Carrier MPW015-045 User Manual

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Page 1

30MPA,MPW015-045

Liquid Chillers with Scroll Compressors

and ComfortLink™ Controls

Controls, Start-Up, Operation,

Service, and Troubleshooting

AQUASNAP

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (elevated structures, mechanical rooms, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment.

When working on this equipment, observe precautions in the literature, and on tags, stickers, and labels attached to the equipment, and any other safety precautions that apply. 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. 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 outdoors 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.

CAUTION

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, always run fluid through heat exchanger when adding or removing refrigerant charge. Use appropriate brine solutions in cooler fluid loop to prevent the freezing of brazed plate heat exchanger 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 shutdown periods without taking precaution to remove all water from heat exchanger and optional hydronic system. Failure to properly protect the system from freezing may constitute abuse and may void warranty.

CAUTION

Compressors require specific rotation. Monitor control alarms during first compressor start up for reverse rotation protection. Damage to unit may result.

CAUTION

Refrigerant charge must be removed slowly to prevent loss of compressor oil that could result in compressor failure.

CAUTION

WARNING

DO NOT attempt to unbraze factory joints when servicing this equipment. Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrigerant lines. Cut lines with a tubing cutter as required when performing service. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to system. DO NOT re-use compressor oil. Damage to equipment or personal injury may result.

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

Catalog No. 04-53300053-01 Printed in U.S.A. Form 30MP-1T Pg 1 1-10 Replaces: New

Puron® refrigerant (R-410A) systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment. If service equipment is not rated for Puron refrigerant, equipment damage or personal injury may result.

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ENTER

CONTENTS

Page

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

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . 2

Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Main Base Board (MBB). . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Energy Management Module (EMM). . . . . . . . . . . . . . . . 14

Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . . . . 14

Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . . . . 14

Emergency On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 14

Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control Module Communication . . . . . . . . . . . . . . . . . . . 14

Carrier Comfort Network

Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

• COOLER LEAVING FLUID SENSOR

• COOLER ENTERING FLUID SENSOR

• CONDENSER LEAVING FLUID SENSOR

• CONDENSER ENTERING FLUID SENSOR

• COMPRESSOR RETURN GAS TEMPERATURE SENSOR

• OUTDOOR-AIR TEMPERATURE SENSOR

• DUAL LEAVING WATER TEMPERATURE SENSOR

• REMOTE SPACE TEMPERATURE SENSOR

Energy Management Module. . . . . . . . . . . . . . . . . . . . . . . 21

Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . . . . . 21

Condenser Flow Protection . . . . . . . . . . . . . . . . . . . . . . . . 21

Thermostatic Expansion Valves (TXV) . . . . . . . . . . . . . 21

Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• LEAD/LAG DETERMINATION

• CAPACITY CONTROL OVERRIDES

Operation of Machine Based on Control Method

and Cooling Set Point Selection Settings . . . . . . . . 24

Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Service Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cooler Pump Sequence of Operation . . . . . . . . . . . . . . 25

Condenser Pump/Condenser Fan Output

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Configuring and Operating Dual Chiller Control. . . . 25

Temperature Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

• DEMAND LIMIT (2-Stage Switch Controlled)

• EXTERNALLY POWERED DEMAND LIMIT

(4 to 20 mA Controlled)

• DEMAND LIMIT (CCN Loadshed Controlled)

Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . . . . . . 32

PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33,34

System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

START-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . 34-36

Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Check Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . 34

Operating Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

• TEMPERATURES

• VOLTAGE — ALL UNITS

OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 36

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-44

Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

• CONTROL COMPONENTS

Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 36

30MPW Condenser and 30MP Cooler . . . . . . . . . . . . . . 36

• BRAZED-PLATE COOLER AND CONDENSER

HEAT EXCHANGER REPLACEMENT

• BRAZED-PLATE COOLER AND CONDENSER

HEAT EXCHANGER CLEANING

Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Check Refrigerant Feed Components . . . . . . . . . . . . . . 37

• FILTER DRIER

• MOISTURE-LIQUID INDICATOR

• THERMOSTATIC EXPANSION VALVE (TXV)

Interface . . . . . . . . . . . . . . . . 14

• MINIMUM LOAD VALVE

• PRESSURE RELIEF DEVICES

Check Unit Safeties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chilled Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . 39

Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Replacing Defective Modules. . . . . . . . . . . . . . . . . . . . 43

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,45

Recommended Maintenance Schedule . . . . . . . . . . . . 44

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-52

Complete Unit Stoppage and Restart . . . . . . . . . . . . . . 44

• GENERAL POWER FAILURE

• UNIT ENABLE-OFF-REMOTE CONTACT SWITCH IS OFF

• CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN

• OPEN 24-V CONTROL CIRCUIT BREAKERS

• COOLING LOAD SATISFIED

• THERMISTOR FAILURE

• LOW SATURATED SUCTION

• COMPRESSOR SAFETIES

Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

APPENDIX A — LOCAL DISPLAY TABLES . . . . . . .53-64

APPENDIX B — CCN TABLES. . . . . . . . . . . . . . . . . . . .65-72

START-UP CHECKLIST FOR 30MP LIQUID

CHILLER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-8

GENERAL

This publication contains Start-Up, Service, Controls, Oper-

ation, and Troubleshooting information for the 30MPW watercooled chillers and the 30MPA air-cooled chillers. See Table 1. These liquid chillers are equipped with ComfortLink controls and conventional thermostatic expansion valves (TXVs). The 30MPA units and the 30MPW units with optional medium temperature brine are also equipped with liquid line solenoid valves (LLSVs).

CAUTION

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

Table 1 — Unit Sizes

UNIT MODEL NOMINAL TONS 30MPA,MPW015 15 30MPA,MPW020 20 30MPA,MPW030 30 30MPA,MPW040 40 30MPA,MPW045 45

Conventions Used in This Manual — The follow-

ing conventions for discussing configuration points for the local display (scrolling marquee or Navigator™ accessory) will be used in this manual.

Point names will be written with the mode name first, then any sub-modes, then the point name, each separated by an arrow symbol (. Names will also be shown in bold and italics. As an example, the Minimum Load Valve Select Point, which is located in the Configuration mode, Option 1 sub-mode, would be written as ConfigurationOPT1 MLV.S.

This path name will show the user how to navigate through the local display to reach the desired configuration. The user would scroll through the modes and sub-modes using the

and keys. The arrow symbol in the path name represents pressing to move into the next level of the menu structure.

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ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

Run Status

Service Test

Temperature

Pressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

Operating Modes

Alarms

Alarm Status

ENTER

MODE

ESCAPE

Fig. 1 — Scrolling Marquee Display

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

When a value is included as part of the path name, it will be shown at the end of the path name after an equals sign. If the value represents a configuration setting, an explanation will be shown in parenthesis after the value. As an example, ConfigurationOPT1MLV.S = 1 (Minimum Load Valve Select).

Pressing the and keys simultaneously will scroll an expanded text description of the point name or value across the display. The expanded description is shown in the local display tables but will not be shown with the path names in text.

The CCN (Carrier Comfort Network

) point names are also referenced in the local display tables for users configuring the unit with CCN software instead of the local display. The CCN tables are located in Appendix B of the manual.

Basic Control Usage

SCROLLING MARQUEE DISPLAY — The scrolling marquee display is the standard interface display to the ComfortLink Control System for 30MP units. 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 the highest operating level is displayed to move through the top 11 mode levels indicated by LEDs (light emitting diodes) on the left side of the display. See Fig. 1 and Tables 2-14.

Once within a mode or sub-mode, pressing the and keys simultaneously will put the scrolling marquee display into expanded text mode where the full meaning of all sub-modes, items and their values can be displayed for the current selection. Press the and keys to return the scrolling marquee display to its default menu of rotating display items (those items in Run Status 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.

NOTE: When the Language Selection (Configuration DISPLANG), variable is changed, all appropriate display expansions will immediately change to the new language. No power-off or control reset is required when reconfiguring languages.

When a specific item is located, the item name alternates with the value. Press the key at a changeable item and the value will be displayed. Press again and the value will begin to flash indicating that the value can be changed. Use the up and down arrow keys to change the value, and confirm the value by pressing the key.



VIEW).



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 ‘PASS’ and ‘WORD’ will alternate on the display when required. The default password is 0111. Press and the 1111 password will be displayed. Press

again and the first digit will begin to flash. Use the arrow keys to change the 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 ComfortWORKS

, ComfortVIEW™

and Service Tool.

See Tables 2-14 and Appendix A for further details.

ACCESSORY NAVIGATOR™ DISPLAY MODULE — The Navigator module provides a mobile user interface to the

ComfortLink™ control system, which is only available as a field-installed accessory. 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 to move through the top 11 mode levels indicated by LEDs on the left side of the display. See Fig. 2.

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

rently 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

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 1111. Use the arrow keys to change the number



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and press to enter the digit. Continue with the re-

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

Fig. 2 — Accessory Navigator™ Display Module

maining digits of the password. The password can only be changed through CCN operator interface software such as ComfortWORKS, ComfortVIEW and Service Tool.

Adjusting the Contrast

— The contrast of the display can be adjusted to suit ambient conditions. To adjust the contrast of the Navigator module, press the key until the display reads, “Select a menu item.” Using the arrow keys move to the Configuration mode. Press to obtain access to this mode. The display will read:

> TEST OFF METR OFF LANG ENGLISH

Pressing 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. 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 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, press the key until the display reads, “Select a menu item.” Using the arrow keys move to the

Table 2 — Scrolling Marquee Display Menu Structure*

MODE

SUB-MODE

LEGEND Ckt — Circuit *Throughout this text, the location of items in the menu structure will be

described in the following format: Item Expansion (Mode Name

RUN

STATUS

Auto

View of

Run Status

(VIEW)

Unit Run

Hour and

Start

(RUN)

Circuit and

Compressor

Run Hours

(HOUR)

Compressor

Starts

(STRT)

Preventive

Maintenance

(PM)

Software

Ver si on (VERS)

SERVICE

TEST

Service

Te s t M o d e

(TEST)

Outputs

and Pumps

(OUTS)

Ciruit A Comp

Te st

(CMPA)



TEMPERATURES PRESSURES

Unit Temperatures

Temperatures

Sub-mode NameITEM)

(UNIT)

Circuit A

(CIR.A)

Pressures

Circuit A (PRC.A)

SET

POINTS

Cooling

Setpoints

(COOL)

Head

Pressure

Setpoint

(HEAD)

Brine

Free ze

Setpoint

(FRZ)

Configuration mode. Press to obtain access to this mode. The display will read:

> TEST OFF METR OFF LANG ENGLISH

Pressing will cause the “OFF” to flash. Use the up

or down arrow keys 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. 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.

Comfort

Link

MODE

Alarm Status

Run S

tatus

Service Test

Temperatures

ressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

ESC

Operating Modes

Alarm

ENTER

INPUTS OUTPUTS CONFIGURATION

General

Inputs

(GEN.I)

Circuit Inputs

(CRCT)

4-20mA

Inputs (4-20)

General Outputs

(GEN.O)

Outputs

Circuit A

(CIR.A)

For example, using the language selection item: Language Selection (Configuration

Display

Configuration

(DISP)

Unit

Configuration

(UNIT)

Unit Options 1

Hardware

(OPT1)

Unit Options 2

Controls

(OPT2)

CCN Network

Configuration

(CCN)

Reset Cool Temp

(RSET)

Set Point and

Ramp Load

(SLCT) Service

Configuration

(SERV)

Broadcast

Configuration

(BCST)

Date, Day,

Schedules

Schedule



DISPLANG)

TIME

CLOCK

Time of

(TIME)

Month,

and Year

(DATE)

Daylight Savings

Time

(DST)

Local

Holiday

(HOL.L)

Number

(SCH.N)

Local Occupancy

(SCH.L)

Override

(OVR)

Day

OPERATING

MODES

Modes

(MODE)

ALARMS

Current (CRNT)

Reset

Alarms

(RCRN)

Alarm

History

(HIST)

Page 5

Table 3 — Run Status Mode and Sub-Mode Directory

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY SUB-ITEM DISPLAY SUB-ITEM DISPLAY

VIEW EWT XXX.X F ENTERING FLUID TEMP

LWT XXX.X F LEAVING FLUID TEMP

SETP XXX.X F ACTIVE SETPOINT

CTPT XXX.X F CONTROL POINT

LOD.F XXX LOAD/UNLOAD FACTOR

STAT X CONTROL MODE 0 = Service Test

OCC YES/NO OCCUPIED

MODE YES/NO OVERRIDE MODES IN EFFECT

CAP XXX % PERCENT TOTAL CAPACITY

STGE X REQUESTED STAGE

ALRM XXX CURRENT ALARMS & ALERTS

TIME XX.XX TIME OF DAY 00.00-23.59

MNTH XX MONTH OF YEAR 1 = January, 2 = February, etc.

DATE XX DAY OF MONTH 01- 31

ITEM

EXPANSION

COMMENT

1 = Off Local 2 = Off CCN 3 = Off Time 4 = Off Emrgcy 5 = On Local 6 = On CCN 7 = On Time 8 = Ht Enabled 9 = Pump Delay

YEAR XX YEAR OF CENTURY

RUN HRS.U XXXX HRS MACHINE OPERATING HOURS

STR.U XXXX MACHINE STARTS

HR.P1 XXXX.X PUMP 1 RUN HOURS

HR.P2 XXXX.X PUMP 2 RUN HOURS

HOUR HR.A1 XXXX HRS COMPRESSOR A1 RUN HOURS

HR.A2 XXXX HRS COMPRESSOR A2 RUN HOURS

HR.A3 XXXX HRS COMPRESSOR A3 RUN HOURS

STRT ST.A1 XXXX COMPRESSOR A1 STARTS

ST.A2 XXXX COMPRESSOR A2 STARTS

ST.A3 XXXX COMPRESSOR A3 STARTS

STRN STRAINER MAINTENANCE

SI.ST XXXX HRS STRAINER SRVC INTERVAL

S.T.DN XXXX HRS STRAINER SRVC COUNTDOWN

S.T.MN YES/NO STRAINER MAINT. DONE User Entry

ST.DT STRAINER MAINT. DATES

S.T.M0 MM/DD/YY HH:MM

S.T.M1 MM/DD/YY HH:MM

S.T.M2 MM/DD/YY HH:MM

S.T.M3 MM/DD/YY HH:MM

S.T.M4 MM/DD/YY HH:MM

Page 6

Table 3 — Run Status Mode and Sub-Mode Directory (cont)

ENTER

ESCAPE

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY SUB-ITEM DISPLAY SUB-ITEM DISPLAY

VERS AUX CESR131333-xx-xx xx-xx is Version number*

MBB CESR131279-xx-xx xx-xx is Version number*

EMM CESR131174-xx-xx xx-xx is Version number*

MARQ CESR131171-xx-xx xx-xx is Version number*

NAVI CESR130227-xx-xx xx-xx is Version number*

*Press and simultaneously to obtain version number.

ITEM

EXPANSION

COMMENT

Table 4 — Service Test Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

TEST ON/OFF SERVICE TEST MODE To Enable Service Test Mode,

OUTS OUTPUTS AND PUMPS

CLR.P ON/OFF COOLER PUMP RELAY

CND.P ON/OFF CONDENSER PUMP

UL.TM 0 to 15 COMP A1 UNLOAD TIME

CC.H ON/OFF CRANKCASE HEATER

CW.VO ON/OFF CONDENSER VALVE OPEN

ITEM

EXPANSION

COMMENT

move Enable/Off/Remote Contact switch to OFF. Change TEST to ON. Move switch to ENABLE.

CW.VC ON/OFF CONDENSER VALVE CLOSE

LL.SV ON/OFF LIQUID LINE SOLENOID

RMT.A ON/OFF REMOTE ALARM RELAY

CMPA CIRCUIT A COMPRESSOR TEST

CC.A1 ON/OFF COMPRESSOR A1 RELAY

UL.TM 0 to 15 COMP A1 UNLOAD TIME

CC.A2 ON/OFF COMPRESSOR A2 RELAY

CC.A3 ON/OFF COMPRESSOR A3 RELAY

MLV ON/OFF MINIMUM LOAD VALVE RELAY

Table 5 — Temperature Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

UNIT ENT AND LEAVE UNIT TEMPS

CEWT XXX.X F COOLER ENTERING FLUID

CLWT XXX.X F COOLER LEAVING FLUID

CDET XXX.X F CONDENSER ENTERING FLUID

CDLT XXX.X F CONDENSER LEAVING FLUID

OAT XXX.X F OUTSIDE AIR TEMPERATURE

SPT XXX.X F SPACE TEMPERATURE

ITEM

EXPANSION

COMMENT

DLWT XXX.X F LEAD/LAG LEAVING FLUID

Page 7

Table 5 — Temperature Mode and Sub-Mode Directory (cont)

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

CIR.A TEMPERATURES CIRCUIT A

SCT.A XXX.X F SATURATED CONDENSING TMP

SST.A XXX.X F SATURATED SUCTION TEMP

RGT.A XXX.X F COMPR RETURN GAS TEMP

D.G AS XXX.X F DISCHARGE GAS TEMP

SH.A XXX.X ^F SUCTION SUPERHEAT TEMP

ITEM

EXPANSION

Table 6 — Pressure Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

PRC.A PRESSURES CIRCUIT A

DP.A XXX.X PSIG DISCHARGE PRESSURE

SP.A XXX.X PSIG SUCTION PRESSURE

ITEM

EXPANSION

Table 7 — Set Points Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

COOL COOLING SETPOINTS

CSP.1 XXX.X F COOLING SETPOINT 1 Default: 44 F

CSP.2 XXX.X F COOLING SETPOINT 2 Default: 44 F

CSP.3 XXX.X F ICE SETPOINT Default: 32 F

HEAD HEAD PRESSURE SETPOINTS

H.DP XXX.X F HEAD SETPOINT Default: 95 F

FRZ BRINE FREEZE SETPOINT

BR.FZ XXX.X F BRINE FREEZE POINT Default: 34 F

ITEM

EXPANSION

COMMENT

Table 8 — Inputs Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

GEN.I GENERAL INPUTS

STST STRT/STOP START/STOP SWITCH

FLOW ON/OFF COOLER FLOW SWITCH

CD.FL OPEN/CLSE CONDENSER FLOW SWITCH

DLS1 ON/OFF DEMAND LIMIT SWITCH 1

DLS2 ON/OFF DEMAND LIMIT SWITCH 2

ICED ON/OFF ICE DONE

DUAL ON/OFF DUAL SETPOINT SWITCH

CRCT CIRCUITS INPUTS

FKA1 ON/OFF COMPRESSOR A1 FEEDBACK

FKA2 ON/OFF COMPRESSOR A2 FEEDBACK

FKA3 ON/OFF COMPRESSOR A3 FEEDBACK

4-20

DMND XX.X MA 4-20 MA DEMAND SIGNAL

RSET XX.X MA 4-20 MA RESET SIGNAL

CSP XX.X MA 4-20 MA COOLING SETPOINT

ITEM

EXPANSION

4-20 MA INPUTS

COMMENT

Page 8

Table 9 — Outputs Mode and Sub-Mode Directory

ENTER

SUB-MODE

GEN.O GENERAL OUTPUTS

CIR.A OUTPUTS CIRCUIT A

KEYPAD

ENTRY

ITEM DISPLAY

C.LWP ON/OFF COOLER PUMP RELAY

C.DWP ON/OFF CONDENSER PUMP

ALRM ON/OFF ALARM RELAY

CDWO ON/OFF CONDENSER VALVE OPEN

CDWC ON/OFF CONDENSER VALVE CLOSE

CC.A1 ON/OFF COMPRESSOR A1 RELAY

D.SOL ON/OFF DIGITAL SCROLL SOLENOID

CC.A2 ON/OFF COMPRESSOR A2 RELAY

CC.A3 ON/OFF COMPRESSOR A3 RELAY

CCH ON/OFF CRANKCASE HEATER RELAY

LLSV ON/OFF LIQUID LINE SOLENOID

MLV.R ON/OFF MINIMUM LOAD VALVE RELAY

EXPANSION

Table 10 — Configuration Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

DISP DISPLAY CONFIGURATION

TEST ON/OFF TEST DISPLAY LEDS

METR ON/OFF METRIC DISPLAY

LANG X LANGUAGE SELECTION Default: 0

PAS.E ENBL/DSBL PASSWORD ENABLE Default: Enable

PASS xxxx SERVICE PASSWORD D e fa u lt : 1111

UNIT UNIT CONFIGURATION

TYPE x UNIT TYPE

SIZE XX UNIT SIZE

SZA.1 XX COMPRESSOR A1 SIZE Unit Dependent

SZA.2 XX COMPRESSOR A2 SIZE Unit Dependent

SZA.3 XX COMPRESSOR A3 SIZE Unit Dependent

ITEM

EXPANSION

ITEM

Off = English On = Metric

0 = English 1 = Espanol 2 = Francais 3 = Portuguese

2=WaterCooled 3=Split System

COMMENT

A1.TY No/Yes COMPRESSOR A1 DIGITAL?

MAX.T 0 to 15 MAXIMUM A1 UNLOAD TIME

Default: Yes (A1 Digital Scroll)

Default: 7

Page 9

Table 10 — Configuration Mode and Sub-Mode Directory (cont)

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

OPT1 UNIT OPTIONS 1 HARDWARE

FLUD X COOLER FLUID

MLV.S YES/NO MINIMUM LOAD VALVE SELECT Default: No

R.G.EN ENBL/DSBL RETURN GAS SENSOR ENABLE

OAT.E ENBL/DSBL ENABLE OAT SENSOR

D.G.EN ENBL/DSBL DISCHARGE GAS TEMP ENABLE

CSB.E ENBL/DSBL CSB BOARDS ENABLE

CPC ON/OFF COOLER PUMP CONTROL Default: On

PM.DY XX MIN COOLER PUMP SHUTDOWN DLY 0 to 10 minutes, Default: 1 min.

DPME x ENABLE CONDENSER PUMP 0 to 2

DFLS ENBL/DSBL ENABLE COND FLOW SWITCH

CDWS ENBL/DSBL ENABLE COND WTR SENSORS

OPT2 UNIT OPTIONS 2 CONTROLS

CTRL X CONTROL METHOD Default: Switch

LCWT XX.X F HIGH LCW ALERT LIMIT

DELY XX MINUTES OFF TIME

ICE.M ENBL/DSBL ICE MODE ENABLE Default: Disable

CCN CCN NETWORK CONFIGURATION

CCNA XXX CCN ADDRESS

CCNB XXX CCN BUS NUMBER

BAUD X CCN BAUD RATE Default: 9600

RSET RESET COOL TEMP

CRST X COOLING RESET TYPE Default: No Reset

MA.DG XX.X F 4-20 - DEGREES RESET

RM.NO XXX.X F REMOTE - NO RESET TEMP

RM.F XXX.X F REMOTE - FULL RESET TEMP

RM.DG XX.X

F REMOTE - DEGREES RESET

RT.NO XXX.X F RETURN - NO RESET TEMP

RT.F XXX.X F RETURN - FULL RESET TEMP

RT.DG XX.X F RETURN - DEGREES RESET

DMDC X DEMAND LIMIT SELECT Default: None

DM20 XXX % DEMAND LIMIT AT 20 MA

SHNM XXX LOADSHED GROUP NUMBER

SHDL XXX % LOADSHED DEMAND DELTA

SHTM XXX MAXIMUM LOADSHED TIME

DLS1 XXX % DEMAND LIMIT SWITCH 1

DLS2 XXX % DEMAND LIMIT SWITCH 2

ITEM

EXPANSION

COMMENT

Default: Water 1 = Water 2 = Medium Temperature Brine

0 = Enable/Off/Remote Switch 2 = Occupancy 3 = CCN Control

Default: 60

Range: 2 to 60 F

Default: 0 Minutes Range: 0 to 15 Minutes

Default: 1 Range: 1 to 239

Default: 0 Range: 0 to 239

1 = 2400 2 = 4800 3 = 9600 4 = 19,200 5 = 38,400

0 = No Reset 1 = 4 to 20 mA Input 2 = Outdoor Air Temperature 3 = Return Fluid 4 = Space Temperature

Default: 0.0F Range: –30 to 30F

Default: 125F (51.7C) Range: 0° to 125F

Default: 0.0F (-17.8C) Range: 0 to 125F

Default: 0.0F Range: –30 to 30F

Default: 10.0F (5.6C) Range: 0 to 125F COOLER T

Default: 0.0F (0.0C) Range: 0 to 125F COOLER T

Default: 0.0F Range: –30 to 30F (–34.4 to -1.1 C)

0 = None 1 = Switch 2 = 4 to 20 mA Input 3 = CCN Loadshed

Default: 100% Range: 0 to 100%

Default: 0 Range: 0 to 99

Default: 0% Range: 0 to 60%

Default: 60 minutes Range: 0 to 120 minutes

Default: 80% Range: 0 to 100%

Default: 50% Range: 0 to 100%

Page 10

Table 10 — Configuration Mode and Sub-Mode Directory (cont)

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

LLEN ENBL/DSBL LEAD/LAG CHILLER ENABLE Default: Disable

MSSL SLVE/MAST MASTER/SLAVE SELECT Default: Master

SLVA XXX SLAVE ADDRESS

RSET (cont)

LLBL X LEAD/LAG BALANCE SELECT

LLBD XXX LEAD/LAG BALANCE DELTA

LLDY XXX LAG START DELAY

PARA YES PARALLEL CONFIGURATION Default: YES (CANNOT BE CHANGED)

SLCT SETPOINT AND RAMP LOAD

CLSP X COOLING SETPOINT SELECT Default: Single

RL.S ENBL/DSBL RAMP LOAD SELECT Default: Enable

CRMP X.X COOLING RAMP LOADING

SCHD XX SCHEDULE NUMBER

Z.GN X.X DEADBAND MULTIPLIER

SERV SERVICE CONFIGURATION

EN.A1 ENBL/DSBL ENABLE COMPRESSOR A1 Unit dependent

EN.A2 ENBL/DSBL ENABLE COMPRESSOR A2 Unit dependent

EN.A3 ENBL/DSBL ENABLE COMPRESSOR A3 Unit dependent

REV.R ENBL/DSBL REVERSE ROTATION ENABLE Default: Enable

BCST BROADCAST CONFIGURATION

T.D.BC ON/OFF CCN TIME/DATE BROADCAST

OAT.B ON/OFF CCN OAT BROADCAST

G.S.BC ON/OFF GLOBAL SCHEDULE BROADCAST

BC.AK ON/OFF CCN BROADCAST ACK’ER

ITEM

EXPANSION

COMMENT

Default: 0 Range: 0 to 239

Default: Master Leads 0 = Master Leads 1 = Slave Leads 2 = Automatic

Default: 168 hours Range: 40 to 400 hours

Default: 5 minutes Range: 0 to 30 minutes

0 = Single 1 = Dual Switch 2 = Dual CCN Occupied 3 = 4 to 20 mA Input (requires

EMM)

Default: 1.0 Range: 0.2 to 2.0

Default: 1 Range: 1 to 99

Default: 1.0 Range: 1.0 to 4.0

Page 11

Table 11 — Time Clock Mode and Sub-Mode Directory

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY SUB-ITEM DISPLAY

TIME TIME OF DAY

HH.MM XX.XX HOUR AND MINUTE Military (00:00 – 23:59)

DATE MONTH,DATE,DAY AND YEAR

MNTH XX MONTH OF YEAR 1-12 (1 = January, 2 = February, etc)

DOM XX DAY OF MONTH Range: 01-31

DAY X DAY OF WEEK 1-7 (1 = Monday, 2 = Tuesday, etc)

YEAR XXXX YEAR OF CENTURY

DST DAYLIGHT SAVINGS TIME

STR.M XX MONTH Default: 4, Range 1 – 12

STR.W X WEEK Default: 1, Range 1 – 5

STR.D X DAY Default: 7, Range 1 – 7

MIN.A XX MINUTES TO ADD Default: 60, Range 0 – 99

STP.M XX MONTH Default: 10, Range 1 – 12

STP.W XX WEEK Default: 5, Range 1 – 5

STP.D XX DAY Default: 7, Range 1 – 7

MIN.S XX MINUTES TO SUBTRACT Default: 60, Range 0 – 99

HOL.L LOCAL HOLIDAY SCHEDULES HD.01 through HD.30

MON XX HOLIDAY START MONTH Range 0 – 12

DAY XX START DAY Range 0 – 31

ITEM

EXPANSION

COMMENT

LEN XX DURATION (DAYS) Range 0 - 99

SCH.N XX SCHEDULE NUMBER Default: 1, Range 1 – 99

SCH.L LOCAL OCCUPANCY SCHEDULE

PER.1 OCCUPANCY PERIOD 1*

OCC.1 XX:XX PERIOD OCCUPIED TIME Military (00:00 – 23:59)

UNC.1 XX.XX PERIOD UNOCCUPIED TIME Militar y (00:00 – 23:59)

MON.1 YES/NO MONDAY IN PERIOD

TUE.1 YES/NO TUESDAY IN PERIOD

WED.1 YES/NO WEDNESDAY IN PERIOD

THU.1 YES/NO THURSDAY IN PERIOD

FRI.1 YES/NO FRIDAY IN PERIOD

SAT.1 YES/NO SATURDAY IN PERIOD

SUN.1 YES/NO SUNDAY IN PERIOD

HOL.1 YES/NO HOLIDAY IN PERIOD

OVR SCHEDULE OVERRIDE

OVR.T X TIMED OVERRIDE HOURS Default: 0, Range 0-4 hours

OVR.L X OVERRIDE TIME LIMIT Default: 0, Range 0-4 hours

T.OVR YES/NO TIMED OVERRIDE User Entry

* Repeats for Occupancy Periods 2 through 8.

Page 12

Table 12 — Operating Mode and Sub-Mode Directory

ENTER

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

MODE MODES CONTROLLING UNIT

MD01 ON/OFF CSM CONTROLLING CHILLER

MD03 ON/OFF MASTER/SLAVE CONTROL

MD05 ON/OFF RAMP LOAD LIMITED

MD06 ON/OFF TIMED OVERRIDE IN EFFECT

MD07 ON/OFF LOW COOLER SUCTION TEMPA

MD09 ON/OFF SLOW CHANGE OVERRIDE

MD10 ON/OFF MINIMUM OFF TIME ACTIVE

MD13 ON/OFF DUAL SETPOINT

MD14 ON/OFF TEMPERATURE RESET

MD15 ON/OFF DEMAND LIMITED

MD16 ON/OFF COOLER FREEZE PROTECTION

MD17 ON/OFF LOW TEMPERATURE COOLING

MD18 ON/OFF HIGH TEMPERATURE COOLING

MD19 ON/OFF MAKING ICE

MD20 ON/OFF STORING ICE

ITEM

EXPANSION

COMMENT

MD21 ON/OFF HIGH SCT CIRCUIT A

MD23 ON/OFF MINIMUM COMP ON TIME

MD24 ON/OFF PUMP OFF DELAY TIME

LEGEND

CSM — Chillervisor System Manager SCT — Saturated Condensing Temperature WSM — Water System Manager

Table 13 — Alarms Mode and Sub-Mode Directory

SUB-MODE

KEYPAD

ENTRY

ITEM

CRNT AXXX OR TXXX CURRENTLY ACTIVE ALARMS

RCRN YES/NO RESET ALL CURRENT ALARMS

HIST AXXX OR TXXX ALARM HISTORY

ITEM

EXPANSION

COMMENT

Alarms are shown as AXXX. Alerts are shown as TXXX.

Page 13

Table 14 — Operating Modes

MODE

NO.

01 CSM CONTROLLING CHILLER Chillervisor System Manager (CSM) is controlling the chiller.

03 MASTER/SLAVE CONTROL Dual Chiller control is enabled.

10 MINIMUM OFF TIME ACTIVE Chiller is being held off by Minutes Off Time (Configuration

ITEM EXPANSION DESCRIPTION

RAMP LOAD LIMITED Ramp load (pull-down) limiting in effect. In this mode, the rate at which leaving fluid temperature

TIMED OVERRIDE IN EFFECT Timed override is in effect. This is a 1 to 4 hour temporary override of the programmed

LOW COOLER SUCTION TEMPA Circuit A cooler Freeze Protection mode. At least one compressor must be on, and the Sat-

SLOW CHANGE OVERRIDE Slow change override is in effect. The leaving fluid temperature is close to and moving

DUAL SETPOINT Dual Set Point mode is in effect. Chiller controls to Cooling Set Point 1 (Set Points

TEMPERATURE RESET Temperature reset is in effect. In this mode, chiller is using temperature reset to adjust leav-

DEMAND LIMITED Demand limit is in effect. This indicates that the capacity of the chiller is being limited by

COOLER FREEZE PROTECTION Cooler fluid temperatures are approaching the Freeze point (see Alarms and Alerts section

LOW TEMPERATURE COOLING Chiller is in Cooling mode and the rate of change of the leaving fluid is negative and

HIGH TEMPERATURE COOLING Chiller is in Cooling mode and the rate of change of the leaving fluid is positive and increasing.

MAKING ICE Chiller is in an unoccupied mode and is using Cooling Set Point 3 (Set Points

STORING ICE Chiller is in an unoccupied mode and is controlling to Cooling Set Point 2 (Set Points

HIGH SCT CIRCUIT A Chiller is in a Cooling mode and the Saturated Condensing Temperature (SCT) is greater than

MINIMUM COMP ON TIME Cooling load may be satisfied, however control continues to operate compressor to ensure

PUMP OFF DELAY TIME Cooling load is satisfied, however cooler pump continues to run for the number of minutes set

is dropped is limited to a predetermined value to prevent compressor overloading. See Cooling Ramp Loading (Configuration desired, to any rate from 0.2° F to 2° F (0.1° to 1° C)/minute.

schedule, forcing unit to Occupied mode. Override can be implemented with unit under Local (Enable) or CCN (Carrier Comfort Network

urated Suction Temperature is not increasing greater than 1.1° F (0.6° C) in 10 seconds. If the saturated suction temperature is less than the Brine Freeze Point (Set Points



BR.FZ) minus 6° F (3.4° C) and less than the leaving fluid temperature minus 14° F (7.8° C) for 2 minutes, a stage of capacity will be removed from the circuit. Or, If the saturated suction temperature is less than the Brine Freeze Point minus 14° F (7.8° C), for 90 seconds, a stage of capacity will be removed from the circuit. The control will continue to decrease capacity as long as either condition exists.

towards the control point.



CSP.1) during occupied periods and Cooling Set Point 2 (Set PointsCOOLCSP.2) during unoccupied periods.

ing fluid set point upward and is currently controlling to the modified set point. The set point can be modified based on return fluid, outdoor-air-temperature, space temperature, or 4 to 20 mA signal.

demand limit control option. Because of this limitation, the chiller may not be able to produce the desired leaving fluid temperature. Demand limit can be controlled by switch inputs or a 4 to 20 mA signal.

for definition). The chiller will be shut down when either fluid temperature falls below the Freeze point.

decreasing faster than -0.5° F per minute. Error between leaving fluid and control point exceeds fixed amount. Control will automatically unload the chiller if necessary.

Error between leaving fluid and control point exceeds fixed amount. Control will automatically load the chiller if necessary to better match the increasing load.



CSP.3) to make ice. The ice done input to the Energy Management Module (EMM) is open.



CSP.2). The ice done input to the Energy Management Module (EMM) is closed.

the calculated maximum limit. No additional stages of capacity will be added. Chiller capacity may be reduced if SCT continues to rise to avoid high-pressure switch trips by reducing condensing temperature.

proper oil return. May be an indication of oversized application, low fluid flow rate or low loop volume.

by the configuration variable Cooler Pump Shutdown Delay (Configuration



PM.DY).



SLCTCRMP). The pull-down limit can be modified, if

) control. Override expires after each use.



OPT2DELY).





COOL



OPT1

FRZ

COOL



COOL



Page 14

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 sections below. See Fig. 3 for a typical control box drawing. See Fig. 4 and 5 for control schematics.

The 30MP liquid scroll chillers contain the

Main Base Board (MBB) — See Fig. 6. The MBB is

the heart of the ComfortLink control system. It contains the major portion of operating software and controls the operation of the machine. The MBB continuously monitors input/output channel information received from its inputs and from all other modules. The MBB receives inputs from the discharge and suction pressure transducers and thermistors. See Table 15. The MBB also receives the feedback inputs from each compressor current sensor board and other status switches. See Table 16. The MBB also controls several outputs. Relay outputs controlled by the MBB are shown in Table 17. Information is transmitted between modules via a 3-wire communication bus or LEN (Local Equipment Network). The CCN (Carrier Comfort Network) bus is also supported. Connections to both LEN and CCN buses are made at the LVT (low voltage terminal).

Energy Management Module (EMM) — The EMM

module is available as a factory-installed option or as a fieldinstalled accessory. The EMM module receives 4 to 20 mA inputs for the leaving fluid temperature reset, cooling set point and demand limit functions. The EMM module also receives the switch inputs for the field-installed 2-stage demand limit and ice done functions. The EMM module 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.

Current Sensor Board (CSB) — The CSB is used to

monitor the status of the compressors by measuring current and providing an analog input to the main base board (MBB).

Enable/Off/Remote Contact Switch — The Enable/

Off/Remote Contact switch is a 3-position switch used to control the chiller. When switched to the Enable position the chiller is under its own control. Move the switch to the Off position to shut the chiller down. Move the switch to the Remote Contact position and 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. See Fig. 7.

Emergency On/Off Switch — The Emergency On/Off

switch should only be used when it is required to shut the chiller off immediately. Power to the MBB, EMM, and marquee display is interrupted when this switch is off and all outputs from these modules will be turned off. See Fig. 7.

Board Addresses — The main base board (MBB) has a

3-position instance jumper that must be set to ‘1.’ The EMM board has 4-position DIP switches. All switches are set to ‘On’ for all boards except the AUX2 board. The AUX2 board DIP switch settings are shown on the wiring schematic.

Control Module Communication

RED LED — Proper operation of the control boards can be visually checked by looking at the red status LEDs (light-emitting diodes). When operating correctly, the red status LEDs should be blinking 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 — The MBB has one green LED. The Local Equipment Network (LEN) LED should always be blinking whenever power is on. All other boards have a LEN LED which should be blinking whenever power is on. Check LEN connections for potential communication errors at the board J3 and/or J4 connectors. Communication between modules is accomplished by a 3-wire sensor bus. These 3 wires run in parallel from module to module. The J4 connector on the MBB provides both power and communication directly to the marquee display only.

YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication.

Carrier Comfort Network® (CCN) Interface —

The 30MP chiller units can be connected to the CCN if desired. The communication bus wiring is a shielded, 3-conductor cable with drain wire and is supplied and installed in the field. See Table 18. 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. This is also required for the negative and signal ground pins of each system element. Wiring connections for CCN should be made at LVT. Consult the CCN Contractor’s Manual for further information.

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. Wire manufactured by Alpha (2413 or 5463), American (A22503), Belden (8772), or Columbia (02525) meets the above mentioned requirements.

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 LVT of the plug, the white wire to COM terminal, and the black wire to the (–) terminal.

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

Page 15

LEGEND FOR FIG. 3-5

ALMR — Alarm Relay AUX — Auxilliary C—Contactor, Compressor CB — Circuit Breaker CCB — Compressor Circuit Breaker CH — Crankcase Heater CCH — Crankcase Heater Relay COMP — Compressor CR — Control Relay CSB — Current Sensor Board CWFS — Chilled Water Flow Switch CWP — Chilled Water Pump DGS — Digital Scroll Compressor DPT — Discharge Pressure Transducer DTT — Discharge Temperature Thermistor DUS — Digital Unloader Solenoid EMM — Energy Management EWT — Entering Water Temperature FB — Fuse Block FIOP — factory Installed Option FU — Fuse GND — Ground HPS — High-Pressure Switch LLSV — Liquid Line Solenoid Valve LON — Local Operating Network LV T — Low Voltage Terminal LWT — Leaving Water Temperature MBB — Main Base Board MLV — Minimum Load Valve MP — Modular Motor Protection NEC — National Electrical Code OAT — Outdoor-Air Thermistor PL — Plug RLY — Relay SPT — Suction Pressure Transducer SW — Switch TB — Terminal Block TRAN — Transformer UPC — Unitary Protocol Converter

Terminal Block

Terminal (Unmarked)

Terminal (Marked)

Splice

Factory Wiring

Field Wiring

Accessory or Option Wiring

To indicate common potential only; not to represent wiring.

Page 16

EQUIP

Fig. 3 — Typical Control Box — 30MP015-045 Units

a30-4963

GND

TB3

UPC LON OPTION

UPC

DISCONNECT OPTION CB1A/TB1A

TRAN1

LVT

CCB-1

CCB-2

CCB-3

EMM

CSB-A1

CSB-A2

CSB-A3

CCH

CA1 CA2

CA3

MBB

FB1

LOCATED OVER EMM

CB1

CB2

REMOTE CONTROL

OFF

SW1

ENABLE

CB3

OFF

SW2

Page 17

COMP A2

TRAN1

SECONDARY 24V

RED

BRN

VIO

FU3

SW2

CONNECT FOR

APPROPRIATE

PRIMARY VOLTAGE

SEE TABLE 1

CB1A

TO FUSED

DISCONNECT

PER NEC

OPTIONAL

DISCONNECT

3.2 AMPS

CB3

GRN/YEL

RED

CA1

BLK

YEL

BLU

13 23

CA2

CCB-1

BLK

YEL

BLU

BLK

YEL

BLU

YEL

BLU BLK

YEL

BLU

BLK

CCB-2

BLK

YEL

BLK

015,020,040: 380V,460V,575V ONLY

030,045: 460V,575V ONLY

BLU

YEL

BLU

GRN/YEL

CA3

BLK

YEL

BLU

CCB-3

BLK

YEL

BLU

YEL

BLU

BLK

BLU

YEL

BLK

YEL

CH-A1

BLK

YEL

L1 T1

L2 T2

BLK

YEL

CH-A2

BLK

YEL

CH-A3

BLK

YEL

BLK

015,020,040: 208/230V ONLY

030,045: 202/230V,380V ONLY

MBB

BRN

VIO

UPC FIOP

UPC

GND

HOT

24VAC

BRN

VIO

DGS FIOP

AUX2

BRN

RED

FIOP/ACCESSORY

EMM

FU1

BLK

FU2

YEL

GRN/YEL

RED

VIO

BRN

PRIMARY

WHT

380V

UNITS ONLY

NOT USED ON

380V UNITS

FB1

BLK

YEL

NOTES:

1. FACTORY WIRING IS IN ACCORDANCE WITH UL 1995 STANDARDS.

ANY FIELD MODIFICATIONS OR ADDITIONS MUST BE IN

COMPLIANCE WITH ALL APPLICABLE CODES.

C MIN WIRE FOR FIELD POWER SUPPLY.

3. ALL FIELD INTERLOCK CONTACTS MUST HAVE A MIN RATING OF

2 AMPS @ 24VAC SEALED. SEE FIELD INTERLOCK WIRING.

4. COMPRESSOR AND FAN MOTORS ARE THERMALLY PROTECTED--

THREE PHASE MOTORS PROTECTED AGAINST PRIMARY SINGLE

PHASE CONDITIONS.

5. TERMINALS 14

& 15 OF LVT ARE FOR FIELD CONNECTION

OF REMOTE ON-OFF. THE CONTACT MUST BE RATED FOR DRY

CIRCUIT APPLICATION CAPABLE OF HANDLING A 5VDC

1 MA TO 20 MA LOAD.

6. FOR 500 SERIES UNIT OPERATION AT 208-3-60V LINE VOLTAGE,

TRAN1 PRIMARY CONNECTIONS MUST BE MOVED TO TERMINALS H3 & H4.

8. MP-A1 NOT USED IN THE FOLLOWING UNITS:

015,020: ALL UNITS

9. MP-A2 NOT USED IN THE FOLLOWING UNITS:

015,020: ALL UNITS

10. MP-A3 NOT USED IN THE FOLLOWING UNITS:

11. JUMPER PLUG REQUIRED WHEN MP NOT USED

WHT

(040,045 ONLY)

VOLTAGE SERIES

TERMINAL

CONNECTIONS

FOR PRIMARY SIDE

575-3-60 100 H1 & H5

380-3-60 200 H1 & H2

230-3-60 500 H2 & H4

208-3-60 500 H3 & H4

460-3-60 600 H1 & H4

TABLE 1

7. MAX LOAD: 5VA SEALED, 10VA INRUSH

(040,045 ONLY)

BLK

YEL

(MPA ONLY)

WHT

BLK

YEL

FU4

FU5

UNIT VOLTAGE

REPLACE

WITH

FNQ-R-3

FU1 & FU2

FUSE

NUMBER

380-3-60

TRAN

SIZE

200VA

FNQ-R-2

208/230-3-60

FNQ-R-10

FU3 (24V)

380-3-60,460-3-60,575-3-60

250VA

208/230-3-60

460-3-60

575-3-60

FNQ-R-1.5

FU4 & FU5

380-3-60,460-3-60,575-3-60

NONE

208/230-3-60

(040,045 ONLY)(040,045 ONLY)

12. IF CHILLED WATER PUMP INTERLOCK IS USED,

REMOVE JUMPER FROM TERMINAL 16 TO 17 AND

WIRE INTERLOCK CONTACT ACROSS TERMINALS 16 & 17.

030-045: 460V UNITS WITHOUT DIGITAL SCROLL

030-045: 460V UNITS

040,045: 460V UNITS

FNQ-R-3

TB3

380V ONLY

PL11-2

PL11-1

PL12-2

PL12-1

CCH

PL13-2

PL13-1

STANDARD

TERMINAL

BLOCK

PER NEC

TO FUSED DISCONNECT

TB1A

EQUIP GND

COMP A1

COMP A3

380V UNITS ONLY

NEUTRAL

CSB-A1

CSB-A2

CSB-A3

Fig. 4 — Typical Power Wiring Schematic — 30MP015-045 Units

a30-4965

Page 18

J10A

Fig. 5 — Typical Control Wiring Schematic — 30MP015-045 Units

a30-4966

J10B

CWPI (SEE NOTE

12)

REMOTE

ON-OFF

SWITCH

(SEE

NOTE 5)

DUAL

SETPOINT

CNPI

CNFS

RED

WHT

BLK

RED

BLK

WHT

RLY 11

RLY 9

RLY 10

RLY 5

RLY 6

RLY 7

RLY 8

RLY 1

RLY 2

RLY 3

RLY 4

MBB

LEN CCN

LVT

(COM)

SHIELD

PORT 2

PORT 1A

(+)

(-)

UPC

NET +

NET -

N/C

SIGNAL

NET +

NET 2

SHIELD

CB2

3.2 AMPS

ORN

BLK

ENABLE

RED

WHT

SW1

RED

BLU

VIO

BRN

RED

BLK

WHT

RED

BLK

WHT

RED

J11

CWFS

BLK

VIO

RED

J13

BLK

WHT

RED

BRN

RED

BLK

WHT

RED

OPTION

UPC OPT

OFF

ORN

LON

GND

NET

SW2

RED

ORN

CB1

ORN

3.2 AMPS

PNK

GRA

PNK

BLU

ORN

PNK

RED

LVT

J12

J11

RED

BLU

HPS-A

BLK

ORN

GRA

VIO

PNK

SEE NOTE 11

MP-A1

VIO

MP-A2

VIO

MP-A3

VIO

GRA

PNK

CSB

RED

WHT

BLK

RED

BRN

(040,045 ONLY)

CONDENSER EWT ACCESSORY

CONDENSER LWT ACCESSORY

RGTA ACCESSORY

COOLER ENTERING FLUID TEMP

COOLER LEAVING FLUID TEMP

DPTA

SPTA

MARQUEE DISPLAY

LVT

J12 T55

BOARD

MAIN BASE

RED

WHT

BLK

BRN

RED

WHT

BLK

RED

ORN

BRN

RED

ORN

BRN

RED

ORN

BRN

BLU

VIO

RED

BLK

RED

BLK

RED

GRN

BLK

RED

GRN

BLK

TRAN1

SECONDARY 24V

FU3

ALMR

ALARM RELAY

SEE NOTE 7

CWP RELAY SEE NOTE 7

CONDENSER FAN/PUMP RELAY

SEE NOTE 7

CONDENSER

WATER VALVE

(MPB ONLY)

RED

GRA

(MPA AND BRINE ONLY)

BLU

PL1-2PL1-1

VIO

ORN

PL2-2PL2-1

VIO

GRA

PL3-2PL3-1

VIO

(040,045 ONLY)

GRA

PNK

BRN

PL1-3

PNK

RED

PL2-3

PNK

RED

PL3-3

PNK

RED

T-55

SEN

ACCSY

OAT ACCESSORY OR DUAL CHILLER LWT

LLSV-A

CCH

(MPA ONLY)

CA1

CA2

CA3

MLV-A

MLV FIOP

CWFS

SEE NOTE 8

T2T1MP-A1

SEE NOTE 9

T2T1MP-A2

SEE NOTE 10

T2T1MP-A3

GRN/YEL

BRN

TB3

TRAN1

BRN

C2C1

BRN

BLU

PL1-4

BRN

PL2-4

BRN

PL3-4

BRN

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

RED

BRN

AUX2

DGS

FIOP

12345678

DARK = SWITCH LOCATION

EMM

FIOP/

ACCESSORY

CWFS-3

LLSV-A

TB3

MLV-A

CA3

MLV-A

PL1-4

PL2-4

PL3-4

CCH

PL3-4

LLSV-A

CCH

TB3

CA1

CA2

CA3

OFF

CH1

CH11

GRA

RED

BLU

VIO

BRN

ORN

PNK

DUS

VIO

BRN

RED

BLK

DTT

LVT

J10

ICE DONE

DLS STEP 1

DLS STEP 2

DEMAND

LIMIT

4-20mA

TEMP

RESET

4-20mA

COOLING

SETPOINT

4-20mA

Page 19

IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent the unit from starting. If abnormal conditions occur, unplug the connector. 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.

Table 15 — Thermistor Designations

THERMISTOR

CLWT J8-13,14 (MBB) Cooler Leaving Fluid CEWT J8-11,12 (MBB) Cooler Entering Fluid

RGTA

OAT

SPT

CNDE

CNDL

LEGEND

LWT — Leaving Water Temperature MBB — Main Base Board

CONNECTION

POINT

J8-9,10 (MBB) Circuit A Return Gas

J8-6,7 (MBB), LVT 4,13

J8-5,6 (MBB) LV T-3 , 4

J8-1,2 Condenser Entering Water

J8-3,4 Condenser Leaving Water

THERMISTOR INPUT

Temperature (accessory) Outdoor-Air Temperature

Sensor (accessory) or Dual LWT Sensor

Accessory Remote Space Temperature Sensor

Temperature Sensor

Table 16 — Status Inputs

STATUS SWITCH PIN CONNECTION POINT

Condenser Flow Switch LVT-11,17, J7-2, J6-2

Dual Set Point LVT-12,13, J7-3,4

Remote On/Off LVT-14,15 Cooler Flow Switch Interlock LVT-16,17, J6-2, J7-10 Compressor Fault Signal, A1 J9-11,12 Compressor Fault Signal, A2 J9-5,6 Compressor Fault Signal, A3 J9-8,9

Table 17 — Output Relays

RELAY

NO.

K1 Energize Compressor A1 K2 Energize Compressor A2 K3 Energize Compressor A3 K4 Energize Minimum Load Valve K5 Water Valve Open K6 Water Valve Close K7 Liquid Line Solenoid Valve K8 Crankcase Heater Relay (30MPA Only)

K9 Chilled Water Pump K10 Condenser Fan/Pump K11 Alarm Relay

DESCRIPTION

Table 18 — 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 NO.

Sensors — The electronic control uses 2 to 7 thermistors to

sense temperatures for controlling chiller operation. See Table 15. These sensors are outlined below. Thermistors

RGTA, CNDE, CNDL, EWT, LWT, and OAT are identical in temperature versus resistance and voltage drop performance. The dual chiller thermistor (DLWT) is 5 k at 77 F (25 C) thermistor. Space temperature thermistor (SPT) is a 10 kat 77 F (25 C). See Thermistors section for temperature-resistance-voltage drop characteristics.

COOLER LEAVING FLUID SENSOR (LWT) — The thermistor is installed in a well in the factory-installed leaving fluid piping coming from the bottom of the brazed-plate heat exchanger.

COOLER ENTERING FLUID SENSOR (EWT) — The thermistor is installed in a well in the factory-installed entering fluid piping coming from the top of the brazed-plate heat exchanger.

CONDENSER LEAVING FLUID SENSOR (CNDL) — The thermistor is installed in a well in the factory-installed leaving fluid piping coming from the bottom of the brazed-plate heat exchanger.

COOLER ENTERING FLUID SENSOR (CNDE) — The thermistor is installed in a well in the factory-installed entering fluid piping coming from the top of the brazed-plate heat exchanger.

COMPRESSOR RETURN GAS TEMPERATURE SENSOR (RGTA) — This accessory thermistor can be installed in a well located in the suction line.

OUTDOOR-AIR TEMPERATURE SENSOR (OAT) — This sensor is an accessory that is remotely mounted and used for outdoor air temperature reset. See Table 15.

DUAL LEAVING WATER TEMPERATURE SENSOR (DLWT) — This input can be connected to the LVT. See Table 15. For dual chiller applications (parallel only are supported), connect the dual chiller leaving fluid temperature sensor (5 kthermistor, Carrier part no. HH79NZ029) to the outside air temperature input of the Master chiller. If outside air temperature is required for reset applications, connect the sensor to the Slave chiller and configure the slave chiller to broadcast the value to the Master chiller.

REMOTE SPACE TEMPERATURE SENSOR (SPT) — The sensor (part no. 33ZCT55SPT) is an accessory sensor that is remotely mounted in the controlled space and used for space temperature reset. The sensor should be installed as a wallmounted thermostat would be (in 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. 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 (Fig. 8):

1. Using a 20 AWG twisted pair conductor cable rated for the application, connect 1 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 3 and 4 on LVT 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 (Fig. 9):

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 18 for acceptable wiring.

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.)

Page 20

CEPL130346-01

STATUS

LEN

J10

CCN

RED LED - STATUS GREEN LED -

LEN (LOCAL EQUIPMENT NETWORK)

YELLOW LED CCN (CARRIER COMFORT NETWORK)

INSTANCE JUMPER

K11

K10 K9

K3 K2

Fig. 6 — Main Base Board

Fig. 7 — Enable/Off/Remote Contact Switch, and Emergency On/Off Switch Locations

SPT (T10) PART NO. 33ZCT55SPT

SENSOR

SEN

LVT

Fig. 8 — Typical Space Temperature

Sensor Wiring

T-55 SPACE SENSOR

CCN+

CCN GND

CCN-

TO CCN COMM 1 BUS (PLUG) AT UNIT

Fig. 9 — CCN Communications Bus Wiring to Optional Space Sensor RJ11 Connector

a30-4967

a30-4968

Page 21

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.

5. Connect the other end of the communication bus cable to the remainder of the CCN communication bus.

Energy Management Module (Fig. 10) — This

factory-installed option (FIOP) or field-installed accessory is used for the following types of temperature reset, demand limit, and/or ice features:

• 4 to 20 mA leaving fluid temperature reset (requires field-supplied 4 to 20 mA generator)

• 4 to 20 mA cooling set point reset (requires fieldsupplied 4 to 20 mA generator)

• Discrete inputs for 2-step demand limit (requires fieldsupplied dry contacts capable of handling a 24 vac, 50 mA load)

• 4 to 20 mA demand limit (requires field-supplied 4 to 20 mA generator)

• Discrete input for Ice Done switch (requires fieldsupplied dry contacts capable of handling a 24 vac, 50 mA load)

See Demand Limit and Temperature Reset sections on

pages 27 and 31 for further details.

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. 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.

Loss-of-Cooler Flow Protection — A proof-of-

cooler flow device is factory installed in all chillers.

Condenser Flow Protection — A proof-of-condens-

er flow protection accessory can be field installed in the condenser water piping of all chillers. The unit must be configured for the input to be enabled.

Thermostatic Expansion Valves (TXV) — All

units are equipped from the factory with conventional TXVs. The 30MPA units and 30MPW units with medium temperature brine also have factory-installed liquid line solenoids. The liquid line solenoid valves are not intended to be a mechanical shut-off. For 30MPW units, when service is required, reclaim the refrigerant from the system.

For 30MPA units when service is required, the compressor and evaporator can be serviced by closing the factory-installed liquid line service valve and field-installed discharge line service valve. After the valves are closed, reclaim the refrigerant from the system.

The TXV is set at the factory to maintain approximately 8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler by monitoring the proper amount of refrigerant into the cooler. All TXVs are adjustable, but should not be adjusted unless abso- lutely necessary.

Capacity Control — The control system cycles com-

pressors, digital scroll modulting solenoid (if equipped), and minimum load valve solenoids (if equipped) to maintain the user-configured leaving chilled fluid temperature set point. Entering fluid temperature is used by the main base board (MBB) to determine the temperature drop across the cooler and is used in determining the optimum time to add or subtract capacity

stages. The chilled fluid temperature set point can be automatically reset by the return fluid temperature, space, or outdoor-air temperature reset features. It can also be reset from an external 4 to 20-mA signal (requires energy management module FIOP or accessory).

The capacity control algorithm runs every 30 seconds. The algorithm attempts to maintain the Control Point at the desired set point. Each time it runs, the control reads the entering and leaving fluid temperatures. The control determines the rate at which conditions are changing and calculates 2 variables based on these conditions. Next, a capacity ratio is calculated using the 2 variables to determine whether or not to make any changes to the current stages of capacity. This ratio value ranges from –100 to +100%. If the next stage of capacity is a compressor, the control starts (stops) a compressor when the ratio reaches +100% (–100%). If installed, the minimum load valve solenoid will be energized with the first stage of capacity. Minimum load valve value is a fixed 30% in the total capacity calculation. The control will also use the minimum load valve solenoid as the last stage of capacity before turning off the last compressor. A delay of 90 seconds occurs after each capacity step change. Refer to Table 19.

MINUTES LEFT FOR START — This value is displayed only in the network display tables (using Service Tool, ComfortVIEW™ or ComfortWORKS represents the amount of time to elapse before the unit will start its initialization routine. This value can be zero without the machine running in many situations. This can include being unoccupied, ENABLE/OFF/REMOTE CONTACT switch in the OFF position, CCN not allowing unit to start, Demand Limit in effect, no call for cooling due to no load, and alarm or alert conditions present. If the machine should be running and none of the above are true, a minimum off time (DELY, see below) may be in effect. The machine should start normally once the time limit has expired.

MINUTES OFF TIME (Configuration DELY) — This user-configurable time period is used by the control to determine how long unit operation is delayed after power is applied/restored to the unit. Typically, this time period is configured when multiple machines are located on a single site. For example, this gives the user the ability to prevent all the units from restarting at once after a power failure. A value of zero for this variable does not mean that the unit should be running.

LEAD/LAG DETERMINATION — This is a configurable choice and is factory set to be automatic for all units unless the unit is equipped with minimum load, then circuit A is lead (Configuration to Circuit A or Circuit B leading as desired. Set at automatic, the control will sum the current number of logged circuit starts and one-quarter of the current operating hours for each circuit. The circuit with the lowest sum is started first. Changes to which circuit is the lead circuit and which is the lag are also made when total machine capacity is at 100% or when there is a change in the direction of capacity (increase or decrease) and each circuit’s capacity is equal.

CAPACITY CONTROL OVERRIDES — The following overrides will modify the normal operation of the routine.

Deadband Multiplier Multiplier (Configuration value of 1.0. The range is from 1.0 to 4.0. When set to other than 1.0, this factor is applied to the capacity Load/Unload Factor. The larger this value is set, the longer the control will delay between adding or removing stages of capacity. Figure 11 shows how compressor starts can be reduced over time if the leaving water temperature is allowed to drift a larger amount above and below the set point. This value should be set in the range of 3.0 to 4.0 for systems with small loop volumes. Figure 12 shows the operating envelope for the compressor.



OPT2 LLCS). The value can be changed

— The user configurable Deadband



SLCTZ.GN) has a default

software) and



OPT2



Page 22

First Stage Override

CEBD430351-0396-01C

TEST 1

CEPL130351-01

PWR

TEST 2

J4 J3

LEN

STATUS

RED LED - STATUS

GREEN LED LEN (LOCAL EQUIPMENT NETWORK)

ADDRESS DIP SWITCH

Fig. 10 — Energy Management Module

— If the current capacity stage is zero, the control will modify the routine with a 1.2 factor on adding the first stage to reduce cycling. This factor is also applied when the control is attempting to remove the last stage of capacity.

Slow Change Override

— The control prevents the capacity stages from being changed when the leaving fluid temperature is close to the set point (within an adjustable deadband) and moving towards the set point.

*Hot gas bypass (minimum load) valve energized. NOTE: These capacity steps may vary due to different capacity

Table 19 — Part Load Data Percent Displacement, Standard Units with Minimum Load Valve

30MP UNIT SIZE

015

020

030

040

045

CONTROL

STEPS

1 2 3

1 2 3 4

staging sequences.

CAPACITY STEPS

(% Displacement)

18*

50 100

25*

50 100

34*

50 100

21*

33 67 100

22*

33 67 100

Page 23

0 200 400 600 800 1000

TIME (SECONDS)

2 STARTS

3 STARTS

DEADBAND EXAMPLE

LWT (F)

MODIFIED DEADBAND

STANDARD DEADBAND

LWT (C)

LEGEND

LWT — Leaving Water Temperature

Fig. 11 — Deadband Multiplier

170

140

150

160

110

120

130

100

-30 -20 -10 0 10 20 304050607080

SCT (F)

SST (F)

LEGEND

Fig. 12 — Operating Envelope for R-410A Compressor

SCT —

Saturated Condensing Temperature

SST —

Saturated Suction Temperature

a30-4969

Ramp Loading

tion



SLCTCRMP) limits the rate of change of leaving

fluid temperature. If the unit is in a Cooling mode and configured for Ramp Loading, the control makes 2 comparisons before deciding to change stages of capacity. The control calculates a 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 Cooling Ramp Loading value (CRMP), the control does not allow any changes to the current stage of capacity.

Low Entering Fluid Temperature Unloading entering fluid temperature is below the control point, the control will attempt to remove 25% of the current stages being used. If exactly 25% cannot be removed, the control removes an amount greater than 25% but no more than necessary. The lowest stage will not be removed.

Hot Gas Bypass energized only when one compressor is running on circuit A. If the close control feature is enabled the hot gas bypass valve

— Ramp loading (Configura-

may be used as needed to obtain leaving fluid temperature close to set point.

Cooler Freeze Protection shutting the chiller down on a Cooler Freeze Protection alarm by removing stages of capacity. If the cooler fluid selected is Water, the freeze point is 34 F (1.1 C). If the cooler fluid selected is Brine, the freeze point is the Brine Freeze Point (Set

Points

references leaving fluid temperature and NOT Brine Freeze point. If the cooler leaving fluid temperature is less than the freeze point plus 2.0° F (1.1° C), the control will immediately

— When the

remove one stage of capacity. This can be repeated once every 30 seconds.

Low Saturated Suction Protection prevent shutting a circuit down due to low saturated suction conditions by removing stages of capacity. The circuit alert condition (T116) compares saturated suction temperature to the

— If equipped, the hot gas bypass valve is

configured Brine Freeze Point (Set Points The Brine Freeze point is a user-configurable value that must be left at 34 F (1.1 C) for 100% water systems. A lower value

— The control will try to prevent



FRZBR.FZ). This alarm condition (A207) only

— The control will try to



FRZBR.FZ).

Page 24

may be entered for systems with brine solutions, but this value

ENTER

ESCAPE

should be set according to the freeze protection level of the brine mixture. Failure to properly set this brine freeze point value may permanently damage the brazed plate heat exchanger. The control will initiate Mode 7 (Circuit A) to indicate a circuit’s capacity is limited and that eventually the circuit may shut down.

Operation of Machine Based on Control Method and Cooling Set Point Selection Settings —

configuration of the Control Method (Configuration



OPT2CTRL) and Cooling Set Point Select

(ConfigurationSLCTCLSP) variables. All units are factory configured with Cooling Set Point Select set to 0 (single set point). With the control method set to 0, simply 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 control mode (Run

Status

switch is Off and will be 5 (ON LOCAL) when in the Enable position or Remote Contact position with external contacts closed.

Two other control methods are available for Machine On/

Off control: OCCUPANCY SCHEDULE (Configuration



CTRL = 1) — The main base board will use the operating schedules as defined under the Time Clock mode in the scrolling marquee display. These schedules are identical. The schedule number must be set to 1 for local schedule.

The schedule number can be set anywhere from 65 to 99 for operation under a CCN global schedule. The Enable/Off/ Remote Contact must be in the Enable or Remote Contact position. The control mode (Run Status 1 when the switch is Off. The control mode will be 3 when the Enable/Off/Remote Contact switch input is On and the time of day is during an unoccupied period. Similarly, the control mode will be 7 when the time of day is during an occupied period.

CCN SCHEDULE (Configuration

2) — An external CCN device such as Chillervisor System Manager controls the On/Off state of the machine. This CCN device forces the variable ‘CHIL_S_S’ between Start/Stop to control the chiller. The control mode (Run Status



VIEWSTAT) will be 1 when the switch is Off. The con-

trol mode will be 2 when the Enable/Off/Remote Contact switch input is On and the CHIL_S_S variable is ‘Stop.’ Similarly, the control mode will be 6 when the CHIL_S_S variable is ‘Start.’

Table 20 illustrates how the control method and cooling set point select variables direct the operation of the chiller and the set point to which it controls. The illustration also shows the ON/OFF state of the machine for the given combinations.

Machine On/Off control is determined by the



VIEWSTAT) will be 1 (OFF LOCAL) when the



VIEWSTAT) will be



OPT2CTRL =

OPT2

Cooling Set Point Select

SINGLE — Unit operation is based on Cooling Set Point 1 (Set Points



COOLCSP.1).

DUAL SWITCH — Unit operation is based on Cooling Set Point 1 (Set Points



COOLCSP.1) when the Dual Set

Point switch contacts are open and Cooling Set Point 2 (Set

Points



COOLCSP.2) when they are closed.

DUAL CCN OCCUPIED — Unit operation is based on Cooling Set Point 1 (Set Points



COOLCSP.1) during the

Occupied mode and Cooling Set Point 2 (Set

Points



COOLCSP.2) during the Unoccupied mode as

configured under the local occupancy schedule accessible only from CCN. Schedule Number in Table SCHEDOVR (See Appendix B) must be configured to 1. If the Schedule Number is set to 0, the unit will operate in a continuous 24-hr Occupied mode. Control method must be configured to 0 (switch). See Table 20.

4 TO 20 mA INPUT — Unit operation is based on an external 4 to 20 mA signal input to the Energy Management Module (EMM).

Cooler Pump Control — The AquaSnap® 30MP ma-

chines are configured with the Cooler Pump Control (Configuration



OPT1CPC) = ON.

The maximum load allowed for the Chilled Water Pump Starter is 5 VA sealed, 10 VA inrush at 24 volts. The starter coil is powered from the chiller control system. The starter should be wired between LVT 24 and TB3-1. If equipped, the field-installed chilled water pump starter auxiliary contacts should be connected in series with the chilled water flow switch between LVT 16 and LVT 17.

Ice Mode — When Ice Mode is enabled Cooling Setpoint

Select must be set to Dual Switch, Dual 7 day or Dual CCN Occupied and the Energy Management Module (EMM) must be installed. Unit operation is based on Cooling Setpoint 1 (CSP.1) during the Occupied mode, Ice Setpoint (CSP.3) dur- ing the Unoccupied mode with the Ice Done contacts open and Cooling Setpoint 2 (CSP.2) during the Unoccupied mode with the Ice Done contacts closed. These 3 set points can be utilized to develop your specific control strategy.

Service Test (See Table 4) — Both main power and

control circuit power must be on.

The Service Test function should be used to verify proper operation of condenser output, compressors, minimum load valve solenoid (if installed), cooler pump, and remote alarm relay. To use the Service Test mode, the Enable/Off/Remote Contact switch must be in the OFF position. Use the display keys and Table 4 to enter the mode and display TEST. Press

twice so that OFF flashes. Enter the password if required. Use either arrow key to change the TEST value to the ON position and press . Press and the button to enter the OUTS or COMP sub-mode.

Table 20 — Control Methods and Cooling Set Points

CONTROL

TYPE

(CTRL)

0 (switch)

2 (Occupancy)

3 (CCN)

*Dual set point switch input used. CSP1 used when switch input is open. CSP2 used when switch input is closed.

†Cooling set point determined from 4 to 20 mA input to energy management module (EMM) to terminals TB6-3,5.

OCCUPANCY

STATE

Occupied ON,CSP1 ON* ON,CSP1 ON† Unoccupied ON,CSP1 ON* ON,CSP2 ON Occupied ON,CSP1 ON* Illegal ON† Unoccupied OFF OFF Illegal OFF Occupied ON,CSP1 ON* ON,CSP1 ON† Unoccupied ON,CSP1 ON* ON,CSP2 ON†

(single)

COOLING SET POINT SELECT (CLSP)

(dual, switch)

(dual, occ)

(4 to 20 mA)

Page 25

Test the condenser output, cooler pump, liquid line solenoid

MASTER CHILLER

SLAVE

CHILLER

LEAVING FLUID

RETURN FLUID

THERMISTOR WIRING*

INSTALL DUAL CHILLER LWT LEAVING FLUID TEMPERATURE THERMISTOR (T10) HERE

*Depending on piping sizes, use either:

• HH79NZ014 sensor/10HB50106801 well (3-in. sensor/well)

• HH79NZ029 sensor/10HB50106802 well (4-in. sensor/well)

Fig. 13 — Dual Chiller Thermistor Location

valve (30MPA only), crankcase heater, water valve (accessory), and alarm relay by changing the item values from OFF to ON. These discrete outputs are then turned off if there is no keypad activity for 10 minutes. When testing compressors, lead compressor must be started first. All compressor outputs can be turned on, but the control will limit the rate by staging one compressor per minute. Minimum load valve can be tested with the compressors on or off. The relays under the COMP mode will stay on for 10 minutes if there is no keypad activity. Compressors will stay on until they are turned off by the operator. The Service Test mode will remain enabled for as long as there is one or more compressors running. All safeties are monitored during this test and will turn a compressor, circuit or the machine off if required. Any other mode or sub-mode can be accessed, viewed, or changed during the TEST mode. The STAT item (Run Status



VIEW) will display “0” as long as the Service mode is enabled. The TEST sub-mode value must be changed back to OFF before the chiller can be switched to Enable or Remote contact for normal operation.

Cooler Pump Sequence of Operation — At any-

time the unit is in an ON status, as defined by the one of the following conditions, the cooler pump relay will be enabled.

1. The Enable-Off-Remote Switch in ENABLE, (CTRL=0).

2. Enable-Off-Remote Switch in REMOTE with a Start-Stop remote contact closure (CTRL=0).

3. An Occupied Time Period from an Occupancy Schedule in combination with items 1 or 2 (CTRL=2).

4. A CCN Start-Stop Command to Start in combination with items 1 or 2 (CTRL=3).

There are certain alarm conditions and Operating Modes that will turn the cooler pump relay ON. This sequence will describe the normal operation of the pump control algorithm.

When the unit cycles from an "On" state to an "Off' state, the cooler pump output will remain energized for the Cooler Pump Shutdown Delay (Configuration This is configurable from 0 to 10 minutes. The factory default is 1 minute. If the pump output was deenergized during the transition period, the pump output will not be energized.

The Cooler Pump Relay will be energized when the machine is "On." The chilled water pump interlock circuit consists of a chilled water flow switch and a field-installed chilled water pump interlock. If the chilled water pump interlock circuit does not close within five (5) minutes of starting, an A200 - Cooler Flow/Interlock failed to close at Start-Up alam1 will be generated and chiller will not be allowed to start.

If the chilled water pump interlock or chilled water flow switch opens for at least three (3) seconds after initially being closed, an A201 - Cooler Flow 1 Interlock Contacts Opened During Normal Operation alarm will be generated and the machine will stop.

Condenser Pump/Condenser Fan Output Control —

control either a condenser fan output or a condenser pump output depending on the unit configuration.

UNITTYPE = 2 (air cooled), then the output will be off as long as capacity is equal to 0 and will be energized 5 seconds before a compressor is started and remain energized until capacity is 0 again.

UNITTYPE = 3 (water cooled), then the output will be used for consenser pump control and additional configuration is required. To enable the condenser pump control use Configura-

tion

pump control, on when occupied, and on when capacity is greater than 0.

The main base board (MBB) has the capability to

If the unit is configured for Configuration



OPT1DPME. The pump can be configured for no



OPT1PM.DY).



Configuring and Operating Dual Chiller Control —

two units supplying chilled fluid on a common loop. This control algorithm is designed for parallel fluid flow arrangement only. One chiller must be configured as the master chiller, the other as the slave. An additional leaving fluid temperature thermistor (Dual Chiller LWT) must be installed as shown in Fig. 13 and 14 and connected to the master chiller. Refer to Sensors section, page 19, for wiring. The CCN communication bus must be connected between the two chillers. Connections can be made to the CCN screw terminals on LVT. Refer to Carrier Comfort Network mation. Configuration examples are shown in Tables 21 and 22.

example the master chiller will be configured at address 1 and the slave chiller at address 2. The master and slave chillers must reside on the same CCN bus (Configuration



ration have Lead/Lag Chiller Enable (ConfigurationRSET



uration

the master chiller and SLVE for the slave. Also in this example, the master chiller will be configured to use Lead/Lag Balance Select (Configuration ance Delta (ConfigurationRSETLLBD) to even out the chiller run-times weekly. The Lag Start Delay (Configura-

tion

will prevent the lag chiller from starting until the lead chiller has been at 100% capacity for the length of the delay time. Parallel configuration (Configuration only be configured to YES. The variables LLBL, LLBD and LLDY are not used by the slave chiller.

tion of Control Method (Configuration the Master chiller. The Slave chiller should always be configured for CTRL=0 (Switch). If the chillers are to be controlled by Remote Contacts, both Master and Slave chillers should be enabled together. Two separate relays or one relay with two sets of contacts may control the chillers. The Enable/Off/ Remote Contact switch should be in the Remote Contact position on both the Master and Slave chillers. The Enable/Off/ Remote Contact switch should be in the Enable position for CTRL=2 (Occupancy) or CTRL=3 (CCN Control).

Remote Contact switch is in the Off position. If the Emergency Stop switch is turned off or an alarm is generated on the Master chiller the Slave chiller will operate in a Stand-Alone mode. If the Emergency Stop switch is turned off or an alarm is generated on the Slave chiller the Master chiller will operate in a Stand-Alone mode.

Control Mode (Run Status ing setpoint or Control Point (Run Status

The dual chiller routine is available for the control of

Interface section, page 14, for wiring infor-

Refer to Table 21 for dual chiller configuration. In this

CCNB) but cannot have the same CCN address (Configu-



CCNCCNA). Both master and slave chillers must

LLEN) configured to ENBL. Master/Slave Select (Config-



RSET MSSL) must be configured to MAST for



RSETLLBL) and Lead/Lag Bal-



RSETLLDY) feature will be set to 10 minutes. This



RSETPARA) can

Dual chiller start/stop control is determined by configura-



OPT1CTRL) of

Both chillers will stop if the Master chiller Enable/Off/

The master chiller controls the slave chiller by changing its



VIEWSTAT) and its operat-



VIEWCT.PT).



CCN

Page 26

Table 21 — Dual Chiller Configuration (Master Chiller Example)

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS

DISP

UNIT

OPT1

CTRL CONTROL METHOD

OPT2

CTRL 0 SWITCH DEFAULT 0

OPT2

CCN

CCNA 1 CCN ADDRESS DEFAULT 1

CCNB

CCN

CCNB 0 CCN BUS NUMBER DEFAULT 0

CCN

RSET

RSET CRST COOLING RESET TYPE

LLEN LEAD/LAG CHILLER ENABLE 15 ITEMS

LLEN DSBL SCROLLING STOPS

DSBL VALUE FLASHES

ENBL SELECT ENBL

LLEN ENBL LEAD/LAG CHILLER ENABLE CHANGE ACCEPTED

LLEN

PROCEED TO

SUBMODE RESET

MSSL MASTER /SLAVE SELECT

MSSL MAST MASTER /SLAVE SELECT DEFAULT MAST

MSSL

SLVA SLAVE ADDRESS

SLVA 0 SCROLLING STOPS

0 VALUE FLASHES

2 SELECT 2

SLVA 2 SLAVE ADDRESS CHANGE ACCEPTED

SLVA

LLBL LEAD/LAG BALANCE SELECT

LLBL 0 SCROLLING STOPS

0 VALUE FLASHES

2 SELECT 2 - Automatic

Page 27

Table 21 — Dual Chiller Configuration (Master Chiller Example) (cont)

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

1/4 N.P.T.

0.505/0.495

0.61 DIA

6” MINIMUM

CLEARANCE FOR

THERMISTOR

REMOVAL

Fig. 14 — Dual Leaving Water Thermistor Well

PA RT

NUMBER

DIMENSIONS in. (mm)

A B 10HB50106801 3.10 (78.7) 1.55 (39.4) 10HB50106802 4.10 (104.1) 1.28 (32.5)

SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS

RSET

NOTES:

1. Master Control Method (CTRL) can be configured as 0-Switch, 2-Occupancy or 3-CCN.

2. Parallel Configuration (PARA) cannot be changed.

LLBL 2 LEAD/LAG BALANCE SELECT CHANGE ACCEPTED

LLBL

LLBD LEAD/LAG BALANCE DELTA

LLBD 168 LEAD/LAG BALANCE DELTA DEFAULT 168

LLBD

LLDY LAG START DELAY

LLDY 5 SCROLLING STOPS

5 VALUE FLASHES

10 SELECT 10

LLDY 10 LAG START DELAY CHANGE ACCEPTED

LLDY

RSET

PARA YES MASTER COMPLETE

Temperature Reset — The control system is capable of

handling leaving-fluid temperature reset based on return cooler fluid temperature. Because the change in temperature through the cooler is a measure of the building load, the return temperature reset is in effect an average building load reset method. The control system is also capable of temperature reset based on outdoor-air temperature (OAT), space temperature (SPT), or from an externally powered 4 to 20 mA signal. Accessory sensors must be used for SPT reset (33ZCT55SPT) and for OAT reset (HH79NZ014). The energy management module (EMM) must be used for temperature reset using a 4 to 20 mA signal. See Tables 23 and 24.

Page 28

Table 22 — Dual Chiller Configuration (Slave Chiller Example)

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ESCAPE

SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS

DISP

UNIT

OPT1

CTRL CONTROL METHOD

OPT2

CCN

RSET CRST COOLING RESET TYPE

CTRL 0 SWITCH DEFAULT 0

OPT2

CCN

CCNA

CCNA 1 CCN ADDRESS SCROLLING STOPS

1 VALUE FLASHES

SELECT 2

(SEE NOTE 2)

CCNA 2 CCN ADDRESS CHANGE ACCEPTED

CCN

CCNB 0 CCN BUS NUMBER

DEFAULT 0

(SEE NOTE 3)

CCN

RSET

PROCEED TO

SUBMODE RSET

LLEN LEAD/LAG CHILLER ENABLE 15 ITEMS

LLEN DSBL SCROLLING STOPS

DSBL VALUE FLASHES

ENBL SELECT ENBL

LLEN ENBL LEAD/LAG CHILLER ENABLE CHANGE ACCEPTED

LLEN

MSSL MASTER /SLAVE SELECT

MSSL MAST SCROLLING STOPS

MAST VALUE FLASHES

SLVE SELECT SLVE

MSSL SLVE MASTER /SLAVE SELECT CHANGE ACCEPTED

MSSL

RSET SLAVE COMPLETE

NOTES:

1. Slave Control Method (CTRL) must be configured for 0.

2. Slave CCN Address (CCNA) must be different than Master.

3. Slave CCN Bus Number (CCNB) must be the same as Master

4. Slave does not require SLVA, LLBL, LLBD, or LLDY to be configured.

Page 29

Table 23 — Menu Configuration of 4 to 20 mA Cooling Set Point Control

ENTER

MODE

(RED LED)

CONFIGURATION

KEYPAD

ENTRY

SUB-MODE

DISP

UNIT

OPT1

OPT2

CCN

RSET

SLCT CLSP 0 COOLING SETPOINT SELECT

KEYPAD

ENTRY

ITEM DISPLAY

Table 24 — 4 to 20 mA Reset

SUB-MODE

RSET

NOTE: The example above shows how to configure the chiller for 4 to 20 mA reset. No reset will occur at 4.0 mA input, and a 5.0 F reset will occur at 20.0 mA. An EMM (energy management module) is required.

KEYPAD

ENTRY

ITEM DISPLAY

CRST 1

MA.DG

5.0 F

(2.8 C)

ITEM

EXPANSION

0 Scrolling Stops

0 Flashing ‘0’

3Select ‘3’

3 Change Accepted

ITEM

EXPANSION

0 = no reset

COOLING RESET

TYPE

DEGREES COOL

RESET

1 = 4 to 20 mA input 2 = Outdoor air temp 3 = Return Fluid 4 = Space Temperature

Default: 0° F (0° C) Reset at 20 mA Range: –30 to 30 F (–16.7 to 16.7 C)

COMMENT

IMPORTANT: Care should be taken when interfacing with other control systems due to possible power supply differences: full wave bridge versus 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 use outdoor air or space temperature reset, four variables must be configured. In the Configuration mode under the submode RSET, items (Configuration



(Configuration

RSETRM.NO), (Configuration



RSETCRST),



RSETRM.F), and (ConfigurationRSETRT.DG) must be properly set. See Table 25 — Configuring Outdoor Air and Space Temperature Reset. The outdoor air reset example provides 0° F (0° C) chilled water set point reset at 85.0 F (29.4 C) outdoor-air temperature and 15.0 F (8.3 C) reset at

55.0 F (12.8 C) outdoor-air temperature. The space temperature reset example provides 0° F (0° C) chilled water set point reset at 72.0 F (22.2 C) space temperature and 6.0 F (3.3 C) reset at 68.0 F (20.0 C) space temperature. The variable CRST should be configured for the type of reset desired. The variable

RM.NO should be set to the temperature that no reset should occur. The variable RM.F should be set to the temperature that maximum reset is to occur. The variable RM.DG should be set to the maximum amount of reset desired. Figures 15 and 16 are examples of outdoor air and space temperature resets.

To use return reset, four variables must be configured. In the Configuration mode under the sub-mode RSET, items CRST, RT.NO, RT.F and RT.DG must be properly set. See Table 26 — Configuring Return Temperature Reset. This example provides 5.0 F (2.8 C) chilled water set point reset at 2.0 F (1.1 C) cooler T and 0° F (0° C) reset at 10.0 F (5.6 C) cooler T. T h e variable RT.NO should be set to the cooler temperature difference (T) where no chilled water temperature reset should occur. The variable RT.F should be set to the cooler temperature difference where the maximum chilled water temperature reset should occur. The variable RM.DG should be set to the maximum amount of reset desired.

To verify that reset is functioning correctly proceed to Run Status mode, sub-mode VIEW, and subtract the active set point (Run Status

Status



VIEWSETP) from the control point (Run

VIEWCTPT) to determine the degrees reset.

Page 30

Table 25 — Configuring Outdoor Air and Space Temperature Reset

ENTER

MODE

(RED LED)

KEYPAD

ENTRY

CONFIGURATION

*1 item skipped in this example.

MODE

(RED LED)

KEYPAD

ENTRY

SUB-

MODE

KEYPAD

ENTRY

ITEM

DISPLAY

Outdoor

Air

Space

DISP

UNIT

OPT1

OPT2

CCN

RSET CRST 2 4

COOLING RESET

RM.NO* 85 °F 72 °F

RM.F 55 °F 68 °F

RM.DG 15 °F 6 °F

REMOTE - FULL

REMOTE - DEGREES

Table 26 — Configuring Return Temperature Reset

SUB-MODE

KEYPAD

ENTRY

ITEM DISPLAY

DISP TEST ON/OFF TEST DISPLAY LEDs

ITEM

EXPANSION

ITEM

EXPANSION

TYPE

REMOTE - NO RESET TEMP

RESET TEMP

RESET

COMMENT

2 = Outdoor-Air Temperature (Connect to LVT-4,5) 4 = Space Temperature (Connect to LVT-3,4)

Default: 125.0 F (51.7 C) Range: 0° to125 F

Default: 0.0° F (-17.7 C) Range: 0° to 125 F

Default: 0° F (0° C) Range: –30 to 30 F (–34.4 to -1.1 °C)

COMMENT

CONFIGURATION

*1 item skipped in this example.

UNIT TYPE X UNIT TYPE

OPT1 FLUD X COOLER FLUID

OPT2 CTRL X CONTROL METHOD

CCN

RSET CRST 3 COOLING RESET TYPE

RT.NO* 10.0

RT.F 2.0

RT.DG 5.0 F

RETURN FLUID - NO

F

RESET TEMP

RETURN FLUID - FULL

RESET TEMP

RETURN - DEGREES

RESET

0 = No Reset 1 = 4 to 20 mA Input (EMM required)

(Connect to EMM TB6-2,3) 2 = Outdoor-Air Temperature 3 = Return Fluid 4 = Space Temperature (Connect to TB5-5,6)

Default: 10.0 Range: 0° to10 F COOLER T

Default: 0 Range: 0° to 30 F COOLER

Default: 0 Range: –30 to 30°F (–16.7 to 16.7 C)

F (5.6 C)

F (–17.8 C)

T

F (0 C)

Page 31

Under normal operation, the chiller will maintain a constant

LEGEND

LWT — Leaving Water (Fluid) Temperature

Fig. 15 — Outdoor-Air Temperature Reset

LEGEND

LWT — Leaving Water (Fluid) Temperature

Fig. 16 — Space Temperature Reset

LEGEND

Fig. 17 — Standard Chilled Fluid

Temperature Control — No Reset

EWT —

Entering Water (Fluid) Temperature

LWT —

Leaving Water (Fluid) Temperature

leaving fluid temperature approximately equal to the chilled fluid set point. As the cooler load varies, the entering cooler fluid will change in proportion to the load as shown in Fig. 17. Usually the chiller size and leaving-fluid temperature set point are selected based on a full-load condition. At part load, the fluid temperature set point may be colder than required. If the leaving fluid temperature was allowed to increase at part load, the efficiency of the machine would increase.

Return temperature reset allows for the leaving temperature set point to be reset upward as a function of the return fluid temperature or, in effect, the building load.

Demand Limit — Demand limit is a feature that allows

the unit capacity to be limited during periods of peak energy usage. There are 3 types of demand limiting that can be configured. The first type is through 2-stage 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 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.

NOTE: The 2-stage switch control and 4 to 20-mA input signal types of demand limiting require the energy management module (EMM).

LWT

To use demand limit, select the type of demand limiting to use. Then configure the demand limit set points based on the type selected.

DEMAND LIMIT (2-Stage Switch Controlled) — To configure demand limit for 2-stage switch control set the Demand Limit Select (Configuration



RSETDMDC) to 1. Then

configure the 2 Demand Limit Switch points (Configura-

tion



RSETDLS1) and (ConfigurationRSETDLS2)

to the desired capacity limit. See Table 27. Capacity steps are controlled by 2 relay switch inputs field wired to LVT as shown in Fig. 5.

For demand limit by 2-stage switch control, closing the first stage demand limit contact will put the unit on the first demand limit level. The unit will not exceed the percentage of capacity entered as Demand Limit Switch 1 set point (DLS1). Closing contacts on the second demand limit switch prevents the unit from exceeding the capacity entered as Demand Limit Switch 2 set point. The demand limit stage 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 staging, the unit will limit capacity to the closest capacity stage.

To disable demand limit configure DMDC to 0. See Table 27.

EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled) — To configure demand limit for 4 to 20 mA control set the Demand Limit Select (Configura-

tion



RSETDMDC) to 2. Then configure the Demand

Limit at 20 mA (Configuration



RSETDM20) to the

maximum loadshed value desired. Connect the output from an externally powered 4 to 20 mA signal to terminal block LVT, terminals 7 and 8 (+,–). Refer to the unit wiring diagram for these connections to the optional/accessory energy management module and terminal block. The control will reduce allowable capacity to this level for the 20 mA signal. See Table 27 and Fig. 18.

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. 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.

Page 32

DEMAND LIMIT (CCN Loadshed Controlled) — To con-

50% CAPACITY AT 20 mA

75% CAPACITY AT 12 mA

100% CAPACITY AT 4 mA

16 18

DEMAND LIMIT SIGNAL – 4 - 20 mA INPUT

100

MAX. ALLOWABLE LOAD (%)

Fig. 18 — 4 to 20-mA Demand Limiting

100 (38)

(27)

(15)

(4.4)

(-7)

(-17)

4 6.3 8.6 10.9 13.1 15.4 17.7 20

4 TO 20 mA SIGNAL TO EMM

SET POINT, F (C)

(32)

(21)

(10)

(-1)

(-12)

(FLUD = 2) MINIMUM SET POINT 14 F (-10 C)

(FLUD = 1) MINIMUM SET POINT 38 F (3.3 C)

MAXIMUM SET POINT 70 F (21.1 C)

Fig. 19 — Cooling Set Point (4 to 20 mA)

EMM — Energy Management Module

figure Demand Limit for CCN Loadshed control set the Demand Limit Select (Configuration



RSETDMDC) to 3.

Then configure the Loadshed Group Number (Configura-

tion



RSETSHNM), Loadshed Demand Delta (Configu-

rationRSETSHDL), and Maximum Loadshed Time (Configuration



RSETSHTM). See Table 27.

The Loadshed Group number is established by the CCN system designer. The ComfortLink™ controls will respond to a Redline command from the Loadshed control. When the Redline command is received, the current stage of capacity is set to the maximum stages available. Should the loadshed control send a Loadshed command, the ComfortLink controls will reduce the current stages by the value entered for Loadshed Demand delta. The Maximum Loadshed Time is the maximum

length of time that a loadshed condition is allowed to exist. The control will disable the Redline/Loadshed command if no Cancel command has been received within the configured maximum loadshed time limit.

Cooling Set Point (4 to 20 mA) — A field supplied

and generated, externally powered 4 to 20 mA signal can be used to provide the leaving fluid temperature set point. Connect the signal to LVT-10,8 (+,–). See Table 27 for instructions to enable the function. Figure 19 shows how the 4 to 20 mA signal is linearly calculated on an overall 10 F to 80 F range for fluid types (Configuration point will be limited by the fluid (FLUD) type. Be sure that the chilled water loop is protected at the lowest temperature.



OPT1FLUD) 1 or 2. The set

Page 33

Table 27 — Configuring Demand Limit

ENTER

MODE

CONFIGURATION

*Seven items skipped in this example.

KEYPAD

ENTRY

SUB-MODE

KEYPAD

ENTRY

DISP TEST ON/OFF Test Display LEDs

UNIT TYPE X Unit Type

OPT1 FLUD X Cooler Fluid

OPT2 CTRL X Control Method

CCN

RSET CRST X Cooling Reset Type

ITEM DISPLAY ITEM EXPANSION COMMENT

CCNA X CCN Address

DMDC* X Demand Limit Select

DM20 XXX % Demand Limit at 20 mA

SHNM XXX

SHDL XXX%

SHTM XXX MIN

DLS1 XXX %

DLS2 XXX %

Loadshed Group

Number

Loadshed Demand

Delta

Maximum Loadshed

Time

Demand Limit

Switch 1

Demand Limit

Switch 2

Default: 0 0 = None 1 = Switch 2 = 4 to 20 mA Input 3 = CCN Loadshed

Default: 100% Range: 0 to 100

Default: 0 Range: 0 to 99

Default: 0% Range: 0 to 60%

Default: 60 min. Range: 0 to 120 min.

Default: 80% Range: 0 to 100%

Default: 50% Range: 0 to 100%

PRE-START-UP

IMPORTANT: Before beginning Pre-Start-Up or Start-Up, complete Start-Up Checklist for 30MP Liquid Chiller at end of this publication (page CL-1 to CL-8). 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 following checks

have been completed.

System Check

1. Check all auxiliary components, such as chilled fluid pumps, air-handling equipment, condenser pump or other equipment to which the chiller supplies liquid. Consult manufacturer's instructions. Verify that any pump interlock contacts have been properly installed. If the unit has field-installed accessories, be sure all are properly installed and wired correctly. Refer to unit wiring diagrams.

2. Use the scrolling marquee display to adjust the Cooling Set Point.

3. Fill chilled fluid circuit with clean water (with recommended inhibitor added) or other non-corrosive fluid to be cooled. Bleed all air out of the high points of the system. If chilled water is to be maintained at a temperature below 40 F (4.4 C), a brine of sufficient concentration must be used to prevent freeze-up at anticipated suction temperatures. To ensure sufficient loop volume, see Table 28.

4. Check tightness of all electrical connections.

5. Oil should be visible in the compressor sightglass(es). See Fig. 20. An acceptable oil level in the compressors is

from

/8 to 3/8 of sight glass when the compressors are off. Adjust the oil level as required. See Oil Charge section on page 37 for Carrier approved oils.

6. Crankcase heaters must be firmly attached to compressors, and must be on for 24 hours prior to start-up (30MPA units only).

7. Electrical power source must agree with unit nameplate.

8. Check rotation of scroll compressors. Monitor control alarms during first compressor start up for reverse rotation protection alarm.

Table 28 — Minimum Flow Rates and Minimum

Loop Volume (for Comfort Cooling)

UNIT SIZE

30MP015 22 1.4 22 1.4 46.2 174.9 30MP020 28 1.8 28 1.8 60.9 230.5 30MP030 43 2.7 43 2.7 92.4 349.7 30MP040 55 3.5 55 3.5 78.4 296.7 30MP045 64 4.0 64 4.0 91.6 346.7

AHRI — Air Conditioning, Heating, and Refrigeration Institute N—Liters per kW V—Gallons per ton

NOTES: Gallons = V x AHRI capacity in tons. Liters = N x AHRI capacity in kW.

EVAPORATOR CONDENSER*

Gal./Min L/s Gal./Min L/s Gal. L

LEGEND

APPLICATION V N

Normal Air Conditioning 33.25 Process Type Cooling 6 to 10 6.5 to 10.8 Low Ambient Operation 6 to 10 6.5 to 10.8

MINIMUM EVAPORATOR

LOOP VOLUME

Page 34

OIL SIGHTGLASS

Fig. 20 — Sight Glass Location

a30-4978

START-UP AND OPERATION

CAUTION

Crankcase heaters on 30MPA units are wired into the control circuit, so they are always operable as long as the main power supply disconnect is on (closed), even if any safety device is open. Compressor heaters must be on for 24 hours prior to the start-up of any compressor. Equipment damage could result if heaters are not energized for at least 24 hours prior to compressor start-up.

Compressor crankcase heaters must be on for 24 hours before start-up. To energize the crankcase heaters, close the field disconnect. Leave the compressor circuit breakers off/open. The crankcase heaters are now energized.

NOTE: Refer to Start-Up Checklist on pages CL-1 to CL-8.

Actual Start-Up — Actual start-up should be done only

under supervision of a qualified refrigeration mechanic.

1. Be sure all service valves are open (30MPA units only).

2. Using the scrolling marquee display, set leaving-fluid set point (Set Points adjustment is necessary.

3. Start chilled fluid pump (if not configured for cooler pump control).

4. Turn ENABLE/OFF/REMOTE CONTACT switch to ENABLE position.

5. Allow unit to operate and confirm that everything is functioning properly. Check to see that leaving fluid temperature agrees with leaving set point (Set Points



CSP.1) or (Set PointsCOOLCSP.2), or if reset is

used, with the control point (Run Status



CTPT).

6. Check the cooler leaving chilled water temperature to see that it remains well above 32 F (0° C), or the brine freezing point if the unit is a medium temperature brine unit.

7. Recheck compressor oil level (see Oil Charge section).



COOLCSP.1). No cooling range

Check Refrigerant Charge — All 30MPW units are

shipped with a complete operating charge of R-410A and should be under sufficient pressure to conduct a leak test after installation. If there is no system pressure, admit nitrogen until a pressure is observed and then proceed to test for leaks. After leaks are repaired, the system must be dehydrated.



COOL

VIEW

All refrigerant charging should be done through the ¼-in. Schraeder connection on the liquid line. Do NOT add refrigerant charge through the low-pressure side of the system. If complete charging is required, weigh in the appropriate charge for the circuit as shown on the unit nameplate. If partial charging is required, operate circuit at full load and add charge until the sight glass is clear of bubbles.

CAUTION

Never charge liquid into low-pressure side of system. Do not overcharge. Overcharging results in higher discharge pressure, possible compressor damage, and higher power consumption. During charging or removal of refrigerant, be sure water is continuously circulating through the cooler to prevent freezing.

The 30MPA units (condenserless) are shipped with a nitrogen holding charge only. After chiller assembly is completed in the field, system must be fully charged. While the unit is running at full capacity, add refrigerant until the sight glass is clear. R-410A is the normal refrigerant.

Do not open the liquid valve until there is a charge in remainder of system. A positive pressure indicates a charge in system. With the unit operating at full load, check liquid line sight glass to be sure the unit is fully charged (bubbles in the sight glass indicate the unit is not fully charged).

If there is no refrigerant vapor pressure in the system, the entire system must be leak tested. After repairing leaks, evacuate the system before recharging.

Follow approved evacuation procedures when removing refrigeration. Release remaining pressure to an approved evacuated cylinder.

The liquid charging method is recommended for complete charging or when additional charge is required.

CAUTION

Be careful not to overcharge the system. Overcharging results in higher discharge pressure, possible compressor damage, and higher power consumption.

EVACUATION AND DEHYDRATION — Because the 30MP systems use polyolester (POE) oil, which can absorb moisture, it is important to minimize the amount of time that the system interior is left exposed to the atmosphere. Minimizing the exposure time of the oil to the atmosphere will minimize the amount of moisture that needs to be removed during evacuation.

Once all of the piping connections are complete, leak test the unit and then pull a deep dehydration vacuum. Connect the vacuum pump to the high flow Schraeder valve in the suction line and liquid line. For best results, it is recommended that a vacuum of at least 500 microns (0.5 mm Hg) be obtained. Afterwards, to ensure that no moisture is present in the system, perform a standing vacuum-rise test.

With the unit in deep vacuum (500 microns or less), isolate the vacuum pump from the system. Observe the rate-of-rise of the vacuum in the system. If the vacuum rises by more than 50 microns in a 30-minute time period, then continue the dehydration process. Maintain a vacuum on the system until the standing vacuum requirement is met. This will ensure a dry system.

By following these evacuation and dehydration procedures, the amount of moisture present in the system will be minimized. It is required that liquid line filter driers be installed between the condenser(s) and the expansion devices to capture any foreign debris and provide additional moisture removal capacity.

Page 35

LIQUID CHARGING METHOD — Add charge to the unit through the liquid line service valve. Never charge liquid into the low-pressure side of the system.

1. Close liquid line ball valve (30MPA only).

2. Connect a refrigerant cylinder loosely to the high flow Schraeder valve connection on the liquid line. Purge the charging hose and tighten the connections.

3. Open the refrigerant cylinder valve.

4. If the system has been dehydrated and is under vacuum, break the vacuum with refrigerant gas. For R-410A, build up system pressure to 101 psig and 32 F (697 kPa and 0° C). Invert the refrigerant cylinder so that the liquid refrigerant will be charged.

5. a. For complete charge of 30MPW units, follow

charging by weight procedure. When charge is nearly full, complete the process by observing the sight glass for clear liquid flow while the unit is operating. The use of sight glass charging is valid only when unit is operating at full capacity.

b. For complete charge of 30MPA units or where

refrigerant cylinder cannot be weighed, follow the condenser manufacturer’s charging procedure or follow charging by sight glass procedure. The use

of sight glass charging is valid only when unit is operating at full capacity.

6. a. The 30MPA condenserless units are shipped

with a nitrogen holding charge. After installation with the field-supplied system high side, the complete system should be evacuated and charged per the condenser manufacturer’s charging procedure or charged until the sight glass is clear (with the unit running at full capacity). To achieve maximum system capacity, add additional charge equal to the difference between the condenser optimal charge and the condenser minimum charge, which can be obtained from the charge data provided in the condenser installation instructions.

b. To ensure maximum performance of 30MPW

units, raise the compressor saturated discharge temperature (SDT) to approximately 100 F (37.8 C) by throttling the condenser water intake. Add charge until there is approximately 9 to 12° F (5.0 to 6.6° C) of system subcooling (SDT minus actual temperature entering the thermostatic expansion valve).

Operating Limitations

TEMPERATURES (See Table 29 for 30MP standard temperature limits).

CAUTION

Do not operate with cooler leaving chiller water (fluid) temperature (LCWT) below 32 F (0° C) for standard units with proper brine solution or 40 F (4.4 C) for the standard units with fresh water, or below 15 F (–9.4 C) for units factory built for medium temperature brine.

High Cooler Leaving Chilled Water (Fluid) Temperatures (LCWT) — During start-up with cooler the LCWT should not be above approximately 60 F (16 C).

Low Cooler LCWT the LCWT must be no lower than 40 F (4.4 C). For standard units with a proper brine solution, the LCWT must be no lower than 32 F (0° C). If the unit is the factory-installed optional

— For standard units with fresh water,

medium temperature brine unit, the cooler LCWT can go down to 15 F (–9.4 C).

Table 29 — Temperature Limits for

Standard 30MP Units

TEMPERATURE LIMIT F C

Maximum Condenser LWT

Minimum Condenser EWT

Maximum Cooler EWT*

Maximum Cooler LWT

Minimum Cooler LWT†

LEGEND

EWT — LWT —

*For sustained operation, EWT should not exceed 85 F (29.4 C). †Unit requires modification below this temperature.

Entering Fluid (Water) Temperature Leaving Fluid (Water) Temperature

140 60 70 21

95 35 70 21

40 4

CAUTION

Medium temperature brine duty application (below 32 F [0° C] LCWT) for chiller normally requires factory modification. Contact your Carrier representative for applicable LCWT range for standard water-cooled chiller in a specific application.

VOLTAGE — ALL UNITS Main Power Supply

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:

% 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.

1. Determine average voltage:

Average voltage =

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

— Minimum and maximum acceptable

a30-4979

max voltage deviation

from avg voltage

average voltage

AB = 243 v

BC = 236 v AC = 238 v

243 + 236 + 238

717

= 239

239

= 1.7%

Page 36

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 your local electric utility company immediately. Do not operate unit until imbalance condition is corrected.

Control Circuit Power

— Power for the control circuit is supplied from the main incoming power through a factoryinstalled control power transformer (TRAN1) for all models. Field wiring connections are made to the LVT.

OPERATION SEQUENCE

The unit is started by putting the ENABLE/OFF/REMOTE CONTACT switch in the ENABLE or REMOTE CONTACT position. When the unit receives a call for cooling (either from the internal control or CCN network command or remote contact closure), the unit stages up in capacity to maintain the leaving fluid set point. The first compressor starts 1

/2 to 3 minutes

after the call for cooling.

For all units, if temperature reset is being used, the unit controls to a higher leaving-fluid temperature as the building load reduces. If demand limit is used, the unit may temporarily be unable to maintain the desired leaving-fluid temperature because of imposed power limitations.

SERVICE

WARNING

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

Electronic Components

CONTROL COMPONENTS — Unit uses an advanced electronic control system that normally does not require service. For details on controls refer to Operating Data section.

Access to the controls is through a hinged panel. Inner panels are secured in place and should not be removed unless all power to the chiller is off.

Compressor Replacement — All models contain

scroll compressors and have two or three compressors. A compressor is most easily removed from the side of the unit or above, depending on where clearance space was allowed during unit installation. See Fig. 21.

Remove the junction box cover bolts and disconnect the compressor power and crankcase heater connections (30MPA only). Remove the cable from the compressor junction box. Remove the connections from the high-pressure switch. Remove the crankcase heater. Knock the same holes out of the new compressor junction box and install the cable connectors from the old compressor.

The compressors are bolted to rails, which are in turn bolted to the unit basepan for all sizes. Remove the 4 bolts holding the compressor to the rail on the basepan. Save the mounting hardware for use with the new compressor. Carefully cut the compressor suction and discharge lines with a tubing cutter as close to the compressor as feasible. Remove high-pressure switch and pressure transducer(s) if required for compressor removal. Lift one corner of the compressor at a time and remove all the steel spacers. Remove the old compressor from the unit.

Slide the new compressor in place on the rails. Lifting one side of the compressor at a time, replace all of the compressor

mounting hardware. Using new tubing as required, reconnect compressor suction and discharge lines. Using hardware saved, reinstall the mounting bolts and washers through the compressor feet. Using proper techniques, braze suction and discharge lines and check for leaks. Reconnect oil equalization line.

Re-install the crankcase heater (30MPA units). Reconnect the compressor power connections and high-pressure switch wiring as on the old compressor. Refer to Fig. 21. Following the installation of the new compressor, tighten all hardware to the following specifications. (See Table 30.)

Table 30 — Unit Torque Specification

FASTENER RECOMMENDED TORQUE

Compressor Mounting Bolts

Compressor Power Connections

Compressor Ground Terminal Connections

7 to 10 ft-lb (9.5 to 13.5 N-m)

24 to 28 in.-lb (2.7- to 3.2 N-m)

14 to 18 in.-lb (1.6 to 2.0 N-m)

30MPW Condenser and 30MP Cooler

BRAZED-PLATE COOLER AND CONDENSER HEAT EXCHANGER REPLACEMENT — Brazed-plate heat exchangers cannot be repaired if they develop a leak. If a leak (refrigerant or water) develops, the heat exchanger must be replaced. To replace a brazed plate heat exchanger:

1. Disconnect the liquid-in and liquid-out connections at the heat exchanger.

2. Check that the replacement heat exchanger is the same as the original heat exchanger. For the condensers, compare part numbers on the heat exchangers. For the coolers, insulation covers the manufacturer’s part number. Make sure the depths of the replacement and original cooler heat exchangers are the same.

3. Recover the refrigerant from the system, and unsolder the refrigerant-in and refrigerant-out connections.

4. Remove the four nuts holding the heat exchanger to the brackets. Save the nuts.

5. Install the replacement heat exchanger in the unit and attach to the bracket using the four nuts removed in Step 4. For sizes 015 and 020, torque is 7-10 ft-lb. For sizes 030045, torque is 35 to 50 ft-lb.

6. Carefully braze the refrigerant lines to the connections on the heat exchanger. Lines should be soldered using silver as the soldering material with a minimum of 45% silver. Keep the temperature below 1472 F (800 C) under normal soldering conditions (no vacuum) to prevent the copper solder of the brazed plate heat exchanger from changing its structure. Failure to do so can result in internal or external leakage at the connections which cannot be repaired.

7. For coolers, ensure that the original size tubing is used

(

/2-in. for sizes 015 and 020 and 5/8-in. for sizes 030-045) between the TXV and the cooler. The TXV must be located within 1 ft of the heat exchanger, with no bends between the TXV outlet and the cooler inlet.

8. Reconnect the water/brine lines.

9. Dehydrate and recharge the unit. Check for leaks.

BRAZED-PLATE COOLER AND CONDENSER HEAT EXCHANGER CLEANING — Brazed-plate heat exchangers must be cleaned chemically. A professional cleaning service skilled in chemical cleaning should be used. Use a weak acid (5% phosphoric acid, or if the heat exchanger is cleaned frequently, 5% oxalic acid). Pump the cleaning solution through the exchanger, preferably in a backflush mode. After cleaning, rinse with large amounts of fresh water to dispose of all the acid. Cleaning materials must be disposed of properly.

Page 37

The strainers in front of the water/brine inlets of the heat

Fig. 21 — Compressor Location — 30MP015-045 Units (30MPW045 Unit Shown)

LEGEND

CWFS — Chilled Water Flow Switch DPT — Discharge Pressure Transducer EWT — Entering Water Thermistor HPS — High Pressure Switch LWT — Leaving Water Thermistor RGT — Return Gas Thermistor (Optional) SPT — Suction Pressure Transducer

a30-5049

exchangers should be cleaned periodically, depending on condition of the chiller water/brine.

Oil Charge

CAUTION

The compressor in a Puron® refigerant (R-410A) system uses a polyol ester (POE) oil. This is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere. Failure to do so could result in possible equipment damage.

Puron refrigerant systems use a polyol ester (POE) oil. Use only Carrier approved compressor oil. Oil should be visible in compressor oil sight glass. An acceptable oil level is from

/8 of sight glass. All compressors must be off when checking oil level. Recommended oil level adjustment method is as follows:

ADD OIL — Recover charge from the unit. Add oil to suction line Schrader valve on tandem compressors sets and the compressor Schrader on the trios. (See Fig. 21.) When oil can be seen at the bottom of the sight glass, add oil in 5 oz increments which is approximately

/8 in oil level. Run all compressors for 20 minutes then shut off to check oil level. Repeat procedure until acceptable oil level is present.

NOTE: Use only Carrier approved compressor oil. Approved sources are:

Totaline . . . . . . . . . . . . . . . . . . . . . . 3MAF POE, P903-1601

Mobil . . . . . . . . . . . . . . . . . . . . . . . . . . . EAL Arctic 32-3MA

Uniqema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RL32-3MAF

/8 to

Do not reuse oil that has been drained out, or oil that has

been exposed to atmosphere.

Check Refrigerant Feed Components

FILTER DRIER — The function of the filter drier is to maintain a clean, dry system. The moisture indicator (described below) indicates any need to change the filter drier. The filter drier is a sealed-type drier. When the drier needs to be changed, the entire filter drier must be replaced.

MOISTURE-LIQUID INDICATOR — The indicator is located immediately ahead of the TXV to provide an indication of the refrigerant moisture content. It also provides a sight glass for refrigerant liquid. Clear flow of liquid refrigerant (at full unit loading) indicates sufficient charge in the system. Bubbles in the sight glass (at full unit loading) indicate an undercharged system or the presence of noncondensables. Moisture in the system, measured in parts per million (ppm), changes the color of the indicator as follows:

Green (safe) —Moisture is below 75 ppm Yellow-Green (caution) — 75 to 150 ppm Yellow (wet) — above 150 ppm

The unit must be in operation at least 12 hours before the moisture indicator gives an accurate reading, and must be in contact with liquid refrigerant. At the first sign of moisture in the system, change the corresponding filter drier.

THERMOSTATIC EXPANSION VALVE (TXV) — The TXV controls the flow of liquid refrigerant to the cooler by maintaining constant superheat of vapor leaving the cooler. The valve(s) is activated by a temperature-sensing bulb(s) strapped to the suction line(s).

The valve(s) is factory-set to maintain between 8° and 10° F (4.4° and 5.6° C) of superheat leaving the cooler. Check the superheat during operation after conditions have stabilized. If necessary, adjust the superheat to prevent refrigerant floodback to the compressor.

HPS

DPT

RGT

SPT

EWT (HIDDEN)

CWFS

LWT

Page 38

MINIMUM LOAD VALVE — On units equipped with the factory-installed hot gas bypass option, a solenoid valve and discharge bypass valve (minimum load valve) are located between the discharge line and the cooler entering-refrigerant line. The MBB cycles the solenoid to perform minimum load valve function and the discharge bypass valve modulates to the suction pressure set point of the valve. The bypass valve has an adjustable opening setting between 95 to 115 psig (655 to 793 kPa). The factory setting is 105 psig (724 kPa).

The amount of capacity reduction achieved by the minimum load valve is not adjustable. The total unit capacity with the minimum load valve is shown in Table 19.

PRESSURE RELIEF DEVICES — All units have one pressure relief device per circuit located in the liquid line which relieves at 210 F (100 C).

The 30MPW unit does not have a condenser pressure relief valve, because the brazed-plate condenser is not considered a pressure vessel, as defined in ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigerating, and Air Conditioning Engineers) safety code requirements.

For 30MPA condenserless units, pressure relief devices designed to relieve at the pressure determined in local codes, must be field-supplied and installed in the discharge line piping in accordance with ANSI/ASHRAE 15 safety code requirements. Additional pressure relief valves, properly selected, must be field-supplied and installed to protect high side equipment and may be required by applicable codes.

Most codes require that a relief valve be vented directly to the outdoors. The vent line must not be smaller than the relief valve outlet. Consult ANSI/ASHRAE 15 for detailed information concerning layout and sizing of relief vent lines.

Check Unit Safeties

HIGH-PRESSURE SWITCH — A high-pressure switch is provided to protect each compressor and refrigeration system from unsafe high pressure conditions. See Table 31 for highpressure switch settings.

The high-pressure switch is mounted in the discharge line of each circuit. If an unsafe, high-pressure condition should exist, the switch opens and shuts off the affected circuit. The CSB (current sensing board) senses the compressor feedback signal and generates an appropriate alarm. The MBB prevents the circuit from restarting until the alert condition is reset. The switch should open at the pressure corresponding to the appropriate switch setting as shown in Table 31.

Table 31 — Factory Settings, High-Pressure

Switch (Fixed)

UNIT

30MP015-045 650 4482 500 3447

Clear the alarm using the scrolling marquee display. The unit should restart after the compressor anti-short-cycle delay, built into the unit control module, expires.

PRESSURE TRANSDUCERS — Each unit is equipped with a suction and discharge pressure transducer. These inputs to the MBB are not only used to monitor the status of the unit, but to also maintain operation of the chiller within the compressor manufacturer's specified limits. The input to the MBB from the suction pressure transducer is also used to protect the compressor from operating at low pressure conditions. If suction return gas thermistors are installed, then additional low superheat conditions are detected. In some cases, the unit may not be able to run at full capacity. The control module will automatically reduce the capacity of a circuit as needed to maintain specified maximum/minimum operating pressures.

CUTOUT CUT-IN

Psig kPa Psig kPa

COOLER FREEZE-UP PROTECTION

WARNING

On medium temperature brine units, the anti-freeze solution must be properly mixed to prevent freezing at a temperature of at least 15 F (8.3 C) below the leaving-fluid temperature set point. Failure to provide the proper antifreeze solution mixture is considered abuse and may impair or otherwise negatively impact the Carrier warranty.

The main base board (MBB) monitors cooler leaving fluid temperature at all times. The MBB will rapidly remove stages of capacity as necessary to prevent freezing conditions due to the rapid loss of load or low cooler fluid flow.

When the cooler is exposed to lower temperatures (40 F [4.4 C] or below), freeze-up protection is required using inhibited ethylene or propylene glycol.

Thermistors — Electronic control uses up to five 5 k

thermistors to sense temperatures used to control operation of the chiller. Thermistors EWT, LWT, RGTA, CNDE, CNDL, and OAT are identical in their temperature and voltage drop performance. The SPT space temperature thermistor has a 10 k input channel and it has a different set of temperature vs. resistance and voltage drop performance. Resistance at various temperatures are listed in Tables 32-35. For dual chiller operation, a dual chiller sensor is required which is a 5 k thermistor.

REPLACING THERMISTORS (EWT, LWT, RGT, CNDE, CNDL) — Add a small amount of thermal conductive grease to the thermistor well and end of probe. For all probes, tighten the retaining nut ¼ turn past finger tight. See Fig. 22.

THERMISTOR/TEMPERATURE SENSOR CHECK — A high quality digital volt-ohmmeter is required to perform this check.

1. Connect the digital voltmeter across the appropriate themistor terminals at the J8 terminal strip on the main base board (see Fig. 23).

2. Using the voltage reading obtained, read the sensor temperature from Tables 32-35.

3. To check thermistor accuracy, measure temperature at probe location with an accurate thermocouple-type temperature measuring instrument. Insulate thermocouple to avoid ambient temperatures from influencing reading. Temperature measured by thermocouple and temperature determined from thermistor voltage reading should be close, ± 5° F (3° C) if care was taken in applying thermocouple and taking readings.

If a more accurate check is required, unit must be shut down and thermistor removed and checked at a known temperature (freezing point or boiling point of water) using either voltage drop measured across thermistor at the J8 terminal, by determining the resistance with chiller shut down and thermistor disconnected from J8. Compare the values determined with the value read by the control in the Temperatures mode using the scrolling marquee display.

Pressure Transducers — The suction and discharge

transducers are different part numbers and can be distinguished by the color of the transducer body, suction (yellow) and discharge (red). No pressure transducer calibration is required. The transducers operate on a 5 vdc supply, which is generated by the main base board (MBB). See Fig. 23 for transducer connections to the J8 connector on the MBB.

TROUBLESHOOTING — If a transducer is suspected of being faulty, first check supply voltage to the transducer. Supply voltage should be 5 vdc ± 0.2 v. If supply voltage is correct, compare pressure reading displayed on the scrolling marquee display module against pressure shown on a calibrated pressure

Page 39

gauge. Pressure readings should be within ± 15 psig. If the

BASE

BOARD

SPTA

DPTA

RED

GRN

RED

BLK

GRN

RED

BLK

BLU

VIO

LVT

T-55 ACCSY

SEN

OAT ACCESSORY OR DUAL CHILLER LWT

CONDENSER EWT ACCESSORY

CONDENSER LWT ACCESSORY

BLK

RED

COOLER ENTERING FLUID TEMP

BLK

RED

COOLER LEAVING FLUID TEMP

RGTA ACCESSORY

J12 T55

Fig. 23 — Thermistor Connections to

Main Base Board, J8 Connector

LEGEND

ACCSY — Accessory DPT — Discharge Pressure Transducer EWT — Entering Water Temperature LWT — Leaving Water Temperature Sensor LV T — Low Voltage Terminal OAT — Outdoor Air Temperature Sensor RGT — Return Gas Temperature Sensor SEN — Sensor Terminal Block SPT — Space Temperature Sensor

a30-5043

Fig. 24— Chilled Water Flow Switch

a30-499

NOTE: Dimensions are in millimeters.

5/8 in. HEX

6" MINIMUM

CLEARANCE FOR

THERMISTOR

REMOVAL

1/4-18 NPT

Fig. 22 — Thermistor Well

two readings are not reasonably close, replace the pressure transducer.

Chilled Water Flow Switch — A factory-installed

flow switch is installed in the leaving fluid piping for all units. This is a thermal-dispersion flow switch with no field adjustments. The switch is set for approximately 0.5 ft/sec of flow. The sensor tip houses two thermistors and a heater element. One thermistor is located in the sensor tip, closest to the flowing fluid. See Fig. 24. This thermistor is used to detect changes in the flow velocity of the liquid. The second thermistor is bonded to the cylindrical wall and is affected only by changes in the temperature of the liquid. The thermistors are positioned to be in close contact with the wall of the sensor probe and, at the same time, to be kept separated from each other within the confines of the probe.

In order to sense flow, it is necessary to heat one of the thermistors in the probe. When power is applied, the tip of the probe is heated. As the fluid starts to flow, heat will be carried away from the sensor tip. Cooling of the first thermistor is a function of how fast heat is conducted away by the flowing liquid.

The difference in temperature between the two thermistors provides a measurement of fluid velocity past the sensor probe. When fluid velocity is high, more heat will be carried away from the heated thermistor and the temperature differential will be small. As fluid velocity decreases, less heat will be taken from the heated thermistor and there will be an increase in temperature differential.

When unit flow rate is above the minimum flow rate, then the output is switched on, sending 24 vac to the MBB to prove flow has been established.

For recommended maintenance, check the sensor tip for build-up every 6 months. Clean the tip with a soft cloth. If necessary, build-up (e.g., lime) can be removed with a common vinegar cleansing agent.

The flow sensor cable is provided with (3) LEDs that indicate if 24 vac power is present and also status of the switch contacts. The LEDs are as follows:

• Green LED ON – 24 vac present

• One Yellow LED ON – Flow sensor switch OPEN

• Two Yellow LED ON – Flow sensor switch CLOSED

If nuisance trips of the sensor are occurring, follow the steps below to correct the situation:

1. Check to confirm that the field-installed strainer is clean.

2. Measure the pressure drop across the cooler and compare

3. Verify that cable connections at the switch and at the ter-

Use the blow-down valve provided or remove the screen and clean it. For the case of VFD controlled pumps, ensure that the minimum speed setting has not been changed.

this to the system requirements.

minal block are secure.

4. Wrong pump motor rotation. Pump must rotate clockwise when viewed from motor end of pump.

Page 40

Table 32 — 5K Thermistor Temperatures (°F) vs. Resistance/Voltage Drop

TEMP

(F)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

–25 3.699 98,010 –24 3.689 94,707 –23 3.679 91,522 –22 3.668 88,449 –21 3.658 85,486 –20 3.647 82,627 –19 3.636 79,871 –18 3.624 77,212 –17 3.613 74,648 –16 3.601 72,175 –15 3.588 69,790 –14 3.576 67,490 –13 3.563 65,272 –12 3.550 63,133 –11 3.536 61,070 –10 3.523 59,081

–9 3.509 57,162 –8 3.494 55,311 –7 3.480 53,526 –6 3.465 51,804 –5 3.450 50,143 –4 3.434 48,541 –3 3.418 46,996 –2 3.402 45,505 –1 3.386 44,066

0 3.369 42,679 1 3.352 41,339 2 3.335 40,047 3 3.317 38,800 4 3.299 37,596 5 3.281 36,435 6 3.262 35,313 7 3.243 34,231 8 3.224 33,185

9 3.205 32,176 10 3.185 31,202 11 3.165 30,260 12 3.145 29,351 13 3.124 28,473 14 3.103 27,624 15 3.082 26,804 16 3.060 26,011 17 3.038 25,245 18 3.016 24,505 19 2.994 23,789 20 2.972 23,096 21 2.949 22,427 22 2.926 21,779 23 2.903 21,153 24 2.879 20,547 25 2.856 19,960 26 2.832 19,393 27 2.808 18,843 28 2.784 18,311 29 2.759 17,796 30 2.735 17,297 31 2.710 16,814 32 2.685 16,346 33 2.660 15,892 34 2.634 15,453 35 2.609 15,027 36 2.583 14,614 37 2.558 14,214 38 2.532 13,826 39 2.506 13,449 40 2.480 13,084 41 2.454 12,730 42 2.428 12,387 43 2.402 12,053 44 2.376 11,730 45 2.349 11,416 46 2.323 11,112 47 2.296 10,816 48 2.270 10,529 49 2.244 10,250 50 2.217 9,979 51 2.191 9,717 52 2.165 9,461 53 2.138 9,213 54 2.112 8,973 55 2.086 8,739 56 2.060 8,511 57 2.034 8,291 58 2.008 8,076

TEMP

(F)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

59 1.982 7,686 60 1.956 7,665 61 1.930 7,468 62 1.905 7,277 63 1.879 7,091 64 1.854 6,911 65 1.829 6,735 66 1.804 6,564 67 1.779 6,399 68 1.754 6,238 69 1.729 6,081 70 1.705 5,929 71 1.681 5,781 72 1.656 5,637 73 1.632 5,497 74 1.609 5,361 75 1.585 5,229 76 1.562 5,101 77 1.538 4,976 78 1.516 4,855 79 1.493 4,737 80 1.470 4,622 81 1.448 4,511 82 1.426 4,403 83 1.404 4,298 84 1.382 4,196 85 1.361 4,096 86 1.340 4,000 87 1.319 3,906 88 1.298 3,814 89 1.278 3,726 90 1.257 3,640 91 1.237 3,556 92 1.217 3,474 93 1.198 3,395 94 1.179 3,318 95 1.160 3,243 96 1.141 3,170 97 1.122 3,099 98 1.104 3,031

99 1.086 2,964 100 1.068 2,898 101 1.051 2,835 102 1.033 2,773 103 1.016 2,713 104 0.999 2,655 105 0.983 2,597 106 0.966 2,542 107 0.950 2,488 108 0.934 2,436 109 0.918 2,385 110 0.903 2,335 111 0.888 2,286 112 0.873 2,239 113 0.858 2,192 114 0.843 2,147 115 0.829 2,103 116 0.815 2,060 117 0.801 2,018 118 0.787 1,977 119 0.774 1,937 120 0.761 1,898 121 0.748 1,860 122 0.735 1,822 123 0.723 1,786 124 0.710 1,750 125 0.698 1,715 126 0.686 1,680 127 0.674 1,647 128 0.663 1,614 129 0.651 1,582 130 0.640 1,550 131 0.629 1,519 132 0.618 1,489 133 0.608 1,459 134 0.597 1,430 135 0.587 1,401 136 0.577 1,373 137 0.567 1,345 138 0.557 1,318 139 0.548 1,291 140 0.538 1,265 141 0.529 1,240 142 0.520 1,214

TEMP

(F)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

143 0.511 1,190 144 0.502 1,165 145 0.494 1,141 146 0.485 1,118 147 0.477 1,095 148 0.469 1,072 149 0.461 1,050 150 0.453 1,029 151 0.445 1,007 152 0.438 986 153 0.430 965 154 0.423 945 155 0.416 925 156 0.408 906 157 0.402 887 158 0.395 868 159 0.388 850 160 0.381 832 161 0.375 815 162 0.369 798 163 0.362 782 164 0.356 765 165 0.350 750 166 0.344 734 167 0.339 719 168 0.333 705 169 0.327 690 170 0.322 677 171 0.317 663 172 0.311 650 173 0.306 638 174 0.301 626 175 0.296 614 176 0.291 602 177 0.286 591 178 0.282 581 179 0.277 570 180 0.272 561 181 0.268 551 182 0.264 542 183 0.259 533 184 0.255 524 185 0.251 516 186 0.247 508 187 0.243 501 188 0.239 494 189 0.235 487 190 0.231 480 191 0.228 473 192 0.224 467 193 0.220 461 194 0.217 456 195 0.213 450 196 0.210 445 197 0.206 439 198 0.203 434 199 0.200 429 200 0.197 424 201 0.194 419 202 0.191 415 203 0.188 410 204 0.185 405 205 0.182 401 206 0.179 396 207 0.176 391 208 0.173 386 209 0.171 382 210 0.168 377 211 0.165 372 212 0.163 367 213 0.160 361 214 0.158 356 215 0.155 350 216 0.153 344 217 0.151 338 218 0.148 332 219 0.146 325 220 0.144 318 221 0.142 311 222 0.140 304 223 0.138 297 224 0.135 289 225 0.133 282

(Voltage Drop for EWT, LWT, RGT, CNDE, CNDL, Dual Chiller, and OAT)

Page 41

Table 33 — 5K Thermistor Temperatures (°C) vs. Resistance/Voltage Drop

TEMP

(C)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

–32 3.705 100,260 –31 3.687 94,165 –30 3.668 88,480 –29 3.649 83,170 –28 3.629 78,125 –27 3.608 73,580 –26 3.586 69,250 –25 3.563 65,205 –24 3.539 61,420 –23 3.514 57,875 –22 3.489 54,555 –21 3.462 51,450 –20 3.434 48,536 –19 3.406 45,807 –18 3.376 43,247 –17 3.345 40,845 –16 3.313 38,592 –15 3.281 38,476 –14 3.247 34,489 –13 3.212 32,621 –12 3.177 30,866 –11 3.140 29,216 –10 3.103 27,633

–9 3.065 26,202 –8 3.025 24,827 –7 2.985 23,532 –6 2.945 22,313 –5 2.903 21,163 –4 2.860 20,079 –3 2.817 19,058 –2 2.774 18,094 –1 2.730 17,184

0 2.685 16,325 1 2.639 15,515 2 2.593 14,749 3 2.547 14,026 4 2.500 13,342 5 2.454 12,696 6 2.407 12,085 7 2.360 11,506 8 2.312 10,959

9 2.265 10,441 10 2.217 9,949 11 2.170 9,485 12 2.123 9,044 13 2.076 8,627 14 2.029 8,231

TEMP

(C)

VOLTAGE

DROP

(V)

RESISTANCE

(Ohms)

15 1.982 7,855 16 1.935 7,499 17 1.889 7,161 18 1.844 6,840 19 1.799 6,536 20 1.754 6,246 21 1.710 5,971 22 1.666 5,710 23 1.623 5,461 24 1.580 5,225 25 1.538 5,000 26 1.497 4,786 27 1.457 4,583 28 1.417 4,389 29 1.378 4,204 30 1.340 4,028 31 1.302 3,861 32 1.265 3,701 33 1.229 3,549 34 1.194 3,404 35 1.160 3,266 36 1.126 3,134 37 1.093 3,008 38 1.061 2,888 39 1.030 2,773 40 0.999 2,663 41 0.969 2,559 42 0.940 2,459 43 0.912 2,363 44 0.885 2,272 45 0.858 2,184 46 0.832 2,101 47 0.807 2,021 48 0.782 1,944 49 0.758 1,871 50 0.735 1,801 51 0.713 1,734 52 0.691 1,670 53 0.669 1,609 54 0.649 1,550 55 0.629 1,493 56 0.610 1,439 57 0.591 1,387 58 0.573 1,337 59 0.555 1,290 60 0.538 1,244 61 0.522 1,200

TEMP

(C)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

62 0.506 1,158 63 0.490 1,118 64 0.475 1,079 65 0.461 1,041 66 0.447 1,006 67 0.433 971 68 0.420 938 69 0.407 906 70 0.395 876 71 0.383 836 72 0.371 805 73 0.360 775 74 0.349 747 75 0.339 719 76 0.329 693 77 0.319 669 78 0.309 645 79 0.300 623 80 0.291 602 81 0.283 583 82 0.274 564 83 0.266 547 84 0.258 531 85 0.251 516 86 0.244 502 87 0.237 489 88 0.230 477 89 0.223 466 90 0.217 456 91 0.211 446 92 0.204 436 93 0.199 427 94 0.193 419 95 0.188 410 96 0.182 402 97 0.177 393 98 0.172 385

99 0.168 376 100 0.163 367 101 0.158 357 102 0.154 346 103 0.150 335 104 0.146 324 105 0.142 312 106 0.138 299 107 0.134 285

(Voltage Drop for EWT, LWT, RGT, CNDE, CNDL, Dual Chiller, and OAT)

Page 42

Table 34 — 10K Thermistor Temperature (°F) vs. Resistance/Voltage Drop

TEMP

(F)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

–25 4.758 196,453 –24 4.750 189,692 –23 4.741 183,300 –22 4.733 177,000 –21 4.724 171,079 –20 4.715 165,238 –19 4.705 159,717 –18 4.696 154,344 –17 4.686 149,194 –16 4.676 144,250 –15 4.665 139,443 –14 4.655 134,891 –13 4.644 130,402 –12 4.633 126,183 –11 4.621 122,018 –10 4.609 118,076

–9 4.597 114,236 –8 4.585 110,549 –7 4.572 107,006 –6 4.560 103,558 –5 4.546 100,287 –4 4.533 97,060 –3 4.519 94,020 –2 4.505 91,019 –1 4.490 88,171

0 4.476 85,396 1 4.461 82,729 2 4.445 80,162 3 4.429 77,662 4 4.413 75,286 5 4.397 72,940 6 4.380 70,727 7 4.363 68,542 8 4.346 66,465

9 4.328 64,439 10 4.310 62,491 11 4.292 60,612 12 4.273 58,781 13 4.254 57,039 14 4.235 55,319 15 4.215 53,693 16 4.195 52,086 17 4.174 50,557 18 4.153 49,065 19 4.132 47,627 20 4.111 46,240 21 4.089 44,888 22 4.067 43,598 23 4.044 42,324 24 4.021 41,118 25 3.998 39,926 26 3.975 38,790 27 3.951 37,681 28 3.927 36,610 29 3.903 35,577 30 3.878 34,569 31 3.853 33,606 32 3.828 32,654 33 3.802 31,752 34 3.776 30,860 35 3.750 30,009 36 3.723 29,177 37 3.697 28,373 38 3.670 27,597 39 3.654 26,838 40 3.615 26,113 41 3.587 25,396 42 3.559 24,715 43 3.531 24,042 44 3.503 23,399 45 3.474 22,770 46 3.445 22,161 47 3.416 21,573 48 3.387 20,998 49 3.357 20,447 50 3.328 19,903 51 3.298 19,386 52 3.268 18,874 53 3.238 18,384 54 3.208 17,904 55 3.178 17,441 56 3.147 16,991 57 3.117 16,552 58 3.086 16,131 59 3.056 15,714 60 3.025 15,317

TEMP

(F)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

61 2.994 14,925 62 2.963 14,549 63 2.932 14,180 64 2.901 13,824 65 2.870 13,478 66 2.839 13,139 67 2.808 12,814 68 2.777 12,493 69 2.746 12,187 70 2.715 11,884 71 2.684 11,593 72 2.653 11,308 73 2.622 11,031 74 2.592 10,764 75 2.561 10,501 76 2.530 10,249 77 2.500 10,000 78 2.470 9,762 79 2.439 9,526 80 2.409 9,300 81 2.379 9,078 82 2.349 8,862 83 2.319 8,653 84 2.290 8,448 85 2.260 8,251 86 2.231 8,056 87 2.202 7,869 88 2.173 7,685 89 2.144 7,507 90 2.115 7,333 91 2.087 7,165 92 2.059 6,999 93 2.030 6,838 94 2.003 6,683 95 1.975 6,530 96 1.948 6,383 97 1.921 6,238 98 1.894 6,098

99 1.867 5,961 100 1.841 5,827 101 1.815 5,698 102 1.789 5,571 103 1.763 5,449 104 1.738 5,327 105 1.713 5,210 106 1.688 5,095 107 1.663 4,984 108 1.639 4,876 109 1.615 4,769 110 1.591 4,666 111 1.567 4,564 112 1.544 4,467 113 1.521 4,370 114 1.498 4,277 115 1.475 4,185 116 1.453 4,096 117 1.431 4,008 118 1.409 3,923 119 1.387 3,840 120 1.366 3,759 121 1.345 3,681 122 1.324 3,603 123 1.304 3,529 124 1.284 3,455 125 1.264 3,383 126 1.244 3,313 127 1.225 3,244 128 1.206 3,178 129 1.187 3,112 130 1.168 3,049 131 1.150 2,986 132 1.132 2,926 133 1.114 2,866 134 1.096 2,809 135 1.079 2,752 136 1.062 2,697 137 1.045 2,643 138 1.028 2,590 139 1.012 2,539 140 0.996 2,488 141 0.980 2,439 142 0.965 2,391 143 0.949 2,343 144 0.934 2,297 145 0.919 2,253 146 0.905 2,209

TEMP

(F)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

147 0.890 2,166 148 0.876 2,124 149 0.862 2,083 150 0.848 2,043 151 0.835 2,003 152 0.821 1,966 153 0.808 1,928 154 0.795 1,891 155 0.782 1,855 156 0.770 1,820 157 0.758 1,786 158 0.745 1,752 159 0.733 1,719 160 0.722 1,687 161 0.710 1,656 162 0.699 1,625 163 0.687 1,594 164 0.676 1,565 165 0.666 1,536 166 0.655 1,508 167 0.645 1,480 168 0.634 1,453 169 0.624 1,426 170 0.614 1,400 171 0.604 1,375 172 0.595 1,350 173 0.585 1,326 174 0.576 1,302 175 0.567 1,278 176 0.558 1,255 177 0.549 1,233 178 0.540 1,211 179 0.532 1,190 180 0.523 1,169 181 0.515 1,148 182 0.507 1,128 183 0.499 1,108 184 0.491 1,089 185 0.483 1,070 186 0.476 1,052 187 0.468 1,033 188 0.461 1,016 189 0.454 998 190 0.447 981 191 0.440 964 192 0.433 947 193 0.426 931 194 0.419 915 195 0.413 900 196 0.407 885 197 0.400 870 198 0.394 855 199 0.388 841 200 0.382 827 201 0.376 814 202 0.370 800 203 0.365 787 204 0.359 774 205 0.354 762 206 0.349 749 207 0.343 737 208 0.338 725 209 0.333 714 210 0.328 702 211 0.323 691 212 0.318 680 213 0.314 670 214 0.309 659 215 0.305 649 216 0.300 639 217 0.296 629 218 0.292 620 219 0.288 610 220 0.284 601 221 0.279 592 222 0.275 583 223 0.272 574 224 0.268 566 225 0.264 557

(For SPT)

Page 43

Table 35 — 10K Thermistor Temperature (°C) vs. Resistance/Voltage Drop

TEMP

(C)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

–32 4.762 200,510 –31 4.748 188,340 –30 4.733 177,000 –29 4.716 166,342 –28 4.700 156,404 –27 4.682 147,134 –26 4.663 138,482 –25 4.644 130,402 –24 4.624 122,807 –23 4.602 115,710 –22 4.580 109,075 –21 4.557 102,868 –20 4.533 97,060 –19 4.508 91,588 –18 4.482 86,463 –17 4.455 81,662 –16 4.426 77,162 –15 4.397 72,940 –14 4.367 68,957 –13 4.335 65,219 –12 4.303 61,711 –11 4.269 58,415 –10 4.235 55,319

–9 4.199 52,392 –8 4.162 49,640 –7 4.124 47,052 –6 4.085 44,617 –5 4.044 42,324 –4 4.003 40,153 –3 3.961 38,109 –2 3.917 36,182 –1 3.873 34,367

0 3.828 32,654 1 3.781 31,030 2 3.734 29,498 3 3.686 28,052 4 3.637 26,686 5 3.587 25,396 6 3.537 24,171 7 3.485 23,013 8 3.433 21,918

9 3.381 20,883 10 3.328 19,903 11 3.274 18,972 12 3.220 18,090 13 3.165 17,255 14 3.111 16,464

TEMP

(C)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

15 3.056 15,714 16 3.000 15,000 17 2.944 14,323 18 2.889 13,681 19 2.833 13,071 20 2.777 12,493 21 2.721 11,942 22 2.666 11,418 23 2.610 10,921 24 2.555 10,449 25 2.500 10,000 26 2.445 9,571 27 2.391 9,164 28 2.337 8,776 29 2.284 8,407 30 2.231 8,056 31 2.178 7,720 32 2.127 7,401 33 2.075 7,096 34 2.025 6,806 35 1.975 6,530 36 1.926 6,266 37 1.878 6,014 38 1.830 5,774 39 1.784 5,546 40 1.738 5,327 41 1.692 5,117 42 1.648 4,918 43 1.605 4,727 44 1.562 4,544 45 1.521 4,370 46 1.480 4,203 47 1.439 4,042 48 1.400 3,889 49 1.362 3,743 50 1.324 3,603 51 1.288 3,469 52 1.252 3,340 53 1.217 3,217 54 1.183 3,099 55 1.150 2,986 56 1.117 2,878 57 1.086 2,774 58 1.055 2,675 59 1.025 2,579 60 0.996 2,488 61 0.968 2,400

TEMP

(C)

VO LTAGE

DROP

(V)

RESISTANCE

(Ohms)

62 0.940 2,315 63 0.913 2,235 64 0.887 2,157 65 0.862 2,083 66 0.837 2,011 67 0.813 1,943 68 0.790 1,876 69 0.767 1,813 70 0.745 1,752 71 0.724 1,693 72 0.703 1,637 73 0.683 1,582 74 0.663 1,530 75 0.645 1,480 76 0.626 1,431 77 0.608 1,385 78 0.591 1,340 79 0.574 1,297 80 0.558 1,255 81 0.542 1,215 82 0.527 1,177 83 0.512 1,140 84 0.497 1,104 85 0.483 1,070 86 0.470 1,037 87 0.457 1,005 88 0.444 974 89 0.431 944 90 0.419 915 91 0.408 889 92 0.396 861 93 0.386 836 94 0.375 811 95 0.365 787 96 0.355 764 97 0.345 742 98 0.336 721

99 0.327 700 100 0.318 680 101 0.310 661 102 0.302 643 103 0.294 626 104 0.287 609 105 0.279 592 106 0.272 576 107 0.265 561

(For SPT)

Strainer — Periodic cleaning of the required field-installed

strainer is required. Pressure drop across strainer in excess of 3 psi (21 kPa) indicates the need for cleaning. Normal (clean) pressure drop is approximately 1 psi (6.9 kPa). Open the blowdown valve to clean the strainer. If required, shut the chiller down and remove the strainer screen to clean. When strainer has been cleaned, enter ‘YES’ for Strainer Maintenance Done (Run Status

Replacing Defective Modules — The Comfort-

™

Link base board (MBB) has been replaced, verify that all configuration data is correct. Follow the Configuration mode table and verify that all items under sub-modes UNIT, OPT1 and OPT2 are correct. Any additional field-installed accessories or options (RSET, SLCT sub-modes) should also be verified as well as any specific time and maintenance schedules.

Refer to the Start-Up Checklist for 30MP Liquid Chillers (completed at time of original start-up) found in the job folder. This information is needed later in this procedure. If the checklist does not exist, fill out the current information in the Configuration mode on a new checklist. Tailor the various options and configurations as needed for this particular installation.

PM

replacement modules are shown in Table 36. If the main

S.T.MN.

1. Check that all power to unit is off. Carefully disconnect

2. Remove the defective module by removing its mounting

3. Verify that the instance jumper (MBB) or address switch-

4. Package the defective module in the carton of the new

5. Mount the new module in the unit’s control box using a

all wires from the defective module by unplugging its connectors.

screws with a Phillips screwdriver, and removing the module from the control box. Save the screws later use.

es (all other modules) exactly match the settings of the defective module.

NOTE: Handle boards by mounting standoffs only to avoid electrostatic discharge.

module for return to Carrier.

Phillips screwdriver and the screws saved in Step 2.

WARNING

Page 44

6. Reinstall all module connectors. For accessory Navigator™ device replacement, make sure the plug is installed at TB3 in the LEN connector.

7. Carefully check all wiring connections before restoring power.

8. Verify the ENABLE/OFF/REMOTE CONTACT switch is in the OFF position.

9. Restore control power. Verify that all module red LEDs blink in unison. Verify that all green LEDs are blinking and that the scrolling marquee or Navigator™ display is communicating correctly.

10. Verify all configuration information, settings, set points and schedules. Return the ENABLE/OFF/REMOTE CONTACT switch to its previous position.

Table 36 — Replacement Modules

MODULE

Main Base Board (MBB) 30MP500346 Scrolling Marquee Display HK50AA031 Energy Management Module (EMM) 30GT515218 Navigator Display HK50AA033

REPLACEMENT

PART N O .

(with Software)

UNIT ENABLE-OFF-REMOTE CONTACT SWITCH IS OFF — When the switch is OFF, the unit will stop immediately. Place the switch in the ENABLE position for local switch control or in the REMOTE CONTACT position for control through remote contact closure.

CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN — After the problem causing the loss of flow has been corrected, reset is manual by resetting the alarm with the scrolling marquee.

OPEN 24-V CONTROL CIRCUIT BREAKER(S) — Determine the cause of the failure and correct. Reset circuit breaker(s). Restart is automatic after MBB start-up cycle is complete.

COOLING LOAD SATISFIED — Unit shuts down when cooling load has been satisfied. Unit restarts when required to satisfy leaving fluid temperature set point.

THERMISTOR FAILURE — If a thermistor fails in either an open or shorted condition, the unit will be shut down. Replace EWT, or LWT as required. Unit restarts automatically, but must be reset manually by resetting the alarm with the scrolling marquee.

CAUTION

MAINTENANCE

Recommended Maintenance Schedule —

lowing are only recommended guidelines. Jobsite conditions may dictate that maintenance schedule is performed more often than recommended.

Routine: Every month:

• 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 compressor oil level.

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 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 and condenser strainers, clean as necessary.

• 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 evaporator if necessary.

The fol-

TROUBLESHOOTING

Complete Unit Stoppage and Restart —

ble causes for unit stoppage and reset methods are shown below and in Table 37. Refer to Fig. 3-7 for component arrangement and control wiring diagrams.

GENERAL POWER FAILURE — After power is restored, restart is automatic through normal MBB start-up.

Possi-

If unit stoppage occurs more than once as a result of any of the safety devices listed, determine and correct cause before attempting another restart.

LOW SATURATED SUCTION — Several conditions can lead to low saturated suction alarms and the chiller controls have several override modes built in which will attempt to keep the chiller from shutting down. Low fluid flow, low refrigerant charge and plugged filter driers are the main causes for this condition. To avoid permanent damage and potential freezing of the system, do NOT repeatedly reset these alert and/or alarm conditions without identifying and correcting the cause(s).

COMPRESSOR SAFETIES — The 30MP units with Com- fortLink™ controls include a compressor protection board that protects the operation of each of the compressors. Each board senses the presence or absence of current to each compressor.

If there is a command for a compressor to run and there is no current, then one of the following safeties or conditions have turned the compressor off:

Compressor Overcurrent

— All compressors have internal line breaks or a motor protection device located in the compressor electrical box.

Compressor Short Circuit

— There will not be current if the compressor circuit breaker that provides short circuit protection has tripped.

Compressor Motor Over Temperature

— The internal line-

break or over temperature switch has opened. High-Pressure Switch Trip

— The high pressure switch has opened. See Table 31 for the factory settings for the fixed high pressure switch.

ASTP Protection Trip

— All non-digital Copeland compressors are equipped with an advanced scroll temperature protection (ASTP). A label located above the terminal box identifies models that contain this technology. See Fig. 25.

Advanced scroll temperature protection is a form of internal discharge temperature protection that unloads the scroll compressor when the internal temperature reaches approximately 300 F. At this temperature, an internal bi-metal disk valve opens and causes the scroll elements to separate, which stops compression. Suction and discharge pressures balance while the motor continues to run. The longer the compressor runs unloaded, the longer it must cool before the bi-metal disk resets. See Fig. 26 for approximate reset times.

Page 45

Fig. 25 — Advanced Scroll Temperature

Protection Label

ENTER

Fig. 26 — Recommended Minimum Cool Down Time After Compressor is Stopped*

100

110

120

0 102030405060708090

Compressor Unloaded Run Time (Minutes)

Recommended Cooling Time

(Mi

nut

es)

*Times are approximate. NOTE: Various factors, including high humidity, high ambient temperature, and the presence of a sound blanket will increase cool-down times.

To manually reset ASTP, the compressor should be stopped and allowed to cool. If the compressor is not stopped, the motor will run until the motor protector trips, which occurs up to 90 minutes later. Advanced scroll temperature protection will reset automatically before the motor protector resets, which may take up to 2 hours.

High Discharge Gas Temperature Protection

— Units equipped with optional digital compressors have an additional thermistor located on the discharge line, If discharge temperature exceeds 265 F (129.4 C), the digital compressor will be shut off.

Alarms will also occur if the current sensor board malfunc-

tions or is not properly connected to its assigned digital input. If

the compressor is commanded OFF and the current sensor reads ON, an alert is generated. This will indicate that a compressor contactor has failed closed. In this case, a special mode, Compressor Stuck on Control, will be enabled and all other compressors will be turned off. An alarm will then be enabled to indicate that service is required. Outdoor fans will continue to operate. The condenser output is turned on immediately.

Alarms and Alerts — These are warnings of abnormal

or fault conditions, and may cause either one circuit or the whole unit to shut down. They are assigned code numbers as described in Table 38.

Automatic alarms will reset without operator intervention if the condition corrects itself. The following method must be used to reset manual alarms:

Before resetting any alarm, first determine the cause of the alarm and correct it. Enter the Alarms mode indicated by the LED on the side of the scrolling marquee display. Press

and until the sub-menu item RCRN “RESET ALL CURRENT ALARMS” is displayed. Press . The control will prompt the user for a password, by displaying PASS and WORD. Press to display the default password, 1111. Press for each character. If the password has been changed, use the arrow keys to change each individual character. Toggle the display to “YES” and press . The alarms will be reset.

Page 46

Table 37 — Troubleshooting

SYMPTOMS CAUSE REMEDY

Compressor Cycles Off on Loss of Charge

Compressor Cycles Off on Out of Range Condition

Compressor Shuts Down on High-Pressure Control

Unit Operates Too Long or Continuously

Unusual or Loud System Noises

Compressor Loses Oil Leak in system Repair leak.

Hot Liquid Line Shortage of refrigerant due to leak Repair leak and recharge. Frosted Liquid Line Restricted filter drier Replace filter drier. Frosted Suction Line Expansion valve admitting excess refrigerant (note: this is a

Freeze-Up Improper charging Make sure a full quantity of fluid is flowing through the cooler

Loss of charge control. Acting erratically. Repair leak and recharge.

Low refrigerant charge Add refrigerant. Low suction temperature Raise cooler leaving fluid temperature set point. Thermistor failure Replace thermistor. System load was reduced faster than controller could

remove stages

Temperature controller deadband setting is too low Raise deadband setting. High-pressure control acting erratically Replace control. Noncondensables in system Purge system. Condenser scaled/dirty Clean condenser. Fans in remote condensing unit (30MPA only) not operating Repair or replace if defective. System overcharged with refrigerant Reduce charge. Low refrigerant charge Add refrigerant. Control contacts fused Replace control. Air in system Purge system. Partially plugged or plugged expansion valve or filter drier Clean or replace as needed. Defective insulation Replace or repair as needed. Service load Keep doors and windows closed. Damaged compressor Check compressor and replace if necessary. Piping vibration Support piping as required.

Expansion valve hissing Add refrigerant.

Compressor noisy Replace compressor (worn bearings).

Mechanical damage (Failed seals or broken scrolls) Replace compressor. Oil trapped in line Check piping for oil traps.

normal condition for brine applications) Stuck TXV Replace valve if defective.

System not drained for winter shutdown Recommended that system be filled with an appropriate gly-

Loose Thermistor Verify thermistors are fully inserted in wells.

Replace control.

Unit will restart after fluid temperature rises back into the control band. Avoid rapidly removing system load or increase loop volume.

Check for loose pipe connections or damaged compressor

Check for plugged liquid line filter drier.

Check for loose compressor holddown bolts.

Replace valve if defective.

while charging, and suction pressure in cooler is equal to or greater than pressure corresponding to 32 F (0° C).

col mixture to prevent freezing of pumps and fluid tubing.

Page 47

Table 38 — Alarm and Alert Codes

ALARM/

ALERT

CODE

ALARM

ALERT

A048 Alarm

T051 Alert

A051 Alarm

T052 Alert

A052 Alarm

T053 Alert

A053 Alarm

A060

A061 Alarm

T062 Alert Condenser Leaving Fluid

T063 Alert Condenser Entering Fluid

T068 None

T073 Alert

T074 Alert

A077 Alarm

T079 Alert

A090 Alarm

A092 Alarm

T094 Alert

A110 Alarm Circuit A Loss of Charge

A112 Alarm

A114 Alarm

Alarm

DESCRIPTION

Circuit A Compressor Availability Alarm

Circuit A, Compressor 1 Failure

Circuit A, Compressor 2 Failure

Circuit A, Compressor 3 Failure

Cooler Leaving Fluid Thermistor Failure

Cooler Entering Fluid Thermistor Failure

Thermistor Failure

Circuit A Return Gas Thermistor Failure

Outside Air Thermistor Failure

Space Temperature/Dual Chiller Thermistor Failure

Circuit A Saturated Suction Temperature exceeds Cooler Leaving Fluid Temperature

Lead/Lag LWT Thermistor Failure

Circuit A Discharge Pressure Transducer Failure

Circuit A Suction Pressure Transducer Failure

Discharge Gas Thermistor Failure

Circuit A High Saturated Suction Temperature

Circuit A Low Suction Superheat

WHY WAS THIS

ALARM

GENERATED?

Two compressors on circuit failed

Compressor feedback signal does not match relay state

Respective current sensor board (CSB) feedback signal is ON when the compressor should be off

Compressor feedback signal does not match relay state

Respective current sensor board (CSB) feedback signal is ON when the compressor should be off

Compressor feedback signal does not match relay state

Respective current sensor board (CSB) feedback signal is ON when the compressor should be off

Thermistor outside range of –40 to 245 F (–40 to 118 C)

If return gas sensors are enabled (RG.EN) and thermistor is outside range of –40 to 245 F (–40 to 118 C)

Thermistor outside range of –40 to 245 F (–40 to 118 C) (if enabled)

Faulty expansion valve, suction pressure transducer or leaving fluid thermistor.

Thermistor outside range of –40 to 245 F (–40 to 118 C)

Outside of range (0 - 667 psig) Circuit A shut down Automatic

Outside of range (0 - 420 psig) Circuit A shut down Automatic

Discharge thermistor (DTT) is either open or shorted

If the compressors are off and discharge pressure reading is < 26 psig for 30 sec.

Circuit saturated suction temperature pressure transducer > 70 F (21.1 C) for 5 minutes

Suction superheat is less than 5° F (2.8 C) for 5 minutes. (if RGT installed)

ACTION TAKEN

BY CONTROL

Circuit shut down Manual

Compressor A1 shut down.

Unit shut down Manual

Compressor A2 shut down.

Unit shut down Manual

Compressor A3 shut down.

Unit shut down Manual

Chiller shut down immediately

Alert only. No action taken.

Circuit A shut down Automatic

Temperature reset disabled. Chiller runs under normal control/set points.

Circuit A shutdown after pumpdown complete.

Chiller runs as a stand alone machine

Digital compressor shut down.

Circuit not allowed to start.

Circuit shut down Manual

Circuit A shut down.

RESET

METHOD

Manual

Automatic

Automatic Thermistor failure, damaged

Automatic

Manual

Automatic

Manual

Automatic restart

after first daily

occurrence.

Manual restart

thereafter.

PROBABLE

CAUSE

Only one compressor operating.

High-pressure switch open, faulty CSB, loss of condenser flow, filter drier plugged, noncondensables, operation beyond capability.

Thermistor failure, damaged cable/wire or wiring error.

cable/wire or wiring error.

Thermistor failure, damaged cable/wire or wiring error.

Faulty expansion valve or suction pressure transducer or leaving fluid thermistor.

Dual LWT thermistor failure, damaged cable/wire or wiring error.

Transducer failure, poor connection to MBB, or wiring damage/error.

Thermistor failure, damaged cable/wire or wiring error.

Refrigerant leak or transducer failure

Faulty Expansion valve, faulty suction pressure transducer or high entering fluid temperature.

Faulty expansion valve, faulty suction pressure transducer, faulty suction gas thermistor, circuit overcharged

Page 48

Table 38 — Alarm and Alert Codes (cont)

ALARM/

ALERT

CODE

A116 Alarm

A122 Alarm

A126 Alarm

T133 Alert

A140 Alert

A150 Alarm Emergency Stop

A151 Alarm Illegal Configuration

A152 Alarm

T153 Alert

A154 Alarm

T155 Alert

A156 Alarm

A157 Alarm A/D Hardware Failure

T173 Alert

T174 Alert

T176 Alert

T177 Alert

See legend on page 51.

ALARM

ALERT

DESCRIPTION

Circuit A Low Cooler Suction Temperature

High Pressure Switch

Trip Circuit A

Circuit A High Discharge Pressure

Circuit A Low Suction Pressure

Reverse Rotation Detected

Unit Down Due to Failure

Real Time Clock Hardware Failure

Serial EEPROM Hardware Failure

Serial EEPROM Storage Failure

Critical Serial EEPROM Storage Failure

Loss of Communication with EMM

4 to 20 mA Cooling Set Point Input Failure

4 to 20 mA Temperature Reset Input Failure

4 to 20 mA Demand Limit Input Failure

WHY WAS THIS

ALARM

GENERATED?

Mode 7 caused the compressor to unload 6 consecutive times with less than a 30-minute interval between each circuit shutdown.

High Pressure A Switch

Input opento MBB

SCT >Maximum condensing temperature from operating envelope

Suction pressure below 34 psig for 8 seconds or below 23 psig

Incoming chiller power leads not phased correctly

CCN emergency stop command received

One or more illegal configurations exists.

Both circuits are down due to alarms/alerts.

Internal clock on MBB fails

Hardware failure with MBB

Configuration/storage failure with MBB

Hardware failure with peripheral device

MBB loses communication with EMM

If configured with EMM and input less than 2 mA or greater than 22 mA

ACTION TAKEN

BY CONTROL

Circuit shut down Manual

Circuit shut down

Chiller not allowed to start.

Chiller shutdown without going through pumpdown.

Chiller is not allowed to start.

Chiller is unable to run.

Occupancy schedule will not be used. Chiller defaults to Local On mode.

Chiller is unable to run.

No Action Manual

Chiller is not allowed to run.

4 to 20 mA temperature reset disabled. Demand Limit set to 100%. 4 to 20 mA set point disabled.

Set point function disabled. Chiller controls to CSP1.

Reset function disabled. Chiller returns to normal set point control.

Demand limit function disabled. Chiller returns to 100% demand limit control.

RESET

METHOD

Automatic, only after first 3 daily occurrences. Manual reset thereafter. Reading from OAT sensor must drop 5 F (2.8 C) before restart

Automatic restart after first daily occurrence. Manual restart thereafter.

Manual

Automatic once CCN command for EMSTOP returns to normal

Manual once configuration errors are corrected

Automatic once alarms/alerts are cleared that prevent the chiller from starting.

Automatic when correct clock control restarts.

Manual

Autom atic

PROBABLE

CAUSE

Faulty expansion valve, low refrigerant charge, plugged filter drier, faulty suction pressure transducer, low cooler fluid flow

Faulty transducer/high pressure switch.

Faulty transducer/high pressure switch, low/ restricted condenser airflow

Faulty or plugged EXV, low refrigerant charge, EXV out of adjustment, liquid line valve partially closed

Reverse any two incoming power leads to correct. Check for correct fan rotation first.

CCN Network command.

Configuration error. Check unit settings.

Alarm notifies user that chiller is 100% down.

Time/Date/Month/ Day/Year not properly set.

Main Base Board failure.

Potential failure of MBB. Download current operating software. Replace MBB if error occurs again.

Main Base Board failure.

Wiring error, faulty wiring or failed Energy Management Module (EMM).

Faulty signal generator, wiring error, or faulty EMM.

Page 49

Table 38 — Alarm and Alert Codes (cont)

ALARM/

ALERT

CODE

T200 Aler t

A201 Alarm

A202 Alarm

T203 Aler t

T204 Aler t

T205 Aler t

T206 Aler t

A207 Alarm

A208 Alarm

A220 Alarm Condenser Pump

A221 Alarm Condenser Pump

A222 Alarm Condenser Pump

ALARM

ALERT

DESCRIPTION

Cooler Flow/Interlock Contacts failed to Close at start-up

Cooler Flow/Interlock Contacts Opened During Normal Operation

Cooler Pump Interlock Closed When Pump is Off

Loss of Communication with slave chiller

Loss of Communication with master chiller

Master and slave chiller with same address

High Leaving Chilled Water Temperature

Cooler Freeze Protection

EWT or LWT Thermistor failure

Interlock Failure to Close at Start-Up

Interlock Opened During Normal Operation

Interlock Closed When Pump is Off

WHY WAS THIS

ALARM

GENERATED?

Cooler flow switch contacts failed to close within 1 minute (if cooler pump control is enabled) or within 5 minutes (if cooler pump control is not enabled) after start-up

Flow switch opens for at least 3 seconds after being initially closed

If configured for cooler pump control and flow switch input is closed for 5 minutes while pump output(s) are off

Master chiller MBB loses communication with slave chiller MBB

Slave chiller MBB loses communication with master chiller MBB

Master and slave chiller have the same CCN address (CCN.A)

LWT read is greater than LCW Alert Limit, Total capacity is 100% and LWT is greater than LWT reading one minute ago

Cooler EWT or LWT is less than Brine Freeze (BR.FZ)

Cooler EWT is less than LWT by 3° F (1.7° C) for 1 minute after a circuit is started

If configured for condenser pump interlock and the flow switch input fails to close within 5 minutes after startup. Also valid when configured for condenser pump control.

If configured for condenser pump interlock and the flow switch opens for 15 seconds during normal operation (or when the condenser pump relay is on when condenser pump control is configured.)

If configured for condenser pump interlock condenser pump control, and the flow switch is closed when pump relay is off.

ACTI ON TAKEN

BY CONTROL

Chiller not allowed to start. For models with dual pumps, the second pump will be started if available

All compressors shut down. For models with dual pumps, the second pump will be started if available

Chiller shut down

Dual chiller control disabled. Chiller runs as a stand-alone machine.

Dual chiller control disabled. Chiller runs as a stand-alone machine

Dual chiller routine disabled. Master/slave run as stand-alone chillers.

Alert only. No action taken.

Chiller shutdown without going through pumpdown. Cooler pump continues to run a minimum of 5 minutes (if control enabled).

Chiller shutdown. Cooler pump shut off (if control enabled).

Condenser and cooler pumps shut off. Chiller shutdown without going through pumpdown.

Chiller is not allowed to start.

RESET

METHOD

Manual

Automatic when aux contacts open

Automatic

Both EWT and LWT must be at least 6 F (3.3 C) above Brine Freeze point (BR.FZ). Automatic for first, Manual reset there after.

Manual

Manual Failure of condenser

Faulty flow switch or interlock.

Cooler pump failure, faulty flow switch or interlock.

Wiring error, faulty pump contactor (welded contacts)

Wiring error, faulty wiring, failed Slave chiller MBB module, power loss at slave chiller, wrong slave address.

Wiring error, faulty wiring, failed master chiller MBB module, power loss at Master chiller.

CCN Address for both chillers is the same. Must be different. Check CCN.A under the OPT2 sub-mode in Configuration at both chillers.

Building load greater than unit capacity, low water/brine flow or compressor fault. Check for other alarms/alerts.

Faulty thermistor (T1/T2), low water flow.

Faulty cooler pump, low water flow, plugged fluid strainer.

pump or controls. Wiring error.

pump relays or interlocks, welded contacts.

PROBABLE

CAUSE

Page 50

Table 38 — Alarm and Alert Codes (cont)

ALARM/

ALERT

CODE

T302 Alert

T500 Alert

T501 Alert

T502 Alert

T950 Alert Loss of Communication

T951 Alert Loss of Communication

CCN — Carrier Comfort Network CSB — Current Sensor Board CSM — Chiller System Manager CXB — Compressor Expansion Board EEPROM — Electronic Eraseable Programmable Read Only Memory EMM — Energy Management Module EWT — Entering Fluid Temperature EXV — Electronic Expansion Valve HSM — Hydronic System Manager LCW — Leaving Chilled Water LWT — Leaving Fluid Temperature MBB — Main Base Board OAT — Outdoor-Air Temperature RGT — Return Gas Thermistor WSM — Water System Manager

ALARM

ALERT

LEGEND

DESCRIPTION

Strainer Blowdown Scheduled Maintenance Due

Current Sensor Board A1 Failure

Current Sensor Board A2 Failure

Current Sensor Board A3 Failure

with Water System Manager

with Chillervisor System Manager

WHY WAS THIS

ALARM

GENERATED?

Strainer Service Countdown (S.T.DN) expired. Complete strainer blowdown and enter 'YES' for Strainer Maintenance Done (S.T.MN) item.

Alert occurs when CSB output is a constant high value

No communications have been received by the MBB within 5 minutes of last transmission

ACTION TAKEN

BY CONTROL

None Automatic

Compressor A1 shut down

Compressor A2 shut down

Compressor A3 shut down

WSM forces removed. Chiller runs under own control

CSM forces removed. Chiller runs under own control

RESET

METHOD

Autom atic

Automatic Failed module, wiring

PROBABLE

CAUSE

Routine strainer maintenance required

CSB failure.

error, failed transformer, loose connection plug, wrong address

COMPRESSOR FAILURE ALERTS A048 (Circuit A Compressor Availability Alarm)

— This alarm occurs when two compressors are unavailable to run on a 3 compressor circuit. The control ensures proper oil return by ensuring a circuit does not operate with one compressor for longer than one hour of cumulative run time.

T051, T052, T053 (Circuit A Compresser Failures)

— Alert codes 051, 052, and 053 are for compressors A1, A2, and A3 respectively. These alerts occur when the current sensor (CS) does not detect compressor current during compressor operation. When this occurs, the control turns off the compressor.

If the current sensor board reads OFF while the compressor

relay has been commanded ON, an alert is generated. POSSIBLE CAUSES Compressor Overload

— Either the compressor internal overload protector is open or the external overload protector (Kriwan module) has activated. The external overload protector modules are mounted in the compressor wiring junction box. Temperature sensors embedded in the compressor motor windings are the inputs to the module. The module is powered with 24 vac from the units main control box. The module output is a normally closed contact that is wired in series with the compressor contactor coil. In a compressor motor overload condition, contact opens, deenergizing the compressor contactor.

Low Refrigerant Charge

— If the compressor operates for an extended period of time with low refrigerant charge, the compressor ASTP device will open, which will cause the compressor to trip on its overload protection device.

Circuit Breaker Trip

— The compressors are protected from

short circuit by a breaker in the control box. Wiring Error

— A wiring error might not allow the compres-

sor to start.

To check out alerts T051-T053:

1. Turn on the compressor in question using Service Test mode. If the compressor does not start, then most likely the problem is one of the following: HPS open, open internal protection, circuit breaker trip, incorrect safety wiring, or incorrect compressor wiring.

2. If the compressor does start, verify it is rotating in the correct direction.

IMPORTANT: Prolonged operation in the wrong direction can damage the compressor. Correct rotation can be verified by a gage set and looking for a differential pressure rise on start-up.

IMPORTANT: If the CS is always detecting current, verify that the compressor is on. If the compressor is on, check the contactor and the relay on the MBB. If the compressor is off and there is no current, verify the CSB wiring and replace if necessary.

IMPORTANT: Return to Normal mode and observe compressor operation to verify that compressor current sensor is working.

COMPRESSOR STUCK ON FAILURE ALARMS Circuit A A051, A052, A053

— Alarm codes 051, 052, and 053 are for compressors A1, A2, and A3. These alarms occur when the CSB detects current when the compressor should be off. When this occurs, the control turns off the compressor.

If the current sensor board reads ON while the compressor relay has been commanded OFF for a period of 4 continuous seconds, an alarm is generated. These alarms are only monitored for a period of 10 seconds after the compressor relay has

Page 51

been commanded OFF. This is done to facilitate a service technician forcing a relay to test a compressor.

In addition, if a compressor stuck failure occurs and the current sensor board reports the compressor and the request off, certain diagnostics will take place as follows:

1. If any of the compressors are diagnosed as stuck on and the current sensor board is on and the request is off, the control will command the condenser fans to maintain normal head pressure.

2. The control will shut-off all other compressors. The possible causes include welded contactor or frozen

compressor relay on the MBB.

To check out alarms A051 to A053:

1. Place the unit in Service Test mode. All compressors should be off.

2. Verify that there is not 24-v at the contactor coil. If there is 24 v at the contactor, check relay on MBB and wiring.

3. Check for welded contactor.

4. Verify CSB wiring.

5. Return to Normal mode and observe compressor operation to verify that compressor current sensor is working and condenser fans are energized.

A060 (Cooler Leaving Fluid Thermistor Failure) sensor reading is outside the range of –40 to 245 F (–40 to 118 C) then the alarm will occur. The cause of the alarm is usually a faulty thermistor, a shorted or open thermistor caused by a wiring error, or a loose connection. Failure of this thermistor will shut down the entire unit.

A061 (Cooler Entering Thermistor Failure) reading is outside the range of –40 to 240 F (–40 to116 C) then the alarm will occur. The cause of the alarm is usually a faulty thermistor, a shorted or open thermistor caused by a wiring error, or a loose connection. Failure of this thermistor will shut down the entire unit.

T062 (Condenser Leaving Fluid Thermistor Failure) sensor reading is outside the range of –40 to 245 F (–40 to 118 C) then the alert will occur. The cause of the alert is usually a faulty thermistor, a shorted or open thermistor caused by a wiring error, or a loose connection. Failure of this thermistor will send out an alert only.

T063 (Condenser Entering Thermistor Failure) sor reading is outside the range of –40 to 240 F (–40 to116 C) then the alert will occur. The cause of the alert is usually a faulty thermistor, a shorted or open thermistor caused by a wiring error, or a loose connection.Failure of this thermistor will send out an alert only.

T068 (Circuit A Compressor Return Gas Temperature Thermistor Failure) — This alert occurs if the RGT is configured and the compressor return gas temperature sensor is outside the range of –40 to 240 F (–40 to 116 C). Failure of this thermistor will shut down the appropriate circuit.

T073 (Outside Air Temperature Thermistor Failure) alert occurs when the outside air temperature sensor is outside the range of –40 to 240 F (–40 to 116 C). Failure of this thermistor will disable any elements of the control which requires its use. The OAT must be configured.

T074 (Space Temperature Thermistor Failure) occurs when the space temperature sensor is outside the range of –40 to 245 F (–40 to 118 C). Failure of this thermistor will disable any elements of the control which requires its use. The cause of the alert is usually a faulty thermistor in the T55, or T58 device, a shorted or open thermistor caused by a wiring error, or a loose connection. The SPT must be configured.

A077 (Circuit Saturated Suction Temperature Exceeds Cooler Leaving Water Temperature) — This alarm occurs when the saturated suction temperature (SST) is greater than

— The

— If the sensor

— The

— If the sen-

— This

— This alert

leaving water for 5 minutes. This alarm will occur if either the suction pressure transducer reading, which is used to calculate SST, or cooler leaving water is incorrect. Potential causes for this alarm are loose wiring connection, sensor not located in well or bad Schrader fitting. Reset is manual.

T079 (Dual Chiller Thermistor Failure) when the dual chiller temperature sensor is outside its range of –40 to 240 F. Failure of this thermistor will disable Dual Chiller operation and return to stand-alone operation. The unit must be configured for Dual Chiller operation for this alert to occur. The cause of the alert is usually a faulty thermistor, a shorted or open thermistor caused by a wiring error, or a loose connection. Reset is automatic.

A090 (Circuit A Discharge Pressure Transducer Failure) This alarm occurs when the pressure is outside the range of 0.0 to 667.0 psig. A circuit cannot run when this alarm is active. Use the scrolling marquee to reset the alarm. The cause of the alarm is usually a faulty transducer, faulty 5-v power supply, or a loose connection.

A092 (Circuit A Suction Pressure Transducer Failure) This alarm occurs when the pressure is outside the range of 0.0 to 420.0 psig. A circuit cannot run when this alarm is active. Use the scrolling marquee to reset the alarm. The cause of the alarm is usually a faulty transducer, faulty 5-v power supply, or a loose connection.

T094 (Discharge Gas Thermistor Failure) curs for units which have the digital compressor installed on circuit A. If discharge gas temperature is open or shorted, the circuit will be shut off. The alert will reset itself when discharge temperature is less than 250 F (121.1 C). The cause of the alert is usually low refrigerant charge or a faulty thermistor.

A110 (Circuit A Loss of Charge) the compressor is OFF and the discharge pressure is less than 26 psig.

A112 (Circuit A High Saturated Suction Temperature) Alarm code 112 occurs when compressors in a circuit have been running for at least 5 minutes and the circuit saturated suction temperature is greater than 70 F (21.1 C). The high saturated suction alarm is generated and the circuit is shut down.

A114 (Circuit A Low Superheat) when the superheat of a circuit is less than 5 F (2.8 C) for 5 continuous minutes. The low superheat alarm is generated and the circuit is shut down. The RGT sensor must be installed.

A122 (Circuit A, High Pressure Switch Failure) high pressure switch is wired in series with the compressor contactor coils of each compressor on the circuit to disable compressor operation immediately upon a high discharge pressure condition. The normally closed contacts in the switches are calibrated to open at 650 ± 10 psig which corresponds to a saturated condensing temperature of 155.6 ± 1.3 F. The pressure switches will automatically reset when the discharge pressure is reduced to 500 ± 15 psig which corresponds to a saturated condensing temperature of 134.1 ± 2.4 F.

The output of the high pressure switch is wired to inputs on the MBB to provide the control with an indication of a high pressure switch trip. This alert could occur when compressors are off if the wiring to the switch is broken or the switch has failed open.

If the high pressure switch trips on a circuit with compressors commanded on, the discharge pressure is recorded. If the recorded discharge pressure is between 630 to 660 psig (saturated condensing temperature between 153.0 and 156.9 F), and is also less than the value recorded on any previous high pressure switch trip, the upper horizontal portion of the compressor operating envelope (see Fig. 12) is lowered 0.4 F (3 psig). The control will not allow the compressor operating envelope to be lowered below 153.0 F (630 psig).

— This alert occurs

—

— This alert oc-

— This alarm occurs when

—

— Alarm code 114 occurs

— The

Page 52

This is done to make a rough calibration of the high pressure switch trip point. In most cases this allows the control to detect a high head pressure condition prior to reaching the high pressure switch trip point.

When the trip occurs, all mechanical cooling on the circuit is shut down for 15 minutes. After 15 minutes, the circuit is allowed to restart.

A126 (Circuit A High Head Pressure) when the appropriate saturated condensing temperature is greater than the operating envelope shown in Fig 12. Prior to the alarm, the control will shut down one compressor on a circuit if that circuit's saturated condensing temperature is greater than the maximum SCT minus 5° F (2.7° C). If SCT continues to rise to greater than the maximum SCT, the alarm will occur and the circuit's remaining compressor will shut down. The cause of the alarm is usually an overcharged system, high outdoor ambient temperature coupled with dirty outdoor coil (30MPA only), plugged filter drier, a faulty high-pressure switch, or loss of condenser water flow.

A140 (Reverse Rotation Detected) power up, for suction pressure change on the first activated circuit. The unit control determines failure as follows:

1. The suction pressure is sampled 5 seconds before the compressor is brought on, right when the compressor is brought on and 5 seconds afterwards.

2. The rate of suction pressure change from 5 seconds before the compressor is brought on to when the compressor is brought on is calculated.

3. The rate of suction pressure change from when the compressor is brought on to 5 seconds afterwards is calculated.

4. With the above information, the test for reverse rotation is made. If the suction pressure change 5 seconds after compression is greater than the suction pressure change 5 seconds before compression – 1.25, then there is a reverse rotation error.

This alarm will disable mechanical cooling and will require manual reset. This alarm may be disabled once the reverse rotation check has been verified by setting REV.R = Yes.

A150 (Unit is in Emergency Stop) stop command is received, the alarm is generated and the unit will be immediately stopped.

If the CCN point name "EMSTOP" in the system table is set to emergency stop, the unit will shut down immediately and broadcast an alarm back to the CCN, indicating that the unit is down. This alarm will clear when the variable is set back to "enable."

A151 (Illegal Configuration) invalid configuration has been entered. The following are illegal configurations.

— An A151 alarm indicates an

— This alarm occurs

— A test is made once, on

— If the CCN emergency

• Invalid unit size has been entered.

• Unit configuration set to invalid type. A152 (Unit Down Due to Failure)

when all alarms are cleared. This alarm indicates the unit is at 0% capacity.

T153 (Real Time Clock Hardware Failure) has been detected with MBB real time clock hardware. Try resetting the power and check the indicator lights. If the alarm continues, the board should be replaced.

A154 (Serial EEPROM Hardware Failure) has been detected with the EEPROM on the MBB. Try resetting the power and check the indicator lights. If the alarm continues, the board should be replaced.

T155 (Serial EEPROM Storage Failure Error) has been detected with the EEPROM storage on the MBB. Try resetting the power and check the indicator lights. If the alert continues, the board should be replaced.

A156 (Critical Serial EEPROM Storage Failure Error) problem has been detected with the EEPROM storage on the MBB. Try resetting the power and check the indicator lights. If the alarm continues, the board should be replaced.

A157 (A/D Hardware Failure) ed with A/D conversion on the boards. Try resetting the power and check the indicator lights. If the alarm continues, the board should be replaced.

T173 (Energy Management Module Communication Failure) — This alert indicates that there are communications problems with the energy management. All functions performed by the EMM will stop, which can include demand limit, reset and capacity input. The alert will automatically reset.

T174 (4 to 20 mA Cooling Set point Input Failure) alert indicates a problem has been detected with cooling set point 4 to 20 mA input. The input value is either less than 2 mA or greater than 22 mA.

T176 (4 to 20 mA Reset Input Failure) cates a problem has been detected with reset 4 to 20 mA input. The input value is either less than 2 mA or greater than 22 mA. The reset function will be disabled when this occurs.

T177 (4 to 20 mA Demand Limit Input Failure) alert indicates a problem has been detected with demand limit 4 to 20 mA input. The input value is either less than 2 mA or greater than 22 mA. The reset function will be disabled when this occurs.

T500, T501, T502 (Current Sensor Board Failure — A xx Circuit A — Alert codes 500, 501, and 502 are for compressors A1, A2, and A3 respectively. These alerts occur when the output of the CSB is a constant high value. These alerts reset automatically. If the problem cannot be resolved, the CSB must be replaced.

— Reset is automatic

— A problem

— A

— A problem has been detect-

— This

— This alert indi-

— This

Page 53

APPENDIX A — LOCAL DISPLAY TABLES

Run Status Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

AUTO VIEW OF RUN STATUS

EWT xxx.x ºF Entering Fluid Temp EWT

LWT xxx.x ºF Leaving Fluid Temp LWT SETP xxx.x ºF Active Setpoint SP CTPT xxx.x ºF Control Point CTRL_PNT LOD.F xxx Load/Unload Factor SMZ

STAT Control Mode STAT OCC NO/YES Occupied OCC

VIEW

RUN

HOUR

STRT

MODE NO/YES

CAP xxx Percent Total Capacity CAP_T STGE x Requested Stage STAGE ALRM xxx Current Alarms & Alerts ALRMALRT

TIME xx.xx Time of Day TIMECOPY 00:00-23:59

MNTH xx Month of Year MOY

DATE xx Day of Month DOM 01-31

YEAR xx Year of Century YOCDISP

HRS.U xxxx HRS

STR.U xxxx Machine Starts CY_MACH 0 to 1000000

HR.P1 xxxx HRS

HR.P2 xxxx HRS

HR.A1 xxxx HRS

HR.A2 xxxx HRS

HR.A3 xxxx HRS

ST.A1 xxxx Compressor A1 Starts CY_A1 0 to 999999 ST.A2 xxxx Compressor A2 Starts CY_A2 0 to 999999 ST.A3 xxxx Compressor A3 Starts CY_A3 0 to 999999

STRN STRAINER MAINTENANCE

SI.ST xxxx HRS Strainer Srvc Interval SI_STRNR 0 to 65535

S.T.DN xxxx HRS

S.T.MN NO/YES Strainer Maint. Done ST_MAINT

ST.DT STRAINER MAINT. DATES

S.T.M0 MM/DD/YY HH:MM S.T.M1 MM/DD/YY HH:MM S.T.M2 MM/DD/YY HH:MM S.T.M3 MM/DD/YY HH:MM S.T.M4 MM/DD/YY HH:MM

AUX CESR131333-xx-xx

Override Modes in

Effect

UNIT RUN HOUR AND START

Machine Operating

Hours

Cooler Pump Run

Hours

Condenser Pump Run

Hours

CIRC AND COMP RUN HOURS

Compressor A1 Run

Hours

Compressor A2 Run

Hours

Compressor A3 Run

Hours

COMPRESSOR STARTS

PREVENTIVE MAINTENANCE

Strainer Srvc Count-

down

SOFTWARE VERSION NUMBERS

MODE

1 - 12 (1 = January,

2 = February, etc.)

HR_MACH 0 to 999999

HR_CPUMP 0 to 999999.9

HR_DPUMP 0 to 999999.9

HOURS_A1 0 to 999999

HOURS_A2 0 to 999999

HOURS_A3 0 to 999999

ST_CDOWN 0 to 65535

VERS

MBB CESR131279-xx-xx

EMM CESR131174-xx-xx

MARQ CESR131171-xx-xx

NAVI CESR130227-xx-xx

Page 54

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Service Test Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

To enable Service Test mode, move

TEST ON/OFF Service Test Mode MAN_CTRL

OUTPUTS AND PUMPS CLR.P OFF/ON Cooler Pump Relay S_CLPMP CND.P OFF/ON Condenser Pump S_CNDPMP UL.TM xx Comp A1 Unload Time S_A1ULTM 0 to 15

OUTS

CMPA

CC.H OFF/ON Crankcase Heater S_CCH

CW.VO OFF/ON Condenser Valve Open S_CWVO

CW.VC OFF/ON Condenser Valve Close S_CWVC

LL.SV OFF/ON Liquid Line Solenoid S_LLSV

RMT.A OFF/ON Remote Alarm Relay S_ALM

CIRCUIT A COMPRESSOR TST CC.A1 OFF/ON Compressor A1 Relay S_A1_RLY UL.TM xx Comp A1 Unload Time S_A1ULTM 0 to 15 CC.A2 OFF/ON Compressor A2 Relay S_A2_RLY CC.A3 OFF/ON Compressor A3 Relay S_A3_RLY

MLV OFF/ON Minimum Load Valve Relay S_MLV

Temperature Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT

ENT AND LEAVE UNIT TEMPS

CEWT xxx.x °F Cooler Entering Fluid COOL_EWT

CLWT xxx.x °F Cooler Leaving Fluid COOL_LWT

UNIT

CIR.A

CDET xxx.x °F Condenser Entering Fluid COND_EWT

CDLT xxx.x °F Condenser Leaving Fluid COND_LWT

OAT xxx.x °F Outside Air Temperature OAT SPT xxx.x °F Space Temperature SPT

DLWT xxx.x °F Lead/Lag Leaving Fluid DUAL_LWT

TEMPERATURES CIRCUIT A

SCT.A xxx.x °F Saturated Condensing Tmp TMP_SCTA

SST.A xxx.x °F Saturated Suction Temp TMP_SSTA

RGT.A xxx.x °F Compr Return Gas Temp TMP_RGTA

D.GAS xxx.x °F Discharge Gas Temp DISGAS

SH.A xxx.x ΔF Suction Superheat Temp SH_A

Pressures Mode and Sub-Mode Directory

Enable/Off/Remote contact switch

OFF. Change TEST to ON.

Move switch to ENABLE

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT

PRESSURES CIRCUIT A

PRC.A

DP.A xxx.x PSIG Discharge Pressure DP_A SP.A xxx.x PSIG Suction Pressure SP_A

Page 55

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Set Points Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION RANGE CCN POINT

COOLING SETPOINTS

COOL

HEAD

FRZ

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT

GEN.I

CRCT

4-20

CSP.1 xxx.x °F Cooling Setpoint 1 –20 to 70 CSP1 CSP.2 xxx.x °F Cooling Setpoint 2 –20 to 70 CSP2 CSP.3 xxx.x °F ICE Setpoint –20 to 32 CSP3

HEAD PRESSURE SETPOINTS

H.DP xxx.x °F Head Setpoint 85 to 120 HSP

BRINE FREEZE SETPOINT

BR.FZ xx.x °F Brine Freeze Point –20 to 34 BRN_FRZ

Inputs Mode and Sub-Mode Directory

GENERAL INPUTS

STST OFF/ON Start/Stop Switch START FLOW OFF/ON Cooler Flow Switch COOLFLOW CD.FL OFF/ON Condenser Flow Switch CONDFLOW

DLS1 OFF/ON Demand Limit Switch 1 DMD_SW1

DLS2 OFF/ON Demand Limit Switch 2 DMD_SW2

ICED OFF/ON Ice Done ICE_DONE

DUAL OFF/ON Dual Setpoint Switch DUAL_IN

CIRCUIT INPUTS FKA1 OFF/ON Compressor A1 Feedback K_A1_FBK FKA2 OFF/ON Compressor A2 Feedback K_A2_FBK FKA3 OFF/ON Compressor A3 Feedback K_A3_FBK

HPS.A OFF/ON High Pressure Switch A HPSA

4-20 MA INPUTS

DMND xx.x 4-20 ma Demand Signal LMT_MA

RSET xx.x 4-20 ma Reset Signal RST_MA

CSP xx.x 4-20 ma Cooling Setpoint CSP_IN

Outputs Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT

GENERAL OUTPUTS

C.LWP OFF/ON Cooler Pump Relay COOLPUMP

GEN.O

CIR.A

C.DWP OFF/ON Condenser Pump CONDPUMP

ALRM OFF/ON Alarm State ALM CDWO OFF/ON Condenser Valve Open COND_WVO CDWC OFF/ON Condenser Valve Close COND_WVC

OUTPUTS CIRCUIT A CC.A1 OFF/ON Compressor A1 Relay K_A1_RLY D.SOL OFF/ON Digital Scroll Solenoid DISCRSOL CC.A2 OFF/ON Compressor A2 Relay K_A2_RLY CC.A3 OFF/ON Compressor A3 Relay K_A3_RLY

CCH OFF/ON Crankcase Heater Relay CCH_RLY

LLSV OFF/ON Liquid Line Solenoid LLSV_A

MLV.R OFF/ON Minimum Load Valve Relay MLV_RLY

Page 56

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION

DISPLAY CONFIGURATION

DISP

UNIT

TEST

METR

LANG X Language Selection LANGUAGE

PAS.E DSBL/ENBL Password Enable PASS_EBL

PASS XXXX Service Password PASSCOPY 0 to 9999

TYPE

SIZE XXX Unit Size SIZE

SZA.1 XX SZA.2 XX Compressor A2 Size SIZE_A2

SZA.3

OFF/ON OFF/ON

Test Display LEDs DISPTEST

Metric Display DISPUNIT Off = English On = Metric

UNIT CONFIGURATION

Unit Type UNIT_TYP

Compressor A1 Size SIZE_A1

Compressor A3 Size SIZE_A3

A1.TY NO/YES Compressor A1 Digital? CPA1TYPE

MAX.T XX Maximum A1 Unload Time MAXULTME 0 to 15

UNIT OPTIONS 1 HARDWARE

FLUD X Cooler Fluid 1 = Water

MLV.S NO/YES Minimum Load Vlv Select MLV_FLG

OPT1

RG.EN

OAT.E

D.G .EN

CSB.E

DSBL/ENBL DSBL/ENBL DSBL/ENBL Dischrge Gas Temp Enable DISGASEN DSBL/ENBL

Return Gas Sensor Enable RGT_ENA

Enable OAT Sensor OAT_ENA

CSB Boards Enable CSB_ENA

CPC OFF/ON Cooler Pump Control CPC

PM.DY XX MIN Cooler Pump Shutdown Dly PUMP_DLY 0 to 10

DSBL/ENBL DSBL/ENBL Enable Cond Wtr Sensors CONDWTRS

Enable Condenser Pump CONDPMPE 0 to 2

Enable Cond Flow Switch CONDFLSW

UNIT OPTIONS 2 CONTROLS

CCN NETWORK CONFIGS

OPT2

CCN

DPME

DFLS

CDWS

CTRL X Control Method

LCWT XX High LCW Alert Limit

DELY XX Minutes Off Time

ICE.M DSBL/ENBL Ice Mode Enable

CCNA XXX CCN Address CCNB XXX CCN Bus Number

BAUD X CCN Baud Rate

CCN POINT

COMMENT

Default: 0

0 = English 1 = Espanol 2 = Francais

3 = Portuguese

2=Water Cooled, 3=Split

System

10 to 100

FLUIDTYP

CONTROL

2 = Medium Temperature

0=Switch, 1=Occupancy,

Brine

2=Occupancy, 3=CCN

LCW_LMT 2 to 60

DELAY

0 to 15

ICE_CNFG

CCNADD 1 to 239 CCNBUS

CCNBAUDD

0 to 239

1 = 2400 2 = 4800

3 = 9600 4 =19,200 5 =38,400

Page 57

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION

RESET COOL TEMP

CRST X Cooling Reset Type

RSET

SLCT

SERV

MA.DG XX.XΔF RM.NO XXX.X °F

RM.F XXX.X °F

RM.DG XX.X °F

RT.NO XXX.XΔF

RT.F XXX.XΔF Return - Full Reset Temp RTN_FULL 0 to 10

RT.DG XX.X °F

DMDC X

DM20 XXX% Demand Limit at 20 mA

SHNM XXX

SHDL XXX% Loadshed Demand Delta

SHTM XXX Maximum Loadshed Time

DLS1 XXX% Demand Limit Switch 1 DLS2 XXX% Demand Limit Switch 2 DLSWSP2 0 to 100

LLEN

MSSL SLVE/MAST Master/Slave Select

SLVA XXX Slave Address

LLBL X Lead/Lag Balance Select

LLBD XXX Lead/Lag Balance Delta LLDY XXX Lag Start Delay PA RA

CLSP X Cooling Set Point Select

RL.S DSBL/ENBL Ramp Load Select

CRMP X.X Cooling Ramp Loading

SCHD XX Schedule Number

Z.GN X.X Deadband Multiplier

EN.A1 DSBL/ENBL Enable Compressor A1 EN.A2 DSBL/ENBL Enable Compressor A2

EN.A3 REV.R

DSBL/ENBL

NO/YES

DSBL/ENBL DSBL/ENBL Reverse Rotation Enable REVR_ENA

4-20 - Degrees Reset 420_DEG

Remote - No Reset Temp REM_NO

Remote - Full Reset Temp REM_FULL 0 to125

Remote - Degrees Reset REM_DEG

Return - No Reset Temp RTN_NO 0 to 30

Return - Degrees Reset RTN_DEG

Demand Limit Select DMD_CTRL

Loadshed Group Number SHED_NUM

Lead/Lag Chiller Enable

Parallel Configuration

SETPOINT AND RAMP LOAD

SERVICE CONFIGURATION

Enable Compressor A3 ENABLEA3

BROADCAST CONFIGURATION

T.D.BC OFF/ON CCN Time/Date Broadcast CCNBC

BCST

OAT.B OFF/ON CCN OAT Broadcast OATBC

G.S.BC

BC.AK

OFF/ON Global Schedule Broadcst GSBC OFF/ON CCN Broadcast Ack'er CCNBCACK

CCN POINT

CRST_TYP

COMMENT

0 = No Reset

1 = 4 to 20 mA Input

2 = Outdoor Air Tempera-

4 = Space Temperature

ture

3 = Return Fluid

-30 to 30 0 to125

-30 to 30

0 = None

1 = Switch

2 - 4 to 20 mA Input

3 = CCN Loadshed

DMT20MA 0 to 100

0 to 99

SHED_DEL 0 to 60

SHED_TIM 0 to 120

DLSWSP1 0 to 100

LL_ENA

MS_SEL

SLV_ADDR

LL_BAL

LL_BAL_D

0 to 239

0 = Master Leads

1 = Slave Leads

2 = Automatic

40 to 400 hours

LL_DELAY 0 to 30 minutes

PARALLEL

0 = Single

CLSP_TYP

1 = Dual Switch

2 = Dual CCN Occupied

3 = 4 to 20 mA Input

RAMP_EBL

CRAMP

0.2 to 2

SCHEDNUM 0 to 99

Z_GAIN

1 to 4

ENABLEA1 ENABLEA2

Page 58

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

TIME

DATE

DST

HOL.L LOCAL HOLIDAY SCHEDULES

HD.01

HD.02

HD.03

HD.04

HD.05

HD.06

HD.07

HD.08

HH.MM XX.XX Hour and Minute TIME

MONTH, DATE, DAY, AND YEAR

MNTH XX Month of Year MOY

DOM XX Day of Month DOM 1 to 31

DAY X Day of Week DOWDISP

YEAR XXXX Year of Century YOCDISP 1999 to 2098

STR.M XX Month STARTM Default: 4 Range 1 to 12

STR.W X Week STARTW Default: 1 Range 1 to 5

STR.D X Day STARTD Default: 7 Range 1 to 7

MIN.A XX Minutes to Add MINADD

STP.M XX Month STOPM

STP.W XX Week STOPW Default: 5 Range 1to 5

STP.D XX Day STOPD Default: 7 Range 1 to 7

MIN.S XX Minutes to Subtract MINSUB

MON XX Holiday Start Month HOLMON01 0 to 12

DAY XX Start Day HOLDAY01 0 to 31 LEN XX Duration (days) HOLLEN01 0 to 99

MON XX Holiday Start Month HOLMON02 0 to 12

DAY XX Start Day HOLDAY02 0 to 31 LEN XX Duration (days) HOLLEN02 0 to 99

MON XX Holiday Start Month HOLMON03 0 to 12

DAY XX Start Day HOLDAY03 0 to 31 LEN XX Duration (days) HOLLEN03 0 to 99

MON XX Holiday Start Month HOLMON04 0 to 12

DAY XX Start Day HOLDAY04 0 to 31 LEN XX Duration (days) HOLLEN04 0 to 99

MON XX Holiday Start Month HOLMON05 0 to 12

DAY XX Start Day HOLDAY05 0 to 31 LEN XX Duration (days) HOLLEN05 0 to 99

MON XX Holiday Start Month HOLMON06 0 to 12

DAY XX Start Day HOLDAY06 0 to 31 LEN XX Duration (days) HOLLEN06 0 to 99

MON XX Holiday Start Month HOLMON07 0 to 12

DAY XX Start Day HOLDAY07 0 to 31 LEN XX Duration (days) HOLLEN07 0 to 99

MON XX Holiday Start Month HOLMON08 0 to 12

DAY XX Start Day HOLDAY08 0 to 31 LEN XX Duration (days) HOLLEN08 0 to 99

TIME OF DAY

DAYLIGHT SAVINGS TIME

HOLIDAY SCHEDULE 01

HOLIDAY SCHEDULE 02

HOLIDAY SCHEDULE 03

HOLIDAY SCHEDULE 04

HOLIDAY SCHEDULE 05

HOLIDAY SCHEDULE 06

HOLIDAY SCHEDULE 07

HOLIDAY SCHEDULE 08

1 to 12 (1 = January,

2 = February, etc.)

1 - 7 (1 = Sunday,

2 = Monday, etc.)

Default: 60 Range 0 to

Default: 10 Range 1 to

Default: 60 Range 0 to

Page 59

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

HOLIDAY SCHEDULE 09

HD.09

HD.10

HD.11

HD.12

HD.13

HD.14

HD.15

HD.16

HD.17

HD.18

HD.19

MON XX Holiday Start Month HOLMON09 0 to 12

DAY XX Start Day HOLDAY09 0 to 31 LEN XX Duration (days) HOLLEN09 0 to 99

HOLIDAY SCHEDULE 10

MON XX Holiday Start Month HOLMON10 0 to 12

DAY XX Start Day HOLDAY10 0 to 31 LEN XX Duration (days) HOLLEN10 0 to 99

HOLIDAY SCHEDULE 11

MON XX Holiday Start Month HOLMON11 0 to 12

DAY XX Start Day HOLDAY11 0 to 31 LEN XX Duration (days) HOLLEN11 0 to 99

HOLIDAY SCHEDULE 12

MON XX Holiday Start Month HOLMON12 0 to 12

DAY XX Start Day HOLDAY12 0 to 31 LEN XX Duration (days) HOLLEN12 0 to 99

HOLIDAY SCHEDULE 13

MON XX Holiday Start Month HOLMON13 0 to 12

DAY XX Start Day HOLDAY13 0 to 31 LEN XX Duration (days) HOLLEN13 0 to 99

HOLIDAY SCHEDULE 14

MON XX Holiday Start Month HOLMON14 0 to 12

DAY XX Start Day HOLDAY14 0 to 31 LEN XX Duration (days) HOLLEN14 0 to 99

HOLIDAY SCHEDULE 15

MON XX Holiday Start Month HOLMON15 0 to 12

DAY XX Start Day HOLDAY15 0 to 31 LEN XX Duration (days) HOLLEN15 0 to 99

HOLIDAY SCHEDULE 16

MON XX Holiday Start Month HOLMON16 0 to 12

DAY XX Start Day HOLDAY16 0 to 31 LEN XX Duration (days) HOLLEN16 0 to 99

HOLIDAY SCHEDULE 17

MON XX Holiday Start Month HOLMON17 0 to 12

DAY XX Start Day HOLDAY17 0 to 31 LEN XX Duration (days) HOLLEN17 0 to 99

HOLIDAY SCHEDULE 18

MON XX Holiday Start Month HOLMON18 0 to 12

DAY XX Start Day HOLDAY18 0 to 31 LEN XX Duration (days) HOLLEN18 0 to 99

HOLIDAY SCHEDULE 19

MON XX Holiday Start Month HOLMON19 0 to 12

DAY XX Start Day HOLDAY19 0 to 31 LEN XX Duration (days) HOLLEN19 0 to 99

Page 60

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

HOLIDAY SCHEDULE 20

HD.20

HD.21

HD.22

HD.23

HD.24

HD.25

HD.26

HD.27

HD.28

HD.29

HD.30

MON XX Holiday Start Month HOLMON20 0 to 12

DAY XX Start Day HOLDAY20 0 to 31 LEN XX Duration (days) HOLLEN20 0 to 99

HOLIDAY SCHEDULE 21

MON XX Holiday Start Month HOLMON21 0 to 12

DAY XX Start Day HOLDAY21 0 to 31 LEN XX Duration (days) HOLLEN21 0 to 99

HOLIDAY SCHEDULE 22

MON XX Holiday Start Month HOLMON22 0 to 12

DAY XX Start Day HOLDAY22 0 to 31 LEN XX Duration (days) HOLLEN22 0 to 99

HOLIDAY SCHEDULE 23

MON XX Holiday Start Month HOLMON23 0 to 12

DAY XX Start Day HOLDAY23 0 to 31 LEN XX Duration (days) HOLLEN23 0 to 99

HOLIDAY SCHEDULE 24

MON XX Holiday Start Month HOLMON24 0 to 12

DAY XX Start Day HOLDAY24 0 to 31 LEN XX Duration (days) HOLLEN24 0 to 99

HOLIDAY SCHEDULE 25

MON XX Holiday Start Month HOLMON25 0 to 12

DAY XX Start Day HOLDAY25 0 to 31 LEN XX Duration (days) HOLLEN25 0 to 99

HOLIDAY SCHEDULE 26

MON XX Holiday Start Month HOLMON26 0 to 12

DAY XX Start Day HOLDAY26 0 to 31 LEN XX Duration (days) HOLLEN26 0 to 99

HOLIDAY SCHEDULE 27

MON XX Holiday Start Month HOLMON27 0 to 12

DAY XX Start Day HOLDAY27 0 to 31 LEN XX Duration (days) HOLLEN27 0 to 99

HOLIDAY SCHEDULE 28

MON XX Holiday Start Month HOLMON28 0 to 12

DAY XX Start Day HOLDAY28 0 to 31 LEN XX Duration (days) HOLLEN28 0 to 99

HOLIDAY SCHEDULE 29

MON XX Holiday Start Month HOLMON29 0 to 12

DAY XX Start Day HOLDAY29 0 to 31 LEN XX Duration (days) HOLLEN29 0 to 99

HOLIDAY SCHEDULE 30

MON XX Holiday Start Month HOLMON30 0 to 12

DAY XX Start Day HOLDAY30 0 to 31 LEN XX Duration (days) HOLLEN30 0 to 99

Page 61

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

SCH.N Schedule Number 0 SCHEDNUM 0 to 99

SCH.L LOCAL OCCUPANCY SCHEDULE

OCCUPANCY PERIOD 1

OCC.1 XX:XX Period Occupied Time PER1OCC

Period Unoccupied

Time

OCCUPANCY PERIOD 2

Period Unoccupied

Time

OCCUPANCY PERIOD 3

Period Unoccupied

Time

OCCUPANCY PERIOD 4

Period Unoccupied

Time

OCCUPANCY PERIOD 5

Period Unoccupied

Time

PER1UNC

PER2UNC

PER3UNC

PER4UNC

PER5UNC

PER.1

PER.2

PER.3

PER.4

PER.5

UNC.1 XX:XX

MON.1 NO/YES Monday In Period PER1MON

TUE.1 NO/YES Tuesday In Period PER1TUE

WED.1 NO/YES Wednesday In Period PER1WED

THU.1 NO/YES Thursday In Period PER1THU

FRI.1 NO/YES Friday In Period PER1FRI

SAT.1 NO/YES Saturday In Period PER1SAT SUN.1 NO/YES Sunday In Period PER1SUN HOL.1 NO/YES Holiday In Period PER1HOL

OCC.2 XX:XX Period Occupied Time PER2OCC

UNC.2 XX:XX

MON.2 NO/YES Monday In Period PER2MON

TUE.2 NO/YES Tuesday In Period PER2TUE

WED.2 NO/YES Wednesday In Period PER2WED

THU.2 NO/YES Thursday In Period PER2THU

FRI.2 NO/YES Friday In Period PER2FRI

SAT.2 NO/YES Saturday In Period PER2SAT SUN.2 NO/YES Sunday In Period PER2SUN HOL.2 NO/YES Holiday In Period PER2HOL

OCC.3 XX:XX Period Occupied Time PER3OCC

UNC.3 XX:XX

MON.3 NO/YES Monday In Period PER3MON

TUE.3 NO/YES Tuesday In Period PER3TUE

WED.3 NO/YES Wednesday In Period PER3WED

THU.3 NO/YES Thursday In Period PER3THU

FRI.3 NO/YES Friday In Period PER3FRI

SAT.3 NO/YES Saturday In Period PER3SAT SUN.3 NO/YES Sunday In Period PER3SUN HOL.3 NO/YES Holiday In Period PER3HOL

OCC.4 XX:XX Period Occupied Time PER4OCC

UNC.4 XX:XX

MON.4 NO/YES Monday In Period PER4MON

TUE.4 NO/YES Tuesday In Period PER4TUE

WED.4 NO/YES Wednesday In Period PER4WED

THU.4 NO/YES Thursday In Period PER4THU

FRI.4 NO/YES Friday In Period PER4FRI

SAT.4 NO/YES Saturday In Period PER4SAT SUN.4 NO/YES Sunday In Period PER4SUN HOL.4 NO/YES Holiday In Period PER4HOL

OCC.5 XX:XX Period Occupied Time PER5OCC

UNC.5 XX:XX

MON.5 NO/YES Monday In Period PER5MON

TUE.5 NO/YES Tuesday In Period PER5TUE

WED.5 NO/YES Wednesday In Period PER5WED

THU.5 NO/YES Thursday In Period PER5THU

FRI.5 NO/YES Friday In Period PER5FRI

SAT.5 NO/YES Saturday In Period PER5SAT SUN.5 NO/YES Sunday In Period PER5SUN

HOL.5 NO/YES Holiday In Period PER5HOL

Page 62

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

OCCUPANCY PERIOD 6

OCC.6 XX:XX Period Occupied Time PER6OCC

Period Unoccupied

Time

OCCUPANCY PERIOD 7

Period Unoccupied

Time

OCCUPANCY PERIOD 8

Period Unoccupied

Time

SCHEDULE OVERRIDE

PER6UNC

PER7UNC

PER8UNC

PER.6

PER.7

PER.8

OVR

UNC.6 XX:XX

MON.6 NO/YES Monday In Period PER6MON

TUE.6 NO/YES Tuesday In Period PER6TUE

WED.6 NO/YES Wednesday In Period PER6WED

THU.6 NO/YES Thursday In Period PER6THU

FRI.6 NO/YES Friday In Period PER6FRI

SAT.6 NO/YES Saturday In Period PER6SAT SUN.6 NO/YES Sunday In Period PER6SUN HOL.6 NO/YES Holiday In Period PER6HOL

OCC.7 XX:XX Period Occupied Time PER7OCC

UNC.7 XX:XX

MON.7 NO/YES Monday In Period PER7MON

TUE.7 NO/YES Tuesday In Period PER7TUE

WED.7 NO/YES Wednesday In Period PER7WED

THU.7 NO/YES Thursday In Period PER7THU

FRI.7 NO/YES Friday In Period PER7FRI

SAT.7 NO/YES Saturday In Period PER7SAT SUN.7 NO/YES Sunday In Period PER7SUN HOL.7 NO/YES Holiday In Period PER7HOL

OCC.8 XX:XX Period Occupied Time PER8OCC

UNC.8 XX:XX

MON.8 NO/YES Monday In Period PER8MON

TUE.8 NO/YES Tuesday In Period PER8TUE

WED.8 NO/YES Wednesday In Period PER8WED

THU.8 NO/YES Thursday In Period PER8THU

FRI.8 NO/YES Friday In Period PER8FRI

SAT.8 NO/YES Saturday In Period PER8SAT SUN.8 NO/YES Sunday In Period PER8SUN HOL.8 NO/YES Holiday In Period PER8HOL

OVR.T X Timed Override Hours OVR_EXT 0 to 4 hours

OVR.L X Override Time Limit OTL 0 to 4 hours T.OVR NO/YES Timed Override TIMEOVER

Page 63

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Operating Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

MODES CONTROLLING UNIT MD01 OFF/ON FSM controlling Chiller MODE_1 MD02 OFF/ON WSM controlling Chiller MODE_2 MD03 OFF/ON Master/Slave control MODE_3 MD05 OFF/ON Ramp Load Limited MODE_5 MD06 OFF/ON Timed Override in effect MODE_6 MD07 OFF/ON Low Cooler Suction TempA MODE_7 MD09 OFF/ON Slow Change Override MODE_9 MD10 OFF/ON Minimum OFF time active MODE_10

MODE

MD13 OFF/ON Dual Setpoint MODE_13 MD14 OFF/ON Temperature Reset MODE_14 MD15 OFF/ON Demand Limited MODE_15 MD16 OFF/ON Cooler Freeze Protection MODE_16 MD17 OFF/ON Low Temperature Cooling MODE_17 MD18 OFF/ON High Temperature Cooling MODE_18 MD19 OFF/ON Making ICE MODE_19 MD20 OFF/ON Storing ICE MODE_20 MD21 OFF/ON High SCT Circuit A MODE_21 MD23 OFF/ON Minimum Comp. On Time MODE_23 MD24 OFF/ON Pump Off Delay Time MODE_24

Page 64

APPENDIX A — LOCAL DISPLAY TABLES (cont)

Alarms Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION CCN POINT COMMENT

CURRENTLY ACTIVE ALARMS

AA01 AA02 AA03 AA04 AA05 AA06 AA07 AA08 AA09 AA10 AA11

CRNT

RCRN NO/YES Reset All Current Alarms ALRESET

HIST

AA12 AA13 AA14 AA15 AA16 AA17 AA18 AA19 AA20 AA21 AA22 AA23 AA24 AA25

AL01 AL02 AL03 AL04 AL05 AL06 AL07 AL08 AL09 AL10 AL11 AL12 AL13 AL14 AL15 AL16 AL17 AL18 AL19 AL20

AXXX TXXX PXXX

Current Alarms 1-25

ALARM HISTORY

Alarm History 1-20

Alarms are shown as

Alerts are shown as TXXX

AXXX

Alarms are shown as

AXXX

Page 65

APPENDIX B — CCN TABLES

CCN DISPLAY TABLES — A_UNIT (General Unit Parameters

DESCRIPTION VALUE UNITS POINT NAME FORCIBLE

Control Mode 10-char ASCII STAT N Occupied No/Yes OCC N CCN Chiller Stop/Start CHIL_S_S Y Alarm State 6-char ASCII ALM N Active Demand Limit NNN % DEM_LIM Y Override Modes in Effect No/Yes MODE N Percent Total Capacity NNN % CAP_T N Requested Stage NN STAGE N Active Setpoint NNN.n degF SP N Control Point NNN.n degF CTRL_PNT Y Entering Fluid Temp NNN.n degF EWT N Leaving Fluid Temp NNN.n degF LWT N Emergency Stop Enable/EMStop EMSTOP Y Minutes Left for Start 5-char ASCII MIN_LEFT N PUMPS Cooler Pump Relay Off/On COOLPUMP N Condenser Pump Off/On CONDPUMP N Cooler Flow Switch Off/On COOLFLOW N

CCN DISPLAY TABLES — CIRCA_AN (Circuit A Analog Parameters)

DESCRIPTION VALUE UNITS POINT NAME FORCIBLE

CIRCUIT A ANALOG VALUES Percent Total Capacity NNN % CAPA_T N Percent Available Cap. NNN % CAPA_A N Discharge Pressure NNN.n PSIG DP_A N Suction Pressure NNN.n PSIG SP_A N Head Setpoint NNN.n degF HSP N Saturated Condensing Tmp NNN.n degF TMP_SCTA N Saturated Suction Temp NNN.n degF TMP_SSTA N Compr Return Gas Temp NNN.n degF TMP_RGTA N Discharge Gas Temp NNN.n degF DISGAS N Suction Superheat Temp NNN.n deltaF SH_A N

CCN DISPLAY TABLES — CIRCADIO (Circuit A Discrete Inputs/Outputs)

DESCRIPTION VALUE UNITS POINT NAME FORCIBLE

CIRC. A DISCRETE OUTPUTS Compressor A1 Relay Off/On K_A1_RLY N Compressor A2 Relay Off/On K_A2_RLY N Compressor A3 Relay Off/On K_A3_RLY Minimum Load Valve Relay Off/On MLV_RLY N

CIRC. A DISCRETE INPUTS Compressor A1 Feedback Off/On K_A1_FBK N Compressor A2 Feedback Off/On K_A2_FBK N Compressor A3 Feedback Off/On K_A3_FBK

Page 66

APPENDIX B — CCN TABLES (cont)

CCN DISPLAY TABLES — OPTIONS (Unit Parameters)

DESCRIPTION VALUE UNITS POINT NAME FORCIBLE

UNIT ANALOG VALUES Cooler Entering Fluid NNN.n degF COOL_EWT N Cooler Leaving Fluid NNN.n degF COOL_LWT N Condenser Entering Fluid NNN.n degF COND_EWT N Condenser Leaving Fluid NNN.n degF COND_LWT N Lead/Lag Leaving Fluid NNN.n degF DUAL_LWT N

TEMPERATURE RESET 4-20 ma Reset Signal NN.n milliAmps RST_MA N Outside Air Temperature NNN.n degF OAT Y Space Temperature NNN.n degF SPT Y

DEMAND LIMIT 4-20 ma Demand Signal NN.n milliAmps LMT_MA N Demand Limit Switch 1 Off/On DMD_SW1 N Demand Limit Switch 2 Off/On DMD_SW2 N CCN Loadshed Signal N DL_STAT N

MISCELLANEOUS Dual Setpoint Switch Off/On DUAL_IN N Cooler LWT Setpoint NNN.n degF LWT_SP N Ice Done Off/On ICE_DONE N

CCN MAINTENANCE TABLES — STRTHOUR

DESCRIPTION VALUE UNITS POINT NAME

Machine Operating Hours NNNNNN hours HR_MACH Machine Starts NNNNNN CY_MACH

Compressor A1 Run Hours NNNNNN.n hours HR_A1 Compressor A2 Run Hours NNNNNN.n hours HR_A2 Compressor A3 Run Hours NNNNNN.n hours HR_A3

Compressor A1 Starts NNNNNN CY_A1 Compressor A2 Starts NNNNNN CY_A2 Compressor A3 Starts NNNNNN CY_A3

PUMP HOURS Cooler Pump Run Hours NNNNNN.n hours HR_CPUMP Condenser Pump Run Hours NNNNNN.n hours HR_DPUMP

Page 67

APPENDIX B — CCN TABLES (cont)

CCN MAINTENANCE TABLES — CURRMODS

DESCRIPTION VALUE POINT NAME

CSM controlling Chiller Off/On MODE_1 WSM controlling Chiller Off/On MODE_2 Master/Slave control Off/On MODE_3 Ramp Load Limited Off/On MODE_5 Timed Override in effect Off/On MODE_6 Low Cooler Suction TempA Off/On MODE_7 Slow Change Override Off/On MODE_9 Minimum OFF time active Off/On MODE_10 Dual Setpoint Off/On MODE_13 Temperature Reset Off/On MODE_14 Demand Limited Off/On MODE_15 Cooler Freeze Protection Off/On MODE_16 Low Temperature Cooling Off/On MODE_17 High Temperature Cooling Off/On MODE_18 Making ICE Off/On MODE_19 Storing ICE Off/On MODE_20 High SCT Circuit A Off/On MODE_21 Minimum Comp. On Time Off/On MODE_23 Pump Off Delay Time Off/On MODE_24 Low Sound Mode Off/On MODE_25

CCN MAINTENANCE TABLES — ALARMS

DESCRIPTION VALUE POINT NAME

Active Alarm #1 4-char ASCII ALARM01C Active Alarm #2 4-char ASCII ALARM02C Active Alarm #3 4-char ASCII ALARM03C Active Alarm #4 4-char ASCII ALARM04C Active Alarm #5 4-char ASCII ALARM05C Active Alarm #6 4-char ASCII ALARM06C Active Alarm #7 4-char ASCII ALARM07C Active Alarm #8 4-char ASCII ALARM08C Active Alarm #9 4-char ASCII ALARM09C Active Alarm #10 4-char ASCII ALARM10C Active Alarm #11 4-char ASCII ALARM11C Active Alarm #12 4-char ASCII ALARM12C Active Alarm #13 4-char ASCII ALARM13C Active Alarm #14 4-char ASCII ALARM14C Active Alarm #15 4-char ASCII ALARM15C Active Alarm #16 4-char ASCII ALARM16C Active Alarm #17 4-char ASCII ALARM17C Active Alarm #18 4-char ASCII ALARM18C Active Alarm #19 4-char ASCII ALARM19C Active Alarm #20 4-char ASCII ALARM20C Active Alarm #21 4-char ASCII ALARM21C Active Alarm #22 4-char ASCII ALARM22C Active Alarm #23 4-char ASCII ALARM23C Active Alarm #24 4-char ASCII ALARM24C Active Alarm #25 4-char ASCII ALARM25C

CCN MAINTENANCE TABLES — VERSIONS

DESCRIPTION VERSION VALUE

AUX CESR131333- 5-char ASCII MBB CESR131279- 5-char ASCII EMM CESR131174- 5-char ASCII MARQUEE CESR131171- 5-char ASCII NAVIGATOR CESR130227- 5-char ASCII

Page 68

APPENDIX B — CCN TABLES (cont)

CCN MAINTENANCE TABLES — LOADFACT

DESCRIPTION VALUE UNITS POINT NAME

CAPACITY CONTROL Load/Unload Factor NNN SMZ Control Point NNN.n degF CTRL_PNT Entering Fluid Temp NNN.n degF EWT Leaving Fluid Temp NNN.n degF LWT

Ramp Load Limited Off/On MODE_5 Slow Change Override Off/On MODE_9 Cooler Freeze Protection Off/On MODE_16 Low Temperature Cooling Off/On MODE_17 High Temperature Cooling Off/On MODE_18 Minimum Comp. On Time Off/On MODE_23

CCN MAINTENANCE TABLES — LEARNFNS

DESCRIPTION VALUE UNITS POINT NAME

SCT Delta for Comp A1 NNN.n deltaF A1SCTDT SCT Delta for Comp A2 NNN.n deltaF A2SCTDT SCT Delta for Comp A3 NNN.n deltaF A3SCTDT SAGP for Compressor A1 NNN.n SAGA1P SAGM for Compressor A1 NNN.n SAGA1M SAGP for Compressor A2 NNN.n SAGA2P SAGM for Compressor A2 NNN.n SAGA2M SAGP for Compressor A3 NNN.n SAGA3P SAGM for Compressor A3 NNN.n SAGA3M Reset short loop gain Yes/No RESET_GN

CCN MAINTENANCE TABLES — PM-STRN

DESCRIPTION VALUE UNITS POINT NAME

Strainer Srvc Interval NNNNN hours SI_STRNR Strainer Srvc Countdown NNNNN hours ST_CDOWN Strainer Maint. Done No/Yes ST_MAINT

Strainer Maint. Date 15-char ASCII STRN_PM0 Strainer Maint. Date 15-char ASCII STRN_PM1 Strainer Maint. Date 15-char ASCII STRN_PM2 Strainer Maint. Date 15-char ASCII STRN_PM3 Strainer Maint. Date 15-char ASCII STRN_PM4

CCN MAINTENANCE TABLES — TESTMODE

DESCRIPTION VALUE UNITS POINT NAME

Service Test Mode Off/On NET_CTRL Compressor A1 Relay Off/On S_A1_RLY Compressor A2 Relay Off/On S_A2_RLY Compressor A3 Relay Off/On S_A3_RLY Cooler Pump Relay Off/On S_CLPMP Condenser Pump Off/On S_CNDPMP Comp A1 Unload Time NN secs S_A1ULTM Remote Alarm Relay Off/On S_ALM

Page 69

APPENDIX B — CCN TABLES (cont)

CCN MAINTENANCE TABLES — RUNTEST

DESCRIPTION VALUE UNITS POINT NAME

Percent Total Capacity NNN % CAPA_T Percent Available Cap. NNN % CAPA_A Discharge Pressure NNN.n PSIG DP_A Suction Pressure NNN.n PSIG SP_A Saturated Condensing Tmp NNN.n degF TMP_SCTA Saturated Suction Temp NNN.n degF TMP_SSTA Compr Return Gas Temp NNN.n degF TMP_RGTA Discharge Gas Temp NNN.n degF DISGAS Suction Superheat Temp NNN.n deltaF SH_A Compressor A1 Relay Off/On K_A1_RLY Compressor A2 Relay Off/On K_A2_RLY Compressor A3 Relay Off/On K_A3_RLY Minimum Load Valve Relay Off/On MLV_RLY Compressor A1 Feedback Off/On K_A1_FBK Compressor A2 Feedback Off/On K_A2_FBK Compressor A3 Feedback Off/On K_A3_FBK

Outside Air Temperature NNN.n degF OAT Space Temperature NNN.n degF SPT Cooler Pump Relay Off/On COOLPUMP Condenser Pump Off/On CONDPUMP Cooler Entering Fluid NNN.n degF COOL_EWT Cooler Leaving Fluid NNN.n degF COOL_LWT Cooler Flow Switch Off/On COOLFLOW

CCN MAINTENANCE TABLES — DUALCHIL

DESCRIPTION VALUE UNITS POINT NAME

Dual Chiller Link Good? No/Yes DC_LINK Master Chiller Role 12-char ASCII MC_ROLE Slave Chiller Role 12-char ASCII SC_ROLE Lead Chiller Ctrl Point NNN.n degF LEAD_CP Lag Chiller Ctrl Point NNN.n degF LAG_CP Control Point NNN.n degF CTRL_PNT

Cool EnteringFluid-Slave NNN.n degF COOLEWTS Cool Leaving Fluid-Slave NNN.n degF COOLLWTS Cooler Entering Fluid NNN.n degF COOL_EWT Cooler Leaving Fluid NNN.n degF COOL_LWT Lead/Lag Leaving Fluid NNN.n degF DUAL_LWT

Percent Avail.Capacity NNN % CAP_A Percent Avail.Cap.Slave NNN % CAP_A_S

Lag Start Delay Time 5-char ASCII LAGDELAY Load/Unload Factor NNN SMZ Load/Unload Factor-Slave NNNN SMZSLAVE Lead SMZ Clear Commanded No/Yes LEADSMZC Lag SMZ Clear Commanded No/Yes LAG_SMZC Lag Commanded Off? No/Yes LAG_OFF

Dual Chill Lead CapLimit NNN.n % DCLDCAPL Dual Chill Lag CapLimit NNN.n % DCLGCAPL

Page 70

APPENDIX B — CCN TABLES (cont)

CCN CONFIGURATION TABLES — UNIT (Unit Configuration)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

Unit Type N UNIT_TYP Unit Size NNN tons SIZE Compressor A1 Size NNN tons SIZE_A1 Compressor A2 Size NNN tons SIZE_A2 Compressor A3 Size NNN tons SIZE_A3 Suction Superheat Setpt NN.n deltaF SH_SP Compressor A1 Digital? No/Yes CPA1TYPE Maximum A1 Unload Time NN secs MAXULTME

CCN CONFIGURATION TABLES — OPTIONS1 (Options 1 Configuration)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

Cooler Fluid N FLUIDTYP Minimum Load Vlv Select No/Yes MLV_FLG Return Gas Sensor Enable Dsable/Enable RGT_ENA Enable OAT Sensor Dsable/Enable OAT_ENA Dischrge Gas Temp Enable Dsable/Enable DISGASEN CSB Boards Enable Dsable/Enable CSB_ENA Reverse Rotation Enable Dsable/Enable REVR_ENA Cooler Pump Control Off/On CPC Cooler Pump Shutdown Dly NN mins PUMP_DLY EMM Module Installed No/Yes EMM_BRD Enable Condenser Pump N CONDPMPE Enable Cond Wtr Sensors Dsable/Enable CONDWTRS Enable Cond Flow Switch Dsable/Enable CONDFLSW

CCN CONFIGURATION TABLES — OPTIONS2 (Options 2 Configuration)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

Control Method N CONTROL Loading Sequence Select N SEQ_TYPE Lead/Lag Circuit Select N LEAD_TYP Cooling Setpoint Select N CLSP_TYP Ramp Load Select Dsable/Enable RAMP_EBL High LCW Alert Limit NN.n deltaF LCW_LMT Minutes off time NN mins DELAY Deadband Multiplier N.n Z_GAIN Ice Mode Enable Dsable/Enable ICE_CNFG

CCN CONFIGURATION TABLES — SCHEDOVR (Timed Override Setup)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

Schedule Number NN 1 SCHEDNUM Override Time Limit N 0 hours OTL Timed Override Hours N 0 hours OVR_EXT Timed Override No/Yes No TIMEOVER

Page 71

APPENDIX B — CCN TABLES (cont)

CCN CONFIGURATION TABLES — RESETCON (Temperature Reset and Demand Limit)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

COOLING RESET Cooling Reset Type N 0 CRST_TYP 4-20 MA RESET 4-20 - Degrees Reset NNN.n deltaF 420_DEG

REMOTE RESET Remote - No Reset Temp NNN.n degF REM_NO Remote - Full Reset Temp NNN.n degF REM_FULL Remote - Degrees Reset NNN.n deltaF REM_DEG

RETURN TEMPERATURE RESET Return - No Reset Temp NNN.n deltaF RTN_NO Return - Full Reset Temp NNN.n deltaF RTN_FULL Return - Degrees Reset NNN.n deltaF RTN_DEG

DEMAND LIMIT Demand Limit Select N DMD_CTRL Demand Limit at 20 mA NNN % DMT20MA Loadshed Group Number NN SHED_NUM Loadshed Demand Delta NN % SHED_DEL Maximum Loadshed Time NNN mins SHED_TIM Demand Limit Switch 1 NNN % DLSWSP1 Demand Limit Switch 2 NNN % DLSWSP2

CCN CONFIGURATION TABLES — DUALCHIL (Dual Chiller Configuration Settings)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

LEAD/LAG Lead/Lag Chiller Enable Dsable/Enable LL_ENA Master/Slave Select Master/Slave MS_SEL Slave Address NNN SLV_ADDR Lead/Lag Balance Select N LL_BAL Lead/Lag Balance Delta NNN hours LL_BAL_D Lag Start Delay NN mins LL_DELAY Parallel Configuration No/Yes PA R AL L E L

CCN CONFIGURATION TABLES — DISPLAY (Marquee Display SETUP)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

Service Password NNNN PASSWORD Password Enable Dsable/Enable PASS_EBL Metric Display Off/On DISPUNIT Language Selection N LANGUAGE

CCN CONFIGURATION TABLES — HPA

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

SCT Delta for Comp A1 NNN.n deltaF A1SCTDT SCT Delta for Comp A2 NNN.n deltaF A2SCTDT

Page 72

APPENDIX B — CCN TABLES (cont)

CCN SERVICE TABLES — SERVICE

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

SERVICE Brine Freeze Point NNN.n degF BRN_FRZ

COMPRESSOR ENABLE Enable Compressor A1 Dsable/Enable ENABLEA1 Enable Compressor A2 Dsable/Enable ENABLEA2 Enable Compressor A3 Dsable/Enable ENABLEA3

CCN SETPOINT TABLES — SETPOINT

DESCRIPTION VALUE DEFAULT UNITS POINT NAME

COOLING Cooling Setpoint 1 NNN.n degF CSP1 Cooling Setpoint 2 NNN.n degF CSP2 ICE Setpoint NNN.n degF CSP3

RAMP LOADING Cooling Ramp Loading N.n CRAMP

Brine Freeze Point NNN.n degF BRN_FRZ

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

Catalog No. 04-53300053-01 Printed in U.S.A. Form 30MP-1T Pg 72 1-10 Replaces: New

Page 73

START-UP CHECKLIST FOR 30MP LIQUID CHILLER

(Remove and use for job file.)

A. Preliminary Information

JOB NAME _______________________________________________________________________________

LOCATION _______________________________________________________________________________

INSTALLING CONTRACTOR _________________________________________________________________

DISTRIBUTOR ____________________________________________________________________________

START-UP PERFORMED BY _________________________________________________________________

EQUIPMENT: Chiller: MODEL NO.

SERIAL NO.

COMPRESSORS:

CIRCUIT A

MODEL NO.

SERIAL NO.

B. Preliminary Equipment Check (Yes or No)

IS THERE ANY SHIPPING DAMAGE?

_________________________________________________________________________________________

WILL THIS DAMAGE PREVENT UNIT START-UP?

CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?

HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)

ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)

HAS THE GROUND WIRE BEEN CONNECTED?

ARE ALL ELECTRICAL TERMINALS TIGHT?

IF SO, WHERE

ON BRINE UNITS, HAS THE COOLER FLUID BEEN PROPERLY PROTECTED FROM FREEZING TO AT LEAST 15° F (8.3° C) BELOW THE LOWEST ANTICIPATED LEAVING FLUID TEMPERATURE SET POINT?

HAVE THE MAIN BASE BOARD, ENERGY MANAGEMENT MODULE (OPTION) AND CONTROL RELAY CONNECTIONS BEEN CHECK FOR TIGHTNESS?

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

Catalog No. 04-53300053-01 Printed in U.S.A. Form 30MP-1T Pg CL-1 1-10 Replaces: New

Page 74

C. Unit Start-Up (insert check mark as each item is completed)

 CHILLER HAS BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE CHILLED

FLUID PUMP STARTER.

 CHILLER HAS BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE

CONDENSER WATER PUMP STARTER.

 CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR A MINIMUM OF 24 HOURS PRIOR TO START-UP.

(30MPA UNITS ONLY)

 COMPRESSOR OIL LEVEL IS CORRECT.

 LIQUID LINE SERVICE VALVE IS BACKSEATED (30MPA UNITS ONLY).

 SET POINT SHOULD BE ADJUSTED TO THE DESIRED COOLER LEAVING FLUID TEMPERATURE.

(refer to installation instructions).

 LEAK CHECK THOROUGHLY: CHECK ALL COMPRESSORS, CONDENSER MANIFOLDS AND HEADERS,

TXVs, SOLENOID VALVES, FILTER DRIERS, FUSIBLE PLUGS, THERMISTORS, AND COOLER CONNECTIONS USING ELECTRONIC LEAK DETECTOR.

 LOCATE, REPAIR, AND REPORT ANY REFRIGERANT LEAKS.

 CHECK VOLTAGE IMBALANCE: AB AC BC

AB + AC + BC (divided by 3) = AVERAGE VOLTAGE = V

MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =

VOLTAGE IMBALANCE =

(MAX. DEVIATION)

AVERAGE VOLTAGE

x 100 =

% VOLTAGE IMBALANCE

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER!

CALL LOCAL POWER COMPANY FOR ASSISTANCE.

 INCOMING POWER VOLTAGE TO CHILLER MODULES IS WITHIN RATED UNIT VOLTAGE

RANGE.

SYSTEM FLUID VOLUME IN LOOP:

GAL (L)

REFER TO INSTALLATION INSTRUCTIONS FOR MINIMUM FLUID VOLUME

CL-2

Page 75

C. Unit Start-Up (cont)

CHECK PRESSURE DROP ACROSS COOLER.

FLUID ENTERING COOLER:

FLUID LEAVING COOLER:

PSIG (kPa)

(PSIG DIFFERENCE) x 2.31 = FT OF FLUID PRESSURE DROP =

PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (LOCATED IN INSTALLATION

INSTRUCTIONS LITERATURE) TO DETERMINE TOTAL GPM (L/s).

TOTAL GPM (L/s) =

UNIT’S RATED MIN GPM (L/s) =

JOB’S SPECIFIED GPM (L/s) (if available):

NOTE: IF UNIT HAS LOW FLUID FLOW, FIND SOURCE OF PROBLEM: CHECK FLUID PIPING, IN-LINE FLUID STRAINER, SHUT-OFF VALVES, CWP ROTATION, ETC.

COOLER LOOP FREEZE PROTECTION IF REQUIRED:

GALLONS (LITERS) ADDED:

PIPING INCLUDES ELECTRIC TAPE HEATERS IF PIPNG IS EXPOSED TO TEMPERATURES BELOW FREEZING (Y/N):

COOLER/CONDENSER PROTECTION:

IN-LINE MINIMUM 40-MESH STRAINER INSTALLED WITHIN 10 FT OF THE COOLER/CONDENSER WATER INLET.

COOLER: YES

CONDENSER: YES NO

VISUALLY CHECK MAIN BASE BOARD FOR THE FOLLOWING:

 INSPECT ALL THERMISTORS AND TRANSDUCERS FOR POSSIBLE CROSSED WIRES.

 CHECK TO BE SURE ALL WELL-TYPE THERMISTORS ARE FULLY INSERTED INTO THEIR

RESPECTIVE WELLS.

TO START THE CHILLER:

TURN THE EMERGENCY ON/OFF SWITCH (SW2) TO ON POSITION.

TURN THE ENABLE/OFF/REMOTE CONTACT SWITCH (SW1) TO THE ENABLE POSITION.

IF EQUIPPED WITH THE OPTIONAL SCROLLING MARQUEE, LEAVE THE ENABLE/OFF/REMOTE CONTACT SWITCH (SW1) IN THE OFF POSITION.

NOTE: USE ESCAPE KEY TO GO UP ONE LEVEL IN THE STRUCTURE.

USE ARROW/ESCAPE KEYS TO ILLUMINATE RUN STATUS LED. PRESS ENTER KEY UNTIL ‘VERS’ IS DISPLAYED. PRESS ENTER KEY. RECORD INFORMATION ON THE FOLLOWING PAGE.

CL-3

Page 76

C. Unit Start-Up (cont)

Record Software Versions MODE — RUN STATUS

SOFTWARE VERSION NUMBERS

AUX CESR131333-xx-xx

MBB CESR131279-xx-xx

VERS

(PRESS ENTER AND ESCAPE SIMULTANEOUSLY TO OBTAIN SOFTWARE VERSIONS)

USE ARROW/ESCAPE KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER KEY. RECORD INFORMATION BELOW.

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

SZA.1 COMPRESSOR A1 SIZE XX

UNIT

SZA.2 COMPRESSOR A2 SIZE XX SZA.3 COMPRESSOR A3 SIZE XX A1.TY COMPRESSOR A1 DIGITAL? NO/YES MAX.T MAXIMUM A1 UNLOAD TIME XX

EMM CESR131174-xx-xx

MARQ CESR131171-xx-xx

NAVI CESR130227-xx-xx

UNIT (Configuration Settings)

UNIT CONFIGURATION

SIZE UNIT SIZE XXX

PRESS ESCAPE KEY TO DISPLAY ‘UNIT’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT1’. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW:

OPTIONS1 (Options Configuration)

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

UNIT OPTIONS 1 HARDWARE FLUD COOLER FLUID X MLV.S MINIMUM LOAD VALVE SELECT NO/YES

RG.EN RETURN GAS SENSOR ENABLE ENBL/DSBL

OAT.E ENABLE OAT SENSOR ENBL/DSBL

OPT1

D.G.EN DISCHRGE GAS TEMP ENABLE ENBL/DSBL

CSB.E CSB BOARDS ENABLE ENBL/DSBL

CPC COOLER PUMP CONTROL ON/OFF

PM.DY COOLER PUMP SHUTDOWN DLY XX MIN

DPME ENABLE CONDENSER PUMP ENBL/DSBL

DFLS ENABLE COND FLOW SWITCH ENBL/DSBL

CDWS ENABLE COND WTR SENSORS ENBL/DSBL

PRESS ESCAPE KEY TO DISPLAY ‘OPT1’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT2’. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION ON NEXT PAGE.

CL-4

Page 77

C. Unit Start-Up (cont)

OPTIONS2 (Options Configuration)

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

UNIT OPTIONS 2 CONTROLS

CTRL CONTROL METHOD X

OPT2

PRESS ESCAPE KEY TO DISPLAY ‘OPT2’. PRESS DOWN ARROW KEY TO DISPLAY ‘CCN’. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW.

SUB-MODE ITEM ITEM EXPANSION DISPLAY ENTRY

CCN

PRESS ESCAPE KEY SEVERAL TIMES TO GET TO THE MODE LEVEL (BLANK DISPLAY). USE THE ARROW KEYS TO SCROLL TO THE SET POINT LED. PRESS ENTER TO DISPLAY SETPOINTS. RECORD CONFIGURATION INFORMATION BELOW:

LCWT HIGH LCW ALERT LIMIT XX.X F

DELY MINUTES OFF TIME XX

ICE.M ICE MODE ENABLE ENBL/DSBL

CCN (CCN Network Configuration)

CCNA CCN ADDRESS XXX

CCNB CCN BUS NUMBER XXX

BAUD CCN BAUD RATE X

SETPOINT

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

COOLING SETPOINTS

COOL

HEAD

FRZ

CSP.1 COOLING SETPOINT 1 XXX.X °F CSP.2 COOLING SETPOINT 2 XXX.X °F CSP.3 ICE SETPOINT XXX.X °F

HEAD PRESSURE SETPOINTS

H.DP HEAD SET POINT XXX.X °F

BRINE FREEZE SETPOINT

BR.FZ BRINE FREEZE POINT XXX.X °F

COMPONENT TEST

USE ESCAPE/ARROW KEYS TO ILLUMINATE CONFIGURATION LED. PRESS ENTER TO DISPLAY ‘DISP’. PRESS ENTER AGAIN TO DISPLAY ‘TEST’ FOLLOWED BY ‘OFF’. PRESS ENTER TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ DISPLAY FLASHES. ‘PASS’ AND ‘WORD’ WILL FLASH IF PASSWORD NEEDS TO BE ENTERED. PRESS ENTER TO DISPLAY PASSWORD FIELD AND USE THE ENTER KEY FOR EACH OF THE FOUR PASSWORD DIGITS. USE ARROW KEYS IF PASSWORD IS OTHER THAN STANDARD. AT FLASHING ‘OFF’ DISPLAY, PRESS THE UP ARROW KEY TO DISPLAY ‘ON’ AND PRESS ENTER. ALL LED SEGMENTS AND MODE LEDS WILL LIGHT UP. PRESS ESCAPE TO STOP THE TEST. PRESS ESCAPE TO RETURN TO THE ‘DISP’ DISPLAY. PRESS THE ESCAPE KEY AGAIN AND USE THE ARROW KEYS TO ILLUMINATE THE SERVICE TEST LED. PRESS ENTER TO DISPLAY ‘TEST’. PRESS ENTER TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ FLASHES. PRESS THE UP ARROW KEY AND ENTER TO ENABLE THE MANUAL MODE. PRESS ESCAPE AND DISPLAY NOW SAYS ‘TEST’ ‘ON’. TURN SWITCH (SW1) TO THE ENABLE POSITION.

PRESS THE DOWN ARROW TO DISPLAY ‘OUTS’. PRESS THE ENTER KEY TO DISPLAY ‘LL.SV’. PRESS THE ENTER KEY TO STOP DISPLAY AT ‘OFF’ AND ENTER AGAIN SO ‘OFF’ FLASHES. PRESS THE UP ARROW KEY AND ENTER TO TURN THE OUTPUT ON. PRESS ENTER SO THE ‘ON’ DISPLAY FLASHES, PRESS THE DOWN ARROW KEY AND THEN ENTER TO TURN THE OUTPUT OFF. OUTPUTS WILL ALSO BE TURNED OFF OR SENT TO 0% WHEN ANOTHER OUTPUT IS TURNED ON. CHECK OFF THE ITEMS IN THE SERVICE TEST TABLE ON THE NEXT PAGE THAT APPLY AFTER BEING TESTED.

CL-5

Page 78

C. Unit Start-Up (cont)

ENTER

USE ESCAPE KEY TO RETURN TO ‘OUTS’ DISPLAY. PRESS DOWN ARROW TO DISPLAY ‘CMPA’. PRESS ENTER KEY TO DISPLAY ‘CC.A1’. NOTE THAT UNLOADERS AND HOT GAS BYPASS SOLENOIDS CAN BE TESTED BOTH WITH AND WITHOUT COMPRESSOR(S) RUNNING. MAKE SURE ALL SERVICE VALVES ARE OPEN AND COOLER/CONDENSER PUMPS HAVE BEEN TURNED ON BEFORE STARTING COMPRESSORS. CHECK OFF EACH ITEM AFTER SUCCESSFUL TEST. THE CONTROL WILL ONLY START ONE COMPRESSOR PER MINUTE. WHEN AT THE DESIRED ITEM, PRESS THE ENTER KEY TWICE TO MAKE THE ‘OFF’ FLASH. PRESS THE UP ARROW KEY AND ENTER TO TURN THE OUTPUT ON. CHECK OFF THE ITEMS IN THE SERVICE TEST TABLE BELOW THAT APPLY AFTER BEING TESTED.

SERVICE TEST

SUB-MODE

TEST

OUTS

CMPA

KEYPAD

ENTRY

ITEM DISPLAY

ON/OFF SERVICE TEST MODE To Enable Service Test Mode,

OUTPUTS AND PUMPS

CLR.P ON/OFF COOLER PUMP RELAY

CND.P ON/OFF CONDENSER PUMP

UL.TM 0 TO 15 COMP A1 UNLOAD TIME

CC.H ON/OFF CRANKCASE HEATER

CW.VO ON/OFF CONDENSER VALVE OPEN

CW.VC ON/OFF CONDENSER VALVE CLOSE

LL.SV ON/OFF LIQUID LINE SOLENOID

RMT.A ON/OFF REMOTE ALARM RELAY

CIRCUIT A COMPRESSOR TEST

CC.A1 ON/OFF COMPRESSOR A1 RELAY

UL.TM 0 TO 15 COMP A1 UNLOAD TIME

CC.A2 ON/OFF COMPRESSOR A2 RELAY

CC.A3 ON/OFF COMPRESSOR A3 RELAY

ITEM

EXPANSION

COMMENT

move Enable/Off/Remote Contact switch to OFF. Change TEST to ON. Move switch to ENABLE.

Completed

(Yes/No)

MLV ON/OFF MINIMUM LOAD VALVE RELAY

USE ARROW/ESCAPE KEYS TO ILLUMINATE THE TEMPERATURES LED. PRESS ENTER TO DISPLAY ‘UNIT’. PRESS ENTER AND USE THE ARROW KEYS TO RECORD TEMPERATURES FOR SENSORS BELOW.

TEMPERATURE

CLWT

CEWT

CDET

CDLT

OAT or DLWT

SPT

CL-6

Page 79

C. Unit Start-Up (cont)

ALL UNITS:

MEASURE THE FOLLOWING (MEASURE WHILE MACHINE IS IN A STABLE OPERATING CONDITION):

CIRCUIT A

DISCHARGE PRESSURE

SUCTION PRESSURE

DISCHARGE LINE TEMP

SUCTION LINE TEMP

SATURATED COND TEMP

COOLER ENTERING FLUID

COOLER LEAVING FLUID

CONDENSER ENTERING FLUID

CONDENSER LEAVING FLUID

CHECK AND ADJUST SUPERHEAT AS REQUIRED.

CL-7

Page 80

C. Unit Start-Up (cont)

COMMENTS:

_________________________________________________________________________________________

SIGNATURES:

START-UP TECHNICIAN ___________________________________________________________________

DATE __________________________________

CUSTOMER REPRESENTATIVE _____________________________________________________________

DATE___________________________________

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

Catalog No. 04-53300053-01 Printed in U.S.A. Form 30MP-1T Pg CL-8 1-10 Replaces: New

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