Carrier 30XA110, 30XA080, 30XA120, 30XA140, 30XA160 Controls, Start-up, Operation, Service And Troubleshooting Instructions

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Page 1

AQUAFORCE

30XA080-500

Air-Cooled Liquid Chillers

Controls, Start-Up, Operation, Service

and Troubleshooting

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .2,3

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Conventions Used in This Manual. . . . . . . . . . . . . . . . 3

Display Module Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

• TOUCH PILOT™ DISPLAY

• NAVIGATOR™ DISPLAY MODULE

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Compressor Protection Module (CPM) . . . . . . . . . . . 9

Electronic Expansion Valve (EXV) Board . . . . . . . . . 9

Fan Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Enable-Off-Remote Contact Switch (SW1). . . . . . . 17

Emergency On/Off Switch (SW2) . . . . . . . . . . . . . . . . 17

Energy Management Module (EMM) . . . . . . . . . . . . . 17

Hot Gas Bypass/Pump Board . . . . . . . . . . . . . . . . . . . 17

Local Equipment Network. . . . . . . . . . . . . . . . . . . . . . . 19

Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Touch Pilot Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Module Communication. . . . . . . . . . . . . . . . . 19

•RED LED

• GREEN LED

• YELLOW LED

Carrier Comfort Network

Remote Alarm and Alert Relays . . . . . . . . . . . . . . . . . 20

CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-59

Touch Pilot Operation Configuration Tables. . . . . 21

Machine Control Methods . . . . . . . . . . . . . . . . . . . . . . . 22

Machine On/Off Control . . . . . . . . . . . . . . . . . . . . . . . . . 22

• TOUCH PILOT MACHINE CONTROL

• NAVIGATOR DISPLAY MACHINE CONTROL

Fluid Set Point Control Location . . . . . . . . . . . . . . . . 27

Cooling Set Point Selection . . . . . . . . . . . . . . . . . . . . . 27

• SET POINT OCCUPANCY

Chilled Water Fluid Type Selection . . . . . . . . . . . . . . 28

• FRESH WATER

• BRINE OR GLYCOL OPERATION

Cooler Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

• NO PUMP CONTROL

• SINGLE PUMP CONTROL

• DUAL PUMP AND MANUAL CONTROL

Machine Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Circuit/Compressor Staging and Loading . . . . . . . 31

• CIRCUIT/COMPRESSOR STAGING

• CIRCUIT/COMPRESSOR LOADING

Minimum Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Dual Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

• DUAL CHILLER CONTROL FOR PARALLEL APPLICATIONS

• DUAL CHILLER PUMP CONTROL FOR PARALLEL CHILLER APPLICATIONS

(CCN) Interface. . . . . . . 20

Page

• DUAL CHILLER CONTROL FOR SERIES APPLICATIONS

• DUAL CHILLER PUMP CONTROL FOR SERIES CHILLER APPLICATIONS

Night Time/Low Noise Applications . . . . . . . . . . . . . 37

Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

• RETURN WATER RESET

• OUTSIDE AIR TEMPERATURE RESET

• SPACE TEMPERATURE RESET

• 4-20 mA TEMPERATURE RESET

Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

• SWITCH CONTROLLED DEMAND LIMIT

• EXTERNALLY POWERED CAPACITY BASED DEMAND LIMIT

• EXTERNALLY POWERED CURRENT BASED DEMAND LIMIT

• CCN LOADSHED CONTROLLED DEMAND LIMIT

Ice Storage Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Broadcast Configuration . . . . . . . . . . . . . . . . . . . . . . . . 46

•ACTIVATE

• OAT BROADCAST

• BROADCAST ACKNOWLEDGER

Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

• ALARM ROUTING CONTROL

• ALARM EQUIPMENT PRIORITY

• COMMUNICATION FAILURE RETRY TIME

• RE-ALARM TIME

• ALARM SYSTEM NAME

Daylight Saving Time Configuration. . . . . . . . . . . . . 47

Capacity Control Overrides . . . . . . . . . . . . . . . . . . . . . 47

Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 50

• LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPTION

• LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPERATING INSTRUCTIONS

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-67

Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

• TEMPERATURES

•VOLTAGE

• MINIMUM FLUID LOOP VOLUME

• FLOW RATE REQUIREMENTS

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-74

Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 67

• ACTUATED BALL VALVE (ABV), FLOODED COOLER ONLY

Dual Chiller Sequence of Operation . . . . . . . . . . . . . 68

•PUMP OPERATION

Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

• THERMISTORS

• TRANSDUCERS

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

Catalog No. 04-53300091-01 Printed in U.S.A. Form 30XA-4T Pg 1 612 10-11 Replaces: 30XA-3T

Page 2

CONTENTS (cont)

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-87

Economizer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 74

• FLOODED COOLER MAIN EXV CONTROL

• DX COOLER MAIN EXV CONTROL

• ECONOMIZER EXV CONTROL

• EXV TROUBLESHOOTING PROCEDURE

Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 77

• COMPRESSOR OIL SYSTEM

Flooded Cooler Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

• FLOODED COOLER SUCTION SERVICE VALVE

• FLOODED COOLER FREEZE PROTECTION

• FLOODED COOLER LOW FLUID TEMPERATURE

• FLOODED COOLER LOSS OF FLUID FLOW PROTECTION

• FLOODED COOLER TUBE PLUGGING

• FLOODED COOLER RETUBING

• FLOODED COOLER TIGHTENING COOLER HEAD BOLTS

• FLOODED COOLER INSPECTING/CLEANING HEAT EXHANGERS

• FLOODED COOLER WATER TREATMENT

DX Cooler Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

• DX COOLER SUCTION SERVICE VALVE

• DX COOLER FREEZE PROTECTION

• DX COOLER LIQUID FLUID TEMPERATURE

• DX COOLER LOSS OF FLUID FLOW PROTECTION

• DX COOLER TUBE PLUGGING

• DX COOLER RETUBING

• DX COOLER TIGHTENING COOLER HEAD BOLTS

• DX COOLER CHILLED WATER FLOW SWITCH

DX Cooler and Flooded Cooler Units . . . . . . . . . . . . 84

• PREPARATION FOR WINTER SHUTDOWN

Microchannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning

Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

RTPF Condenser Coil Maintenance and Cleaning

Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

• REMOVE SURFACE LOADED FIBERS

• PERIODIC CLEAN WATER RINSE

• ROUTINE CLEANING OF RTPF COIL SURFACES

Condenser Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Refrigerant Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

• LEAK TESTING

• REFRIGERANT CHARGE

Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

• COMPRESSOR PROTECTION

• OIL SEPARATOR HEATERS

• COOLER PROTECTION

Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

• PRESSURE RELIEF VALVES

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87,88

Recommended Maintenance Schedule . . . . . . . . . . 87

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . 88-109

Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

• DIAGNOSTIC ALARM CODES AND POSSIBLE CAUSES

Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

APPENDIX A — TOUCH PILOT™

DISPLAY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . 110-127

APPENDIX B — NAVIGATOR™

DISPLAY TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . 128-141

APPENDIX C — CCN TABLES . . . . . . . . . . . . . . 142-156

APPENDIX D — 30XA080-500 CPM

DIP SWITCH ADDRESSES. . . . . . . . . . . . . . . . 157-160

APPENDIX E — PIPING AND

INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . 161-164

612

Page

APPENDIX F — MAINTENANCE SUMMARY

AND LOG SHEETS. . . . . . . . . . . . . . . . . . . . . . . . . . 165-167

APPENDIX G — BACNET COMMUNICATONS

OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168-178

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

START-UP CHECKLIST

FOR 30XA LIQUID CHILLERS . . . . . . . . CL-1 to CL-8

SAFETY CONSIDERATIONS

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

WARNING

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

WARNING

DO NOT VENT refrigerant relief valves within a building. Outlet from relief valves must be vented in accordance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of Heating, Refrigerating and Air Conditioning Engineers) 15 (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. Provide adequate ventilation in enclosed or low overhead areas. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.



DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure.

To remove a component, wear protective gloves and goggles and proceed as follows:

a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from sys-

tem using both high-pressure and low pressure ports.

c. Traces of vapor should be displaced with nitrogen

and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.

d. Cut component connection tubing with tubing cutter

and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.

e. Carefully unsweat remaining tubing stubs when nec-

essary. Oil can ignite when exposed to torch flame.

Failure to follow these procedures may result in personal injury or death.

WARNING

Page

Page 3

CAUTION

ENTER

ESCAPE

ENTER

Fig. 1 — Touch Pilot™ Display

Figure-1

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

CAUTION

To prevent potential damage to heat exchanger tubes, always run fluid through heat exchanger when adding or removing refrigerant charge. Use appropriate antifreeze solutions in cooler fluid loop to prevent the freezing of heat exchanger or interconnecting piping when the equipment is exposed to temperatures below 32 F (0° C). Proof of flow switch is factory installed on all models. Do NOT remove power from this chiller during winter shut down periods without taking precaution to remove all water from heat exchanger. Failure to properly protect the system from freezing may constitute abuse and may void warranty.

CAUTION

Compressors require specific rotation. Test condenser fan(s) first to ensure proper phasing. Swap any two incoming power leads to correct condenser fan rotation before starting compressors. Operating the unit without testing the condenser fan(s) for proper phasing could result in equipment damage.



DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations. DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed. Failure to follow these procedures may result in damage to equipment.

CAUTION

configuration. The user would scroll through the modes and sub-modes using the and keys on the Navigator display. For the Touch Pilot display, the user would simply touch the menu item on the screen. The arrow symbol in the path name represents pressing to move into the next level of the menu structure for the Navigator module, or touching the menu item on the screen for the Touch Pilot display.

When a value is included as part of the point name, it will be shown after the point name after an equals sign. If the value represents a configuration setting, an explanation will be shown in parentheses after the value. The Touch Pilot name will be shown first with the Navigator name following. As an example, (Staged Loading Sequence = 1, LLCS = Circuit A leads).

Press the and keys simultaneously on the Navigator module to display an expanded text description of the point name or value. The expanded description is shown in the Navigator display tables (Appendix B) but will not be shown with the path names in text. The Touch Pilot display will show an expanded description of the point name. To view the expanded point name for the Touch Pilot display go to Appendix A.

The Touch Pilot display configures the unit via the CCN (Carrier Comfort Network

) Tables, which are located in Ap-

pendix C of this manual.

Display Module Usage

TOUCH PILOT DISPLAY — The Touch Pilot display is the standard user interface for the AquaForce 30XA chillers with the ComfortLink control system. The display includes a large LCD (liquid crystal display) touch screen for display and user configuration, a Start/Stop button, and an Alarm Indicator LED (light-emitting diode). See Fig. 1.

LCD TOUCH SCREEN

ALARM INDICATOR LIGHT

GENERAL

This publication contains Controls, Operation, Start-Up, Service and Troubleshooting information for the 30XA080500 air-cooled liquid chillers with electronic controls. The 30XA chillers are equipped with ComfortLink™ controls and electronic expansion valves. The AquaForce offer two different user interface devices, the Touch Pilot™ display and the Navigator ™ display.

Conventions Used in This Manual — The follow-

ing conventions for discussing configuration points for the Navigator module and Touch Pilot display will be used in this manual.

Point names for the Touch Pilot display will be shown in bold. See Appendix A for a complete list of point names. Item names for the Navigator module will be shown in bold italics. See Appendix B for the complete path name preceeding the item name. The point and item names in Appendices A and B will be listed in alphabetical order and the path name for each will be written with the mode name first, then any sub-modes, each separated by an arrow symbol (.

This path name will show the user how to navigate through the Navigator module or the Touch Pilot display to reach the desired

30XA chillers

STA RT- STOP BUTTON

The Touch Pilot display can be used to access various

Carrier Comfort Network

devices. For operation under these

circumstances, contact your Carrier representative.

Operation of the Touch Pilot display is driven from the displays on the touch screen. The Touch Pilot display uses the following screen “buttons” to allow the user to operate the display and navigate within and between screens.

“BACK” Returns to the next higher screen in the hierarchy.

“HOME” Displays the Default Group Display screen

for Touch Pilot display. The Default Screen is a userconfigured display of up to 9 points on each of 8 screens. This allows for quick access to various, frequently viewed points, without navigating through the Main Menu structure. This button is available at all menu levels and returns the user to the first Default Group Display screen.

612

Page 4

“MAIN MENU” Displays the Main Menu screen.

Fig. 2 — Group Display Screen

Fig. 3 — Point Data Dialog Box

a30-4470

a30-4471

This allows access for viewing and configuration, where possible, of all points supported by the controller. This includes points such as set point and operational configuration. This button is available at all menu levels and returns the user to the Main Menu screen.

“PREVIOUS” In a group of sequential screens of the

same type, pressing this button moves the user to the next earlier screen in the group.

“NEXT” In a group of sequential screens of the same

type, pressing this button advances the user to the next screen in the group.

“OK” Agrees with, or says “yes” to a prompt and per-

forms the appropriate processing.

“NO” Rejects, or says “no” to a prompt and performs

the appropriate processing.

“CANCEL” Terminates an ongoing action and returns

to the current screen without any other processing.

“CLEAR DATA” Clears the data value in a data entry

dialog box. This button is used to clear incorrect data.

“RESET DATA” Zeros the data value in a data entry

dialog box.

“ADD” Adds the active point to a Group Display

screen.

“REMOVE” Deletes a point from a Group Display

screen.

“INCREASE” Modifies the value of a field within its

defined limits or “SCROLL UP” and shifts the screen view up by one item.

“DECREASE” Modifies the value of a field within its

defined limits or “SCROLL DOWN” and shifts the screen view down by one item.

“PAGE DOWN” If the current table or list has more

data than will fit on the screen, pressing this button will replace the items currently on the screen with the next group of items.

“PAGE UP” If the current table or list has more data

than will fit on the screen, pressing this button will replace the items currently on the screen with the previous group of items.

“FORCE” Begins the process of forcing or overriding

the value of a point.

“AUTO” Begins the process of removing a force from

a point.

“MODIFY” Begins the process of modifying a con-

figuration value.

“ALARM INDICATOR LIGHT” An LED alarm

indicator light is activated when a new alarm condi-

tion occurs. The alarm indicator light, located on the right side of the display, remains activated until it is manually reset using the Reset button on the Main menu.

“START/STOP BUTTON” The Touch Pilot™ dis-

play includes an equipment Start/Stop Button that

enables the user to start or stop the chiller from the display. See Enable-Off-Remote Contact Switch (SW1) on page 17 for additional information.

Several items are password protected. When required, a Password dialog box will be displayed for field input of the password. The default password is 3333. The password can be changed if desired.

Power-Up Display

— When the Touch Pilot display is powered up, it displays an initialization progress bar and attaches (initiates communication) to the Main Base Board. The Touch Pilot display then shows that controller’s default Group Display screen. See Fig. 2. This is a user-configured display screen

with up to 9 points on 8 separate screens. For more information on adding or removing points from the Group Display screen, see the Group Display Screens section on page 6.

Touch any of the screen point buttons and Point Data Dialog box will be displayed with expanded information. In the example shown below, the CTRL_PNT button in the bottom left corner was selected. See Fig. 2 and 3.

To exit the box, press . Main Menu Display

— The default screen for the Touch Pilot controller is the Group Display screen. To access the Main Menu, press the button. The screen shown in Fig. 4 will be displayed. Selecting a button will display the screens associated with that category. The user can also access the login screen from the Main Menu if needed.

Touch Pilot Menu Structure

— The user can navigate through the Touch Pilot display screens by selecting the buttons that appear on the screen. When a button is selected, either a submenu or a list of point names and values will be shown. Submenus will display a list of associated point names. See Fig. 5 for the Touch Pilot menu structure.

If the list of point names and values are shown, the top line of the display is the table name. The line and total line counter is displayed in the upper right corner of the display. Selecting an item will cause a Point Data dialog box to appear.

Setup Menu Screen

— The Setup Menu screen, shown in Fig. 6, is accessed by pressing the Setup button from the Main Menu. This configuration allows the user to configure the basic operation and look of the display. Table 1 summarizes the Setup Menu functions.

Page 5

Fig. 4 — Main Menu Display

a30-4472

Fig. 6 — Setup Menu Display

a30-4474

User interface

Group display x 8 Main menu

Status

GENUNIT

CIRCA_AN

CIRCA_D

CIRCB_AN

CIRCB_D

CIRCC_D

CIRCC_AN

STATEGEN

RECLAIM

MODES

STRTHOUR

FANHOURS

FREECOOL

QCK_TST1

QCK_TST2

SERV_TST

Setpoint Schedule

OCC1PO1S

OCC2PO2S

Service

FACTORY

FACTORY2

SERVICE1

CP_UNABL

UPDTHOUR

UPDHRFAN

MAINTCFG

Maint

LOADFACT

FANCTRL

M_MSTSLV

DEFROSTM

LAST_POR

PR_LIMIT

BOARD_PN

SERMAINT

EXV_CTRL

CUR_PHAS

OCCDEFCFM

Config

Ctrl-ID

DISPCONF

USER

MST_SLV

CFG_TAB1

…

CFG_TAB8

BRODEFS

OCCDEFCS

HOLIDAY

ALARMDEF

Alarms

ALARHIST

ALARHIS2

ALAM_CUR

Reset Time Attach Setup

Regional

Language

Contrast

Backlight

Calibrate

Password

Display

CCN

Fig. 5 — Touch Pilot™ Display Menu Structure

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Table 1 — Setup Menu

SETUP MENU BUTTON FUNCTION

This button specifies the time and date format and the base unit of measure. Time display can be configured as 12-

REGIONAL

LANGUAGE

CONTRAST

BACKLIGHT This button specifies whether backlighting should be kept on at all times or turned off during inactive periods.

CALIBRATE

PASSWORDS

DISPLAY

CCN This button is used to configure the bus and element numbers and the baud rate of the control on the network.

hour AM/PM setting or as a 24-hour setting. The date can be formatted in one of 3 settings, MM-DD-YYYY (MonthDay-Year), DD-MM-YYYY (Day-Month-Year), or YYYY-MM-DD (Year-Month-Day). Units of measure can be either US (English) or Metric (SI).

This button selects the active language and font of the display. Available languages are English and Spanish (Espanol). If a preferred language is not available, additional software for the Main Base Board (MBB) and the Touch Pilot™ display are required. Contact your Carrier representative for instructions and software.

This button adjusts the LCD contrast. Press and hold the [MOON] button to increase/darken the contrast or the [STAR] button to decrease/lighten the current contrast. NOTE: Touching the screen anywhere for 5 seconds while powering-up will prompt the user to restore contrast and calibration settings to factory defaults.

This button is used to adjust the LCD touch screen calibration. Touch the screen in the circular targets located first in the upper left and then in the lower right corner of the screen to adjust.

This button is used to configure the limited and full logged-in access system passwords. In order to change passwords, the user must be logged in with full access to view and change the passwords. All passwords must consist of 4-digits, which can be entered using the numeric keypad. Access levels and associated privileges are as follows:

Limited Logged-in Access - Provides the user with read/write access to all available tables (except service configuration tables, where the user will not be permitted to modify point data, and Group Display tables, where the user will not be permitted to add points.) This access level also provides read/write access to all Touch Pilot display setup properties except Display, CCN, and Password.

Full Logged-in Access - Provides user with read/write access to all available tables for the attached device and all Touch Pilot display properties.

If the user does not log in, read-only access to all tables is allowed. The user will be prompted to log in when attempting to access password-required functions.

This button is used to view the description data and part number from the Ctlr-ID Table and to specify the Operating Mode. The Operating mode can be configured for Equipment mode or Network mode. For Touch Pilot displays that are standard with the unit, Operating mode should not be changed from Equipment mode. Equipment mode provides access only to the chiller’s MBB via the Local Equipment Network (LEN) Bus. For remote access, a remote Touch Pilot display can be set to Network mode. Network mode provides access to all devices on the CCN (Carrier Comfort Net-

work

) bus.

NOTE: When changing the operating mode, a power cycle is required in order for the new operating mode to take effect. The user should view and correct the following CCN data: address and baud rate, alarm acknowledger, and broadcast acknowledger designation.

Setting the Time and Date

— The ComfortLink™ control has a time and date function. This can be useful for diagnostics to determine when alarms occur. The control is factory configured for the proper date and is set for the Eastern Time Zone. The date and time zone must be checked and corrected if necessary, to allow the machine to function on an internal time schedule and to display a proper time and date stamp for alarms. The time and date is displayed on the Group Display Screen.

To change the Time and Date, press the Main Menu

button. Select Time. On the display, a day and date box

with a time box will be shown. To change the day and date,

press the day and date box. A calendar will be displayed. If the

correct month is displayed, touch the correct date. If the wrong

month is displayed, use the or to change to the correct

month and select the correct date. The date will highlighted.

Press to accept the change. The previous screen will be

displayed with the corrected day and date shown. To correct

the time, use the or on the left to change the hour. Use

the or on the left to change the minutes. Continuously

touching the or will sequence the numbers. The time is

shown in a 24-hour format. To accept the changes, press the

or buttons. A “Save” dialog box is displayed with the

words, “Do you wish to save changes?” Press to accept

the changes.

Group Display Screens

— The Touch Pilot™ display supports up to eight Group Display screens. Group Display screens show status information along the top of the screens and nine buttons that display nine point names and point values that are chosen by the user. All Group Display screen points are user configurable. The bottom line of the screen contains navigation buttons that can be used to move between the Group Display screens.

Pressing a point button will show that point’s Point Data dialog box. See Fig. 2 and 3. This box contains buttons that remove the point from the group display and apply or remove a force (point override). When touching any button in the display screen, the button will be outlined to acknowledge input. There may be a delay in response to input, but if the button is outlined, do NOT press any other button until the previous input has been processed.

If there is a communication failure with the MBB (Main Base Board), all point buttons will be displayed in inverse video and the message Communication Failure will be displayed in the top left line of the screen.

Default Group Designation — The default group is the first of the 8 Group Display screens. This is the default screen of the display. Information on this screen as well as the other 7 screens can be user-modified to meet the needs of the site.

To Add a Point To a Group Display — From the Main Menu, press the desired menu button (Status, Setpoint, Service, Maint, or Config) and, if necessary, the sub-menu button to access the point to be added. Press the point button to show the source point’s Point Data dialog box. See Fig. 3. From the Point Data dialog box, press the ADD button. The display will show the last Group Display accessed. Use the navigation buttons to access the destination Group Display. Press an existing

Page 7

point button or a blank button to update the highlighted button

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

Run Status

Service Test

Temperatures

Pressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

Operating Modes

Alarms

ENTER

ESC

MODE

Alarm Status

ComfortLink

Fig. 7 — Navigator Display Module

a30-3924

with the source point’s name. Press to add the highlighted point to the group and return to the table display.

To Remove a Point From a Group Display — From the Point Data Dialog box, press the REMOVE button and follow the prompts. The display will return to the Group Display screen from which the point was removed, and the button corresponding to the deleted point will be blank and disabled.

NAVIGATOR™ DISPLAY MODULE — The Navigator display module provides a mobile user interface to the ComfortLink control system. The display has up and down arrow keys, an key, and an key. These keys are used to navigate through the different levels of the display structure. Press the key until ‘Select a Menu Item’ is displayed. Use the up and down arrow keys to move through the top 11 mode levels indicated by LEDs on the left side of the display. See Fig. 7. See Table 2 and Appendix B for more details about the display menu structure.

Once within a mode or sub-mode, a “>” indicates the

currently selected item on the display screen. Pressing the

and keys simultaneously will put the Navigator module into expanded text mode where the full meaning of all sub-modes, items, and their values can be displayed. Pressing the and keys when the display says ‘Select Menu Item’ (Mode LED level) will return the Navigator module to its default menu of rotating display items (those items in Run StatusVIEW). In addition, the password will be disabled, requiring that it be entered again before changes can be made to password protected items. Press the key to exit out of the expanded text mode.

When a specific item is located, the item name appears on the left of the display, the value will appear near the middle of the display and the units (if any) will appear on the far right of the display. Press the key at a changeable item and the value will begin to flash. Use the up and down arrow keys to change the value, and confirm the value by pressing the

key.

Changing item values or testing outputs is accomplished in the same manner. Locate and display the desired item. Press

so that the item value flashes. Use the arrow keys to change the value or state and press the key to accept it. Press the key to return to the next higher level of structure. Repeat the process as required for other items.

Items in the Configuration and Service Test modes are password protected. The words Enter Password will be displayed when required, with 1111 also being displayed. The default password is 0111. Use the arrow keys to change each number and press to accept the digit. Continue with the remaining digits of the password. The password can only be changed through CCN operator interface software such as

, ComfortVIEW™ and Service Tool.

— When the Navigator display is powered

ComfortLink

Navigator

Carrier

ComfortWORKS

Power-Up Display up it will display:

This indicates an initialization period while the Navigator™ display initiates communication with the Main Base Board. Once communication is established, the default rotating

display will be shown. If communication is not established, the Navigator module will display:

Communication

Failure

If the Navigator module is connected to a Main Base Board without software loaded, the display will remain at the powered-up initialization display.

Setting the Time and Date

— The ComfortLink control has a time and date function. This can be useful for diagnostics to determine when alarms occur. The control is factory configured for the proper date and for use in the Eastern Time Zone. The control must be checked and corrected if necessary. The correct time is important if the machine is to function on an internal time schedule and display a proper time and date stamp for alarms. The time and date will be displayed on the default rotating display of the Navigator module. The time and date can also be checked and changed under the Time Clock mode as described below.

ITEM ITEM EXPANSION PATH VALUE

HH.MM Time of Day Time ClockTIME XX.XX

To change the time, press the arrow key to move to the correct hour and press . The minutes can be changed in a similar manner.

To check or change the date, the following items must be checked and changed if necessary.

ITEM ITEM EXPANSION PATH VALUE

MNTH Month of Year Time ClockDATE WW DOM Day of Month Time ClockDATE XX DAY Day of Week Time ClockDATE YY YEAR Year of Century Time ClockDATE ZZ

NOTE: WW is the current month of the controller, (01=January,

02=February, etc.). XX is the current day of the month YY is the day of the week, (01=Monday, 02-Tuesday, etc.) ZZ is the year of the century, (06=2006, 07=2007)

Changing the Unit of Measure — The Navigator display has two options for unit of measure on the display, English or SI (metric). The factory default for the units of measure is English. To change the unit of measure, the following item must be changed.

ITEM ITEM EXPANSION PATH VALUE

METR Metric Display ConfigurationDISP

OFF – English ON – SI (Metric)

Page 8

RUN

ENTER

ESCAPE

ENTER

STATUS

Auto Display

(VIEW)

Machine

Starts/Hours

(RUN)

Compressor

Run Hours

(HOUR)

Compressor

Starts

(STRT)

Fan Run

Hours

(FAN)

Compressor

Disable

(CP.UN)

Predictive

Maintenance

(MAIN)

Software Versions

(VERS)

SERVICE

TEST

Manual

Test Mode

(TEST)

Quick

Test Mode

(QUIC)

Table 2 — ComfortLink™ Navigator™ Display Menu Structure

MODE

TEMPERATURES PRESSURES

Unit

Temperatures

(UNIT)

Circuit A

Temperatures

(CIR.A)

Circuit B

Temperatures

(CIR.B)

Circuit C

Temperatures

(CIR.

Circuit A

Pressures

(PRC.A) Circuit B

Pressures

(PRC.B)

Circuit C

Pressures

(PRC.C)

SET

POINTS

Cooling

Setpoints

(COOL) Heating

Setpoints

(HEAT)

Misc.

Setpoints

(MISC)

INPUTS OUTPUTS CONFIGURATION

General

Inputs

(GEN.I)

Circuit A

Outputs (CIR.A)

Circuit B

Outputs (CIR.B)

Circuit C

Outputs (CIR.C)

General Outputs

(GEN.O)

Display

Configuration

(DISP)

Unit

Configuration

(UNIT)

Service

Configurations

(SERV) Options

Configuration

(OPTN)

Reset,

Demand Limit,

Master/Slave

(RSET)

TIME

CLOCK

Time of Day

(TIME)

Day, Date

(DATE)

Schedule 1

(SCH1)

Schedule 2

(SCH2)

Holidays

(HOLI)

Service Maintenance Configuration

(MCFG)

OPERATING

MODES

Operating

Control Type

(SLCT)

Operating

Modes

(MODE)

ALARMS

Reset Current

Alarms

(R.ALM)

Current

Alarms

(ALRM)

Alarm

History

(H.ALM)

Changing the Display Language

— The Navigator display has five language options to select from, English, Espanol, Francais, Portugues, and Translated. The “Translated” option is not supported at this time. The factory default language is English. To change the display language, the following item must be changed.

ITEM ITEM EXPANSION PATH VALUE

English

LANG Language Selection ConfigurationDISP

Espanol Francais Portugues Translated

NOTE: When the Language Selection (Configuration DISPLANG) variable is changed, all appropriate display expansions will immediately change to the new language. The four letter/digit code will not change. No power-off or control reset is required when reconfiguring languages.

Adjusting the Contrast

— The contrast of the display can be adjusted to suit ambient conditions. To adjust the contrast, enter the LED Test mode of the device.

ITEM ITEM EXPANSION PATH VALUE

TEST Test Display LEDs ConfigurationDISP

Pressing will access the TEST point. Pressing

again will cause the “OFF” to flash. Use the up or down arrow to change “OFF” to “ON.” Pressing will illuminate all LEDs and display all pixels in the view screen. Pressing and simultaneously allows the user to adjust the display contrast. The display will read:

Adjust Contrast

- - - -+ - - - - - - - - - - - - - - Use the up or down arrows to adjust the contrast. The

screen’s contrast will change with the adjustment. Press

to accept the change. The Navigator module will keep this setting as long as it is plugged in to the LEN (Local Equipment Network) bus.

Adjusting the Backlight Brightness

— The backlight of the

display can be adjusted to suit ambient conditions. The factory

default is set to the highest level. To adjust the backlight of the Navigator module, enter the LED Test mode of the device.

ITEM ITEM EXPANSION PATH VALUE TEST Test Display LEDs Configuration ModeDISP

Pressing will access the TEST point. Pressing

again will cause the “OFF” to flash. Use the up or down arrow to change “OFF” to “ON.” Pressing will illuminate all LEDs and display all pixels in the view screen. Pressing the up and down arrow keys simultaneously allows the user to adjust the display brightness. The display will read:

Adjust Brightness

- - - - - - - - - - - - - - - - - +

Use the up or down arrow keys to adjust screen brightness. Press to accept the change. The Navigator module will keep this setting as long as it is plugged in to the LEN bus.

CONTROLS

General —

ComfortLink™ electronic control system that controls and monitors all operations of the chiller. The control system is composed of several components as listed in the following sections. All machines have a Main Base Board (MBB), Touch Pilot™ module, electronic expansion valve board (EXV), fan board, Compressor Protection board, Emergency On/Off switch, and an Enable-Off-Remote Contact switch.

The 30XA air-cooled liquid chillers contain the

Main Base Board (MBB) — The MBB is the core of

the ComfortLink control system. It contains the major portion of operating software and controls the operation of the machine. See Fig. 8. The MBB continuously monitors input/ output channel information received from its inputs and from all other modules. The MBB receives inputs from status and feedback switches, pressure transducers and thermistors. The MBB also controls several outputs. Some inputs and outputs that control the chiller are located on other boards, but are transmitted to or from the MBB via the internal communications bus. Information is transmitted between modules via a 3wire communication bus or LEN (Local Equipment Network). The CCN (Carrier Comfort Network Connections to both LEN and CCN buses are made at TB3.

) bus is also supported.

Page 9

For a complete description of Main Base Board inputs and out-

Fig. 8 — Main Base Board

a30-4255

puts and their channel identifications, see Table 3.

Compressor Protection Module (CPM) — There

is one CPM per compressor. See Fig. 9. The device controls the compressor contactors, oil solenoid, loading/unloading the solenoid, motor cooling solenoid (30XA080,082 only) and the oil separator heater. The CPM also monitors the compressor motor temperature, high pressure switch, oil level switch, discharge gas temperature, oil pressure transducer, motor current, MTA (must trip amps) setting and economizer pressure transducer. The CPM responds to commands from the MBB (Main Base Board) and sends the MBB the results of the channels it monitors via the LEN (Local Equipment Network). The CPM has three DIP switch input banks, Switch 1 (S1), Switch 2 (S2), and Switch 3 (S3). The CPM board DIP switch (S1) configures the board for the type of starter, the location and type of the current transformers and contactor failure instructions. See Table 4 for description of DIP switch 1 (S1) inputs. See Appendix D for DIP switch settings.

The CPM board DIP switch S2 setting determines the must trip amps (MTA) setting. See Appendix D for DIP switch settings. The MTA setting which is calculated using the settings S2 must match the MTA setting in the software or an MTA alarm will be generated.

See below for CPM board DIP switch S3 address information. See Table 5 for CPM inputs and outputs.

CPM-A DIP Switch 1 2 3 4

Address: OFF OFF OFF OFF

CPM-B DIP Switch 1 2 3 4

Address: OFF OFF ON OFF

CPM-C DIP Switch 1 2 3 4

Address: OFF OFF OFF ON

NOTE: The CPM-A and CPM-B DIP switches are for all units. The CPM-C DIP switches are for 30XA400-500 units.

Electronic Expansion Valve (EXV) Board —

The 30XA080,082 unit has one EXV board. The 30XA090500 units have one EXV board per circuit. See Fig. 10. The board is responsible for monitoring the suction gas temperature and economizer gas temperature thermistors. The board also signals the main EXV and economizer EXV (ECEXV) motors to open or close. The electronic expansion valve board responds to commands from the MBB and sends the MBB the results of the channels it monitors via the LEN (Local Equipment Network). See below for DIP switch information. See Tables 6 and 7 for EXV inputs and outputs.

EXV BOARD A

(080-500)

DIP SWITCH

Address: ON ON ON ON ON ON OFF ON

EXV BOARD B

(090-500)

DIP SWITCH

Address: OFF ON ON ON ON ON OFF ON

EXV BOARD C

(400-500)

DIP SWITCH

Address: ON OFFONONONONOFFON

123456 7 8

1 23456 7 8

1 2 3456 7 8

J1A

J10

12/11

221

TR1 TR2 TR3 TR4 TR5

MOV1

24 VAC

C41

C42 C43

C32

C33

J2A

CH19 CH20 CH21 CH22 CH23 CH24 CH25 CH26

C34

J2B

CCN J13 J9D

221

RELAY

C35

OUTPUTS

J2C

+ G -

D15

CCN

ANALOG

INPUTS

STATUS

CH10

SIO

(LEN)

CH11 CH12

+ G –

195

LEN

J9C

CH13

LEN

+ G –

J9B

195

CH14

195

C16

CH 15A

LOCATION OF SERIAL NUMBER

195

15a

DISCRETE

+C+CCH

LEN

+ G –

J9A

INPUTS

J5A

16a+CCH16b

J7A J7B J7C J7D

THERMISERS PRESSURES

J5B

CH17

J5C

CH18

CH6 CH7 CH8 CH9

CH5

CH4

CH1 CH2 CH3

Page 10

Table 3 — Main Base Board Inputs and Outputs

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network —— —

Carrier Communication

Network

Chilled Water Flow Switch CWFS Switch Cooler Flow Switch, LOCK

Demand Limit Switch No. 1 Demand Limit SW1 Switch Limit Switch 2 Status, DLS1 MBB-J4-CH13

Circuit A Discharge

Pressure Transducer

Circuit B Discharge

Pressure Transducer

Dual Chiller

LWT Thermistor

Dual Set Point Input Dual Set Point Switch Remote Setpoint Switch, DUAL MBB-J4-CH12

Entering Water Thermistor EWT 5k Thermistor Cooler Entering Fluid, EWT MBB-J6-CH2

Leaving Water Thermistor LWT 5k Thermistor Cooler Leaving Fluid, LWT MBB-J6-CH1

Outdoor Air Thermistor OAT 5k Thermistor External Temperature, OAT MBB-J6-CH4

External Chilled

Water Pump Interlock

Circuit A Suction

Pressure Transducer

Circuit B Suction

Pressure Transducer

Unit Status Remote Contact-Off-Enable Switch On/Off Remote Switch, ONOF MBB-J4-CH11

Alarm Relay ALM R Relay Alarm Relay Output, ALRM MBB-J3-CH24

Alert Relay ALT R Relay Alert Relay Output, ALRT MBB-J3-CH25

Cooler Heater CL-HT Contactor Cooler Heater Command, CO.HT MBB-J3-CH26 Isolation Valve A ISVA Contactor Ball Valve Position, BVL.A MBB-J2A-CH19 Isolation Valve B ISVB Contactor Ball Valve Position, BVL.B MBB-J2A-CH20

Isolation Valve C (Size 400-500) ISVC Contactor Ball Valve Position, BVL.C MBB-J2C-CH22 Oil Heater A (Size 080, 082 only) OIL HT_A Contactor Circuit A Oil Heater, HT.A MBB-J2C-CH22 Oil Heater B (Size 080, 082 only) OIL HT_A Contactor Circuit B Oil Heater, HT.B MBB-J2C-CH23

Pump #1 Interlock Pump #2 Interlock

LEGEND

I/O — Input or Output LWT — Leaving Water Temperature

—— —

DPTA Pressure Transducer Discharge Pressure, DP.A

DPTB Pressure Transducer Discharge Pressure, DP.B

DUAL 5k Thermistor CHWS Temperature, CHWS MBB-J6-CH3

PMPI Switch Electrical Box Interlock, ELEC MBB-J4-CH15A

SPTA Pressure Transducer Suction Pressure, SP.A

SPTB Pressure Transducer Suction Pressure, SP.B

PMP1 PMP2

Switch Cooler Pump Run Status, PUMP MBB-J5C-CH18

CONNECTION POINT

Pin Notation

MBB-J1, MBB-J1A,

MBB-J1B 11 24 vac 12 Ground

MBB-J9A, MBB-J9B,

MBB-J9C, MBBJ9D

+RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-) MBB-J12

+RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-)

MBB-J5B-CH17

MBB-J7A-CH6

5V +5 vdc Ref.

SSignal

RReturn

MBB-J7C-CH8

5V +5 vdc Ref.

SSignal

RReturn

MBB-J7B-CH7

5V +5 vdc Ref.

SSignal

RReturn

MBB-J7D-CH9

5V +5 vdc Ref.

SSignal

RReturn

Page 11

123 45678

123 4

102

151

102

101

100 K

620

561

151

151 151 151

151

561

13CH14

J11

J10A

J10B

24 VDC/OLL

HPS

LOADERS OLS MOTOR COOLING

OIL

PRESS

CH01

CH02

CH03

CH04

SMT

MOT

TMP

AUX

102

100 K

CH 08

J12

151

R20

102

– G +

3 2 1

– G +

3 2 1

100K

101

PRESS

ECO

SI0 STATU S

CT1

CT2

CT3

151

561

151

(LEN)

MTA

DIP

SWITCH 3

(S3)

DIP

SWITCH 2

(S2)

DIP

SWITCH 1

(S1)

LOCATION OF

SERIAL NUMBER

STAT US

SIO

(LEN)

Fig. 9 — Compressor Protection Module

a30-4215

DIP SWITCH POSITION FUNCTION SETTING MEANING

2, 3

4, 5, 6

8 Not Used — —

Starter Configuration OFF Across-the-line Start

Current Transformer (CT) Position OFF (2), OFF (3) CT is located in the Delta of the motor

Current Transformer (CT) Selection OFF (4), OFF (5), OFF (6) 100A/1V CT1

Table 4 — DIP Switch 1 (S1) Inputs

ON Wye-Delta Start

ON (2), OFF (3) CT is located in the main line OFF (2), ON (3) Reserved for future use ON (2), ON (3) Invalid; will cause MTA configuration alarm

ON (4), OFF (5), OFF (6) 100A/0.503V CT2 OFF (4), ON (5), OFF (6) 100A/0.16V CT3 ON (4), ON (5), OFF (6) Invalid; will cause MTA configuration alarm OFF (4), OFF (5), ON (6) Invalid; will cause MTA configuration alarm ON (4), OFF (5), ON (6) Invalid; will cause MTA configuration alarm OFF (4), ON (5), ON (6) Invalid; will cause MTA configuration alarm ON (4), ON (5), ON (6) Invalid; will cause MTA configuration alarm

Contactor Failure Action OFF All units should be off

ON Used when Shunt Trip is available in the unit

Page 12

Table 5 — Compressor Protection Module Inputs and Outputs*

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network —— —

Circuit X High Pressure Switch HPS-X Switch Not available

Oil Level Switch Oil LS X Switch Circuit X Oil Solenoid, OLS.X

Must Trip Amps† MTA (S2) 8-Pin DIP Switch Must Trip Amps, MTA.X

Configuration Switch† S1 8-Pin DIP Switch S1 Config Switch, C.SW.X

Compressor X Motor Temperature MTR-X NTC Thermistor Motor Temperature, CTP.X

Compressor X Discharge Gas Temperature DGT X NTC Thermistor Discharge Gas Temp, DGT.X

Oil Pressure Transducer OPT X Pressure Transducer Oil Pressure, OP.X

Economizer Pressure Transducer EPT X Pressure Transducer Economizer Pressure, ECP.X

Compressor Current X Phase A Current Sensor CUR.A

Compressor Current X Phase B Current Sensor CUR.B

Compressor Current X Phase C Current Sensor CUR.C

Compressor X 1M Contactor C X 1M Contactor Compressor Output, CP.X

Compressor X 2M Contactor C X 2M Contactor Not available

Compressor X S Contactor C X S Contactor Not available

Oil Heater Relay X (090-500 Only)

Oil Solenoid X Oil solenoid-X Solenoid Oil Solenoid Output, OLS.X

Load Solenoid X Loading Solenoid-X Solenoid Slide Valve 1 Output, SL1.X

Unload Solenoid X Unloading Solenoid-X Solenoid Slide Valve 2 Output, SL2.X

Gas Cooling Solenoid X (080,082 Only) Gas Cooling Solenoid-X Solenoid DGT Cooling Solenoid, DGT.X

*“X” denotes the circuit, A, B or C. †See Appendix D for MTA settings.

Oil HTR X Contactor Oil Heater Output, HT.X

CONNECTION POINT

Pin Notation

CPM-X-J1 11 24 vac 12 Ground

CPM-X-JP12 1 RS485 Port (D+) 2 RS485 Port (Gnd) 3 RS485 Port (D-)

CPM-X-J12 1 RS485 Port (D+) 2 RS485 Port (Gnd) 3 RS485 Port (D-)

CPM-X-J7-CH05

CPM-X-J6-CH06

CPM-X-J9-CH01

CPM-X-J9-CH02

CPM-X-J10B-CH04

5V + 5 vdc ref

S Signal

RReturn

CPM-X-J10A

5V + 5 vdc ref

S Signal

RReturn

CPM-X-J8-CH01

CPM-X-J8-CH02

CPM-X-J8-CH3

CPM-X-J1-CH07 1 2

CPM-X-J2-CH8 1 2

CPM-X-J2-CH9 1 2

CPM-X-J2-CH10 1 2

CPM-X-J2-CH12 1 2

CPM-X-J2-CH13 1

CPM-X-J2-CH14 1 2

CPM-X-J2-CH10 1 2

Page 13

100

257-01

712

100K

100

J2A EXVA

J2B EXVB

24VAC

STATUS

MOV1

LOCATION OF SERIAL NUMBER

432 1

THA THB

C15

C16

Q2 Q1

12/11

C17

Q45

Q42Q37

Q35

Q25

Q27

Q30

Q20

Q22

Q17

Q15

Q12

Q10

C10

C11

C37C39

D15

C25

C49

Q4Q5

R3 L3

TEMP

D29

D9 D8

SI0 (LEN)

COMM J4

DIP SWITCH

Fig. 10 — EXV Board

a30-4216

Page 14

Table 6 — EXVA Board Inputs and Outputs (30XA080,082)

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network —— —

Circuit A Suction Gas Thermistor SGTA 5k Thermistor Compressor Suction Temp, SGT.A

Circuit B Suction Gas Thermistor SGTB 5k Thermistor Compressor Suction Temp, SGT.B

Circuit A EXV EXV-A Stepper Motor EXV Position, EXV.A

Circuit B EXV EXV-B Stepper Motor EXV Position, EXV.B

CONNECTION POINT

Pin Notation

EXVA-J1 11 24 vac 12 Ground

EXVA-J4

1 RS485 Port (D+) 2 RS485 Por t (Gnd) 3 RS485 Port (D–)

EXVA-J3

EXVA-J2A 1 2 3 4

EXVA-J2B 1 2 3 4

Table 7 — EXV A,B,C Board Inputs and Outputs* (30XA090-500)

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network ——

Circuit X Suction Gas Thermistor SGT X 5k Thermistor Compressor Suction Temp, SGT.X

Circuit X Economizer Gas Thermistor ECT X 5k Thermistor Economizer Gas Temp, ECT.X

Circuit X EXV EXV-X Stepper Motor EXV Position, EXV.X

Circuit X Economizer EXV ECEXV-X Stepper Motor Cir X Economizer EXV Pos, ECO.X

*“X” denotes the circuit, A, B or C.

—

CONNECTION POINT

Pin Notation

EXVX-J1 11 24 vac 12 Ground

EXVX-J4

1 RS485 Port (D+) 2 RS485 Port (Gnd) 3 RS485 Port (D–)

EXVX-J3

EXVX-J2A 1 2 3 4

Page 15

Fan Boards — At least one fan board is installed in each

100K

CH1

CH2 CH3

CH4 CH5 CH6 CH7 CH8

TR1 TR2 TR3 TR4 TR5 TR6 TR7 TR8

STATU S SIO (LEN)

LOCATION OF SERIAL NUMBER

24 VAC

CH13 CH14

CH9

CH10

CH11

CH12

JP2

C61

CH13

D12

JP1

U21

Q10

Q11

U10

Q12

Q60

3 2 1

– G +

3 2 1

– G +

DIP SWITCH

100K

LOCATION OF SERIAL NUMBER

TR1 TR2 TR3 TR4 TR5 TR6 TR7 TR8

CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8

STAT US SIO (LEN)

24 VAC

Q10

Q11Q12

Q13

3 2 1

– G +

3 2 1

– G +

DIP SWITCH

Fig. 11 — Fan Board (AUX 1) with Low Ambient Temperature Head Pressure Control

Fig. 12 — Fan Board (AUX 2) without Low Ambient Temperature Head Pressure Control

a30-4046

a30-4047

unit. See Fig. 11 and 12. There are two types of fan boards. One with and one without an analog output signal for the low ambient temperature head pressure control fan speed controllers. If a unit does not have low ambient temperature head pressure control installed, it will not have the analog connection terminals. The fan board responds to commands from the MBB and sends the MBB the results of the channels it monitors via the Local Equipment Network (LEN). See below for fan board A, B and C DIP switch addresses. See Tables 8-10 for inputs and outputs.

FAN BOARD

(080,082)

123 45678

DIP SWITCH

Address: OFF ON OFF OFF ON OFF ON OFF

FAN BOARD A

(090-500)

DIP SWITCH

12345678

Address: OFF ON OFF OFF ON OFF ON OFF

FAN BOARD B

(140-500)

DIP SWITCH

123 45678

Address: ON ON OFF OFF ON OFF ON OFF

FAN BOARD C

(400-500)

12345678

DIP SWITCH

Address: OFF OFF ON OFF ON OFF ON OFF

Page 16

Table 8 — Fan Board A Outputs (30XA080-122)

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network —— —

Circuit A Low Ambient Temperature

Head Pressure Control Speed Signal

Circuit B Low Ambient Temperature

Head Pressure Control Speed Signal

Fan Contactor A1 FCA1 Contactor FBA-J2-CH1 Fan Contactor A2 FCA2 Contactor FBA-J2-CH2 Fan Contactor A3 FCA3 Contactor FBA-J2-CH3

Fan Contactor A4 FCA4 Contactor

Fan Contactor B1 FCB1 Contactor FBA-J3-CH5 Fan Contactor B2 FCB2 Contactor FBA-J3-CH6 Fan Contactor B3 FCB3 Contactor FBA-J3-CH7

Fan Contactor B4 FCB4 Contactor

*Output only on low ambient temperature head pressure control (AUX1).

MM-A* 0-10 VDC Head Press Actuator Pos, SPD.A

MM-B* 0-10 VDC Head Press Actuator Pos, SPD.B

CONNECTION POINT

Pin Notation

FBA-J1 11 24 vac 12 Ground

FBA-J9

+ RS485 Port (D+)

G RS485 Port (Gnd)

-RS485 Port (D-)

+ RS485 Port (D+)

G RS485 Port (Gnd)

-RS485 Port (D-) FBA-CH9

+ Signal

- Ground

FBA-CH10

+ Signal

- Ground

FBA-J2-CH4

(090-122)

FBA-J3-CH8

(090-122)

Table 9 — Fan Board X Outputs (30XA140-352)

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network —— —

Circuit X Low Ambient Temperature

Head Pressure Control

Speed Signal

Fan Contactor X1 FCX1 Contactor FBX-J2-CH01 Fan Contactor X2 FCX2 Contactor FBX-J2-CH02 Fan Contactor X3 FCX3 Contactor FBX-J2-CH03 Fan Contactor X4 FCX4 Contactor FBX-J2-CH04 Fan Contactor X5 FCX5 Contactor FBX-J3-CH05 Fan Contactor X6 FCX6 Contactor FBX-J3-CH06 Fan Contactor X7 Fan Contactor X8 FCX8 Contactor FBX-J3-CH08

*Output only on units with low ambient temperature head pressure control installed (AUX1). NOTES:

1. Fan Board B used on 30XA140-350.

2. “X” indicates circuit A or circuit B.

3. See page 109, Fig. 65 for which contactor is used with circuit A or B.

MM-n* 0-10 VDC Head Press Actuator Pos, SPD.X

FCX7 Contactor FBX-J3-CH07

CONNECTION POINT

Pin Notation

FBX-J1 11 24 vac 12 Ground

FBX-J9

+ RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-)

+ RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-) FBX-CH9

+ Signal

- Ground

Page 17

Table 10 — Fan Board C Inputs and Outputs (30XA400-500)

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

Power (24 vac supply) —— —

Local Equipment Network —— —

Circuit C Discharge

Pressure Transducer

Circuit C Suction

Pressure Transducer

Circuit C Low Ambient

Temperature Head Pressure

Control Speed Signal

Fan Contactor C1 FCC1 Contactor FBC-J2-CH1 Fan Contactor C2 FCC2 Contactor FBC-J2-CH2 Fan Contactor C3 FCC3 Contactor FBC-J2-CH3 Fan Contactor C4 FCC4 Contactor FBC-J2-CH4 Fan Contactor C5 FCC5 Contactor FBC-J3-CH5 Fan Contactor C6 FCC6 Contactor FBC-J3-CH6 Fan Contactor C7 FCC7 Contactor FBC-J3-CH7 Fan Contactor C8 FCC8 Contactor FBC-J3-CH8

DPTC Pressure Transducer Discharge Pressure, DP.C FBC-J7-CH13

SPTC Pressure Transducer Suction Pressure, SP.C FBC-J8-CH14

MM-C 0-10 VDC Head Press Actuator Pos, SPD.C

CONNECTION POINT

Pin Notation

11 24 vac 12 Ground

+ RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-) + RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-)

+ Signal

- Ground

(Unit Size)

FBC-J1

FBC-J9

FBC-CH9

Enable-Off-Remote Contact Switch (SW1) —

This switch is installed in all units and provides the owner and service person with a local means of enabling or disabling the machine. It is a 3-position switch and it is used to control the chiller. When switched to the Enable position, the chiller will be under its own control. When switched to the Off position, the chiller will shut down. When switched to the Remote Contact position, a field-installed dry contact can be used to start the chiller. The contacts must be capable of handling a 24-vac, 50-mA load. In the Enable and Remote Contact (dry contacts closed) positions, the chiller is allowed to operate and respond to the scheduling configuration, CCN configuration, and set point data.

For units with a Touch Pilot™ display, the position of the Enable/Off/Remote contact switch is ignored except when the “remote mode” control type is selected. Refer to the Machine Control Methods section on page 22 for more details.

Emergency On/Off Switch (SW2) — This switch is

installed in all units. The Emergency On/Off switch should only be used when it is required to shut the chiller off immediately. Power to all modules is interrupted when this switch is off and all outputs from these modules will be turned off.

Energy Management Module (EMM) — The EMM

is available as a factory-installed option or as a field-installed accessory. See Fig. 13. The EMM receives 4 to 20 mA inputs for the temperature reset, cooling set point and demand limit functions. The EMM also receives the switch inputs for the field-installed second stage 2-step demand limit and ice done functions. The EMM communicates the status of all inputs with the MBB, and the MBB adjusts the control point, capacity

limit, and other functions according to the inputs received. See Tab l e 11.

CAUTION

Care should be taken when interfacing with other manufacturer’s control systems due to possible power supply differences, full wave bridge versus half wave rectification, which could lead to equipment damage. The two different power supplies cannot be mixed. ComfortLink™ controls use half wave rectification. A signal isolation device should be utilized if incorporating a full wave bridge rectifier signal generating device is used.

Hot Gas Bypass/Pump Board — The hot gas by-

pass (HGBP) and pump board controls the ON/OFF of the HGBP solenoids and pump contactors, and responds to MBB commands via the LEN connection. Hot gas bypass is available as a factory-installed option or as a field-installed accessory for 30XA080-500, and the pump package is available as factory-installed option for sizes 30XA090-162. See Fig. 14. The board is not required for single pump operation. See below for DIP switch information. See Table 12 for HGBP/Pump board inputs and outputs.

HGBP/Pump

BOARD

DIP SWITCH

Address: ON ON ON OFF ON OFF ON OFF

123 45678

Page 18

Table 11 — Energy Management Module (EMM) Inputs and Outputs

221

100K

CH 17

CH 16

CH 18

CH 19

CH 20

CH 22

CH 21

CH 23

24 VAC

12 11

11b

CH 5

CH 6

CH 7

SIO LEN

+ G -

SIO LEN

J7B

J7A

J4 J3 J2B

J2A

Fig. 13 — Energy Management Module

a30-4465

INPUT/OUTPUT DESCRIPTION I/O TYPE DISPLAY MODULE POINT NAME CONNECTION POINT 4-20 mA Demand Limit 4-20 mA Demand Limit 4-20 mA* Limit 4-20 mA Signal, DMD EMM-J7B-CH6 4-20 mA Temperature

Reset/Cooling Setpoint Demand Limit SW2 Demand Limit Step 2 Switch Input Switch Limit Setpoint 2, DLS2 EMM-J4-CH9 Ice Done Ice Done Switch Switch Input Ice Done Storage Switch, ICE.D EMM-J4-CH11A Occupancy Override Occupied Schedule Override Switch Input Occupied Override Switch, OCCS EMM-J4-CH8 Remote Lockout Switch Chiller Lockout Switch Input Remote Interlock Switch, RLOC EMM-J4-CH10 SPT Space Temperature Thermistor 10k Thermistor Optional Space Temp, SPT EMM-J6-CH2 % Total Capacity Percent Total Capacity Output 0-10 vdc Chiller Capacity Signal, CATO EMM-J8-CH7 RUN R Run Relay Relay Running Status, RUN EMM-J3-CH25 SHD R Shutdown Relay Relay Shutdown Indicator State, SHUT EMM-J3-CH24

* A field-supplied 1/2 watt 250 ohm resistor is required across terminals TB6-1,2 (CH6) and/or TB6-3, 4 (CH5).

4-20 mA Temperature Reset/ Cooling Set point

4-20 mA*

Reset/Setpnt 4-20 mA Signal, RSET

EMM-J7A-CH5

Page 19

Table 12 — Hot Gas Bypass/Pump Board Inputs and Outputs

100K

LOCATION OF SERIAL NUMBER

TB1 TB2 TB3 TB4 TB5 TB6 TB7 TB8

CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8

STATUS SIO (LEN)

24 VAC

Q10

Q11Q12

Q13

3 2 1

– G +

3 2 1

– G +

DIP SWITCH

Fig. 14 — Hot Gas Bypass/Pump Board

a30-4047

DESCRIPTION INPUT/OUTPUT I/O TYPE DISPLAY MODULE POINT NAME

—— — HGBP/PMP-J1

Power (24 vac supply)

—— — HGBP/PMP-J9

Local Equipment Network

Circuit A Minimum Load Control MLV-A Solenoid Valve Hot Gas Bypass A Output, HGB.A HGBP/PMP-J2-CH3 Circuit B Minimum Load Control MLV-B Solenoid Valve Hot Gas Bypass B Output, HGB.B HGBP/PMP-J2-CH4 Circuit C Minimum Load Control MLV-C Solenoid Valve Hot Gas Bypass C Output, HGB.C HGBP/PMP-J2-CH5 Pump #1 Starter PMP1 Contactor Water Exchanger Pump 1, PMP.1 HGBP/PMP-J2-CH1 Pump #2 Starter PMP2 Contactor Water Exchanger Pump 2, PMP.2 HGBP/PMP-J2-CH2

CONNECTION POINT

Pin Notation

11 24 vac 12 Ground

+ RS485 Port (D+)

G RS485 Port (Gnd)

- RS485 Port (D-)

Local Equipment Network — Information is trans-

mitted between modules via a 3-wire communication bus or LEN (Local Equipment Network). External connection to the LEN bus is made at TB3.

Board Addresses — All boards (except the Main Base

Board and Energy Management Module Board) have 8-position DIP switches.

Touch Pilot™ Display — The Touch Pilot display port

connections are shown in Table 13. Wiring is shown in Fig. 15.

Control Module Communication

RED LED — Proper operation of the control boards can be visually checked by looking at the red status LEDs (lightemitting diodes). When operating correctly, the red status LEDs will blink in unison at a rate of once every 2 seconds. If the red LEDs are not blinking in unison, verify that correct power is being supplied to all modules. Be sure that the Main

Base Board (MBB) is supplied with the current software. If necessary, reload current software. If the problem still persists, replace the MBB. A red LED that is lit continuously or blinking at a rate of once per second or faster indicates that the board should be replaced.

GREEN LED — All boards have a green LEN (SIO) LED which should be blinking whenever power is on. If the LEDs are not blinking as described check LEN connections for potential communication errors at the board connectors. See Input/Output Tables 3-12 for LEN connector designations. A 3-wire bus accomplishes communication between modules. These 3 wires run in parallel from module to module. The J9A connector on the MBB provides communication directly to the Navigator™ display module.

YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network

(CCN) LED will blink during times

of network communication.

Page 20

Table 13 — Touch Pilot™ Display Port

a30-4082

Fig. 16 — ComfortLink™ CCN Communication Wiring

Fig. 15 — Touch Pilot™ Display Wiring

Connections

CONNECTOR PIN FUNCTION

1 24VAC +

J1 (Power)

J2 (COM1)

J3 (RJ11)

2 24VAC 3 Earth Ground 1 RS485 Port (D+) 2 RS485 Port (GND) 3 RS485 Port (D-) 1 24VAC (+) 2 RS485 Port (D+) 3 RS485 Port (GND) 4 Unused (no connect) 5 RS485 Port (D-) 6 24VAC(-)

Carrier Comfort Network® (CCN) Interface —

All 30XA units can be connected to the CCN, if desired. The communication bus wiring is a shielded, 3-conductor cable with drain wire and is field supplied and installed. The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system elements on either side of it. The negative and signal ground pins of each system element must also be wired in the same manner. Wiring connections for CCN should be made at TB3. Consult the CCN Contractor’s Manual for further information. See Fig. 16.

NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 C to 60 C is required. See Table 14 for recommended wire manufacturers and part numbers.

Table 14 — CCN Communication Bus Wiring

MANUFACTURER

Alpha 1895 — American A21451 A48301 Belden 8205 884421 Columbia D6451 — Manhattan M13402 M64430 Quabik 6130 —

Regular Wiring Plenum Wiring

PART NU M B E R

It is important when connecting to a CCN communication bus that a color-coding scheme be used for the entire network to simplify the installation. It is recommended that red be used for the signal positive, black for the signal negative, and white for the signal ground. Use a similar scheme for cables containing different colored wires.

At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to a ground at one point only. If the communication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building (one point per building only). To connect the unit to the network:

1. Turn off power to the control box.

2. Cut the CCN wire and strip the ends of the red (+), white (ground), and black (–) conductors. (Substitute appropriate colors for different colored cables.)

3. Connect the red wire to (+) terminal on TB3 of the plug, the white wire to COM terminal, and the black wire to the (–) terminal.

4. The RJ14 CCN connector on TB3 can also be used, but is only intended for temporary connection (for example, a laptop computer running Service Tool).

IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent the unit from starting. If abnormal conditions occur, disconnect the CCN bus. If conditions return to normal, check the CCN connector and cable. Run new cable if necessary. A short in one section of the bus can cause problems with all system elements on the bus.

Remote Alarm and Alert Relays — The 30XA chill-

er can be equipped with a remote alert and remote alarm annunciator contacts. Both relays connected to these contacts must be rated for a maximum power draw of 10 va sealed, 25 va inrush at 24 volts. The alarm relay, indicating that the complete unit has been shut down, can be connected to TB5-12 and TB5-13. Refer to unit wiring diagrams. For an alert relay, indicating that at least 1 circuit is off due to the alert, a fieldsupplied and installed relay must be connected between MBBJ3-CH25-3 and TB5-13. The action of the alarm and alert relays can be reversed from normally open to normally closed by using the Reverse Alarms Relay configuration (Reverse Alarms Relay, RV.AL).

Page 21

CONFIGURATION

Fig. 16 — ComfortLink™ CCN Communication Wiring

Touch Pilot™ Operation Configuration Table s —

configuration information entered in the following configuration tables. These tables are accessible by using Network

The Touch Pilot display operation is controlled by

Service Tool or ComfortVIEW™ software. The tables are the CtrlID (Controller Identification) configuration table and the USERCONF (User Configuration) table. See Tables 15 and 16.

NOTE: Always perform an Upload to obtain the latest configuration before making configuration table changes.

Table 15 — Touch Pilot Controller Identification Configuration Table

CONTROLLER ID DATA BLOCK NO. VALUE AND RANGE QUALIFIERS

Device Name 1

Local address 2 115 Default Bus number 2 0 Default

Device (driver) type 2

Primary baud rate 3 38400 Default Secondary baud rate 3 38400 Fixed

Device description 4

Device location 4

Software part number 4 CESR-131363-01 Fixed Model number 4 (Blank) Fixed Serial number 4 (Blank) Fixed Reference number 4 Version 1.0 Fixed

Broadcast address processing list (primary) 5

Broadcast address processing list (secondary) 5 none Not applicable

CHILLDSP 8 character Name field

0 = Non-bridge 3 = Broadcast Acknowledger

Global Chiller Display 24 character text field

(Blank) 24 character text field

241-251, 254, 255 enabled 241-255 enabled/disabled

Default Optional

Defaults Optional

Table 16 — Touch Pilot™ User Configuration (USERCONF) Table

DESCRIPTION LIMITS UNITS NAME DEFAULT Backlight always on? No - Yes BACKLITE No Full access password 0 - 9999 PSWDFULL 3333 Limited access password 0 - 9999 PSWDLMTD 2222 Active language 0 - 1 ACTLANG 0 Time format 0 - 1 TIMEFMT 0 Date format 0 - 2 DATEFMT 0 Units base US - Metric UNITBASE US Contrast control Manual - Auto CONTRAST Auto Network mode 0 - 1 NETWORK 0 Network settings

Alarm acknowledger No - Yes ALARMACK No Broadcast acknowledger No - Yes BROADACK No

Equipment CCN address

Bus number 0 - 239 EQUIPBUS 0 Element number 1 - 239 EQUIPELE 1

Control variables

Equipment status (Not Used) Name char 8 EQSTATUS NOT USED Equipment start/stop (Not Used) Name char 8 STARSTOP NOT USED Alarm status (Not Used) Name char 8 ALSTATUS NOT USED Alarm reset (Not Used) Name char 8 ALRESET NOT USED

Page 22

BACKLIGHT ALWAYS ON? — This configuration is used to keep the backlight on continuously or to turn it off after 60 seconds with no activity.

Allowable Entries: No/Yes (No=0 or Yes=1) Default Value: No FULL ACCESS PASSWORD — This configuration is used

to specify the full access password. Refer to Table 1, Setup Menu, for additional information on passwords.

Allowable Entries: 0 through 9999 Default Value: 3333 LIMITED ACCESS PANEL — This configuration is used to

specify the limited access password. Allowable Entries: 0 through 9999 Default Value: 2222 ACTIVE LANGUAGE — This configuration is used to spec-

ify the display’s active language. All translatable text will be displayed in this language.

Allowable Entries: 0, 1 Default Value: 0 TIME FORMAT — This configuration is used to specify the

format for display of time. Allowable Entries: 0 = H:MM AM/PM without leading zero

1 = HH:MM with leading zero when

necessary Default Value: 0 DATE FORMAT — This configuration is used to specify the

format for display of date. Allowable Entries: 0 = MM-DD-YYYY with leading zero

when necessary

1 = DD-MM-YYYY with leading zero

when necessary

2 = YYYY-MM-DD Default Value: 0 UNITS BASE — This configuration is used to specify the for-

mat of the units of measure. Allowable Entries: U.S.

Metric Default Value: U.S. CONTRAST CONTROL — This configuration is used to en-

able or disable the display’s auto contrast adjustment feature. When enabled, the display’s contrast will be automatically adjusted as required, based on temperature.

Allowable Entries: Manual

(Auto Contrast Adjustment Disabled)

Auto

(Auto Contrast Adjustment Enabled) Default Value: Auto NETWORK MODE — This configuration is used to set the

display’s operating mode. For additional information on operating mode, refer to Display in the Table Setup Menu. This decision will be ignored and the mode will default to Equipment when the display is connected to a device (the LEN Bus).

NOTE: A power cycle is required for this decision to take effect.

Allowable Entries: 0 (Disable) = Equipment Mode

1 (Enable) = Network Mode Default Value: 0 (Disable) ALARM ACKNOWLEDGER — This configuration is used

to specify whether the Touch Pilot™ display will act as the alarm acknowledger for the CCN. There can be only one alarm acknowledger per CCN. Therefore, if another CCN device

such as ComfortVIEW™ software, the Autodial Gateway or TeLINK is already set as the alarm acknowledger for the CCN network then this decision should be set to No.

NOTE: The display must be in Network mode and connected to the primary CCN bus and this decision set to Ye s for alarm acknowledgement to be enabled.

Allowable Entries: No

Ye s Default Value: No BROADCAST ACKNOWLEDGER — This configuration

is used to indicate whether the Touch Pilot display will act as the broadcast acknowledger for its CCN bus. There can be only one broadcast acknowledger per CCN bus.

NOTE: The display must be in Network mode and this decision set to Ye s for broadcast acknowledgement to be enabled.

Allowable Entries: No

Ye s Default Value: No EQUIPMENT CCN ADDRESS — When in equipment

mode (USERCONF Table’s Network Mode decision is set to Disable), the Bus Number and Element Number decisions are used to specify the CCN address of the piece of equipment to communicate with. An Attach or power cycle must be performed for changes to take effect. These decisions will be ignored when the display is connected to the LEN bus or in Network mode. In Network mode, specify the bus and element number the equipment communicates with using the display’s Attach function.

NOTE: In Network mode, these configurations will be overwritten with the default device address if it is changed through the Attach process.

BUS NUMBER — This configuration is used to specify the Equipment Controller bus number.

Allowable Entries: 0 through 239 Default Value: 0 ELEMENT NUMBER — This configuration is used to speci-

fy the Equipment Controller element number. Allowable Entries: 1 through 239 Default Value: 1

Machine Control Methods — Three variables con-

trol how the machine operates. These variables control the On-Off function, set point operation, and Heat-Cool operation.

Machine On/Off Control — Machine On/Off control

depends on which interface display is used. The control is different for Touch Pilot™ or Navigator™ displays. Select the correct configuration procedure below based on which interface is being used.

TOUCH PILOT MACHINE CONTROL — Machine On/Off control is determined locally by pushing the Start/Stop button on the Touch Pilot display. Pressing this button will cause the Equipment Start screen to be displayed. See Fig. 17.

Table 17 summarizes the unit control type and stop or go

status with regard to the following parameters:

• Operating type: this is selected by using the start/stop button

on the front of the user interface.

• Remote start/stop contacts: these contacts are used when the

unit is in remote operating type (Remote mode).

• CHIL_S_S: this network command variable relates to the

chiller start/stop when the unit is in CCN control (CCN mode). When this variable forced to Disable, then the unit is stopped. When this variable is forced to Enable, then the unit runs in accordance with schedule 1.

Page 23

• Start/Stop schedule: occupied or unoccupied status of the

Fig. 17 — Equipment Start Screen

unit as determined by the chiller start/stop program (Schedule 1).

• Master control type: This parameter is used when the unit is the master unit in a two chiller lead/lag arrangement. The master control type determines whether the unit is to be controlled locally, remotely or through CCN (this parameter is a Service configuration).

• CCN emergency shutdown: if this CCN command is activated, it shuts the unit down whatever the active operating type.

• General alarm: the unit is totally stopped due to failure.

Local Mode

— To start the machine in local mode, press the Start/Stop button on the Touch Pilot display. The Equipment Start screen will be displayed. Select Local On. The control will ignore the position of Enable/Off/Remote Contact switch and all CCN network force commands, except an Emergency Stop Command. The Run Status variable, indicating the cur- rent status of the machine, will change to RUNNING, DELAY or READY. The Chiller Occupied? variable will change to YES. The Control Type variable indicates the type of control. For this configuration, Control Type will be Local. The Oper- ating Type variable will change to L-On (Local On).

Local Schedule

— To start the machine with a local schedule, press the Start/Stop button on the Touch Pilot display. The Equipment Start screen will be displayed. Select Local Schedule. The unit will start and stop according to the schedule defined in the Time Schedule menu. Two Internal Time Schedules are available and must be field programmed. Time Schedule 1 is used for single set point On-Off control. Time Schedule 2 is used for Dual Set Point/Occupied-Unoccupied set point control. The control will ignore the position of Enable/Off/Remote Contact switch and all CCN network force commands, except the Emergency Stop Command.

The Run Status variable will indicate the current status of the machine — OFF, RUNNING, DELAY, or READY. The Chiller Occupied? variable will indicate the occupied state of the machine according to Time Schedule 1 and will be either YES (occupied) or NO (unoccupied). The Control Type vari- able will indicate the type of control. For this configuration,

Control Type will be Local. The Operating Type variable will change to L-Sched (Local Schedule).

The schedules consist of 8 user-configurable occupied time periods. The control supports time schedules for local control, remote control, and ice building. These time periods can be flagged to be in effect or not in effect on each day of the week. The day begins at 00.00 and ends at 24.00. The machine will be in unoccupied mode unless a scheduled time period is in effect. If an occupied period extends past midnight, the occupied period will automatically end at 24:00 hours (midnight) and the new occupied period must be programmed to begin at 00:00 hours.

In the following example, the occupied period starts at 6:00 AM, Monday through Friday and 10:00 AM on Saturday and Sunday. The occupied time ends at 6:30 PM on Monday through Friday and 2:00 PM on Saturday and Sunday. See Fig. 18.

Table 17 — Touch Pilot™ Start/Stop Control

ACTIVE OPERATING TYPE PARAMETER STATUS

LocalOnLocalOnLocal

-- - - - - - - - - Active - - Off

-- - - - - - - - - - Yes - Off

Active - - - - - - - - - - - Local Off

- - Active - - - - - - Unoccupied - - Local Off

- - - Active - - - Off - - - - Remote Off

- - - Active - - - - - Unoccupied - - Remote Off

- - - - Active - Off - - - - - CCN Off

- - - - Active - - - - - - - CCN Off

- - - - - Active - - Local Unoccupied - - Local Off

- - - - - Active - Off Remote - - - Remote Off

- - - - - Active - - Remote Unoccupied - - Remote Off

- - - - - Active Off - CCN - - - CCN Off

- - - - - Active - - CCN Unoccupied - - CCN Off

- Active - - - - - - - - Disabled No Local On

- - Active - - - - - - Occupied Disabled No Local On

- - - Active - - - On Cool - Occupied Disabled No Remote On

- - - - Active - On - - Occupied Disabled No CCN On

- - - - - Active - - Local Occupied Disabled No Local On

- - - - - Active - On Cool Remote Occupied Disabled No Remote On

- - - - - Active On - CCN Occupied Disabled No CCN On

Schedule

Remote

Mode

CCN

Mode

Master

Mode

CHIL_S_S

Varia ble

Remote

Start/Stop

Contact

Master Unit

Control Type

Start/Stop

Schedule

Mode

CCN

Emergency

Shutdown

General

Alarm

CONTROL

TYPE

UNIT

STATUS

Page 24

Table 19 — Programming Holiday Schedules with

Fig. 18 — Chiller Schedule Screen

Touch Pilot Display

NOTE: This schedule was designed to illustrate the programming of the schedule function and is not intended as a recommended schedule for chiller operation.

If the chiller is to be controlled to a single set point, use Schedule 1 (OCCPC01S). This will start and stop the machine. During the unoccupied times, the chiller will be off. If the chiller is to be controlled to 2 set points, occupied and unoccupied, use Schedule 2 (OCCPC02S). This will cause the chiller to control to an occupied set point and an unoccupied set point. The machine will be able to provide cooling at any time.

To configure this option on the Touch Pilot™ display see Table 18.

Table 18 — Configuring the Schedule with

Touch Pilot Display

DISPLAY NAME PATH

Period 1 DOW (MTWTFSSH) Occupied from 3 00:00 Occupied to 4 03:00 Period 2 DOW (MTWTFSSH) 5 11000000 Occupied from 6 07:00 Occupied to 7 18:00 Period 3 DOW (MTWTFSSH) 8 00100000 Occupied from 9 07:00 Occupied to 10 21:30 Period 4 DOW (MTWTFSSH) 11 00011000 Occupied from 12 07:00 Occupied to 13 17:00 Period 5 DOW (MTWTFSSH) 14 00000100 Occupied from 15 07:00 Occupied to 16 12:00

Holiday Schedule

— For the Touch Pilot display, the control

Config\

OCCDEFCS\

OCC1P01S

or OCC1P02S

LINE

VAL UE

NO.

2 10000000

allows up to 16 holiday periods. All holidays are entered with numerical values. To configure, first change the month (Holi- day Start Month), then the day (Holiday Start Day), then the duration (Holiday Duration) of the holiday period in days. If a holiday in included in one of the Occupied Time Periods of the schedule, the machine will follow that operating condition for the holiday. In the following examples, the holidays July 4 and December 25-26 are programmed for Holiday 1 and Holiday 2, respectively. To configure these holidays with the Touch Pilot display, see Table 19. To configure Holidays with the Navigator display, check the H (holiday) schedule on the Schedule screen and program in the desired occupied times. See Fig. 18.

DISPLAY NAME PATH

Holiday Start Month Start Day 24 Duration (days) 31 Holiday Start Month Start Day 225 Duration (days) 32

Timed Override

Config\HOLIDAY\HOLDY_01

Config\HOLIDAY\HOLDY_02

— With the Touch Pilot display only, each

LINE

VAL UE

NO.

112

time schedule can be overridden to keep the chiller in an Occupied mode (Timed Override Hours) for 1, 2, 3 or 4 hours on a one-time basis. To configure this option for the Touch Pilot display, see Table 20.

Table 20 — Configuring Timed Override

DISPLAY NAME PATH

Timed Override Hours

Config\OCCDEFCS\

OCC1P01S or OCC1P02S

LINE

NO.

VAL UE

Range: 0 to 4

Default: 0

If configured for a timed override, the override can be can-

celled by changing the Timed Override Hours to 0. CCN Global Time Schedule

— A CCN Global Schedule can be utilized with the chiller controls. The schedule number can be set anywhere from 65 to 99 to configure operation under a CCN global schedule. The 30XA chillers can be configured to follow a CCN Global Time Schedule broadcast by another system element. ComfortVIEW™ Network Manager’s Configure and Modify commands or the Service Tool’s Modify/Names function must be used to change the number of the Occupancy Equipment Part Table Name (OCC1P01E) to the Global Schedule Number. The Schedule Number can be set from 65 to 99 (OCC1P65E to OCC1P99E).

CCN Mode

— To allow machine control by CCN commands, press the Start/Stop button on the Touch Pilot™ display. The Equipment Start screen will be displayed. Select CCN Mode. The unit will be controlled by a CCN command to the CCN Chiller Star t/Stop variable. An external CCN device, such as Chillervisor, controls the On/Off state of the machine. When controlled by a Chillervisor, it is recommended that the Auto Start W hen SM Lost configuration be set to Yes. In the event of a loss of communication with the network, the machine will start and be controlled locally.

Careful evaluation of chilled water plant control should be reviewed. In the event local control is established, be sure that all pumps, valves, and other devices are capable of operating properly. The control will ignore the position of Enable/Off/ Remote Contact switch. The Run Status variable will indicate the current status of the machine — OFF, RUNNING, DELAY, or READY. The Control Type variable will change to CCN. The Operating Type variable will change to CCN.

For dual chiller control applications, the slave chiller must be enabled using the CCN Mode button.

Remote Mode

— To allow machine to start and stop via a remote contact closure, press the Start/Stop button on the Touch Pilot display. The Equipment Start screen will be

Page 25

displayed. Select Remote Mode. The unit will be controlled by

Fig. 19 — Equipment Stop Screen

the Enable/Off/Remote Contact switch. Switching the Enable/ Off/Remote Contact switch to the Enable or Remote Contact position (external contacts closed) will force the unit into an occupied state. In this mode, all CCN network force commands, except the Emergency Stop Command will be ignored. The Run Status variable will indicate the current status of the machine (OFF, RUNNING, DELAY, or READY), depending on the position of the Remote/Off/Enable Switch closure. The

Chiller Occupied? variable will change to YES. The Control Type variable will change to Remote. The Operating Type

variable will change to Remote. Master Mode

— To activate Dual Chiller Control, each machine must be individually configured for Dual Chiller Control. To operate the machines in Dual Chiller Mode, one machine must be designated as the master unit and one machine as the slave unit. On the master unit, press the Start/Stop button on the Touch Pilot display. The Equipment Start screen will be displayed. Select Master Mode. Failure to start the Master unit in this manner will cause both machines to operate in local mode.

The Master Unit Control can be done locally, remotely or through CCN commands per the master/slave configuration (Master Control Type). The control will ignore the position of Enable/Off/Remote Contact switch if the Master Control

Type is configured for Local Control or CCN Control. The Run Status variable, Chiller Occupied? variable, and Control Type variable will change based on the Master Control Type configured above and the Machine On/Off Control de-

fined above. The Operating Type variable will change to Master.

To Turn Machine Off

— To turn the machine off, press the Start/Stop button on the Touch Pilot display. See Fig. 19. The machine will shut down. While the unit is in Local Off, it will remain shut down and ignore all CCN commands as well as the position of Enable/Off/Remote Contact switch. The Run Status variable, indicating the current status of the machine, will change to OFF. The Chiller Occupied? variable will change to NO. The Control Type variable will indicate Local. The Operating Type variable will change to L-OFF (Local Off).

NAVIGATOR™ DISPLAY MACHINE CONTROL — Machine On/Off control with the Navigator display is determined by the configuration of the Operating Type Control (OPER). Options to control the machine locally via a switch, from a local Time Schedule, or via a Carrier Comfort Net-

work

command are offered. See Table 21.

Switch Control

— In the Switch Control operating type, the Enable/Off/Remote Contact switch controls the machine locally. All models are factory configured with Operating Type Control (OPER) set to SWITCH CTRL (Switch Control). With SWITCH CTRL, switching the Enable/Off/Remote Contact switch to the Enable or Remote Contact position (external contacts closed) will put the chiller in an occupied state. The Unit Run Status (STAT) will indicate the current status of the machine and will change from OFF to RUNNING or DELAY. The unit Occupied Status (OCC) will change from NO to YES. The Status Unit Control Type (CTRL) will change from LOCAL OFF when the switch is Off to LOCAL ON when in the Enable position or in the Remote Contact position with external contacts closed.

ITEM ITEM EXPANSION PATH VALUE

Operating Control

OPER

Ty p e

Time Schedule

— With Time Schedule Operating Type con-

Operating Modes

SLCTOPER

SWITCH CTRL

trol, the machine operates under a local schedule programmed by the user as long as the Enable/Off/Remote Contact switch is in the Enable or Remote Contact position (external contacts closed). To operate under this Operating Type Control (OPER) must be set to TIME SCHED (Time Schedule).

CONTROL

METHOD

(OPER)

All Local Off

Switch

Control

Time

Schedule

CCN

Control

ACTI VE

OPERATING

TYPE

Local On

Local

Schedule

CCN

REMOTE/OFF/ENABLE

SWITCH

Off — — — — —

Remote Open — — — — — Off

————Enable——Off —————Yes—Off — — — — — — Closed Off

Enable — — — Disable — — On

Remote Closed — — Disable — — On

Enable — Occupied — Disable — — On

Remote Closed Occupied — Disable — — On

— — Unoccupied — Disable — — Off Remote Closed — Enable Disable — — On Remote Closed — Disable Disable — — Off

Enable — — Enable Disable — — On Enable — — Disable Disable — — Off

Table 21 — Navigator Start/Stop Control

REMOTE ON/OFF

SWITCH

TIME SCHEDULE 1

CCN CHILLER

START/STOP

(CHIL_S_S)

EMERGENCY

STOP

(EMSTOP)

ALARM

REMOTE

LOCKOUT

SWITCH

—

UNIT

STATUS

Off

Page 26

Two Internal Time Schedules are available and must be field programmed. Time Schedule 1 (SCH1) is used for single set point On-Off control. Time Schedule 2 (SCH2) is used for dual set point On-Off and Occupied-Unoccupied set point control. The control will use the operating schedules as defined under the Time Clock mode in the Navigator display module.

ITEM ITEM EXPANSION PATH VALUE

OPER

Operating Control Ty pe

Operating Modes

SLCTOPER

TIME SCHED

The schedules consist of 8 user-configurable occupied time periods. The control supports time schedules for local control, remote control, and ice building. These time periods can be flagged to be in effect or not in effect on each day of the week. The day begins at 00.00 and ends at 24.00. The machine is in unoccupied mode unless a scheduled time period is in effect. If an occupied period is to extend past midnight, the occupied period must end at 24:00 hours (midnight) and a new occupied period must be programmed to begin at 00:00 hours.

In the following example, a early morning pulldown time period is scheduled for Monday morning from 12:00 AM to 3:00 AM. The occupied period starts at 7:00 AM, Monday through Saturday. The occupied time ends at 6:00 PM on Monday and Tuesday, 9:30 PM on Wednesday, 5:00 PM on Thursday and Friday, and 12:00 PM on Saturday.

NOTE: This schedule was designed to illustrate the programming of the schedule function and is not intended as a recommended schedule for chiller operation.

If the chiller is to be controlled to a single set point, use Schedule 1 (SCH1). This type of schedule will start and stop the machine only. During the unoccupied times, the chiller will be off. If the chiller is to be controlled to 2 set points, occupied and unoccupied, use Schedule 2 (SCH2). This will cause the chiller to control to an occupied set point and an unoccupied set point. The machine will be able to provide cooling at any time.

To configure this option while using the Navigator™ display, see Table 22.

Holiday Schedule

— The unit control allows up to 16 holiday periods. All holidays are entered with numerical values. First enter the month (MON.x), then the day (DAY.x), then the duration (DUR.x) of the holiday period in days. If a holiday in included in one of the Occupied Time Periods of the schedule, the machine will follow that operating condition for the holiday. In the following examples, the holidays July 4 and December 25-26 are programmed for Holiday 1 and Holiday 2 respectively.

To configure this option for the Navigator display, see

Table 23. CCN Global Time Schedule

— A CCN global schedule can be used if desired. The schedule number can be set anywhere from 65 to 99 for operation under a CCN global schedule. The 30XA chillers can be configured to follow a CCN Global Time Schedule broadcast by another system element. The ComfortVIEW™ Network Manager’s Configure and Modify commands or the Service Tool’s Modify/Names function must be used to change the number of the Occupancy Equipment Part Table Name (OCC1P01E) to the Global Schedule Number. The Schedule Number can be set from 65 to 99 (OCC1P65E to OCC1P99E).

Table 22 — Configuring Schedules with

Navigator™ Display

ITEM ITEM EXPANSION PATH VALUE OCC.1 Occupied Time UNO.1 Unoccupied Time 03:00 MON.1 Monday Select Yes TUE.1 Tuesday Select No WED.1 Wednesday Select No THU.1 Thursday Select No FRI.1 Friday Select No SAT.1 Saturday Select No SUN.1 Sunday Select No HOL.1 Holiday Select No OCC.2 Occupied Time UNO.2 Unoccupied Time 18:00 MON.2 Monday Select Yes TUE.2 Tuesday Select Yes WED.2 Wednesday Select No THU.2 Thursday Select No FRI.2 Friday Select No SAT.2 Saturday Select No SUN.2 Sunday Select No HOL.2 Holiday Select No OCC.3 Occupied Time UNO.3 Unoccupied Time 21:30 MON.3 Monday Select No TUE.3 Tuesday Select No WED.3 Wednesday Select Yes THU.3 Thursday Select No FRI.3 Friday Select No SAT.3 Saturday Select No SUN.3 Sunday Select No HOL.3 Holiday Select No OCC.4 Occupied Time UNO.4 Unoccupied Time 17:00 MON.4 Monday Select No TUE.4 Tuesday Select No WED.4 Wednesday Select No THU.4 Thursday Select Yes FRI.4 Friday Select Yes SAT.4 Saturday Select No SUN.4 Sunday Select No HOL.4 Holiday Select No OCC.5 Occupied Time UNO.5 Unoccupied Time 12:00 MON.5 Monday Select No TUE.5 Tuesday Select No WED.5 Wednesday Select No THU.5 Thursday Select No FRI.5 Friday Select No SAT.5 Saturday Select Yes SUN.5 Sunday Select No HOL.5 Holiday Select No

Clock

Clock ClockSCH2PER.3

Clock

Time

SCH1PER.1

or Time

SCH2PER.1

Time

SCH1PER.2

or Time

SCH2PER.2

Time

SCH1PER.3

or Time

Time

SCH1PER.4

or Time

SCH2PER.4

Time

SCH1PER.5

or Time

SCH2PER.5

00:00

07:00

Table 23 — Configuring Holiday Schedules

for Navigator Display

ITEM ITEM EXPANSION PATH VALUE

MON.1 Holiday Start Month DAY.1 Holiday Start Day 4 DUR.1 Holiday Duration in Day 1 MON.2 Holiday Start Month DAY.2 Holiday Start Day 25 DUR.2 Holiday Duration in Day 2

Clock

Time

HOLIHOL.1

Time

HOLIHOL.2

Page 27

The Occupancy Supervisory Part table name (OCC1P01S) number must be changed to configure the unit to broadcast a Global Time Schedule. The Schedule Number can be set from 65 to 99 (OCC1P65S to OCC1P99S). When OCC1PxxS is set to a value greater than 64, an occupancy flag is broadcast over the CCN every time it transitions from occupied to unoccupied or vice-versa. By configuring their appropriate Time Schedule decisions to the same number, other devices on the network can follow this same schedule. The Enable/Off/Remote Contact must be in the Enable position or the Remote Contact position with the contacts closed for the unit to operate. The Unit Run Status (STAT) will indicate the current status of the machine (OFF, RUNNING, STOPPING or DELAY), depending on the schedule. The unit Occupied status (OCC) will indicate the current occupied schedule according to the schedule, either NO or YES. The Status Unit Control Type (CTRL) will be LOCAL OFF when the switch is Off. The Status Unit Control Type will be CCN when the Enable/Off/Remote Contact switch input is On.

CCN Control

— With CCN Operating Type control, the machine operates under CCN control as long as the Enable/Off/ Remote Contact Switch is in the Enable or Remote Contact position (external contacts closed.) To operate under this Operating Control, OPER must be set to CCN CONTROL. An external CCN device, such as Chillervisor, controls the On/Off state of the machine. When controlled by a Chillervisor, it is recommended that the Auto Start When SM Lost (AU.SM) be set to Yes.

Careful evaluation of Chilled Water Plant control should be reviewed. In the event Local Control is established, be sure that all pumps, valves, and other devices are capable of operating properly. In the event of a loss of communication with the network, the machine will start and be controlled locally. The CCN device forces the variable CHIL_S_S to control the chiller. The Unit Run Status (STAT) will indicate the current status of the machine (OFF, RUNNING, STOPPING or DELAY), depending on the CCN command. The unit Occupied status (OCC) will indicate the current occupied state according to the CCN command and will be displayed as either NO or YES. The Status Unit Control Type (CTRL) will be LOCAL OFF when the Enable/Off/Remote Contact switch is Off. The Status Unit Control Type will be CCN when the Enable/Off/Remote Contact switch input is Closed and the CHIL_S_S variable is Stop or Start.

For Dual Chiller Control applications, the Slave Chiller must be enabled using the CCN CONTROL option.

ITEM ITEM EXPANSION PATH VALUE

OPER

AU.SM

Operating Control Ty p e

Auto Start when SM Lost

Operating Modes

SLCTOPER

ConfigurationSERV YES

CCN CONTROL

Fluid Set Point Control Location — The factory

default for the chilled water fluid set point is controlling to the leaving water temperature. An option to configure the machine for entering water control is available. The control operation remains the same except the control point is focused on the entering water temperature, rather than the leaving water temperature when configured.

To configure this option for the Touch Pilot™ display:

DISPLAY NAME PATH

Entering Fluid Control

Service\ SERVICE1

LINE

NO.

No = Leaving Water Control

Yes = Entering Water Control

VAL UE

To configure this option for the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

EWTO Entering Water

Control

Configuration

SERV No = Leaving

Water Control Yes = Entering Water Control

Cooling Set Point Selection — Several options for

controlling the Leaving Chilled Water Set Point are offered and are configured by the Cooling Set Point Select (Setpoint Se- lect, SP.SE) variable. In addition to the Cooling Set Point Se- lect, Ice Mode Enable discussed later in this book, and Heat Cool Select (Heat/Cool Select, HC.SE) variables also have a role in determining the set point of the machine. All units are shipped from the factory with the Heat Cool Select set to 0.

All default set points are based on Leaving Water Control (Entering Fluid Control, EWTO) set to No. Values must be confirmed for the individual set points. Limits for the set points are listed in the configurations noted below.

To configure these options for the Touch Pilot display, see Table 24A. To configure these options for the Navigator display, see Table 24B.

Table 24A — Cooling Set Point Selection

with Touch Pilot Display

DISPLAY NAME PATH

Cooling Setpoint 1 Setpoint 2 Range: 14 to 70 F

Cooling Setpoint 2 Setpoint 3 Range: 14 to 70 F

Cooling Ice Setpoint Setpoint 4 Range: -20 to 32 F

Table 24B — Cooling Set Point Selection

with Navigator Display

ITEM ITEM EXPANSION PATH VALUE

CSP.1 Cooling Setpoint 1 Setpoints

CSP.2 Cooling Setpoint 2 Setpoints

CSP.3 Ice Setpoint Setpoints

In all cases, there are limits on what values are allowed for each set point. These values depend on the Cooler Fluid Type and the Brine Freeze Set point, discussed later. See Table 25.

Table 25 — Configuration Set Point Limits

SET POINT LIMITS

Minimum * 38 F (3.3 C) 14 F (–10.0 C) Maximum 60 F (15.5 C)

*The minimum set point for Medium Temperature Brine applications

is related to the Brine Freeze Point. The set point is limited to be no less than the Brine Freeze Point +5° F (2.8° C).

The Setpoint Select configuration can be set to five different control options: Set Point Occupancy, Set Point 1, Set Point 2, 4-20 mA Input, and Dual Switch.

SET POINT OCCUPANCY — Set Point Occupancy is the default configuration for the Setpoint Select variable. When Setpoint Select (Setpoint Select, SP.SE) is configured to 0 (Setpoint Occ), the unit’s active set point is based on Cooling

LINE

NO.

COOL

COOLER FLUID TYPE

(COOLER FLUID TYPE, FLUD)

1, Water 2, Brine

VALU E

(–10.0 to 21.1 C) Default: 44 F (6.6 C)

(–28.9 to 0 C) Default: 44 F (6.6 C)

Range: 14 to 70 F (–10.0 to 21.1 C) Default: 44 F (6.6 C)

Range: -20 to 32 F (–28.9 to 0 C) Default: 44 F (6.6 C)

Page 28

Set Point 1 (Cooling Setpoint 1, CSP.1) during the occupied period while operating under Time Schedule 1 (SCH1). If the Time Schedule 2 (SCH2) is in use, the unit’s active set point is based on Cooling Set Point 1 (Cooling Setpoint 1, CSP.1) dur- ing the occupied period and Cooling Set Point 2 (Cooling Set- point 2, CSP.2) during the unoccupied period. See Tables 26 and 27.

To configure this option while using a Touch Pilot display:

DISPLAY NAME PATH Setpoint select StatusGENUNIT 25 0 (Setpoint Occupied)

LINE

NO.

VAL UE

To change this value, a Control Point Force must be applied. When configured correctly, Setpoint Control (Setpoint Control, SP.SE) will indicate Auto.

To configure this option while using a Navigator display:

ITEM ITEM EXPANSION PATH VALUE

SP.SE Setpoint Select Operating Modes

Set Point 1

— When Set Point Select (Setpoint Select, SP.SE)

SLCT Setpoint Occ

is configured to 1 (Setpoint 1), the unit’s active set point is based on Cooling Set Point 1 (Cooling Setpoint 1, CSP.1).

To configure this option with the Touch Pilot display:

The following equation is used to control the set point. See

Fig. 20.

Fahrenheit Set Point = 10 + 70(mA – 4)/16 (deg F) Celsius Set Point = –12.2 + 38.9(mA – 4)/16 (deg C) To configure this option while using a Touch Pilot display:

DISPLAY NAME PATH

Setpoint select StatusGENUNIT 25 3 (4-20 mA Input)

LINE

NO.

VAL UE

To change this value, a Control Point Force must be applied. When configured correctly, Setpoint Control will indicate 420 mA.

To configure this option while using a Navigator display:

ITEM ITEM EXPANSION PATH VALUE

SP.SE Setpoint Select Operating Modes

Dual Switch

— When Set Point Select (Setpoint Select,

SLCT 4-20 mA Setp

SP.SE) is configured to 4 (Dual Setp Sw), the unit’s active set point is based on Cooling Set Point 1 (Cooling Setpoint 1, CSP.1) when the Dual Set Point switch contact is open and Cooling Set Point 2 (Cooling Setpoint 2, CSP.2) when it is closed.

To configure this option while using a Touch Pilot display:

DISPLAY NAME PATH

Setpoint select Status

GENUNIT 25 1 (Set Point 1)

LINE

NO.

VAL UE

To change this value, a Control Point Force must be applied. When configured correctly, Setpoint Control will indicate Setp 1.

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

SP.SE Setpoint Select Operating Modes

Set Point 2

— When Set Point Select (Setpoint Select, SP.SE)

SLCT Setpoint 1

is configured to 2 (Setpoint 2), the unit’s active set point is based on Cooling Set Point 2 (Cooling Setpoint 2, CSP.2).

To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Setpoint select Status

GENUNIT 25 2 (Set Point 2)

LINE

NO.

VAL UE

To change this value, a Control Point Force must be applied. When configured correctly, Setpoint Control (Status GENUNIT) will indicate Setp 2.

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

SP.SE Setpoint Select Operating Modes

4 to 20 mA Input

— When Set Point Select (Setpoint Select,

SLCT Setpoint 2

SP.SE) is configured to 3 (4-20 mA Setp), the unit’s active set point is based on an field supplied, external 4 to 20 mA signal input to the Energy Management Module (EMM). Care should be taken when interfacing with other manufacturer’s control systems, due to power supply differences of full wave bridge versus half wave rectification. The two different power supplies cannot be mixed. ComfortLink™ controls use half wave rectification. A signal isolation device should be utilized if a full wave bridge signal generating device is used.

DISPLAY NAME PATH

Setpoint select Status

GENUNIT 25

LINE

NO.

4 (Dual Setpoint Switch)

VAL UE

To change this value, a Control Point Force must be applied. When configured correctly, Setpoint Control will indicate Setp Sw.

To configure this option while using a Navigator display:

ITEM ITEM EXPANSION PATH VALUE

SP.SE Setpoint Select Operating Modes

SLCT

Dual Setp Sw

Chilled Water Fluid Type Selection — The chilled

water fluid must be configured. The fluid type must be configured to obtain the proper leaving water set point control range and freeze protection. The Cooler Fluid Type (Cooler Fluid Typ e, FLUD) can be set to water or brine.

FRESH WATER — Configure the unit for Cooler Fluid Type (Cooler Fluid Type, FLUD) to water for units without brine or glycol installed in the chilled water loop. The factory default fluid type is fresh water. Use this option for fresh water systems. This will allow for a water temperature set point of 38 to 60 F (3.3 to 15.5 C). With water as the selection, the Freeze Point is fixed at 34 F (1.1 C).

To configure this option with the Touch Pilot display:

DISPLAY

NAME

Cooler Fluid Type

Main Menu

PATH

ServiceSERVICE1 1 1 = Water

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

FLUD Cooler Fluid Type Configuration

LINE

VAL UE

NO.

SERV Water

Page 29

Table 26 — Cooling Set Point Selection Touch Pilot™ Parameters

02 468 10 12 14 16 18 20

mA Signal

Set Point

Max LWT

Min LWT, Cooler Fluid Type = 1, FLUD=Brine

Min LWT, Cooler Fluid Type = 1, FLUD=Water

Fig. 20 — 4 to 20 mA Set Point Control

a30-4476

SET POINT

CONFIGURATION

(Setpoint Select)

(Auto)

1 (Setp 1) — — — — Cooling Setpoint 1 2 (Setp 2) — — — — Cooling Setpoint 2

3 (4-20 mA) — — — — 4 to 20 mA Input

4 (Setp Sw)

Table 27 — Cooling Set Point Selection Navigator™ Parameters

Control Method

(OPER)

LOCAL COOL

CCN COOL

Heat/Cool

Select (HC.SE)

ICE MODE

ENABLE

(ice_cnfg)

DUAL SET

POINT INPUT

(SETP_SW)

— — Occupied Cooling Setpoint 1 — — Unoccupied Cooling Setpoint 2 — Open Unoccupied Cooling Ice Setpoint

YES

— Closed Unoccupied Cooling Setpoint 2 — — Occupied Cooling Setpoint 1

Open — — Cooling Setpoint 1

Closed — — Cooling Setpoint 2

Open — — Cooling Setpoint 1

YES

Closed Open — Cooling Ice Setpoint Closed Closed — Cooling Setpoint 2

PARAMETER STATUS

Setpoint

Select (SP.SE)

Ice Mode

Enable (ICE.M)

Setpoint Occ — — — Occupied CSP.1 Setpoint Occ — — — Unoccupied CSP.2 Setpoint Occ Enable Open — Unoccupied CSP.3

Setpoint 1 — — — — CSP.1 Setpoint 2 — — — — CSP.2

4-20mA Setp — — — — 4_20mA

— Enable Open Closed — CSP.3 — Enable Closed Closed — CSP.2 — — — Open — CSP.1

Dual Setp Sw — — Closed — CSP.2

— — — — Occupied CSP.1 — — — — Unoccupied CSP.2

ICE DONE INPUT

(ICE_SW)

Ice Done

(ICE.D)

TIME

SCHEDULE 2

Dual Setpoint

Switch (DUAL)

SET POINT

Setpoint

Occupied

(SP.OC)

ACTIVE

SET POINT

Page 30

BRINE OR GLYCOL OPERATION — Configure the unit for Cooler Fluid Type (Cooler Fluid Type, FLUD) to brine for brine or glycol chilled water loops. This option will allow for a set point temperature range of 14 to 60 F (–10.0 to 15.5 C). Before configuring this selection, confirm that a suitable antifreeze has been added and is at a sufficient concentration to protect the loop. Additionally, the Brine Freeze Set Point (Brine Freeze Setpoint, LOSP) must be set for proper freeze protection operation. Set the Brine Freeze Set Point to the burst protection provided by the glycol concentration. This value will be Freeze Point for the fluid.

To configure this option with the Touch Pilot display:

DISPLAY

NAME

Cooler Fluid Type

Brine Freeze Setpoint

PAT H

Main Menu

ServiceSERVICE1

Main Menu

ServiceSERVICE1

LINE

NO.

12 = Brine

VAL UE

Dependent on fluid concentration

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

FLUD Cooler Fluid Type Configuration

Brine Freeze

LOSP

Setpoint

ConfigurationSERV

SERV Brine

Dependent on fluid concentration

Cooler Pump Control — It is required for flooded

cooler units that cooler pump control be utilized on all chillers unless the chilled water pump runs continuously or the chilled water system contains a suitable antifreeze solution. The 30XA units can be configured for single external pump control as standard. Control of dual external pumps requires installation of the external pump control accessory package (Part No. 00EFN900003200A).

Cooler Pumps Sequence (Cooler Pumps Sequence, PUMP) is the variable that must be confirmed in the field. Proper configuration of the cooler pump control is required to provide reliable chiller operation. Pump control can be accomplished for both on-board and external pumps. For external pump control, control connections to the pump contactor and a feedback circuit from the contactor must be supplied. The Cooler Pumps Sequence configuration can be set to 5 different control settings: No Pump Control, Single Pump Control, Dual Pump Control, Pump 1 Manual, and Pump 2 Manual.

When the Cooler Pumps Sequence is configured, the cooler pump output will be energized when the chiller enters an “ON” mode. The cooler pump output is also energized when certain alarms are generated. The cooler pump output should be used as an override to the external pump control if cooler pump control is not utilized. The cooler pump output is energized if a P.01 Water Exchanger Freeze Protection alarm is generated, which provides additional freeze protection if the system is not protected with a suitable antifreeze solution.

A chilled water pump interlock contact PMP-I is connected across TB5 terminals 1-2, as an alternative to the standard jumper. This interlock is an optional field-installed device which would provide extra protection in the event of the flow switch failing closed. It may be used regardless of whether or not pump control is enabled. However, this interlock should NOT be confused with the pump contactor feedback auxiliary contacts which MUST be wired to MBB channel 18 at connector J5C if the pump control feature is enabled (with or without the optional on-board hydronic package).

NO PUMP CONTROL — The factory default setting for Cooler Pumps Sequence (Cooler Pumps Sequence, PUMP) is 0 (No Pump), for units without the factory-installed hydronic package.

When Cooler Pumps Sequence is set to 0 (No Pump), closure of both the chilled water flow switch (CWFS) and the chilled water pump interlock contact (connected across TB-5 terminals 1 and 2) are required for the unit to start mechanical cooling.

To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Cooler Pumps Sequence

Main Menu

ConfigUSER

LINE

NO.

VAL UE

0 (No Pump Control)

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

PUMP

Cooler Pumps Sequence

Configuration

OPTN No Pump

SINGLE PUMP CONTROL — For units with the single pump hydronic package, the factory default setting for Cooler Pumps Sequence (Cooler Pumps Sequence, PUMP) is 1 (1 Pump Only). This control algorithm may be used to control an external pump, as long as the same controls are applied as noted below.

When the Cooler Pumps Sequence configuration is set to 1 Pump Only, closure of both the chilled water flow switch (CWFS) and the chilled water pump interlock contact (connected across TB-5 terminals 1 and 2) are required for the unit to start mechanical cooling. Additionally, the normally open auxiliary contacts for Pump 1 contactor must be connected to the violet and pink wires located in the harness from the MBBJ5C-CH18 connector. The wires in the harness are marked “PMP1-13” and “PMP1-14”. See the field wiring diagram in the 30XA Installation Instructions.

Three additional parameters are configurable for pump control with single pump control. Periodic pump start and check flow if pump is off parameters can customize the pump operation for the application. Another parameter, to stop the pump in standby mode is not supported.

Another configuration to check the status of the chilled water flow switch can be selected. When configured, if Flow Checked if Pump Off (Flow Checked if C Pump Off, P.LOC) is set to YES, the control will monitor the chilled water flow switch status and will alarm if the pump is commanded off and the chilled water flow switch is closed. This can provide the user with information of a faulty cooler pump contactor or a failed chilled water flow switch. This parameter should be set to NO for series flow machines. The factory default for this item is YES.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Cooler Pumps Sequence

Pump Sticking Protection

Flow Checked if C Pump Off

Main Menu

ConfigUSER

Main Menu

ConfigUSER

Main Menu

ConfigUSER

LINE

NO.

1 (Single

Pump Control) Default = No

No = Disabled Ye s = E na bl ed

Default = Yes No = Disabled Ye s = E na bl ed

VAL UE

Page 31

To configure this option with the Navigator display:

To configure these options with the Touch Pilot™ display:

ITEM ITEM EXPANSION PATH VALUE

Cooler Pumps

PUMP

PM.PS

P. LO C

Sequence

Periodic Pump Start

Flow Checked if Pmp Off

ConfigurationOPTN 1 Pump Only

Configuration

OPTN

Default = No No = Disabled Ye s = E na bl ed

Default = Yes No = Disabled Ye s = E na bl ed

DUAL PUMP AND MANUAL CONTROL — For units with the dual pump hydronic package, the factory default setting for Cooler Pumps Sequence (Cooler Pumps Sequence, PUMP) is 2 (2 Pumps Auto). This control algorithm may be used to control two external pumps, as long as the same controls are applied as noted below. For dual pump hydronic option units, three control options exist. The control will start the pumps and automatically alternate the operation of the pumps to even the wear of the pumps based on the hours configured under Pump Auto Rotation Delay (Pump Auto Rotation Delay, ROT.P). If the difference between the operating hours of the 2 pumps exceeds the Pump Auto Rotation Delay the lead pump will change. If a flow failure is detected, the other pump will attempt to start.

Two manual control options also exist. When the Cooler Pumps Sequence (Cooler Pumps Sequence, PUMP) is set to 3 (PMP 1 Manual), Cooler Pump 1 will always operate. When the Cooler Pumps Sequence (Cooler Pumps Sequence, PUMP) is set to 4 (PMP 2 Manual), Cooler Pump 2 will always operate.

If the Cooler Pumps Sequence configuration is set to 2 (2 Pumps Auto), 3 (PMP 1 Manual), or 4 (PMP 2 Manual), closure of both the chilled water flow switch (CWFS) and the chilled water pump interlock contact (connected across TB-5 terminals 1 and 2) are required for the unit to start mechanical cooling. Additionally, the normally open auxiliary contacts for Pump 1 and Pump 2 contactors (wired in parallel) must be connected to the violet and pink wires located in the harness from the MBB-J5C-CH18 connector. The wires in the harness are marked “PMP1-13” and “PMP1-14”. See the field wiring diagram in the 30XA Installation Instructions.

Three additional parameters are configurable for pump control with single pump control. The Periodic Pump Start (Pump Sticking Protection, PM.PS) and Flow Checked if Pump Off (Flow Checked if C Pump Off, P.LOC) parameters can cus- tomize the pump operation for the application. Another parameter, that is used to stop the pump in standby mode, is not supported.

The control system has the ability to periodically start the pumps to maintain the bearing lubrication and seal integrity. If Periodic Pump Start (Pump Sticking Protection, PM.PS) is set to YES and if the unit is off at 2:00 PM, a pump will be started once each day for 2 seconds. If the unit has 2 pumps, Pump 1 will be started on even days (such as day 2, 4, or 6 of the month); Pump 2 will be started on odd days (such as day 1, 3 or 5 of the month). The default for this option is NO.

A configuration to check the status of the chilled water flow switch can be selected. When Flow Checked if Pump Off (Flow Checked if C Pump Off, P.LOC) is configured to YES, the control will monitor the chilled water flow switch status and will alarm if the pump is commanded off and the chilled water flow switch is closed. This can provide the user with information of a faulty cooler pump contactor or a failed chilled water flow switch. This parameter should be set to NO for series flow machines. The factory default for this item is YES.

DISPLAY NAME PATH

Cooler Pumps Sequence

Pump Auto Rotation Delay

Pump Sticking Protection

Flow Checked if C Pump Off

Main Menu

ConfigUSER

Main Menu

ConfigUSER

Main Menu

ConfigUSER

Main Menu

ConfigUSER

LINE

NO.

14 Default = 48 hours

VAL UE

2 (2 Pumps Automatic) 3 (Pump 1 Manual) 4 (Pump 2 Manual)

Default = No No = Disabled Yes = Enabled

Default = Yes No = Disabled Yes = Enabled

To configure these options with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

PUMP

ROT.P

PM.PS

P. LO C

Cooler Pumps Sequence

Pump Rotation Delay

Periodic Pump Start

Flow Checked if Pmp Off

Configuration

ConfigurationOPTN

Configuration

OPTN

2 Pumps Auto PMP1 Manual PMP2 Manual

Default = 48 hours

Default = No No = Disabled Yes = Enabled

Default = Yes No = Disabled Yes = Enabled

Machine Start Delay — An option to delay the start of

the machine is also available. This parameter is useful in keeping multiple machines from starting at the same time in case of a power failure. The parameter has a factory default of 1 minute. This parameter also has a role in the timing for a chilled water flow switch alarm.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Unit Off to On Delay

Main Menu

ConfigUSER

LINE

NO.

6 Default = 1 Minute

VAL UE

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

DELY Minutes Off Time Configuration

OPTN

Default = 1 Minute

Circuit/Compressor Staging and Loading —

The AquaForce® 30XA chillers employ one compressor per circuit. As a result, circuit and compressor staging are the same. The control has several control option parameters to load the compressors. The circuit/compressor start can be configured as well as the loading of each circuit/compressor.

CIRCUIT/COMPRESSOR STAGING — The control can be configured to decide which circuit/compressor starts first, by configuring Lead/Lag Circuit Select (Staged Loading Sequence, LLCS). Four options for this variable are allowed: Automatic Lead-Lag, Circuit A Leads, Circuit B Leads, or Circuit C Leads (30XA400-500 only). The factory default is Automatic Lead-Lag.

The automatic lead-lag function determines which circuit/ compressor starts. When enabled, the control will determine which circuit/compressor starts to even the wear of the compressor. The compressor wear factor (combination of starts and run hours) is used to determine which compressor starts.

Compressor Wear Factor = (Compressor Starts) + 0.1 (Compressor Run Hours)

The circuit/compressor with the lowest compressor wear factor is the circuit that starts first.

If starting a particular circuit/compressor first is desired, that can also be configured with the same variable.

Page 32

To configure this option with the Touch Pilot display:

To configure this option with the Navigator display:

DISPLAY NAME PATH

Circuit Loading Sequence

Main Menu

ConfigUSER

LINE

NO.

VAL UE

0 (Automatic Lead-lag) 1 (Circuit A Leads) 2 (Circuit B Leads) 3 (Circuit C Leads) Default = 0 (Automatic Lead-lag)

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

Range: Automatic,

LLCS

Lead/Lag Circuit Select

Configuration

OPTN

Cir A Leads, Cir B Leads, Cir C Leads Default – Automatic

CIRCUIT/COMPRESSOR LOADING — The control can be configured to stage the circuit/compressors. The Loading Sequence Select (Circuit Loading Sequence, LOAD) setting determines how the control will perform loading. The configuration can be set to Equal or Staged.

Equal Loading

— With Equal loading, the circuit which starts first will maintain the minimum stage of capacity with the slide valve fully unloaded. When additional capacity is required, the next circuit with the lowest compressor wear factor is started with its slide valve at minimum position. As additional capacity is required, the slide valve for a circuit will be adjusted in approximately 5% increments to match capacity requirements. The control will alternate between circuits to maintain the same percentage of capacity on each circuit. See Fig. 21.

Staged Loading

— If staged loading is selected, the circuit which starts first will gradually load its slide valve to match capacity requirements until the circuit is fully loaded. Once the circuit is fully loaded and additional capacity is required, the control will start an additional circuit fully unloaded. The control will gradually unload the circuit which was fully loaded to match capacity requirements. See Fig. 21.

To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Staged Loading Sequence

Main

ConfigUSER

LINE

NO.

VAL UE

Default = No No (Equal) Yes (Staged)

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

Loading Sequence

LOAD

Select

Configuration

OPTN

Default = Equal Equal Staged

Minimum Load Control — Minimum Load Control

can be a factory-installed option or a field-installed accessory. If installed, and its operation is desired, the Minimum Load Control must be enabled. Once enabled, the valve will be operational only during the first stage of cooling.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Hot Gas Bypass Select

Main Menu

Service

FACTO RY

LINE

NO.

VALU E

Default = No No (No Minimum Load Control) Yes (Minimum Load Control Installed)

ITEM

HGBP

ITEM

EXPANSION

Hot Gas Bypass Select

PATH VALUE

Configuration

UNIT

No = No Minimum Load Control Yes = Minimum Load Control Installed

Dual Chiller Control — The dual chiller routine is

available for the control of two units installed in series or parallel supplying chilled fluid on a common loop. One chiller must be configured as the master chiller, the other as the slave chiller. An additional leaving fluid temperature thermistor (Dual Chiller LWT) must be installed in the common chilled water piping as described in the Installation Instructions for both the master and slave chillers. See the Field Wiring section in the 30XA Installation Instructions for Dual Chiller LWT sensor control wiring.

The control algorithm relies on several parameters that must be field configured for operation. Both chillers must be on the same Carrier Comfort Network On both chillers, Master/Slave Select (Master/Slave Select, MSSL) must be enabled. The water piping arrangement, Chillers in Series (Chiller in Series, SERI), must be configured. The master chiller must be programmed with the Slave Chiller Address (Slave Address, SLVA). Additional optional pro- gramming parameters may be configured to meet application requirements.

Lead/Lag Balance Select (Lead Lag Select, LLBL) determines which chiller is the lead machine. The options are Always Lead, Lag if Fail, and Runtime Select. Under Runtime Select control, the lead chiller will change based on the time increment selected in the Lead/Lag Balance Delta configuration (Lead/Lag Balance Data, LLBD). If the run hour difference between the master and the slave remains less than the Lead/ Lag Balance Delta, the chiller designated as the lead will remain the lead chiller. The Lead/Lag changeover between the master and the slave chiller due to hour balance will occur during chiller operating odd days, such as day 1, day 3, and day 5 of the month, at 12:00 a.m. If a lead chiller is not designated, the master chiller will always be designated the lead chiller.

The dual chiller control algorithm has the ability to delay the start of the lag chiller in two ways. The Lead Pulldown Time parameter (Lead Pulldown Type, LPUL) is a one-time time delay initiated after starting the lead chiller, before checking whether to start an additional chiller. This time delay gives the lead chiller a chance to remove the heat that the chilled water loop picked up while being inactive during an unoccupied period. The second time delay, Lead/Lag Delay (Lag Start Timer, LLDY) is a time delay imposed between the last stage of the lead chiller and the start of the lag chiller. This prevents enabling the lag chiller until the lead/lag delay timer has expired.

A quicker start of the lag chiller can be accomplished by configuring the Start if Error Higher parameter (Start if Error Higher, LL.ER). If the difference between the common leav- ing water temperature and the set point is greater than the configured value, then the lag chiller will start.

A minimum on time for the lag chiller can be programmed with the Lag Minimum Running Time configuration (Lag Minimum Running Time, LAG.M). This parameter causes the control to run the lag chiller for the programmed minimum on time. The Lag Unit Pump Select (Lag Unit Pump Control, LAGP) can be configured such that the pump can be on or off while the chiller is off. This parameter is only active in Parallel Chiller Operation.

bus with different addresses.

Page 33

Compressor Loading Unloading (Staged circuit loading)

100

Load (%)

Compressor Capacity (%)

Lead Compressor Loading

Lag Compressor Loading

Lead Compressor Unloading

Lag Compressor Unloading

100

Lead compressor can fall anywhere in this area

UNLOADING

Compressor Capacity (%)

Equal Circuit Loading

Staged Circuit Loading

Fig. 21 — Compressor Loading and Unloading

a30-4466

a30-4477

when load between 40%~65%

Lag compressor can fall anywhere in this area when load between 40%~65%

Lead Compressor Loading Lag Compressor Loading Lead Compressor Unloading

Compressor Unloadin

0 0

100

Load (%)

For units with a Touch Pilot display, two additional steps must be completed to start the machine. On the master chiller, the Master Control Type must be configured for the start control defined in the Machine Control configuration. To start the machines, the master chiller must be started with the Start/Stop button and Master Mode selected. The slave chiller must be started with the CCN Mode selected.

Each application, Parallel and Series, are described separately below.

DUAL CHILLER CONTROL FOR PARALLEL APPLICATIONS — To configure the master chiller for parallel applications using the Touch Pilot display, see Table 28. To configure the master chiller for parallel applications using the Navigator display, see Table 29.

To configure the slave chiller for parallel applications using the Touch Pilot display, see Table 30. To configure the slave chiller for parallel applications using the Navigator display, see Table 31. A power cycle is required for the values to take effect.

Page 34

Table 28 — Dual Master Chiller Control Parameters for Parallel Applications with Touch Pilot™ Display

DISPLAY NAME PATH LINE NO. VALUE

Master/Slave Select Main Menu

Master Control Type Main Menu

Slave Address Main Menu

Lead Lag Select Main Menu

Lead/Lag Balance Delta Main Menu

Lag Start Timer Main Menu

Lead Pulldown Time Main Menu

Start If Error Higher Main Menu

Lag Minimum Running Time Main Menu

Lag Unit Pump Control Main Menu

Chiller In Series Main MenuConfigMST_SLV 22

NOTE: If pump control is configured to OFF, then LAG UNIT PUMP SELECT = 1. If pump control is set to any other value, then LAG UNIT PUMP SELECT = 0. This configuration must be set consistently for both master and slave chillers.

ConfigMST_SLV 3

ConfigMST_SLV 7

ConfigMST_SLV 11

ConfigMST_SLV 12

ConfigMST_SLV 16

ConfigMST_SLV 17

ConfigMST_SLV 18

ConfigMST_SLV 19

ConfigMST_SLV 20

ConfigMST_SLV 21

1 (Master) Default: 0 (Disable)

1=Local Control 2=Remote Control 3=CCN Control Default: 1 Configure for proper control type.

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

0 (Master Always Leads) 1 (Lag Once Failed Only) 2 (Lead/Lag Runtime Select) Default: 0 (Master Always Leads)

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 0 to 60 minutes Default: 0 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: 0 to 150 minutes Default: 0 minutes

0 (Stop If Unit Stops) 1 (Run If Unit Stops) Default: 0 (Stop If Unit Stops)

Default: No Value: No

Table 29 — Dual Master Chiller Control Parameters for Parallel Applications with Navigator™ Display

ITEM ITEM EXPANSION PATH VALUE

MSSL Master/Slave Select ConfigurationRSET

SLVA Slave Address ConfigurationRSET

LLBL Master Lead Lag Select Configuration

LLBD Lead/Lag Balance Delta Configuration

LLDY Lag Start Delay Configuration

LL.ER Start If Error Higher Configuration

LAG.M Lag Unit Pump Select Configuration

LPUL Lead Pulldown Time Configuration

SERI Chillers in Series Configuration

OPER Operating Control Type Operating Modes

RSET

SLCT Set to desired control

Master Default: Disable

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

Range: Always Lead, Lag if Fail, Runtime Sel Default: Always Lead

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: Off If U Stp, On If U Stop Default: Off If U Stp

Range: 0 to 60 minutes Default: 0 minutes

No Default: No

Page 35

Table 30 — Dual Slave Chiller Control Parameters for Parallel Applications with Touch Pilot™ Display

DISPLAY NAME PATH LINE NO. VALUE

Master/Slave Select Main Menu

Master Control Type Main Menu

Slave Address Main Menu

Lead Lag Select Main Menu

Lead/Lag Balance Delta Main Menu

Lag Start Timer Main Menu

Lead Pulldown Time Main Menu

Start If Error Higher Main Menu

Lag Minimum Running Time Main Menu

Lag Unit Pump Control Main Menu

Chiller In Series Main MenuConfigMST_SLV 22

ConfigMST_SLV 3

ConfigMST_SLV 7

ConfigMST_SLV 11

ConfigMST_SLV 12

ConfigMST_SLV 16

ConfigMST_SLV 17

ConfigMST_SLV 18

ConfigMST_SLV 19

ConfigMST_SLV 20

ConfigMST_SLV 21

2 (Slave) Default: 0 (Disable)

1 (Local Control) 2 (Remote Control) 3 (CCN Control) Default: 1 Configure for proper control type.

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

0 (Master Always Leads) 1 (Lag Once Failed Only) 2 (Lead/Lag Runtime Select) Default: 0 (Master Always Leads)

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 0 to 60 minutes Default: 0 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: 0 to 150 minutes Default: 0 minutes

0 (Stop If Unit Stops) 1 (Run If Unit Stops) Default: 0 (Stop If Unit Stops)

No Default: No

Table 31 — Dual Slave Chiller Control Parameters for Parallel Applications with Navigator™ Display

ITEM ITEM EXPANSION PATH VALUE

MSSL Master/Slave Select ConfigurationRSET

SLVA Slave Address Configuration

LLBL Master Lead Lag Select Configuration

LLBD Lead/Lag Balance Delta Configuration

LLDY Lag Start Delay Configuration

LL.ER Start If Error Higher Configuration

LAG.M Lag Unit Pump Select Configuration

LPUL Lead Pulldown Time Configuration

SERI Chillers in Series Configuration OPER Operating Control Type Operating ModesSLCT CCN Control

RSET

Slave Default: Disable

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

Range: Always Lead, Lag if Fail, Runtime Sel Default: Always Lead

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: Off If U Stp, On If U Stop Default: Off If U Stp

Range: 0 to 60 minutes Default: 0 minutes

No, Default: No

Page 36

DUAL CHILLER PUMP CONTROL FOR PARALLEL CHILLER APPLICATIONS — It is recommended that a dedicated pump be used for each unit. The chiller must start and stop its own water pump located on its own piping. If pumps are not dedicated for each chiller, chiller isolation valves are required and each chiller must open and close its own isolation valve.

DUAL CHILLER CONTROL FOR SERIES APPLICATIONS — To configure the master chiller for series applications using the Touch Pilot™ display, see Table 32. To configure the master chiller for series applications using the Navigator™ display, see Table 33.

To configure the slave chiller for series applications using the Touch Pilot™ display, see Table 34. To configure the slave chiller for series applications using the Navigator™ display, see Table 35. A power cycle is required for the values to take effect.

Table 32 — Dual Master Chiller Control Parameters for Series Applications with Touch Pilot™ Display

DISPLAY NAME PATH LINE NO. VALUE

Master/Slave Select Main Menu

Master Control Type Main Menu

Slave Address Main Menu

Lead Lag Select Main Menu

Lead/Lag Balance Delta Main Menu

Lag Start Timer Main Menu

Lead Pulldown Time Main Menu

Start If Error Higher Main Menu

Lag Minimum Running Time Main Menu

Lag Unit Pump Control Main Menu

Chiller In Series Main MenuConfigMST_SLV 22

NOTE: If pump control is configured to OFF, then LAG UNIT PUMP SELECT = 1. If pump control is set to any other value, then LAG

ConfigMST_SLV 3

ConfigMST_SLV 7

ConfigMST_SLV 11

ConfigMST_SLV 12

ConfigMST_SLV 16

ConfigMST_SLV 17

ConfigMST_SLV 18

ConfigMST_SLV 19

ConfigMST_SLV 20

ConfigMST_SLV 21

UNIT PUMP SELECT = 0. This configuration must be set consistently for both master and slave chillers.

1 (Master) Default: 0 (Disable)

1 (Local Control) 2 (Remote Control) 3 (CCN Control) Default: 1 (Local Control) Value: Configure for proper control type.

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

0 (Master Always Leads) 1 (Lag Once Failed Only) 2 (Lead/Lag Runtime Select) Default: 0 (Master Always Leads)

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 0 to 60 minutes Default: 0 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: 0 to 150 minutes Default: 0 minutes

0 (Stop If Unit Stops) 1 (Run If Unit Stops) Default: 0 (Stop If Unit Stops)

Ye s Default: No

Table 33 — Dual Master Chiller Control Parameters for Series Applications with Navigator™ Display

ITEM ITEM EXPANSION PATH VALUE

MSSL Master/Slave Select ConfigurationRSET

SLVA Slave Address Configuration

LLBL Master Lead Lag Select Configuration

LLBD Lead/Lag Balance Delta Configuration

LLDY Lag Start Delay Configuration

LL.ER Start If Error Higher Configuration

LAG.M Lag Unit Pump Select Configuration

LPUL Lead Pulldown Time Configuration

SERI Chillers in Series Configuration OPER Operating Control Type Operating ModesSLCT Set to desired value

RSET

Master Default: Disable

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

Range: Always Lead, Lag if Fail, Runtime Sel Default: Always Lead

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: Off If U Stp, On If U Stop Default: Off If U Stp

Range: 0 to 60 minutes Default: 0 minutes

YES Default: NO

Page 37

Table 34 — Dual Slave Chiller Control Parameters for Series Applications with Touch Pilot Display

DISPLAY NAME PATH LINE NO. VALUE

Master/Slave Select Main MenuConfigMST_SLV 3

Master Control Type Main Menu

Slave Address Main Menu

Lead Lag Select Main Menu

Lead/Lag Balance Delta Main Menu

Lag Start Timer Main Menu

Lead Pulldown Time Main Menu

Start If Error Higher Main Menu

Lag Minimum Running Time Main Menu

Lag Unit Pump Control Main Menu

Chiller In Series Main MenuConfigMST_SLV 22

NOTE: If pump control is configured to OFF, then LAG UNIT PUMP SELECT = 1. If pump control is set to any other value, then LAG

ConfigMST_SLV 7

ConfigMST_SLV 11

ConfigMST_SLV 12

ConfigMST_SLV 16

ConfigMST_SLV 17

ConfigMST_SLV 18

ConfigMST_SLV 19

ConfigMST_SLV 20

ConfigMST_SLV 21

UNIT PUMP SELECT = 0. This configuration must be set consistently for both master and slave chillers.

2 (Slave) Default: 0 (Disable)

1 (Local Control) 2 (Remote Control) 3 (CCN Control) Default: 1 (Local Control) Value: Configure for proper control type.

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

0 (Master Always Leads) 1 (Lag Once Failed Only) 2 (Lead/Lag Runtime Select) Default: 0 (Master Always Leads)

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 0 to 60 minutes Default: 0 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: 0 to 150 minutes Default: 0 minutes

0 (Stop If Unit Stops) 1 (Run If Unit Stops) Default: 0 (Stop If Unit Stops)

Ye s Default: No

Table 35 — Dual Slave Chiller Control Parameters for Series Applications with Navigator Display

ITEM ITEM EXPANSION PATH VALUE

MSSL Master/Slave Select ConfigurationRSET

SLVA Slave Address ConfigurationRSET

LLBL Master Lead Lag Select Configuration

LLBD Lead/Lag Balance Delta Configuration

LLDY Lag Start Delay Configuration

LL.ER Start If Error Higher Configuration

LAG.M Lag Unit Pump Select Configuration

LPUL Lead Pulldown Time Configuration

SERI Chillers in Series Configuration OPER Operating Control Type Operating ModesSLCT CCN Control

RSET

DUAL CHILLER PUMP CONTROL FOR SERIES CHILLER APPLICATIONS — Pump control for series chiller applications is controlled by the master chiller only. The control of the slave chiller is directed through commands emitted by the master chiller. The slave chiller has no action in master/slave operations. The slave chiller only verifies that CCN communication with the master chiller is present. See the Dual Chiller Sequence of Operation section on page 68.

Slave Default: Disable

Must be set to the Slave Chiller’s address. The master and slave chiller must have different addresses and be on the same Bus Number Default: 2

Range: Always Lead, Lag if Fail, Runtime Sel Default: Always Lead

Range: 40 to 400 hours Default: 168 hours

Range: 2 to 30 minutes Default: 10 minutes

Range: 3.0 to 18 F (1.7 to 10.0 C) Default: 4.0 F (2.2 C)

Range: Off If U Stp, On If U Stop Default: Off If U Stp

Range: 0 to 60 minutes Default: 0 minutes

YES Default: NO

Night Time/Low Noise Operation — The Com-

fortLink™ controls have the ability to lower the sound level of

the machine by reducing the number of fans that are running, provided that the conditions are acceptable. Reducing the number of running fans also limits the capacity. Three parameters must be configured for this operation. A start and end time for the mode of operation is required and an optional capacity limit set point must also be configured.

Page 38

If the Start and End Time remain at the factory default (0:00), then the unit is not programmed for Night Time/Low Noise Operation.

To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Start Hour Main Menu End Hour Main Menu Capacity Limit Main Menu

ConfigUser 39 Default: 00:00 ConfigUser 40 Default: 00:00 ConfigUser 41 Default: 100%

LINE

NO.

VAL UE

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

Night Low Noise

LS.ST

Start Night Low Noise

LS.ND

End Low Noise Capacity

LS.LT

Lim

Configuration

OPTN Default: 00:00

OPTN Default: 100%

Ramp Loading — Ramp Loading limits the rate of

change of the leaving fluid temperature. If the unit is in a Cooling mode and configured for Ramp Loading Select (Ramp Loading Select, RL.S), the control makes two comparisons before deciding to increase capacity. First, the control calculates the temperature difference between the control point and leaving fluid temperature. If the difference is greater than 4° F (2.2° C) and the rate of change (°F or °C per minute) is more than the configured Cool Ramp Loading rate (Cooling Ramp Loading, CRMP), then the control does not allow any increase of capacity.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Ramp Loading Select

Cooling Ramp Loading

Main Menu

ConfigUSER

Main Menu

Setpoint

LINE

NO.

5Yes

VALU E

Range: 0.2 to 2.0 °F (0.1 to 1.1 °C) Default: 1.0 °F (0.5 °C)

To configure this option with the Navigator display:

ITEM

RL.S

CRMP

ITEM

EXPANSION

Ramp Load Select

Cool Ramp Loading

Configuration

Setpoints

PAT H VA LU E

OPTN Yes

COOL

Range: 0.2 to 2.0 °F (0.1 to 1.1 °C) Default: 1.0 °F (0.5 °C)

Temperature Reset — Temperature reset is a value

added to the basic leaving fluid temperature set point and the resulting sum of these values is the new control point. When a non-zero temperature reset is applied, the chiller controls to the new control point, not the set point. The type of temperature reset is configured with the Cooling Reset Type (Cooling Reset Select, CRST) variable. Four types of temperature reset are available: Return Water Reset, Outside Air Temperature Reset, Space Temperature Reset, and 4-20 mA Temperature Reset.

Under normal operation, the chiller will maintain a constant entering or leaving fluid temperature, based on the configuration, approximately equal to the chilled fluid set point. As the cooler load varies, the cooler fluid temperature difference will change in proportion to the load. For example, if the chiller was selected for a Entering to Leaving Water Temperature difference of 10 F (5.5 C) at full load, at 50% load the temperature difference would be 5 F (2.2 C). See Fig. 22. Because the change in temperature through the cooler is a measure of the building load, the temperature difference reset is the average building load. Usually the chiller size and fluid temperature set point are selected based on a full load condition. At part load, the fluid temperature set point may be lower than required. If the fluid temperature were allowed to increase at part load, the efficiency of the machine would increase. The chiller can also be set for return water temperature control. See Fig. 23.

Other indirect means of estimating building load and controlling temperature reset are also available and are discussed below.

To verify that reset is functioning correctly, subtract the Setpoint Select (Current Setpoint, SETP) from the Control Point (Control Point, CTPT) to determine the degrees reset.

RETURN WATER RESET — The control system is capable of performing fluid temperature reset based on cooler fluid temperature difference. Because the change in temperature through the cooler is a measure of the building load, the temperature difference reset is, in effect, an average building load reset method.

Return Water Temperature Reset allows for the chilled water temperature set point to be reset upward as a function of the fluid temperature difference (building load).

NOTE: Return Water Temperature Reset should not be used with variable cooler flow rate systems.

To use Return Water Temperature Reset, four variables must be configured. Cooling Reset Type (Cooling Reset Select, CRST) must be enabled. The variable Delta T No Reset Tem p ( Delta T No Reset Value, CRT1) should be set to the cooler temperature difference (T) where no chilled water temperature reset should occur. The variable Delta T Full Reset Tem p ( Delta T Full Reset Value, CRT2) should be set to the cooler temperature difference where the maximum chilled water temperature reset should occur. The variable Degrees Cool Reset (Cooling Reset Deg. Value, DGRC) should be set to the maximum amount of reset desired.

To configure this option with the Touch Pilot display:

DISPLAY

NAME

Cooling Reset Select

Delta T No Reset Temp

Delta T Full Reset Temp

Cooling Reset Deg. Value

PATH

Main Menu

ConfigUSER

Main MenuSetpointSETPOINT

Main Menu

SetpointSETPOINT

Main Menu

SetpointSETPOINT

LINE

NO.

VALU E

Default =0 (No Reset) 2 (Delta T)

Default = 0 F (0 C)

Page 39

1009080706050403020100

% Load

Fluid Temperature (deg F)

EWT

LWT

Design

Rise

(typical)

Load%

Fluid Temperature (deg F)

EWT

LWT

1009080706050403020100

Design

Rise

(typical)

Fig. 22 — Leaving Chilled Water Temperature Control

Fig. 23 — Return Water Temperature Control Load Profile

a30-4066

a30-4478

Page 40

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

CRST

CRT1

CRT2

DGRC

Cooling Reset Ty p e

Delta T No Reset Temp

Delta T Full Reset Temp

Degrees Cool Reset

Configuration

Setpoints

COOL

RSET

Default = No Reset Delta T Temp

Default = 0 F (0 C)

In the example in Fig. 24 using Return Water Temperature Reset, the chilled water temperature will be reset by 5° F (2.8° C) when the Fluid Temperature Difference is 2° F (1.1° C) and 0° F (0° C) reset when the Temperature Difference is 10° F.

OUTSIDE AIR TEMPERATURE RESET — The control system is also capable of temperature reset based on outdoor-air temperature (OAT).

To use Outdoor Air Temperature Reset, four variables must be configured. Cooling Reset Type (Cooling Reset Select, CRST) must be enabled. The outside temperature at which no temperature reset is required, OAT No Reset Temp (OAT No Reset Value, CRO1) must be set. The outside temperature at which full temperature reset is required, OAT Full Reset Temp (OAT Full Reset Value, CRO2) must be set. Finally, the amount of temperature reset desired, Degrees Cool Reset (Cooling Reset Deg. Value, DRGC) must be set.

To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Cooling Reset Select

OAT No Reset Value

OAT Full Reset Value

Cooling Reset Deg. Value

Main Menu

ConfigUSER

Main MenuSetpointSETPOINT

Main Menu

SetpointSETPOINT

Main Menu

SetpointSETPOINT

LINE

NO.

VAL UE

Default =0 (No Reset) 1 (OAT)

Default = 14 F (–10 C)

Default = 0 F (0 C)

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

CRST

CRO1

CRO2

DGRC

Cooling Reset Ty pe

OAT No Reset Te mp

OAT Full Reset Te mp

Degrees Cool Reset

Configuration

SetpointsCOOL

Setpoints

RSET

COOL

Default = No Reset Out Air Temp

Default = 14 F (–10 C)

Default = 0 F (0 C)

In the example in Fig. 25, the outdoor air temperature reset example provides 0° F (0° C) chilled water set point reset at 85 F (29.4 C) outdoor-air temperature and 15° F (8.3° C) reset at 55 F (12.8 C) outdoor-air temperature.

SPACE TEMPERATURE RESET — The control system is also capable of temperature reset based on space temperature (SPT). An accessory sensor must be used for SPT reset (33ZCT55SPT). The Energy Management Module (EMM) is also required for temperature reset using space temperature.

To use Space Temperature Reset, four variables must be configured. Cooling Reset Type (Cooling Reset Select, CRST) must be enabled. The space temperature at which no temperature reset is required, Space T No Reset Temp (Space T No Reset Value, CRS1) must be set. The space temperature at which full temperature reset is required, Space T Full Reset Tem p ( Space T Full Reset Value, CRS2) must be set. Finally, the amount of temperature reset desired, Degrees Cool Reset (Cooling Reset Deg. Value, DRGC), must be set.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Cooling Reset Select

Space T No Reset Value

Space T Full Reset Value

Cooling Reset Deg. Value

Main Menu

ConfigUSER

Main Menu

SetpointSETPOINT

Main Menu

SetpointSETPOINT

Main Menu

SetpointSETPOINT

LINE

NO.

VAL UE

Default =0 (No Reset) 4 (Space Temp)

Default = 14 F (–10 C)

Default = 0 F (0 C)

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

CRST Cooling Reset Type Configuration

Space T No Reset

CRS1

Te m p Space T Full Reset

CRS2

Te m p

DGRC Degrees Cool Reset Setpoints

Setpoints

COOL

RSET

Default = No Reset Space Temp

Default = 14 F (–10 C)

Default = 0 F (0 C)

In the space temperature reset example in Fig. 26, 0° F (0° C) chilled water set point reset at 72 F (22.2 C) space temperature and 6° F (3.3° C) reset at 68 F (20.0 C) space temperature.

4-20 mA TEMPERATURE RESET — The control system is also capable of temperature reset based on an externally powered 4 to 20 mA signal. The Energy Management Module (EMM) is required for temperature reset using a 4 to 20 mA signal.

To use 4-20 mA Temperature Reset, four variables must be configured. Cooling Reset Type (Cooling Reset Select, CRST) must be enabled. The milliamp signal at which no temperature reset is required, Current No Reset Value (Current No Reset Va lu e, CRV1), must be set. The milliamp signal at which full temperature reset is required, Current Full Reset Value (Current Full Reset Value, CRV2), must be set. Finally, the amount of temperature reset desired, Degrees Cool Reset (Cooling Reset Deg. Value, DRGC), must be set.

CAUTION

Care should be taken when interfacing with other control systems due to possible power supply differences such as a full wave bridge versus a half wave rectification. Connection of control devices with different power supplies may result in permanent damage. The ComfortLink™ controls incorporate power supplies with half wave rectification. A signal isolation device should be utilized if the signal generator incorporates a full wave bridge rectifier.

Page 41

Entering-Leaving Water Temperature (deg F)

Degrees Reset (deg F)

Cooling

Reset

Deg. Value,

DGRC

Delta T No Reset Temp,

CRT1

Delta T Full Reset Temp,

CRT2

6 8

Fig. 24 — Return Water Reset

Fig. 25 — OAT Temperature Reset

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a30-4480

Reset Amount (deg F)

Cooling Reset

Deg. Value,

DGRC

OAT Full Reset Value,

20 40 60 801001200

CRO2

Outdoor Temperature

OAT No Reset Value,

CRO1

Page 42

To configure this option with the Touch Pilot™ display:

60 65 70 75 80

Space Temperature (deg F)

Degrees Reset (deg F)

Cooling Reset

Deg. Value,

DGRC

Space T Full Reset Value,

CRS2

Space T No Reset Value,

CRS1

Fig. 26 — Space Temperature Reset

a30-4481

DISPLAY NAME PATH

Cooling Reset Select

Current No Reset Value

Current Full Reset Value

Cooling Reset Deg. Value

Main Menu

ConfigUSER

Main Menu

SetpointSETPOINT

Main Menu

SetpointSETPOINT

Main Menu

SetpointSETPOINT

LINE

NO.

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

Cooling Reset

CRST

Ty p e

Current No

CRV1

Reset Temp Current Full

CRV2

Reset Temp Degrees Cool

DGRC

Reset

In the example in Fig. 27, at 4 mA no reset takes place and

Configuration

Setpoints

RSET

COOL

at 20 mA, 5° F (2.8° C) chilled water set point reset is required.

Demand Limit — Demand limit is a feature that allows

the unit capacity to be limited during periods of peak energy usage. This allows the owner to keep energy costs down. There are three types of demand limiting that can be configured. The first type is through 2-step switch control, which will reduce the maximum capacity to 2 user configurable percentages. The second type is by 4 to 20 mA signal input which will reduce the

VAL UE

Default =0 (No Reset) 3 (4-20mA Control)

4.0 mA

Default = 0.0

30.0 mA Default = 0.0

Default =

0.0 F (0.0 C)

Default = No Reset 4-20mA Input

4.0 mA Default = 0.0

20.0 mA Default = 0.0

5.0 F (2.8 C) Default = 0.0

maximum capacity linearly between 100% at a 4 mA input signal (no reduction) down to the user-configurable level at a 20 mA input signal. The third type uses the CCN Loadshed module and has the ability to limit the current operating capacity to maximum and further reduce the capacity if required. Demand limit control can be based on a calculated capacity level or by compressor current level.

NOTE: If using the compressor current level for demand limit, take into account the other power draws such as the condenserfan motors when determining the limit value desired.

SWITCH CONTROLLED DEMAND LIMIT — The control system is capable of demand limit based on a field-supplied switch for 1-step demand limit or 2 switches for 2-step demand limit. One-step Demand Limit is standard. The 2-step switch control of demand limiting requires the Energy Management Module (EMM). Demand Limit steps are controlled by two relay switch inputs field wired to TB5-5 and TB5-14 for Switch 1 and TB6-14 and TB6-15 for Switch 2.

For demand limit by switch control, closing the first demand limit contact will put the unit on the first demand limit level, either by capacity or compressor current. The unit will not exceed the percentage of capacity or compressor current entered as Demand Limit Switch 1 set point. Closing contacts on the second demand limit switch prevents the unit from exceeding the demand limit entered as Demand Limit Switch 2 set point. The demand limit percent capacity or compressor current that is set to the lowest demand takes priority if both demand limit inputs are closed. If the demand limit percentage does not match unit operation, the unit will limit capacity or current to the closest step without exceeding the value.

To use Demand Limit, select the type of demand limiting to use by configuring the Demand Limit Select variable (De- mand Limit Type Select, DMDC) to Switch. Configure the Demand Limit set points based on the type selected.

Page 43

Switch Controlled (Capacity Based)

0 10 15 20

mA Signal

Degrees Reset (deg F)

Cooling Reset Deg. Value (DGRC)

Current Full Reset Value (CRV2)

Current No Reset Value (CRV1)

Fig. 27 — 4 to 20 mA Temperature Reset

a30-4482

— If using 2-step Demand Limit control, an Energy Management Module must be installed. One-step Demand Limit control does not require the Energy Management Module. To configure Demand Limit for switch control, three parameters for 1-step switch control must be configured. For 2-step control, four parameters must be configured. The parameters are: the type of Demand Limit Selection (Demand Limit Type Select, DMDC), the setting for Switch Limit Set Point 1 (Switch Limit Setpoint 1, DLS1), The setting for Switch Limit Set Point 2 (Switch Limit Set-

point 2, DLS2), and Current Limit Select (Current Limit Select, CUR.S). Current Limit Select must be set to NO.

To configure this option with the Touch Pilot™ display:

capacity to 40%. Demand Limit Switch 1 is 60% and Demand Limit Switch 2 is 40%.

TOUCH PILOT DISPLAY NAVIGATOR DISPLAY

Display Name Value Item Value Demand Limit Type Select 1 DMDC SWITCH Switch Limit Setpoint 1 60% DSL1 60% Switch Limit Setpoint 2 40% DSL2 40% Current Limit Select No CUR.S NO

Switch Controlled (Current Based) mand limit control, an Energy Management Module must be installed. One-step demand limit control does not require the Energy Management Module. Four parameters for 1-step

DISPLAY NAME PATH

Demand Limit Type Select

Switch Limit Setpoint 1

Switch Limit Setpoint 2

Current Limit Select

USER 24

Config

Setpoints

Config

SETPOINT 33 Default = 100%

SETPOINT 34

USER 30

LINE

NO.

1 (Switch Control) Default = 0 (None)

(Not required for 1-Step) Default = 100%

No Default = No

VALU E

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

DMDC

DLS1

DLS2

CUR.S

Demand Limit Select

Switch Limit Setpoint 1

Switch Limit Setpoint 2

Current Limit Select

Configuration

Setpoints

Configuration

MISC Default = 100%

MISC

RSET

OPTN

SWITCH Default = NONE

(Not required for 1-Step) Default = 100%

NO Default: NO

switch control must be configured. For 2-step control, five parameters must be configured. The parameters are: the type of Demand Limit Selection (Demand Limit Type Select,

DMDC), the setting for Switch Limit Set Point 1 (Switch Lim- it Setpoint 1, DLS1), the setting for Switch Limit Set Point 2

(Switch Limit Setpoint 2, DLS2), the Current Limit Select (Current Limit Select, CUR.S), and the Compressor Current limit at 100% signal, (Current Limit at 100%, CUR.F).

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Demand Limit Type Select

Switch Limit Setpoint 1

Switch Limit Setpoint 2

Current Limit Select

Current Limit at 100%

In the following example, 2-step demand limit based on

capacity is desired with the first switch closure limiting the capacity to 60%. The second switch closure is to limit the

USER 24

Config

Setpoints

Config

USER 30

USER 31

Config

— If using 2-step de-

LINE

NO.

VAL UE

1 (Switch Control) Default = 0 (None)

SETPOINT 33 Default = 100%

SETPOINT 34

(Not required for 1-Step) Default = 100%

Ye s Default = No

Default =

2000.0 Amps

Page 44

To configure this option with the Navigator™ display:

ITEM ITEM EXPANSION PATH VALUE

DMDC

DSL1

DSL2

CUR.S

CUR.F

Demand Limit Select

Switch Limit Setpoint 1

Switch Limit Setpoint 2

Current Limit Select

Current Limit at 100%

Configuration

Setpoints

Configuration

MISC

RSET

OPTN

SWITCH Default = NONE

Default = 100%

(Not required for 1-Step) Default = 100%

NO Default: NO

Default = 2000

EXTERNALLY POWERED (4 to 20 mA) CAPACITY BASED DEMAND LIMIT — The Energy Management Module is required for 4 to 20 mA demand limit control. An externally powered 4 to 20 mA signal must be connected to TB6-1 and TB6-2. To configure demand limit for 4 to 20 mA control based on unit capacity, four parameters must be configured. The parameters are: the type of Demand Limit Selection (Demand Limit Type Select, DMDC), the current at which 100% capacity limit takes place (mA For 100% Demand Limit, DMMX), the current at which 0% capacity limit takes place (mA For 0% Demand Limit, DMZE), and the Current Limit Selection (Current Limit Select, CUR.S).

CAUTION

20 mA signal is connected to TB6-1 and TB6-2. The demand limit is a linear interpolation between the two values entered. In Fig. 28, if the machine receives a 12 mA signal, the machine controls will limit the capacity to 50%.

EXTERNALLY POWERED (4 to 20 mA) CURRENT BASED DEMAND LIMIT — The Energy Management Module is required for 4 to 20 mA demand limit control. An externally powered 4 to 20 mA signal must be connected to TB6-1 and TB6-2. To configure demand limit for 4 to 20 mA control based on compressor current, five parameters must be configured. The parameters are: the type of Demand Limit Selection (Demand Limit Type Select, DMDC), the current at which 100% capacity limit takes place (mA For 100% Demand Limit, DMMX), the current at which 0% capacity limit takes place (mA For 0% Demand Limit, DMZE), the Current Limit Selection (Current Limit Select, CUR.S), and the Compressor Current limit at 100% signal (Current Limit at 100%, CUR.F).

CAUTION

Care should be taken when interfacing with other control systems due to possible power supply differences such as a full wave bridge versus a half wave rectification. Connection of control devices with different power supplies may result in permanent damage. ComfortLink controls incor- porate power supplies with half wave rectification. A signal isolation device should be utilized if the signal generator incorporates a full wave bridge rectifier.

Care should be taken when interfacing with other control systems due to possible power supply differences such as a full wave bridge versus a half wave rectification. Connection of control devices with different power supplies may result in permanent damage. ComfortLink™ controls incorporate power supplies with half wave rectification. A signal isolation device should be utilized if the signal generator incorporates a full wave bridge rectifier.

To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Demand Limit Type Select

mA For 100% Demand Limit

mA For 0% Demand Limit

Current Limit Select

Config

USER 24

Config

USER 28

Config

USER 29

Config

USER 30

LINE

NO.

2 (4-20mA Control) Default = 0 (None)

4.0 mA Default = 0.0 mA

20.0 mA Default = 10.0 mA

No Default = No

VAL UE

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

DMDC

DMMX

DMZE

CUR.S

Demand Limit Select

mA for 100% Demand Lim

mA for 0% Demand Limit

Current Limit Select

Config

RSET

OPTN

4-20MA INPUT Default = NONE

4.0 mA Default = 0.0 mA

20.0 mA Default = 10.0 mA

NO Default: NO

In the following example, a 4 mA signal is Demand Limit

100% and a 20 mA Demand Limit signal is 0%. The 4 to

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Demand Limit Type Select

mA For 100% Demand Limit

mA For 0% Demand Limit

Current Limit Select

Current Limit at 100%

Config

USER 24

Config

USER 28

Config

USER 29

Config

USER 30

Config

USER 31 Default = 2000.0 Amps

LINE

NO.

2 (4-20mA Control) Default = 0 (None)

4.0 mA Default = 0.0 mA

20.0 mA Default = 10.0 mA

Ye s Default = No

VAL UE

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

DMDC

DMMX

DMZE

CUR.S

CUR.F

Demand Limit Select

mA for 100% Demand Lim

mA for 0% Demand Limit

Current Limit Select

Current Limit at 100%

Config

RSET

Config

RSET

Config

RSET

Config

OPTN

Config

OPTN Default = 2000

4-20MA INPUT Default = NONE

4.0 mA Default = 0.0 mA

20.0 mA Default = 10.0 mA

YES Default: NO

In the following example, a 4 mA signal is Demand Limit for compressor current is 2000 amps and a 20 mA Demand Limit signal corresponds with a compressor current of 0 amps. The 4 to 20 mA signal is connected to TB6-1 and TB6-2. The demand limit is a linear interpolation between the two values entered. If the machine receives a 12 mA signal, the machine controls will limit the total compressor current capacity to 1000 amps. See Fig. 29.

Page 45

100

12 14 16 18

mA Demand Limit Signal

% Demand Limit

mA For 0% Demand Limit,

DMZE

mA For 100% Demand Limit,

DMMX

8 10

400

600

800

1000

1200

1400

1600

1800

2000

mA Signal

Compressor Current

mA For 100% Demand Limit,

DMMX

mA For 0% Demand Limit,

DMZE

24 6 8 10 12 14 16 18 20

Fig. 28 — 4 to 20 mA Demand Limit (Capacity)

Fig. 29 — 4 to 20 mA Demand Limit (Compressor Current)

a30-4483

a30-4484

Page 46

CCN LOADSHED CONTROLLED DEMAND LIMIT — To configure Demand Limit for CCN Loadshed control, the unit Operating Type Control must be in CCN control. With the Touch Pilot™ display, the machine must be started with CCN Control. For the Navigator™ display, the Operating Control Type (I/O Button, OPER) must be CCN CONTROL.

The unit must be controlled by a Chillervisor module. The Chillervisor module can force the demand limit variable and directly control the capacity of the machine. Additionally, the unit’s set point will be artificially lowered to force the chiller to load to the demand limit value.

Ice Storage Operation — Chiller operation can be

configured to make and store ice. The Energy Management Module and an Ice Done Switch are required for operation in the Ice Mode. In this configuration, the machine can operate with up to three cooling set points: Cooling Set Point 1 (Cool- ing Setpoint 1, CSP.1) is used during the Occupied period; Cooling Set Point 2 (Cooling Setpoint 2, CSP.2) is used dur- ing the Unoccupied period when the ice build is complete (Ice Done Switch is closed); and Cooling Ice Set Point (Cooling Ice Setpoint, CSP.3) is used during the unoccupied period while ice is building (Ice Done Switch is open).

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Ice Mode Enable Config

LINE

NO.

USER 42 Yes

VALU E

To configure this option with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE

ICE.M Ice Mode Enable Configuration

OPTN ENBL

Broadcast Configuration — The 30XA chiller is ca-

pable of broadcasting outside-air temperature (OAT), time, date, and holiday status to all elements in the CCN system. In the stand-alone mode, broadcast must be activated to utilize holiday schedules and adjust for daylight saving time. If the chiller is to be connected to a CCN system, determine which system element is to be the network broadcaster and activate broadcast in all other system elements. Broadcast is activated and deactivated in the BRODEFS Table. It is accessible from Touch Pilot display (Config work Service Tool. It is not accessible through Navigator display.

Only one element should be configured as a broadcaster. If a broadcast is activated by a device that has been designated as a network broadcaster, then broadcasted time, date, and holiday status will be updated over the CCN system. If broadcast is enabled, a broadcast acknowledger must also be enabled. The acknowledger cannot be the same machine as the broadcasting machine.

ACTIVATE — The Activate variable enables the broadcast function of the ComfortLink™ controls. If this variable is set to 0, this function is not used and holiday schedules and daylight savings compensation are not possible. Setting this variable to 1 allows the machine to broadcast and receive broadcasts on the network. The following information is broadcast: the time with compensation for daylight savings, date, holiday flag, and the outdoor-air temperature.

Set this variable to 2 for stand-alone units that are not connected to a CCN. With this configuration, daylight saving time and holiday determination will be done without broadcasting through the bus. This variable can only be changed when using the Touch Pilot display, ComfortVIEW™ software, or Network Service Tool. This variable cannot be changed with the Navigator display.



BRODEFS) or through Net-

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Activate Config

BRODEFS 1

LINE

NO.

VAL UE

Range = 0 to 2 Default = 2

OAT BROADCAST — To enable the outside air temperature (OAT) broadcast, the unit broadcasting the temperature must be configured with its own CCN Bus and CCN Address. Leaving the parameters at the factory default of 0 for the CCN Bus and CCN Address disables the OAT Broadcast function. Once configured, the first broadcast of OAT will be within 5 minutes. This variable can only be changed when using the Touch Pilot display, ComfortVIEW software, or Network Service Tool. This variable cannot be changed with the Navigator display.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Activate Config OAT Broadcast ConfigBRODEFS 3 Bus # ConfigBRODEFS 4

Element # Config

BRODEFS 1

BRODEFS 5

LINE

NO.

VAL UE

Range = 0 to 2 Default = 2

Range = 0 to 239 Default = 0

BROADCAST ACKNOWLEDGER — This configuration defines if the chiller will be used to acknowledge broadcast messages on the CCN bus. One broadcast acknowledger is required per bus, including secondary buses created by the use of a bridge. This variable can only be changed with the Touch Pilot display, ComfortVIEW software, or Network Service Tool. This variable cannot be changed with the Navigator display.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Broadcast acknowledger Config

Ctlt-ID 10 Yes

LINE

NO.

VAL UE

Alarm Control

ALARM ROUTING CONTROL — Alarms recorded on the chiller can be routed through the CCN. To configure this option, the ComfortLink controls must be configured to determine which CCN elements will receive and process alarms. Input for the decision consists of eight digits, each of which can be set to either 0 or 1. Setting a digit to 1 specifies that alarms will be sent to the system element that corresponds to that digit. Setting all digits to 0 disables alarm processing. The factory default is 00000000. See Fig. 30. The default setting is is based on the assumption that the unit will not be connected to a network. If the network does not contain a ComfortVIEW, ComfortWORKS enabling this feature will only add unnecessary activity to the CCN Communication Bus.

This option can be modified by the Touch Pilot display. It

cannot be modified with the Navigator display.

Typical configuration of the Alarm Routing variable is

11010000. This Alarm Routing status will transmit alarms to ComfortView software, TeLink, BACLink, and DataLINK.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Alarm Routing Control

, TeLink, DataLINK™, or BACLink module,

LINE

NO.

Config

ALARMDEF 1 Default = 00000000

VAL UE

Page 47

ALARM EQUIPMENT PRIORITY — The ComfortVIEW

DESCRIPTION STATUS POINT

Alarm Routing 0 0 0 0 0 0 0 0 ALRM_CNT

ComfortView™, or ComfortWorks

TeLink

Unused

BacLink or DataLink™

Unused

Fig. 30 — Alarm Routing Control

a30-4485

software uses the equipment priority value when sorting alarms by level. The purpose of the equipment priority value is to determine the order in which to sort alarms that have the same level. A priority of 0 is the highest and would appear first when sorted. A priority of 7 would appear last when sorted. For example, if two chillers send out identical alarms, the chiller with the higher priority would be listed first. The default is 4. This variable can only be changed when using the Touch Pilot display, ComfortVIEW software, or Network Service Tool. This variable cannot be changed with the Navigator™ display. To configure this option with the Touch Pilot™ display:

DISPLAY NAME PATH

Alarm Equipment Priority

Config

ALARMDEF 2

LINE

NO.

VALU E

Range = 0 to 7 Default = 4

COMMUNICATION FAILURE RETRY TIME — This vari-

able specifies the amount of time that will be allowed to elapse between alarm retries. Retries occur when an alarm is not acknowledged by a network alarm acknowledger, which may use either ComfortVIEW software or TeLink. If acknowledgement is not received, the alarm will be re-transmitted after the number of minutes specified in this decision. This variable can only be changed with the Touch Pilot display, ComfortVIEW, or Network Service Tool. This variable cannot be changed with the Navigator display. To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Comm Failure Retry Time

Config

ALARMDEF 3

LINE

NO.

VAL UE

Range = 1 to 240 minutes Default = 10 minutes

characters in length. This variable can only be changed when using the Touch Pilot display, ComfortVIEW, or Network Service Tool. This variable cannot be changed with the Navigator display.

To configure this option with the Touch Pilot display:

DISPLAY NAME PATH

Alarm System Name

Config

ALARMDEF 5

Daylight Saving Time Configuration — The 30XA

chiller control contains software which can automatically correct for daylight saving time. This software is accessible from the Touch Pilot display, ComfortVIEW, or Network Service Tool. It is not accessible through the Navigator display.

To enable this feature, Daylight Saving Select must be set to

1. The start of Daylight Saving must be configured by setting the Month, Day of Week, and Week of Month. The end for Daylight Saving must also be configured. To configure this option with the Touch Pilot display, see Table 36.

Table 36 — Daylight Savings Time Configuration

DISPLAY NAME PATH

Activate Config

Daylight Saving Select

Entering ConfigBRODEFS 8

Month Config

Day of Week (1=Monday)

BRODEFS 1

Config

BRODEFS 7

BRODEFS 9

Config

BRODEFS 10

RE-ALARM TIME — This variable specifies the amount of time that will be allowed to elapse between re-alarms. A re-

Week of Month Config

BRODEFS 11

alarm occurs when the conditions that caused the initial alarm continue to persist for the number of minutes specified in this

Leaving Config

BRODEFS 12

decision. Re-alarming will continue to occur at the specified interval until the condition causing the alarm is corrected. This

Month Config

BRODEFS 13

variable can only be changed with the Touch Pilot display, ComfortVIEW, or Network Service Tool. This variable cannot

be changed with the Navigator display. To configure this option with the Touch Pilot display:

DISPLAY

NAME

Realarm Time

Config

ALARM SYSTEM NAME — This variable specifies the system element name that will appear in the alarms generated by the unit control. The name can be up to 8 alphanumeric

PATH

ALARMDEF 4

LINE

NO.

Range = 1 to 254 minutes 255 = Re-Alarm Disabled Default = 30 minutes

VAL UE

Day of Week (1=Monday)

Week of Month Config

BRODEFS 14

Config

BRODEFS 15

Capacity Control Overrides — The following ca-

pacity control overrides (Active Capacity Override, CAP.S) will modify the normal operation routine. If any of the override conditions listed below are satisfied, the override will determine the capacity change instead of the normal control. Overrides are listed by priority order and are often linked to unit

LINE

NO.

LINE

NO.

1 or 2 Default = 2

Enable Default = Dsble

Enter Starting Month for Daylight Saving

Enter the Day of the Week Daylight Saving Starts

Enter Week of the Month Daylight Saving Starts

Enter Ending Month for Daylight Saving

Enter the Day of the Week Daylight Saving ends

Enter Week of the Month Daylight Saving ends

VAL UE

Default = PRO_RGRW

VALU E

Page 48

operating modes. See Table 37 for a list of overrides. See the Operating Modes section on page 68 for more information regarding operating modes.

Override #1: Cooler Freeze Protection

— This override attempts to avoid the freeze protection alarm. If the Leaving Water Temperature is less than Brine Freeze Set Point (Brine Freeze Setpoint, LOSP) + 2.0° F (1.1º C) then a stage of capacity is removed.

NOTE: The freeze set point is 34 F (1.1 C) for fresh water systems (Cooler Fluid Type, FLUD=1). The freeze set point is Brine Freeze Set Point (Brine Freeze Setpoint, LOSP), for Medium Temperature Brine systems (Cooler Fluid Type, FLUD=2).

Override #2: Circuit A Low Saturated Suction Temperature in Cooling Override #3: Circuit B Low Saturated Suction Temperature in Cooling Override #4: Circuit C Low Saturated Suction Temperature in Cooling — These overrides attempt to avoid the low suction temperature alarms and are active only when the compressor is running beyond the fully unloaded level. The slide valve in the affected circuit will be decreased in position if the Saturated Suction Temperature is less than Brine Freeze Set Point (Brine Freeze Setpoint, LOSP) –18.0 F (–10 C) for 90 seconds, or the Saturated Suction Temperature is less than –4 F (–20 C).

Override #5: Low Temperature Cooling and High Temperature Heating — This override decreases capacity when the difference between the Control Point (Control Point, CTPT) and the Leaving Water Temperature (Cooler Leaving Fluid, LWT) reaches a predetermined limit and the rate of change of the water is 0º F per minute or still decreasing.

Override #6: Low Temperature Cooling and High Temperature Heating — This override decreases capacity (approximately 5% of circuit capacity) when the Entering Water Temperature (Cooler Entering Fluid, EWT) is less than the Control Point (Control Point, CTPT).

Override #7: Ramp Loading

— No capacity stage increase will be made if the unit is configured for ramp loading (Ramp Loading Select, RL.S=ENBL) and the difference between the Leaving Water Temperature and the Control Point is greater than 4º F (2.2º C) and the rate of change of the leaving water is greater than Cool Ramp Loading Rate (Cooling Ramp Load- ing, CRMP). Operating mode 5 (MD05) will be in effect.

Override #8: Service Manual Test Override

— This override mode places the unit into Service Test mode. The user can then use Service Test functions to test the unit. All safeties and higher priority overrides are monitored and acted upon.

Override # 9: Demand Limit

— This override mode is active when a command to limit the capacity is received. If the current unit capacity is greater than the active capacity limit value, a stage is removed. If the current capacity is lower than the capacity limit value, the control will not add a stage that will result in the new capacity being greater then the capacity limit value. Operating mode 4 (MD04) will be in effect.

Override #10: Cooler Interlock Override

— This override prohibits compressor operation until the Cooler Interlock (Cooler Flow Switch, LOCK) is closed.

Override #11: High Temperature Cooling and Low Temperature Heating — This override algorithm runs once when the unit is switched to ON. If the difference between the Leaving Water Temperature (Cooler Leaving Fluid, LWT) and the Control Point (Control Point, CTPT) exceeds a calculated value and the rate of change of the water temperature is greater than –0.1º F/min, a stage will be added.

Table 37 — Capacity Control Overrides

CAPACITY CONTROL OVERRIDES 1 Cooler Freeze Protection 2 Circuit A Low Saturated Suction Temperature in Cooling 3 Circuit B Low Saturated Suction Temperature in Cooling 4 Circuit C Low Saturated Suction Temperature in Cooling 5 Low Temperature Cooling and High Temperature Heating (LWT) 6 Low Temperature Cooling and High Temperature Heating (EWT) 7 Ramp Loading 8 Service Manual Test Override 9 Demand Limit

10 Cooler Interlock Override 11 High Temperature Cooling and Low Temperature Heating 12 High Temperature Cooling and Low Temperature Heating

(minimum load control in effect)

13 Minimum On/Off and Off/On Time Delay 14 Slow Change Override 15 System Manager Capacity Control 16 Circuit A High Pressure Override 17 Circuit B High Pressure Override 18 Circuit C High Pressure Override 19 Standby Mode 20 — 21 — 22 Minimum On Time Delay 23 Circuit A Low Saturated Suction Temperature in Cooling 24 Circuit B Low Saturated Suction Temperature in Cooling 25 Circuit C Low Saturated Suction Temperature in Cooling 26 Circuit A High Discharge Gas Override 27 Circuit B High Discharge Gas Override 28 Circuit C High Discharge Gas Override 29 — 30 — 31 — 32 — 33 — 34 Circuit A Low Refrigerant Charge 35 Circuit B Low Refrigerant Charge 36 Circuit C Low Refrigerant Charge 37 — 38 — 39 — 40 — 41 Circuit A High Current Override 42 Circuit B High Current Override 43 Circuit C High Current Override 44 Circuit A High Suction Superheat at Part Load 45 Circuit B High Suction Superheat at Part Load 46 Circuit C High Suction Superheat at Part Load 47 — 48 — 49 —

Circuit A MCHX MOP Control

50 51 Circuit B MCHX MOP Control 52 Circuit C MCHX MOP Control 53 Circuit A Delay for Unloading the Slide Valve 54 Circuit B Delay for Unloading the Slide Valve 55 Circuit C Delay for Unloading the Slide Valve 56 Circuit A Delay for Refrigeration Isolation Valve to Open 57 Circuit B Delay for Refrigeration Isolation Valve to Open 58 Circuit C Delay for Refrigeration Isolation Valve to Open 59 Circuit A Low Oil Level 60 Circuit B Low Oil Level 61 Circuit C Low Oil Level 62 Circuit A High Motor Temperature Override 63 Circuit B High Motor Temperature Override 64 Circuit C High Motor Temperature Override

77 Boostload Function

Page 49

Override #12: High Temperature Cooling and Low Temperature Heating — This override runs only when Minimum Load Control is Enabled, (Hot Gas Bypass Select, HGBP) and is set to 1, 2 or 3. This override will add a stage of capacity if the next stage is Minimum Load Control, when the difference between the Leaving Water Temperature (Cooler Leav- ing Fluid, LWT) and the Control Point (Control Point, CTPT) exceeds a calculated value and the rate of change of the water temperature is greater than a fixed value.

Override #13: Minimum On/Off and Off/On Time Delay

— Whenever a capacity change has been made, the control will remain at this capacity stage for the next 90 seconds. During this time, no capacity control algorithm calculations will be made. If the capacity step is a compressor, an additional 90-second delay is added to the previous hold time (see Override #22). This override allows the system to stabilize before another capacity stage is added or removed. If a condition of a higher priority override occurs, the higher priority override will take precedence. Operating Mode 10 (MD10) will be in effect.

Override #14: Slow Change Override

— This override prevents compressor stage changes when the leaving temperature is close to the control point and slowly moving towards it.

Override #15: System Manager Capacity Control

— If a Chillervisor module is controlling the unit and multiple chillers, the unit will increase capacity to attempt to load to the demand limited value.

Override #16: Circuit A High Pressure Override Override #17: Circuit B High Pressure Override Override #18: Circuit C High Pressure Override — This override attempts to avoid a high pressure failure. The algorithm is run every 4 seconds. If the Saturated Condensing Temperature for the circuit is above the High Pressure Threshold (High Pressure Threshold, HP.TH) then the position of slide valve will be unloaded.

Override #19: Standby Mode

— This override algorithm will not allow a compressor to run if the unit is in Standby mode, (Heat/Cool Status, HC.ST=2).

Override #22: Minimum On Time Delay

— In addition to Override #13 Minimum On/Off and Off/On Time Delay, for compressor capacity changes, an additional 90-second delay will be added to Override #13 delay. No compressor will be deenergized until 3 minutes have elapsed since the last compressor has been turned ON. When this override is active, the capacity control algorithm calculations will be performed, but no capacity reduction will be made until the timer has expired. A control with higher precedence will override the Minimum On Time Delay.

Override #23: Circuit A Low Saturated Suction Temperature in Cooling Override #24: Circuit B Low Saturated Suction Temperature in Cooling Override #25: Circuit C Low Saturated Suction Temperature in Cooling — If the circuit is operating close to the operational limit of the compressor, the circuit capacity will remain at the same point or unload to raise the saturated suction temperature. This algorithm will be active if the circuit is on and one of the following conditions is true:

1. Saturated Suction Temperature is less than the Brine Freeze Setpoint (Brine Freeze Setpoint, LOSP) –6º F (3.3º C).

2. Saturated Suction Temperature is less than the Brine Freeze Setpoint (Brine Freeze Setpoint, LOSP) and the circuit approach (Leaving Water Temperature – Saturated Suction Temperature) is greater than 15º F (8.3º C) and the Circuit Superheat (Discharge Gas Temperature – Saturated Discharge Temperature) is greater than 25º F (13.9º C).

NOTE: The freeze set point is 34 F (1.1 C) for fresh water systems (Cooler Fluid Type, FLUD=1). The

freeze set point is Brine Freeze Set Point (Brine Freeze Setpoint, LOSP), for Medium Temperature Brine systems (Cooler Fluid Type, FLUD=2).

If any of these conditions are met, the appropriate operating mode, 21 (Circuit A), 22 (Circuit B) or 23 (Circuit C) will be in effect.

Override #26: Circuit A High Discharge Gas Override Override #27: Circuit B High Discharge Gas Override Override #28: Circuit C High Discharge Gas Override — When the temperature is above the limit curve minus 2° F (1.1° C) increase in capacity will not be allowed. This override will remain active until the discharge gas temperature drops below the limit curve by –3° F (–1.7° C).

Override #34: Circuit A Low Refrigerant Charge Override #35: Circuit B Low Refrigerant Charge Override #36: Circuit C Low Refrigerant Charge — The capacity override attempts to protect the compressor from starting with no refrigerant in the circuit. This algorithm runs only when the circuit is not operational (compressor is OFF). There are several criteria that will enable this override:

1. The saturated suction temperature or saturated discharge temperature is less than –13 F (–10.6 C).

2. All of these conditions must be true:

a. The saturated suction temperature or saturated

discharge temperature is less than leaving water temperature by more than 5.4º F (3.0º C).

b. Saturated suction temperature or saturated dis-

charge temperature is less than 41 F (5 C). c. Outdoor air temperature is less than 32 F (0º C). d. Saturated suction temperature or saturated discharge

temperature is less than the outdoor air temperature

by more than 5.4º F (3.0º C).

3. All of these conditions must be true: a. The saturated suction temperature or saturated

discharge temperature is less than leaving water temperature by more than 5.4º F (3.0º C).

b. Saturated suction temperature or saturated dis-

charge temperature is less than 41 F (5 C).

c. Saturated suction temperature or saturated dis-

charge temperature is less than the brine freeze point (Brine Freeze Setpoint, LOSP) by more than 6º F (3.3º C).

NOTE: The freeze set point is 34 F (1.1 C) for fresh water systems (Brine Freeze Setpoint, FLUD=1). The freeze set point is brine freeze set point (Brine Freeze Setpoint, LOSP), for medium temperature brine systems (Cooler Fluid Type, FLUD=2).

4. All of these conditions must be true: a. The saturated suction temperature or saturated

discharge temperature is less than leaving water temperature by more than 5.4º F (3.0º C).

b. Saturated suction temperature or saturated discharge

temperature is less than 41 F (5 C).

c. Saturated suction temperature or saturated discharge

temperature is less than the outdoor-air temperature by more than 9º F (5º C).

If any of these conditions 1, 2, 3 or 4 are met, the appropriate operating mode, 21 (Circuit A), 22 (Circuit B) or 23 (Circuit C) will be in effect.

Override #41: Circuit A High Current Override Override #42: Circuit B High Current Override Override #43: Circuit C High Current Override — This override attempts to avoid an overcurrent failure. The algorithm is run every 4 seconds. If the compressor current is greater than 79% of must trip amps (MTA) but less than 85% MTA then the

Page 50

capacity will be held at current capacity. If the compressor current is greater than 85% MTA then capacity will be reduced by repositioning the slide valve until the current is less than 85% MTA (Must Trip Amps, MTA.X).

Override #44: Circuit A High Suction Superheat at Part Load Override #45: Circuit B High Suction Superheat at Part Load Override #46: Circuit C High Suction Superheat at Part Load — If the compressor of the circuit is on, the compressor current is no more than 30% of the MTA, main EXV is more than 90% open and the suction superheat is higher than the superheat control point for more than 5 minutes, then the circuit will be shut down.

Override #50: Circuit A MCHX MOP Control Override Override #51: Circuit B MCHX MOP Control Override Override #52: Circuit C MCHX MOP Control Override — This override shall prevent the compressor from increasing capacity when saturated suction temperature is greater than the MOP setpoint and saturated condensing temperature is greater than the maximum condensing temperature setpoint minus 15 F on units equipped with MCHX condenser option. This is to avoid high pressure alarm and operation outside the compressor envelope.

Override #53: Circuit A Delay for Unloading the Slide Valve Override #54: Circuit B Delay for Unloading the Slide Valve Override #55: Circuit C Delay for Unloading the Slide Va lv e — This override prevents the compressor from re-starting with locked rotor failure after being shutdown due to an alarm or power cycle. The delay varies depending on the size of the compressor. Refer to Table 38 for compressor nominal capacities. A delay of 20 minutes will elapse for 165 and 185 ton compressors, a delay of 8 minutes will elapse for 90 and 120 ton compressors, and 5 minutes will elapse for 45 and 50 ton compressors. The delay allows the slide valve of the compressor to move back to its fully unloaded position. The delay is adjusted according to the percent of the compressor running capacity before it is shut down. If the compressor is stopped normally, no delay will be applied. If the compressor is shut down by the locked rotor alarm, a full delay will be applied before the compressor is allowed to re-start. See Table 38 for compressor nominal capacity.

Override #56: Circuit A Delay for Refrigeration Isolation Valve to Open Override #57: Circuit B Delay for Refrigeration Isolation Valve to Open Override #58: Circuit C Delay for Refrigeration Isolation Valve to Open — This override allows the discharge motorized ball valve to open before the compressor starts. The delay is 2 minutes and 30 seconds. (Does not apply to units with DX cooler option.)

Override #59: Circuit A Low Oil Level Override #60: Circuit B Low Oil Level Override #61: Circuit C Low Oil Level — This override is only effective when the circuit is not running. The override will prevent the circuit from starting up with a low oil level. If this override occurs three times, the low oil level alarm will be tripped.

Override #62: Circuit A High Motor Temperature Override Override #63: Circuit B High Motor Temperature Override Override #64: Circuit C High Motor Temperature Override — This override prevents the compressor motor temperature from rising above the high temperature limit, but still allows the chiller to run close to the high temperature limit by unloading the compressor. If the motor temperature is greater than 214 F (101.1 C), the compressor will not load. This override will remain active until the temperature drops below 214 F (101.1 C). If the motor temperature is greater than 225 F (107.2 C) for 60 seconds, the circuit capacity will decrease by one stage. If the motor temperature is greater than 228 F (108.9), the circuit capacity will decrease by one stage immediately.

Override #77: Boostload Function

— This override can be present when boostload function is enabled. It is set in the following conditions :

if cool_lwt > ctrl_pnt + 5.4 and cool_ewt > ctrl_pnt + 9.0

and demand limit > 99%.

Head Pressure Control — The Main Base Board

(MBB) controls the condenser fans to maintain the lowest condensing temperature possible, and thus, the highest unit efficiency. The MBB uses the saturated condensing temperature input from the discharge pressure transducer to control the fans. Head pressure control is maintained through a calculated set point which is automatically adjusted based on actual saturated condensing and saturated suction temperatures so that the compressor(s) is (are) always operating within the manufacturer’s specified envelope (see Fig. 31). Each time a fan is added, the calculated head pressure set point will be raised 25° F (13.9° C) for 35 seconds to allow the system to stabilize. The control will automatically reduce the unit capacity as the saturated condensing temperature approaches an upper limit. See capacity overrides #16-18. The control will indicate through an operating mode that high ambient unloading is in effect. If the saturated condensing temperature in a circuit exceeds the calculated maximum, the circuit will be stopped. For these reasons, there are no head pressure control methods or set points to enter. The control will turn off a fan stage when the condensing temperature is below the minimum head pressure requirement for the compressor. Fan sequences are shown in Fig. 31. See Table 38 for compressor nominal capacity.

LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPTION — Units will start and operate down to 32 F (0° C) as standard. Operation to –20 F (–29 C) requires optional low ambient head pressure control as well as wind baffles (field fabricated and installed on all units for operation below 32 F [0° C]) if wind velocity is anticipated to be greater than 5 mph (8 kp/h). Inhibited propylene glycol or other suitable corrosion-resistant anti-freeze solution must be field supplied and installed in all units for unit operation below 34 F (1.1 C). Solution must be added to fluid loop to protect loop down to 15° F (8.3° C) below minimum operating ambient temperature. Concentration should be based on expected minimum temperature and either “Burst” or “Freeze” protection levels. At least 6 gal per ton (6.5 l/kW) of water volume is the recommended minimum for a moderate system load.

For low-ambient temperature operation, the lead fan on a circuit can be equipped with low ambient temperature head pressure control option or accessory. The controller adjusts fan speed to maintain the calculated head pressure set point.

LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPERATING INSTRUCTIONS — The 30XA low ambient control is a variable speed drive (VFD) that varies the speed of the lead condenser fan in each circuit to maintain the calculated head pressure control set point. The fan speed varies in proportion to the 0 to 10 vdc analog signal produced by the AUX1 fan board. The display indicates motor speed in Hz by default.

Table 38 — 30XA Compressor Nominal Capacity

30XA

UNIT SIZE

Compressor Nominal Capacity (tons)

Circuit A 45 45 50 60 60 90 100 90 100 120 Circuit B 45 45 50 50 60 50 60 90 100 100 Circuit C ——————————

30XA

UNIT SIZE

Compressor Nominal Capacity (tons)

Circuit A 120 165 165 185 165 185 120 185 185 Circuit B 120 100 120 120 165 165 120 90 120 Circuit C — — — — — — 165 185 185

080,

082

240, 242

090,

092

260,

262

100,

102

280,

282

110,

112

300, 302

120,

122

325,

327

140,

142

160,

162

350,

400 450 500

352

180, 182

200,

202

220,

222

Page 51

COMP B COMP A

FM1

FM2

FM3

FM4

FM5

FM6

FM7

FM8

FM9

FM10

COMP A

PEB

COMP B

FM1

FM2

FM3

FM4

FM5

FM6

FM7

FM8

FM9

FM10

FM11

FM12

COMP A

PEBCOMP B

FM1

FM2

FM3

FM4

COMP A

FM5

FM6

FM7

FM9

FM10

FM11

FM12

FM13

FM14

PEB

COMP B

FM1

FM2

FM3

FM4

COMP A

FM5

FM6

FM7

FM9

FM10

FM11

FM12

FM13

FM14

FM15

FM16

PEB

COMP B

FM1

FM2

FM3

FM4

COMP A

FM5

FM6

FM7

FM8

FM9

FM10

FM11

FM12

FM13

FM14

FM15

FM16

PEB

COMP B

FM1

FM2

FM3

FM4

COMP A

FM5

FM6

FM7

FM8

FM9

FM10

FM11

FM12

FM13

FM14

FM15

FM16

FM17

FM18

PEB

COMP B

FM1

FM3

FM5

FM2

FM4

FM6

30XA080,082

COMP B COMP A

FM1

FM2

FM3

FM4

FM5

FM6

FM7

FM8

30XA090-122

30XA140-162

30XA180-202

30XA220-242

30XA260,262

COMP B

FM3

FM1

FM2

FM4

LEGEND

COMP — Compressor FM — Fan Motor FC — Fan Contactor PEB — Power Electrical Box

COMP A

FM7

FM8

FM9

FM10

FM5

FM6

30XA280,282

30XA300,302

30XA325-352

PEB

FM11

FM12

FM13

FM14

CIRCUIT STAGE

CIRCUIT

Fan stage A 1 2 3

Contactor # FC A1 FC A2 FC A3

Fan position FM5 FM3 FM6

Fan stage B 1 2 3

Contactor # FC B1 FC B2 FC B3

Fan position FM1 FM4 FM2

Fan stage A 1 2 3 4

Contactor # FC A1 FC A2 FC A3 FC A4

Fan position FM7 FM5 FM8 FM6

Fan stage B 1 2 3 4

Contactor # FC B1 FC B2 FC B3 FC B4

Fan position FM1 FM3 FM2 FM4

Fan stage A123456

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6

Fan position FM9 FM7 FM5 FM10 FM8 FM6

Fan stage B 1 2 3 4

Contactor # FC B1 FC B2 FC B3 FC B4

Fan position FM1 FM3 FM2 FM4

Fan stage A123456

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6

Fan position FM11 FM9 FM7 FM12 FM10 FM8

Fan stage B123456

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6

Fan position FM1 FM3 FM5 FM2 FM4 FM6

Fan stage A1234567

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7

Fan position FM13 FM11 FM9 FM7 FM14 FM12 FM10

Fan stage B123456

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6

Fan position FM1 FM3 FM5 FM2 FM4 FM6

Fan stage A1234567 8

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8 FC A9

Fan position FM15 FM13 FM11 FM9 FM7 FM16 FM14 FM12 FM10

Fan stage B123456

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6

Fan position FM1 FM3 FM5 FM2 FM4 FM6

Fan stage A1234567 8

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8 FC A9

FM15

FM16

Fan position FM15 FM13 FM11 FM9 FM7 FM16 FM14 FM12 FM10

Fan stage B1234567

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6 FC B7

Fan position FM1 FM3 FM5 FM8 FM2 FM4 FM6

Fan stage A123456 7 8

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8 FC A9 FC A10

Fan position FM15 FM13 FM11 FM9 FM7 FM16 FM14 FM12 FM10 FM8

Fan stage B123456

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6

Fan position FM1 FM3 FM5 FM2 FM4 FM6

Fan stage A1234567 8

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8 FC A9

Fan position FM17 FM15 FM13 FM11 FM9 FM18 FM16 FM14 FM12

Fan stage B1234567 8

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6 FC B7 FC B8 FC B9

Fan position FM1 FM3 FM5 FM7 FM10 FM2 FM4 FM6 FM8

Fig. 31 — Fan Staging

Page 52

CIRCUIT STAGE

FM1

FM2

FM3

FM4

COMP C

FM5

FM6

FM7

FM8

FM9

FM10

FM11

FM12

FM13

FM14

FM15

FM16

FM17

FM18

FM19

FM20

PEB

COMP

PEB A/B COMP A

FM1

FM2

FM3

FM4

COMP C

FM5

FM6

FM7

FM8

FM9

FM10

FM11

FM12

FM13

FM14

FM15

FM16

FM17

FM18

FM19

FM20

FM21

FM22

PEB C

COMP

PEB A/B COMP A

D C

TO CONDENSER

FAN MOTOR

Fig. 32 — Siemens Low Ambient Temperature

Control Power Wiring

a30-4049

Fig. 33 — Siemens Low Ambient Temperature

Control Signal Wiring

a30-4230

a30-4219

30XA400

a30-4220

30XA450, 500

LEGEND

COMP — Compressor FM — Fan Motor FC — Fan Contactor PEB — Power Electrical Box

a30-4221

Fig. 31 — Fan Staging (cont)

Operation

— The low ambient temperature head pressure controller is pre-configured to operate from a 0 to 10 vdc analog input signal present on terminals 3 (AIN+) and 4 (AIN–). Jumpers between terminals 2 and 4 and terminals 5 and 8 (5 and 9 for 575-v drives) are required for proper operation. The drive is enabled based on an increase in the analog input signal above 0 vdc. Output is varied from 0 Hz to 60 Hz as the analog signal increases from 0 vdc to 10 vdc. When the signal is at 0 vdc the drive holds the fan at 0 rpm. The head pressure control set point is not adjustable. The MBB determines the control set point as required.

Replacement

— If the controller is replaced the parameters in

Table 39 must be configured. See Fig. 32 and 33.

CIRCUIT

Fan stage A12345678

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6

Fan position FM11 FM9 FM7 FM12 FM10 FM8

Fan stage B123456

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6

Fan position FM1 FM3 FM5 FM2 FM4 FM6

Fan stage C12345678

Contactor # FC C1 FC C2 FC C3 FC C4 FC C5 FC C6 FC C7 FC C8

Fan position FM19 FM17 FM15 FM13 FM20 FM18 FM16 FM14

Fan stage A12345678

Contactor # FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8

Fan position FM13 FM11 FM9 FM7 FM14 FM12 FM10 FM8

Fan stage B123456

Contactor # FC B1 FC B2 FC B3 FC B4 FC B5 FC B6

Fan position FM1 FM3 FM5 FM2 FM4 FM6

Fan stage C12345678

Contactor # FC C1 FC C2 FC C3 FC C4 FC C5 FC C6 FC C7 FC C8

Fan position FM21 FM19 FM17 FM15 FM22 FM20 FM18 FM16

ENABLE JUMPER

AOUT+ AOUT- P+

12 13 14 15

DIN1

N-

24V+

DIN2 DIN3

10V+ 0V AIN+ AIN-

RLC

RLB

10 11

DIP Switch 2 50 / 60 Hz kW / hp ON = 60 Hz

2 3

–

0-10 VDC SIGNAL FROM FAN BOARD

JUMPER

Page 53

Table 39 — Siemens VFD Control Parameters

P - - - -

Fig. 34 — Siemens Low Ambient Temperature

Controller

a30-4061

CHANGING P0004 — PARAMETER FILTER FUNCTION

CHANGING P0719 AN INDEXED PARAMETER

SELECTION OF COMMAND/SETPOINT SOURCE

Fig. 35 — Changing Parameters

with the Operator Panel

STEP

RESULT ON

DISPLAY

1 Press to access parameters

2 Press until P0004 is displayed

3 Press to access the parameter

value level

4 Press or to the required

value

5 Press to confirm and store the

value

6 Only the command parameters are

visible to the user.

STEP

RESULT ON

DISPLAY

1 Press to access parameters

2 Press until P0719 is displayed

3 Press to access the parameter

value level

4 Press to display current set value

5 Press or to the required

value

6 Press to conform and store the

value

7 Press until r0000 is displayed

8 Press to return the display to the

standard drive display (as defined by

the customer)

PARAMETER* VALUE DESCRIPTION

P0010 1 Enter Quick Commissioning

P0311

P0757 0.50 Control Signal Scaling Offset P0761 0.50 Control Signal Scaling Offset P3900 1 End of Quick Commissioning P0003 3 User Access Level P1210 6 Automatic Restart P1310 10% Continuous Boost

*Remove jumper from terminals 5 and 8 (or terminals 5 and 9 for

575 v) before configuring parameter. Reinstall jumper after configu-

ration is complete. †High Ambient option. **Standard.

1140†

850**

Rated Motor Speed

The DIP switches must also be set. DIP switch 1 is not used and DIP switch 2 is the motor frequency. (OFF = 50 Hz, ON = 60 Hz)

Drive Programming

— Parameter values can be altered via the operator panel. The operator panel features a five-digit, seven-segment display for displaying parameter numbers and values, alarm and fault messages, set points, and actual values. See Fig. 34 and 35. See Table 40 for additional information on the operator panel.

NOTE: The operator panel motor control functions are disabled by default. To control the motor via the operator panel, parameter P0700 should be set to 1 and P1000 set to 1. The operator panel can be fitted to and removed from the drive while power is applied. If the operator panel has been set as the I/O control (P0700 = 1), the drive will stop if the operator panel is removed.

Changing Parameters with the Operator Panel for the procedure for changing the value of parameter P0004. Modifying the value of an indexed parameter is illustrated in Fig. 35 using the example of P0719. Follow the same procedure to alter other parameters using the operator panel.

NOTE: In some cases when changing parameter values the display on the operator panel displays . This means the drive is busy with tasks of higher priority.

— See Fig. 35

Page 54

Changing Single Digits in Parameter Values

PFnP

— For changing the parameters value rapidly, the single digits of the display can be changed by performing the following actions:

Ensure the operator panel is in the parameter value changing level as described in the Changing Parameters with the Operator Panel section.

1. Press (function button), which causes the farthest

right digit to blink.

2. Change the value of this digit by pressing or .

3. Pressing (function button) again to cause the next

digit to blink.

4. Perform steps 2 to 4 until the required value is displayed.

5. Press (parameter button) to exit the parameter value

changing level.

NOTE: The function button may also be used to acknowledge a fault condition.

Quick Commissioning (P0010=1)

— It is important that pa- rameter P0010 is used for commissioning and P0003 is used to select the number of parameters to be accessed. The P0010 parameter allows a group of parameters to be selected that will enable quick commissioning. Parameters such as motor settings and ramp settings are included. At the end of the quick commissioning sequences, P3900 should be selected, which, when set to 1, will carry out the necessary motor calculations and clear all other parameters (not included in P0010=1) to the default settings. This will only occur in Quick Commissioning mode. See Fig. 36.

Reset to Factory Default

— To reset all parameters to the factory default settings, the following parameters should be set as follows:

1. Jumpers must be in place from terminals 2 and 4 and 5 and 8 (5 and 9 for 575v drives only).

2. Remove the keypad (pull out from top) and verify that DIP switch 1 is OFF and 2 is ON. Replace keypad.

3. Power up the drive. Press Parameter key. Press

to Parameter P0010.

4. Press , then to change the 0 to a 1. Press

again to accept the change.

5. Press to Parameter P0311. Press and press

to change this value to 1140 for 6-pole motors

or 850 for units with 8-pole motors. Press to accept.

6. Press to Parameter P3900. Press and use

to change this value to 1. Press to accept.

7. The drive will finish standard programming. Remove one end of the jumper wire from terminal 8.

8. Press again and go to Parameter P0003. Press

and use to change this value to 3. Press to

accept.

9. Press to Parameter P1210. Press and use

to change this value to 6. Press to accept.

10. Press to Parameter P1310. Press and use

to change this value to 10%. Press to accept.

11. Press the Function key and then . The display

will read 0.00 Hz.

12. Replace the wire jumper in terminal 8.

13. The drive is now active. Check fan rotation prior to testing.

If the fan is spinning forward, further adjustment is needed.

Fan should sit still when commanded speed is 0%. If the

fan is spinning forward slightly, press and to

Parameter P0761. Press and use to change this

value to 0.1. Press to accept. Check the fan. If rotation

has stopped no further adjustment is required. If the fan

is still rotating forward, press and use to change

this value to 0.2. Press to accept. Repeat as needed

until the fan is holding still or is just barely moving in

either direction. Do NOT enter a value greater than 0.5

for this parameter without first contacting your Carrier

representative.

Troubleshooting with the Operating Panel

— Warnings and faults are displayed on the operating panel with Axxx and Fxxx. The individual messages are shown in Table 41.

If the motor fails to start, check the following:

• Power is present on T1, T2 and T3.

• Configuration jumpers are in place.

• Control signal between 1 vdc and 10 vdc is present on

terminals 3 and 4.

• P0010 = 0.

• P0700 = 2. Fault Messages (Tables 41 and 42)

— In the event of a failure, the drive switches off and a fault code appears on the display.

NOTE: To reset the fault code, one of the following methods can be used:

1. Cycle the power to the drive.

2. Press the button on the operator panel.

Schneider Altivar VFD Operation

— The low ambient temperature head pressure controller is pre-configured to operate from a 0 to 10 vdc analog input signal present on terminals AI1 and COM. A jumper between terminals 24V and LI1 is required for proper operation. The drive is enabled based on an increase in the analog input signal above 0 vdc. Output is varied from 0 Hz to 60 Hz as the analog signal increases from 0 vdc to 10 vdc. When the signal is at 0 vdc the drive holds the fan at 0 rpm. The head pressure control set point is not adjustable. The MBB determines the control set point as required. The operating panel is shown in Fig. 37. Refer to the Quick Start Guide for how to access the programming mode, or the documentation on CD-ROM (shipped with each VFD) for a complete set of VFD parameters, fault codes and troubleshooting information.

Schneider Altivar VFD Replacement

— For Altivar 21 VFDs, if the controller is replaced the parameters in Table 43 must be configured. It is recommended that the configuration of the VFD is verified per Table 43 prior to proceeding. Also, the following must be wired:

1. A jumper must be in place from terminal P24 to F.

2. Connect the red and black wires from fan board 0-10 VDC output to terminal VIA and CC respectively.

3. Connect the motor power wires T1, T2 and T3 respectively to terminal U/T1, V/T2 and W/T3 of the drive.

4. Connect the line power wires L1, L2 and L3 from control box respectively to terminal R/L1, S/L2 and T/L3 of the drive.

Page 55

Table 40 — Siemens Low Ambient Temperature Controller Operator Panel

jog

PANEL/BUTTON FUNCTION DESCRIPTION

Indicates Status The LCD displays the settings currently used by the converter.

Start Converter The Start Converter button is disabled by default. To enable this button set P0700 = 1.

Stop Converter Press the Stop Converter button to cause the motor to come to a standstill at the selected

Change Direction Press the Change Direction button to change the direction of rotation of the motor.

Jog Motor Press the Jog Motor button while the inverter has no output to cause the motor to start and

Functions The Functions button can be used to view additional information. Press and hold the but-

Access Parameters Allows access to the parameters.

Increase Value Press the Increase Value button to increase the displayed value. To change the Frequency

ramp down rate. Disabled by default, to enable set P0700 = 1. Press the Stop Converter button twice (or hold) to cause the motor to coast to a standstill.

This function is always enabled.

Reverse is indicated by a minus (–) sign or a flashing decimal point. Disabled by default, to enable set P0700 = 1.

run at the preset jog frequency. The motor stops when the button is released. The Jog Motor button is not enabled when the motor is running.

ton to display the following information starting from any parameter during operation:

1. DC link voltage (indicated by d – units V).

2. Output current. (A)

3. Output frequency (Hz)

4. Output voltage (indicated by o – units V).

5. The value selected in P0005 (If P0005 is set to show any of the above [3, 4, or 5] then this will not be shown when toggling through the menu).

Press the Functions button repeatedly to toggle through displayed values.

Jump Function

Press of the Fn button from any parameter (rXXXX or PXXXX) to immediately jump to r0000, when another parameter can be changed, if required. Return to r0000 and press the Functions button again to return.

Setpoint using the operator panel set P1000 = 1.

Decrease Value Press the Decrease Value button to decrease the displayed value. To change the

Frequency Setpoint using the operating panel set P1000 = 1.

Page 56

P0010 Start Quick Commissioning

0 Ready to Run 1 Quick Commissioning 30 Factory Setting

NOTE: P0010 must always be set back to ‘0’ before operating the motor. However if P3900 = 1 is set after commissioning this is done automatically.

P0100 Operation

0 Power in kW; f default 50 Hz 1 Power in hp; f default 60 Hz 2 Power in kW; f default 60 Hz

NOTE: Settings 0 and 1 should be changed using the DIP switches to allow permanent setting.

P0304 Rated Motor Voltage*

10 V — 2000 V Nominal motor voltage (V) from rating plate

P0305 Rated Motor Current*

0 — 2 x inverter rated current (A) Nominal motor current (A) from rating plate

P0307 Rated Motor Power*

0 kW — 2000 kW Nominal motor power (kW) from rating plate. If P0100 = 1, values will be in hp

P0310 Rated Motor Frequency*

12 Hz — 650 Hz Nominal motor frequency (Hz) from rating plate

P0311 Rated Motor Speed*

0 — 4000 1/min Nominal motor speed (rpm) from rating plate

P0700 Selection of Command Source

(on/off/reverse) 0 Factory Setting 1 Basic Operator Panel 2 Terminal/Digital Inputs

P1000 Selection of Frequency Setpoint

0 No frequency setpoint 1 Operator panel frequency control  2 Analog Setpoint

P1080 Min. Motor Frequency

Sets minimum motor frequency (0-650Hz) at which the motor will run independent of the frequency setpoint. The value set here is valid for both clockwise and counterclockwise rotation.

P1082 Max. Motor Frequency

Sets maximum motor frequency (0-650Hz) at which the motor will run at independent of the frequency setpoint. The value set here is valid for both clockwise and counterclockwise rotation.

P1120 Ramp-Up Time

0 s - 650 s Time taken for the motor to accelerate from standstill up to maximum motor frequency.

P1121 Ramp-Down Time

0 s - 650 s Time taken for motor to decelerate from maximum motor frequency down to a standstill.

P3900 End Quick Commissioning

0 End Quick Commissioning without motor calculation or

factory reset.

1 End Quick Commissioning with motor calculation and

factory reset (Recommended)

2 End Quick Commissioning with motor calculation and with

I/O reset

3 End Quick Commissioning with motor calculation but

without I/O reset

*Motor-specific parameters — see motor rating plate. NOTE: Shaded boxes are for reference only.

Fig. 36 — Siemens Low Ambient Temperature Controller Flow Chart Quick Commissioning

Page 57

Table 41 — Siemens Low Ambient Temperature Controller Fault Messages

FAULT POSSIBLE CAUSES TROUBLESHOOTING

F0001

Overcurrent

F0002

Overvoltage

F0003

Undervoltage

F0004

Drive

Overtemperature

F0005

Drive I

F0011 Motor

Overtemperature I

F0041

Stator Resistance

Measurement Failure

Parameter EEPROM Fault

F0051

F0052

Powerstack Fault

F0060

Asic Timeout

F0070

Communications

Board Set Point Error

F0071

No Data for RS232 Link During Telegram Off Time

F0072

No Data from RS485 Link During Telegram Off Time

F0080

Analog Input -

Lost Input Signal

F0085

External Fault

F0101

Stack Overflow

F0221

PI Feedback

Below Minimum Value

F0222

PI Feedback Above

Maximum Value

F0450

(Service Mode Only)

BIST Tests Failure

LEGEND NOTE: To reset the fault code, one of the following methods can be used:

ASIC — Application Specific Instruction BIST — Built-in Self Test BOP — Basic Operating Panel

t—Current Squared Time PI — Proportional Integral PID — Propor tional Integral Derivative

• Motor power does not correspond to the inverter power

• Motor lead short circuit

• Ground fault

• DC-link voltage (r0026) exceeds trip level (P2172)

• Overvoltage can be caused either by too high main supply voltage or if motor is in regenerative mode

• Regenerative mode can be caused by fast ramp downs or if the motor is driven from an active load

• Main supply failed

• Shock load outside specified limits

• Ambient temperature outside of limits

• Fan failure

• Drive overloaded

• Duty cycle too demanding

• Motor power (P0307) exceeds drive power capability (P0206)

• Motor overloaded

• Motor data incorrect

• Long time period operating at low speeds

Stator resistance measurement failure 1. Check if the motor is connected to the drive

Reading or writing of the non-volatile parameter storage has failed

Reading of the powerstack information has failed or the data is invalid

Internal communications failure 1. Acknowledge fault

No setpoint received from communications board during telegram off time

No response during telegram off time via BOP link

No response during telegram off time via COM link

• Broken wire

• Signal out of limits

Check the following:

1. Motor power (P0307) must correspond to inverter power (P0206)

2. Motor cable and motor must have no short-circuits or ground faults

3. Motor parameters must match the motor in use

4. Motor must not be obstructed or overloaded After Steps 1-4 have been checked, increase the ramp time (P1120) and reduce the

boost level (P1310, P1311, P1312). Check the following:

1. Supply voltage (P0210) must lie within limits indicated on rating plate

2. DC-link voltage controller must be enabled (P1240) and have parameters set correctly

3. Ramp-down time (P1121) must match inertia of load

Check the following:

1. Supply voltage (P0210) must lie within limits indicated on rating plate

2. Supply must not be susceptible to temporary failures or voltage reductions

Check the following:

1. Fan must turn when inverter is running

2. Pulse frequency must be set to default value

3. Air inlet and outlet points are not obstructed

4. Ambient temperature could be higher than specified for the drive.

Check the following:

1. Load duty cycle must lie within specified limits

2. Motor power (P0307) must match drive power (P0206)

1. Check motor data

2. Check loading on motor

3. Boost settings too high (P1310,P1311, P1312)

4. Check parameter for motor thermal time constant

5. Check parameter for motor I

2. Check that the motor data has been entered correctly

1. Factory reset and new parameters set

2. Replace drive

Replace drive

2. Replace drive if repeated

1. Check connections to the communications board

2. Check the master

1. Check connections to the communications board

2. Check the master

1. Check connections to the communications board

2. Check the master

Check connection to analog input

External fault is triggered via terminal inputs Disable terminal input for fault trigger

Software error or processor failure 1. Run self test routines

PID Feedback below minimum value P2268 1. Change value of P2268

PID Feedback above maximum value P2267 1. Change value of P2267

Faul t va lu e 1 Some of the power section tests have failed 2 Some of the control board tests have failed 4 Some of the functional tests have failed 8 Some of the IO module tests have failed 16 The Internal RAM has failed its check on

power-up

2. Replace drive

2. Adjust feedback gain

1. Inverter may run but certain actions will not function correctly

2. Replace drive

1. Cycle the power to the drive.

2. Press the button on the operator panel.

t warning level

Page 58

Table 42 — Siemens Low Ambient Temperature Controller Alarm Messages

Fig. 37 — Schnieder Altivar 21 VFD Display Panel

CALL

OUT

LED/KEY DESCRIPTION

Display RUN LED

Illuminates when a run command is applied to the drive controller. Flashes when a speed reference is present with the run command.

Display PRG LED

Illuminates when Programming mode is active. Flashes when -GrU menus are active.

Display MON LED

Illuminates when Monitoring mode is active. Flashes in fault record display mode.

Display Unit

4 digits, 7 segments

Display Unit LED

The % LED illuminates when a displayed numeric value is a percentage. The Hz LED illuminates when a displayed numeric value is in hertz.

Up/Down arrows

Depending on the mode, use the arrows to: navigate between the menus, change a value, or change the speed reference when Up/Down LED (7) is lit.

Up/Down LED

Illuminates when the Up/Down arrows are controlling the speed reference.

Loc/Rem LED

Illuminates when Local mode is selected.

CALL

OUT

LED/KEY DESCRIPTION

MODE Press to select the Keypad mode. Modes are: Run

mode (default on power-up), Programming mode, and Monitoring mode. Can also be used to go back to the previous menu.

10 Loc/Rem Switches between Local and Remote modes.

ENT Press to display a parameter’s value or to save a

changed value.

12 RUN LED Illuminates when the Run key is enabled.

RUN Pressing this key when the RUN LED is illuminated

starts the drive controller.

STOP Stop/reset key. In Local mode, pressing the STOP key

causes the drive controller to stop based on the setting of parameter F721. In Remote mode, pressing the STOP key causes the drive controller to stop based on the setting of parameter F603. The display will indicate a flashing “E”. If F735 is set to 0 (default setting), pressing the stop key twice will reset all resettable faults if the fault condition has been resolved.

FAU LT POSSIBLE CAUSES TROUBLESHOOTING A0501

Current Limit

A0502

Overvoltage Limit

A0503

Undervoltage Limit

A0504

Drive

Overtemperature

A0505

Drive I2t

A0506

Drive Duty Cycle

A0511 Motor

Overtemperature I

A0541

Motor Data

Identification Active

A0600

RTOS Overrun Warning

LEGEND

I2t—Current Squared Time RTOS — Run Time Operating System

• Motor power does not correspond to the drive power

• Motor leads are too short

• Ground fault

• Mains supply too high

• Load regenerative

• Ramp-down time too short

• Mains supply too low

• Short mains interruption

Warning level of inverter heat-sink temperature (P0614) is exceeded, resulting in pulse frequency reduction and/or output frequency reduction (depending on parameters set (P0610)

Warning level is exceeded; current will be reduced if parameters set (P0610 = 1)

Heatsink temperature and thermal junction model are outside of allowable range

Motor overloaded Check the following:

Motor data identification (P1910) selected or running

Software error —

1. Check whether the motor power corresponds to the drive power

2. Check that the cable length limits have not been exceeded

3. Check motor cable and motor for short-circuits and ground faults

4. Check whether the motor parameters correspond with the motor being used

5. Check the stator resistance

6. Increase the ramp-up-time

7. Reduce the boost

8. Check whether the motor is obstructed or overloaded

1. Check that mains supply voltage is within allowable range

2. Increase ramp down times NOTE: If the vdc-max controller is active, ramp-down times will be automatically

increased Check main supply voltage (P0210)

1. Check if ambient temperature is within specified limits

2. Check load conditions and duty cycle

3. Check if fan is turning when drive is running

Check if duty cycle is within specified limits

1. P0611 (motor I

2. P0614 (motor I

3. Are long periods of operation at low speed occurring

4. Check that boost settings are not too high Wait until motor identification is finished

t time constant) should be set to appropriate value

t overload warning level) should be set to suitable level

RUN

PRG

MON

RUN STOP

Loc Rem

MODE

ENT

Page 59

Table 43 — Schnieder Altivar 21 VFD Operating Parameters

PARAMETER NAME VALUE

uLu Rated Motor Voltage Nominal motor voltage(V) from rating plate F201 VIA Speed Reference Level 1 5 F202 VIA Output Frequency Level 1 0 F203 VIA Speed Reference Level 2 100 F204 VIA Output Frequency Level 2 60 F401 Slip compensation 60% F415 Rated Motor Current Nominal motor current(A) from rating plate F417 Rated Motor Speed Nominal motor speed(RPM) from rating plate F701 Keypad display: % or A/V 1

tHr Motor Rated Current Overload Setting Nominal motor current(A) from rating plate

uL Rated Motor Frequency 60 Hz FH Maximum Frequency 60 Hz LL Low Speed 0 Hz

UL High Speed 60 Hz ACC Ramp-up Time 10 Sec dEC Ramp-down Time 10 Sec

cnod Remote Mode Start/Stop Control 0 (Control terminal logic inputs)

fnod

Remote Mode Primary Speed reference

Source

1 (VIA)

PRE-START-UP

IMPORTANT: Complete the Start-Up Checklist for 30XA Liquid Chillers at the end of this publication.

The checklist assures proper start-up of a unit, and provides a record of unit condition, application requirements, system information, and operation at initial start-up.

Do not attempt to start the chiller until the following checks

have been completed.

System Check

1. Check auxiliary components, such as the chilled fluid circulating pump, air-handling equipment, or other equipment to which the chiller supplies liquid are operational. Consult manufacturer’s instructions. If the unit has field-installed accessories, be sure all are properly installed and wired correctly. Refer to unit wiring diagrams.

2. Open compressor suction service valves (if equipped).

3. Open discharge line, liquid line, oil line, and economizer (if equipped) service valves.

4. Fill the chiller fluid circuit with clean water (with recommended inhibitor added) or other non-corrosive fluid to be cooled. Bleed all air out of high points of system. If outdoor temperatures are expected to be below 32 F (0° C), and unit has a flooded cooler option, sufficient inhibited propylene glycol or other suitable corrosion inhibited antifreeze should be added to the chiller water circuit to prevent possible freeze-up.

The chilled water loop must be cleaned before the unit is

connected. Units supplied with the accessory hydronic package include a run-in screen. If the run-in screen is left in the suction guide/strainer, it is recommended that the Service Maintenance be set to alert the operator within 24 hours of start-up to be sure that the run-in screen in the suction guide/strainer is removed. To set the time for the parameter, go to Water Filter Ctrl (days), W.FIL. Val- ues for this item are counted as days. Refer to the hydronic pump package literature if unit is equipped with the optional hydronic pump package.

5. Check tightness of all electrical connections.

6. Electrical power source must agree with unit nameplate.

7. Oil separator heaters must be firmly seated under the oil separator, and must be energized for 24 hours prior to start-up.

8. Verify power supply phase sequence. Fan motors are 3 phase. Check rotation of non low-ambient controlled fans by using the quick test. Fan rotation is counterclockwise as viewed from top of unit. If fan is not turning counterclockwise, reverse 2 of the power wires at the main terminal block.

9. Perform service test to verify proper operation.

START-UP

CAUTION

Do not manually operate contactors. Serious damage to the machine may result.

Actual Start-Up —

under supervision of a qualified refrigeration technician.

1. Be sure all oil, suction valves, discharge valves (if equipped) and liquid line service valves are open.

2. Using the unit control, set leaving-fluid set point (Cool- ing Setpoint 1, CSP.1). No cooling range adjustment is necessary.

3. If optional control functions or accessories are being used, the unit must be properly configured. Refer to Configuration Options section for details.

4. Start the chilled fluid pump, if unit is not configured for pump control. (Cooler Pumps Sequence, PUMP=0)

5. Complete the Start-Up Checklist to verify all components are operating properly.

6. If unit is equipped with navitgator turn Enable/Off/Remote contact switch to Enable position. If unit is equipped with Touch Pilot press the Start/Stop button and select Local On.

7. Allow unit to operate and confirm that everything is functioning properly. Check to see that leaving fluid temperature agrees with leaving set point Control Point (Control Point, CTPT).

Actual start-up should be done only

Page 60

Operating Limitations

TEMPERATURES — Unit operating temperature limits are listed in the table below.

TEMPERATURE F C Maximum Ambient Temperature 125 52 Minimum Ambient Temperature 32 0 Maximum Cooler EWT* 95 35 Maximum Cooler LWT 60 15 Minimum Cooler LWT† 40 4.4

LEGEND

EWT — Entering Fluid (Water) Temperature LWT — Leaving Fluid (Water) Temperature

*For sustained operation, EWT should not exceed 70 F (21.1 C).

†Unit requires brine modification for operation below this

temperature.

Low Ambient Temperature Operation — If unit operating temperatures below 32 F (0° C) are expected, refer to separate unit installation instructions for low ambient temperature operation using accessory low ambient temperature head pressure control, if not equipped. Contact your Carrier representative for details.

NOTE: If wind velocity is expected to be greater than 5 mph (8 km/h) wind baffles and brackets must be field-fabricated and installed for all units using accessory low ambient head pressure control. See the 30XA Installation Instructions or the low ambient temperature head pressure control accessory installation instructions for more information.

CAUTION

Brine duty application (below 40 F [4.4 C] LCWT) for chiller normally requires factory modification. Contact a Carrier Representative for details regarding specific applications. Operation below 40 F (4.4 C) LCWT without modification can result in compressor failure.

VOLTAGE Main Power Supply — Minimum and maximum acceptable

supply voltages are listed in the Installation Instructions. Unbalanced 3-Phase Supply Voltage — Never operate a motor

where a phase imbalance between phases is greater than 2%.

To determine percent voltage imbalance:

max voltage deviation from

% Voltage Imbalance = 100 x

The maximum voltage deviation is the largest difference between a voltage measurement across 2 legs and the average across all 3 legs.

Example: Supply voltage is 240-3-60.

AB = 243v

BC = 236v

AC = 238v

avg voltage

average voltage

1. Determine average voltage:

Average voltage =

243+236+238

717

= 239

2. Determine maximum deviation from average voltage: (AB) 243 – 239 = 4 v

(BC) 239 – 236 = 3 v (AC) 239 – 238 = 1 v

Maximum deviation is 4 v.

3. Determine percent voltage imbalance:

% Voltage Imbalance = 100 x

239

= 1.7%

This voltage imbalance is satisfactory as it is below the maximum allowable of 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact the local electric utility company immediately. Do not operate unit until imbalance condition is corrected.

MINIMUM FLUID LOOP VOLUME — To obtain proper temperature control, loop fluid volume must be at least 3 gallons per ton (3.25 L per kW) of chiller nominal capacity for air conditioning and at least 6 gallons per ton (6.5 L per kW) for process applications or systems that must operate at low ambient temperatures (below 32 F [0° C]). Refer to application information in Product Data literature for details.

FLOW RATE REQUIREMENTS — Standard chillers should be applied with nominal flow rates within those listed in the Minimum and Maximum Cooler Flow Rates table. Higher or lower flow rates are permissible to obtain lower or higher temperature rises. Minimum flow rates must be exceeded to assure turbulent flow and proper heat transfer in the cooler. See Table 44. See Fig. 38A-38D for cooler pressure drop curves.

CAUTION

Operation below minimum flow rate could generate alarms, which could result in damage to the cooler.

Consult application data section in the Product Data literature and job design requirements to determine flow rate requirements for a particular installation.

Page 61

Table 44 — 30XA Minimum and Maximum Cooler Flow Rates

Cooler Leaving Water Temperature* 40 F (4.4 C) 60 F (15 C)

30XA

UNIT SIZE

80 180.4 11.4

82 172.8 10.9 DX Cooler — 86 5.4 346 21.8

90 201.9 12.7

92 193.7 12.2 DX Cooler — 97 6.1 387 24.4

100 225.5 14.2

102 214.3 13.5 DX Cooler — 107 6.7 429 27.0

110 244.9 15.5

112 235.2 14.8 DX Cooler — 118 7.4 470 29.6

120 264.8 16.7

122 254.7 16.0 DX Cooler — 127 8.0 509 32.1

140 317.8 20.1

142 303.5 19.1 DX Cooler — 152 9.6 607 38.2

160 365.1 23

162 347 21.9 DX Cooler — 174 10.9 694 43.7

180 409.6 25.8

182 401.7 25.3 DX Cooler — 201 12.6 803 50.6

200 463.9 29.3

202 447.1 28.2 DX Cooler — 224 14.1 894 56.3

220 505.9 31.9

222 493 31.1 DX Cooler — 246 15.5 950 59.9

240 545.8 34.4

242 530 33.5 DX Cooler — 265 16.7 950 59.9

260 600.3 37.9

262 583 36.8 DX Cooler — 292 18.4 950 59.9

280 642.2 40.5

282 627 39.5 DX Cooler — 313 19.8 950 59.9

300 687.5 43.4

302 665 42.0 DX Cooler — 333 21.0 1331 83.9

325 733.4 46.3

327 720 45.4 DX Cooler — 360 22.7 1440 90.8

350 775.4 48.9

352 757 47.8 DX Cooler — 379 23.9 1514 95.5

400 917.6 57.9

450 1019.3 64.3

500 1092.8 68.9

Nominal Flow Rate

(gpm) (L/s) (gpm) (L/s) (gpm) (L/s)

LEGEND

DX — Direct Expansion

*For applications requiring cooler leaving water temperature operation at less than

40 F (4.4 C), the units require the use of antifreeze and application may require the brine option. Contact your local Carrier representative for more information.

†For applications requiring cooler entering water temperature operation at less

than 45 F (7.2 C), contact your local Carrier representative for unit selection using the Carrier electronic catalog.

Cooler Entering Water Temperature† 45 F (7.2 C) 70 F (21.1 C)

ITEM MINIMUM MAXIMUM

Cooler

Standard, Flooded 2 95 6 379 23.9

Plus One Pass, Flooded 3 43 2.7 192 12.1

Minus One Pass, Flooded 1 196 12.4 782 49.3

Standard, Flooded 2 101 6.4 403 25.4

Plus One Pass, Flooded 3 43 2.7 200 12.6

Minus One Pass, Flooded 1 229 14.4 917 57.9

Standard, Flooded 2 101 6.4 403 25.4

Plus One Pass, Flooded 3 43 2.7 200 12.6

Minus One Pass, Flooded 1 229 14.4 917 57.9

Standard, Flooded 2 125 7.9 501 31.6

Plus One Pass, Flooded 3 61 3.8 244 15.4

Minus One Pass, Flooded 1 254 16 1014 64

Standard, Flooded 2 125 7.9 501 31.6

Plus One Pass, Flooded 3 73 4.6 293 18.5

Minus One Pass, Flooded 1 281 17.7 1124 70.9

Standard, Flooded 2 134 8.5 538 33.9

Plus One Pass, Flooded 3 73 4.6 293 18.5

Minus One Pass, Flooded 1 324 20.4 1296 81.8

Standard, Flooded 2 165 10.4 660 41.6

Plus One Pass, Flooded 3 98 6.2 391 24.7

Minus One Pass, Flooded 1 354 22.3 1418 89.5

Standard, Flooded 2 202 12.7 807 50.9

Plus One Pass, Flooded 3 73 4.6 391 24.7

Minus One Pass, Flooded 1 416 26.2 1662 104.9

Standard, Flooded 2 223 14.1 892 56.3

Plus One Pass, Flooded 3 98 6.2 391 24.7

Minus One Pass, Flooded 1 458 28.9 1833 115.6

Standard, Flooded 2 235 14.8 941 59.4

Plus One Pass, Flooded 3 122 7.7 489 30.9

Minus One Pass, Flooded 1 501 31.6 2004 126.4

Standard, Flooded 2 266 16.8 1063 67.1

Plus One Pass, Flooded 3 147 9.3 587 37

Minus One Pass, Flooded 1 538 33.9 2151 135.7

Standard, Flooded 2 257 16.2 1027 64.8

Plus One Pass, Flooded 3 141 8.9 562 35.5

Minus One Pass, Flooded 1 584 36.8 2334 147.3

Standard, Flooded 2 293 18.5 1173 74

Plus One Pass, Flooded 3 141 8.9 562 35.5

Minus One Pass, Flooded 1 620 39.1 2481 156.5

Standard, Flooded 2 327 20.6 1308 82.5

Plus One Pass, Flooded 3 174 11 697 44

Minus One Pass, Flooded 1 687 43.3 2750 173.5

Standard, Flooded 2 361 22.8 1442 91

Plus One Pass, Flooded 3 211 13.3 843 53.2

Minus One Pass, Flooded 1 724 45.7 2897 182.8

Standard, Flooded 2 379 23.9 1516 95.6

Plus One Pass, Flooded 3 244 15.4 978 61.7

Minus One Pass, Flooded 1 767 48.4 3068 193.6

Standard, Flooded 1 501 31.6 2004 126.4

Plus One Pass, Flooded — — — — —

Minus One Pass, Flooded — — — — —

Standard, Flooded 1 501 31.6 2004 126.4

Plus One Pass, Flooded — — — — —

Minus One Pass, Flooded — — — — —

Standard, Flooded 1 501 31.6 2004 126.4

Plus One Pass, Flooded — — — — —

Minus One Pass, Flooded — — — — —

Number of

Passes

NOTES:

1. The 30XA units will start and pull down with loop temperatures up to 95 F (35 C).

2. Nominal flow rates required at AHRI conditions 44 F (7 C) leaving fluid temperature, 54 F (12 C) entering water temperature, 95 F (35 C) ambient. Fouling factor

0.00010 ft

3. To obtain proper temperature control, cooler loop fluid volume must be at least 3 gal/ton (3.23 L/kW) of chiller nominal capacity for air conditioning and at least 6 gal/ton (6.5 L/kW) for process applications or systems that must operate in low ambient temperatures (below 32 F [0° C]).

Minimum Flow Rate Maximum Flow Rate

-hr-F/Btu (0.000018 m2-K/kW).

Page 62

(149.5)

Cooler Flow, GPM (l/s)

Pressure Drop, ft wg (kPa)

080

090,100

110

120

(134.6)

(119.6)

(104.7)

(89.7)

(74.8)

(59.8)

(44.9)

(29.9)

(15)

100

(6.3)

200

(12.6)

300

(18.9)

400

(25.2)

500

(31.6)

600

(37.9)

Unit Sizes 30XA080, 90, 100, 110, 120

Unit Sizes 30XA140, 160, 180, 200, 220, 240

Fig. 38A — Cooler Pressure Drop Curves, Standard Pass Flooded Cooler

a30-4233

a30-4256

(179.4)

(149.5)

(119.6)

(89.7)

(59.8)

Pressure Drop, ft wg (kPa)

(29.9)

200

(12.6)

400

(25.2)

600

(37.9)

140

160

(50.5)

800

180

200

1000

(63.1)

220

240

1200

(75.7)

1400

(88.3)

Cooler Flow, GPM (l/s)

Page 63

260

280

300

325

350

400

450

500

Pressure Drop, ft wg (kPa)

(179.4)

(149.5)

(119.6)

(89.7)

(59.8)

(29.9)

500

(31.6)

1000

(63.1)

1500

(94.6)

2000

(126.2)

2500

(157.7)

3000

(189.3)

Cooler Flow, GPM (l/s)

0 100 200 300 400 500 600 700 800

Pressure Drop, ft wg (kPa)

Cooler Flow, GPM (l/s)

(12.62)

(25.24) (37.85) (50.47)(6.31) (18.93)(31.55) (44.16)

(29.9)

(59.8)

(89.7)

(119.6)

(149.5)

(179.4)

(209.3)

112, 122

082, 092, 102

182, 202

142, 162

Unit Sizes 30XA260, 280, 300, 325, 350, 400, 450, 500

Fig. 38A — Cooler Pressure Drop Curves, Standard Pass Flooded Cooler (cont)

a30-4257

Unit Sizes 30XA082, 092, 102, 112, 122, 142, 162, 182, 202

a30-5308

Fig. 38B — Cooler Pressure Drop Curves, DX (Direct Expansion) Cooler

Page 64

(149)

100

(299)

150

(488)

200

(598)

250

(747)

0 100

(6.3)

200

(12.6)

300

(18.9)

400

(25.2)

500

(31.6)

600

(37.9)

Cooler Flow, GPM (l/s)

Pressure Drop, ft wg (kPa)

080

090,100

110

120

0 200 400 600 800 1000 1200 1400 1600 1800

Pressure Drop,  wg (kPa)

Cooler Flow, GPM (l/s)

222, 242

262, 282

302, 327, 352

(12. 62)

(25. 24) (37.85) (50. 47) ( 75.71)(63.09) (88.32)

(59. 8)

(119. 6)

(179. 4)

(239. 1)

(100. 94) (113.56)

Fig. 38C — Cooler Pressure Drop Curves, Plus One-Pass Flooded Cooler

Unit Sizes 30XA080, 090, 100, 110, 120

a30-4486

a30-5393

Fig. 38B — Cooler Pressure Drop Curves, DX (Direct Expansion) Cooler (cont)

Unit Sizes 30XA222, 242, 262, 282, 302, 327, 352

Page 65

(149)

100

(299)

150

(488)

200

(598)

250

(747)

0 200

(12.6)

400

(25.2)

600

(37.9)

800

(50.6)

1000

(63.3)

1200

(75.9)

1400

(88.6)

1600

(101.3)

1800

(114.0)

COOLER FLOW, GPM (l/s)

Pressure Drop, ft wg (kPa)

260

280

300

325

350

NOTE: Plus-one-pass coolers are not available for 30XA400-500 units.

Fig. 38C — Cooler Pressure Drop Curves, Plus One-Pass Flooded Cooler (cont)

Unit Sizes 30XA260, 280, 300, 325, 350

a30-4489

250

Unit Sizes 30XA140, 160, 180, 200, 220, 240

a30-4487

(747)

180

200

(598)

150

(488)

100

(299)

Pressure Drop, ft wg (kPa)

(149)

0 200

(12.6)

400

(25.2)

140

600

(37.9)

COOLER FLOW, GPM (l/s)

160

(50.6)

800

200

1000

(63.3)

220

240

1200

(75.9)

1400

(88.6)

Page 66

(5.3)

(11.6)

(17.4)

(23.2)

(29.9)

(35.7)

0200

(12.6)

400

(25.2)

600

(37.9)

800

(50.6)

1000

(63.3)

1200

(75.9)

1400

(88.6)

COOLER FLOW, GPM (l/s)

Pressure Drop, ft wg (kPa)

140

160

180

200

220

240

NOTE: Minus-one-pass coolers are not available for 30XA400-500 units.

Fig. 38D — Cooler Pressure Drop Curves, Minus One-Pass Flooded Cooler

Unit Sizes 30XA140, 160, 180, 200, 220, 240

a30-4491

(2.9)

(5.8)

(8.7)

(11.6)

(14.5)

(17.4)

(20.3)

(23.2)

(26.1)

(29.9)

0100

(6.3)

200

(12.6)

300

(18.9)

400

(25.2)

500

(31.6)

600

(37.9)

700

(44.2)

COOLER FLOW, GPM (l/s)

Pressure Drop, ft wg (kPa)

080

090,100

110

120

140

Unit Sizes 30XA080, 090, 100, 110, 120, 140

a30-4490

Page 67

(2.9)

(5.5)

(8.7)

(11.6)

(14.5)

(17.4)

(20.3)

(23.2)

(26.1)

(29.9)

0200

(12.6)

400

(25.2)

600

(37.9)

800

(50.6)

1000

(63.3)

1200

(75.9)

1400

(88.6)

1600

(101.3)

1800

(114.0)

COOLER FLOW, GPM (l/s)

Pressure Drop, ft wg (kPa)

260

280 300

325

350

Unit Sizes 30XA260, 280, 300, 325, 350

NOTE: Minus-one-pass coolers are not available for 30XA400-500 units.

Fig. 38D — Cooler Pressure Drop Curves, Minus One-Pass Flooded Cooler (cont)

a30-4492

OPERATION

Sequence of Operation —

the chiller, the cooler pump will start. After verifying water flow, the control will monitor the entering and leaving water temperature. If the need for mechanical cooling is determined, the control decides which circuit and compressor to start. The control will start the required compressor completely unloaded and deenergize the oil separator heater (if already energized). The control will continue to load this circuit by moving the slide valve to satisfy cooling requirements. Once fully loaded, the control will start additional circuits to satisfy the load as required. Shutdown of each circuit under normal conditions occurs in the opposite sequence to loading. Once the A circuit is fully unloaded the compressor is shut off and the EXV will close completely.

If the outside-air temperature is less than the brine freeze point plus 17º F (9.4º C) then the circuit will perform a pump down cycle. The EXV will be closed and the compressor continues to operate until the saturated suction temperature (SST) is 10º F (5.6º C) lower than the starting SST or 10º F (5.6º C) less than the brine freeze point. Once the compressor is shut off the actuated ball valve (located in the discharge line) will be closed if equipped (flooded cooler option units only).

ACTUATED BALL VALVE (ABV), FLOODED COOLER ONLY — There is either one or two discharge ABVs located in the discharge line of each circuit of the unit. See Fig. 39 for a typical ABV assembly with enclosure. The ABV is a motorized ball valve, which is used to close the discharge line to prevent refrigerant migrating from condenser to the cooler when the circuit is off. The valve will be opened before the compressor is started and will normally close when pressure equalizes between suction and discharge lines. If the outside air temperature is less than the brine freeze point plus 17º F (9.4º C) then

With a command to start

the valve will close immediately without waiting for pressure equalization.

The actuated ball valves are linked to the cooler heater oper-

ation in the controls. Cooler Heater option (Configuration



Unit CO.HT , SERVICE FACTORY Cooler Heater Select) must be enabled for the Actuated Ball Valve to operate.

See Fig. 40 for a view of a fully open ball valve with the actuator removed. The flat surface at the top of the valve shaft is parallel to the discharge line. The ball valve motor mounting plate should be perpendicular to the discharge line at all times. If not, adjust it by loosening the set screw on the side of the valve, reposition assembly and tighten set screw.

See Fig. 41 for a view of the ball valve motor mounting with a fully open valve. The motor actuator arm should be at a counterclockwise position, with the valve shaft in a parallel position. If not in a parallel position, loosen the clamping screw and push the disengagement button to rotate the actuator arm until it stops. Retighten the clamping screw.

ABV Manual Operation

— The ABV can be operated manually as a discharge service valve by completing the following steps:

1. Remove the actuator cover.

2. With the compressor off hold down the Push button.

3. Close the ABV by turning the shaft adapter by hand or with a wrench so that the flats on the end of the shaft are perpendicular to the discharge line.

4. Release the Push button.

5. Disconnect the control power cable to the ABV.

Page 68

BASE PLATE

VALVE MOTOR

VALVE MOTOR COVER

VALVE SHAFT

CLAMPING SCREW

ACTUATOR ARM

DISENGAGEMENT BUTTON

MOUNTING - FULLY CLOSED

MOUNTING - FULLY OPEN

Fig. 39 — Typical ABV Assembly with Enclosure

Fig. 40 — Fully Open Ball Valve

with Actuator Removed

Fig. 41 — Ball Valve Motor

a30-4236

a30-4237

a30-4238

Dual Chiller Sequence of Operation — With a com-

mand to start the chiller, the master chiller determines which chiller will become the lead chiller based on the configuration of Lead Lag Select, LLBL and Lead/Lag Balance Data, LLBD. The lead chiller is always started first and the lag chiller is held at zero percent capacity by the master chiller forcing the lag demand limit value to 0%. If Lead Pulldown Time (Lead Pulldown Time, LPUL) has been configured, the lead chiller will continue to operate alone for that specified time. After the Lead Pulldown Time timer has elapsed and when the lead chiller is fully loaded, either all available compression is on or at the master demand limit value, then the lag start timer (Lag Start Timer, LLDY) is initiated. When the pulldown timer and lag start timer has elapsed and the Combined Leaving Chilled Water Temperature is more than 3° F (1.7° C) above the set point, then the lag chiller is started. If the lag chiller’s water pump was not started when the machines went into occupied mode, the lag chiller water pump will be started. The lag chiller will start with the master chiller forcing the lag chiller demand limit value (LAG_LIM) to the master’s demand limit value. If lead/ lag capacity balance is selected, once the lag chiller has started, the master shall try to keep the difference in capacity between lead and lag less than 20%. The master shall then be responsible for water loop capacity calculation, and will determine which chiller, the lead or lag, will increase or decrease capacity. When the load reduces, the lag chiller will be the first chiller to unload. To accomplish this, the lead chiller set point is decreased by 4° F (–2.2° C) until the lag chiller unloads.

PUMP OPERATION — For parallel chiller pump operation, the lead chiller’s water pump will be started. The lag chiller’s water pump will be maintained off if Lag Unit Pump Control, LAGP=0. The internal algorithm of lead chiller will control ca- pacity of the lead chiller.

For series chiller operation, the pump is always controlled

by the master chiller.

Operating Modes — Operating modes are override

modes that affect normal operation of the equipment. More than one operating mode can be in effect at the same time. Some operating modes have corresponding capacity control overrides in the Capacity Control Overrides section on page 47.

For the Touch Pilot™ display, the status of the operating modes can be found in the MODES submenu, which is under the STATUS menu. Each operating mode and its status (Yes = active, No = inactive) is listed.

For the Navigator™ display, the status of the operating modes can be found in the MODE submenu under the OPER- ATING MODES menu. The 6 top priority operating modes are displayed in MD01 through MD06. To view the modes with the Navigator display:

ITEM ITEM EXPANSION PATH VALUE MD01 First Active Mode Operating modes MD02 Second Active Mode Operating modes MD03 Third Active Mode Operating modes MD04 Fourth Active Mode Operating modes MD05 Fifth Active Mode Operating modes MD06 Sixth Active Mode Operating modes

MODE 0-32 MODE 0-32 MODE 0-32 MODE 0-32 MODE 0-32 MODE 0-32

See Table 45 for a list of operating modes.

STARTUP DELAY IN EFFECT — This mode is checked for when the unit is started. This mode is active when the Minutes Off Time (Unit Off to On Delay, DELY) timer is active. The unit will not start until the timer has expired. The mode will terminate when the timer expires.

Page 69

NAVIGATOR OPERATING

MODE NUMBER

01 Star tup Delay in Effect Startup Delay in Effect 2 Yes/No 02 Second Setpoint in Use Second Setpoint in Use 3 Yes/No 03 Reset in Effect Reset in Effect 4 Yes/No 04 Demand Limit Active Demand Limit Active 5 Yes/No 05 Ramp Loading Active Ramp Loading Active 6 Yes/No 06 Cooler Heater Active Cooler Heater Active 7 Yes/No 07 Cooler Pumps Rotation Cooler Pumps Rotation 8 Yes/No 08 Pump Periodic Start Pump Periodic Start 9 Yes/No 09 Night Low Noise Active Night Low Noise Active 10 Yes/No 10 System Manager Active System Manager Active 11 Yes/No 11 Mast Slave Ctrl Active Mast Slave Active 12 Yes/No 12 Auto Changeover Active Auto Changeover Active 13 Yes/No 13 Free Cooling Active Free Cooling Active 14 Yes/No 14 Reclaim Active Reclaim Active 15 Yes/No 15 Electric Heat Active Electric Heat Active 16 Yes/No 16 Heating Low EWT Lockout Heating Low EWT Lockout 17 Yes/No 17 Condenser Pumps Rotation Condenser Pumps Rotation 18 Yes/No 18 Ice Mode in Effect Ice Mode in Effect 19 Yes/No 19 Defrost Active on Cir A Defrost Active on Cir A 20 Yes/No 20 Defrost Active on Cir B Defrost Active on Cir B 21 Yes/No 21 Low Suction Circuit A Low Suction Circuit A 22 Yes/No 22 Low Suction Circuit B Low Suction Circuit B 23 Yes/No 23 Low Suction Circuit C Low Suction Circuit C 24 Yes/No 24 High DGT Circuit A High DGT Circuit A 25 Yes/No 25 High DGT Circuit B High DGT Circuit B 26 Yes/No 26 High DGT Circuit C High DGT Circuit C 27 Yes/No 27 High Pres Override Cir A High Pres Override Cir A 28 Yes/No 28 High Pres Override Cir B High Pres Override Cir B 29 Yes/No 29 High Pres Override Cir C High Pres Override Cir C 30 Yes/No 30 Low Superheat Circuit A Low Superheat Circuit A 31 Yes/No 31 Low Superheat Circuit B Low Superheat Circuit B 32 Yes/No 32 Low Superheat Circuit C Low Superheat Circuit C 33 Yes/No

Table 45 — 30XA Operating Modes

NAVIGATOR EXPANSION TOUCH PILOT DISCRIPTION

TOUCH PILOT

LINE NUMBER

TOUCH PILOT

VAL UE

SECOND SETPOINT IN USE — This mode is checked for when the unit is ON. The mode is active when Cooling Setpoint 2 (Cooling Setpoint 2, CSP.2) or Ice Setpoint (Cooling Ice Setpoint, CSP.3) is in use. While in this mode, the Active Setpoint (Current Setpoint, SETP) will show the CSP.2 or CSP.3 value.

While in this mode, the unit will operate to the Cooling Setpoint 2 (CSP.2) or Ice Setpoint (CSP.3). The mode will termi- nate when the Cooling Setpoint 2 (CSP.2) or Ice Setpoint (CSP.3) is no longer in use.

RESET IN EFFECT — This mode is checked for when the unit is ON. The mode will be active when Temperature Reset (Cooling Reset Select, CRST) is enabled either by CRST=1 (Outside Air Temperature), CRST=2 (Return Water), CRST=3 (4-20 mA Input), or CRST=4 (Space Temperature) and reset is active.

While in this mode, the Active Setpoint (Current Setpoint, SETP) will be modified according to the programmed information and will be displayed as the Control Point (Control Point, CTPT). The mode will terminate when the Temperature Reset is not modifying the active leaving water set point, causing SETP to be the same as CTPT.

DEMAND LIMIT ACTIVE — This mode is chacked for when the unit is ON. The mode is active when Demand Limit (Demand Limit Type Select, DMDC) is enabled either by DMDC=1 (Switch), DMDC=2 (4-20 mA Input), or the Night Time Low Sound Capacity Limit (Capacity Limit, LS.LT).

The Active Demand Limit Value (Active Demand Limit Va l, LIM) will display the current demand limit according to the programmed information and the unit’s capacity will be reduced to the amount shown or lower. The mode will terminate when the Demand Limit command has been removed.

RAMP LOADING ACTIVE — This mode is checked for when the unit is ON. The mode is active when Ramp Loading

(Ramp Loading Select, RL.S) is enabled and the following conditions are met:

1. The leaving water temperature is more than 4° F (2.2° C) from the Control Point (

Control Point, CTPT), and

2. The rate of change of the leaving water temperature is greater than the Cool Ramp Loading (Cooling Ramp Loading, CRMP).

The control will limit the percent capacity increase until one of the two conditions above are no longer met, then the mode will terminate.

COOLER HEATER ACTIVE — This mode is checked for whether the unit is ON or OFF. The mode is active when the cooler heater is energized. The cooler heater is energized when the Outdoor Air Temperature (External Temperature, OAT) is less than the calculated value, (Freeze Setpoint + Cooler Heater Delta T Setpoint [Cooler Heater Delta Spt, HTR] default – 2° F [1.1° C]) and either the Leaving Water Temperature (Cooler Leaving Fluid, LWT) or the Entering Water Temperature (Cooler Entering Fluid, EWT) are less than or equal to the Freeze Setpoint + Cooler Heater Delta T Setpoint (HTR).

The Freeze Setpoint is 34 F (1.1 C), for fresh water systems (Cooler Fluid Type, FLUD=1). The Freeze Setpoint is Brine Freeze Setpoint (Brine Freeze Setpoint, LOSP), for Medium Temperature Brine systems (Cooler Fluid Type, FLUD=2).

When in this mode, the cooler heater will be energized. The cooler heater will be deenergized when both the Entering Water Temperature (EWT) and Leaving Water Temperature (LWT) are above the Freeze Setpoint + Cooler Heater Delta T Setpoint (HTR).

This mode is enabled for freeze protection. If the temperatures are not as described above, check the accuracy of the outside air, entering and leaving water thermistors.

COOLER PUMPS ROTATION — This mode is checked for whether the unit is ON or OFF. The mode is active when the

Page 70

Cooler Pump Sequence (Cooler Pump Run Status, PUMP=2) (2 Pumps Automatic Changeover) and the Pump Rotation Delta Timer (Pump Auto Rotation Delay, ROT.P) have expired.

The control will switch the operation of the pumps. The lead pump will operate normally. The lag pump will be started, becoming the lead, and then the original lead pump will be shut down. This mode will terminate when the pump operation has been completed.

PUMP PERIODIC START — This mode is active when the cooler pump is started due to the Periodic Pump Start configuration (Pump Sticking Protection, PM.PS=YES). If the pump has not run that day, a pump will be started and will run for 2 seconds at 2:00 PM. If the machine is equipped with dual pumps, Pump no. 1 will run on even days (such as day 2, 4, 6 of the month). Pump no. 2 will run on odd days (such as day 1, 3, 5 of the month). The mode will terminate when the pump shuts down.

NIGHT LOW NOISE ACTIVE — This mode is active when the Night Time Low Noise Option has been configured and the current time is within the configured time frame. Programming a Night Low Noise Start Time (Start Ho ur, LS.ST) and a Night Low Noise End Time (End Hour, LS.ND) configures the option.

The control will raise the head pressure set point to reduce the number of condenser fans on, thereby reducing the sound level of the machine. Additionally, if the Night Time Low Sound Capacity Limit (Start Hour, LS.LT) has been configured, the unit’s capacity will be limited to the programmed level. This mode will terminate once the Night Low Noise End Time (LS.ND) has been reached.

SYSTEM MANAGER ACTIVE — This mode is checked when the unit is ON or OFF. This mode is active if a System Manager such as Building Supervisor, Chillervisor System Manager, or another CCN device is controlling the machine.

When this mode is active, the machine will respond to the specific commands received from the System Manager. The mode will be terminated if the System Manager control is released.

MASTER SLAVE CONTROL ACTIVE — This mode is checked for if the machine is ON. This mode is active if Master Slave Control has been enabled. This occurs when two machines are programmed, one as the master (Master/Slave Se-

lect, MSSL=1 [Master]) and the other as a slave (Master/ Slave Select, MSSL=2 [Slave]).

Both the master and slave machines will respond to the capacity control commands issued by the master controller. This may include control point changes and demand limit commands. This mode will terminate when Master Slave Control has been disabled.

AUTO CHANGEOVER ACTIVE — This mode is not supported.

FREE COOLING ACTIVE — This mode is not supported. RECLAIM ACTIVE — This mode is not supported. ELECTRIC HEAT ACTIVE — This mode is not supported. HEATING LOW EWT LOCKOUT — This mode is not

supported. CONDENSER PUMPS ROTATION — This mode is not

supported. ICE MODE IN EFFECT — This mode is checked for when

the unit is ON. This mode is active when Ice Setpoint (Cooling Ice Setpoint, CSP.3) is in use. While in this mode, the Active Setpoint (Current Setpoint, SETP) will show the Cooling Ice Setpoint, CSP.3, value and the unit will operate to the Ice

Setpoint (

CSP.3). This mode will terminate when the Ice

Setpoint (CSP.3) is no longer in use. DEFROST ACTIVE ON CIR A — This mode is not

supported. DEFROST ACTIVE ON CIR B — This mode is not

supported. LOW SUCTION CIRCUIT A

LOW SUCTION CIRCUIT B LOW SUCTION CIRCUIT C — These modes are checked when the circuit is ON. The appropriate circuit mode will be active if one of the following conditions is true:

1. If the circuit’s saturated suction temperature (SST) is more than 6° F (3.3° C) less than the freeze point and both the cooler approach (Leaving Water Temperature – SST) and superheat (Suction Gas Temperature – SST) are greater than 15° F (8.3° C).

2. If the circuit is ON and the circuit’s SST is more than 18º F (10.0º C) below the freeze point for more than 90 seconds.

3. If the circuit’s saturated suction temperature is more than 6° F (3.3° C) below the freeze point for more than 3 minutes.

For a fresh water system (Cooler Fluid Type, FLUD =1), the freeze point is 34° F (1.1° C). For medium temperature brine systems, (Cooler Fluid Type, FLUD=2), the freeze point is Brine Freeze Set Point (Brine Freeze Setpoint, LOSP).

For criterion 1, no additional capacity will be added. For criteria 2 and 3 capacity will be decreased on the circuit. The mode will terminate when the circuit’s SST is greater than the freeze point minus 6° F (3.3° C) or the circuit has alarmed.

If this condition is encountered, see Possible Causes for Alarms 56-58 on page 98.

HIGH DGT CIRCUIT A — This mode is not supported. HIGH DGT CIRCUIT B — This mode is not supported. HIGH DGT CIRCUIT C — This mode is not supported. HIGH PRES OVERRIDE CIR A

HIGH PRES OVERRIDE CIR B HIGH PRES OVERRIDE CIR C — This mode is checked for when the circuit is ON. The appropriate circuit mode will be active if the discharge pressure for the circuit, Discharge Pressure Circuit A (Discharge Pressure, DP.A), Discharge Pressure Circuit B (Discharge Pressure, DP.B), or Discharge Pressure Circuit C (Discharge Pressure, DP.C), is greater than the High Pressure Threshold (High Pressure Threshold, HP.TH).

The capacity of the affected circuit will be reduced. Two minutes following the capacity reduction, the circuit’s saturated condensing temperature (SCT affected circuit will not be allowed to add capacity for at least 5

) is calculated and stored. The

t+2

minutes following the capacity reduction. If after 5 minutes, the circuit’s saturated condensing temperature is less than SCT

–3° F (1.7° C), and then if required, percent capacity

t+2

will be added. If additional capacity is required, the control will look for other circuits to add capacity.

This mode will terminate once the circuit’s saturated condensing temperature is less than SCT

–3° F (1.7° C).

t+2

If this condition is encountered, see Possible Causes for Alarm A1.03. on page 103.

LOW SUPERHEAT CIRCUIT A LOW SUPERHEAT CIRCUIT B LOW SUPERHEAT CIRCUIT C — This mode is checked for when the circuit is ON. The appropriate circuit mode will be active if the circuit’s superheat (discharge gas temperature – SCT) is less than 18° F (10° C).

Page 71

No additional capacity will be added until the circuit’s superheat is greater than 18° F (10° C). The control will look for other circuits to add capacity if additional steps of capacity are required. This mode will terminate once the affected circuit’s superheat is greater than 18° F (10° C).

If this condition is encountered, see Possible Causes for Alarms P.11, P.12 and P.13 on page 98.

Sensors — The electronic control uses up to 17 thermistors

to sense temperatures and up to 12 transducers to sense pressure for controlling chiller operation. These sensors are outlined below.

THERMISTORS (Tables 46-47B) — Thermistors that are monitoring the chiller’s operation include: Cooler Entering Water, Cooler Leaving Water, Dual Chiller Leaving Water, Compressor Suction Gas Temperature, Compressor Discharge Gas Temperature, Economizer Temperature, Compressor Motor Temperature, and Outdoor Air Temperature Thermistors. These thermistors are 5 kat 77 F (25 C) and are identical in temperature versus resistance. The Space Temperature Thermistor is 10 k at 77 F (25 C) and has a different temperature vs. resistance.

Cooler Leaving Water Sensor is installed in a friction fit well in the leaving water nozzle of the cooler. See Fig. 42 and 43.

Cooler Entering Water Sensor is factory-installed in a friction fit well in the entering water nozzle of the cooler.

Suction Gas Temperature factory-installed in a friction fit well located on the compressor of each circuit. There is one thermistor for each circuit.

Compressor Discharge Gas Temperature thermistor is factory-installed in a friction fit well located in the discharge end of the compressor for the circuit. There is one thermistor for each circuit.

Economizer Temperature this thermistor is factory-installed in a friction fit well located in the economizer line for the circuit. There is one thermistor for each circuit.

Compressor Motor Temperature istor is embedded in the motor windings. There are two thermistors in each compressor. One spare is provided.

Outdoor Air Temperature to the back of the control box.

Remote Space Temperature 33ZCT55SPT) is a field-installed accessory mounted in the indoor space and is used for water temperature reset. The sensor should be installed as a wall-mounted thermostat would be (in

— On all sizes, this thermistor

— On all sizes, this thermistor is

— On all sizes, this

— On all sizes except 080 and 082,

— On all sizes, this therm-

— This sensor is factory-installed

— This sensor (part no.

the conditioned space where it will not be subjected to either a cooling or heating source or direct exposure to sunlight, and 4 to 5 ft above the floor).

Space temperature sensor wires are to be connected to terminals in the unit main control box. See Fig. 44. The space temperature sensor includes a terminal block (SEN) and a RJ11 female connector. The RJ11 connector is used access into the Carrier Comfort Network

(CCN) at the sensor.

To connect the space temperature sensor (see Fig. 44):

1. Using a 20 AWG twisted pair conductor cable rated for the application, connect one wire of the twisted pair to one SEN terminal and connect the other wire to the other SEN terminal located under the cover of the space temperature sensor.

2. Connect the other ends of the wires to terminals 7 and 8 on TB6 located in the unit control box.

Units on the CCN can be monitored from the space at the sensor through the RJ11 connector, if desired. To wire the RJ11 connector into the CCN:

1. Cut the CCN wire and strip ends of the red (+), white (ground), and black (–) conductors. (If another wire color scheme is used, strip ends of appropriate wires.)

2. Insert and secure the red (+) wire to terminal 5 of the space temperature sensor terminal block.

3. Insert and secure the white (ground) wire to terminal 4 of the space temperature sensor.

4. Insert and secure the black (–) wire to terminal 2 of the space temperature sensor.

IMPORTANT: The cable selected for the RJ11 connector wiring MUST be identical to the CCN communication bus wire used for the entire network. Refer to Table 14 for acceptable wiring.

5. Connect the other end of the communication bus cable to the remainder of the CCN communication bus.

NOTE: The Energy Management Module (EMM) is required for this accessory.

TRANSDUCERS — There are four pressure transducers per circuit, and two different types of transducers: low pressure (green connector) and high pressure (black connector).

Low Pressure Type: Suction Pressure Transducer (SPT), Economizer Pressure Transducer (EPT).

High Pressure Type: Discharge Pressure Transducer (DPT), Oil Pressure Transducer (OPT). See Fig. 45A and 45B for transducer locations.

THERMISTOR ID DESCRIPTION RESISTANCE AT 77 F (25 C) CONNECTION POINT

EWT Entering Water Thermistor 5k  MBB-J6-CH2

LWT Leaving Water Thermistor 5k  MBB-J6-CH1 OAT Outdoor Air Thermistor 5k  MBB-J6-CH4

SGTA* Circuit A Suction Gas Thermistor 5k  EXVA-J3-THA

SGTB* Circuit B Suction Gas Thermistor 5k  EXVB-J3-THA

SGTC Circuit C Suction Gas Thermistor 5k  EXVC-J3-THA

DGTA Circuit A Discharge Gas Thermistor 5k  CPM-A-J9-CH02 DGTB Circuit B Discharge Gas Thermistor 5k  CPM-B-J9-CH02 DGTC Circuit C Discharge Gas Thermistor 5k  CPM-C-J9-CH02

ECTA Circuit A Economizer Thermistor 5k  EXVA-J3-THB

ECTB Circuit B Economizer Thermistor 5k  EXVB-J3-THB

ECTB Circuit C Economizer Thermistor 5k  EXVC-J3-THB

DUAL Dual Chiller LWT Thermistor 5k  MBB-J6-CH3 CAMT Circuit A Motor Temperature 5k  CPM-A-J9-CH01 CBMT Circuit B Motor Temperature 5k  CPM-B-J9-CH01 CCMT Circuit C Motor Temperature 5k  CPM-C-J9-CH01

SPT Space Temperature Thermistor 10k  EMM-J6-CH2

*SGTA and SGTB for 30XA080,082 units are connected to the EXVA board.

Table 46 — Thermistor Identification

Page 72

O-RING

BRASS NUT 3/8 - 24 FOR ASSEMBLY ON BRASS WELL

6" MINIMUM

CLEARANCE FOR

THERMISTOR

REMOVAL

1.188 in.

2.315 in.

1/4-18 NPT

Fig. 42 — 5K Thermistor (Sensor 00PPG000008105A, Connector: HY06AM016)

Fig. 43 — Dual Leaving Water Thermistor Well

(00PPG000008000A)

Fig. 44 — Typical Remote Space Temperature

Sensor (33ZCT55SPT) Wiring

SENSOR

a30-4079

a30-4080

a30-4081

ECONOMIZER PRESSURE TRANSDUCER (EPT A)

ECONOMIZER PRESSURE TRANSDUCER (EPT B)

OIL PRESSURE TRANSDUCER (OPT A)

OIL PRESSURE TRANSDUCER (OPT B)

DISCHARGE PRESSURE TRANSDUCER (DPT A)

DISCHARGE PRESSURE TRANSDUCER (DPT B)

SUCTION PRESSURE TRANSDUCER (SPT A)

SUCTION PRESSURE TRANSDUCER (SPT B)

CIRCUIT A CIRCUIT B

COOLER

OIL SEPARATOR

COMPRESSOR

Fig. 45A — Transducer Locations (Flooded Cooler Units)

a30-4467

SEN

TB6

Page 73

(

SUCTION PRESSURE

Fig. 45B — Transducer Locations (DX Cooler Units)

a30-5329

TEMP

(F)

RESISTANCE

(Ohms)

–25 98,010 –24 94,707 –23 91,522 –22 88,449 –21 85,486 –20 82,627 –19 79,871 –18 77,212 –17 74,648 –16 72,175 –15 69,790 –14 67,490 –13 65,272 –12 63,133 –11 61,070 –10 59,081

–9 57,162 –8 55,311 –7 53,526 –6 51,804 –5 50,143 –4 48,541 –3 46,996 –2 45,505 –1 44,066

0 42,679 1 41,339 2 40,047 3 38,800 4 37,596 5 36,435 6 35,313 7 34,231 8 33,185

9 32,176 10 31,202 11 30,260 12 29,351 13 28,473 14 27,624 15 26,804 16 26,011 17 25,245 18 24,505 19 23,789 20 23,096 21 22,427 22 21,779 23

21,153

24 20,547 25 19,960

TEMP

(F)

RESISTANCE

(Ohms)

77 4,976 78 4,855 79 4,737 80 4,622 81 4,511 82 4,403 83 4,298 84 4,196 85 4,096 86 4,000 87 3,906 88 3,814 89 3,726 90 3,640 91 3,556 92 3,474 93 3,395 94 3,318 95 3,243 96 3,170 97 3,099 98 3,031

99 2,964 100 2,898 101 2,835 102 2,773 103 2,713 104 2,655 105 2,597 106 2,542 107 2,488 108 2,436 109 2,385 110 2,335 111 2,286 112 2,239 113 2,192 114 2,147 115 2,103 116 2,060 117 2,018 118 1,977 119 1,937 120 1,898 121 1,860 122 1,822 123 1,786 124 1,750 125

1,715

126 1,680 127 1,647

TEMP

(F)

RESISTANCE

(Ohms)

179 570 180 561 181 551 182 542 183 533 184 524 185 516 186 508 187 501 188 494 189 487 190 480 191 473 192 467 193 461 194 456 195 450 196 445 197 439 198 434 199 429 200 424 201 419 202 415 203 410 204 405 205 401 206 396 207 391 208 386 209 382 210 377 211 372 212 367 213 361 214 356 215 350 216 344 217 338 218 332 219 325 220 318 221 311 222 304 223 297 224 289 225 282

TEMP

(F)

RESISTANCE

(Ohms)

26 19,393 27 18,843 28 18,311 29 17,796 30 17,297 31 16,814 32 16,346 33 15,892 34 15,453 35 15,027 36 14,614 37 14,214 38 13,826 39 13,449 40 13,084 41 12,730 42 12,387 43 12,053 44 11,730 45 11,416 46 11,112 47 10,816 48 10,529 49 10,250 50 9,979 51 9,717 52 9,461 53 9,213 54 8,973 55 8,739 56 8,511 57 8,291 58 8,076 59 7,686 60 7,665 61 7,468 62 7,277 63 7,091 64 6,911 65 6,735 66 6,564 67 6,399 68 6,238 69 6,081 70 5,929 71 5,781 72 5,637 73 5,497 74 5,361 75 5,229 76 5,101

TEMP

(F)

RESISTANCE

(Ohms)

128 1,614 129 1,582 130 1,550 131 1,519 132 1,489 133 1,459 134 1,430 135 1,401 136 1,373 137 1,345 138 1,318 139 1,291 140 1,265 141 1,240 142 1,214 143 1,190 144 1,165 145 1,141 146 1,118 147 1,095 148 1,072 149 1,050 150 1,029 151 1,007 152 986 153 965 154 945 155 925 156 906 157 887 158 868 159 850 160 832 161 815 162 798 163 782 164 765 165 750 166 734 167 719 168 705 169 690 170 677 171 663 172 650 173 638 174 626 175 614 176 602 177 591 178 581

TRANSDUCER (SPT A)

ECONOMIZER PRESSURE TRANSDUCER (EPT A)

ECONOMIZER PRESSURE TRANSDUCER (EPT B)

SUCTION PRESSURE TRANSDUCER (SPT B)

COOLER

DISCHARGE PRESSURE TRANSDUCER (DPT A)

OIL PRESSURE TRANSDUCER

OPT A)

Table 47A — 5K Thermistor Temperature (°F) vs Resistance

CIRCUIT A CIRCUIT B

OIL PRESSURE TRANSDUCER (OPT B)

OIL SEPARATOR

DISCHARGE PRESSURE TRANSDUCER (DPT B)

COMPRESSOR

Page 74

Table 47B — 5K Thermistor Temperature (°C) vs Resistance/Voltage

TEMP

(C)

RESISTANCE

(Ohms)

–32 100,260 –31 94,165 –30 88,480 –29 83,170 –28 78,125 –27 73,580 –26 69,250 –25 65,205 –24 61,420 –23 57,875 –22 54,555 –21 51,450 –20 48,536 –19 45,807 –18 43,247 –17 40,845 –16 38,592 –15 38,476 –14 34,489 –13 32,621 –12 30,866 –11 29,216 –10 27,633

–9 26,202 –8 24,827 –7 23,532 –6 22,313 –5 21,163 –4 20,079 –3 19,058 –2 18,094 –1 17,184

0 16,325 1 15,515 2 14,749 3 14,026 4 13,342 5 12,696 6 12,085 7 11,506 8 10,959

9 10,441 10 9,949 11 9,485 12 9,044 13 8,627 14 8,231

TEMP

(C)

RESISTANCE

(Ohms)

15 7,855 16 7,499 17 7,161 18 6,840 19 6,536 20 6,246 21 5,971 22 5,710 23 5,461 24 5,225 25 5,000 26 4,786 27 4,583 28 4,389 29 4,204 30 4,028 31 3,861 32 3,701 33 3,549 34 3,404 35 3,266 36 3,134 37 3,008 38 2,888 39 2,773 40 2,663 41 2,559 42 2,459 43 2,363 44 2,272 45 2,184 46 2,101 47 2,021 48 1,944 49 1,871 50 1,801 51 1,734 52 1,670 53 1,609 54 1,550 55 1,493 56 1,439 57 1,387 58 1,337 59 1,290 60 1,244 61 1,200

TEMP

(C)

RESISTANCE

(Ohms)

62 1,158 63 1,118 64 1,079 65 1,041 66 1,006 67 971 68 938 69 906 70 876 71 836 72 805 73 775 74 747 75 719 76 693 77 669 78 645 79 623 80 602 81 583 82 564 83 547 84 531 85 516 86 502 87 489 88 477 89 466 90 456 91 446 92 436 93 427 94 419 95 410 96 402 97 393 98 385

99 376 100 367 101 357 102 346 103 335 104 324 105 312 106 299 107 285

Economizer Assembly —

30XA090-500 units has an economizer assembly. The 30XA080,082 units do not have an economizer and have one main electronic expansion valve. The 30XA080,082 units are controlled the same way as units with a separate economizer assembly. See Fig. 46.

Electronic Expansion Valve (EXV) — See Fig. 47

for a cutaway view of the EXV. High-pressure liquid refrigerant enters valve through the top. As refrigerant passes through the orifice, pressure drops and refrigerant changes to a 2-phase condition (liquid and vapor). The electronic expansion valve operates through an electronically controlled activation of a stepper motor. The stepper motor stays in position unless power pulses initiate the two discrete sets of motor stator windings for rotation in either direction. The direction depends on the phase relationship of the power pulses.

The motor directly operates the spindle, which has rotating movements that are transformed into linear motion by the transmission in the cage assembly. The valve cone is a V-port type which includes a positive shut-off when closed.

The large number of steps and long stroke results in very accurate control of the refrigerant flow. The stepper motor has either 3690 (main) or 2785 (economizer) steps.

FLOODED COOLER MAIN EXV CONTROL — Each circuit has a thermistor located in the discharge end of the compressor (DGT) and another one located in the compressor motor cavity (SGT). Each circuit also has discharge and suction

SERVICE

Each circuit on the

pressure transducer. Discharge and suction pressure as measured by the transducers are converted to saturated temperatures. The main control logic for the EXV uses discharge superheat to control the position of the EXV. The difference between the temperature of the discharge gas and the saturated discharge temperature is the superheat. The EXV module controls the position of the electronic expansion valve stepper motor to maintain the discharge superheat set point.

The EXV control logic has several overrides, which are also

used to control the position of the EXV.

• Approach between SST (Saturated Suction Temperature) and LWT

• Maximum Operating Pressure (MOP)

Approach

— If the approach (pinch), which is the difference between leaving fluid temperature and saturated suction temperature, is equal to or less than the pinch set point then the EXV will not open any further even though discharge superheat set point is not met. Pinch set point is calculated using suction superheat, discharge superheat and pinch offset. Pinch offset is used to adjust calculated pinch set point do to accuracy of transducers and thermistors.

MOP

— The EXV is also used to limit cooler saturated suction temperature to 62 F (16.6 C). This makes it possible for the chiller to start at higher cooler fluid temperatures without overloading the compressor. This is commonly referred to as MOP (maximum operating pressure). If the SST is equal to or greater than the MOP set point then the MBB will try to control the EXV position to maintain the MOP set point.

Page 75

The discharge superheat leaving the compressor is main-

Fig. 46 — Economizer Assembly

a30-4468

tained between approximately 18° and 25° F (10° and 14° C), or less. Because EXV status is communicated to the Main Base Board (MBB) and is controlled by the EXV modules, it is possible to track the valve position. The unit is then protected against loss of charge and a faulty valve. During initial start-up, the EXV is fully closed. After an initialization period, valve position is tracked by the EXV module by constantly monitoring the amount of valve movement.

DX (Direct Expansion) COOLER MAIN EXV CONTROL — Each circuit has a thermistor located in a well in the discharge of the compressor (DGT) and another one located in the compressor motor cavity (SGT). Thermistors are also located in a well in the water inlet and outlet nozzles. Apart from thermistors, each circuit also has a discharge and suction pressure transducer. Discharge and suction pressures as measured by the transducers are converted to saturated temperatures. The main control logic for the EXV uses approach temperature in the cooler (Water Inlet Temperature – Saturated Suction Temperature) and suction superheat (Suction Temperature – Saturated Suction Temperature) to control the position of the EXV. The EXV module controls the position of the electronic expansion valve stepper motor to maintain a minimum approach and a suction superheat set point.

The EXV control logic has several overrides, which are also

used to control the position of the EXV.

• Maximum Operating Pressure (MOP)

• High Discharge Gas Temperature

• Low Discharge Superheat MOP

— The EXV is also used to limit cooler saturated suction

temperature to 62 F (16.6 C). This makes it possible for the

chiller to start at higher cooler fluid temperatures without overloading the compressor. This is commonly referred to as MOP (maximum operating pressure). If the SST (Saturated Suction Temperature) is equal to or greater than the MOP set point then the MBB will try to control the EXV position to maintain the MOP set point.

High Discharge Gas Temperature

— The EXV is also used to limit the discharge gas temperature to 200 F (93.3 C). This makes it possible for the chiller to operate at low load and high ambient temperature without overloading the compressor. If the DGT is approaching the High DGT limit then the control will try to control the EXV position to bring the DGT down by opening the EXV.

Low Discharge Superheat

— The EXV is also used to limit the discharge superheat (DSH) to 18° F (10° C). This makes it possible for the chiller to operate at high load and low ambient temperature without overloading the compressor. If the DSH goes below 18° F (10° C) the MBB will try to control the EXV position to bring the discharge superheat up by closing the EXV valve.

The suction superheat entering the compressor is maintained between approximately 15° and 25° F (8.3° and 14° C) while maintaining a constant approach in the cooler. Because EXV status is communicated to the Main Base Board (MBB) and is controlled by the EXV modules, it is possible to track the valve position. During initial start-up, the EXV is fully closed. After an initialization period, valve position is tracked by the EXV module by constantly monitoring the amount of valve movement.

BRAZE PLATE HEAT EXCHANGER

MAIN EXV

*SIGHT GLASS

*Economizer EXV has sight glass

on opposite side of valve shown.

MAIN FLOW TO COOLER

ECONOMIZER RELIEF

ECONOMIZER FLOW TO COMPRESSOR

ECONOMIZER EXV

ECONOMIZER RELIEF

LIQUID LINE SHUT OFF VALV E

FILTER DRIER

Page 76

ECONOMIZER EXV CONTROL — The economizer EXV

Fig. 47 — Cutaway Views of the Electronic Expansion Valve

1. Cable

2. Glass Seal

3. Motor Housing

4. Stepper Motor

5. Bearing

6. Lead Screw

7. Insert

8. Valve Piston

9. Valve Seat

10. Valve Port

a30-4241

is controlled by the circuit EXV board. There is an economizer gas temperature thermistor and economizer pressure transducer located in the line, which runs from the economizer assembly to the compressor. The economizer pressure is converted to saturated temperature and is used to calculate economizer superheat. Economizer superheat equals economizer temperature minus saturated economizer temperature. The economizer EXV only operates during normal conditions when the capacity of the circuit is greater than 75%. Once the capacity of the circuit is greater than 75% the MBB will start controlling the economizer EXV to maintain economizer superheat set point, which is approximately 8° to 12° F (4.4° to 6.7° C). If the circuit capacity is less than 75%, the economizer EXV will be closed.

The economizer EXV has one override. If the discharge gas temperature exceeds 195 F (90.6 C) the economizer EXV will start to open. The EXV will be controlled to maintain discharge gas temperature at approximately 195 F (90.6 C).

If it appears that main EXV or economizer EXV is not properly controlling circuit operation to maintain correct superheat, there are a number of checks that can be made using test functions and initialization features built into the microprocessor control. See the Service Test section to test EXVs.

EXV TROUBLESHOOTING PROCEDURE — There are two different economizer EXVs. Both of the economizer EXVs have a total of 2785 steps. There are three different main EXVs, which all have a total of 3690 steps. The EXV motor moves at 150 steps per second. Commanding the valve to either 0% or 100% will add an additional 160 steps to the move, to ensure the valve is open or closed completely.

Follow the steps below to diagnose and correct EXV problems. Check EXV motor operation first. Switch the Enable/Off/Remote (EOR) Contact switch to the Off position. Check the appropriate circuit EXV, Circuit A EXV % Open (Circuit A EXV Position, EXV.A), Circuit B EXV % Open

(Circuit B EXV Position, EXV.B), or Circuit C EXV % Open (Circuit C EXV Position, EXV.C). The current value of 0 will be displayed. Increase the EXV position to select 100% valve position. The actuator should be felt moving through the EXV. To close the valve, select 0%. The actuator should knock when it reaches the bottom of its stroke. See Table 48 for a list of EXV modes and submodes.

If the valve is not working properly, continue with the fol-

lowing test procedure:

Check the 8-position DIP switch on the board for the proper address (see page 11). Check the EXV output signals at appropriate terminals on the EXV module. For 30XA080 units, connect the positive test lead to EXV-J2A terminal 5 for Circuit A and to EXV-J2B terminal 5 for Circuit B.

For 30XA090-500 units connect positive test lead to EXV(X)-J2A terminal 5 for EXV(X) and EXV(X)-J2B terminal 5 for Economizer EXV(X). Using the Service Test procedure on page 105, move the valve output under test to 100%. DO NOT short meter leads together or pin 5 to any other pin, as board damage will occur. During the next several seconds, carefully connect the negative test lead to pins 1,2,3 and 4 in succession. Digital voltmeters will average this signal and display approximately 6 vdc. If the output remains at a constant voltage other than 6 vdc or shows 0 volts, remove the connector to the valve and recheck.

Select 0% to close the valve. NOTE: Twelve vdc is the output from the EXV board when

the valve is stationary.

See Tables 6 and 7. If a problem still exists, replace the EXV board. If the reading is correct, the expansion valve and EXV wiring should be checked. Check the EXV connector and interconnecting wiring.

1. Check color-coding and wire connections. Make sure they are connected to the correct terminals at the EXV board and EXV plug and that the cables are not crossed.

2. Check for continuity and tight connection at all pin terminals.

Check the resistance of the EXV motor windings. For 30XA080,082 units remove the EXV module plug EXV-J2A for Circuit A EXV and EXV-J2B for Circuit B EXV. For 30XA090-500 units remove the EXV module plug EXV(X)J2A for main EXV and EXV(X)-J2B for economizer EXV. Check the resistance of the two windings between pins 1 and 3 for one winding and pins 2 and 4 for the other winding. The resi

stance should be 52 ohms (± 5.2 ohms). Also check pins 1-4

for any shorts to ground.

Page 77

Table 48 — EXV Modes and Submodes

EXV TYPE AND CIRCUIT TOUCH PILOT™ PATH NAVIGATOR™ PATH



EXV, Circuit A Main Menu EXV, Circuit B Main Menu EXV, Circuit C Main Menu Economizer EXV, Circuit A Main Menu Economizer EXV, Circuit B Main Menu Economizer EXV, Circuit C Main Menu

StatusCIRCA_AN Service Test ModeQUICEXV.A



StatusCIRCB_AN Service Test ModeQUICEXV.B



StatusCIRCC_AN Service Test ModeQUICEXV.C



StatusQCK_TST1 Service Test ModeQUICECO.A



StatusQCK_TST1 Service Test ModeQUICECO.B



StatusQCK_TST1 Service Test ModeQUICECO.C

Inspecting/Opening Electronic Expansion Valves

IMPORTANT: Obtain replacement gaskets before opening EXV. Do not re-use gaskets.

To check the physical operation of an EXV, the following steps must be performed if the unit does not have service valve option or activated ball valves (ABV) (flooded coolers only) the complete charge needs to be recovered using proper recovery techniques Steps 1-3 shown below. If the unit has ABV or discharge service valves, only perform Steps 1 and 2.

1. Close the liquid line service valve of the circuit to be checked. Put the Enable/Off/Remote Contact switch in the Off position. Enter the Service Test mode and change Service Test Enable, T.REQ from OFF to ON. A pass- word may be required. Switch the EOR switch to the Enable position. Under the COMP sub-mode, enable one of the compressors (CP.xn) for the circuit. Let compres- sor run until gage on suction pressure port reads 10 psig (68.9 kPa). Turn the compressor off. The compressor will turn off. Immediately after the compressor shuts off, manually close the actuated ball valve (ABV) (see the Actuated Ball Valve section for instructions). If the unit is equipped with suction service valves, discharge service valve, and economizer service valves, close all valves. Closing the valves will minimize the amount of charge that will have to be removed from the system after pump down.

2. Remove any remaining refrigerant from the system low side using proper recovering techniques. The economizer assembly has a

/4-in. access connection which can be used to remove charge from the inlet of the EXVs. Turn off the line voltage power supply to the compressors.

CAUTION

Ensure refrigerant is removed from both the inlet and outlet of EXV assemblies. Equipment damage could result.

3. The expansion valve motor is hermetically sealed inside the top portion of the valve. See Fig. 47. Disconnect the EXV plug. Carefully unscrew the motor portion from the body of the valve. The EXV operator will come out with the motor portion of the device. Reconnect the EXV plug.

4. Enter the appropriate EXV test step under the (QUIC) Service Test mode Locate the desired item Circuit A

EXV Position, EXV.A, Circuit B EXV Position, EXV.B, or Circuit C EXV Position, EXV.C. Change the

position to 100%. Observe the operation of the lead screw. See Fig. 47. The motor should be turning, raising the operator closer to the motor. Motor actuator movement should be smooth and uniform from fully closed to fully open position. Select 0% and check open to closed operation. If the valve is properly connected to the processor and receiving correct signals, yet does not operate as described above, the sealed motor portion of the valve should be replaced.

Installing EXV Motor

IMPORTANT: Obtain replacement gasket before opening EXV. Do not re-use gaskets.

If re-installing the motor, be sure to use a new gasket in the assembly. See Fig. 48. It is easier to install the motor assembly with the piston in the fully closed position. Insert the motor into the body of the EXV. Tighten the motor to the body to 36 ft-lb (50 N-m) and then tighten the valve another 30 degrees.

Moisture Liquid Indicator — Clear flow of liquid refrigerant indicates sufficient charge in system. Bubbles in the sight glass indicate undercharged system or presence of noncondensables. Moisture in system, measured in parts per million (ppm), changes color of indicator. See Table 49. Change filter drier at first sign of moisture in system.

Table 49 — Color Indicators when Moisture is Present in Refrigerant

COLOR

INDICATOR

Green — Dry <30 <45 Yellow-green — Caution 30-100 45-170 Yellow — Wet >100 >170

R-134A,

75 F (24 C)

(ppm)

R-134A,

125 F (52 C)

(ppm)

IMPORTANT: Unit must be in operation at least

12 hours before moisture indicator can give an accu-

rate reading.

With unit running, indicating element must be in con-

tact with liquid refrigerant to give true reading.

Filter Drier — Whenever moisture-liquid indicator shows presence of moisture, replace filter drier(s). There is one filter drier assembly on each circuit with either one or two cores. The 30XA080-122 units have one core per circuit. The 30XA140-162 units have two cores, in circuit A and one for circuit B. The 30XA180-500 units have two cores per circuit. Refer to the Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, for details on servicing filter driers.

Liquid Line Service Valve — This valve is located immediately ahead of filter drier, and has a

/4-in. access connection for field charging. In combination with compressor discharge service valve, each circuit can be pumped down into the high side for servicing.

Compressor Assembly — The 30XA units utilize

screw compressors with a modulating slide valve which varies capacity from 30% to 100% of compressor capacity for each circuit. See Fig. 49 for a view of a typical 06T compressor. The slide valve position is varied by opening and closing the 2 solenoid valves located on the compressor. To unload the compressor, both solenoids are deenergized. To increase in capacity both solenoid valves are energized together which will cause the slide valve to slide towards the fully loaded position. To stop the loading process solenoid 2 is energized and solenoid 1 is deenergized. This will cause the slide valve to maintain its current position. There is no feedback for the position of the slide valve. The control utilizes compressor current

Page 78

as an indicator of the slide valve position. Once the calculated

Closed

Open

Closed

Open

EF05BD271 EF05BD331

GASKET

OPEN VALVE IN QUICK TEST SUB-MODE BEFORE DISASSEMBLING

DISASSEMBLY

ASSEMBLY

NOTES:

1. Push down on valve piston to close valve before assembling.

2. After valve is assembled close valve in Quick Test sub-mode or cycle power before opening service valve.

Fig. 48 — Disassembly and Assembly of EXV Motor

NOTE: Open valve in Quick Test sub-mode before disassembling.

a30-4072

position of the slide valve reaches 100% circuit capacity, the control will try to increase capacity again if the compressor current continues to increase. The control will continue to load the compressor until the compressor current no longer increases. At that time the control will energize both solenoids and the circuit will be considered fully loaded.

COMPRESSOR OIL SYSTEM — Each compressor/circuit has its own oil system which includes an oil filter, oil solenoid, check valve, oil level switch, oil separator heater, oil pressure transducer, and an oil shut-off valve. A typical oil system is shown in Fig. 50. See Table 50.

Table 50 — Unit Oil Quantities

30XA UNIT SIZE

080-122 5.5 [20.8] 5.5 [20.8] — 140-162 6.25 [23.7] 5.5 [20.8] — 180-202 6.25 [23.7] 6.25 [23.7] — 220,222 6.75 [25.6] 6.25 [23.7] — 240,242 6.75 [25.6] 6.75 [25.6] — 260,262 7.50 [28.4] 6.75 [25.6] — 280-302 7.50 [28.4] 6.75 [25.6] — 325-352 7.50 [28.4] 7.50 [28.4] —

400 6.75 [25.6] 6.75 [25.6] 7.50 [28.4] 450 7.50 [28.4] 6.25 [23.7] 7.50 [28.4] 500 7.50 [28.4] 6.75 [25.6] 7.50 [28.4]

Oil Charge

— When additional oil or a complete charge is

OIL CHANGE (gal, [liters])

Circuit A Circuit B Circuit C

required it must meet the following specifications:

• Manufacturer . . . . . . . . . . . . . . . . . . . . . Emkarate RL220XL

• Oil Type. . . . . . . . . . . . . . . . . . . Inhibited polyolester-based

synthetic compressor lubricant for use with screw compressors.

• ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Do not reuse drained oil or any oil that has been exposed to the atmosphere.

Oil is available in the following quantities from your local Carrier representative:

QUANTITY TOTALINE PART NO. 1 Quart P903-2325 1 Gallon P903-2301 5 Gallon P903-2305

If unsure if there is low oil charge in the system, follow the steps below:

1. If the unit shuts off repeatedly from a low oil level alert it may be an indication of inadequate oil charge; however, it could also indicate that the oil is not being reclaimed from the low-side of the system.

2. Begin running the unit at full load for 1

/2 hours. Use the manual Test Mode feature of Service Test if the unit does not normally run at full load.

NOTE: An adequate load must be available.

3. After running the unit for 1

/2 hours at full load, allow the unit to restart and run normally. If low oil alarms persist, continue with the following steps.

4. Close the liquid line service valve and place a pressure gage on top of the cooler or suction line service port. Enable the Service Test feature and turn the Enable/Off/Remote switch to the enable position. Start the desired circuit by turning it on under the TEST function: CP.A for compressor A, CP.B for compressor B, or CP.C for com- pressor C.

Page 79

5. When the compressor starts successfully, observe the

SOLENOID 1

SOLENOID 2

HIGH PRESSURE SWITCH

MOTOR TEMPERATURE SENSOR 2

COMMON

MOTOR TEMPERATURE SENSOR 1

text

Compre ssion

Process

High Pressure Oil

De-energized

FLOW

Valve #2 (NO)

De-energized

NO FLOW

Valve #1 (NC)

Bleed Line to Low Pres sure Suction

Discharge

Port

Unloader Piston

Chamber

text

Compression

Process

Loaded Position

High Pressure Oil

Energized

NO FLOW

Valve #2 (NO)

Energized

FLOW

Valve #1 (NC)

Bleed Line to Low Pressure Suction

Slide Valve

Discharge

Port

Unlo ader Piston

Chamber

Loaded Position

High with

High

Pressure

Oil

Drain to

Low Pressure

Unloaded Position

Slide Valve

text

High Pressur e Oil

Trapped

Oil at

High

Pressure

Compression

Process

Part Load Position

Energized

NO FLOW

Valve #2 (NO)

De-energized

NO FLOW

Valve #1 (NC)

Bleed Line to Low Pressure Suction

Slide Valve

Discharge

Port

Unloader Piston

Chamber

Slide Valve

FULLY LOADED OPERATION FULLY UNLOADED OPERATION

MAINTAIN POSITION

OIL PRESSURE TRANSDUCER LOCATION

DISCHARGE GAS THERMISTOR

ACCESS FITTING

SUCTION TEMPERATURE

Fig. 49 — Typical 06T Compressor (All Units)

a30-4469

cooler pressure. When the pressure reads 10 psig (68.9 kPa), turn the Emergency Switch (SW2) to the OFF position. The compressor should stop.

6. Open the liquid line service valve and allow the unit to restart normally. If low oil level alarms persist, continue with the following steps.

7. If none of the previous steps were successful, the unit is low on oil charge. Add oil to the oil separator using the

/4 in. access fitting that the discharge pressure transducer

is mounted to. NOTE: To facilitate the oil charging process, ensure that

the unit is not running when adding oil. The system is under pressure even when the unit is not running, so it is necessary to use a suitable pump to add oil to the system. Using a suitable pump, add tem. Continue adding oil in

/2 gal (1.9 l) of oil to the sys-

/2 gal (1.9 l) increments until the problem is resolved, up to a maximum of 1.5 gal (5.7 l). If it is necessary to add factory oil charge levels to the system contact your local Carrier representative.

Oil Filter Maintenance

— Each circuit has one oil filter located externally to the compressor. Oil line pressure drop is monitored by the control. Oil line pressure drop is calculated by subtracting oil pressure (OP) from discharge pressure (DP). If the oil line pressure drop exceeds 30 psi (206.8 kPa) for 5 minutes the control will generate a High Oil Filter Pressure Drop alert. The High Oil Filter Pressure Drop alert will not shut down the compressor, but instead indicates that the oil filter is dirty. If oil pressure line losses exceed 50 psi (344.7 kPa) then the control will shut down the circuit on Maximum Oil Filter Differential Pressure Failure.

CAUTION

Compressor oil is pressurized. Use proper safety precautions when relieving pressure.

Replacing the Oil Filter ed in front of the oil filter. Connect a charging hose to the

— Close the oil line ball valve locat-

/4-in. access fitting port located downstream of the valve and bleed off oil trapped between the service valve and the oil solenoid valve. A quart of oil is typically what is removed during this process. Remove the charging hose. Unscrew the nuts from both ends of the oil filter and remove the oil filter. Remove the protective caps from the new oil filter and install, being careful not to lose or damage the new O-ring located on the new oil filter. Draw a vacuum at the Schrader port. Remove the charging hose and open the oil line ball valve. Check both fittings for leaks.

Flooded Cooler Units

FLOODED COOLER UNIT SUCTION SERVICE VALVE — The suction service valve is a factory-installed option for 30XA units. It is located in the suction outlet of the cooler. The suction service valve is bolted between the cooler outlet and the suction flange piping. The suction service valve shaft has a locking device located on the shaft to lock the valve in either a fully open position or a fully closed position. The locking device must be pulled out prior to moving the valve handle to a fully open or a fully closed position. See Fig. 51A and 51B.

Page 80

OIL SHUT OFF VALV E

OIL LEVEL SWITCH (BOTTOM)

CHECK VALV E

OIL

SOLENOID

VALV E

OIL

PRESSURE

TRANSDUCER

OIL

FILTER

OIL SEPARATOR HEATER (BOTTOM)

HIGH

PRESSURE

TRANSDUCER

Fig. 50 — Typical Oil System (All Units)

a30-4243

Fig. 51B — Suction Service Valve Locking Device,

Open and Locked (Flooded Cooler Units)

a30-5246

a30-5247

Fig. 51A — Suction Service Valve Locking Device,

Closed and Unlocked (Flooded Cooler Units)

VALV E LOCKED

OPEN

FLOODED COOLER FREEZE PROTECTION — All coolers are equipped with cooler heaters and are controlled by the Main Base Board. The control logic uses the unit status, outdoor air temperature, and the saturated suction temperatures for all circuits to decide if the cooler heater should be energized. The cooler heaters can only be energized when the state of the unit is OFF. The cooler heaters will be energized if the outdoor-air temperature is less than the Cooler Heater Set Point and the lowest circuit Saturated Suction Temperature is less than the heater set point plus 6° F (3.3° C). See Table 51. The cooler heater set point = freeze point + Cooler Heater DT Setp (Cooler Heater Delta Spt, HTR). If the entering or leaving water temperature is less than the Heater Set Point and the outdoor air temperature is less than the Heater Set Point –2° F (1.1° C), then the heater will be turned on.

If the Entering or Leaving Water Temperature is less than the Brine Freeze Setpoint (Brine Freeze Setpoint, LOSP) +1.0° F (0.5° C), then the heater will be turned on along with the pump.

The entire cooler is covered with closed-cell insulation applied over the heater. The heater plus insulation protects cooler against low ambient temperature freeze-up to 0° F (–17.8 C).

IMPORTANT: If unit is installed in an area where ambient temperatures fall below 32 F (0° C), a suitable corrosion-inhibited antifreeze solution or cooler heater must be used in the chilled water circuit.

FLOODED COOLER LOW FLUID TEMPERATURE — Main Base Board is programmed to shut chiller down if leaving fluid temperature drops below 34 F (1.1 C) for cooler fluid type water or below Brine Freeze Setpoint (Brine Freeze Set- point, LOSP) for cooler fluid type brine. The unit will shut down without a pumpout. When fluid temperature rises to 6° F (3.3° C) above the leaving fluid set point, safety resets and chiller restarts. Reset is automatic as long as this is the first occurrence.

Page 81

Table 51 — Cooler Heater Operation Examples for Flooded Coolers

Fig. 52 — Elliott Tube Plug

a30-4083

OAT

F (C)

(10)

(4.4)

LEGEND

N/A — Not Applicable OAT — Outdoor-Air Temperature SSTA — Saturated Suction Temperature, Circuit A SSTB — Saturated Suction Temperature, Circuit B SSTC — Saturated Suction Temperature, Circuit C

UNIT

STATUS

OFF

BRINE

FREEZE

POINT

F (C)

(2.2)

(–9.4)

(2.2)

COOLER

DELTA T

F (C)

(3.3)

COOLER

HEATER

SETPOINT

F (C)

(5.6)

(–6.1)

(5.6)

FLOODED COOLER LOSS OF FLUID FLOW PROTECTION — All 30XA ma-chines include an integral flow switch that protects the cooler against loss of cooler flow.

FLOODED COOLER TUBE PLUGGING — A leaky tube can be plugged until retubing can be done. The number of tubes plugged determines how soon the cooler must be retubed. All tubes in the cooler may be removed. Loss of unit capacity and efficiency as well as increased pump power will result from plugging tubes. Failed tubes should be replaced as soon as possible. Up to 10% of the total number of tubes can be plugged before retubing is necessary. Figure 52 shows an Elliott tube plug and a cross-sectional view of a plug in place. See Tables 52 and 53 for plug components. If the tube failure occurs in both circuits using tube plugs will not correct the problem. Contact your local Carrier representative for assistance.

CAUTION

Use extreme care when installing plugs to prevent damage to the tube sheet section between the holes.

FLOODED COOLER RETUBING — When retubing is required, obtain service of qualified personnel experienced in boiler maintenance and repair. Most standard procedures can be followed when retubing the coolers. An 8% crush is recommended when rolling replacement tubes into the tubesheet.

Place one drop of Loctite No. 675 or equivalent on top of tube prior to rolling. This material is intended to “wick” into the area of the tube that is not rolled into the tube sheet, and prevent fluid from accumulating between the tube and the tube sheet. New tubes must also be rolled into the center tubesheet to prevent circuit to circuit leaks.

SSTA

F (C)

N/A N/A N/A OFF

(5)

52.1

(11.2)

N/A N/A N/A OFF

SSTB

F (C)

N/A N/A ON

N/A N/A OFF

52.1

(11.2)

SSTC

F (C)

52.1

(11.2)

COOLER

HEATER STATUS

OFF

COMMENTS

OAT

>42 F

(5.6 C)

SSTA <42 F

(5.6 C)

SSTA >21 F

(–6.1 C)

All SST

Temperatures

>52 F

(11.2 C)

Unit Status

Table 52 — Plug Component Parts

(Flooded Cooler Units Only)

COMPONENT PART NUMBER

For Tubes

Brass Pin 853103-1*

Brass Ring

For Holes without tubes

Brass Pin 853103-1A

Brass Ring 85102-738 Loctite No. 675 † Locquic “N”† Roller Extension S82-112/11

*Order directly from Elliot Tube Company, Dayton, OH or RCD.

†Can be obtained locally.

853002-640 or 657*

(measure tube

before ordering)

Table 53 — Flooded Cooler Tube Components

COMPONENT

Tube sheet hole diameter 0.756 19.20 Tube O D 0.750 19.05 Tube ID after rolling (includes

expansion due to clearance.)

NOTE: Tubes replaced along heat exchanger head partitions must be flush with tube sheet (both ends).

0.650 to

0.667

SIZE

in. mm

16.51 to 16.94

FLOODED COOLER TIGHTENING COOLER HEAD BOLTS

Preparation

— When reassembling cooler heads, always check the condition of the O-rings first. The O-ring should be replaced if there is visible signs of deterioration, cuts or damage. Apply a thin film of grease to the O-ring before installation. This will aid in holding the O-ring in the groove while the head is installed. Torque all bolts to the following specification and in sequence:

/4-in. Diameter Perimeter Bolts (Grade 5) . . . 200 to 225 ft-lb

(271 to 305 N-m)

Page 82

1. Install all bolts finger tight.

SINGLE PAS S ONLY

Fig. 53 — Flooded Cooler Unit Head

Recommended Bolt Torque Sequence

a30-4246

2. Bolt tightening sequence is outlined in Fig. 53. Follow the numbering or lettering sequence so that pressure is evenly applied to O-ring.

3. Apply torque in one-third steps until required torque is reached. Load all bolts to each one-third step before proceeding to next one-third step.

4. No less than one hour later, retighten all bolts to required torque values.

5. After refrigerant is restored to system, check for refrigerant leaks using recommended industry practices.

6. Replace cooler insulation.

FLOODED COOLER INSPECTING/CLEANING HEAT EXCHANGERS — Inspect and clean cooler tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes. Tube condition in the cooler will determine the scheduled frequency for cleaning, and will indicate whether water treatment is adequate in the chilled water/brine circuit. Inspect the entering and leaving water thermistor wells for signs of corrosion or scale. Replace the well if corroded or remove any scale if found.

located in the suction line for each circuit. The suction service valve is either a ball valve type valve or a butterfly type valve.

DX COOLER FREEZE PROTECTION — Coolers can be ordered with heaters installed in the factory. If equipped, the main base board based on the outdoor-air temperature and the entering and leaving water thermistors controls the cooler heaters. The Heater Set Point is the sum of the freeze point and Cooler Heater DT Setp (Configuration



SERVHTR).

If the entering or leaving water temperature is less than the Heater Set Point and the outdoor air temperature is less than the Heater Set Point – 2° F (1.1° C), then the heater will be turned on.

If the Entering or Leaving Water Temperature is less than the Brine Freeze Setpoint (Configuration



SERVLOSP) +

1.0° F (0.5° C), then the heater will be turned on along with the pump.

Entire cooler is covered with closed-cell insulation applied over the heater. Heater plus insulation protect cooler against low ambient temperature freeze-up to –20 F (–28 C).

IMPORTANT: If unit is installed in an area where ambient temperatures fall below 32 F (0° C), it is recommended that a suitable corrosion-inhibited antifreeze solution be used in chilled water circuit.

DX COOLER LIQUID FLUID TEMPERATURE — Main Base Board is programmed to shut chiller down if leaving fluid temperature drops below 34 F (1.1 C) for cooler fluid type water or below Brine Freeze Setpoint (Brine Freeze Setpoint, LOSP) for cooler fluid type brine. The unit will shut down without a pumpout. When fluid temperature rises to 6 F (3.3 C) above the leaving fluid set point, safety resets and chiller restarts. Reset to automatic as long as this is the first occurance.

DX COOLER LOSS OF FLUID FLOW PROTECTION — All 30XA machines include an integral flow switch that protects the cooler against loss of cooler flow.

DX COOLER TUBE PLUGGING — A leaky tube can be plugged until retubing can be done. The number of tubes plugged determines how soon the cooler must be retubed. If several tubes require plugging, check with a local Carrier representative to find out how the number and location of tubes can affect unit capacity. Fig. 54 shows an Elliott tube plug and a cross-sectional view of a plug in place. See Tables 54 and 55 for plug components.

CAUTION

Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper treatment procedures.

FLOODED COOLER WATER TREATMENT — Untreated or improperly treated water may result in corrosion, scaling, erosion or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program.

CAUTION

Water must be within design flow limits, clean and treated to ensure proper machine performance and reduce the potential of tubing damage due to corrosion, scaling, and algae. Carrier assumes no responsibility for cooler damage resulting from untreated or improperly treated water.

DX Cooler Units

DX COOLER SUCTION SERVICE VALVE — The suction service valve is a factory-installed option for 30XA units. It is

CAUTION

Use extreme care when installing plugs to prevent damage to the tube sheet section between the holes.

Table 54 — DX Cooler Unit Plug Component Part

Numbers

COMPONENTS FOR PLUGGING PART NUMBER

For Tubes

Brass Pin 853103-312* Brass Ring 853002-322*

For Holes without tubes

Brass Pin 853103-375

Brass Ring 853002-377 Loctite No. 675 † Locquic “N” †

*Order directly from Elliot Tube Company, Dayton, OH or RCD.

†Can be obtained locally.

Page 83

Table 55 — DX Cooler Unit Plug Component

Fig. 54 — Elliott Tube Plug

Fig. 55 — Bolt Tightening Sequence, 30XA082,092,102,122

a30-5330

Dimensions

PLUG COMPONENT

Tube sheet hole diameter 0.377-0.382 9.58-9.70 Tube O D 0.373-0.377 9.47-9.58 Tube ID after rolling (includes

expansion due to clearance.)

NOTE: Tubes next to gasket webs must be flush with tube sheet (both ends).

SIZE

in. mm

0.328 8.33

For the 30XA142,162,182,202,222,242,262,282,302,327, 352 DX coolers, the pass partition has a perforated distribution plate in the inlet pass to more uniformly distribute the refrigerant as it enters the tubes of the cooler. The perforated distribution plate is on the tubesheet side of the pass partition. A tube plug will interfere with the installation of pass partition. The tube plug must be flush with the tube sheet to prevent this interference. The pass partition is symmetrical, meaning the partition plate can be rotated 180 degrees, however, the performance of the machine will be affected if the pass partition is installed incorrectly.

DX COOLER RETUBING — When retubing is required, obtain service of qualified personnel experienced in boiler maintenance and repair. Most standard procedures can be followed when retubing the coolers. An 8% crush is recommended when rolling replacement tubes into the tubesheet.

The following Elliott Co. tube rolling tools are required:

• Expander Assembly

• Cage

• Mandrel

•Rolls

DX COOLER TIGHTENING COOLER HEAD BOLTS (Fig. 55-58)

Gasket Preparation

— When reassembling cooler heads, always use new gaskets. Gaskets are neoprene-based and are brushed with a light film of compressor oil. Do not soak gasket or gasket deterioration will result. Use new gaskets within 30 minutes to prevent deterioration. Reassemble cooler nozzle end or plain end cover of the cooler with the gaskets. Torque all cooler bolts to the following specification and sequence:

/8-in. Diameter Perimeter Bolts (Grade 5) . . . 150 to 170 ft-lb

(201 to 228 N-m)

/2-in. Diameter Flange Bolts (Grade 5) . . . . . . . . 70 to 90 ft-lb

(94 to 121 N-m)

/2-in. Diameter Center Stud (Grade 5). . . . . . . . . 70 to 90 ft-lb

(94 to 121 N-m)

1. Install all bolts finger tight, except for the suction flange bolts. Installing these flanges will interfere with tightening the center stud nuts.

2. Bolt tightening sequence is outlined in Fig. 55-58. Follow the numbering or lettering sequence so that pressure is evenly applied to gasket.

3. Apply torque in one-third steps until required torque is reached. Load all bolts to each one-third step before proceeding to next one-third step.

4. No less than one hour later, retighten all bolts to required torque values.

5. After refrigerant is restored to system, check for refrigerant leaks using recommended industry practices.

6. Replace cooler insulation.

Page 84

Fig. 56 — Bolt Tightening Sequence, 30XA142,162,182,202

a30-5331

Fig. 57 — Bolt Tightening Sequence, 30XA222, 242, 262, 282

a30-5407

Fig. 58 — Bolt Tightening Sequence, 30XA302, 327, 352

a30-5408

2 1

27 30

29 31

DX COOLER CHILLED WATER FLOW SWITCH — A factory-installed flow switch is installed in the entering water nozzle for all machines. See Fig. 59 and 60. This is a thermaldispersion flow switch. Figure 59 shows typical installation. If nuisance trips of the sensor are occurring, follow the steps below to correct:

1. Check to confirm that all strainers are clean, valves are open and pumps are running. For the case of variable frequency drive (VFD) controlled pumps, ensure the minimum speed setting has not been changed.

2. Measure the pressure drop across the cooler. Use the cooler pressure drop curves on pages 62-67 to calculate the flow and compare this to system requirements.

DX Cooler and Flooded Cooler Units

PREPARATION FOR WINTER SHUTDOWN — If the unit is not operational during the winter months, at the end of cooling season complete the following steps.

CAUTION

Failure to remove power before draining heater equipped coolers and hydronic packages can result in heater tape and insulation damage.

1. If the unit has optional heater tapes on the cooler and the cooler will not be drained, do not shut off power disconnect during off-season shutdown. If the unit has optional

Page 85

heater tapes on the cooler and the cooler is drained, open

STANDARD FLOODED COOLER

OUT

FLOW SWITCH

Fig. 59 — Chilled Water Flow Switch

Fig. 60 — Flow Switch

a30-5335

a30-5334

the circuit breaker for the heater, CB-13 or shut off power during off-season shutdown.

2. Draining the fluid from the system is highly recommended. If the unit is equipped with a hydronic package, there are additional drains in the pump housing and strainer that must be opened to allow for all for all of the water to drain.

3. Isolate the cooler from the rest of the system with water shutoff valves.

4. Replace the drain plug and completely fill the cooler with a mixture of water and a suitable corrosion-inhibited antifreeze solution such as propylene glycol. The concentration should be adequate to provide freeze protection to 15° F (8.3° C) below the expected low ambient temperature conditions. Antifreeze can be added through the vent on top of the cooler. If the unit has a hydronic pump package, the pump must be treated in the same manner.

5. Leave the cooler filled with the antifreeze solution for the winter, or drain if desired. Be sure to deenergize heaters (if installed) as explained in Step 1 to prevent damage. Use an approved method of disposal when removing antifreeze solution.

24 VAC

BRN

WHT

BLK

BLU

At the beginning of the next cooling season, be sure that there is refrigerant pressure on each circuit before refilling cooler, add recommended inhibitor, and reset the CB-HT (circuit breaker heater) (if opened) or restore power.

Microchannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning Recommendations — Routine cleaning of coil surfaces is

essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit. The following steps should be taken to clean MCHX condenser coils:

CAUTION

Do not apply any chemical cleaners to MCHX condenser coils. These cleaners can accelerate corrosion and damage the coil.

1. Remove any foreign objects or debris attached to the coil face or trapped within the mounting frame and brackets.

2. Put on personal protective equipment including safety glasses and/or face shield, waterproof clothing and gloves. It is recommended to use full coverage clothing.

3. Start high pressure water sprayer and purge any soap or industrial cleaners from sprayer before cleaning condenser coils. Only clean potable water is authorized for cleaning condenser coils.

4. Clean condenser face by spraying the coil steady and uniformly from top to bottom while directing the spray straight toward the coil. Do not exceed 900 psig (6205 kPa) or 30 degree angle. The nozzle must be at least 12 in. (304.8 mm) from the coil face. Reduce pressure and use caution to prevent damage to air centers.

CAUTION

Excessive water pressure will fracture the braze between air centers and refrigerant tubes.

RTPF (Round Tube Plate Fin) Condenser Coil Maintenance and Cleaning Recommendations —

maintain proper operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil.

REMOVE SURFACE LOADED FIBERS — Surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

PERIODIC CLEAN WATER RINSE — A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments. However, it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning as described below is recommended.

Routine cleaning of coil surfaces is essential to

Page 86

ROUTINE CLEANING FOR RTPF COIL SURFACE — Monthly cleaning with Totaline

environmentally sound coil cleaner is essential to extend the life of coils. This cleaner is available from Carrier Replacement Parts division as part number P902-0301 for a one gallon container, and part number P902-0305 for a five gallon container. It is recommended that all coils, including the standard copper tube aluminum fin, precoated fin, copper fin, or e-coated coils be cleaned with the Totaline environmentally sound coil cleaner as described below. Coil cleaning should be part of the unit’s regularly scheduled maintenance procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment. Avoid the use of:

• coil brighteners

• acid cleaning prior to painting

• high pressure washers

• poor quality water for cleaning

Totaline environmentally sound coil cleaner is non-flammable, hypoallergenic, nonbacterial, and a USDA accepted biodegradable agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended coil cleaners is stongly discouraged since coil and unit durability could be affected.

Totaline Environmentally Sound Coil Cleaner Application Equipment

•21/2 gallon garden sprayer

• Water rinse with low velocity spray nozzle

CAUTION

Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of any kind. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil, use the Totaline environmentally sound coil cleaner as described above.

CAUTION

High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdown may occur.

Totaline Environmentally Sound Coil Cleaner Application Instructions

1. Proper eye protection such as safety glasses is recommended during mixing and application.

2. Remove all surface loaded fibers and dirt with a vacuum cleaner as described above.

3. Thoroughly wet finned surfaces with clean water and a low velocity garden hose, being careful not to bend fins.

4. Mix Totaline environmentally sound coil cleaner in a

/2 gallon garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 100 F.

NOTE: Do NOT enzymatic activity will be destroyed.

5. Thoroughly apply Totaline environmentally sound coil cleaner solution to all coil surfaces including finned area, tube sheets and coil headers.

6. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage.

USE water in excess of 130 F (54.4 C), as the

7. Ensure cleaner thoroughly penetrates deep into finned areas.

8. Interior and exterior finned areas must be thoroughly cleaned.

9. Finned surfaces should remain wet with cleaning solution for 10 minutes.

10. Ensure surfaces are not allowed to dry before rinsing. Reapplying cleaner as needed to ensure 10-minute saturation is achieved.

11. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle.

Condenser Fans — A formed metal mount bolted to fan

deck supports each fan and motor assembly. A shroud and a wire guard provide protection from the rotating fan. See Fig. 61. The exposed end of the fan motor shaft is protected from weather by grease. If fan motor must be removed for service or replacement, be sure to regrease fan shaft and reinstall fan guard. The fan motor has a step in the motor shaft. For proper performance, fan should be positioned such that it is securely seated on this step. Tighten the bolt to 15 ft lb ± 2.0 (20.34 Nm ± 2.7 Nm) .

Refrigerant Circuit

LEAK TESTING — Units are shipped with complete operating charge of refrigerant R-134a (see Physical Data tables supplied in the 30XA installation instructions) and should be under sufficient pressure to conduct a leak test. If there is no pressure in the system, introduce enough nitrogen to search for the leak. Repair the leak using good refrigeration practices. After leaks are repaired, system must be evacuated and dehydrated.

REFRIGERANT CHARGE — Refer to Physical Data tables supplied in the 30XA installation instructions). Immediately ahead of filter drier in each circuit is a factory-installed liquid line service valve. Each valve has a for charging liquid refrigerant.

Charging with Unit Off and Evacuated service valve before charging. Weigh in charge shown on unit nameplate. Open liquid line service valve; start unit and allow it to run several minutes fully loaded. Check for a clear sight glass. Be sure clear condition is liquid and not vapor.

Charging with Unit Running

— If charge is to be added while unit is operating, all condenser fans and compressors must be operating. It may be necessary to block condenser coils at low ambient temperatures to raise condensing pressure to approximately 198 psig (1365 kPa) to turn all condenser fans on. Do not totally block a coil to do this. Partially block all coils in uniform pattern. Charge each circuit until sight glass shows clear liquid, and has a liquid line temperature of 103 F (39 C) for 30XA080352 units and 108 F (42 C) for 30XA400-500 units.

Add 3 to 5 lb (1.36 to 2.27 kg) depending on unit size of liquid charge into the fitting located on the tube entering the cooler. This fitting is located between the electronic expansion valve (EXV) and the cooler.

Allow the system to stabilize and then recheck the liquid temperature. If needed, add additional liquid charge, 3 to 5 lb at a time, allowing the system to stabilize between each charge addition. Slowly add charge as the sight glass begins to clear to avoid overcharging.

IMPORTANT: When adjusting refrigerant charge, circulate fluid through cooler continuously to prevent freezing and possible damage to the cooler. Do not overcharge, and never charge liquid into the low-pressure side of system.

/4-in. access connection

— Close liquid line

Page 87

WIRE GUARD

FAN BLADE

FAN DECK

FORMED METAL MOUNT

MOTOR

Fig. 61 — Fan Mounting

a30-4249

Safety Devices — The 30XA chillers contain many

safety devices and protection logic built into the electronic control. Following is a description of the major safeties.

COMPRESSOR PROTECTION Motor Overload

(CPM) protect each compressor against overcurrent. Do not bypass the current transformers or make any changes to the factory-installed and configured headers. The configuration of these headers defines the Must Trip Amps (MTA) at which the CPM will turn the compressors off. Determine the cause for trouble and correct the problem before resetting the CPM. See Appendix D for MTA settings and configuration headers.

Each CPM board also reads the status of each compressor’s high-pressure switch. All compressors have factory-installed high-pressure switches. See Table 56.

Table 56 — High-Pressure Switch Settings

UNIT

30XA 304.5 +7.25, –14.5 2099 +50, –100

If the switch opens during operation, the compressor will be shut down. The CPM will reset automatically when the switch closes, however, a manual reset of the control is required to restart the compressor.

OIL SEPARATOR HEATERS — Each oil separator circuit has a heater mounted on the underside of the vessel. The heater is deenergized anytime the compressor is on. If the compressor is off and outdoor-air temperature (OAT) is greater than 100 F (37.8 C) the heater is deenergized. The heater will also be deenergized if OAT – SST >32 F (17.8° C) and the OAT – LWT > 32 F (17.8° C).

COOLER PROTECTION Low Water Temperature

to shut the chiller down if the leaving fluid temperature drops below 34 F (1.1 C) for water or more than 8 F (4.4 C) below set point for Fluid Type = brine. When the fluid temperature rises 6 F (3.3 C) above the leaving fluid set point, the safety resets and the chiller restarts. Reset is automatic as long as this is the first occurrence of the day.

— The compressor protection modules

SWITCH SETTING

psig kPa

— Microprocessor is programmed

Relief Devices — Fusible plugs are located in each cir-

cuit between the condenser and the liquid line shutoff valve. PRESSURE RELIEF VALVES — Valves are installed in each

circuit and are located on the coolers and oil separators. These valves are designed to relieve if an abnormal pressure condition arises. Relief valves on all coolers relieve at 220 psi (1517 kPa). Relief valves on oil separators relieve at 350 psi (2413 kPa). These valves should not be capped. If a valve relieves, it should be replaced. If the valve is not replaced, it may relieve at a lower pressure, or leak due to trapped dirt from the system which may prevent resealing.

See Table 57. Some local building codes require that relieved gases be exhausted to a specific location. This connection allows conformance to this requirement.

Table 57 — Relief Valve Connection Specs

LOCATION CONNECTION SIZES

Oil Separator 3/8 SAE Flare

DX Cooler Option 5/8 SAE Flare

Flooded Cooler Option 3/4 in. NPT Female

MAINTENANCE

Recommended Maintenance Schedule —

lowing are only recommended guidelines. Jobsite conditions may dictate that maintenance schedule is performed more often than recommended.

Routine: For machines with e-coat condenser coils:

• Check condenser coils for debris; clean as necessary with

Carrier approved coil cleaner.

• Periodic clean water rinse, especially in coastal and indus-

trial applications.

The fol-

Page 88

Every month:

Alarm Descriptor

Alarm Suffix

Code Number to identify source

.01

Alarm Prefix

A1 – Compressor A1 Failure B1 – Compressor B1 Failure C1 – Compressor C1 Failure Co – Communication Failure FC – Factory Configuration Error MC – Master Chiller Configuration Error P – Process Failure Pr – Pressure Transducer Failure Sr – Service Notification th – Thermistor Failure

Alarm

Fig. 62 — Alarm Description

a30-4250

• Check condenser coils for debris; clean as necessary with Carrier approved coil cleaner.

• Check moisture indicating sight glass for possible refrigerant loss and presence of moisture.

Every 3 months (for all machines):

• Check refrigerant charge.

• Check all refrigerant joints and valves for refrigerant leaks; repair as necessary.

• Check chilled water flow switch operation.

• Check all condenser fans for proper operation.

• Check oil filter pressure drop.

• Check oil separator heater operation.

• Inspect pump seal, if equipped with a hydronic pump package.

Every 12 months (for all machines):

• Check all electrical connections; tighten as necessary.

• Inspect all contactors and relays; replace as necessary.

• Check accuracy of thermistors; replace if greater than ±2° F (1.2° C) variance from calibrated thermometer.

• Check accuracy of transducers; replace if greater than ±5 psi (34.47 kPa) variance.

• Check to be sure that the proper concentration of antifreeze is present in the chilled water loop, if applicable.

• Verify that the chilled water loop is properly treated.

• Check refrigerant filter driers for excessive pressure drop; replace as necessary.

• Check chilled water strainers, clean as necessary.

• Check cooler heater operation.

• Check condition of condenser fan blades and that they are securely fastened to the motor shaft.

• Perform Service Test to confirm operation of all components.

• Check for excessive cooler approach (Leaving Chilled Water Temperature – Saturated Suction Temperature) which may indicate fouling. Clean cooler vessel if necessary.

• Obtain oil analysis; change as necessary.

TROUBLESHOOTING

See Table 58 for an abbreviated list of symptoms, possible

causes and possible remedies.

Alarms and Alerts — The integral control system con-

stantly monitors the unit and generates warnings when abnormal or fault conditions occur. Alarms may cause either a circuit (Alert) or the whole machine (Alarm) to shut down. Alarms and Alerts are assigned codes as described in Table 59. The alarm/alert indicator LED on the Navigator™ module is illuminated when any alarm or alert condition is present. If an Alert is active, the Alarm Indicator LED will blink. If an Alarm is active, the Alarm Indicator LED will remain on. Currently active Alerts and Alarms can be found in (Current Alarm, ALRM).

The controller generates two types of alarms. Automatic

reset alarms will reset without any intervention if the condition that caused the alarm corrects itself. Manual reset alarms require the service technician to check for the alarm cause and

reset the alarm. The following method must be followed to reset manual alarms:

Before resetting any alarm, first determine the cause of the alarm and correct it. To reset the alarm, set R.ALM to YES. The alarms will be reset. Indicator light will be turned off when switched correctly. Do not reset the chiller at random without first investigating and correcting the cause(s) of the failure.

Each alarm is described by a three or four-digit code. The first one or two digits indicate the alarm source and are listed in Fig. 62. The last two digits pinpoint the problem. See Table 59.

DIAGNOSTIC ALARM CODES AND POSSIBLE CAUSES

Thermistor Failure Alarm 1 — Cooler Fluid Entering (th.01)

Alarm 2 — Cooler Fluid Leaving (th.02) Criteria for Trip — This alarm criterion is tested whether the

unit is on or off if the temperature as measured by the thermistor is outside of the range –40 to 245 F (–40 to 118.3 C).

Action to be Taken — The unit shuts down normally, or is not allowed to start.

Reset Method — Automatic, the alarm will reset once the thermistor reading is within the expected range.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the Main Base Board

• sensor accuracy

See the Thermistors section on page 71 for thermistor description, identifiers and connections.

Defrost Thermistor Failure Alarm 3 — Circuit A (th.03)

Alarm 4 — Circuit B (th.04)

NOTE: These alarms are not used or supported. If this condition is encountered, confirm machine configuration.

Page 89

Table 58 — Troubleshooting

SYMPTOM POSSIBLE CAUSE POSSIBLE REMEDY

Unit Does Not Run Check for power to unit • Check overcurrent protection device.

• Check non-fused disconnect (if equipped).

• Restore power to unit.

Wrong or incorrect unit

Check unit configuration.

configuration Active alarm Check Alarm status. See the Alarms and Alerts section

and follow troubleshooting instructions.

Active operating mode Check for Operating Modes. See the Operating Modes

section and follow troubleshooting instructions

Unit Operates too Long or Continuously

Low refrigerant charge Check for leak and add refrigerant. Compressor or control

Replace contactor or relay.

contacts welded Air in chilled water loop Purge water loop. Non-condensables in

Remove refrigerant and recharge.

refrigerant circuit. Inoperative EXV • Check EXV, clean or replace.

• Check EXV cable, replace if necessary.

• Check EXV board for output signal.

Load too high Unit may be undersized for application

Circuit Does Not Run Active alarm Check Alarm status. See the Alarms and Alerts section

and follow troubleshooting instructions.

Active operating mode Check for Operating Modes. See the Operating Modes

section and follow troubleshooting instructions.

Circuit Does Not Load

Active alarm Check Alarm status. See the Alarms and Alerts section

and follow troubleshooting instructions.

Active operating mode Check for Operating Modes. See the Operating Modes

section and follow troubleshooting instructions.

Low saturated suction

See Operating Modes 21, 22 and 23.

temperature High circuit suction superheat The circuit capacity is not allowed increase if circuit super-

heat is greater than 36°F (20 C). See Alarms 59-61 for potential causes.

Low suction superheat The circuit capacity is not allowed to increase if the circuit

superheat is less than 18° F (10° C). See Alarms 62-64 for potential causes.

Compressor Does Not Run

Active alarm Check Alarm status. See the Alarms and Alerts section

and follow troubleshooting instructions.

Active operating mode Check for Operating Modes. See the Operating Modes

section and follow troubleshooting instructions.

Inoperative compressor contactor

• Check control wiring.

• Check scroll protection module.

• Check contactor operation, replace if necessary.

Chilled Water Pump is ON, but the

Cooler freeze protection Chilled water loop temperature too low. Check cooler

heater.

Machine is OFF

LEGEND

EXV — Electronic Expansion Valve

Page 90

Table 59 — Alarm Codes

PREFIX

CODE

CCN — Carrier Comfort Network® HPS — High Pressure Switch CPM — Compressor Protection Module LW T — Leaving Water Temperature DX — Direct Expansion MOP — Maximum Operating Pressure EMM — Energy Management Module MTA — Must Trip Amps EWT — Entering Water Temperature OAT — Outdoor Air Temperature EXV — Electronic Expansion Valve SST — Saturated Suction Temperature HGBP — Hot Gas Bypass UL — Underwriters Laboratories

SUFFIX

CODE

th 01 1 Cooler Entering Fluid

02 2 Cooler Leaving Fluid

03 3 Circuit A Defrost Thermistor Temperature measured 04 4 Circuit B Defrost Thermistor 06 5 Condenser Entering

07 6 Condenser Leaving

08 7 Reclaim Condenser

09 8 Reclaim Condenser

10 9 OAT Thermistor Temperature measured

11 10 Master/Slave Common Fluid

12 11 Circuit A Suction Gas

13 12 Circuit B Suction Gas

14 13 Circuit C Suction Gas

15 14 Circuit A Discharge Gas

16 15 Circuit B Discharge Gas

17 16 Circuit C Discharge Gas

18 17 Circuit A Condenser Sub-

19 18 Circuit B Condenser Sub-

21 19 Space Temperature

23 20 Cooler heater feedback

24 21 Circuit A Economizer Gas

25 22 Circuit B Economizer Gas

26 23 Circuit C Economizer Gas

Pr 01 24 Circuit A Discharge

02 25 Circuit B Discharge

03 26 Circuit C Discharge

04 27 Circuit A Suction Transducer 05 28 Circuit B Suction Transducer 06 29 Circuit C Suction Transducer 07 30 Circuit A Reclaim Pump-

08 31 Circuit B Reclaim Pump-

ALARM

NUMBER

ALARM DESCRIPTION REASON FOR ALARM

Thermistor

Fluid Thermistor

Entering Thermistor

Leaving Thermistor

Thermistor

cooling Liquid Thermistor

Thermistor

thermistor

Thermistor

Transducer

down Pressure Transducer

LEGEND

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Temperature measured

by the controller is

outside of the range

of –40 F to 245 F (–40 C to 118 C)

Measured voltage is

0 vdc or SST > EWT and

EXV < 50% for 1 minute

Measured voltage is

0 vdc or SST > EWT and

EXV < 50% for 1 minute

ACTION TAKEN

BY CONTROL

Unit be shut down or

not allowed to start

None

Unit be shut down or

not allowed to start

Dual chiller deacti-

vated. Master and

slave machines

operate in stand-

alone mode

Circuit shut down or

not allowed to start

None

Alarm tripped

None

Circuit economizer

function disabled

Circuit shut down or

not allowed to start

None

RESET

TYPE

Automatic Faulty Sensor,

Automatic

Automatic Faulty transducer,

Automatic

PROBABLE CAUSE

wiring error or failed

main base board

Configuration error

Faulty Sensor,

wiring error or failed

main base board

Faulty Sensor,

wiring error, failed

EXV or CPM board

Configuration error

Faulty Sensor, wiring

error, failed EMM

board

Configuration error

Faulty Sensor,

wiring error, failed

EXV board

wiring error, failed

main base board or

fan board

Configuration error

Page 91

Table 59 — Alarm Codes (cont)

PREFIX

CODE

Co A1 38 Loss of communication with

SUFFIX

CODE

Pr 10 32 Circuit A Oil Pressure

P 01 52 Cooler Freeze Protection Entering or leaving therm-

ALARM

NUMBER

11 33 Circuit B Oil Pressure

12 34 Circuit C Oil Pressure

13 35 Circuit A Economizer

14 36 Circuit B Economizer

15 37 Circuit C Economizer

B1 39 Loss of communication with

C1 40 Loss of communication with

E1 41 Loss of communication with

E2 42 Loss of communication with

E3 43 Loss of communication with

F1 44 Loss of communication with

F2 45 Loss of communication with

F3 46 Loss of communication with

01 47 Loss of communication with

02 48 Loss of communication with

03 49 Loss of communication with

04 50 Loss of communication with

05 51 Loss of communication with

02 53 Condenser Freeze Protection

03 54 Condenser Freeze Protection

04 55 Condenser Freeze Protection

ALARM DESCRIPTION REASON FOR ALARM

Transducer

Pressure Transducer

Compressor Board A

Compressor Board B

Compressor Board C

EXV Board A

EXV Board B

EXV Board C

Fan Board 1

Fan Board 2

Fan Board 3

Free Cooling Board 1

Free Cooling Board 2

Energy Management Board

Heat Reclaim Board

AUX Board 6

Circuit A

Circuit B

Circuit C

LEGEND

Measured voltage is

0 vdc or SST > EWT and

EXV < 50% for 1 minute

Measured voltage is

0 vdc

No communication

with CPM board

No communication with

EXV board

No communication with

fan board

No communication with

fan board

No communication with

fan board

No communication with

free cooling board

No communication with

EMM board

No communication

with Free Cooling Board

No communication

with HGBP/PUMP Board

istor sensed a tempera-

ture at or below freeze

point

— None Automatic Configuration error

ACTION TAKEN

BY CONTROL

Circuit shut down or

not allowed to start

Circuit shut down or

not allowed to start

Affected

compressor shut

down

Affected

compressor

shut down

Circuit A/B shut

down or not allowed

to start (080-120

ton), Circuit A shut

down or not allowed

to start

(130-500 ton)

Circuit B shut down

or not allowed to

start (130-500 ton)

Circuit C shut down

or not allowed to

start (400-500 ton)

None Automatic Configuration error

Disable or not allow

EMM functions

3 step and 4-20 mA

and space tempera-

ture reset, occu-

pancy override and

ice build)

None Automatic Configuration error

Unit shut down or

not allowed to start

Unit shut down or

not allowed to start

RESET

TYPE

Automatic

Automatic Faulty transducer,

Automatic Wrong CPM address,

Automatic Wrong EXV board

Automatic Wrong board address,

Automatic Wrong board

Automatic

Automatic, first

occurrence in

24 hours;

manual if multiple alarms within 24 hours

PROBABLE CAUSE

Faulty transducer,

wiring error, failed CPM

wrong unit configura-

tion, wiring error, power

address, wrong unit configuration, wiring

error, power loss,

failed EXV board

wrong unit configuration, wiring error, loss of power, failed board

address, wrong unit configuration, wiring

error, power loss to

module, failed module

address, wrong unit configuration, wiring

error, power loss to

module, failed module

Faulty thermistor, faulty

wiring, low water flow,

low loop volume, fouled

cooler, or freeze

board

loss, failed

CPM board

Wrong board

conditions

Page 92

Table 59 — Alarm Codes (cont)

PREFIX

CODE

SUFFIX

CODE

P 05 56 Circuit A Low Suction

MC nn 81 Master chiller configura-

FC n0 82 No factory configuration No Configuration Unit not allowed to

P 31 84 Unit is in CCN emer-

ALARM

NUMBER

06 57 Circuit B Low Suction

07 58 Circuit C Low Suction

08 59 Circuit A High Suction

09 60 Circuit B High Suction

10 61 Circuit C High Suction

11 62 Circuit A Low Suction

12 63 Circuit B Low Suction

13 64 Circuit C Low Suction

14 65 Interlock Failure Lockout Switch Closed Unit shut down or

28 66 Electrical Box Thermo-

29 67 Loss of communication

30 68 Master/Slave communi-

67 69 Circuit A Low Oil

68 70 Circuit B Low Oil

69 71 Circuit C Low Oil

70 72 Circuit A Max Oil Filter

71 73 Circuit B Max Oil Filter

72 74 Circuit C Max Oil Filter

84 75 Circuit A High Oil Filter

85 76 Circuit B High Oil Filter

86 77 Circuit C High Oil Filter

75 78 Circuit A Low Oil Level Oil level switch open Circuit shut down 76 79 Circuit B Low Oil Level 77 80 Circuit C Low Oil Level

nn 83 Illegal factory configura-

32 85 Cooler pump #1 fault Pump interlock status does 33 86 Cooler pump #2 fault

15 87 Condenser Flow Switch

ALARM DESCRIPTION REASON FOR ALARM

Temperature

Superheat

stat Failure/Reverse Rotation

with System Manager

cation Failure

Pressure

Differential Pressure

Drop Pressure

tion error Number 01 to nn

tion Number 01 to 04

gency stop

Failure

LEGEND

Low saturated suction tem-

peratures detected for a

period of time

EXV>98%,

suction superheat > 30 F

(–1 C), and SST<MOP for

more than 5 minutes

EXV<5% and either the suc-

tion superheat is less than

the set point by at least 5 F

(–15 C) or the suction tem-

perature is greater than

MOP set point for more than

Communication between the

5 minutes

External pump interlock

Loss of communication with

an external control device

master and slave machines

Oil pressure and suction

pressure differential is less

Difference between discharge pressure and oil pressure is greater than

Wrong or incompatible con-

Emergency stop command

open

for more than

2 minutes

lost

than the set point

50 psi for more than

30 seconds

30 psi for more than

5 minutes

figuration data

has been received

not match pump

status

— None Manual Configuration error

ACTI ON TAKEN

BY CONTROL

Circuit shut down Automatic, first

Circuit shut down Manual Faulty transducer, faulty wir-

not allowed to

start

Unit shut down or

not allowed to

start

Unit change to

stand-alone

operation

Unit change to

stand-alone

operation

Circuit shut down Automatic, first

Circuit shut down Manual Plugged oil filter, closed oil

Alert generated Manual Plugged oil filter

or not allowed to

start

Unit not allowed to

start in Master-

slave control

start

Unit not allowed to

start

Unit shut down or

not allowed to

start

Unit shuts down, if

available, another

pump will start

RESET

TYPE

occurrence in 24

hours;

manual if multiple alarms within 24 hours

Automatic Lockout Switch Closed

Automatic External pump off. Faulty

Automatic Faulty communication wir-

occurrence in 24

hours;

manual if multiple alarms within 24 hours

Automatic, first

occurrence in 24

hours; manual if

multiple alarms within 24 hours

Automatic Configuration error

Automatic Carrier Comfort

Manual Faulty contacts, wiring error

PROBABLE CAUSE

Faulty thermistor, faulty wir-

ing, low water flow, low loop

volume, fouled cooler, or

freeze conditions.

Closed suction valve, DX

ing, faulty thermistor, faulty

EXV, low refrigerant charge,

plugged or restricted liquid

ing, faulty thermistor, faulty

jumper wiring when channel

ing, no power supply to the

ing, no power or control

Plugged oil filter, faulty oil

transducer, oil check valve

stuck, plugged oil strainer

valve, bad oil solenoid, oil

check valve stuck, faulty oil

Low oil level, faulty switch,

Network

or low control voltage. Con-

units.

line

EXV, or incorrect

configuration

on EMM board

not used

external controller

power to the main base

board of either module

pressure transducer

wiring error, failed CPM

board

(see Table 61)

Emergency Stop

command received

figuration error.

Page 93

PREFIX

CODE

A1, B1, C1 01 111-01,

SUFFIX

CODE

P 34 88 Circuit A Reclaim Operation

Sr nn 110 Service maintenance alert

ALARM

NUMBER

35 89 Circuit B Reclaim Operation

37 90 Circuit A — Repeated high

38 91 Circuit B — Repeated high

39 92 Circuit C — Repeated high

40 93 Circuit A — Repeated low

41 94 Circuit B — Repeated low

42 95 Circuit C — Repeated low

43 96 Low entering water tempera-

73 97 Condenser pump #1 default — None Manual Configuration error 74 98 Condenser pump #2 default 78 99 Circuit A High Discharge

79 100 Circuit B High Discharge

80 101 Circuit C High Discharge

81 102 Circuit A Low Economizer

82 103 Circuit B Low Economizer

83 104 Circuit C Low Economizer

87 105 Circuit A Slide Valve Control

88 106 Circuit B Slide Valve Control

89 107 Circuit C Slide Valve Control

90 108 Cooler flow switch set point

91 109 Cooler flow switch failure Flow switch open Unit shut down Manual if unit

97 127 Water Exchanger Tempera-

112-01,

113-01

02 111-02,

112-02,

113-02

03 111-03,

112-03,

113-03

ALARM DESCRIPTION REASON FOR ALARM

Failure

discharge gas overrides

suction temp overrides

ture in heating

Temperature

Pressure

Unverifiable

configuration failure

ture Sensors Swapped

Number # nn

Compressor Motor temperature too high

Compressor Motor temperature out of range

Compressor High pressure switch protection

LEGEND

Table 59 — Alarm Codes (cont)

ACTION TAKEN

BY CONTROL

— None Manual Configuration error

Multiple capacity over-

rides due to high

saturated discharge

temperature

Multiple capacity overrides due to low saturated suction temperature

Not supported — — —

Discharge gas tempera-

ture is higher than 212 F

(100 C) for more than

90 seconds

The economizer pressure is below the suction pres-

sure more than 14.5 psi

for more than 10 seconds

If 100% load current is

less than 1.1 times of 30%

load current, or for 1 min-

ute when active cooling

setpoint is greater than

32 F (0°C).

— None Manual Configuration error

Control detects EWT

below LWT for 1 minute

Field programmed

elapsed time has expired

for maintenance time

Compressor temperature higher than 232 F (111 C) for more than 90 seconds

Compressor temperature

reading out of the range of

–40 F to 245 F

(–40 C to 118 C)

HPS input on CPM board

open

Circuit shut down Automatic Condenser air

Circuit shut down Automatic Inaccurate

Circuit shut down Manual Faulty transducer/high

Circuit shut down Manual Faulty transducer,

Unit shut down Manual Wiring error, EWT and

Circuit shut down Manual Motor cooling solenoid

Circuit shut down Manual Faulty thermistor, faulty

Circuit shut down Manual, press

RESET

TYPE

None Manual Slide valve stuck, inac-

is running,

automatic otherwise

None Manual Maintenance required

reset button on

HPS

PROBABLE CAUSE

recirculation, dirty or

plugged condenser

coils, inaccurate

discharge transducer,

faulty condenser fan

transducer, faulty EXV,

low refrigerant charge,

plugged or restricted

liquid line filter drier.

pressure switch, low/

restricted condenser

flow

faulty main base board,

faulty wiring, closed

suction service valve,

faulty EXV

curate initial current

reading

Faulty flow switch, low

cooler flow, faulty

wiring, faulty cooler pump, faulty main base board, minutes off time

set to 0

LWT sensors swapped

or economizer

(080,082 only) EXV

failure, faulty CPM

board, low refrigerant

charge (090-500)

wiring, faulty CPM

board

Loss of condenser air

flow, operation beyond

compressor envelope,

faulty high pressure switch, faulty wiring,

faulty CPM board

Page 94

Table 59 — Alarm Codes (cont)

PREFIX

CODE

A1, B1, C1 04 111-04,

SUFFIX

CODE

NUMBER

05 111-05,

06 111-06,

07 111-07,

08 111-08,

09 111-09,

10 111-10,

11 111-11,

12 111-12,

13 111-13,

14 111-14,

15 111-15,

16 111-16,

17 111-17,

18 111-18,

19 111-19,

ALARM

112-04,

113-04

112-05,

113-05

112-06,

113-06

112-07,

113-07

112-08,

113-08

112-09,

113-09

112-10,

113-10

112-11,

113-11

112-12,

113-12

112-13,

113-13

112-14,

113-14

112-15,

113-15

112-16,

113-16

112-17,

113-17

112-18,

113-18

112-19,

113-19

ALARM DESCRIPTION REASON FOR ALARM

Compressor Over current CPM board detects high

Compressor Locked rotor CPM board detects locked

Compressor Phase loss L1 CPM board detects cur-

Compressor Phase loss L2

Compressor Phase loss L3

Compressor Low current alarm

Compressor Y delta starter current increase failure alarm

Compressor Contactor failure CPM board detects

Compressor Unable to stop motor

Compressor Phase reversal CPM board detects phase

Compressor MTA configuration fault

Compressor Configuration switch mismatch

Compressor Unexpected switch setting change

Compressor Power on reset CPM board detects a

Compressor UL 1998 critical section software error

Compressor UL 1998 current measure dual channel mismatch

LEGEND

motor current compared

with MTA setting

rotor current compared

with MTA setting

rent unbalance greater

than 65% for more than

1 second

CPM detects motor cur-

rent less than a certain percentage of the MTA

setting, compressor not

operating

If the delta mode current

is not 25% greater than

the current in Y mode

greater than 15% of MTA

current for 10 seconds

after shutting off the com-

pressor contactor. Oil solenoid is energized.

CPM board detects

greater than 15% of MTA

current for 10 seconds

after three attempts

reversal from current

toroid

MTA setting is out of the

allowed MTA range

CPM board MTA setting

do not match factory

configuration

CPM board dipswitch S1

setting changed

power failure

Software error Circuit shut down Manual Electric noise, faulty

ACTION TAKEN

BY CONTROL

Circuit shut down Manual Operating beyond

Circuit shut down Manual Compressor motor fail-

Circuit shut down Manual Blown fuse, wiring

Circuit shut down Manual Power supply discon-

Circuit shut down Manual Power supply to delta

Circuit shut down Manual Faulty contactor, con-

Circuit shut down Manual Faulty contactor,

Circuit shut down Manual Terminal block power

Circuit shut down Manual Incorrect MTA setting,

Circuit shut down Manual Incorrect CPM dip-

Circuit shut down Manual Power supply

RESET

TYPE

PROBABLE CAUSE

compressor envelope, incorrect configuration

ure, unloader slide

valve failure, compres-

sor mechanical failure

error, loose terminals

nected, blown fuse, wiring error, contact

deenergized, faulty

current toroid high

pressure switch trip.

contactor not

connected, faulty delta

contactor or wiring,

faulty CPM board

tactor welded, wiring

error

contactor welded,

wiring error

supply lead not in

correct phase. Power

supply leads going

through toroid crossed

faulty CPM board

switch setting,

incorrect factory MTA

setting, faulty CPM

board

switch setting, faulty

CPM board

interruption

CPM board

Page 95

Thermistor Failure Alarm 5 — Condenser Entering Fluid (th.06) Alarm 6 — Condenser Leaving Fluid (th.07) NOTE: These alarms are not used or supported. If this condi-

tion is encountered, confirm machine configuration. Condenser Reclaim Thermistor Alarm 7— Reclaim Entering Fluid (th.08) Alarm 8 — Reclaim Leaving Fluid (th.09) NOTE: Alarms 7 and 8 are not used or supported. If this condi-

tion is encountered, confirm machine configuration. Alarm 9 — Outdoor Air Temperature Thermistor Failure

(th.10) Criteria for Trip — This alarm criterion is tested whether the

unit is ON or OFF. The alarm is tripped if the temperature measured by the outdoor air thermistor sensor is outside the range of –40 to 245 F (–40 to 118.3 C).

Action to be Taken — The unit shuts down normally, or is not allowed to start.

Reset Method — Automatic, the alarm will reset once the thermistor reading is within the expected range.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the Main Base Board

• a faulty thermistor See the Thermistors section on page 71 for thermistor de-

scription, identifiers and connections. Alarm 10 — Master/Slave Common Fluid Thermistor

(th.11) Criteria for Trip — This alarm criterion is tested whether the

unit is ON or OFF. The alarm will be tripped if the unit is configured as a master or a slave (Master/Slave Select,

MSSL), leaving temperature control is selected (Entering Fluid Control, EWTO), and if the temperature measured by

the CHWS (chilled water sensor) fluid sensor is outside the range of –40 to 245 F (–40 to 118.3 C).

Action to be Taken — Master/slave operation is disabled and the chiller returns to stand alone mode.

Reset Method — Reset is automatic when the thermistor reading is inside the range of –40 to 245 F (–40 to 118.3 C).

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the Main Base Board

• a faulty thermistor

See the Thermistors section on page 71 for thermistor description, identifiers and connections.

Suction Gas Thermistor Alarm 11 — Circuit A (th.12)

Alarm 12 — Circuit B (th.13) Alarm 13 — Circuit C (th.14)

Criteria for Trip — This alarm criterion is tested whether the unit is ON or OFF. If the suction gas temperature as measured by the thermistor is outside of the range –40 to 245 F (–40 to

118.3 C).

Action to be Taken — The affected circuit shuts down normally.

Reset Method — Automatic, once the thermistor reading is within the expected range. The affected circuit will restart once the alarm has cleared.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the EXV board

• board for a faulty channel

• a faulty thermistor

See the Thermistors section on page 71 for thermistor de-

scription, identifiers and connections. Circuit Discharge Gas Thermistor Sensor Failure Alarm 14 — Circuit A (th.15)

Alarm 15 — Circuit B (th.16) Alarm 16 — Circuit C (th.17)

Criteria for Trip — This alarm criterion is tested whether the unit is ON or OFF. The alarm is tripped if the temperature measured by the Outdoor Air Thermistor sensor is outside the range of –40 to 245 F (–40 to 118.3 C).

Action to be Taken — The unit shuts down normally, or is not allowed to start.

Reset Method — Automatic, the alarm will reset once the thermistor reading is within the expected range.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the CPM board

• a faulty thermistor

• a faulty channel on the board See the Thermistors section on page 71 for thermistor descrip-

tion, identifiers and connections. Condenser Subcooling Liquid Thermistor Alarm 17 — Circuit A (th.18)

Alarm 18 — Circuit B (th.19) NOTE: Alarms 17 and 18 are not used or supported. If this

condition is encountered, confirm machine configuration. Alarm 19 — Space Temperature Sensor Failure (th.21) Criteria for Trip — This alarm criterion is checked whether the

unit is ON or OFF and if Space Temperature Reset has been enabled. This alarm is generated if the outdoor-air temperature as measured by the thermistor is outside of the range –40 to 245 F (–40 to 118.3 C).

Action to be Taken — Unit operates under normal control. Temperature Reset based on Space Temperature is disabled.

Reset Method — Automatic, once the thermistor reading is within the expected range. The Space Temperature Reset will resume once the alarm has cleared.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the Energy Management Module

• board for a faulty channel

• a faulty thermistor For thermistor descriptions, identifiers and connections, see

the Thermistors section. Alarm 20 — Cooler Heater Feedback Sensor Thermistor

(th.23) NOTE: Alarm 20 is not used or supported. If this condition is

encountered, confirm machine configuration. Economizer Gas Thermistor Alarm 21 — Circuit A (th.24)

Alarm 22 — Circuit B (th.25) Alarm 23 — Circuit C (th.26)

Criteria for Trip — This alarm criterion is tested whether the unit is ON or OFF. The alarm is tripped if the Economizer gas reading is outside the range of –40 to 245 F (–40 to 118.3 C).

Action to be Taken — The unit shuts down normally, or is not allowed to start.

Reset Method — Automatic, the alarm will reset once the thermistor reading is within the expected range.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to the EXV board

• a faulty thermistor

• a faulty channel on the board

Page 96

See the Thermistors section on page 71 for thermistor description, identifiers and connections.

Discharge Transducer

Alarm 24 — Circuit A (Pr.01)

Alarm 25 — Circuit B (Pr.02) Alarm 26 — Circuit C (Pr.03)

Criteria for Trip — The criterion is tested whether the circuit is ON or OFF. This alarm is generated if the voltage as sensed by the MBB or Fan Board C (FBC) is 0 vdc, which corresponds to the Navigator™ display of –7 psi (–48.3 kPa).

Action to be Taken — The circuit is shut down normally, or not allowed to start.

Reset Method — Automatic, once the transducer voltage is greater than 0 vdc, which corresponds to the Navigator display of a value greater than –7 psi (–48.3 kPa).

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to Main Base Board (Alarms 24 and 25)

• sensor wiring to Fan Board C (Alarm 26)

• board for a faulty channel

• for a faulty transducer

• confirm unit configuration Suction Pressure Transducer Failure

Alarm 27 — Circuit A (Pr.04) Alarm 28 — Circuit B (Pr.05)

Alarm 29 — Circuit C (Pr.06) Criteria for Trip — The criteria are tested whether the circuit is

ON or OFF. The alarm is generated if one of the following criteria is met:

1. If the voltage as sensed by the MBB or Fan Board C is 0 vdc, which corresponds to the Navigator™ display of –7 psi (–48.3 kPa).

2. The circuit is ON in cooling mode and the Saturated Suction Temperature (Saturated Suction Temp, SST) for the circuit is greater than the Entering Water Temperature and EXV opening is less than 50% for more than 60 seconds.

Action to be Taken — The circuit is shut down immediately, or not allowed to start.

Reset Method

1. Automatic, once the transducer voltage is greater than 0 vdc, which corresponds to the Navigator display of a value greater than –7 psi (–48.3 kPa).

2. Automatic once the circuit’s saturated suction temperature is lower than the Entering Water Temperature by 3° F (1.6° C). If this criterion trips the alarm 3 times within a 24-hour period, the alarm changes to a manual reset.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to Main Base Board (Alarms 27 and 28)

• sensor wiring to Fan Board C (Alarm 29)

• board for a faulty channel

• faulty transducer

• faulty entering water temperature sensor

• unit configuration Reclaim Pumpdown Pressure Transducer Alarm 30 — Circuit A (Pr.07)

Alarm 31 — Circuit B (Pr.08) NOTE: Alarms 30 and 31 are not used or supported. If this

condition is encountered, confirm machine configuration. Oil Pressure Transducer Alarm 32 — Circuit A (Pr.10)

Alarm 33 — Circuit B (Pr.11) Alarm 34 — Circuit C (Pr.12)

Criteria for Trip — The criteria are tested whether the circuit is ON or OFF. The alarm is generated if one of the following criteria is met:

1. If the voltage as sensed by the MBB or Fan Board C is 0 vdc, which corresponds to the Navigator display of –7 psi (–48.3 kPa).

2. The circuit is OFF and outside air temperature is below

35.6 F (2 C).

3. The circuit is OFF and the fluid type is brine.

Action to be Taken — The circuit is shut down immediately, or not allowed to start.

Reset Method — Automatic, once the transducer voltage is greater than 0 vdc.

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to CPM board

• board for a faulty channel

• faulty transducer

• plugged oil filter

• faulty oil solenoid valve coil

• stuck oil solenoid valve

• confirm unit configuration Economizer Pressure Transducer Failure Alarm 35 — Circuit A (Pr. 13)

Alarm 36 — Circuit B (Pr. 14) Alarm 37 — Circuit C (Pr. 15)

Criteria for Trip — The criteria are tested whether the circuit is ON or OFF. The alarm is generated if the voltage as sensed by the MBB or Fan Board C is 0 vdc, which corresponds to the Navigator display of –7 psi (–48.3 kPa).

Action to be Taken — The circuit is shut down immediately, or not allowed to start.

Reset Method — Automatic, once the transducer voltage is greater than 0 vdc, which corresponds to the Navigator display of a value greater than –7 psi (–48.3 kPa).

Possible Causes — If this condition is encountered, check the following items:

• sensor wiring to EXV Board

• EXV board for a faulty channel

• faulty transducer

• faulty economizer EXV or EXV wiring

• faulty economizer EXV channel on the board

• closed or partially closed suction service valve

• confirm unit configuration Loss of Communication with Compressor Board

Alarm 38 — Compressor Board A (Co.A1) Alarm 39 — Compressor Board B (Co.B1) Alarm 40 — Compressor Board C (Co.C1) Criteria for Trip — The alarm criterion is tested whether the unit is ON or OFF. If communication with the Compressor Protection Module Board (CPM) is lost for a period of 10 seconds, the alarm will be generated.

Action to be Taken — The affected compressor will be shut down.

Reset Method — Automatic, if communication is established. If called for, the compressor will start normally.

Possible Causes — If this condition is encountered, check the following items:

• power supply to the affected CPM board

• address of the CPM

• local equipment network (LEN) wiring

• confirm unit configuration Loss of Communication with EXV Board Alarm 41 — Circuit A, EXV Board A (Co.E1)

Alarm 42 — Circuit B, EXV Board B (Co.E2) Alarm 43 — Circuit C, EXV Board C (Co.E3)

Page 97

Criteria for Trip — The alarm criterion is tested whether the unit is ON or OFF. If communication with EXVA, B or C is lost for a period of 10 seconds, the alarm will be triggered.

Action to be Taken — If running, Circuit A, B or C will shut down normally. If Circuit A, B or C is not operating, it will not be allowed to start.

Reset Method — Automatic, if communication is established, the unit will start normally.

Possible Causes — If this condition is encountered, check the following items:

• power supply to EXVA, B or C

• address of the EXV board

• local equipment network (LEN) wiring

• confirm unit configuration Alarm 44

— Loss of Communication with Fan Board 1

(Co.F1) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF. If communication with Fan Board A is lost for a period of 10 seconds, the alarm will be triggered.

Action to be Taken — If the number of fans per circuit is greater than four fans per circuit, Circuit A will shut down normally if they are running. Circuit B will continue to run. If the circuit or circuits controlled by the board are not running, then they will not be allowed to start.

Reset Method — Automatic, if communication is established, the unit will start normally.

Possible Causes — If this condition is encountered, check the following items:

• power supply to Fan Board A

• address of the Fan Board A

• local equipment network (LEN) wiring

• confirm unit configuration Alarm 45 — Loss of Communication with Fan Board 2

(Co.F2) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF, and only if Circuit A or B has more than four fans per circuit.

NOTE: Fan Board B controls Circuit B only. Action to be Taken — If communication with Fan Board B is

lost for a period of 10 seconds, the alarm will be triggered. If running, Circuit B will shut down normally. If Circuit B is not running, then it will not be allowed to start.

Reset Method — Automatic, if communication is established, the unit will start normally.

Possible Causes — If this condition is encountered, check the following items:

• power supply to Fan Board B

• address of the Fan Board B

• local equipment network (LEN) wiring

• confirm unit configuration Alarm 46 — Loss of Communication with Fan Board 3

(Co.F3) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF, and on units with three circuits only. If communication with Fan Board C is lost for a period of 10 seconds, the alarm will be triggered.

Action to be Taken — If running, Circuit C will shut down normally. If the circuit is not running, then it will not be allowed to start.

Reset Method — Automatic, if communication is established, the unit will start normally.

Possible Causes — If this condition is encountered, check the following items:

• power supply to Fan Board C

• address of the Fan Board C

• local equipment network (LEN) wiring

• confirm unit configuration Loss of Communication with Free Cooling Board Alarm 47 — Board 1 (Co.01)

Alarm 48 — Board 2 (Co.02) NOTE: Alarms 47 and 48 are not used or supported. If this

condition is encountered, confirm machine configuration. Alarm 49 — Loss of Communication with Energy Manage-

ment Module Board (Co.03) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF and when a function that requires the Energy Management Module (EMM) is configured. If communication with the EMM is lost for a period of 10 seconds, the alarm will be triggered.

Action to be Taken — If any function controlled by the EMM (3-Step and 4-20 mA Demand Limit, 4-20 mA and Space Temperature Reset, Occupancy Override, and Ice Build) is active, that function will be terminated. If an EMM function is programmed, and communication is lost, the function will not be allowed to start.

Reset Method — Automatic, if communication is established, the functions will be enabled.

Possible Causes — If this condition is encountered, check the following items:

• The EMM is installed, (EMM NRCP2 Board, EMM). If EMM NRCP2 Board, EMM=YES, then check for a con- trol option that requires the EMM that may be enabled (correct configuration if not correct).

• power supply to EMM

• address of the EMM

• local equipment network (LEN) wiring

• confirm unit configuration to be sure that no options that require the EMM are enabled

Alarm 50 — Loss of Communication with Heat Reclaim Board (Co.04)

NOTE: Alarm 50 is not used or supported. If this condition is encountered, confirm machine configuration.

Alarm 51 — Loss of Communication with AUX Board 6 (Co.05)

Criteria for Trip — The alarm criteria are checked whether the unit is ON or OFF. If units are configured for dual cooler pump control (Cooler Pumps Sequence, PUMP=2,3,4) or HGBP = YES. If communication with the AUX board is lost then the alarm will be generated.

Action to be Taken — Unit shut down or not allowed to start. Reset Method — Automatic, if communication is established,

the unit will start normally. Possible Causes — If this condition is encountered, check the

following items:

• power supply to the HGBP/PUMP board

• address of the HGBP/PUMP board

• local equipment network (LEN) wiring

• confirm network configuration

Alarm 52 — Cooler Freeze Protection (P.01) Criteria for Trip — The alarm criteria are checked whether the

unit is ON or OFF. If the entering or leaving water thermistor senses a temperature at the freeze point or less, the alarm will be generated. For a fresh water system (Cooler Fluid Type, FLUD=1), the freeze point is 34 F (1.1 C). For medium temperature brine systems (Cooler Fluid Type, FLUD=2), the freeze point is Brine Freeze Set Point (Brine Freeze Setpoint, LOSP).

Action to be Taken — Unit shut down or not allowed to start. Chilled water pump will be started.

Reset Method — Automatic, first occurrence in 24 hours if LWT rises to 6° F (3° C) above set point. Manual, if more than one occurrence in 24 hours.

Page 98

Possible Causes — If this condition is encountered, check the following items:

• entering and leaving fluid thermistors for accuracy

•water flow rate

• loop volume — low loop volume at nominal flow rates can in extreme cases bypass cold water to the cooler

• freezing conditions

• heater tape and other freeze protection items for proper operation

• glycol concentration and adjust LOSP accordingly

• If the Leaving Water Set Point is above 40 F (4.4 C) and there is glycol in the loop, consider using the Medium Temperature Brine option (Cooler Fluid Type, FLUD=2) to utilize the brine freeze point instead of 34 F (1.1 C)

Condenser Freeze Protection Alarm 53 — Circuit A (P.02)

Alarm 54 — Circuit B (P.03) Alarm 55 — Circuit C (P.04)

NOTE: Alarms 53-55 are not used or supported. If this condition is encountered, confirm machine configuration.

Low Saturated Suction Temperature Alarm 56 — Circuit A (P.05)

Alarm 57 — Circuit B (P.06) Alarm 58 — Circuit C (P.07)

Criteria for Trip — The criteria are tested only when the circuit is ON. This alarm is generated if one of the following criteria is met:

• If the circuit Saturated Suction Temperature is below –13 F (–25 C) for more than 30 seconds or 40 seconds if OAT is less than 14 F (–10 C) or LWT is less than 36 F (2.2 C).

• If the circuit Saturated Suction Temperature is below –22 F (–30 C) for more than 10 seconds, or 20 seconds if OAT less than 50 F (10 C).

Action to be Taken — The circuit is shut down immediately.

Prior to the alarm trip, the control will take action to avoid

the alarm. See Operating Modes 21, 22 and 23 on page 68. Reset Method — Automatic, first occurrence in 24 hours.

Manual, if more than one occurrence in 24 hours. Possible Causes — If this condition is encountered, check the

following items:

• sensor wiring to Main Base Board (Alarm 56 and 57) or Fan Board C (Alarm 58)

• board for a faulty channel

• faulty suction transducer

• cooler water flow

• loop volume

• EXV operation

• liquid line refrigerant restriction, filter drier, service valve, etc.

• refrigerant charge

• Closed suction service valve on DX Cooler units.

High Suction Superheat

Alarm 59 — Circuit A (P.08)

Alarm 60 — Circuit B (P.09) Alarm 61 — Circuit C (P.10)

Criteria for Trip — The criteria are tested only when the circuit is ON. This alarm is generated if all of the following criteria are met:

• The EXV position is equal to or greater than 98%.

• The circuit’s Suction Superheat (Suction Gas Temperature – Saturated Suction Temperature) is greater than the superheat control set point.

• The circuit’s Saturated Suction Temperature is less than Maximum Operating Pressure (MOP) set point (EXV MOP Setpoint, MOP) for more than 5 minutes.

Action to be Taken — The circuit is shut down normally. Reset Method — Manual. Possible Causes — If this condition is encountered, check the

following items:

• suction pressure transducer wiring to Main Base Board (Alarm 59 and 60) or Fan Board C (Alarm 61)

• board for a faulty channel

• a faulty suction transducer

• suction gas thermistor wiring to EXV Board 1 (Alarm 41) or to EXV Board 2 (Alarm 43)

• suction gas thermistor sensor for accuracy

• for EXV Board 1 (Alarm 41) or EXV Board 2 (Alarm 42) faulty channel

• EXV operation

• a liquid line refrigerant restriction, filter drier, service valve, etc.

• refrigerant charge

Low Suction Superheat Alarm 62 — Circuit A (P.11)

Alarm 63 — Circuit B (P.12) Alarm 64 — Circuit C (P.13)

Criteria for Trip — The criteria are tested when the circuit is ON. This alarm is generated if the following criterion is met:

The EXV position is equal to or less than 5% and the cir-

cuit’s Suction Superheat (Suction Gas Temperature – Saturated Suction Temperature) is less than the Suction Superheat Set Point (EXVA Superheat Setpoint, SHP.A, EXVB Superheat Setpoint, SHP.B, or EXVC Superheat Setpoint, SHP.C) by at least 5° F (2.8° C) or the circuit Saturated Suction Temperature is greater than Maximum Operating Pressure (MOP) set point (EXV MOP Setpoint, MOP) for more than 5 minutes.

Action to be Taken — The circuit is shut down normally. Reset Method — Automatic, first occurrence in 24 hours.

Manual, if more than one occurrence in 24 hours. Possible Causes — If this condition is encountered, check the

following items:

• suction pressure transducer wiring to Main Base Board (Alarm 62 and 63) or Fan Board C (Alarm 64)

• board for a faulty channel

• faulty suction transducer

• suction gas thermistor wiring to EXV Board 1 (Alarm 41) or to EXV Board 2 (Alarm 42)

• suction gas thermistor sensor for accuracy

• EXV Board 1 (Alarm 41) or EXV Board 2 (Alarm 42) faulty channel

• EXV operation

• confirm maximum operating pressure set point

• refrigerant charge level

Alarm 65 — Interlock Failure (P.14) Criteria for Trip — The criteria are tested whether the unit is

ON or OFF. This alarm is generated if the lockout switch (located in the Energy Management Module) is closed during normal operation.

Action to be Taken — All compressors are shut down immediately without going through pumpdown. and is not allowed to start.

Reset Method — Automatic, first occurrence in 24 hours. Manual, if more than one occurrence in 24 hours.

Possible Causes — If this condition is encountered, check the following items:

• chilled water flow switch operation

• water flow. Be sure all water isolation valves are open and check water strainer for a restriction

• interlock wiring circuit

Page 99

• power supply to the pump

• control signal to the pump controller

• chilled water pump operation

• cooler pump contactor for proper operation Alarm 66 — Electrical Box Thermostat Failure/Reverse

Rotation (P.28) Criteria for Trip — The alarm criteria are checked whether the

unit is ON or OFF. If channel 15A on the MBB, which is used for field wired external pump interlock, is open then the alarm will be generated.

Action to be Taken — Unit shut down or note allowed to start. Reset Method — Automatic, if the channel is closed, the unit

will start normally. Possible Causes — If this condition is encountered, check the

following items:

• jumper wiring on TB5-1 and TB5-2 when channel is not in use

• external pump status

• field wiring for the external pump interlock

Alarm 67 — Loss of Communication with System Manager (P.29)

Criteria for Trip — The criterion is tested whether the unit is ON or OFF. This alarm is generated if the System Manager had established communications with the machine and is then lost for more than 2 minutes.

Action to be Taken — The action to be taken by the control depends on the configuration. If Auto Start when SM lost is enabled, (Cooler Heater Delta Spt, AU.SM=YES), then the unit will force the CCN Chiller Start Stop to ENBL and clear all forced points from the System Manager. The unit will revert to stand-alone operation.

Reset Method — Automatic, once communication is re-established.

Possible Causes — If this condition is encountered, check the following items:

• communication wiring

• power supply to the System Manager and unit controls

Alarm 68 — Master/Slave Communication Failure (P.30) Criteria for Trip — The criterion is tested whether the units are

ON or OFF and a master and slave machine has been configured, (Master/Slave Select, MSSL=1 and Master/Slave Select, MSSL=2). If communication is lost for more than 3 minutes, this alarm is generated.

Action to be Taken — Dual chiller control will be disabled and each unit will operate in Stand-Alone mode.

Reset Method — Automatic, once communication is re-established.

Possible Causes — If this condition is encountered, check the following items:

•CCN wiring

• control power to each Main Base Board, master and slave

• confirm correct configuration

Low Oil Pressure Alarm 69 — Circuit A (P.67)

Alarm 70 — Circuit B (P.68) Alarm 71 — Circuit C (P.69)

Criteria for Trip — The criteria are tested only when the compressor is ON. The alarm is generated if one of the following occurs, where:

oil = oil pressure transducer reading for the appropriate compressor

sp = suction pressure reading for the affected circuit dp = discharge pressure reading for the affected circuit

oil_sp1 = 0.7 x (dp-sp) + sp oil_sp2 = sp + 7.2 psi (15 seconds after start)

oil_sp2 = sp + 14.5 psi (45 seconds after start)

If the compressor starts with the ambient temperature (OAT less than 36° F [2° C] the oil pressure monitoring is delayed by 30 seconds.

Action to be Taken — The affected compressor will be stopped. The other compressors will continue to operate.

Reset Method — Manual. Possible Causes — If this condition is encountered, check the

following items:

• sensor wiring to the CPM Board

• board for a faulty channel

• faulty transducer

• plugged oil filter

• faulty oil solenoid valve coil

• stuck oil solenoid valve

• stuck check valve

• manual shut off valve to ensure it is fully open

• confirm unit configuration Max Oil Filter Differential Pressure Failure Alarm 72 — Circuit A (P.70)

Alarm 73 — Circuit B (P.71) Alarm 74 — Circuit C (P.72)

Criteria for Trip — The criterion is tested when the compressor has been operating for at least 5 seconds. The alarm is generated if the difference between the Circuit Discharge Pressure and the Compressor Oil Pressure is greater than 50 psi (345 kPa) for more than 30 seconds.

Action to be Taken — The affected compressor will be turned off.

Reset Method — Manual Possible Causes — If this condition is encountered, check the

following items:

• check the discharge and oil sensor wiring to the Main Base Board and CPM board

• boards for a faulty channel

• faulty transducer

• plugged oil filter

• faulty oil solenoid valve coil

• stuck oil solenoid valve

• stuck check valve

• manual shut off valve to ensure it is fully open

Check the power supply to the System Manager and unit controls.

High Oil Filter Pressure Drop Alarm 75 — Circuit A (P.84)

Alarm 76 — Circuit B (P.85) Alarm 77 — Circuit C (P.86)

Action to be Taken — The compressor will continue to run. Reset Method — Manual Possible Causes — If this condition is encountered, check the

following items:

• discharge and oil sensor wiring to the Main Base Board and CPM board

• boards for a faulty channel

• faulty transducer

• plugged oil filter

• faulty oil solenoid valve coil

• oil solenoid valve stuck open

• stuck check valve

• manual shut off valve to ensure it is fully open

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Check the power supply to the System Manager and unit controls.

Low Oil Level Failure Alarm 78 — Circuit A (P.75)

Alarm 79 — Circuit B (P.76) Alarm 80 — Circuit C (P.77)

Criteria for Trip — The criteria are tested whether the compressor is on or off. The alarm is generated if:

• The compressor is not running and an increase in capacity is required and the compressor is not started.

• The compressor is running and the oil level switch is open for more than 45 seconds.

Action to be Taken — The affected compressor will be turned off.

Reset Method — Automatic, when the oil level is elevated, first three times the alarm is tripped in a 24-hour period. Manual if alarm is tripped more than three times in a 24-hour period.

Possible Causes — If this condition is encountered, check the following items:

• oil level in the oil separator

• oil level switch wiring to the CPM board

• CPM board for a faulty channel

• faulty oil level switch

• oil solenoid valve stuck open

Alarm 81 — Master Chiller Configuration Error (MC.nn) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF. The units must be configured as a Master and Slave machine (Master/Slave Select, MSSL=1 and Master/ Slave Select, MSSL=2), and one of the following configura- tion errors has been found. The “nn” refers to the error code listed in Table 60.

Action to be Taken — Unit not allowed to start in Master Slave

control.

Reset Method — Automatic Possible Causes — If this condition is encountered, check the

following:

• CCN wiring.

• Control power to each Main Base Board, master and slave.

• Move to first position.

• Confirm unit configuration.

Alarm 82 — Initial Factory Configuration Required (FC.n0) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF. The alarm will be generated if the Unit Capacity Model, TONS=0.

Action to be Taken — The unit is not allowed to start. Reset Method — Automatic after factory configuration is com-

plete. The configuration must be manually completed. Possible Causes — If this condition is encountered, confirm

the unit configuration. Alarm 83 — Illegal Configuration (FC.nn) Criteria for Trip — The criterion is tested whether the unit is

ON or OFF. The alarm will be generated if the one of the following configuration errors is detected by the control. The “nn” refers to the error code listed in Table 61.

Action to be Taken — The unit is not allowed to start. Reset Method — Automatic after reconfiguration is completed. Possible Causes — If this condition is encountered, confirm

the unit configuration (None, UNIT). Alarm 84 — Unit is in Emergency Stop (P.31) Criteria for Trip — The criterion is tested whether the units are

ON or OFF and when the machine receives a Carrier Comfort Network

(CCN) command for an Emergency Stop.

Action to be Taken — Unit will stop, or will not allowed to start.

Reset Method — Automatic, once a return to normal command is received.

Possible Causes — If this condition is encountered, check for CCN Emergency Stop command.

Cooler Pump Fault Alarm 85 — Pump 1 Fault (P.32)

Alarm 86 — Pump 2 Fault (P.33) Criteria for Trip — The criterion is tested whether the units are

ON or OFF. This alarm will be generated if the cooler pump interlock opens. When starting the pump, the control must read an open circuit for 3 consecutive reads. If the pump is operating and the circuit opens, the alarm will be generated immediately.

Action to be Taken — The pump and machine will be shut down. If there is another pump available, the control will start that pump, restart the machine and clear the alarm. If no other pump is available, the unit will remain OFF.

Reset Method — Manual. Possible Causes — If this condition is encountered, check the

following items:

• interlock wiring circuit

• control signal to the pump controller

• cooler pump contactor for proper operation

• control voltage for proper voltage (on 208-volt systems, be sure the proper tap on TRAN1 is utilized)

Alarm 87 — Condenser Flow Switch Failure (P.15) NOTE: Alarm 87 is not used or supported. If this condition is

encountered, confirm machine configuration. Reclaim Operation Failure Alarm 88 — Circuit A (P.34)

Alarm 89 — Circuit B (P.35) Repeated High Discharge Gas Overrides Alarm 90 — Circuit A (P.37)

Alarm 91 — Circuit B (P.38) Alarm 92 — Circuit C (P.39)

Criteria for Trip — The criterion is tested when the circuit is ON. This alarm will be tripped if the circuit capacity is reduced more than 8 times in 30 minutes due to high discharge gas temperatures. If no override occurs in a 30-minute period, the counter is reset.

Action to be Taken — The affected circuit will be shut down. Reset Method — Automatic, after 30 minutes. If the alarm is

cleared via the Manual method, the counter will be reset to zero.

Possible Causes — If this condition is encountered, check the following items:

• Maximum Condensing Temperature (MCT) for the proper setting

• noncondensables in the refrigerant circuit

• condenser air re-circulation

• proper refrigerant charge (overcharged)

• operation beyond the limit of the machine

• condenser coils for debris or restriction

• condenser fans and motors for proper rotation and operation

• discharge service valve to be sure that it is open. Check the discharge pressure transducer for accuracy

• confirm unit configuration

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