Operating instructions

2
CONTENTS (cont)
Page
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-87
Economizer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 74
• FLOODED COOLER MAIN EXV CONTROL
• DX COOLER MAIN EXV CONTROL
• ECONOMIZER EXV CONTROL
• EXV TROUBLESHOOTING PROCEDURE
Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 77
• COMPRESSOR OIL SYSTEM
Flooded Cooler Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
• FLOODED COOLER SUCTION SERVICE VALVE
• FLOODED COOLER FREEZE PROTECTION
• FLOODED COOLER LOW FLUID TEMPERATURE
• FLOODED COOLER LOSS OF FLUID FLOW
PROTECTION
• FLOODED COOLER TUBE PLUGGING
• FLOODED COOLER RETUBING
• FLOODED COOLER TIGHTENING COOLER HEAD
BOLTS
• FLOODED COOLER INSPECTING/CLEANING
HEAT EXHANGERS
• FLOODED COOLER WATER TREATMENT
DX Cooler Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• DX COOLER SUCTION SERVICE VALVE
• DX COOLER FREEZE PROTECTION
• DX COOLER LIQUID FLUID TEMPERATURE
• DX COOLER LOSS OF FLUID FLOW PROTECTION
• DX COOLER TUBE PLUGGING
• DX COOLER RETUBING
• DX COOLER TIGHTENING COOLER HEAD BOLTS
• DX COOLER CHILLED WATER FLOW SWITCH
DX Cooler and Flooded Cooler Units . . . . . . . . . . . . 84
• PREPARATION FOR WINTER SHUTDOWN
Microchannel Heat Exchanger (MCHX) Condenser
Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RTPF Condenser Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
• REMOVE SURFACE LOADED FIBERS
• PERIODIC CLEAN WATER RINSE
• ROUTINE CLEANING OF RTPF COIL SURFACES
Condenser Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Refrigerant Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
• LEAK TESTING
• REFRIGERANT CHARGE
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• COMPRESSOR PROTECTION
• OIL SEPARATOR HEATERS
• COOLER PROTECTION
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• PRESSURE RELIEF VALVES
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87,88
Recommended Maintenance Schedule . . . . . . . . . . 87
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . 88-109
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
• DIAGNOSTIC ALARM CODES AND POSSIBLE
CAUSES
Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
APPENDIX A — TOUCH PILOT™
DISPLAY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . 110-127
APPENDIX B — NAVIGATOR™
DISPLAY TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . 128-141
APPENDIX C — CCN TABLES . . . . . . . . . . . . . . 142-156
APPENDIX D — 30XA080-500 CPM
DIP SWITCH ADDRESSES. . . . . . . . . . . . . . . . 157-160
APPENDIX E — PIPING AND
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . 161-164
Page
APPENDIX F — MAINTENANCE SUMMARY
AND LOG SHEETS. . . . . . . . . . . . . . . . . . . . . . . . . . 165-167
APPENDIX G — BACNET COMMUNICATONS
OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168-178
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
START-UP CHECKLIST
FOR 30XA LIQUID CHILLERS . . . . . . . . CL-1 to CL-8
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, etc.). Only
trained, qualified installers and service technicians should
install, start up, and service this equipment. When working on
this equipment, observe precautions in the literature, on tags,
stickers, and labels attached to the equipment, and any other
safety precautions that apply. Follow all safety codes. Wear
safety glasses and work gloves. Use care in handling, rigging,
and setting this equipment, and in handling all electrical
components.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
WARNING
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented in accordance
with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigerating and Air Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and
cause asphyxiation. Provide adequate ventilation in
enclosed or low overhead areas. Inhalation of high concen-
trations of vapor is harmful and may cause heart irregulari-
ties, unconsciousness or death. Misuse can be fatal. Vapor
is heavier than air and reduces the amount of oxygen avail-
able for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.
WARNING
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig-
erant in contact with an open flame produces toxic
gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal
injury or death.

612