Controls, Start-Up, Operation, Service And Troubleshooting - Carrier

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CONTENTS (cont)Page• COOLER LEAVING FLUID SENSOR• COOLER ENTERING FLUID SENSOR• DUAL CHILLER LWT• COMPRESSOR RETURN GAS TEMPERATURE• OUTDOOR AIR TEMPERATURE• REMOTE SPACE TEMPERATUREService Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74APPENDIX A — LOCAL DISPLAY TABLES . . . . . . 81-92APPENDIX B — CCN TABLES . . . . . . . . . . . . . . . . . . 93-106APPENDIX C — CCN ALARM DESCRIPTION . . 107-110APPENDIX D — R-410A PRESSURE VS.TEMPERATURE CHART. . . . . . . . . . . . . . . . . . . . . . . . . 111INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112,113START-UP CHECKLIST FOR 30RBLIQUID CHILLER . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-9SAFETY CONSIDERATIONSInstalling, starting up, and servicing this equipment can behazardous due to system pressures, electrical components, andequipment location (roof, elevated structures, etc.). Onlytrained, qualified installers and service mechanics shouldinstall, start up, and service this equipment. When working onthis equipment, observe precautions in the literature, and ontags, stickers, and labels attached to the equipment, and anyother 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 electricalcomponents.Electrical shock can cause personal injury and death. Shutoff all power to this equipment during installation and service.There may be more than one disconnect switch. Tagall disconnect locations to alert others not to restore poweruntil work is completed.This unit uses a microprocessor-based electronic controlsystem. Do not use jumpers or other tools to short out components,or to bypass or otherwise depart from recommendedprocedures. Any short-to-ground of the controlboard or accompanying wiring may destroy the electronicmodules or electrical components.To prevent potential damage to heat exchanger tubes,always run fluid through heat exchanger when adding orremoving refrigerant charge. Use appropriate anti-freezesolutions in cooler fluid loop to prevent the freezing of heatexchanger, optional hydronic section and/or interconnectingpiping when the equipment is exposed to temperaturesbelow 32 F (0 °C). Proof of flow switch and strainer (whenhydronic kit is supplied) are factory installed on all models.Do NOT remove power from this chiller during winter shutdown periods without taking precaution to remove allwater from heat exchanger and optional hydronic system.Failure to properly protect the system from freezing mayconstitute abuse and may void warranty.Compressors and optional hydronic system pumps requirespecific rotation. Test condenser fan(s) first to ensureproper phasing. Swap any two incoming power leads tocorrect condenser fan rotation before starting any othermotors. Operating the unit without testing the condenserfan(s) for proper phasing could result in equipmentdamage.Refrigerant charge must be removed slowly to prevent lossof compressor oil that could result in compressor failure.DO NOT VENT refrigerant relief valves within a building.Outlet from relief valves must be vented in accordancewith the latest edition of ANSI/ASHRAE (AmericanNational Standards Institute/American Society of Heating,Refrigeration and Air Conditioning Engineers) 15 (SafetyCode for Mechanical Refrigeration). The accumulation ofrefrigerant in an enclosed space can displace oxygen andcause asphyxiation. Provide adequate ventilation inenclosed or low overhead areas. Inhalation of high concentrationsof vapor is harmful and may cause heart irregularities,unconsciousness or death. Misuse can be fatal. Vaporis heavier than air and reduces the amount of oxygen availablefor breathing. Product causes eye and skin irritation.Decomposition products are hazardous.DO NOT attempt to unbraze factory joints when servicingthis equipment. Compressor oil is flammable and there isno way to detect how much oil may be in any of the refrigerantlines. Cut lines with a tubing cutter as required whenperforming service. Use a pan to catch any oil that maycome out of the lines and as a gage for how much oil to addto system. DO NOT re-use compressor oil.This system uses Puron® refrigerant which has higherpressures than R-22 and other refrigerants. No other refrigerantcan be used in this system. Failure to use gage set,hoses, and recovery system designed to handle Puronrefrigerant may result in personal injury. If you are unsure,consult the equipment manufacturer.GENERALThis publication contains Controls, Operation, Start-Up,Service and Troubleshooting information for the 30RB060-390air-cooled liquid chillers with electronic controls. The 30RBchillers are equipped with ComfortLink controls andelectronic expansion valves.NOTE: Unit sizes 315-390 are modular units that are shippedin separate sections as modules A or B as noted in position 8 ofthe unit model number. Installation directions specific to theseunits are noted in these instructions. For modules 315A, 315B,330A, 330B, 345A, 345B, and 360B, follow all generalinstructions as noted for unit sizes 30RB160,170. For modules,360A, 390A, and 390B follow instructions for 30RB190. SeeTable 1 for a listing of unit sizes and modular combinations.NOTE: The nameplate for modular units contains only the firsttwo digits in the model number. For example, 315A and 315Bnameplates read 31A and 31B.2
Table 1 — Modular Unit CombinationsUNIT SIZE MODULE A MODULE B30RBA315 30RBA160 30RBA16030RBA330 30RBA170 30RBA16030RBA345 30RBA170 30RBA17030RBA360 30RBA190 30RBA17030RBA390 30RBA190 30RBA190NOTE: An “A” in the model number indicates the design series.Conventions Used in This Manual — The followingconventions for discussing configuration points for thelocal display (scrolling marquee or Navigator accessory)will be used in this manual.Point names will be written with the mode name first, thenany sub-modes, then the point name, each separated by anarrow symbol (→). Names will also be shown in boldand italics. As an example, the Lead/Lag Circuit Select Point,which is located in the Configuration mode, Option sub-mode,would be written as Configuration →OPTN→LLCS.This path name will show the user how to navigate throughthe local display to reach the desired configuration. The userwould scroll through the modes and sub-modes using theand keys. The arrow symbol in the path name representspressing ENTER to move into the next level of themenu structure.When a value is included as part of the path name, it will beshown at the end of the path name after an equals sign. If thevalue represents a configuration setting, an explanation willbe shown in parenthesis after the value. As an example,Configuration→OPTN→LLCS = 1 (Circuit A leads).Pressing the ESCAPE and ENTER keys simultaneouslywill scroll an expanded text description of the point name orvalue across the display. The expanded description is shown inthe local display tables but will not be shown with the pathnames in text.The CCN (Carrier Comfort Network ® ) point names are alsoreferenced in the local display tables for users configuring theunit with CCN software instead of the local display. The CCNtables are located in Appendix B of the manual.CONTROLSGeneral — The 30RB air-cooled liquid chillers contain theComfortLink electronic control system that controls andmonitors all operations of the chiller. The control system iscomposed of several components as listed in the following sections.All machines have at the very least a main base board(MBB), scrolling marquee display, electric expansion valveboard (EXV), fan board, one scroll protection module (SPM)per compressor, Emergency On/Off switch, an Enable-Off- RemoteContact switch and a reverse rotation board.Main Base Board (MBB) — The MBB is the heart ofthe ComfortLink control system, which contains the majorportion of operating software and controls the operation of themachine. See Fig. 1. The MBB continuously monitors input/output channel information received from its inputs and fromall other modules. The MBB receives inputs from status andfeedback switches, pressure transducers and thermistors. TheMBB also controls several outputs. Some inputs and outputs tocontrol the machine are located on other boards, but are transmittedto or from the MBB via the internal communicationsbus. Information is transmitted between modules via a 3-wirecommunication bus or LEN (Local Equipment Network). TheCCN (Carrier Comfort Network) bus is also supported. Connectionsto both LEN and CCN buses are made at TB3. For acomplete description of main base board inputs and outputsand their channel identifications, see Table 2.STATUSSIO(LEN)+ G –+ G –+ G –J1A12/11 12/11J15J10MOV122122119 J12221221TR1 TR2 TR3 TR4 TR5C41 C42 C43C32 C33 C34 C35J2A J2B J2CRELAYOUTPUTSJ13 J9D+ G -CCND15K1 K2ANALOGJ3 INPUTSJ8195195J9C195J9B19519511195C16J4195J9ADISCRETEINPUTSJ5ATHERMISERS PRESSURESJ5BJ5CJ7A J7B J7C J7DJ6CH5 CH6 CH7 CH8 CH9CH1 CH2 CH3 CH4CH19 CH20 CH21 CH22 CH23 CH24 CH25 CH26CH10CH11 CH12CH13 CH14 CH15ACH15BCC16ACCH16BCH17CH18LOCATION OFSERIAL NUMBERFig. 1 — Main Base Board3
Page 4 and 5: Table 2 — Main Base Board Inputs
Page 6 and 7: Table 3 — Scroll Protection Modul
Page 8 and 9: Table 4 — EXV1 Board Inputs and O
Page 10 and 11: Table 6 — Fan Board 1 (AUX1, AUX2
Page 12 and 13: Table 8 — Fan Board 3 (AUX1) Inpu
Page 14 and 15: SIO LENSIO LEN+ G - + G -2212212212
Page 16 and 17: Table 10 — ComfortLink Display Me
Page 18 and 19: Table 12 — Configuring the Master
Page 20 and 21: Capacity Control — The control sy
Page 22 and 23: STAGETOTALCAP.LEGENDMLC — Minimum
Page 24 and 25: If any of these conditions are met,
Page 26 and 27: Table 19 — Head Pressure Control
Page 28 and 29: Table 20 — Low Ambient Temperatur
Page 30 and 31: LEGENDI 2 t — Current Squared Tim
Page 32 and 33: Control Method(OPER)0(Switch Ctrl)1
Page 34 and 35: Temperature Reset — Temperature r
Page 36 and 37: 5654FLUID TEMPERATURE (deg F)525048
Page 38 and 39: To use 4-20 mA Temperature Reset in
Page 40 and 41: Table 28 — 4 to 20 mA Temperature
Page 42 and 43: Table 29 — 2-Step Demand Limit Co
Page 44 and 45: PRE-START-UPIMPORTANT: Complete the
Page 46 and 47: Operation below minimum flow rate c
Page 48 and 49: MODE 12 (MD12) — Auto Changeover
Page 50 and 51: 1. Cable2. Glass Seal3. Motor Housi
Page 52 and 53:
DISASSEMBLYClosedOpenNOTE: Open val
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1130 26 2218 137 16 9 20243 5 28343
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Charging with Unit Off and Evacuate
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Table 37 — TroubleshootingSYMPTOM
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PREFIXCODECoCtFCMCSUFFIXCODE.F1.F2.
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Table 38 — Alarm Codes (cont)PREF
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Possible Causes — If this conditi
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a control option that requires the
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interlock (PMPI) contacts. The pump
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Suction Transducer FailurePr.04 —
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NOTE: The energy management module
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Table 43B — 5K Thermistor Tempera
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ALM RALT RCL-HTCWFSDLSVDPTEXVEMMFIO
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COMPRESSOR AND FAN LOCATIONFig. 37
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COMPRESSOR AND FAN LOCATIONFig. 39
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APPENDIX A — LOCAL DISPLAY TABLES
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Page 86 and 87:
Page 88 and 89:
Page 90 and 91:
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NOTE: See operating modes starting
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APPENDIX B — CCN TABLES (cont)STA
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Page 98 and 99:
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NOTES:1. Compressor capacity will b
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APPENDIX B — CCN TABLES (cont)SET
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APPENDIX B — CCN TABLES (cont)MAI
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APPENDIX B — CCN TABLES (cont)SER
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APPENDIX C — CCN ALARM DESCRIPTIO
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APPENDIX C — CCN ALARM DESCRIPTIO
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Actual start-up 44Alarms and alerts
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Copyright 2007 Carrier CorporationM
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7. Electrical circuit protection ha
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Record Configuration InformationMOD
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Component Test — Complete the fol
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Operating Data:Record the following
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Copyright 2007 Carrier CorporationM
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