Specifications

ManualsBrandsCarrier ManualsRefrigeratorAQUASNAP MPW015-045

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

Catalog No. 04-53300078-01 Printed in U.S.A. Form 30MP-2T Pg 1 12-13 Replaces: 30MP-1T

Controls, Start-Up, Operation,

Service, and Troubleshooting

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Conventions Used in this Manual . . . . . . . . . . . . . . . . 3

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

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Energy Management Module (EMM) . . . . . . . . . . . . . . 7

Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . . 7

Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . . 7

Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . 7

Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Control Module Communication. . . . . . . . . . . . . . . . . . 7

Carrier Comfort Network

Interface . . . . . . . . . . . . . . 7

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

• 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

• DISCHARGE TEMPERATURE SENSOR

• REMOTE SPACE TEMPERATURE SENSOR

Energy Management Module . . . . . . . . . . . . . . . . . . . . 14

Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . . 14

Condenser Flow Protection . . . . . . . . . . . . . . . . . . . . . 14

Thermostatic Expansion Valves (TXV). . . . . . . . . . . 14

Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• CAPACITY CONTROL OVERRIDES

Operation of Machine Based on Control Method

and Cooling Set Point Selection Settings . . . . . 17

Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . . . . 17

Cooler Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Service Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cooler Pump Sequence of Operation. . . . . . . . . . . . 18

Condenser Pump/Condenser Fan Output

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Configuring and Operating Dual Chiller Control. 18

Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

• 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) . . . . . . . . . . . . . . . . . . 24

Digital Scroll Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26,27

System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Page

START-UP AND OPERATION . . . . . . . . . . . . . . . . . 27-29

Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . 27

Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

• TEMPERATURES

• VOLTAGE — ALL UNITS

OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 29

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-34

Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . 29

• CONTROL COMPONENTS

Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . 29

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

• BRAZED-PLATE COOLER AND CONDENSER

HEAT EXCHANGER REPLACEMENT

• BRAZED-PLATE COOLER AND CONDENSER

HEAT EXCHANGER CLEANING

Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Check Refrigerant Feed Components . . . . . . . . . . . 30

•FILTER DRIER

• MOISTURE-LIQUID INDICATOR

• THERMOSTATIC EXPANSION VALVE (TXV)

• MINIMUM LOAD VALVE

• PRESSURE RELIEF DEVICES

Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Pressure Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chilled Water Flow Switch. . . . . . . . . . . . . . . . . . . . . . . 33

Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Replacing Defective Modules . . . . . . . . . . . . . . . . . . . 38

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Recommended Maintenance Schedule . . . . . . . . . . 38

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 39-50

Complete Unit Stoppage and Restart. . . . . . . . . . . . 39

• 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

APPENDIX A — LOCAL DISPLAY TABLES . . . 51-59

APPENDIX B — CCN TABLES . . . . . . . . . . . . . . . . 60-64

APPENDIX C — BACNET COMMUNICATION

OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-71

APPENDIX D — MAINTENANCE SUMMARY AND

LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72,73

START-UP CHECKLIST FOR 30MP LIQUID

CHILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-7

AquaSnap

30MPA,MPW015-045

Liquid Chillers with Scroll Compressors

and ComfortLink Controls

Summary of content (84 pages)

PAGE 1
AquaSnap® 30MPA,MPW015-045 Liquid Chillers with Scroll Compressors and ComfortLink Controls Controls, Start-Up, Operation, Service, and Troubleshooting CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Conventions Used in this Manual . . . . . . . . . . . . . . . . 3 Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONTROLS . . . . . . . . . . . . . . . . .
PAGE 2
SAFETY CONSIDERATIONS CAUTION 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.
PAGE 3
structure. Press the ESCAPE 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 Table 2. GENERAL This publication contains Start-Up, Service, Controls, Operation, and Troubleshooting information for the 30MPW watercooled chillers and the 30MPA air-cooled chillers. See Table 1.
PAGE 4
to the Configuration mode. Press ENTER to obtain access to this mode. The display will read: keys are used to navigate through the different levels of the display structure. Press the ESCAPE 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. > TEST OFF METR OFF LANG ENGLISH Pressing ENTER will cause the “OFF” to flash. Use the up or down arrow to change “OFF” to “ON”.
PAGE 5
Table 2 — Scrolling Marquee Display Menu Structure* MODE SUB-MODE RUN SERVICE STATUS TEST Auto Service View of Test Mode Run Status (TEST) (VIEW) Unit Run Outputs Hour and and Pumps Start (OUTS) (RUN) Circuit and A Comp Compressor CiruitTest Run Hours (CMPA) (HOUR) TEMPERATURES PRESSURES Unit Temperatures (UNIT) Temperatures Circuit A (CIR.A) Pressures Circuit A (PRC.A) SET POINTS INPUTS OUTPUTS CONFIGURATION TIME CLOCK OPERATING MODES ALARMS Cooling Setpoints (COOL) General Inputs (GEN.
PAGE 6
Table 3 — Operating Modes MODE NO. ITEM EXPANSION DESCRIPTION 01 CSM CONTROLLING CHILLER Chillervisor System Manager (CSM) is controlling the chiller. 02 WSM CONTROLLING CHILLER Water System Manager (WSM) is controlling the chiller. 03 MASTER/SLAVE CONTROL Ramp load (pull-down) limiting in effect. In this mode, the rate at which leaving fluid temperature is dropped is limited to a predetermined value to prevent compressor overloading. See Cooling Ramp Loading (ConfigurationSLCTCRMP).
PAGE 7
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.
PAGE 8
LEGEND FOR FIG.
PAGE 9
EQUIP GND TB3 UPC LON OPTION UPC 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 LVT DISCONNECT OPTION CB1A/TB1A L1 L2 L3 CCB-1 CCB-2 CCB-3 EMM CSB-A1 2 4 CSB-A2 CSB-A3 6 CCH CA1 CA2 CA3 TRAN1 MBB FB1 LOCATED OVER EMM CB1 CB2 CB3 REMOTE CONTROL SW1 OFF ENABLE Fig.
PAGE 10
TO FUSED DISCONNECT PER NEC 10 RED B1 A1 SW2 XF FU3 VIO VIO 380V ONLY CB3 3.
PAGE 11
TRAN1 A2 CB2 3.
PAGE 12
Sensors — The electronic control uses 2 to 7 thermistors to 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. sense temperatures for controlling chiller operation. See Table 4.
PAGE 13
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): Table 8 — Thermistors and Wells THERMISTOR PART NO. DESCRIPTION WELL PART NO. 3 in., 5,000 ohm Thermistor 4 in.
PAGE 14
a30-4968 SPT (T10) PART NO. 33ZCT55SPT 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 15
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.
PAGE 16
Table 9 — Part Load Data Percent Displacement, Standard Units with Minimum Load Valve CONTROL STEPS 1 2 3 1 2 3 1 2 3 1 2 3 4 1 2 3 4 30MP UNIT SIZE 015 020 030 040 045 *Hot gas bypass (minimum load) valve energized. CAPACITY STEPS (% Displacement) 18* 50 100 25* 50 100 34* 50 100 21* 33 67 100 22* 33 67 100 NOTE: These capacity steps may vary due to different capacity staging sequences.
PAGE 17
StatusVIEWSTAT) will be 1 (OFF LOCAL) when the 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OPT2 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.
PAGE 18
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.
PAGE 19
Table 11 — Dual Chiller Configuration (Master Chiller Example) SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS ENTER CTRL CONTROL METHOD ENTER 0 SWITCH DEFAULT 0 ESCAPE OPT2 CCN ADDRESS DEFAULT 1 CCN BUS NUMBER DEFAULT 0 DISP UNIT OPT1 OPT2 CTRL CCN CCNA ENTER 1 CCNB CCN CCNB ENTER 0 ESCAPE CCN PROCEED TO SUBMODE RESET RSET RSET ENTER LLEN LLEN MSSL CRST COOLING RESET TYPE LLEN LEAD/LAG CHILLER ENABLE ENTER DSBL SCROLLING STOPS ENTER DSBL VALUE FLASHES
PAGE 20
Table 11 — Dual Chiller Configuration (Master Chiller Example) (cont) SUB-MODE RSET ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS LLBL ENTER 2 LEAD/LAG BALANCE SELECT CHANGE ACCEPTED ESCAPE LLBL LLBD LLBD LEAD/LAG BALANCE DELTA ENTER 168 LEAD/LAG BALANCE DELTA ESCAPE LLBD LLDY LLDY LLDY PARA DEFAULT 168 LAG START DELAY ENTER 5 SCROLLING STOPS ENTER 5 VALUE FLASHES 10 SELECT 10 ENTER 10 ESCAPE LLDY ESCAPE RSET ENTER YES LAG START DELAY CHANGE ACCEPTED MASTER CO
PAGE 21
Table 12 — Dual Chiller Configuration (Slave Chiller Example) SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS ENTER CTRL CONTROL METHOD 0 SWITCH DEFAULT 0 CCN ADDRESS SCROLLING STOPS DISP UNIT OPT1 OPT2 CTRL ESCAPE OPT2 CCN CCNA CCNA ENTER 1 ENTER 1 VALUE FLASHES 2 SELECT 2 (SEE NOTE 2) CCN CCNA CCNB ENTER 2 ESCAPE CCN ENTER 0 ESCAPE CCN CCN ADDRESS CHANGE ACCEPTED CCN BUS NUMBER DEFAULT 0 (SEE NOTE 3) PROCEED TO SUBMODE RSET RSET RSET ENTER LLEN LLEN
PAGE 22
(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.
PAGE 23
Table 15 — Configuring Outdoor Air and Space Temperature Reset MODE (RED LED) KEYPAD ENTRY SUBMODE ENTER DISP KEYPAD ENTRY DISPLAY ITEM Outdoor Air Space ITEM EXPANSION COMMENT CRST 2 4 COOLING RESET TYPE 2 = Outdoor-Air Temperature (Connect to LVT-4,5) 4 = Space Temperature (Connect to LVT-3,4) RM.NO* 85 °F 72 °F REMOTE - NO RESET TEMP Default: 125.0 F (51.7 C) Range: 0° to125 F (–17.8 to 51.7 C) RM.F 55 °F 68 °F REMOTE - FULL RESET TEMP Default: 0.0° F (-17.
PAGE 24
To use demand limit, select the type of demand limiting to use. Then configure the demand limit set points based on the type selected. configure the 2 Demand Limit Switch points (ConfigurationRSETDLS1) and (ConfigurationRSETDLS2) to the desired capacity limit. See Table 17. Capacity steps are controlled by 2 relay switch inputs field wired to LVT as shown in Fig. 5.
PAGE 25
MAX. ALLOWABLE LOAD (%) 100 50% CAPACITY AT 20 mA 80 60 40 100% CAPACITY AT 4 mA 75% CAPACITY AT 12 mA 20 0 0 2 6 4 12 8 10 14 DEMAND LIMIT SIGNAL – 4 - 20 mA INPUT 16 18 20 Fig. 18 — 4 to 20-mA Demand Limiting 100 (38) 90 (32) 80 (27) SET POINT, F (C) 70 (21) MAXIMUM SET POINT 70 F (21.1 C) 60 (15) 50 (10) 40 (4.4) (FLUD = 1) MINIMUM SET POINT 38 F (3.
PAGE 26
Table 17 — Configuring Demand Limit MODE CONFIGURATION KEYPAD ENTRY SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION ENTER DISP ENTER TEST ON/OFF Test Display LEDs UNIT ENTER TYPE X Unit Type OPT1 ENTER FLUD X Cooler Fluid OPT2 ENTER CTRL X Control Method CCN ENTER CCNA X CCN Address RSET ENTER CRST X Cooling Reset Type COMMENT Default: 0 0 = None 1 = Switch 2 = 4 to 20 mA Input 3 = CCN Loadshed DMDC* X Demand Limit Select DM20 XXX % Demand Limit at 20 mA Defau
PAGE 27
5. 6. 7. 8. 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COOL CSP.1) or (Set PointsCOOLCSP.2), or if reset is used, with the control point (Run StatusVIEW 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.
PAGE 28
2. Connect a refrigerant cylinder loosely to the high flow Schrader 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.
PAGE 29
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.
PAGE 30
the installation of the new compressor, tighten all hardware to the following specifications. (See Table 21.) Oil Charge CAUTION Table 21 — Unit Torque Specification FASTENER Compressor Mounting Bolts Compressor Power Connections Compressor Ground Terminal Connections The compressor in a Puron® refigerant (R-410A) system uses a polyol ester (POE) oil. This is extremely hygroscopic, meaning it absorbs water readily.
PAGE 31
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. THERMOSTATIC EXPANSION VALVE (TXV) — The TXV controls the flow of liquid refrigerant to the cooler by maintaining constant superheat of vapor leaving the cooler.
PAGE 32
COOLER FREEZE-UP PROTECTION 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).
PAGE 33
4. Wrong pump motor rotation. Pump must rotate clockwise when viewed from motor end of pump. gauge. Pressure readings should be within ± 15 psig. If the two readings are not reasonably close, replace the pressure transducer. Chilled Water Flow Switch — A factory-installed 1 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.
PAGE 34
Table 25 — 5K Thermistor Temperatures (°F) vs. Resistance/Voltage Drop (Voltage Drop for EWT, LWT, RGT, CNDE, CNDL, Dual Chiller, and OAT) TEMP (F) –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 VOLTAGE DROP (V) 3.699 3.689 3.679 3.668 3.658 3.647 3.636 3.624 3.613 3.601 3.588 3.576 3.563 3.550 3.
PAGE 35
Table 26 — 5K Thermistor Temperatures (°C) vs. Resistance/Voltage Drop (Voltage Drop for EWT, LWT, RGT, CNDE, CNDL, Dual Chiller, and OAT) TEMP (C) –32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 VOLTAGE DROP (V) 3.705 3.687 3.668 3.649 3.629 3.608 3.586 3.563 3.539 3.514 3.489 3.462 3.434 3.406 3.376 3.345 3.313 3.281 3.247 3.212 3.177 3.140 3.103 3.065 3.025 2.985 2.945 2.903 2.860 2.817 2.774 2.
PAGE 36
Table 27 — 10K Thermistor Temperature (°F) vs. Resistance/Voltage Drop (For SPT) TEMP (F) –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 VOLTAGE DROP (V) 4.758 4.750 4.741 4.733 4.724 4.715 4.705 4.696 4.686 4.676 4.665 4.655 4.644 4.633 4.621 4.609 4.597 4.585 4.572 4.560 4.546 4.533 4.519 4.
PAGE 37
Table 28 — 10K Thermistor Temperature (°C) vs. Resistance/Voltage Drop (For SPT) TEMP (C) –32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 VOLTAGE DROP (V) 4.762 4.748 4.733 4.716 4.700 4.682 4.663 4.644 4.624 4.602 4.580 4.557 4.533 4.508 4.482 4.455 4.426 4.397 4.367 4.335 4.303 4.269 4.235 4.199 4.162 4.124 4.085 4.044 4.003 3.961 3.917 3.873 3.828 3.781 3.734 3.686 3.637 3.587 3.537 3.485 3.433 3.
PAGE 38
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. Strainer — Periodic cleaning of the required field-installed strainer is required.
PAGE 39
pressor when the internal temperature reaches approximately 300 F (149 C). 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 40
Recommended Cooling Time (Minutes) 120 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 Compressor Unloaded Run Time (Minutes) *Times are approximate. NOTE: Various factors, including high humidity, high ambient temperature, and the presence of a sound blanket will increase cool-down times. Fig.
PAGE 41
Table 31 — Troubleshooting SYMPTOMS 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 CAUSE Loss of charge control. Acting erratically.
PAGE 42
Table 32 — Alarm and Alert Codes ALARM/ ALERT CODE ALARM OR ALERT A048 Alarm Circuit A Compressor Availability Alarm Two compressors on circuit failed Circuit shut down Manual Only one compressor operating. T051 Alert Circuit A, Compressor 1 Failure Compressor feedback signal does not match relay state Compressor A1 shut down. Manual High-pressure switch open, faulty CSB, loss of condenser flow, filter drier plugged, noncondensables, operation beyond capability.
PAGE 43
Table 32 — Alarm and Alert Codes (cont) ALARM/ ALERT CODE ALARM OR ALERT A116 Alarm A122 Alarm A126 Alarm DESCRIPTION Circuit A Low Cooler Suction Temperature High Pressure Switch Trip Circuit A WHY WAS THIS ALARM GENERATED? ACTION TAKEN BY CONTROL Mode 7 caused the compressor to unload 3 consecutive times with less than a Circuit shut down 30-minute interval between each circuit shutdown.
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Table 32 — Alarm and Alert Codes (cont) ALARM/ ALERT CODE T200 T201 A202 T203 T204 T205 T206 ALARM OR ALERT DESCRIPTION WHY WAS THIS ALARM GENERATED? Alert Cooler Flow/Interlock Contacts failed to Close at start-up 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 Alert Cooler Flow/Interlock Contacts Opened During Normal Operation RESET METHOD PROBABLE CAUSE Chiller not
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Table 32 — Alarm and Alert Codes (cont) ALARM/ ALERT CODE ALARM OR ALERT DESCRIPTION WHY WAS THIS ALARM GENERATED? ACTION TAKEN BY CONTROL RESET METHOD Strainer Service Countdown (S.T.DN) expired. Complete strainer blowdown and enter 'YES' for Strainer Maintenance Done (S.T.MN) item.
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this alarm are loose wiring connection, sensor not located in well or bad Schrader fitting. Reset is manual. T079 (Dual Chiller Thermistor Failure) — This alert occurs when the dual chiller temperature sensor is outside its range of –40 to 240 F (–40 to 116 C). 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.
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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.
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• Check the pump contactor for proper operation. • Check the chilled water pump for proper operation. Look for overload trips. • Check the chilled water strainer for a restriction. • Check to be sure that all isolation valves are open completely. A202 (Cooler Pump Interlock Closed When Pump Is Off Alarm) — This alarm will be generated if the unit is configured for CPC=ON Cooler Pump Control, (Configuration→OPT1) without a call for the Chilled Water Pump, C.LWP=OFF (Outputs→GEN.
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• Check the entering and leaving water thermistors for accuracy. • Check to be sure the entering and leaving water thermistors are correctly wired and installed in the proper location. A220 (Condenser Pump Interlock Failure to Close At StartUp Alarm) — This alarm will be generated if the unit is configured for D.FL.S=ENBL Enable Cond Flow Switch (Configuration→OPT1) and condenser flow interlock (if used) circuit fails to close within 5 minutes of the condenser pump start.
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T951 (Loss of Communication with Chillervisor System Manager) — This alarm will be generated if no communications have been received by the Main Base Board for five (5) minutes. When this alert is generated the Chillervisor System Manager (CSM) forces are removed, and chiller runs in standalone mode. If this condition is encountered, check the following items: • Check CCN wiring. • Check for power at the Chillervisor System Manager. • Check Main Base Board for a communication failure. automatically.
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APPENDIX A — LOCAL DISPLAY TABLES Run Status Mode and Sub-Mode Directory ITEM VIEW EWT LWT SETP CTPT LOD.F STAT OCC MODE CAP DEM.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Temperature Mode and Sub-Mode Directory ITEM UNIT CEWT CLWT CDET CDLT OAT SPT DLWT CIR.A SCT.A SST.A RGT.A D.GAS SH.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Configuration Mode and Sub-Mode Directory ITEM DISP TEST METR EXPANSION DISPLAY CONFIGURATION Test Display LEDs Metric Display LANG Language Selection PAS.E PASS UNIT TYPE Password Enable Service Password UNIT CONFIGURATION Unit Type SIZE SZA.1 Unit Size Compressor A1 Size SZA.2 Compressor A2 Size SZA.3 Compressor A3 Size A1.TY MAX.T Compressor A1 Digital? Maximum A1 Unload Time OPT1 FLUD UNIT OPTIONS 1 HARDWARE Cooler Fluid MLV.S RG.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Configuration Mode and Sub-Mode Directory (cont) ITEM RSET CRST EXPANSION RESET COOL TEMP Cooling Reset Type MA.DG 4-20 - Degrees Reset RM.NO Remote - No Reset Temp RM.F Remote - Full Reset Temp RM.DG Remote - Degrees Reset RT.NO Return - No Reset Temp RT.F Return - Full Reset Temp RT.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory ITEM TIME HH.MM DATE MNTH DOM DAY YEAR DST STR.M STR.W STR.D MIN.A STP.M STP.W STP.D MIN.S HOL.L HD.01 HD.01MON HD.01DAY HD.01LEN HD.02 HD.02MON HD.02DAY HD.02LEN HD.03 HD.03MON HD.03DAY HD.03LEN HD.04 HD.04MON HD.04DAY HD.04LEN HD.05 HD.05MON HD.05DAY HD.05LEN HD.06 HD.06MON HD.06DAY HD.06LEN HD.07 HD.07MON HD.07DAY HD.07LEN HD.08 HD.08MON HD.08DAY HD.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory ITEM HOL.L HD.14 HD.14MON HD.14DAY HD.14LEN HD.15 HD.15MON HD.15DAY HD.15LEN HD.16 HD.16MON HD.16DAY HD.16LEN HD.17 HD.17MON HD.17DAY HD.17LEN HD.18 HD.18MON HD.18DAY HD.18LEN HD.19 HD.19MON HD.19DAY HD.19LEN HD.20 HD.20MON HD.20DAY HD.20LEN HD.21 HD.21MON HD.21DAY HD.21LEN HD.22 HD.22MON HD.22DAY HD.22LEN HD.23 HD.23MON HD.23DAY HD.23LEN HD.24 HD.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory (cont) ITEM SCH.L PER.1 PER.1OCC.1 PER.1UNC.1 PER.1MON.1 PER.1TUE.1 PER.1WED.1 PER.1THU.1 PER.1FRI.1 PER.1SAT.1 PER.1SUN.1 PER.1HOL.1 PER.2 PER.2OCC.2 PER.2UNC.2 PER.2MON.2 PER.2TUE.2 PER.2WED.2 PER.2THU.2 PER.2FRI.2 PER.2SAT.2 PER.2SUN.2 PER.2HOL.2 PER.3 PER.3OCC.3 PER.3UNC.3 PER.3MON.3 PER.3TUE.3 PER.3WED.3 PER.3THU.3 PER.3FRI.3 PER.3SAT.3 PER.3SUN.3 PER.3HOL.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory (cont) ITEM SCH.L (cont) PER.8 PER.8OCC.8 PER.8UNC.8 PER.8MON.8 PER.8TUE.8 PER.8WED.8 PER.8THU.8 PER.8FRI.8 PER.8SAT.8 PER.8SUN.8 PER.8HOL.8 OVR OVROVR.T OVROVR.L OVRT.
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APPENDIX A — LOCAL DISPLAY TABLES (cont) Alarms Mode and Sub-Mode Directory ITEM CRNT AA01 AA02 AA03 AA04 AA05 AA06 AA07 AA08 AA09 AA10 AA11 AA12 AA13 AA14 AA15 AA16 AA17 AA18 AA19 AA20 AA21 AA22 AA23 AA24 AA25 RCRN HIST AL01 AL02 AL03 AL04 AL05 AL06 AL07 AL08 AL09 AL10 AL11 AL12 AL13 AL14 AL15 AL16 AL17 AL18 AL19 AL20 EXPANSION CURRENTLY ACTIVE ALARMS Current Alarms 1-25 Reset All Current Alarms ALARM HISTORY Alarm History 1-20 RANGE UNITS CCN POINT COMM
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APPENDIX B — CCN TABLES CCN DISPLAY TABLES TABLE A-UNIT CIRCA_AN CIRCADIO OPTIONS DISPLAY NAME RANGE GENERAL UNIT PARAMETERS Control Mode 10-char ASCII Occupied No/Yes CCN Chiller Stop/Start Alarm State 6-char ASCII Active Demand Limit NNN Override Modes in Effect No/Yes Percent Total Capacity NNN Requested Stage NN Active Setpoint NNN.n Control Point NNN.n Degrees of Reset NN.n Entering Fluid Temp NNN.n Leaving Fluid Temp NNN.
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APPENDIX B — CCN TABLES (cont) CCN MAINTENANCE TABLES TABLE STRTHOUR DISPLAY NAME RANGE UNITS POINT NAME Machine Operating Hours Machine Starts Compressor A1 Run Hours Compressor A2 Run Hours Compressor A3 Run Hours Compressor A1 Starts Compressor A2 Starts Compressor A3 Starts PUMP HOURS Cooler Pump Run Hours Condenser Pump Run Hours NNNNNN NNNNNN NNNNNN.n NNNNNN.n NNNNNN.n NNNNNN NNNNNN NNNNNN hours hours hours hours HR_MACH CY_MACH HR_A1 HR_A2 HR_A3 CY_A1 CY_A2 CY_A3 NNNNNN.n NNNNNN.
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APPENDIX B — CCN TABLES (cont) CCN MAINTENANCE TABLES (cont) TABLE VERSIONS LOADFACT DISPLAY NAME RANGE UNITS 5-char ASCII 5-char ASCII 5-char ASCII 5-char ASCII 5-char ASCII POINT NAME CESR131333CESR131482CESR131174CESR131171CESR131227CAPACITY CONTROL Load/Unload Factor Control Point Entering Fluid Temp Leaving Fluid Temp Ramp Load Limited Slow Change Override Cooler Freeze Protection Low Temperature Cooling High Temperature Cooling Minimum Comp. On Time AUX MBB EMM MARQUEE NAVIGATOR NNN NNN.
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APPENDIX B — CCN TABLES (cont) CCN MAINTENANCE TABLES (cont) TABLE DUALCHIL DISPLAY NAME RANGE Dual Chiller Link Good? Master Chiller Role Slave Chiller Role Lead Chiller Ctrl Point Lag Chiller Ctrl Point Control Point Cool EnteringFluid-Slave Cool Leaving Fluid-Slave Cooler Entering Fluid Cooler Leaving Fluid Lead/Lag Leaving Fluid Percent Avail.Capacity Percent Avail.Cap.
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APPENDIX B — CCN TABLES (cont) CCN CONFIGURATION TABLES (cont) TABLE RESETCON DUALCHILL DISPLAY DISPLAY NAME RANGE TEMPERATURE RESET AND DEMAND LIMIT COOLING RESET Cooling Reset Type N 4-20 MA RESET 4-20 - Degrees Reset NNN.n REMOTE RESET Remote - No Reset Temp NNN.n Remote - Full Reset Temp NNN.n Remote - Degrees Reset NNN.n RETURN TEMPERATURE RESET Return - No Reset Temp NNN.n Return - Full Reset Temp NNN.n Return - Degrees Reset NNN.n DEMAND LIMIT Demand Limit Select N Demand Limit at 20 mA NNN.
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APPENDIX C — BACNET COMMUNICATION OPTION 6 5 7 8 2 34 5 6 10's 1 9 0 2 34 7 8 9 0 1 The following section is used to configure the UPC Open controller which is used when the BACnet* communication option is selected. The UPC Open controller is mounted in the main control box per unit components arrangement diagrams. TO ADDRESS THE UPC OPEN CONTROLLER — The user must give the UPC Open controller an address that is unique on the BACnet network.
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APPENDIX C — BACNET COMMUNICATION OPTION (cont) CONFIGURING THE BAS PORT FOR BACNET MS/ TP — Use the same baud rate and communication settings for all controllers on the network segment. The UPC Open controller is fixed at 8 data bits, No Parity, and 1 Stop bit for this protocol's communications. If the UPC Open controller has been wired for power, pull the screw terminal connector from the controller's power terminals labeled Gnd and HOT.
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APPENDIX C — BACNET COMMUNICATION OPTION (cont) Fig. E — BT485 Terminator Installation temperature rating specifications list two acceptable alternatives. The Halar specification has a higher temperature rating and a tougher outer jacket than the SmokeGard specification, and it is appropriate for use in applications where the user is concerned about abrasion. The Halar jacket is also less likely to crack in extremely low temperatures.
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APPENDIX C — BACNET COMMUNICATION OPTION (cont) Table D — Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS Wire Type RECOMMENDED VENDORS AND PART NUMBERS Connect Air Contractors Belden RMCORP Wire and Cable International Description 22 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
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APPENDIX C — BACNET COMMUNICATION OPTION (cont) traffic based on the baud rate set. The higher the baud rate the more solid the LEDs become. See Fig. A for location of LEDs on UPC Open module. REPLACING THE UPC OPEN BATTERY — The UPC Open controller's 10-year lithium CR2032 battery provides a minimum of 10,000 hours of data retention during power outages.
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APPENDIX C — BACNET COMMUNICATION OPTION (cont) Table G — Network Points List POINT DESCRIPTION 4-20 ma Demand Signal 4-20 ma Reset Signal Active Demand Limit Active Setpoint Alarm State CCN Chiller CCN Loadshed Signal Comp A1 Unload Time Compr Return Gas Temp Compressor A1 Feedback Compressor A1 Relay Compressor A1 Run Hours Compressor A1 Starts Compressor A2 Feedback Compressor A2 Relay Compressor A2 Run Hours Compressor A2 Starts Compressor A3 Feedback Compressor A3 Relay Compressor A3 Run Hours Compress
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APPENDIX C — BACNET COMMUNICATION OPTION (cont) Table G — Network Points List (cont) POINT DESCRIPTION Dual Setpoint Dual Setpoint Switch Element Comm Status Emergency Stop Entering Fluid Temp High SCT Circuit A High Temperature Cooling Ice Done ICE Setpoint Lead/Lag Circuit Select Lead/Lag Leaving Fluid Leaving Fluid Temp Loading Sequence Select Low Cooler Suction TempA Low Sound Mode Low Temperature Cooling Machine Operating Hours Machine Starts Making ICE Master/Slave control Minimum Comp.
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APPENDIX D — MAINTENANCE SUMMARY AND LOG SHEETS 30MP Weekly Maintenance Log Plant ___________________________ Machine Model No.
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yes/no yes/no yes/no amps yes/no PSI yes/no yes/no yes/no yes/no yes/no yes/no yes/no yes/no yes/no 0-100% deg.
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 Carrier Corporation 2013 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300078-01 Printed in U.S.A.
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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 _______________ B.
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Has the refrigerant piping been done per the installation guide?  YES  NO Piping dehydrated and evacuated per installation guide?  YES  NO Unit charged per the installation guide?  YES  NO Crankcase heaters have been energized for a minimum of 24 hours prior to start-up?  YES  NO SIGNATURE REQUIRED Preliminary check complete. Installing/Mechanical Contractor_______________________________________Date____________ C.
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CHECK PRESSURE DROP ACROSS COOLER. Fluid entering cooler: psig (kpa)____________ 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).
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Record Software Versions MODE — RUN STATUS SOFTWARE VERSION NUMBERS VERS MBB CESR131482-xx-xx EMM CESR131174-xx-xx AUX1 CESR131333-xx-xx MARQ CESR131171-xx-xx NAVI CESR130227-xx-xx (Press ENTER and ESCAPE simultaneously to obtain software versions) Use arrow/escape keys to illuminate configuration led. press enter key. record information below. UNIT (Configuration Settings) SUBMODE UNIT ITEM TYPE SIZE SZA.1 SZA.2 SZA.3 A1.TY MAX.
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C. Unit Start-Up (cont) OPTIONS2 (Options Configuration) SUBMODE OPT2 ITEM ITEM EXPANSION UNIT OPTIONS 2 CONTROLS CONTROL METHOD HIGH LCW ALERT LIMIT MINUTES OFF TIME ICE MODE ENABLE CTRL LCWT DELY ICE.M DISPLAY ENTRY X XX.X F XX DSBL/ENBL Press ESCAPE key to display ‘OPT2’. Press down arrow key to display ‘CCN’. Press ENTER key. Record configuration information below.
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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.
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C. Unit Start-Up (cont) ALL UNITS: Measure the following (measure while machine is in a stable operating condition): Check and adjust superheat as required. CIRCUIT A DISCHARGE PRESSURE SUCTION PRESSURE DISCHARGE LINE TEMP SUCTION LINE TEMP COOLER ENTERING FLUID COOLER LEAVING FLUID CONDENSER ENTERING FLUID CONDENSER LEAVING FLUID Check and adjust superheat as required.
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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. 04-53300078-01 Printed in U.S.A.