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

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MODE 12 (MD12) — Auto Changeover ActiveCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 13 (MD13) — Free Cooling ActiveCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 14 (MD14) — Reclaim ActiveCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 15 (MD15) — Electric Heat ActiveCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 16 (MD16) — Heating Low EWT LockoutCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 17 (MD17) — Boiler ActiveCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 18 (MD18) — Ice Mode in EffectCriteria for Mode — Tested when the unit is ON. This modeis active when Ice Setpoint (Setpoints→COOL→CSP.3) isin use. While in this mode, the Active Setpoint (Run Status→VIEW→SETP) will show the CSP.3 value.Action Taken — The unit will operate to the Ice Setpoint(CSP.3).Termination — This mode will terminate when the Ice Setpoint(CSP.3) is no longer in use.Possible Causes — This mode is in effect only due to programmingoptions.MODE 19 (MD19) — Defrost Active on Cir AMODE 20 (MD20) — Defrost Active on Cir BCriteria for Mode — This mode is not supported for CoolingOnly units.Action Taken — None.Termination — None.Possible Causes — This mode is in effect only due to programmingoptions.MODE 21 (MD21) — Low Suction Circuit AMODE 22 (MD22) — Low Suction Circuit BMODE 23 (MD23) — Low Suction Circuit CCriteria for Mode — The criteria are tested when the circuit isON. The appropriate circuit mode will be active if one of thefollowing conditions is true:1. If the circuit’s Saturated Suction Temperature (SST) ismore than 6° F (3.3° C) less than the freeze point andboth the cooler approach (Leaving Water Temperature-SST) and superheat (Suction Gas Temperature – SST) aregreater than 15° F (8.3° C).2. If there is more than 1 compressor ON in the circuit andthe circuit’s SST is greater than 18° F (10.0° C) below thefreeze point for more than 90 seconds.3. If there is more than 1 compressor ON in the circuit andthe circuit’s SST is greater than –4° F (–20.0° C) and theSST 30 seconds ago was 18° F (10.0° C) below the freezepoint.4. If the circuit’s saturated suction temperature is greaterthan 6° F (3.3° C) below the freeze point for more than3 minutes.For a fresh water system (Configuration→SERV→FLUD=1), the freeze point is 34° F (1.1° C). For medium temperaturebrine systems, (Configuration→SERV→FLUD=2), the freezepoint is Brine Freeze Set Point (Configuration→SERV→LOSP).Action Taken — For criterion 1, no additional stages will beadded. For criteria 2, 3 and 4, 1 stage of capacity will beremoved.Termination — The mode will terminate when the circuit’sSaturated Suction Temperature is greater than the freeze pointminus 6° F (3.3° C) or the circuit has alarmed.Possible Causes — If this condition is encountered, see PossibleCauses for Alarms P.05, P.06, and P.07 on page 67.MODE 24 (MD24) — High DGT Circuit AMODE 25 (MD25) — High DGT Circuit BMODE 26 (MD26) — High DGT Circuit CCriteria for Mode — This mode is tested for when any circuitis running. The circuit saturated condensing and suction temperaturesare monitored to ensure that the compressors alwaysoperate withing their allowed “map.” Operation at conditionsat or outside the “map” boundries will cause this mode to be ineffect. Operation at extremely low suction pressures and highcondensing temperatures will cause the mode to be generated.Action Taken — The circuit will not be allowed to increase capacityand may be automatically unloaded or stopped.Termination — This mode will terminate when/if the circuitrefrigerant conditions return to within the compressor “map.”Possible Causes — This mode could be in effect due to a lowfluid flow rate, overcharge of oil in a circuit, dirty condensercoils, refrigerant overcharge, or excessive brine concentration.MODE 27 (MD27) — High Pres Override Cir AMODE 28 (MD28) — High Pres Override Cir BMODE 29 (MD29) — High Pres Override Cir CCriteria for Mode — Tested when the circuit is ON. Theappropriate circuit mode will be active if the discharge pressurefor the circuit, Discharge Pressure Circuit A (Pressure→PRC.A→DP.A), Discharge Pressure Circuit B (Pressure→PRC.B→DP.B),or Discharge Pressure Circuit C(Pressure→PRC.C→DP.C) is greater than the High PressureThreshold (Configuration→SERV→HP.TH).48
Action Taken — The capacity of the affected circuit will bereduced. If the unit is equipped with Minimum Load Controland has been configured for High Ambient (Configuration→UNIT→HGBP=3), the minimum load control valve will beenergized. Two minutes following the capacity reduction, thecircuit’s saturated condensing temperature (SCT) is calculatedand stored. The affected circuit will not be allowed to add capacityfor at least 5 minutes following the capacity reduction. Ifafter 5 minutes, the circuit’s saturated condensing temperatureis less than SCT – 3° F (1.7° C), if required, another stage ofcapacity will be added.If additional steps of capacity are required, the control willlook for other circuits to add capacity.Termination — This mode will terminate once the circuit’ssaturated condensing temperature is less than SCT – 3° F(1.7° C).Possible Causes — If this condition is encountered, see PossibleCauses for Alarm A1.03. on page 63.MODE 30 (MD30) — Low Superheat Circuit AMODE 31 (MD31) — Low Superheat Circuit BMODE 32 (MD32) — Low Superheat Circuit CCriteria for Mode — Tested when the circuit is ON with atleast 1 compressor ON. The appropriate circuit mode will beactive is the circuit’s superheat is less than 5° F (2.8° C).Action Taken — No additional stages of circuit capacity willbe added until the circuit’s superheat is greater than 5° F(2.8° C).The control will look for other circuits to add capacity ifadditional steps of capacity are required.Termination — This mode will terminate once the affectedcircuit’s superheat is greater than 5° F (2.8° C).Possible Causes — If this condition is encountered, see PossibleCauses for Alarms P.11, P.12 and P.13 on page 67.SERVICEElectronic Expansion Valve (EXV) — See Fig. 24for a cutaway view of the EXV. High-pressure liquid refrigerantenters valve through the top. As refrigerant passes throughthe orifice, pressure drops and refrigerant changes to a 2-phasecondition (liquid and vapor). The electronic expansion valveoperates through an electronically controlled activation of astepper motor. The stepper motor stays in position, unlesspower pulses initiate the two discrete sets of motor stator windingsfor rotation in either direction. The direction depends onthe phase relationship of the power pulses.The motor directly operates the spindle, which has rotatingmovements that are transformed into linear motion by thetransmission in the cage assembly. The valve cone is a V-porttype which includes a positive shut-off when closed.There are two different EXVs. For circuits with 1 or 2 compressors,the total number of steps is 2785. For circuits with 3or 4 compressors, the total number of steps is 3690. The EXVmotor moves at 150/300 steps per second. Commanding thevalve to either 0% or 100% will add extra 160 steps to themove, to ensure the value is open or closed completely.The EXV board controls the valve. Each circuit has a thermistorlocated in a well in the suction manifold before the compressor.Suction pressure as measured by the suction pressuretransducer is converted to a saturated suction temperature. Thethermistor measures the temperature of the superheated gasentering the compressor and the pressure transducer determinesthe saturated temperature of suction gas. The differencebetween the temperature of the superheated gas and thesaturated suction temperature is the superheat. The EXV boardcontrols the position of the electronic expansion valve steppermotor to maintain superheat set point.The MBB controls the superheat leaving cooler to approximately7.2° F (4° C). Because EXV status is communicated tothe main base board (MBB) and is controlled by the EXVboards, it is possible to track the valve position. The unit is thenprotected against loss of charge and a faulty valve. Duringinitial start-up, the EXV is fully closed. After initialization period,valve position is tracked by the EXV board by constantlymonitoring the amount of valve movement.The EXV is also used to limit cooler saturated suction temperatureto 50 F (10 C). This makes it possible for the chiller tostart at higher cooler fluid temperatures without overloadingthe compressor. This is commonly referred to as MOP (maximumoperating pressure).If it appears that the EXV module is not properly controllingcircuit operation to maintain correct superheat, there are anumber of checks that can be made using test functions andinitialization features built into the microprocessor control. Seethe EXV Troubleshooting Procedure section to test EXVs.EXV TROUBLESHOOTING PROCEDURE — Follow thesteps below to diagnose and correct EXV problems. CheckEXV motor operation first. Switch the Enable/Off/Remote(EOR) Contact switch to the Off position. Press ESCAPE onthe scrolling marquee until the highest operating level is displayed.Use the arrow keys to select the Service Test mode andpress ENTER . The display will be TEST. Use the arrow keysuntil display shows QUIC. Press ENTER (password entrymay be required) and use or to change OFF to ON.The Quick Test sub-mode is now enabled. Move the arrowdown to the appropriate circuit EXV, Circuit A EXV % Open(Service Test Mode→QUIC→EXV.A), Circuit B EXV %Open (Service Test Mode→QUIC→EXV.B), or Circuit CEXV % Open (Service Test Mode→QUIC→ EXV.C), andpress ENTER . The current value of 0 will be displayed. PressENTER and the value will be flashing. Using the increasethe EXV position to select 100% valve position (holdfor quick movement) and press ENTER . The actuatorshould be felt moving through the EXV. Press ENTER againtwice if necessary to confirm this has occurred. This will attemptto force the EXV to 100% again. To close the valve,press ENTER , select 0% with and press ENTER . Theactuator should knock when it reaches the bottom of its stroke.If it is believed that the valve is not working properly, continuewith the following test procedure:Check the 8-position DIP switch on the board for the properaddress. Check the EXV output signals at appropriate terminalson the EXV module. Connect positive test lead to EXV-J2Aterminal 5 for sizes 060-190 or EXV1-J2A terminal 5 for sizes210-300 for Circuit A. Connect lead to EXV-J2B terminal 5for sizes 060-190 or EXV1-J2B terminal 5 for sizes 210-300for Circuit B. Connect lead to EXV2-J2A terminal 5 for sizes210-300 for Circuit C. Set meter to approximately 20 vdc. Usingthe Service Test procedure above, move the valve outputunder test to 100%. DO NOT short meter leads together or pin5 to any other pin, as board damage will occur. During the nextseveral seconds, carefully connect the negative test lead to pins1,2,3 and 4 in succession. Digital voltmeters will average thissignal and display approximately 6 vdc. If the output remainsat a constant voltage other than 6 vdc or shows 0 volts, removethe connector to the valve and recheck.49
Page 2 and 3: CONTENTS (cont)Page• COOLER LEAVI
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 50 and 51: 1. Cable2. Glass Seal3. Motor Housi
Page 52 and 53: DISASSEMBLYClosedOpenNOTE: Open val
Page 54 and 55: 1130 26 2218 137 16 9 20243 5 28343
Page 56 and 57: Charging with Unit Off and Evacuate
Page 58 and 59: Table 37 — TroubleshootingSYMPTOM
Page 60 and 61: PREFIXCODECoCtFCMCSUFFIXCODE.F1.F2.
Page 62 and 63: Table 38 — Alarm Codes (cont)PREF
Page 64 and 65: Possible Causes — If this conditi
Page 66 and 67: a control option that requires the
Page 68 and 69: interlock (PMPI) contacts. The pump
Page 70 and 71: Suction Transducer FailurePr.04 —
Page 72 and 73: NOTE: The energy management module
Page 74 and 75: Table 43B — 5K Thermistor Tempera
Page 76 and 77: ALM RALT RCL-HTCWFSDLSVDPTEXVEMMFIO
Page 78 and 79: COMPRESSOR AND FAN LOCATIONFig. 37
Page 80 and 81: COMPRESSOR AND FAN LOCATIONFig. 39
Page 82 and 83: APPENDIX A — LOCAL DISPLAY TABLES
Page 92 and 93: NOTE: See operating modes starting
Page 94 and 95: APPENDIX B — CCN TABLES (cont)STA
Page 96 and 97: APPENDIX B — CCN TABLES (cont)STA
Page 98 and 99:
APPENDIX B — CCN TABLES (cont)STA
Page 100 and 101:
NOTES:1. Compressor capacity will b
Page 102 and 103:
APPENDIX B — CCN TABLES (cont)SET
Page 104 and 105:
APPENDIX B — CCN TABLES (cont)MAI
Page 106 and 107:
APPENDIX B — CCN TABLES (cont)SER
Page 108 and 109:
APPENDIX C — CCN ALARM DESCRIPTIO
Page 110 and 111:
APPENDIX C — CCN ALARM DESCRIPTIO
Page 112 and 113:
Actual start-up 44Alarms and alerts
Page 114 and 115:
Copyright 2007 Carrier CorporationM
Page 116 and 117:
7. Electrical circuit protection ha
Page 118 and 119:
Record Configuration InformationMOD
Page 120 and 121:
Component Test — Complete the fol
Page 122 and 123:
Operating Data:Record the following
Page 124:
Copyright 2007 Carrier CorporationM
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