprocessor.

If you're anywhere around Houston, TX, it would be alot easier to show you than it is to try to explain it. It really is easier than it sounds if you have all the correct parts and pieces.

Good luck and stay in touch.

[hvac-alan]

MMC

You have been a great help. You have filled in the part that I did not understand. I haven't been in commercial too long (1 year) and most of the guys in my department are far more advanced in chillers, but my niche is that I know a little more than they do about computers--i am looking forward to broadening their horizons a bit, like they have done for me. Accessing the board in this manner will be something that none of them have done.

Thanks again. I am in North Carolina but if I can't figure it out I may have to come to Houston--but a suppose right now accomodations are alittle limited.

[ac eagle]

Did you or any other tech from your company replace exv board?? do you have one exv board or one for each circuit??? if singular board switch circuit b and a and see if your exv operates properly that would tell you if you have a bad board... I would suggest replacing the sensors only cause that you and I saw the same sitution not saying your wrong... Please keep me inform with this chiller would love to get more information and help in any way possible... Are you base in Mass??? if not where??? just an fyi.

[hvac-alan]

Hey ac eagle

The board has not been replaced. Though it may turn out that it needs to. The literature and several guys on this site have mentioned an exv driver board. I am fairly certain that I do not have one, but I will double check tomorrow. The exv cable is plugged directly into the J7 plug of the microprocessor board.

Sensors:

I should have mentioned much earlier when you brought it up that many of the sensors have been replaced. I know both cooler saturation sensors have been replaced along with the LWT. I also think that the return gas for Circuit B was replaced, but not certain. I am confident that they are reading correctly, but I will not completely rule it out because so many people, including you have seen odd things with the sensors.

Location:

I am in Raleigh, North Carolina. How is your summer going in MA, it has been a hot busy one here.

[ac eagle]

Very busy summer up here in Mass,we just got caught up from summer,we are starting to do and get caught with mid summer and regular schedule inspections. So you working on and older flowtronics Carrier chiller,but same sitution. The chiller I work on has an exv board(micropressor board) with both exv vales. You mentioned your going back on Tuesday??

[hvac-alan]

Hey ac eagle

I am going back Tuesday. I am hoping the converter will be here soon, but I will have to start without it. I will check and double check the sensors and make sure they are wired correctly. Also, I am almost certain that I do not have an exv drive board. Apparently, some of the 30GT units don't have them.

I also want to check that I have continuity between all terminals A-E. Then I will go through the troubleshooting section of the manual.

I had thought about doing the suggestion you offered on Friday (switching plugs on A and B circuits), but I would have to switch the thermistors as well. Not impossible, but it was getting late.

The board can move the EXV. I can hear it. Also heard it open after I restarted the machine after pulling a vaccum from the exv to the LL shutoff I(when I changed the cores)

Do you know anything about these EXV's. I thought that I had a 760 step motor, (think I got that from one of our techs), but the literature says it is a 1500 step motor.

OLD: The machine is a 1996. I suppose the technology has changed plenty since then. But it seems like 1996 wasnt that long ago. Time flies.

[gyhooyabat]

hvac-alan,
We started using the 1500 step EXV motor in the machines made from week 20 of year 1995 and forward. That means your machine, with serial 4496 (week 44 of year 1996) will have the 1500 step EXV.

Your contol board part numbers should be as follows:
Microprocessor - # 32GB501074
Relay Board - # 32GB500004
Display Board - # 32GB500044
Driver Board - NONE
EXV - # 30GT660003
EPROM - # HT207101-1-24
RCD Repair Kit # 30GT660009
The Eprom set point is for 29* F. Super heat.

Good luck!

[hvac-alan]

Thanks John:

That clears up the confusion I had with the number of steps this motor has. I have read in the historical part of this site that these type problems have occured when the incorrect EXV was installed.

I will keep everyone posted.

Alan

[hvac-alan]

Hello all,

Thanks for all your input. I went back today and went through the Carrier EXV troublshooting suggestions. Before that, I verified that the EXV was the correct one. It was. Checked senors again. All looked good

During the troubleshooting steps, it appeared that the EXV did the opposite that it should have. When it was supposed to be closed, it was open.

After completing that I checked for continuity in my plug. As I stated before, the last tech told me that he found that the new cable was different than the old one, requiring that the brown wire be switched with the white. This was incorrect. I reversed the wires, reset the machine and the unit ran and maintained 29 degrees of Superheat. As I checked the sensors, I saw that the EXV was reacting to changes in the sensors in the correct way. This solution, of coarse, was not as exotic as I was making it out to be, but has been instructive in checking all the simple things and things that have been changed recently before moving to the more exotic diagnosis.

The bright spot in all this is that I learned alot about this machine and I was able to get some good software---That I have yet to use---still waiting on the Converter.

[chill bill]

Originally posted by klrogers

Originally posted by hvac-alan
I contacted Carrier on Friday. They gave me a software program (DOS) that could give me all the thermistor readings in real time and the position of the EXV. I need to get a Telebyte Model 65 Converter in order to hook the unit's board to the my laptop. Is this what you are referring to??? And have you done this before. Apparently I hook up to the no. 3 and 6 pins of the J8 plug on the board.

"Flashing" the board means that they rewrite the code onto the EPROM or whatever memory they use to store the code. The DOS program they gave you just allows you to read the sensors and EXV position directly.
Are you willing to share this DOS program with others on this site? If so my email is in the bottom left corner of my website.

Kevin

alan, I have recently worked on 30gt-045 and had similar probs, high superheat fault, swapped the leads on the EXV from the other circuit, all worked ok. Found that the plastic connector plugs become loose and if EXV/sensor leads are to be replaced, replace these connector plugs also, using the correct tool. The EXV is a 760 step (P/No: 32GB402554), replaces the old style EXV. Hope this helps you out. It would be greatly appreciated if you could email the DOS program to me as well (look in profile). Thanks.

[hvac-alan]

Chill Bill

Would be happy to send the little program, but can't find your email address in your profile, please advise

mine is hvac-alan at nc.rr dot com

Alan

EDIT: No email addies in post. Please put it in your profile biography. Thanks!

[Edited by Mod01 on 12-16-2005 at 07:13 PM]

[ac eagle]

No didnt have to change wires,but have heard sometimes you have too change wires. I believe it was brown and red but dont hold me to that change

[hvac-alan]

It has been a while, but Chill Bill revived this thread and I noticed that I did not give comment on the converter and using the little Dos program to watch all the temperature inputs.

I have used it now and let me tell you it is really niffty. The data changes quickly and you can even see the position of the EXV. The machine really reacts to the changes in superheat. Thanks to all that helped me set up with the converter. It it is certainly worth it when you are getting stumped and want see what the bocard is seeing. I would not condemn another EXV without hooking this one up.

Alan

[pennycuff]

i had same problem years ago and found that the exv had taken too many steps and cross threaded had to replace exv and sensors.the original problem lied within the sensors.

[lin]

Is it too late to get a copy of Flotronic Manager?
i have a 30GT110 with too low superheat.

lincheng@netease.com

[engine chiller]

LIN,

I just spent helf a day and night with this problem on a 30GT-190. Snesors and all boards and exv checked out ok.

BUT sometimes the sensors went way out of line. changed both refrigerqant sensors in cooler and in compressor. ALL fine now.

[lin]

engine,
I think it's problem of sensor(or exv driver?). so i need the software to check which sensor is wrong.

[steam638]

check the crankcase htrs

[engine chiller]

the sensors are cheap enough that you can replace then for what you spend in time trouble shooting them, if it is an intermittentent problem.

[master mechanic]

I have been using the Carrier flowtronic monitor program for several years. On the program it displays the exv output signal from the processor (in steps ) and the actual position of the valve( feed back). I often find the sensors out of calibration causing the problem however I have found several valves getting stuck as well as clogged liquid line driers.I find that a lot of mechanic 's with out the software tend to guess and just part change. Using the out dated software is very helpfull in troubleshooting I would recommend it to everyone.

[justcool]

Any idea where can I get The DOS based software called Flotronic Manager? We have two of this chillers on campus and both of them have problems with the EXV's. Two of them have been replaced already and problem continues, need help.

[wally r]

What a coincidence...I'm needing the exact same thing for the same reasons.

I called the local Carrier office and I'm waiting for a callback. Their initial response was not encouraging...

[jrbenny]

Shoot me an email. I'll send you the software. It will be a *.zip file that you'll need to save to disk. You will need to read the IOM that's in the zip file and order the interface from Telebyte. It's not something that we provide.

Benny.

[wally r]

Email sent. Thanks in advance!

[jrbenny]

Send it to the email in my profile...not the gmail account in my credentials.

[chillrdude]

Any of you guys that have this software mind sharing, was going out there tomorrow, going to overnite the converter.
Thanks, my email is in my profile.

[ACCMan]

The EPROM everyone was referring to contains the operating parameters or software program for the unit. the older the machine..the older the program.
There were many revisions to the software programs on the 30GB's.
Your local rep for Carrier Tech support is George Bradshaw out of Greensboro. He can help you with any future problems on the EPROMs. The older machines had issues with headpressure control, number of fans coming on during start-up... etcc.

The reason so many people suggest the sensors is due to the high number of sensors that read a few degrees off. When they go bad the unit shuts down...when they drift...the unit runs high superheat, low superhheat, oil washes out..oil pressure drops...refrigerant and oil mix to show a high oil level but you still get low oil pressure...condenser fans don't cycle properly due to the condenser sensor drifting...etc..

Was the old chiller barrel leaking at the tubesheet?

[pwn01]

I wonder if someone could email me the Flotronic Manager software that you're speaking of? We have a 30GB200 that it would help with.

[elvis66]

Have not read entire thread, but am having the same problem with my 080 chiller. I have found that the c/fans are not cycling properly and bringing all c/fans with single compressor unloaded (1 stage). The only fan that does not come on is the other circuit c/fan being controlled by Motormaster. Would not think it is a sensor issue as it doesn't matter which circuit starts first, A or B, the same thing happens, although it doesn't seem to affect B circuit like it does A circuit (2 compressors), and the common part to that would be the board.

I can't find any info on the relay board for troubleshooting.

We are in the low 40's and my understanding from the manual is that #1 fan energizes with compressor (currently controlled by Motormaster) and other fans stage based on sensor input. #1 fan is on MM, which I believe was field installed at installation and not factory.

Anyway, still need to verify sensors, but any input on this would be greatly appreciated.

[w~p]

Send it to the email in my profile...not the gmail account in my credentials.

Do not find your email in your profile other than gmail.com.

Please kindly email this software to info@w-sathaworn.com

Thank you so much,

[ACCMan]

Have not read entire thread, but am having the same problem with my 080 chiller. I have found that the c/fans are not cycling properly and bringing all c/fans with single compressor unloaded (1 stage). The only fan that does not come on is the other circuit c/fan being controlled by Motormaster. Would not think it is a sensor issue as it doesn't matter which circuit starts first, A or B, the same thing happens, although it doesn't seem to affect B circuit like it does A circuit (2 compressors), and the common part to that would be the board.

I can't find any info on the relay board for troubleshooting.

We are in the low 40's and my understanding from the manual is that #1 fan energizes with compressor (currently controlled by Motormaster) and other fans stage based on sensor input. #1 fan is on MM, which I believe was field installed at installation and not factory.

Anyway, still need to verify sensors, but any input on this would be greatly appreciated.


What problem do you have?
On start-up the fans will come on and run for a predetermined time and then scale back to operate off of the motormaster. Early problems consisted of not enough fans starting and system tripping on head pressure.
The eprom is located in the center of the board with a sticker on it listing its version. Obtain the eprom version and check with your local Carrier parts distributor to see if a newer version is available. Use the resistance/temperature method to check the sensors.... the voltage method can be misleading by a couple of degrees. Pumpdown and remove the sensors from the refrigerant circuit and place in a cup of water with a thermometer. Check the listed resistance for the temperature being shown. Just a couple of degrees off will cause oil foaming, low oil pressure, system trips due to low superheat. The troubleshooting manual will provide you with all of the details. Some of the newer 30GB's and 30GT's had a temperature well the sensors inserted into. The older ones were held in the refrigerant circuit or the water circuit by a compression fitting. Removal of the sensor without removing the pressure (refrigerant or water) cannot be done safely or legally.

[Mrfixit39]

sounds like a thermistor circuit problem, ohm it for measurable resistance

[Coremech]

Master Mechanic could you share this software i have plenty of this seris machines under contract.

[Coremech]

i had same problem years ago and found that the exv had taken too many steps and cross threaded had to replace exv and sensors.the original problem lied within the sensors.
My journeyman and I had the same problem but we isolated the curcit and took the exv aprt and screwed it up and down because it had gotten into a bind over stepped it steps as to say but also we had the cooler sensors out of wack and the superheat sensor failed too. Changed them out put a little anti-sieze on the screw of the exv and all was good.

[Ausccn]

The attached file is actually fm.exe so copy it and change the .doc to .exe then run the program from DOS. It will run in a DOS box, dont know if comms works under windows!!

It is a Flotronic anyliser that allows to see all operating parameters. It also requires a current loop convertor for the comms side of things Telebyte model 65 or black box also makes one.

Aus..

[Airmechanical]

My journeyman and I had the same problem but we isolated the curcit and took the exv aprt and screwed it up and down because it had gotten into a bind over stepped it steps as to say but also we had the cooler sensors out of wack and the superheat sensor failed too. Changed them out put a little anti-sieze on the screw of the exv and all was good.


yap that is the cure for the EXV problem!

also those particular chillers love to chew up thermistors and discharge temp sensors!

the gt series chillers, once you master them, there not fun anymore:(



.

[fmohdkhan]

[i have a problems in 30gt,problem in ckt .a when i start the ckt a,a1 comp running normally,if start a2 after 5 min tripped in 66 code.

[CENAIR]

This Carrier product 30 GT is probably one of the worst Chillers ever produced with all the problems with sensors and EXV, we service over 50 of them under contract and compared to other brands like Trane we maintain and install, the Carrier Flotronic Chiller has so many problems with the sensors and EXV's, and is probably the most unrelaliable Chiller product we have ever seen, install a nice Trane problem solved.

[Dallas Duster]

This Carrier product 30 GT is probably one of the worst Chillers ever produced with all the problems with sensors and EXV, we service over 50 of them under contract and compared to other brands like Trane we maintain and install, the Carrier Flotronic Chiller has so many problems with the sensors and EXV's, and is probably the most unrelaliable Chiller product we have ever seen, install a nice Trane problem solved.

Probably due to being well ahead of it`s time.

[budglo]

I agree, they were a little ahead of their time.Lets face it , most of the GTs are getting up there in years too. I actually have not replaced a ton of exvs on this particular model.Sensors is another issue.Once you learn your way around them, they arent too bad.

[CENAIR]

I put some of the first few in New England and went through all the early problems, we had a project we went to every day just to reset and start it with all the errors and alarms, had Carriers Engineers on the project many times and went through all the e-prom upgrades etc.

One interesting note is the smaller units 125 ton and under have very few problems, but the 200 ton and up are more problematic as all it takes is one set of discharge valves leaking back into the suction side and the comp sensor interpets the hot gas as high superheat Error on the 4 stage circuits. The EXV's seem to go after 10+ year old machines, most of my systems for chilled water are on 100% outside air applications so they have higher run time hours than other applications.

The Flotronic-II was better than the Flotronic-I, still amazes me on the Flotronic one till we switched to Trane, through the display you couldn't read the entering and leaving temperatures.

[Jack Morris]

Any idea where can I get The DOS based software called Flotronic Manager? And any other items that will be need

[prorefco]

I worked on one flotronic chiller years ago and had the same reliability problems as everyone here describes. It ate compressors, sensors, EXV's etc... I called an engineer friend in Syracuse and he refered me to a project engineer who was one of the designers of that chiller... He admitted to all of the issues and went on to say that Carrier DOES (or did anyway) make a TXV retrofit kit for that chiller. It included the TXV's, some fitttings, and a new eprom for the CPU... It was little known (at that time at least) as the Carrier distributor had never heard of it, but when I gave them the part number the engineer gave me, it came up in their parts list.

As it turned out, I never did order it as the customer didn't want to spend the money for a conversion.. Instead they opted for 2 new compressors and new EXV's from a competitor,,,go figure... I heard all that new stuff didn't last more than a year....

Had it been MY chiller, I would have done the conversion in a heart beat....

[Ausccn]

Any idea where can I get The DOS based software called Flotronic Manager? And any other items that will be need
Jack see my post in this forum....

[BKS60]

Wonder if this chiller is stil running since the thread is ............5 years old!!!!!!!!

[toptech]

Is this Flowtronics Manager software more useful than Network Service Tool?
Anyone successfully comunicated with XP?
I have the program and it runs on XP, not sure if its worth buying the loop convertor.
Im assuming its real time data thats faster than service tool.
Maybe I should start a new thread for this in Controls
Thanks

[Ed_LMCO]

***EDIT*** Nevermind. Apparently I am blind as well as confused! I found your post and link seconds after posting this. Thanks!



Can someone email me a copy of that software to monitor the sensors and superheat with? It would be greatly appreciated!

(Ausccn, I tried looking for your previously mentioned posts, but did not find what I was looking for)

Email address is in my profile.

Thanks!

Ed_LMCO

[joey791]

Just saw this thread, Ausccn, I downloaded what you posted, if there is any other software besides what you posted floating can I please have a copy.

[Ausccn]

Just saw this thread, Ausccn, I downloaded what you posted, if there is any other software besides what you posted floating can I please have a copy.

Sorry Joey, thats the only on that I have.

Aus..

[spencer91]

Make sure you have enough refrigerant in circuit.

cheers

[ac eagle]

Please make sure the wires are proper from old to new also check to make sure old board is compatiable with new exv as sometimes have to change board, I would get papaerwork on exv for proper wiring as sounds like possible wired wrong.

[mcguire07]

One of my mechanics is working on a 30GT040 and has recently replaced the main board and the exv board. Everything works just fine when it cycles down normally but when it is shut off at the toggle and then restarted it trips the exv fuse because both exv's try to close at the same time and draws more than 5 amps. If he switches the toggle twice in rapid succession it restarts with no problems. Any one have any ideas?

[Ausccn]

What version s/ware is in it??

It sould B 19+ Or 4 that matter 20+......email me and i will send it....




One of my mechanics is working on a 30GT040 and has recently replaced the main board and the exv board. Everything works just fine when it cycles down normally but when it is shut off at the toggle and then restarted it trips the exv fuse because both exv's try to close at the same time and draws more than 5 amps. If he switches the toggle twice in rapid succession it restarts with no problems. Any one have any ideas?