30HXC 075-370
30GX 080-350
Screw Compressor
Water-Cooled Chillers and
Air-Cooled Chillers
30HXC Nominal cooling capacity 268-1290 kW
30GX Nominal cooling capacity 262-1160 kW
50 Hz
Installation, operation and maintenance instructions
The cover photograph is for illustrative purposes only
and is not part of any offer for sale or contract.
2
List of contents
INTRODUCTION ...................................................................... 4
SAFETY CONSIDERATIONS ................................................. 4
DIMENSIONS, CLEARANCES,
WEIGHT DISTRIBUTION ...................................................... 5
30HXC 075-185 ........................................................................... 5
30HXC 215-280 ........................................................................... 6
30HXC 300-370 ........................................................................... 7
30GX 080-160 .............................................................................. 8
30GX 175 ..................................................................................... 9
30GX 205-265 ............................................................................ 10
30GX 280-350 ............................................................................ 11
FIELD POWER SUPPLY ........................................................
30HXC 075-185 .........................................................................
30HXC 215-280 .........................................................................
30HXC 300-370 .........................................................................
30GX 080-160 ............................................................................
30GX 175 ...................................................................................
30GX 205-265 ............................................................................
30GX 280-350 ............................................................................
28
28
29
30
31
32
33
34
MAJOR SYSTEM COMPONENTS
AND OPERATION DATA ....................................................... 35
ELECTRICAL DATA .............................................................. 15
30HXC ........................................................................................ 15
Compressor ................................................................................. 15
Geared twin screw compressor ...................................................
Cooler .........................................................................................
Condenser and oil separator (30HXC) .......................................
Oil separator (30GX) ..................................................................
Electronic Expansion Device (EXD) ..........................................
Economizer .................................................................................
Oil pumps ...................................................................................
Motor cooling valves ..................................................................
Back pressure valve (GX only) ..................................................
Sensors ........................................................................................
Thermistors .................................................................................
Pressure transducers ...................................................................
Control components ....................................................................
PHYSICAL DATA .................................................................... 16
CONTROL OPERATION ....................................................... 39
30GX .......................................................................................... 16
Keypad and display module usage (HSIO II) .............................
Functions and subfunctions ........................................................
Accessing functions and subfunctions ........................................
Status function ............................................................................
Test function and subfunctions ...................................................
Schedule function .......................................................................
Service function ..........................................................................
History function and subfunctions ..............................................
Setpoint function ........................................................................
Head pressure control .................................................................
MAIN COMPONENT LOCATION ....................................... 12
30HXC 075-185 ......................................................................... 12
30HXC 215-280 ......................................................................... 13
PHYSICAL DATA .................................................................... 14
30HXC ........................................................................................ 14
ELECTRICAL DATA .............................................................. 17
30GX .......................................................................................... 17
Compressor ................................................................................. 17
APPLICATION DATA ............................................................. 18
Unit operating range ................................................................... 18
Minimum chilled water flow ...................................................... 18
Maximum chilled water flow ..................................................... 18
Cooler flow rate (l/s) ................................................................... 19
Condenser flow rate (l/s) ............................................................ 19
Variable flow evaporator ............................................................. 19
System minimum water volume ................................................. 19
Flow controllers .......................................................................... 20
INSTALLATION ...................................................................... 20
Check equipment received .......................................................... 20
Moving and siting the unit .......................................................... 20
LIFTING INSTRUCTIONS .................................................... 21
30HXC 075-185 .........................................................................
30HXC 215-280 .........................................................................
30HXC 300-370 .........................................................................
30GX 080-160 ............................................................................
30GX 175 ...................................................................................
30GX 205-265 ............................................................................
30GX 280-350 ............................................................................
21
22
23
24
24
25
25
PIPING CONNECTIONS ....................................................... 26
Operating precautions ................................................................. 26
Cooler and condenser connections ............................................. 26
Pipe connections ......................................................................... 26
Freeze protection ........................................................................ 26
ELECTRICAL CHARACTERISTICS .................................. 27
Power supply .............................................................................. 27
35
35
35
35
35
35
36
36
36
36
36
36
37
39
39
40
41
43
44
44
46
47
48
PRE-START-UP PROCEDURE ............................................. 50
System Check .............................................................................
Start-up and operation ................................................................
Actual Start-up ............................................................................
Operating Sequence ....................................................................
50
50
50
50
TROUBLESHOOTING ........................................................... 51
Checking display codes ..............................................................
Unit shutoff .................................................................................
Complete unit stoppage ..............................................................
Single Circuit Stoppage ..............................................................
Restart procedure ........................................................................
Alarms and alert .........................................................................
Alarms and alerts codes table .....................................................
Low oil pressure alert criteria and setpoints (Alert 40 to 43) .....
51
51
51
51
51
51
52
56
MAINTENANCE ..................................................................... 57
Refrigerant Charging - Adding Charge ......................................
Oil Charging - Low oil recharging .............................................
Service replacement compressor ................................................
EXV Troubleshooting Procedure ...............................................
57
58
59
59
START-UP CHECKLIST FOR 30HXC/30GX ...................... 60
Preliminary information ............................................................. 60
Preliminary equipment check ..................................................... 60
Unit start-up ................................................................................ 61
3
INTRODUCTION
Prior to initial start-up of the 30HXC and 30GX unit, those
involved in the start-up, operation, and maintenance should be
thoroughly familiar with these instructions and other necessary
job data. This book provides an overview so that you may become
familiar with the control system before performing start-up
procedures. Procedures in this manual are arranged in the sequence
required for proper machine start-up and operation.
SAFETY CONSIDERATIONS
30HXC and 30GX liquid chillers are designed to provide safe
and reliable service when operated within design specifications.
When operating this equipment, use good judgment and safety
precautions to avoid damage to equipment and property or injury
to personnel.
Be sure you understand and follow the procedures and safety
precautions contained in the machine instructions as well as those
listed in this guide.
DANGER
DO NOT VENT refrigerant relief valves within a building. Outlet
from relief valve must be vented outdoors. The accumulation of
refrigerant in an enclosed space can displace oxygen and cause
asphyxiation.
PROVIDE adequate ventilation, especially for enclosed and low
overhead spaces. 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.
DO NOT USE OXYGEN to purge lines or to pressurize a
machine for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
NEVER EXCEED specified test pressures, VERIFY the
allowable test pressure by checking the instruction literature
and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed
before operating any machine.
WARNING
DO NOT WELD OR FLAMECUT any refrigerant line or vessel
until all refrigerant (liquid and vapor) has been removed from
chiller. Traces of vapor should be displaced with dry air nitrogen
and the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including control
panels, switches, relays etc, until you are sure ALL POWER IS
OFF and residual voltage can leak from capacitors or solid
state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.
DO NOT siphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it into
the eyes. USE SAFETY GOGGLES. Wash any spills from the
skin with soap and water. If liquid refrigerant enters the eyes,
4
IMMEDIATELY FLUSH EYES with water and consult a
physician.
NEVER APPLY an open flame or live steam to refrigerant
cylinder. Dangerous overpressure can result. If it is necessary
to heat refrigerant, use only warm water.
DO NOT REUSE disposable (non-returnable) cylinders or
attempt to refill them. It is DANGEROUS AND ILLEGAL.
When cylinders are emptied, evacuate remaining gas pressure,
loosen the collar and unscrew and discard the valve stem. DO
NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding
refrigerant to the machine. The introduction of the wrong
refrigerant can cause damage or malfunction to this machine.
DO NOT ATTEMPT TO REMOVE fittings, components, etc.,
while machine is under pressure or while machine is running.
Be sure pressure is at 0 kPa before breaking refrigerant
connection.
CAREFULLY INSPECT all relief devices, AT LEAST ONCE
A YEAR. If machine operates in a corrosive atmosphere, inspect
the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any
relief device when corrosion or build-up of foreign material
(rust, dirt, scale, etc.) is found within the valve body or
mechanism. Replace the device.
DO NOT install relief devices in series or backwards.
CAUTION
DO NOT STEP on refrigerant lines. Broken lines can whip
about and release refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, or staging.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift
or move heavy components. Even if components are light, use
mechanical equipment when there is a risk of slipping or losing
your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE TOWER FAN, OR PUMPS. Open the disconnect
ahead of the tower fans, or pumps.
USE only repair or replacement parts that meet the code
requirements of the original equipment.
DO NOT VENT OR DRAIN water boxes containing industrial
brines, without the permission of your process control group.
DO NOT LOOSEN water box bolts until the water box has been
completely drained.
DO NOT LOOSEN a packing gland nut before checking that
the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for
corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate or
rain water.
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION
30HXC 075-185
15
ØR
1
14
13
10
34
34
33
33
P1
ØS
P3
P2
G
H
30HXC
A
B
C
D
E
F
L
M
N
ØR
075-095
2730
1775
875
1217
1220
222.5 332
268.3 265.4 2360
1000
593
279
114.3 139.7
105
115-145
2730
3535
1825
1775
875
1035
1217
1635
1220
1220
222.5 332
222.5 332
276.5 300
286
230
2360
3220
1000
1000
593
593
279
734
139.7 139.7
19.7 139.7
160-170
3550
1900
1195
1635
1328
306
257
340
300
3220
1000
620
804
139.7 168.3
185
3550
1900
1195
1635
1328
306
257
360
260
3220
1000
620
804
168.3 168.3
Weight distribution
Total
at the four
operating
mounting holes (kg)
weight (kg)
J
K
P4
ØS
Legend :
Services clearances required
30HXC
P1
P2
P3
P4
PT
Space required to remove
075
703
613
634
553
2503
cooler and condenser tubes
085
095
707
719
617
627
637
647
557
567
2518
2560
105
115
767
795
670
695
691
716
603
627
2731
2833
125
135
807
830
705
726
726
746
634
654
2872
2956
145
160
835
922
730
808
750
818
656
735
2971
3283
170
936
848
848
771
3403
185
968
876
876
797
3517
Electrical supply entry
NOTE : Refer to certified dimensional drawings 99DI 075HX when designing an installation.
5
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (CONT.)
30HXC 215-280
Weight distribution
Total
at the four
operating
mounting holes (kg)
weight (kg)
30HXC
P1
P2
P3
P4
PT
215
250
1319
1348
1127
1207
1232
1288
1052
1154
4730
4996
265
1354
1213
1295
1159
5021
280
1361
1218
1302
1165
5046
Legend :
Services clearances required
Space required to remove
cooler and condenser tubes
Electrical supply entry
NOTE : Refer to certified dimensional drawings 99DI 215HX when designing an installation.
6
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (CONT.)
30HXC 300-370
Weight distribution
Total
at the four
operating
mounting holes (kg)
weight (kg)
30HXC
P1
P2
P3
P4
PT
300
1573
1444
1498
1375
5890
315
340
1625
1647
1479
1499
1552
1555
1413
1414
6070
6115
370
1659
1507
1571
1428
6165
Legend :
Services clearances required
Space required to remove
cooler and condenser tubes
Electrical supply entry
NOTE : Refer to certified dimensional drawings 99DI 300HX when designing an installation.
7
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (CONT.)
30GX 080-160
30GX
A
B
C
D
D2
D3
E
G
H
J
K
R
080-090
2882
2200
627
609.6
409.6
609.6
N/A
515
249
128
2300
114.3
105
115-135
2882
3340
2200
2200
627
856
609.6
609.6
409.6
409.6
609.6
609.6
N/A
N/A
558
558
256
256
120
348.5
2300
2100
139.7
139.7
150
4254
2200
627
658.3
1170.5
658.3
2800
497
267
283
N/A
139.7
160
4254
2200
627
658.3
1170.5
658.3
2800
497
267
275
N/A
139.7
Weight distribution
Total
at the eight
operating
mounting holes (kg)
weight (kg)
Notes :
1. Unit must have clearances for air flow as follows :
TOP : do not restrict in any way
End and side space required (from solid surface)
30GX
P1
P2
P3
P4
P5
P6
P7
P8
PT
080
090
456
456
583
583
252
252
286
288
252
252
286
288
587
587
708
712
3410
3420
105
115
456
456
645
689
252
252
348
390
252
252
348
390
587
587
770
813
3658
3829
125
135
456
456
700
703
252
252
403
406
252
252
403
406
587
587
824
827
3877
3889
3. Unit must have clearances for cooler tube removal as
follows :
150
268
166
463
630
403
615
655
990
4189
Additional space required to remove cooler tubes
160
268
166
463
646
403
631
655
1007
4239
Multiple chiller installation (see note 2 and sketch on page 9)
2. In case of multiple chillers (up to four units), the respective
clearance between them should be increased from 1830 to
2000 mm for the side space requirement.
Electrical box
NOTE : Refer to certified dimensional drawings 99DI 080GX when designing an installation.
8
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (CONT.)
30GX 175
Weight distribution
Total
at the ten
operating
mounting holes (kg)
weight (kg)
30GX
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
PT
175
506
323
322
635
467
687
527
702
321
181
4671
Multiple chiller installation (see note 2)
SOLID SURFACE AREA
Notes :
1. Unit must have clearances for air flow as follows :
Top : do not restrict in any way
SOLID SURFACE AREA
2. In case of multiple chillers (up to four units), the respective
clearance between them should be increased from 1830 to
2000 mm for the side space requirement.
2000
2000
2000
1830
1830
End and Side space required (from solid surface)
2000
1525
3. Unit must have clearances for cooler tube removal as
follows :
Additional space required to remove cooler tubes
1525
Electrical box
NOTE : Refer to certified dimensional drawings 99DI 175GX when designing an installation.
9
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (CONT.)
30GX 205-265
Weight distribution
Total
at the twelve
operating
mounting holes (kg)
weight (kg)
30GX
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
PT
205
573
321
453
857
575
902
655
923
367
184
-
-
5810
225
250
573
593
370
330
453
453
904
860
575
575
950
912
655
655
970
920
367
367
231
195
250
200
6048
6310
265
593
382
453
906
575
962
655
970
367
243
250
200
6556
Multiple chiller installation (see note 2)
SOLID SURFACE AREA
Notes :
1. Unit must have clearances for air flow as follows :
Top : do not restrict in any way
SOLID SURFACE AREA
2. In case of multiple chillers (up to four units), the respective
clearance between them should be increased from 1830 to
2000 mm for the side space requirement.
2000
2000
2000
1830
1830
End and Side space required (from solid surface)
2000
1525
3. Unit must have clearances for cooler tube removal as
follows :
Additional space required to remove cooler tubes
1525
Electrical box
NOTE : Refer to certified dimensional drawings 99DI 205GX when designing an installation.
10
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (CONT.)
30GX 280-350
Weight distribution
Total
at the sixteen
operating
mounting holes (kg)
weight (kg)
30GX
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
PT
280
-
-
400
300
650
900
650
900
550
900
650
900
300
203
-
-
7303
295
325
300
200
400
300
300
200
650
640
936
920
650
630
930
920
550
533
900
920
650
640
900
920
200
200
150
150
150
150
130
130
7496
7753
350
300
200
300
200
650
930
650
930
550
930
650
930
250
150
150
132
7852
Multiple chiller installation (see note 2)
SOLID SURFACE AREA
Notes :
1. Unit must have clearances for air flow as follows :
Top : do not restrict in any way
SOLID SURFACE AREA
2. In case of multiple chillers (up to four units), the respective
clearance between them should be increased from 1830 to
2000 mm for the side space requirement.
2000
2000
2000
1830
1830
End and Side space required (from solid surface)
2000
1525
3. Unit must have clearances for cooler tube removal as
follows :
Additional space required to remove cooler tubes
1525
Electrical box
NOTE : Refer to certified dimensional drawings 99DI 280GX when designing an installation.
11
MAIN COMPONENTS LOCATION
30HXC 075-185
2
5
30
27
9
19
26
6
4
28 29
5
9
27
19
26
18
6
4
28
18
30HXC
30HXC
30HXC
30HXC
30HXC
30HXC
30HXC
29
2
115
125
135
145
160
170
185
20
25
21
30HXC
30HXC
30HXC
30HXC
20
25
21
31 32
31 32
3
A
12
11
3
24
23
B
7
22
8
8
24
23
7
22
12
ITEM
DESIGNATION
ITEM
DESIGNATION
1
Cooler water inlet and outlet
18
Capacity loaders
2
3
Cooler 3/8" NPT air vent
Cooler 3/8" NPT water drain
19
20
Oil solenoïd valve
External muffler
4
5
Refrigerant charging valve
Cooler safety relief valve
21
22
Discharge valve
Oil level switch
6
7
Oil charging valve
Closing valve and oil drain
23
24
Prelube oil pump
Oil check valve
8
9
Refrigerant recovery valve
Condenser safety relief valve
25
26
Oil prefilter
Compressor oil filter housing
10
11
Condenser inlet and outlet
Condenser 3/8" NPT air vent
27
28
Cooler liquid level sensor
Motor cooling valve
12
13
Condenser 3/8" NPT water drain
Cooler entering fluid thermistor
29
30
Economizer pressure transducer
Suction pressure transducer
14
15
Cooler leaving fluid thermistor
Electrical box
31
32
Discharge pressure transducer
Discharge temperature thermistor
16
17
Power terminal block (see field power supply)
Main disconnect switch option (see field power supply)
33
Liquid valve
34
Electronic expansion valve
Legend:
A
Circuit A
B
Circuit B
Water inlet (flanges supplied)
Water outlet (flanges supplied)
12
11
075
085
095
105
MAIN COMPONENTS LOCATION (CONT.)
30HXC 215-280
2
4
5
9
6
26
18
29
31
11
12
3
4
25
5
9
21
19
18
6
3
20
29
2
25
32
22
23
7
24
8
8
23
ITEM
DESIGNATION
ITEM
DESIGNATION
1
Cooler water inlet and outlet
18
Capacity loaders
2
3
Cooler 3/8" NPT air vent
Cooler 3/8" NPT water drain
19
20
Oil solenoïd valve
External muffler
4
5
Refrigerant charging valve
Cooler safety relief valve
21
22
Discharge valve
Oil level switch
6
7
Oil charging valve
Closing valve and oil drain
23
24
Prelube oil pump
Oil check valve
8
9
Refrigerant recovery valve
Condenser safety relief valve
25
26
Oil prefilter
Compressor oil filter housing
10
11
Condenser inlet and outlet
Condenser 3/8" NPT air vent
27
28
Cooler liquid level sensor
Motor cooling valve
12
13
Condenser 3/8" NPT water drain
Cooler entering fluid thermistor
29
30
Economizer pressure transducer
Suction pressure transducer
14
15
Cooler leaving fluid thermistor
Electrical box
31
32
Discharge pressure transducer
Discharge temperature thermistor
16
17
Power terminal block (see field power supply)
Main disconnect switch option (see field power supply)
33
Liquid valve
34
Economizer
7
22
11
12
Legend :
A
Circuit A
B
Circuit B
13
PHYSICAL DATA
30HXC
30HXC
075
085
095
105
115
125
135
145
160
170
185
Nominal gross cooling capacity*
kW
268
295
346
373
404
439
485
519
550
593
639
Operating weight**
Refrigerant
kg
2503
2518
HFC-134a
2560
2731
2833
2872
2956
2971
3283
3403
3517
Refrigerant charge CKT A/CKT B
Oil
kg
See unit nameplate
Polyolester oil CARRIER SPEC : PP 47-32
Oil charge CKT A/CKT B
Compressor
l
20/20
20/20
20/20
Semi-hermetic twin screw
20/20
20/20
20/20
20/20
20/20
20/20
20/20
20/20
Ckt A (nominal capacity compressor A1)
Ckt B (nominal capacity compressor B1)
Tons
Tons
39
39
46
39
56
39
66
39
66
46
66
56
80
56
80
66
80
80
66
80
80
80
Economizer
Capacity steps
No.
No
6
No
6
No
6
No
6
No
6
No
6
No
6
No
6
No
6
Yes
6
Yes
6
Minimum capacity
Cooler
%
20
20
20
20
20
One shell & tube cooler with enhanced copper tubes
20
20
20
20
20
20
Net water volume
Refrigerant circuits
l
No.
65
2
81
2
81
2
91
2
91
2
109
2
109
2
127
2
Water connection
Inlet & outlet diameter
inches
Factory supplied flat flange to be site welded
4
4
4
5
5
5
5
5
5
5
6
Air vent diameter (on water box)
Water drain diameter (on water box)
inches
inches
3/8” NPT
3/8” NPT
Maximum operating pressure water side
Condenser
kPa
1000
One shell & tube condenser with enhanced copper tubes
Net water volume
Refrigerant circuits
l
No.
67
2
89
2
96
2
110
2
110
2
132
2
136
2
145
2
Water connection
Inlet & outlet diameter
inches
Factory supplied flat flange to be site welded
5
5
5
5
5
5
5
5
6
6
6
Air vent diameter (on water box)
Water drain diameter (on water box)
inches
inches
3/8” NPT
3/8” NPT
Maximum operating pressure water side
kPa
1000
215
250
265
280
300
315
340
370
Nominal gross cooling capacity*
kW
757
879
921
965
1054
1140
1195
1290
Operating weight**
Refrigerant
kg
4730
4996
HFC-134a
5021
5046
5890
6070
6115
6165
Refrigerant charge CKT A/CKT B
Oil
kg
See unit nameplate
Polyolester oil CARRIER SPEC : PP 47-32
Oil charge CKT A/CKT B
Compressor
l
40/20
40/20
40/20
Semi-hermetic twin screw
40/20
40/40
40/40
40/40
40/40
Ckt A (nominal capacity compressor A1)
Ckt B (nominal capacity compressor B1)
Tons
Tons
80/56
80
50/56
80
50/66
80
80/80
80
56/66
66/66
56/80
56/80
66/80
66/80
80/80
80/80
Economizer
Capacity steps
No.
No
8
Yes
8
Yes
8
Yes
8
Yes
10
Yes
10
Yes
10
Yes
10
30HXC
65
2
67
2
73
2
67
2
87
2
74
2
Minimum capacity
Cooler
%
15
15
15
15
10
One shell & tube cooler with enhanced copper tubes
10
10
10
Net water volume
Refrigerant circuits
l
No.
165
2
203
2
229
2
229
2
229
2
Water connection
Inlet & outlet diameter
inches
Factory supplied flat flange to be site welded
6
6
6
6
8
8
8
8
Air vent diameter (on water box)
Water drain diameter (on water box)
inches
inches
3/8” NPT
3/8” NPT
Maximum operating pressure water side
Condenser
kPa
1000
One shell & tube condenser with enhanced copper tubes
Net water volume
Refrigerant circuits
l
No.
208
2
231
2
251
2
251
2
251
2
Water connection
Inlet & outlet diameter
inches
Factory supplied flat flange to be site welded
6
6
6
6
8
8
8
8
Air vent diameter (on water box)
Water drain diameter (on water box)
inches
inches
3/8” NPT
3/8” NPT
Maximum operating pressure water side
kPa
1000
Legend :
* Eurovent conditions :
Evaporator entering/leaving water temperature 12°C and 7°C,
Condenser entering/leaving water temperature 30°C and 35°C.
** Weight includes weight of water or brine and refrigerant.
14
181
2
208
2
181
2
208
2
181
2
208
2
ELECTRICAL DATA
30HXC
30HXC
075
085
095
105
115
125
135
145
160
170
185
68
80.5
86.4
90.6
98.4
108.7
117.9
124
133
144.3
Mains power supply
Nominal voltage
V-ph-Hz
400-3-50
Voltage range
%
± 10
Control circuit voltage*
V-ph-Hz
230-1-50
Nominal unit power input**
kW
62.1
Nominal operating current**
A
87
96
122
133
139
165
178
189
203
206
239
Maximum operating current***
A
142
157
175
195
210
228
255
275
302
300
330
Maximum starting current
Across the line start****
A
415
494
577
676
691
709
819
839
866
992
1021
Optional star delta start****
A
180
205
231
262
277
295
330
350
377
406
435
215
250
265
280
300
315
340
370
30HXC
Mains power supply
*
**
***
****
Nominal voltage
V-ph-Hz
400-3-50
Voltage range
%
± 10
Control circuit voltage*
V-ph-Hz
230-1-50
Nominal unit power input**
kW
171.8
192.3
204
216.3
229.2
246.5
263.1
289.2
Nominal operating current**
A
308.0
327.9
342.5
360.3
398.5
416.2
443.3
480.9
Maximum operating current***
A
Circuit A
255
278
300
330
248
278
300
330
Circuit B
151
165
165
165
271
278
300
330
Maximum starting current
Across the line start****
A
970
1134
1156
1186
1099
1247
1292
1350
Optional star delta start****
A
481
548
570
600
610
661
706
764
Legend :
Control power circuit is supplied through factory installed transformer
Unit power input kW and current drawn at cooler entering/leaving temperature 12°C/7°C, condenser entering/leaving temperature 30°C/35°C and at 400 Volts nominal voltage
Maximum current drawn by compressors at full load and at minimum voltage 360 Volts
Maximum instantaneous starting current (maximum operating current of the smallest compressor + locked rotor amps of the largest compressor)
Compressor
PART NUMBER
Tons
LRA (Y)
LRA (Delta)
MHA
06NW 1146 S7 N
39
109
344
71
06NW 1174 S7 N
46
134
423
86
06NW 1209 S7 N
56
160
506
104
06NW 1250 S7 N
66
191
605
124
06NW 1300 S5 N
80
226
715
151
06NW 1209 S7 E
56
191
605
113
06NW 1250 S7 E
66
226
715
136
06NW 1300 S5 E
80
270
856
165
Legend :
LRA (Y)
LRA (Delta)
MHA
06NW
N
E
Locked Rotor Amps with optional star delta start
Locked Rotor Amps with standard across the line start
Compressor Must Hold Amps (Maximum Operating Current at 360 V)
Water-cooled condensing compressor
Non Economized compressor
Economized compressor
15
PHYSICAL DATA
30GX
30GX
Nominal gross cooling capacity*
Operating weight
Refrigerant
Refrigerant charge CKT A/CKT B
Compressor
Ckt A, nominal capacity per compressor
Ckt B, nominal capacity per compressor
Economizer
Capacity steps
Minimum capacity
Cooler
Net water volume
Refrigerant circuits
Water connection
Inlet & outlet diameter
Air vent diameter (on water box)
Water drain diameter (on water box)
Maximum operating pressure water side
Condenser fans
Number
Total air flow
Speed
080
kW
kg
kg
Tons
Tons
No.
%
l
No.
inches
inches
inches
kPa
l/s
rps
Condenser coils
30GX
Nominal gross cooling capacity*
Operating weight
Refrigerant
Refrigerant charge CKT A/CKT B
Compressor
Ckt A, nominal capacity per compressor A1/A2
Ckt B, nominal capacity per compressor B1/B2
Economizer
Capacity steps
Minimum capacity
Cooler
Net water volume
Refrigerant circuits
Water connection
Inlet & outlet diameter
Air vent diameter (on water box)
Water drain diameter (on water box)
Maximum operating pressure water side
Condenser fans
Number
Total air flow
Speed
090
115
125
135
150
160
175
373
3829
405
3877
438
3889
484
4189
526
4239
576
4671
66
39
Yes
6
20
66
46
Yes
6
20
66
56
Yes
6
20
80
56
Yes
6
20
80
66
Yes
6
20
80
80
Yes
6
20
101
2
101
2
91
2
109
2
109
2
5
5
5
5
5
6
29505
15.8
6
28268
15.8
8
37714
15.8
8
37714
15.8
10
48370
15.8
265
854
6556
280
918
7303
295
977
7496
325
1066
7753
350
1158
7852
80/80
80
Yes
8
15
66/66
56/66
Yes
10
10
56/80
56/80
Yes
10
10
66/80
66/80
Yes
10
10
80/80
80/80
Yes
10
10
203
2
203
2
229
2
229
2
8
8
8
8
12
56571
15.8
14
66000
15.8
16
75428
15.8
16
75428
15.8
73
73
87
87
2
2
2
2
Customized flat flange supplied to be welded on site
4
4
5
5
3/8” NPT
3/8” NPT
1000
Airfoil blades
4
4
4
6
20518
20518
20518
29505
15.8
15.8
15.8
15.8
Copper tubes & aluminium fins
kW
kg
kg
Tons
Tons
No.
%
l
No.
inches
inches
inches
kPa
l/s
rps
Condenser coils
Legend :
* Eurovent conditions :
Cooler entering/leaving water temperature : 12°C and 7°C,
Condenser entering air temperature : 35°C.
16
105
262
290
330
3410
3420
3658
HFC-134a
See unit nameplate
Semi-hermetic twin screw
46
56
56
39
39
39
No
No
Yes
6
6
6
20
20
20
205
225
250
666
745
825
5810
6048
6310
HFC-134a
See unit nameplate
Semi-hermetic twin screw
39/80
46/80
66/80
66
80
80
Yes
Yes
Yes
8
8
8
15
15
15
140
165
181
181
2
2
2
2
Customized flat flange supplied to be welded on site
6
6
6
6
3/8” NPT
3/8” NPT
1000
Airfoil blades
10
10
12
12
47142
47142
56571
56571
15.8
15.8
15.8
15.8
Copper tubes & aluminium fins
ELECTRICAL DATA
30GX
30GX
080
090
105
115
125
135
150
160
175
211,5
Main power supply
Nominal voltage
V-ph-Hz
400-3-50
Voltage range
%
± 10
Control circuit supply*
V-ph-Hz
230-1-50
Nominal unit power input**
kW
94,2
108,9
124
137,2
151,2
167
178
200,4
Nominal operating current**
A
183
200
216
238
256
271
299
325
353
Maximum operating current***
A
230
256
286
322
347
375
424
461
510
Maximum starting current
Across the line start****
A
829
970
1087
1358
1383
1410
1454
1491
1545
Optional star delta start****
A
340
384
430
519
544
571
589
626
680
205
225
250
265
280
295
325
350
30GX
Main power supply
*
**
***
****
Nominal voltage
V-ph-Hz
400-3-50
Voltage range
%
± 10
Control circuit supply*
V-ph-Hz
230-1-50
Nominal unit power input**
kW
243,2
289,1
307,9
327,7
352,5
368,6
397,7
459,9
Nominal operating current**
A
415
476
505
547
571
612
652
736
Maximum operating current***
A
Circuit A
387
412
481
530
426
444
481
530
Circuit B
216
265
265
265
390
439
481
530
Maximum starting current
Across the line start****
A
1612
1687
1756
1805
1837
1894
1971
2070
Optional star delta start****
A
747
822
891
940
N/A
N/A
N/A
N/A
Legend :
Control power circuit is supplied through factory installed transformer
Unit power input kW and current drawn at cooler entering/leaving temperature 12°C/7°C, condenser entering air temperature 35°C and at 400 Volts nominal voltage
Maximum current drawn by compressors and fans at full load and at minimum voltage 360 Volts
Maximum instantaneous starting current (maximum operating current of the smallest compressor + locked rotor amps of the largest compressor)
N/A - not available
Compressor
PART NUMBER
Tons
LRA (Y)
LRA (Delta)
MHA
06NA 1146 S7 N
39
191
605
104
06NA 1174 S7 N
46
226
715
126
06NA 1209 S7 N
56
270
856
152
06NA 1146 S7 E
39
226
715
117
06NA 1174 S7 E
46
270
856
142
06NA 1209 S7 E
56
303
960
169
06NA 1250 S7 E
66
387
1226
206
06NA 1300 S5 E
80
400
1265
255
Legend :
LRA (Y)
LRA (Delta)
MHA
06NA
N
E
Locked Rotor Amps with optional star delta start
Locked Rotor Amps with standard across the line start
Compressor Must Hold Amps (Maximum Operating Current at 360 V)
Air-cooled condensing compressor
Non Economized compressor
Economized compressor
17
APPLICATION DATA
Maximum chilled water flow
Unit operating range
The maximum chilled water flow (> 0.09 l/s per kW or < 2.8 K
temperature difference) is limited by the maximum permitted pressure
drop in the evaporator. It is provided in the following table :
a - Select a non-standard evaporator with one water pass less
which will allow a higher maximum water flow rate.
b - Bypass the evaporator as shown in the diagram to obtain a
highter temperature difference with a lower evaporator flow
rate.
Cooler
Cooler entering water temperature
°C
Minimum
6.8*
Maximum
21
Cooler leaving water temperature
Condenser (water-cooled)
°C
4**
Minimum
15
Maximum
Condenser entering water temperature
Condenser leaving water temperature
°C
°C
20***
23
42
45
Condenser (air-cooled)
Outdoor ambient operating temperature
°C
Minimum
0
Maximum
45
Notes :
* For application requiring operation at less than 6.8°C, contact Carrier s.a. for unit selection
using the Carrier electronic catalog.
** For application requiring operation at less than 4°C, the units require the use of antifreeze.
*** Water-cooled units (30HXC) operating at less than 20°C for condenser entering water require
the use of head pressure control with analogue water valves (see head pressure control
paragraph).
COOLER
BY-PASS
Minimum chilled water flow
The minimum chilled water flow (maximum chilled water
temperature difference) is shown in the table below. If the flow
is less than this (a high temperature difference) three solutions
are possible :
a - Check for availability of a non-standard evaporator (plus one
pass) which will allow a lower water flow rate (contact factory).
b - The evaporator flow can be recirculated as shown in the
diagram. The temperature of the mixture leaving the evaporator
must never be less than 2.8 K lower than the chilled water
entering temperature.
c - Link several chillers in series with each making a contribution
to the total temperature difference.
COOLER
RECIRCULATION
FOR MINIMUM CHILLED WATER FLOW RATE
18
FOR MAXIMUM CHILLED WATER FLOW RATE
Cooler flow rate (l/s)
Variable flow evaporator
30HXC
Min.*
Max.**
075-085
095
6.6
6.7
26.2
27.0
105
115-125
9.1
9.3
36.2
37.0
135-145
160-170
11.2
14.1
44.7
56.3
185
215
16.4
17.0
65.5
67.9
250-280
300
21.0
22.2
84.0
88.7
315-370
26.8
107.2
30GX
Min.*
Max.**
080-090
5.8
21.0
105-115
125-135
6.3
7.4
26.5
31.8
Application
N
150
160-175
9.1
10.8
36.0
41.9
Normal air conditioning
Process type cooling
3.25
6.5
205
225
12.4
14.5
46.0
54.0
250-265
280-300
16.5
18.0
60.0
66.0
325-350
21.0
72.0
* Based on a water velocity of 0.9 m/s.
** Based on a water velocity of 3.6 m/s.
Condenser flow rate (l/s)
30HXC
Min.*
Max.**
Closed loop
Open loop
075-095
105
2.5
2.9
7.5
8.8
29.9
35.0
115
125
3.1
3.2
9.3
9.7
37.2
38.8
135-145
160
3.8
4.6
11.4
13.8
45.6
55.3
170
185
4.9
5.3
14.9
16.0
59.8
64.0
215-280
7.2
21.5
86.2
300-370
7.9
23.6
94.5
Variable evaporator flow can be used in standard 30HXC and 30GX
chillers. The chillers maintain a constant leaving water temperature
under all flow conditions. For this to happen, the minimum flow
rate must be higher than the minimum flow given in the table of
permissible flow rates and must not vary by more than 10% per
minute.
If the flow rate changes more rapidly, the system should contain
a minimum of 6.5 liters of water per kW instead of 3.25 l/kW.
System minimum water volume
Whichever the system, the water loop minimum capacity is given
by the formula :
Capacity = Cap (kW) x N Liters
Where Cap is the nominal system cooling capacity (kW) at the
nominal operating conditions of the installation.
This volume is necessary for stable operation and accurate
temperature control.
It is often necessary to add a buffer water tank to the circuit in
order to achieve the required volume. The tank must itself be
internally baffled in order to ensure proper mixing of the liquid
(water or brine). Refer to the examples below.
NOTE
The compressor must not restart more than 6 times in an hour.
BAD
GOOD
BAD
GOOD
* Based on a water velocity of 0.3 m/s in a closed loop and 0.9 m/s in an open loop.
** Based on a water velocity of 3.6 m/s.
19
Flow controllers
INSTALLATION
Cooler flow switch and chilled water pump interlock
Check equipment received
IMPORTANT
It is mandatory to install cooler flow switch and also to connect
chilled water pump interlock on 30HXC and 30GX units using
flooded cooler. Failure to this instruction will void Carrier
guarantee.
• Inspect the unit for damage or missing parts. If damage is
detected, or if shipment is incomplete, immediately file a claim
with the shipping company.
• Confirm that the unit received is the one ordered.
Compare the nameplate data with the order.
• Confirm that all accessories ordered for on-site installation have
been delivered, and are complete and undamaged.
• Do not store units in an area exposed to weather because of
sensitive control mechanism and electronic devices.
The cooler flow switch controller is factory supplied and wired
on 30HXC and 30GX units.
Follow the manufacturer instruction for installation.
The flow switch may be mounted in a horizontal pipe or a vertical
pipe with upward liquid flow. It should not be used when liquid
flow is downwards.
Mount in a section of pipe where there is a straight run of at least
five pipe diameters on each side of the flow switch. Do not locate
adjacent to valves, elbows or orifices. The paddle must never touch
the pipe or any restriction in the pipe. Screw the flow switch in
position so the flat part of the paddle is at right angles to the flow.
The arrows on the cover and in the bottom, inside the case, must
point in the direction of the flow. The switch should be mounted
so that the terminals are accessible for easy wiring.
Terminals 34 and 35 are provided for field installation of a chilled
water pump interlock (auxiliary contact of chilled water pump
contactor).
5 x D MINI
FLOW
5 x D MINI
FLOW
Condenser flow switch (30HXC)
The condenser flow switch controller is a field installed device.
It is configurable from the HSIO II when <2> <SRVC> is entered.
20
Moving and siting the unit
Moving
Do not remove skids, pallets or protective packaging until the
unit is in its final position. Move the chiller using tubes or rollers,
or lift it, using slings of the correct capacity.
CAUTION (30HXC)
Only use slings at the designated lifting points which are marked
on the unit, on the top of the cooler heat exchanger. Rigging
from the bottom of the heat exchanger will cause the unit to be
lifted unsafely. Personal injury or damage to the unit may occur.
Follow the rigging instruction given on the certified dimensional
drawing supplied with the unit.
Siting
Always refer to the chapter "Dimensions and clearances" to
confirm that there is adequate space for all connections and service
operation. For the center of gravity coordinates, the position of
the unit mounting holes, and the weight distribution points, refer
to the certified dimensional drawing supplied with the unit.
We recommend that these chillers be installed either in a basement
or at ground level. If one is to be installed above ground level,
first check that the permissible floor loading is adequate and that
the floor is strong enough and level. If necessary, strengthen and
level the floor.
With the chiller in its final location remove the skids, and other
devices used to aid in moving it. Level the unit using a spirit
level, and bolt the unit to the floor or plinth. Operation of these
units may be impaired if they are not level and not securely fixed
to their mountings. If required use isolation pads under the unit
to aid in vibration isolation.
LIFTING INSTRUCTIONS
30HXC 075-185
This diagram is shown for information only. Refer to “certified
drawings” delivered with the unit.
1500 mm min.
1075 mm min.
80° max.
CENTER OF GRAVITY
30HXC
X (mm)
Y (mm)
Z (mm)
075-095
1265
376.5
900
105
115-145
1265
1665
376.5
376.5
950
900
160
1855
371.5
950
170-185
1855
380.5
950
4 LIFTING LUGS (SEE NOTE)
NOTE
When all lifting and positioning operations are finished, it is
recommended to touch up all surfaces where paint has been
removed on lifting lugs.
21
LIFTING INSTRUCTIONS (CONT.)
30HXC 215-280
This diagram is shown for information only. Refer to “certified
drawings” delivered with the unit.
2800 mm min.
70°C max.
50 mm min.
1050 mm min.
CENTER OF GRAVITY
NOTE
When all lifting and positioning operations are finished, it is
recommended to touch up all surfaces where paint has been
removed on lifting lugs.
22
LIFTING INSTRUCTIONS (CONT.)
30HXC 300-370
1000 mm min.
50 mm min.
This diagram is shown for information only. Refer to “certified
drawings” delivered with the unit.
70° max.
CENTER OF GRAVITY
NOTE
When all lifting and positioning operations are finished, it is
recommended to touch up all surfaces where paint has been
removed on lifting lugs.
23
LIFTING INSTRUCTIONS (CONT.)
30GX 080-160
This diagram is shown for information only. Refer to “certified
drawings” delivered with the unit.
30GX
X (mm)
Y (mm)
Z (mm)
080
1550
1391
932
090-105
115-135
1550
1800
1391
1391
982
982
150-160
2186
1391
932
30GX 175
CENTER OF GRAVITY
24
LIFTING INSTRUCTIONS (CONT.)
30GX 205-265
This diagram is shown for information only. Refer to “certified
drawings” delivered with the unit.
30GX
X (mm)
Y (mm)
Z (mm)
205-225
2878
1300
900
250-265
3044
1300
900
30GX 280-350
CENTER OF GRAVITY
30GX
X (mm)
Y (mm)
Z (mm)
280
3412
1300
900
295
3500
1300
900
325-350
4325
1300
900
25
PIPING CONNECTIONS
Refer to the certified dimensional drawings for the sizes and
positions of all water inlet and outlet connections. The water pipes
must not transmit any radial or axial force to the heat exchangers
or any vibration to the pipework or building.
The water supply must be analysed and appropriate filtering,
treatment, control devices, isolation and bleed valves and circuits
built in, as necessary. Consult either a water treatment specialist
or appropriate literature on the subject.
e - Disconnect the pipework.
f - Tighten the head bolts to their final torque (middle of the
range) in the sequence illustrated.
g - Reconnect the pipes, tightening the flange bolts to the midrange torque value.
h - Refill the system with water.
i - Pressurize the system.
NOTE
We recommend draining the system and disconnecting the
pipework to ensure that the bolts of the heads to which the
pipework is connected are correctly and uniformly tightened.
Operating precautions
The water circuit should be designed to have the least number of
elbows and horizontal pipe runs at different levels. The following
basic checks should be done (see also the illustration of a typical
hydraulic circuit below).
• Note the water inlets and outlets of the heat exchangers.
• Install manual or automatic air purge valves at all high points
in the water circuit.
• Use an expansion chamber or an expansion/relief valve to
maintain pressure in the system.
• Install water thermometers in both the entering and leaving
water connections close to the evaporator.
• Install drain valves at all low points to allow the whole circuit
to be drained. Connect a stop valve in the drain line before
operating the chiller.
• Install stop valves, close to the evaporator, in the entering and
leaving water lines.
• Install cooler flow switch.
• Use flexible connections to reduce the transmission of vibration
to the pipework.
• Insulate all pipework, after testing for leaks, both to reduce
thermal leaks and to prevent condensation.
• Cover the insulation with a vapour barrier.
Cooler and condenser connections
The cooler and condenser are of the multi-tube shell and tube
type with removable water boxes to facilitate cleaning of the tubes.
If there is a leak outside the water head :
a - Drain the system.
b - Disconnect the water pipes.
c - In the correct sequence, retighten the head bolts to the
maximum torque given for the bolt size.
d - Reconnect the pipework, tightening the bolts to their final torque
value, i.e. the middle value in the range given for the bolt size.
e - Refill the system with water.
f - Pressurize the system.
IMPORTANT
Before starting the unit, be sure all of the air has been purged
from the system.
Freeze protection
Cooler and water-cooled condenser protection
If the chiller or the water piping is in an area where the ambient
temperature can fall below 0°C it is recommended to add an
antifreeze solution to protect the unit and the water piping to a
temperature of 8 K below the lowest anticipated temperature.
Use only antifreeze solutions, approved for heat exchanger duty.
If the system is not protected by an antifreeze solution and will
not be used during the freezing weather conditions, draining of
the cooler and outdoor piping is mandatory.
Water box tightening sequence
Before making water connections tighten the bolts in both heads to
the lower torque shown, following the method described. Tighten
in the pairs and sequence indicated according to the size of bolt (see
table) using a torque value at the low end of the range given.
SEQUENCE 1 : 1 2 3 4
SEQUENCE 2 : 5 6 7 8
SEQUENCE 3 : 9 10 11 12
1
CAUTION
Remove the factory supplied flat flange from the water box
before welding piping to the flange. Failure to remove the flange
may damage the sensors and insulation.
3
4
7
11
6
2
TIGHTENING TORQUE
BOLT SIZE M16 - 171 - 210 Nm
Typical hydraulic circuit diagram
CONTROL
VALVE
After welding the pipes to the flanges previously removed from
the water boxes :
26
9
8
10
Pipe connections
a - Reinstall the pipes and tighten lightly to a torque at the low
end of the range.
b - Fill the system with water.
c - Wait for 10 minutes and check for minor leaks
- at the water box joints
- at the flange joints
d - Drain the system.
5
12
AIR
VENT
FLOW SWITCH
FLEXIBLE CONNECTION
HEAT
EXCHANGER
DRAIN
PRESSURE TAP
THERMOSTAT SLEEVE
BUFFER
TANK
FILL VALVE
FILTER
EXPANSION TANK
insignifiant particulates)
· Presence of corrosives and contaminants, classification 4C2
(negligible)
· Vibration, shock : classification 4M2
Competence of personnel : classification BA4(2) (personnel
qualified in accordance with IEC 364).
ELECTRICAL CHARACTERISTICS
• The 30HXC 075-185 and 30GX 080-175 have only one power
terminal block.
• The 30HXC 215-370 and 30GX 205-350 have two power
terminal blocks.
• The control box incorporates the following as standard :
- Starters and motor protection devices for each compressor
and the fans
- Control components
• Connections on site :
All mains connections and electrical installation must be carried
out in accordance with the European directives applicable to
the site.
• The 30HXC and 30GX are designed to facilitate compliance
with these directives. The engineering of the electrical
equipment for the 30HXC and 30GX takes account of European
standard EN 60204-1 (safety of machinery - electrical
equipment of machines - Part 1 : general rules).
IMPORTANT
• Standard EN 60204-1 is a good means of responding to the
requirements of the Machinery Directive § 1.5.1. The normative
recommendation IEC 364, is generally recognized as meeting
the requirements of the installation regulation.
• Annex B of standard EN 60204-1 may be used to describe the
electrical characteristics under which the machines operate.
30HXC
1. The operating conditions for a standard 30HXC are
described below:
- Environmental conditions (1) . The environmental
classification is described in standard IEC 364 § 3 :
· Ambient temperature range: + 6°C to + 40°C, classification
AA4
· Humidity range (non condensing)
50 % rh at 40°C
90 % rh at 20°C
· Altitude ≤ 2000 m(1)
· For indoor installation
· Presence of water : classification AD2(1) (possibility of water
droplets)
· Presence of solids: classification AE2(1) (presence of
insignifiant particulates)
· Presence of corrosives and contaminants, classification AF1
(negligible)
· Vibration, shock: classification AG2, AH2
Competence of personnel: classification BA4(1) (personnel
qualified in accordance with IEC 364).
(1)
The protection standard required in respect of this classicfication
is IP21B (in accordance with the reference document IEC 529).
All 30HXC have a protection standard of IP23C and therefore
fulfil this protection requirement.
30GX
2. The operating conditions for 30GX are described below :
- Environmental conditions (2) . The environmental
classification is described in standard EN 60721:
· For outdoor installation(2)
· Ambient temperature range: - 25°C to + 46°C, classification
4K3(2)
· Altitude ≤ 2000 m(2)
· Presence of solids: classification 422 (presence of
(2)
The protection standard required in respect of this classicfication
is IP43BW (in accordance with the reference document IEC
529). All 30GX have a protection standard of IP44CW and
therefore fulfil this protection requirement.
30HXC/GX
3.Fluctuation in power supply frequency : ± 2 Hz
4.Overcurrent protection for the power supply conductors is
not supplied with the device.
5.The factory-fitted isolating switch (if ordered) is a type “a”
isolator. (EN60204-1 § 5.3.2).
NOTE
If particular aspects of an installation require characteristics
other than those listed above (or characteristics not referred to
here) contact your Carrier representative.
Power supply
The power supply must conform to the specification on the chiller
nameplate. The supply voltage must be within the range specified
in the electrical data table.
For connections refer to the wiring diagrams.
WARNING
Operation of the chiller with an improper supply voltage or
excessive phase imbalance constitutes abuse which will
invalidate the Carrier warranty. If the phase imbalance exceeds
2% for voltage, or 10% for current, contact your local electricity
supply at once and ensure that the chiller is not switched on
until corrective measures have been taken.
Voltage phase imbalance (%) :
100 x max. deviation from average voltage
Average voltage
Example :
On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages
were measured to be :
AB = 406 V ; BC = 399 ; AC = 394 V
Average voltage = (406 + 399 + 394)/3 = 1199/3
= 399.7 say 400 V
Calculate the maximum deviation from the 400 V average :
A
(AB) = 406 - 400 = 6
(BC) = 400 - 399 = 1
(CA) = 400 - 394 = 6
B
C
MOTOR
The maximum deviation from the average is 6 V. The greatest
percentage deviation is :
100 x 6/400 = 1.5 %
This is less than the permissible 2 % and is therefore acceptable.
27
FIELD POWER SUPPLY
30HXC 075-185
15
PE M10
GROUND FIELD
CONNECTION
Electrical box
Power terminal block
Main disconnect switch
PE M10
GROUND FIELD
CONNECTION
16
17
S mm2
S mm2
PE M10
GROUND FIELD
CONNECTION
S mm2
S mm2
30HXC
A (mm)
B (mm)
B1 (mm)
Min.
Max.
30HXC
A (mm)
B (mm)
Min.
Max.
075-115
125
70
70
40
40
25
25
70
95
120
120
075-115
125
125
125
236
236
70
95
120
120
135-185
70
62.5
40
120
300
135-185
136
200
120
185
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features :
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Condenser Flow Switch (Field supplied)
- Remote Heat / Cool switch
28
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Condenser pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
FIELD POWER SUPPLY (CONT.)
30HXC 215-280
PE M10
GROUND FIELD CONNECTION
CONNECTION
Electrical box
CKT B
Power terminal block
15
CKT A
Main disconnect switch
PE
PE M10
M10
GROUND
GROUND FIELD
FIELD
CONNECTION
CONNECTION
16
SA mm2
17
SB mm2
PE
PEM10
M10
GROUND
GROUNDFIELD
FIELD
CONNECTION
CONNECTION
SA mm2
SB mm2
30HXC
A (mm)
Min.
Max.
Min.
Max.
30HXC
A (mm)
Min.
Max.
Min.
Max.
215-280
70
120
300
70
120
215-280
125
120
185
70
120
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features :
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Condenser Flow Switch (Field supplied)
- Remote Heat / Cool switch
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Condenser pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
29
FIELD POWER SUPPLY (CONT.)
PE
PEM10
M10
GROUND
FIELD
CONNECTION
GROUND
FIELD
CONNECTION
30HXC 300-370
Electrical box
CKT B
Power terminal block
CKT A
Main disconnect switch
PE M10
GROUND FIELD
CONNECTION
PE
PE M10
M10
GROUND
GROUND FIELD
FIELD
CONNECTION
CONNECTION
SA mm2
SA mm2
2
SB mm2
SB mm
30HXC
A (mm)
B (mm)
C (mm)
Min.
Max.
30HXC
A (mm)
B (mm)
Min.
Max.
300
70
40
85
95
120
300
125
236
95
120
315-370
70
62.5
40
120
300
315-370
125
200
120
185
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features :
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Condenser Flow Switch (field-supplied)
- Remote Heat / Cool switch
30
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Condenser pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
FIELD POWER SUPPLY (CONT.)
30GX 080-160
Electrical box
PE M12
PE
M10
GROUND FIELD
GROUND
FIELD
CONNECTION
CONNECTION
Ø 12
Power terminal block
Main disconnect switch
S mm2
S mm2
30GX
B (mm)
Min.
Max.
30GX
A (mm)
B (mm)
Min.
Max.
080
540
120
300
080
46
510
120
300
090-105
115
540
540
150
185
300
300
090-105
115
46
46
510
510
150
185
300
300
125-135
540
240
300
150-160
540
2x95
2x120
125-135
150
46
46
510
510
240
2x95
300
2x185
160
62
510
2x95
2x185
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features :
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Remote Heat / Cool switch
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
31
FIELD POWER SUPPLY (CONT.)
30GX 175
Electrical box
PEM10
M12
PE
GROUNDFIELD
FIELD
GROUND
CONNECTION
CONNECTION
Ø 12
Power terminal block
Main disconnect switch
S mm2
S mm2
30GX
Min.
Max.
30GX
Min.
Max.
175
2x120
2x300
175
2x120
2x185
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features :
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Remote Heat / Cool switch
32
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
FIELD POWER SUPPLY (CONT.)
30GX 205-265
Electrical box
PE M12
PE M12 FIELD
GROUND
GROUND FIELD
CONNECTION
CONNECTION
Power terminal block
Main disconnect switch
SA mm2
SB mm2
SA mm2
SB mm2
30GX
Min.
Max.
Min.
Max.
30GX
Min.
Max.
Min.
Max.
205
240
300
95
120
205
240
300
95
185
225
250
240
2x120
300
2x300
120
120
300
300
225
250
240
2x120
300
2x185
120
120
185
185
265
2x150
2x300
120
300
265
2x150
2x185
120
185
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features:
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Remote Heat / Cool switch
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
33
FIELD POWER SUPPLY (CONT.)
30GX 280-350
Electrical box
PE M12
GROUND FIELD
CONNECTION
Power terminal block
Main disconnect switch
SA mm2
SB mm2
SA mm2
SB mm2
30HXC
Min.
Max.
Min.
Max.
30HXC
Min.
Max.
Min.
Max.
280-295
325
2x120
2x150
2x300
2x300
240
2x120
300
2x300
280-295
325
2x120
2x150
2x185
2x185
240
2x120
300
2x185
350
2x150
2x300
2x150
2x300
350
2x150
2x185
2x150
2x185
IMPORTANT
Before the connection of the main power cables (L1 - L2 - L3) on the power terminal block, it is imperative to check the right order
of the 3 phases before proceeding to the connection on the terminal block or the main disconnect switch.
FIELD CONTROL WIRING
Refer to the Certified Electrical Wiring Diagram supplied with
the unit for the field control wiring of the following features:
- Cooler pump interlock (mandatory)
- Remote on/off switch
- Remote Heat / Cool switch
34
- Demand limit external switch 1
- Demand limit external switch 2
- Remote dual set point
- General alarm contact
- Cooler pump control (Option)
- Outdoor air temperature (Option)
- Remote Reset 4-20 mA (Option)
- Demand limit 4-20 mA (Option)
MAJOR SYSTEM COMPONENTS
AND OPERATION DATA
which separates the two refrigerant circuits. The tubes are 3/4" or
1" diameter copper with enhanced surface inside and out. There is
just one water circuit with two water passes.
Geared twin screw compressor
• 30HXC and 30GX units use 06N geared twin screw
compressors
• 06NA are used on 30GX (air-cooled condensing application)
• 06NW are used on 30HXC (water-cooled condensing application)
• Nominal capacities range from 39 to 80 tons. Economized or non
economized models are used depending on the 30HXC and 30GX
unit size.
Oil separator (30GX)
In the air-cooled units, the oil separator is a pressure vessel that is
mounted under the outside vertical condenser coils. Discharge gas
enters at the top of the separator where much of the oil separates
and drains to the bottom. The gas then flows through a wire mesh
screen where the remaining oil is separated and drains to the bottom.
Electronic Expansion Device (EXD)
Oil Filter
The 06N screw compressor has an oil filter integral in the compressor
housing. This filter is field replaceable.
Refrigerant
The 06N screw compressor is specially designed to be used in R134
a system only.
Lubricant
The 06N screw compressor is approved for use with the following
lubrifiant.
CARRIER MATERIAL SPEC PP 47-32
Oil Supply Solenoid Valve
An oil supply solenoid valve is standard on the compressor to isolate
the compressor from oil flow when the compressor is not operating.
The oil solenoid is field replaceable.
Suction & Economizer Screens
To increase the reliability of the compressor, a screen has been
incorporated as a standard feature into suction and economizer inlets
of the compressor.
Unloading System
The 06N screw compressor has an unloading system that is standard
on all compressors. This unloading system consists of two steps of
unloading that decrease the compressor capacity by rerouting
partially compressed gas back to suction.
Cooler
30HXC and 30GX chillers use a flooded cooler. Flooded style
coolers have refrigerant in the shell and water in the tubes. One
vessel is used to serve both refrigerant circuits. There is a center
tube sheet which separates the two refrigerant circuits. The tubes
are 3/4" diameter copper with an enhanced surface inside and out.
There is just one water circuit, and depending on the size of the
chiller, there may be two or three water passes. A cooler liquid level
sensor provides optimized flow control.
At the top of the cooler are the two suction pipes, one in each
circuit. Each has a flange welded to it, and the compressor mounts
on the flange.
Condenser and oil separator (30HXC)
30HXC chiller use a vessel that is a combination condenser and oil
separator. It is mounted below the cooler. Discharge gas leaves the
compressor and flows through an external mufler to the oil separator,
which is the upper portion of the vessel. It enters the top of the
separator where oil is removed, and then flows to the bottom portion
of the vessel, where gas is condensed and subcooled. One vessel is
used to serve both refrigerant circuits. There is a center tube sheet
The microprocessor controls the EXD through the EXV control
module. The EXD will either be an EXV or an Economizer. Inside
both these devices is a linear actuator stepper motor.
High-pressure liquid refrigerant enters the valve through the bottom.
A series of calibrated slots are located inside the orifice assembly.
As refrigerant passes through the orifice, the pressure drops and the
refrigerant changes to a 2-phase condition (liquid and vapor). To
control refrigerant flow for different operating conditions, the sleeve
moves up and down over the orifice, thereby changing orifice size.
The sleeve is moved by a linear stepper motor. The stepper motor
moves in increments and is controlled directly by the processor
module. As the stepper motor rotates, motion is transferred into
linear movement by the lead screw. Through the stepper motor and
lead screws, 1500 discrete steps of motion are obtained. The large
number of steps and long stroke result in very accurate control of
refrigerant flow. Each circuit has a liquid level sensor mounted
vertically into the top of the cooler shell. The level sensor consists
of a small electric resistance heater and three thermistors wired in
series positioned at different heights inside the body of the well.
The heater is designed so that the thermistors will read approximately
93.3°C in dry air. As the refrigerant level rises in the cooler, the
resistance of the closest thermistor(s) will greatly change. This large
resistance difference allows the control to accurately maintain a
specified level. The level sensor monitors the refrigerant liquid level
in the cooler and sends this information to the PSIO-1. At initial
start-up, the EXV position is at zero. After that, the microprocessor
keeps accurate track of the valve position in order to use this
information as input for the other control functions. It does this by
initializing the EXV’s at startup. The processor sends out enough
closing pulses to the valve to move it from fully open to fully closed,
then resets the position counter to zero. From this point on, until the
initialization, the processor counts the total number of open and
closed steps it has sent to each valve.
Economizer
Economizers are installed on 30HXC 170 to 370 (except 30HXC
215) and 30GX 105 to 350.
The economizer improves both the chiller capacity and efficiency
as well as providing compressor motor cooling. Inside the
economizer are both a linear EXV stepper motor and a float valve.
The EXV is controlled by the PIC to maintain the desired liquid
level in the cooler (as is done for Non-Economized chillers). The
float valve maintains a liquid level in the bottom of the economizer.
Liquid refrigerant is supplied from the condenser to the bottom of
the economizer. As the refrigerant passes through the EXV, its
pressure is reduced to an intermediate level of about 500 kPa. This
pressure is maintained inside the economizer shell. Next, the
refrigerant flows through the float valve, its pressure is further
reduced to slightly above the pressure in the cooler. The increase in
performance is realized when some of the refrigerant passing through
35
the EXV flashes to vapor, further subcooling the liquid that is
maintained at the bottom of the economizer. This increase in
subcooling provides additional capacity. Since no additional power
is required to accomplish this, the efficiency of the machine also
improves. The vapor that flashes will rise to the economizer where
it passes to the compressor and is used as needed to provide motor
cooling. After passing over the motor windings, the refrigerant
reenters the cycle at an intermediate port in the compression cycle.
Oil pumps
The 30GX/HXC screw chillers use one externally mounted prelubricating oil pump per circuit. This pump is operated as part ot
the start-up sequence. On 30GX units, the pumps are mounted to
the base rails on the oil separator side of the unit. The pumps are
mounted to a bracket on the condensers of 30HXC units. When a
circuit is required to start, the controls will energize the oil pump
first and read the current oil pressure transducer reading. The
pump will be operated for a period of 20 seconds, after which the
oil solenoid will be energized to open the oil inlet valve at the
compressor. The control will again read the pressure from the oil
pressure transducer. If the pump has built up sufficient oil pressure,
the compressor will be allowed to start. Once the compressor has
started, the oil pump will be turned off within 10 seconds and
will not be used again until the next start-up. If the pump was not
able to build up enough oil pressure, the pump will be turned off.
Within 3 seconds, the pump will be re-energized and will make
one additional attempt to build oil pressure. The control will
generate an alarm if the second attempt fails.
Motor cooling valves
Compressor motor winding temperatures are controlled to a
setpoint of 85°C. The control accomplishes this by cycling the
motor cooling solenoid valve to allow liquid refrigerant to flow
across the motor windings as needed. On units equipped with
economizers, flash gas leaves the top of the economizer and
continually flows to the motor windings. All refrigerant used for
motor cooling re-enters the rotors through a port located midway
along the compression cycle and is compressed to discharge
pressure.
Cooler entering fluid
This sensor is used to measure the cooler entering fluid temperature.
It is located in the entrering cooler nozzle. It is used to provide
automatic temperature compensation for the leaving fluid
temperature control with entering fluid compensation.
Discharge gas temperature (circuits A & B)
This sensor used to measure the discharge gas temperature and
control the discharge temperature superheat. It is located on the
discharge pipe of each circuit (30HXC) or on the top of the oil
separator (30GX).
Motor temperature
The Compressor Protection Module (CPM) monitors the motor
temperature. Thermistor terminals are located in the compressor
junction box.
Cooler liquid level (circuits A & B)
Cooler liquid level thermistor is used to provide optimized flow
control in the cooler. It is installed in the top of the cooler.
Condenser entering fluid (optional on 30HXC)
This sensor is used to measure the temperature of the fluid entering
the water cooled condensers. It is located in the common fluid line
entering the condensers (field installed). On Heat Machines it is
used by the capacity control routine. On water cooled condensers it
is only used for monitoring of the condenser fluid temperature.
Condenser leaving fluid (optional on 30HXC)
This sensor is used to measure the temperature of the fluid leaving
the water cooled condensers. It is located in the common fluid line
leaving the condensers (field installed). On Heat Machines it is used
by the capacity control routine. On water cooled condensers it is
only used for monitoring of the condenser fluid temperature.
Space temperature, outdoor air temperature (optional)
These temperatures are used to measure the temperature of the space
or the outside air temperature respectively for reset control based
on Outside Air or Space Temperature reset options.
Pressure transducers
Back pressure valve (GX only)
On GX units, this valve is located on the oil separator outlet. The
valve's function is to ensure that there is sufficient system
differential pressure to allow for oil to be driven back to the
compressor. A small copper line (Economizer pressure) is
connected to the top of the valve and an internal spring is
connected to a valve which will close if the pressure in the oil
separator is not at least 100 kPa greater than the economizer
pressure.
Discharge pressure (circuits A & B)
This input is used to measure the high side pressure of each circuit
of the unit. It is located on the discharge pipe of each circuit (30HXC)
or on the top of the oil separator (30GX). It is used to provide the
pressure to replace the discharge pressure gauge and to control the
head pressure.
Suction pressure (circuits A & B)
This input is used to measure the pressure of the low side of the
unit. It is located on the top of the cooler of each circuit.
Sensors
The units use eight standard thermistors (including two motor temperature
thermistors) and two level thermistors and eight standard pressure
transducers to monitor and control system operation.
Oil pressure (each compressor)
This input is used to measure the oil pressure of each compressor of
the unit. The ecomizer pressure is substracted from this reading to
determine the oil pressure differential. It is located on the oil pressure
port of each compressor.
Thermistors
Cooler leaving fluid
This temperature is used to measure the leaving cooler fluid
temperature (water or brine). The temperature is used for leaving
fluid temperature control and to protect against cooler freeze-up. It
is located in the cooler fluid nozzle.
36
Economizer pressure (circuits A & B)
This input is used to monitor the oil pressure differential supplied to
the compressor. It is located on the economizer suction pipe of each
circuit.
Compressor Protection Module (CPM)
This module monitors several of the compressor safeties and controls
four of the outputs used to control the compressor. The CPM
monitors compressor current, compressor voltage, high pressure
switch status, and compressor motor temperature. It controls the
compressor contactor oil solenoid, motor cooling solenoid, and star
delta transition relay. Each CPM sends the PSIO its circuit motor
temperature, alarm status and the output status of the module.
The CPM provides the following functions:
• Compressor main contactor control
• Star delta contactor transition
• Compressor ground current protection
• Reads motor temperature
• High-pressure protection
• Reverse rotation protection
• Voltage imbalance protection
• Current imbalance protection
• Compressor oil solenoid control
• Motor cooling solenoid control
• Sensor bus communications
• Starting and running overcurrent protection
The CPM has four output relays and four inputs.
LINE VOLTAGE INPUTS
COMPRESSOR MUST
TRIP AMPS HEADER
COMMUNICATION BUS
COMM3
T
T
3
L1
24 VAC
INPUTS/
OUTPUTS
PLUG 2
Control switch
Control of the chiller is defined by the position of the LOCAL/
OFF/REMOTE (LOR) switch. This is a 3-position manual switch
that allows the chiller to be put under the control of its own controls,
manually stopped or controlled through a set of remote contacts.
CCN control is done through the HSIO II. In the LOCAL position,
the chiller is allowed to operate and respond to the scheduling
configuration, CCN configuration and set point data. In the remote
position the unit operates similar to the LOCAL position except the
remote contact must be closed for the unit to be able to operate.
ADDRESS DIP SWITCH
Compressor Protection Module (CPM)
2
Optional control module
An optional control module with 4 analogue inputs and 2 discrete
outputs is added for remote control. Demand limit control (4-20
mA) and chilled water temperature reset (4-20 mA).
On the board, at the top left is a 9-pin plug 2, where power is
supplied to the board and where the outputs loads are connected.
To verify proper Must Trip Amps header configuration, press <1>
key on the HSIO II.
<SRVC> and use the
1
Electronic expansion valve module
This module has four outputs. It receives signals from the PSIO
module and operates the electronic espansion device.
A diagram of the CPM board is shown below. There are line
voltage inputs at L1, L2 and L3. Next to these inputs are the
current torroid inputs at plug 1. Next to plug 1 are the three
COMM3 communication terminals. In the lower right corner of
the board are the inputs for motor winding temperature. The
address dip switch and compressor Must Trip Amps header are
factory set.
CURRENT TOROID
INPUT PLUG 1
Basic board
It is used as input/output module as there is no unit software
downloaded in this module. It contains 8 analogue inputs, 14 discrete
inputs and 8 discrete outputs.
INPUTS:
• Motor temperature
• 3-phase voltage
• 3-phase current
• High pressure switch
L3
Processor module (PSIO)
It contains the operating software and controls the operation of the
machine. It has 12 input channels and 6 output channels.
It continuously monitors input/output channel information received
from all the modules and controls all output signals for all output
channels. It also controls relays. The processor module also controls
the EXV control module, commanding it to open or close each
EXD in order to maintain the proper cooler level. Information is
transmitted between the processor module, CPM modules, the EXV
control module, the basic board and HSIO II display module through
a 3-wire communications bus called COMM3.
OUTPUTS:
• Compressor contactor
• Compressor oil solenoid
• Compressor motor cooling solenoid
• Star delta transition relay
L2
Control components
MOTOR
TEMPERATURE INPUT
Tons
MTA
06NW 1146 S7 N
39
81
00010000
06NW 1174 S7 N
46
99
00011000
06NW 1209 S7 N
56
119
00100011
06NW 1250 S7 N
66
143
00101110
06NW 1300 S5 N
80
174
00111110
06NW 1209 S7 E
56
130
00101000
06NW 1250 S7 E
66
156
00110101
06NW 1300 S5 E
80
189
01000110
06NA 1146 S7 N
39
119
00100011
06NA 1174 S7 N
46
145
00110000
06NA 1209 S7 N
56
175
00111111
06NA 1146 S7 E
39
134
00101010
06NA 1174 S7 E
46
163
00111000
06NA 1209 S7 E
56
195
01001000
06NA 1250 S7 E
66
236
01011101
06NA 1300 S5 E
80
293
01111010
COMPRESSOR
Legend:
MTA
N
E
06NW
06NA
Compressor MTA
Header Configuration
PART NUMBER
Header configuration:
Compressor Must Trip Amps
0 broken jumper from left to right
Non Economized compressor
1 existing jumper from left to right
Economized compressor
Water-cooled condensing compressor
Air-cooled condensing compressor
37
The CPM communicates on the COMM3 communication bus to
the PSIO module. Proper operation of the CPM board can be verified
by observing the three LED's located on the board. The left LED is
red and blinks to indicate that the module is powered and operating
correctly. The middle LED is yellow and blinks when there is an
automatic reset alarm condition. The yellow LED will remain on
and will not blink for manual reset alarm conditions. The right LED
is green and will blink when the module is satisfactorily
communicating with the PSIO module. The CPM communicates
the status of its inputs, outputs and reports different alarm conditions
to the PSIO. The alarms are listed in table below:
The PSIO will generate an alert when it receives an alarm input
from the CPM. The alert will be generated in a y.xx format where
"y" refers to the compressor and "xx" to the alarm value. For example,
the HSIO II would display Alert 1.65 for a single phase voltage loss
occurring on compressor A1. Similarly, the display would read 5.85
for a motor over-temperature condition on compressor B1.
The high-pressure switch is wired in series with the relay coils of
the four relays on the CPM. If this switch opens during operation,
all relays on the CPM will be de-energized and the compressor
stopped. The failure is reported to the PSIO and the processor module
will lock off the compressor from restarting until the alarm is
manually reset.
Compressor protection module code table
Condition
Value
High pressure switch trip
No motor current
Current imbalance warning 10 %
Current imbalance alarm 10 %
Current imbalance 18 %
Single phase current loss
High motor current
Ground fault
Voltage imbalance warning 3 %
Voltage imbalance alarm 3 %
Voltage imbalance 7 %
Single phase voltage loss
Voltage phase reversal
Contactor failure
Current phase reversal
Motor over temperature
Open thermistor
Configuration header fault
Shorted thermistor
1.0
2.0
2.5
2.7
3.0
3.5
4.0
5.0
5.5
5.7
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
No Error
0
WARNING
The CPM module has many features that were specifically
designed to protect the compressor including reverse rotation
protection. Do not attempt to bypass or alter any of the factory
wiring. Any compressor operation in the reverse direction will
result in a compressor failure that will require replacement.
38
Keypad and Display Module (HSIO II)
This device consists of a keypad with 8 function keys, 4 operative
keys, 12 numeric keys, and a 2 line-24 character alphanumeric LCD
(liquid crystal display). Key usage is explained in the Control
Operation section.
Keypad and display module
CONTROL OPERATION
Keypad and display module usage (HSIO II)
FUNCTION
USE
OPERATIVE
KEYS
USE
KEYS
<STAT>
STATUS - For displaying diagnostic codes and current
operating information about the machine.
<EXPN/EDIT>
EXPAND - For displaying a non-abbreviated expansion
of the display.
<HIST>
HISTORY - For displaying run time, cycles and previous
alarms.
<CLEAR>
CLEAR - For clearing the screen of all displays.
<↑>
UP ARROW - For returning to previous display position.
SERVICE - For entering specific unit configuration and
enabling manual control function.
<↓>
DOWN ARROW - For advancing to next display position.
<ENTER>
ENTER - For entering data
<SRVC>
<SCHD>
SCHEDULE - For entering occupied/unoccupied
schedules for unit operation.
<SET>
SET POINT - For entering operating set points and day/
time information.
<TEST/ALARM>
TEST - For testing operating of the analogue and discrete
outputs.
Automatic default display
When the keypad has not been used for 10 minutes, the display
automatically switches to the rotating automatic default display.
This display contains the five parts shown below:
xx.x °C
xx.x °C
xxx.x %
xx
current active modes
Entering fluid temperature
Leaving fluid temperature
Percent total capacity
Total number of alarms
MODES: MODE_TBL
All functions are made up of a group of subfunctions. To enter a
subfunction, first press subfunction number desired. Then press
the function key in which the subfunction resides. To move within
that subfunction, press the up or down arrow keys.
1 - At any time, another subfunction may be entered by pressing
the subfunction number, then the function key.
2 - Prior to starting unit, check leaving fluid set point for correct
setting. Refer to Set Point Function section.
3 - Depending on system configuration, all displays may not be
shown
Functions and subfunctions
SUB
FUNCTION
NO.
1
2
3
4
FUNCTIONS
Status
Test
Schedule
Service
History
Set Point
<STAT>
<TEST>
<SCHD>
<SRVC>
<HIST>
<SET>
Operating Hours
Set Points
English/Metric
Alarm
Circuit A
Ice Build
Factory
Display
Discrete Outputs
Occupancy Schedule
Configuration
General Parameters
Circuit B
Local/Normal
Options
Alarm
Display
Discrete Outputs
Occupancy Schedule
Configuration 1
History
Circuit A
Unit
Remote CCN
Options
Analogue Values
Discrete Outputs
Occupancy Schedule
Configuration 2
Circuit A
Valves and
Holiday 01
Reset/Demand Limit
Motor Master
Configuration
Configuration
Circuit B
Holiday 02
Machine
CCN
Analogue Values
Configuration
Configuration Codes
Enable/Disable
Circuit B
Holiday 03
Discrete Inputs
Configuration
Discrete Inputs
Outputs Table
5
6
Bus Address
Time/Date
Configuration
Outputs Table
7
8
9
Unit Analogue
Holiday 04
Parameters
Configuration
Calibration
Miscellaneous
Holiday 05
Manual Control
Inputs/Outputs
Configuration
Operating Modes
Transducer
Holiday 06
Configuration
10
Capacity Control
Holiday 07
Configuration**
Note:
** Subfunction <11> through <33> <SCHD> are for configuration Holidays 08-30.
39
Accessing functions and subfunctions
OPERATION
KEYPAD ENTRY
DISPLAY RESPONSE
To access a function, press subfunction
no. and function name key.
Display shows subfunction group
<1> <TEST>
Circuit A Discrete Outputs
To move to other elements,
scroll up or down using arrow
keys.
<↓>
Loader A2
Relay is OFF
<↓>
Hot Gas Bypass Valve A
Relay is OFF
Circuit A Oil Heater
Relay is OFF
A1 Mtr. Cooling Solenoid
Relay is OFF
A2 Mtr. Cooling Solenoid
Relay is OFF
Circuit A Oil Pump
Relay is OFF
Oil Solenoid A1
Relay is OFF
Oil Solenoid A2
Relay is OFF
Loader A1
Relay is OFF
<↓>
<↓>
<↓>
<↓>
<↓>
<↓>
When the last element in a
subfunction has been displayed,
the first element is repeated.
<↓>
Loader A1
Relay is OFF
To move to next subfunction
It is not necessary to use
subfunction number. Press
function name key to
advance display through all
subfunctions within a
function and then back
to the first.
<TEST>
Circuit B Discrete Outputs
To move to another function,
either depress function name
key for desired function
(display shows the first
subfunction).
or
Access a specific
subfunction by using the
subfunction number and the
function name key.
Loader B1
Relay is OFF
<TEST>
<TEST>
<TEST>
Unit Discrete Outputs
Valves and Motor Master
Circuit A Discrete Outputs
<STAT>
Alarms: XX
Reset Alarms: 1 <ENTER>
<4> <STAT>
CIR. A DISCRETE OUTPUTS
GENERAL REMARK
Screw chiller PIC control software is capable of controlling
water-cooled and air-cooled units with dual independent
refrigerant circuits. Circuits are identified as circuits A and B.
These may be equipped with 1 or 2 compressors per circuit.
A1 and A2 compressors are dedicated for circuit A.
B1 and B2 compressors are dedicated for circuit B.
In Status and History functions, only the compressor
information for existing compressors will be displayed.
40
Status function
This function shows the rotating display, current status of alarm
and alert (diagnostic) codes, capacity stages, operating modes,
chilled water setpoint, all measure system temperatures and
pressures, analog inputs, and switch inputs.
Alarms/Alerts
Alarms and alerts are messages that indicate that one or more
faults have been detected. See Table for definitions. The alarms
and alerts indicate failures that cause the unit to shut down,
terminate an option (such as reset) or result in the use of a default
value as set point.
Capacity Control
Pressing <10> <STAT>, this subfunction displays the load/unload
factor, control point and leaving water temperature. Scrolling
down will also reveal the liquid level sensor values in degrees
format.
STATUS
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
1 Alarms
<1>
Alarm: xx
<STAT>
Reset Alarms: 1 <ENTER>
<↓>
Scroll down to display all current alarms. Use
EXPN key when needed.
2 General Parameters <2>
Up to 10 alarms/alerts can be stored at once. To view them press
<1> <STAT>. The control will display the current total number
of alarms/alerts. Use the arrow keys to scroll through the list.
Depress the <EXPN> key when needed to view the full description
of an alarm or alert. Press <1> <ENTR> to clear all the alarms.
When an alarm or alert is stored in the display and the machine
automatically resets, the alarm/alert is deleted. Codes for safeties
which do not automatically reset are not deleted until the problem
is corrected and the machine is switched to the OFF position,
then back to LOCAL/REMOTE or under CCN control. To clear
manual reset alarms from the CPM control modules, the control
circuit breaker must be switched off, then back on.
Unit analogue parameters and temperature reset
Press the <7> and <STAT> keys and scroll down to display the
unit entering and leaving fluid temperatures as well as the
temperature reset signal and calculated values.
Miscellaneous Inputs and Outputs
Pressing <8> <STAT> and scrolling down will display the demand
limit settings, pump relay and switch status and miscellaneous
items such as Heat/Cool and Dual Setpoint switch positions. See
status function and subfunctions table for a complete list.
Modes
The operating modes are displayed to indicate the operating status
of the unit at a given time. See status function and subfunctions
table for a complete list of all modes.
General parameters
<STAT>
<↓>
Control Mode
Displays LOCAL
ON/OFF or CCN
ON/OFF
<↓>
Run Status
Displays Off/On
<↓>
Occupied ?
Displays Yes/No
<↓>
CCN Enable
Displays Off/On
<↓>
CCN Chiller Start/Stop
Displays Start/Stop
<↓>
Alarm State
Displays
Normal/Alarm
General parameters
General operating parameters are displayed including control
mode, run status, CCN status and the five most current alarms.
Press <2> <STAT> to display these and the other values as shown
in status function and subfunctions table.
Circuit A and B analogue and discrete information
Circuit A analogue values can be viewed by pressing <3> <STAT>
and scrolling down to see current system operating conditions
such as pressures and temperatures. Pressing <4> <STAT> will
bring up Circuit A Discrete Inputs and outputs. Scroll down to
view the On/Off status of the compressor(s), loaders, solenoids
and pumps. Oil switch and feedback inputs are also displayed.
Press <5> and <6> <STAT> to view the identical analogue values
and discrete inputs and outputs for Circuit B. See status function
and subfunctions table for a complete display.
COMMENT
<↓>
Current Alarm 1
Displays x.xx
<↓>
Current Alarm 2
Displays x.xx
<↓>
Current Alarm 3
Displays x.xx
<↓>
Current Alarm 4
Displays x.xx
<↓>
Current Alarm 5
Displays x.xx
<↓>
Active Demand Limit
Displayed as xxx.x %
<↓>
Percent Total Capacity
Displayed as xxx.x %
<↓>
Water/Brine Setpoint
Displayed as xx.x °C
<↓>
Control Point
Displayed as xx.x °C
<↓>
Entering Fluid Temperature
Displayed as xx.x °C
<↓>
Leaving Fluid Temperature
Displayed as xx.x °C
<↓>
Emergency Stop
Displayed Emstop
<↓>
Minutes Left for Start
Displayed as xx min
<↓>
Heat-Cool Status
Displayed Heat/Cool
3 Circuit A Analogue <3>
Circuit A analogue
Values
<STAT>
VALUES
<↓>
Total Capacity
Displayed as xxx.x %
<↓>
Available Capacity
Displays xxx.x %
<↓>
Discharge Pressure
Displays xxx.x kPa
<↓>
Suction Pressure
Displays xxx.x kPa
<↓>
A1 Oil Pressure Diff.
Displays xxx.x kPa
<↓>
A2 Oil Pressure Diff.
Displays xxx.x kPa
<↓>
A1 Oil Pressure
Displays xxx.x kPa
<↓>
A2 Oil Pressure
Displays xxx.x kPa
<↓>
Discharge Gas Temperature
Displays xxx.x °C
<↓>
A1 Motor Temperature
Displays xxx.x °C
<↓>
A2 Motor Temperature
Displays xxx.x °C
<↓>
SAT Condensing Temp
Displays xxx.x °C
<↓>
Saturated Suction Temp
Displays xxx.x °C
<↓>
EXV Percent Open
Displays xxx.x %
<↓>
Motormaster Speed
Displays xxx.x %
<↓>
Water Valve Position
Displays xxx.x %
<↓>
Cooler Level Indicator
Displays xxx.x
<↓>
CPM A1 Feedback
Displays x.x Volts
<↓>
CPM A2 Feedback
Displays x.x Volts
<↓>
Circuit A Econ Pressure
Displays xxx.x kPa
To enter the MODES subfunction, press <9> <STAT> and use
the <↓> key to view all current modes of operation.
41
STATUS (CONT.)
STATUS (CONT.)
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
COMMENT
4 Circuit A discrete
<4><STAT>
CIR. A DISCRETE OUTPUTS
Outputs
SUBFUNCTION
KEYPAD
ENTRY
7 Unit Analogue
<7><STAT>
UNIT ANALOGUE PARAMETERS
Parameters
<↓>
Cooler Entering Fluid
COMMENT
Displays xx.x °C
Displays xx.x °C
<↓>
Compressor A1
Displays Off/On
<↓>
Cooler Leaving Fluid
<↓>
Compressor A2
Displays Off/On
<↓>
Condenser Entering Fluid Displays xx.x °C
<↓>
Loader A1
Displays Off/On
<↓>
Condenser Leaving Fluid Displays xx.x °C
<↓>
Loader A2
Displays Off/On
<↓>
Reclaim Entering Fluid
Displays xx.x °C
<↓>
Hot Gas Bypass Valve A
Displays Off/On
<↓>
Reclaim Leaving Fluid
Displays xx.x °C
<↓>
Circuit A Oil Heater
Displays Off/On
<↓>
5 Volt Supply
Displays x.x Volt
<↓>
A1 Mtr Cooling Solenoid Displays Off/On
<↓>
TEMPERATURE RESET
<↓>
A2 Mtr Cooling Solenoid Displays Off/On
<↓>
4-20 mA Reset Signal
<↓>
Circuit A Oil Pump
Displays Off/On
<↓>
Return Reset Signal
Displays xx.x °C
<↓>
Oil Solenoid A1
Displays Off/On
<↓>
Exterminal Reset Signal
Displays xx.x °C
<↓>
Oil Solenoid A2
Displays Off/On
<↓>
Outdoor Air Temp
Displays xx.x °C
<↓>
Calculated Reset
Displays xx.x °C
8 Misc. Inputs/
<8><STAT>
MISC. INPUT/OUTPUTS
Outputs
CIR. A DISCRETE INPUTS
Displays Open/Close
Displays xx.x mA
<↓>
Circuit A Oil Switch
<↓>
Compressor A1 Feedback Displays Off/On
<↓>
Fan 1
Displays on/off
<↓>
Compressor A2 Feedback Displays Off/On
<↓>
Fan 2
Displays on/off
CIRCUIT B ANALOGUE VALUES
<↓>
Fan 3
Displays on/off
<↓>
Fan 4
Displays on/off
5 Circuit B Analogue <5><STAT>
Values
6 Circuit B discrete
DISPLAY
<↓>
Total Capacity
Displayed as xxx.x%
<↓>
Fan 5
Displays on/off
<↓>
Available Capacity
Displays as xxx.x%
<↓>
Fan 6
Displays on/off
<↓>
Discharge Pressure
Displays xxx.x KPa
<↓>
DEMAND LIMIT
<↓>
Suction Pressure
Displays xxx.x KPa
<↓>
4-20 mA Demand Signal Displays xx.x mA
<↓>
B1 Oil Pressure Diff.
Displays xxx.x KPa
<↓>
Demand Switch 1
<↓>
B2 Oil Pressure Diff.
Displays xxx.x KPa
<↓>
Demand Switch 2
Displays Off/On
<↓>
B1 Oil Pressure
Displays xxx.x KPa
<↓>
CCN Loadshed Signal
Displays Normal
<↓>
B2 Oil Pressure
Displays xxx.x KPa
<↓>
Max Allowable CAP
Displays xxx.x %
<↓>
Discharge Gas Temperature Displays xxx.x °C
<↓>
PUMPS
<↓>
B1 Motor Temperature
Displays xxx.x °C
<↓>
Cooler Pump Relay
<↓>
B2 Motor Temperature
Displays xxx.x °C
<↓>
Cooler Pump Flow Switch Displays Off/On
<↓>
SAT Condensing Temp
Displays xxx.x °C
<↓>
Condenser Pump Relay
Displays Off/On
<↓>
Saturated Suction Temp
Displays xxx.x °C
<↓>
Condenser Pump Flow Switch
Displays Off/On
<↓>
EXV Percent Open
Displays xxx.x %
<↓>
MISCELLANEOUS
<↓>
Motormaster Speed
Displays xxx.x %
<↓>
Ice Valve
<↓>
Cooler Level Indicator
Displays xxx.x
<↓>
Ice Build Complete
Displays Yes/No
<↓>
CPM B1 Feedback
Displays x.x Volts
<↓>
Heat/Cool Switch
Displays Heat/Cool
Displays Off/On
Displays Off/On
Displays Off/On
Displays Off/On
<↓>
CPM B2 Feedback
Displays x.x Volts
<↓>
Dual Setpoint Switch
<↓>
Circuit B Econ Pressure
Displays xxx.x KPa
<↓>
Cooler Heater
Displays Off/On
<6><STAT>
CIR. B DISCRETE OUTPUTS
<↓>
Options Temperature 1
Displays xx.x °C
<↓>
Compressor B1
<↓>
Compressor B2
Displays Off/On
<↓>
Loader B1
Displays Off/On
<↓>
LOCAL OFF
<↓>
Loader B2
Displays Off/On
<↓>
CCN OFF
<↓>
Hot Gas Bypass Valve B
Displays Off/On
<↓>
CLOCK OFF
<↓>
Circuit B Oil Heater
Displays Off/On
<↓>
LOCAL ON
<↓>
B1 Mtr Cooling Solenoid Displays Off/On
<↓>
CCN ON
<↓>
B2 Mtr Cooling Solenoid Displays Off/On
<↓>
CLOCK ON
<↓>
Circuit B Oil Pump
Displays Off/On
<↓>
DUAL SP ACTIVE (1st SP)
<↓>
Oil Solenoid B1
Displays Off/On
<↓>
DUAL SP ACTIVE (2nd SP)
<↓>
Oil Solenoid B2
Displays Off/On
<↓>
TEMPERATURE RESET
Displays Open/Close
<↓>
DEMAND LIMIT ACTIVE
Outputs
Displays Off/On
9 Operating Modes
<↓>
Options Temperature 2
Displays xx.x °C
<9><STAT>
MODES MODE TBL
Only active modes
mode name on/off
displayed
CIR. B DISCRETE INPUTS
ACTIVE
<↓>
Circuit B Oil Switch
<↓>
Compressor B1 Feedback Displays Off/On
<↓>
LOAD LIMIT ACTIVE
<↓>
Compressor B2 Feedback Displays Off/On
<↓>
LOW SOURCE TEMP
PROTECT
Legend
CCN: Carrier Confort Network
EXV: Electronic Expansion Value
CPM: Compressor Protection Module
42
<↓>
RAMP LOADING ACTIVE
<↓>
TIMED OVERRIDE ACTIVE
<↓>
LOW COOLER SUCTION TEMP
<↓>
WSM CONTROLLING
<↓>
SLOW CHANGE OVERRIDE
<↓>
OFF TO ON DELAY ACTIVE
<↓>
FSM CONTROLLING
<↓>
2 CHILLR LEAD LAG ACTIVE
STATUS (CONT.)
SUBFUNCTION
10 Capacity Control
TEST (CONT.)
KEYPAD
ENTRY
DISPLAY
<↓>
<↓>
<↓>
<↓>
COMMENT
SUBFUNCTION
KEYPAD
ENTRY
2 CHLLR COMM FAILURE
3 Unit Discrete
<3><TEST>
UNIT DISCRETE OUTPUT.
CIR A LOW DISCHG SUPERHT
Output
<↓>
Fan 1
CIR B LOW DISCHG SUPERHT
<↓>
Fan 2
CIR A HIGH SDT
<↓>
Fan 3
<↓>
CIR B HIGH SDT
<↓>
Fan 4
<10><STAT>
CAPACITY CONTROL
<↓>
Fan 5
<↓>
Load/Unload Factor
Displays xxx.x %
<↓>
Fan 6
<↓>
Control Point
Displays xx.x °C
<↓>
Cooler Pump
Similarly, use
<↓>
Leaving Water Temp
Displays xx.x °C
<↓>
Condenser Pump
<1><ENTR> to test
<↓>
MISC. INDICATORS
<↓>
Cooler Heater
remaining outputs.
<↓>
Liquid Lvl Sensor Cir. A
Displays xx.x °C
<↓>
Alarm
Press the down
<↓>
Liquid Lvl Sensor Cir. B
Displays xx.x °C
<↓>
Remote Alarm 1
arrow key or
<↓>
Remote Alarm 2
<0><ENTR> to turn
<↓>
Remote Alarm 3
an output off.
<↓>
Remote Alarm 4
<↓>
Remote Alarm 5
<↓>
Remote Alarm 6
<↓>
Remote Alarm 7
<↓>
Remote Alarm 8
<↓>
Remote Alarm 9
<↓>
Remote Alarm 10
<↓>
Remote Alarm 11
<↓>
Remote Alarm 12
Test function and subfunctions
The test function operates the diagnostic program. To initiate the
test function, the LOCAL/OFF/REMOTE switch must be in the
OFF position.
To reach a particular test, press its subfunction number followed
by the Enter key then scroll to the desired test by pressing the
down arrow key.
TEST
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
COMMENT
1 Circuit A Discrete
<1><TEST>
CIRCUIT A DISCRETE OUTPUT
Output
<↓>
Loader A1
<1><ENTR>
Loader A1
DISPLAY
COMMENT
<↓>
Remote Alarm 13
<↓>
Remote Alarm 14
*Output will display
<↓>
Remote Alarm 15
Relay is ABSENT
<↓>
Remote Alarm 16
when not configured
relay is OFF
relay is ON
<↓>
Loader A2
<↓>
Minimum load Valve A
<↓>
Circuit A Oil Heater
<↓>
A1 Mtr. Cooling Solenoid
<↓>
A2 Mtr. Cooling Solenoid
<↓>
Circuit A Oil Pump
<↓>
Oil Solenoid A1
<↓>
Oil Solenoid A2
Similarly, use
<1><ENTR> to test
remaining outputs.
Press the down
arrow key or
<0><ENTR> to turn
an output off.
*Output will display
Relay is ABSENT
when not configured
2 Circuit B Discrete
<2><TEST>
CIRCUIT B DISCRETE OUTPUT
Output
<↓>
Loader B1
<1><ENTR>
Loader B1
relay is OFF
relay is ON
<↓>
Loader B2
<↓>
Minimum load Valve B
<↓>
Circuit B Oil Heater
<↓>
B1 Mtr. Cooling Solenoid
<↓>
B2 Mtr. Cooling Solenoid
<↓>
Circuit B Oil Pump
<↓>
Oil Solenoid B1
<↓>
Oil Solenoid B2
Similarly, use
<1><ENTR> to test
remaining outputs.
Press the down
arrow key or
<0><ENTR> to turn
the output off.
*Output will display
Relay is ABSENT
when not configured
43
TEST (CONT.)
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
COMMENT
4 Valves and
<4><TEST>
VALVES AND MOTOR MASTER
Motor Master
<↓>
Circuit A EXV Valve
Target Percent = 0 %
<1><ENTR>
<1><ENTR>
Step in 25%
increments. EXV
may be moved to a
specific percent by
entering the desired
value and pressing
<ENTR>. Wait 30
seconds between
each step for valve
to stop moving.
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
1 Service
<1><SRVC>
SOFTWARE CESR 500100
<↓>
Unit Type
Configuration
Ver. xxx
x
<↓>
Valve may be closed
in 25% increments
by keying in
<0><ENTR>. Wait
30 seconds between
each step for valve
to stop moving.
Compressor A1 Tonnage
Compress A2 Tonnage
xx
<↓>
Capacity high
0 = Disabled
temperature override
1 = Enabled
x
CIRCUIT A EXV VALVE
<↓>
Number of Cir B Comp
x
CIRCUIT A EXV VALVE
<↓>
Compressor B1 Tonnage
xx
Target Percent = 0 %
Circuit B Water Valve
3 = Split system
Number of Cir A Comp
xx
<↓>
Target Percent = 100 %
<↓>
1 = Air-cooled,
x
<↓>
Target Percent = 75 %
<1><ENTR>
COMMENT
2 = Water-cooled
CIRCUIT A EXV VALVE
Target Percent = 50 %
<1><ENTR>
SERVICE
CIRCUIT A EXV VALVE
Target Percent = 25 %
The use of the service function is reserved to the Carrier service
personal only.
<↓>
Test same method
as for Circuit A.
Compressor B2 Tonnage
xx
<↓>
<5><0><ENTR> CIRCUIT A WATER VALVE Test same method
as for EXV valves.
Max. Cond. Temp Setpoint 30GX = 70°C
xxx.x °C
Target Percent = 50 %
30HXA = 70°C
30HXC = 50°C
<↓>
Circuit A% Fan Speed
Test same method
as for EXV valves.
<↓>
MOP Setpoint
xx.x °C
Default = 11.1°C
<↓>
Circuit B% Fan Speed
Test same method
as for EXV valves.
<↓>
Fan Staging Select
Displays Not Used
or a number
x
<↓>
CPM Board Used?
Yes
Schedule function
<↓>
The schedule function key is used to configure the occupancy
schedule.
Compr. A1 Must Trip
Amps
xxx.x
Verify with
Compressor
Electrical Data
<↓>
Compr. A2 Must Trip
Amps
xxx.x
Verify with
Compressor
Electrical Data
<↓>
Compr. B1 Must Trip
Amps
xxx.x
Verify with
Compressor
Electrical Data
<↓>
Compr. B2 Must Trip
Amps
xxx.x
Verify with
Compressor
Electrical Data
<2><SRVC>
COOLER FLUID SELECT
1 = Water (Default),
This function provides a means to automatically switch the chiller
from an occupied mode to an unoccupied mode.
The schedules consist of eight user-configurable occupied time
periods. The control supports time schedules for local control,
remote control and ice building. These time periods can be flagged
to be in effect or not in effect on each day of the week and for
holidays (30 days).
Ice build control automatically sets the chilled water/brine control
point of the machine to a temperature where an ice building
operation for thermal storage can be accomplished.
2 Options
Configuration 1
2 = Medium Temp
brine
<↓>
<↓>
Service function
This function allows the technician to view and input configuration
data. Factory configuration data (subfunction 1) cannot be
modified.
Options configuration 1 and 2 (subfunctions 2 & 3) as well as all
the other subfunctions, reset/demand limit (subfunction 4), factory
configuration codes (subfunction 5), transducer calibration
(subfunction 7), manual control (subfunction 8) will need a
password to be entered.
44
x
3 = Low Temp Brine
(HX only).
Min. Load Valve Select
Displays Enable
Disable
x
Default: Disable.
Loading Sequence Select 1 = Equal circuit.
2 = Staged circuit
x
<↓>
x
<↓>
<↓>
Default: 1
Lead/Lag Sequence Select 1 = Automatic
(Default),
2 = Circuit A leads,
3 = Circuit B leads
Head Press. Control Type 0 = None (Default),
1 = Air cooled,
x
2 = Water cooled,
3 = Fixed air cooled
Motormaster Select
x
0 = None (Default),
1 = Direct control
SERVICE (CONT.)
SUBFUNCTION
SERVICE (CONT.)
KEYPAD
ENTRY
DISPLAY
COMMENT
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
<↓>
Water Valve Type
0 = None (Default),
1 = 4-20 mA,
2 = 0-10 V,
3 = 20-4 mA,
4 = 10-0 V
4 Reset
<4> <SRVC>
COOLING RESET TYPE 1
Configuration table
<↓>
Degrees reset at 20 mA
xx.x dC
<↓>
<↓>
<↓>
<↓>
<↓>
COOLING RESET TYPE 2
Ext. Reset Sensor Select 0 = Space Temp.
Thermistor (Default)
<↓>
Remote temp = no reset
xx.x dC
x
1 = outside air
thermistor
<↓>
Remote temp = full reset
xx.x dC
Cooler Pump Interlock
0 = No interlock
<↓>
x
1 = Interlock
enabled (Default)
Degrees reset
xx.x dC
<↓>
COOLING RESET TYPE 3
CHW ∆T = no reset
xx.x dC
Cooler Pump Control
0 = Not controlled
(Default)
<↓>
x
1 = On/Off Control
<↓>
Condenser Pump Control 0 = Not controlled
(Default)
CHW ∆T = full reset
xx.x dC
<↓>
Degrees reset
xx.x dC
<↓>
COOLING RESET
<↓>
Select/enable reset type
x
x
1 = On/Off Control
2 = Off when
Stages = 0
<↓>
<↓>
<↓>
Condenser Flow Switch
Displays Enable/
Disable
x
Default: Disable
<↓>
Condenser Water Sensors 0 = Not used
(Default)
HEATING RESET TYPE 1
xx.x dC
<↓>
HEATING RESET TYPE 2
x
1 = Used
<↓>
Heat Reclaim Sensors
0 = Not used
(Default)
Remote temp = no reset
xx.x dC
<↓>
x
1 = Used
Remote temp = full reset
xx.x dC
<↓>
Degrees reset
xx.x dC
COMMENT
0 = no reset
1 = 4-20 mA reset
2 = external reset
3 = return fluid reset
3 Options
<3> <SRVC>
OPTIONS 2
Configuration 2
<↓>
Cooling Setpoint Select
0 = Single setpoint
(Default)
<↓>
HEATING RESET TYPE 3
x
1 = Dual Setpoint
(switch controlled)
<↓>
HTW ∆T = no reset
xx.x dC
2 = Dual Setpoint
(clock controlled)
<↓>
HTW ∆T = full reset
xx.x dC
Heating Setpoint Select
0 = Single setpoint
(Default)
<↓>
Degrees reset
xx.x dC
x
1 = Dual Setpoint
(switch controlled)
<↓>
HEATING RESET
<↓>
Select/enable reset type
x
<↓>
DEMAND LIMIT
<↓>
Demand limit at 20 mA
xxx.x %
Enter 0-100 %
<↓>
Demand limit select
x
0 = none
1 = two step switch
2 = 4-20 mA
3 = CCN loadshed
<↓>
2 = Dual Setpoint
(clock controlled)
<↓>
<↓>
Ramp Load Select
0 = Disabled
x
1 = Enabled
(Default)
0 = no reset
1 = 4-20 mA reset
2 = external reset
3 = return fluid reset
Clock Control Select
0 = No clock control
(Default)
x
1-64 = Local clock
control
Ice Configuration Select
0 = No clock control
(Default)
<↓>
1-64 = Local clock
control
Loadshed group No.
x
0-99
x
<↓>
OAT Sensor Select
0 = Disabled,
1 = Enabled
Loadshed demand delta
xxx %
0-60 %
<↓>
<↓>
0-120 min
x
Default: 0
Max. loadshed time
xx min
<↓>
Remote Alarm Select
0 = Disabled,
1 = Enabled
<↓>
WATER VALVE PID
<↓>
Proportional PID gain
x.x
Default = 1.0
Adjustable from
- 20.0 to 20.0
<↓>
<↓>
<↓>
<↓>
x
Default: 0
Alarm Reset Select
0 = Not Selected
(Default)
<↓>
Integral PID gain
x.x
x
1 = Selected (Allows
use of LOR switch
to reset alarms)
Default = 1.0
Adjustable from
- 20.0 to 20.0
<↓>
Derivative PID gain
x.x
Default = 1.0
Adjustable from
- 20.0 to 20.0
Close Control Select
0 = Disabled,
1 = Enabled
<↓>
AIR MOTORMASTER PID
x
Default: 0
<↓>
Dead Band Multiplier
Default: 1.0
Proportional PID gain
x.x
Default = 1.0
Adjustable from
- 20.0 to 20.0
<↓>
Integral PID gain
x.x
Default = 1.0
Adjustable from
- 20.0 to 20.0
<↓>
Derivative PID gain
x.x
Default = 1.0
Adjustable from
- 20.0 to 20.0
x.x
<↓>
Current Unbalance Alarm 0 = Disabled,
1 = Enabled
x
<↓>
Default: 1
Voltage Unbalance Alarm 0 = Disabled,
1 = Enabled
x
Default: 1
45
SERVICE (CONT.)
SERVICE (CONT.)
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
5 Factory
<5> <SRVC>
COOLING RESET TYPE 1
COMMENT
Configuration codes <↓>
Configuration code 1
xxxxxxxx
Factory set
<↓>
Configuration code 2
xxxxxxxx
Factory set
<↓>
Configuration code 3
xxxxxxxx
Factory set
<↓>
SERVICE CODES
<↓>
Configuration code 4
xxxxxxxx
Factory set
<↓>
Configuration code 5
xxxxxxxx
Factory set
7 Transducer
<7> <SRVC>
CALIBRATION OFFSET
calibration
<↓>
CIRCUIT A PRESSURE
<↓>
Discharge pressure
xxx.x kPa
<↓>
Suction pressure
xxx.x kPa
<↓>
A1 oil pressure
xxx.x kPa
<↓>
A2 oil pressure
xxx.x kPa
<↓>
Economizer pressure
xxx.x kPa
<↓>
CALIBRATION OFFSET
<↓>
CIRCUIT B PRESSURE
<↓>
Discharge pressure
xxx.x kPa
6 NOT USED
8 Manual control
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
COMMENT
<↓>
Circuit B compressor 1
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
<↓>
Circuit B loader 1
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
<↓>
Circuit B loader 2
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
<↓>
Circuit B hot gas bypass
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
History function and subfunctions
HISTORY
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
1 Operating Hours
<1> <HIST>
Machine Operating Hours
xxx.x hours
<↓>
Machine Starts
xxx
<↓>
Circuit A
<↓>
Operating hours
xxx.x hours
<↓>
Compressor A1 Hours
xxx.x hours
<↓>
Compressor A2 Hours
xxx.x hours
<↓>
Starts
<↓>
Compressor A1 Starts
xxx
<↓>
Compressor A2 Starts
xxx
<↓>
Circuit B
<↓>
Operating hours
xxx.x hours
<↓>
Suction pressure
xxx.x kPa
<↓>
B1 oil pressure
xxx.x kPa
<↓>
B2 oil pressure
xxx.x kPa
<↓>
Economizer pressure
xxx.x kPa
<↓>
<↓>
Calibrate all at 0 kPa
Yes/No
Compressor B1 Hours
xxx.x hours
<↓>
<↓>
Last calibration date
mmm dd - yy
Compressor B2 Hours
xxx.x hours
<↓>
Starts
<8> <SRVC>
Manual control enable
LOR switch should
<↓>
Dsable
be in OFF position
Compressor B1 Starts
xxx
Password protected
Enter:
Will be displayed if
not entered earlier
in current HSIO use
<↓>
Compressor B2 Starts
xxx
<2> <HIST>
PREVIOUS ALARM 1 description
Alarm description time/
day of occurence
<↓>
Previous Alarm 2 - description
Alarm description time/
day of occurence
<↓>
Previous Alarm 3 - description
Alarm description time/
day of occurence
<↓>
Previous Alarm 4 - description
Alarm description time/
day of occurence
table
<1> <ENTR>
2 Alarm History
<1111> <ENTR> Manual control enable
Dsable
46
COMMENT
<1> <ENTR>
Manual control enable
Enable
<↓>
Circuit A compressor 1
Off
Switch LOR switch
to local before
proceeding
Lists 10 most
recent alarms.
Use EXPN key when
necessary
<↓> <1> <ENTR> Circuit A compressor 1
On
Provided no alarms
exist, control will
attempt circuit start
within 2 minutes.
Press <0> <ENTR>
to stop circuit
<↓>
<↓>
Circuit A compressor 2
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
Previous Alarm 5 - description
Alarm description time/
day of occurence
<↓>
<↓>
Circuit A loader 1
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
Previous Alarm 6 - description
Alarm description time/
day of occurence
<↓>
<↓>
Circuit A loader 2
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
Previous Alarm 7 - description
Alarm description time/
day of occurence
<↓>
<↓>
Circuit A hot gas bypass
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
Previous Alarm 8 - description
Alarm description time/
day of occurence
<↓>
<↓>
Circuit B compressor 1
Off
<1> <ENTR>
to enable,
<0> <ENTR> to stop
Previous Alarm 9 - description
Alarm description time/
day of occurence
<↓>
Previous Alarm 10 - description
Alarm description time/
day of occurence
Setpoint function
SETPOINT (CONT.)
SUBFUNCTION
KEYPAD
ENTRY
DISPLAY
<↓>
Minutes off time
xxx min.
<↓>
Motor Temp. setpoint
xxx.x °C
2 Units
<2> <SET>
US IMPERIAL/METRIC
0
3 Address
<3> <SET>
TARGET ADDRESS
x
<↓>
TARGET BUS NUMBER
x
<4> <SET>
Day of week
Monday
Mon = 1, Tues = 2
etc.
<3> <ENTER>
Day of week
Wednesday
Day of week set
<↓>
TIME (HOUR:MIN)
00:00
Enter military
format
<10.30>
TIME (HOUR:MIN)
Time of day set
<ENTER>
10:30
<↓>
DAY OF MONTH
xx
Setpoints are entered through the keypad. Setpoints can be
changed within the upper and lower limits, which are fixed. The
ranges are listed below.
Cooling setpoint 1,2
Water:
Medium temperature brine:
Low temperature brine:
Heating and setpoint 1,2
Water and medium
temperature brine:
Reset setpoints
Maximum reset range:
External temperature reset:
Chiller fluid ∆T:
External signal reset:
Demand limit setpoints
Switch input:
External signal:
Head pressure setpoints
Air-cooled chillers:
Water-cooled chillers:
3.3 to 21.1°C
-10 to 21.1°C
-25 to 21.1°C
4 Time
26.7 to 60°C
-17 to 17°C
-40 to 115°C
0 to 8°C
4 to 20 mA
<20> <ENTER> DAY OF MONTH
20
<↓>
Step 1 – 0 to 100 %
capacity reduction
Step 2 – 0 to 100 %
capacity reduction
Maximum demand limit:
4 to 20 mA
Minimum demand limit:
4 to 20 mA
Loadshed demand Delta:
0 to 60 %
Maximum loadshed time:
0 to 120 min.
5 Disable
0 = English
1 = Metric
Day of month set
MONTH OF YEAR
xx
<05> <ENTER> MONTH OF YEAR
05
<↓>
COMMENT
Month of year set
YEAR OF CENTURY
xx
<96> <ENTER> YEAR OF CENTURY
96
Year of century set
<5> <SET>
0 = no, 1 = yes
Disable CCN control
26.7 to 57.2°C
26.7 to 53.3°C
SETPOINT
SUBFUNCTION
1 Setpoint table
KEYPAD
ENTRY
DISPLAY
<1> <SET>
COOLING
<↓>
Cool setpoint 1
xx.x °C
<↓>
Cool setpoint 2
xx.x °C
<↓>
Cooling ramp loading
xx.x °C
<↓>
HEATING
<↓>
Head setpoint 1
xx.x °C
<↓>
Head setpoint 2
xx.x °C
<↓>
Heating ramp loading
xx.x °C
<↓>
HEAD PRESSURE
<↓>
Head pressure setpoint A
xxx.x °C
<↓>
Head pressure setpoint B
xxx.x °C
<↓>
DEMAND LIMIT
<↓>
Demand switch setpoint 1
xxx.x %
<↓>
Demand switch setpoint 2
xxx.x %
<↓>
LCW delta alarm limit
xxx.x °C
COMMENT
47
Head pressure control
General
The microprocessor controls the condenser fans (30GX) or
analogue water valve (30HXC) to maintain the saturated
condensing temperature to a configurable setpoint. The fans will
be staged (30GX) or water valve controlled (30HXC) based on
each circuit's saturated condensing temperature and compressor
status. Water-cooled units (30HXC) operating at less than 20°C
for entering condenser water require the use of head pressure
control.
The chiller must be field configured for the options appearing
below:
CONFIGURATION
OPTION
DESCRIPTION
HSIO
LOCATION
FACTORY
CONFIGURATION
Fan staging select
A/C staging method
<1> <SRVC>
Yes
Motormaster select
Applies to A/C only
<2> <SRVC>
Yes. 0 = none
Set to 1 to enable
(Motormaster only)
Water valve type
Applies to W/C only
<2> <SRVC>
Yes. 0 = none
Set to 1 = 4-20 mA
2 = 0-10 V, 3 = 20-4 mA
4 = 10-0 V
two Saturated Condensing Temperature values for 30GX 080160 units. For the 30GX 175 to 350 units, each circuit's fan stage
is independently controlled based on the circuit Saturated
Condensing Temperature.
30GX head pressure control flow charts
Read circuit
saturated
condensing
temperature
andd current
fan stage
Is SCT greater
than head
pressure
setpoint ?
no
Has SCT been
19.4 °C less than
head pressure
setpoint for 2
minutes ?
yes
yes
Increase
current fan
stage by one
Decrease
current fan
stage by one
no
Add 8.3°C to
head pressure
setpoint for
next 35
seconds
Fan staging settings for A/C units
UNIT MODEL
NUMBER
DESCRIPTION
FAN STAGE
ON HSIO
FAN STAGING
SELECT
NUMBER
30GX 080-105
1st stage compressor status
2nd and 3rd stage common
control based on highest SCT
FAN-5
FAN-1 and 2
16
30GX 115-135
1st stage compressor status
2nd and 3rd stage common
control based on highest SCT
FAN-5
FAN-1 and 2
14
30GX 150-160
1st stage compressor status
2nd and 3rd stage common
control based on highest SCT
FAN-5
FAN-1 and 2
16
30GX 175-265
1st stage each circuit,
compressor status
2nd and 3rd stage circuit A
independent
2nd stage circuit B independent
FAN-5 and 6
8
1st stage each circuit,
compressor status
2nd and 3rd stage circuit A
independent
2nd and 3rd stage circuit B
independent
FAN-5 and 6
1st stage each circuit,
compressor status
2nd and 3rd stage circuit A
independent
2nd and 3rd stage circuit B
independent
FAN-5 and 6
1st stage each circuit,
compressor status
2nd and 3rd stage circuit A
independent
2nd and 3rd stage circuit B
independent
FAN-5 and 6
30GX 280
30GX 295
30GX 325-350
FAN-1 and 2
FAN-3
4
FAN-1 and 2
FAN-3 and 4
10
FAN-1 and 2
FAN-3 and 4
6
FAN-1 and 2
FAN-3 and 4
Air-cooled units head pressure control
The fans are controlled based on Saturated Condensing
Temperature. The first fan stage for each circuit will be turned
on whenever the compressor is turned on and SCT greater than
35°C. A fan stage will be added when the Saturated Condensing
Temperature (SCT) exceeds the Head Pressure Setpoint. Once a
fan stage has been added, the software will temporarily modify
the head pressure setpoint by adding 8.3°C for 35 seconds. A
fan stage will be removed when the Saturated Condensing
Temperature has been less than the Head Pressure Setpoint 19.4°C for two minutes. The control will use the higher of the `
48
Water-cooled head pressure control
The 30HXC chillers can be configured to control direct or reverse
acting water valves that are controlled by a 4-20 mA signal. A
2-10 VDC signal can be used by installing a 500 ohm resistor
across the two output terminals of the 4-20 mA signal. This control
scheme reads the Condenser Leaving Water temperature and uses
a PID loop to control the head pressure. Proportional, Integral
and Derivative gain parameters for water-cooled controls are
adjustable and can be found in the Service subfunction. Checkout
and adjustment of the PID loop should only be performed by
certified Carrier Comfort Network technicians.
30GX fan arrangement
30GX 080-090-105
30GX 250-265
30GX 115-125-135
30GX 280
30GX 150-160
30GX 295
30GX 175-205-225
30GX 325-350
Fan stage
Fans controlled on the unit
on HSIO
FAN 1
FAN 2
FAN 3
FAN 4
FAN 5
FAN 6
080-105
115-135
EV 12
EV 13,14
EV 13,14
EV 15,16
-
-
EV 11
EV 11,12
-
150-160
175-225
EV 13,14
EV 13,14
EV 15 to 18
EV 15,16
EV 33,34
-
EV 11,12
EV 11,12
EV 31,31
250-265
280
EV 13,14
EV 13,14
EV 15,16
EV 15,16
EV 33,34
EV 33,34
EV 35,36
EV 11,12
EV 11,12
EV 31,32
EV 31,32
295
EV 13,14
EV 15 to 18
EV 33,34
EV 35,36
EV 11,12
EV 31,32
325-350
EV 13,14
EV 15 to 18
EV 33,34
EV 35 to 38
EV 11,12
EV 31,32
30GX
49
PRE-START-UP PROCEDURE
START-UP AND OPERATION
Do not attempt to start the chiller until the following checks have
been completed.
Actual Start-up
System Check
1 - Check all auxiliary components such as the chilled fluid
circulating pump, air-handling equipment, or other equipment
to which the chiller supplies liquid. Consult the manufacturer’s
instructions. If the unit has field-installed accessories, be sure
all are properly installed and wired correctly. Refer to the unit
wiring diagrams.
2 - Check the cooler flow switch for proper configuration and
operation (<8> <STAT> from HSIO II). Ensure the switch
closes when the pump is on and opens when the pump is
turned off.
3 - Open the discharge and liquid valves in each circuit.
4 - If suction valve is installed, open the suction service valves in
each circuit. Service valve is located below the compressor in
the cooler suction connection flange.
5 - Open the oil shut off valves located by the oil pre-filter.
6 - Check the tightness of all electrical connections.
7 - Check to ensure the unit is level per the installation instructions.
8 - Check the incoming power supply for proper phasing. This
can be done by turning on both the line voltage and control
voltage power supplies. Leave the LOCAL/OFF/REMOTE
switch in the OFF position. If the incoming power is not
phased correctly, the CPM will generate an alarm for voltage
phase reversal. Press <1> <STAT> at the HSIO II to check for
this alarm. If this alarm is present, shut down power supplies
and switch any two incoming power leads at the control box
terminal block.
ATTENTION
DO NOT make any changes to the factory installed compressor
power wiring in the control box or at the compressor junction
box. Doing so will cause permanent damage to the compressor
and will require compressor replacement.
9 - Check all field configuration data and setpoints.
10 - Enter correct date, time and operating schedule(s).
11 - Verify operation of solenoids, pumps, valves, compressors,
etc. as listed in the Checklist.
12 - Check incoming power supply for proper nameplate voltage
and for any voltage imbalance as defined below.
13 - Open condenser water valves. Check condenser water pump
for proper operation.
50
Actual start-up should be done only under supervision of a
qualified refrigeration mechanic.
1 - Set leaving fluid temperature. No cooling range adjustment is
necessary.
2 - Start chilled fluid pump.
3 - Switch LOCAL/OFF/REMOTE switch to LOCAL or
REMOTE.
4 - Provided there is a load on the chiller, allow the machine to
operate and confirm that everything is functioning properly.
Verify that the leaving fluid temperature agrees with the
cooling setpoint (1 or 2), or if reset is being used, the modified
setpoint. Chiller is controlling to the Control Point displayed
under <2> <STAT>.
Operating Sequence
The chiller is started by switching the LOCAL/OFF/REMOTE
switch to either LOCAL or REMOTE. On a command for cooling,
the oil pump will be turned on to start the pre-lubrication process.
After a short period of time, the oil solenoid will be opened and
the control will read the oil pressure from the transducer and
determine if sufficient pressure has been built up. If there is not
sufficient pressure, an alarm will be generated and the compressor
will not be started. Upon building pressure, the compressor will
be allowed to start. For across the line (XL) start chillers, the
compressor will start and come up to full speed within 1-3 seconds.
For star delta start chillers, contactors KM1 and KM1-B (starter
contactor assembly) will be closed and the compressor will be
started in a Wye configuration. This method reduces the locked
rotor current requirements by approximately 60%, while
maintaining enough torque to bring the compressor up to full
speed. After 6-8 seconds, the CPM module will switch out
contactor KM1-B and bring in contactor KM1-A which will run
the motor in a Delta configuration (same configuration that XL
units run).
Once the compressor is successfully running, the control will load
the compressor and add additional stages of capacity as needed
to satisfy the leaving fluid setpoint. Head pressure can be
controlled with a field installed condenser water valve.
TROUBLESHOOTING
Single Circuit Stoppage
The 30HXC/GX Screw chiller control has many features to aid
the technicians in troubleshooting. By using the keypad and
display module and the status function, actual operating conditions
of the chiller are displayed while the unit is running. The test
function allows for operational checkout of compressor loaders,
EXV’s, solenoids and other components while the chiller is
stopped. The Service function displays how configurable items
are configured and provides a manual control mode where the
compressors can be started and loaded. If an operating fault is
detected, an alarm is generated and an alarm code is displayed
under the subfunction <1> <STAT> along with an explanation of
the fault. Up to 10 current alarm codes are stored under this
subfunction.
Single circuit stoppage can be caused by the following:
Checking display codes
After the cause for stoppage has been corrected, restart is either
automatic or manual, depending on the fault. Manual reset requires
that the alarm(s) be reset via the HSIO II. Press <1> <STAT> and
then <1> <ENTR> to clear manual reset alarms. If the Alarm
Reset Select feature is selected (<3> <SRVC>), a manual reset
alarm can also be reset by switching the LOR switch from
LOCAL/REMOTE to OFF and back to LOCAL/REMOTE again.
If an alarm was from the CPM module, manual reset requires
that the alarm(s) be reset via the control circuit breaker QF2. Some
typical fault conditions are described below. For a complete list
of fault conditions, codes, and reset type, see the Alarm and Alert
codes table.
To determine how the machine has been programmed to operate,
check the diagnostic information displayed in the Status function
and the configuration displayed in the Service function.
Unit shutoff
To shut the unit off, move the LOCAL/OFF/REMOTE switch to
OFF position. All compressors and solenoids stop immediately.
Complete unit stoppage
Complete unit stoppage can be caused by any of the following
conditions:
1 - Cooling load satisfied.
2 - Remote on/off contacts open.
3 - Programmed schedule.
4 - Emergency stop command from CCN.
5 - General power failure.
6 - Blown fuse in control power feed disconnect.
7 - Open control circuit fuse(s)
8 - LOCAL/OFF/REMOTE switch moved to OFF position.
9 - Freeze protection trip.
10 - Low flow protection trip.
11 - Open contacts in chilled water flow switch.
12 - Open contacts in any auxiliary interlock. Terminals that are
jumpered from factory are in series with control switch.
Opening the circuit between these terminals places unit in
stop mode, similar to moving the control switch to OFF
position. Unit cannot start if these contacts are open. If they
are open while unit is running, the unit stops.
13 - Cooler entering or leaving fluid thermistor failure.
14 - Low/high transducer supply voltage.
15 - Loss of communications between processor module and
other control modules.
16 - Low refrigerant pressure.
17 - Off-to-on delay is in effect.
18 - Low oil pressure.
19 - Open contacts in high pressure switch (1330 kPa on 30HXC
and 2180 kPa on 30GX)
20 - Low refrigerant pressure.
21 - Thermistor failure.
22 - Transducer failure.
23 - Alarm condition from CPM module.
24 - Overload relay trip. Stoppage of one circuit by a safety device
action does not affect other circuit. When a safety device trips,
the circuit is shut down immediately and EXV closes.
Restart procedure
Power failure external to the unit - Unit restarts automatically
when power is restored.
Alarms and alert
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 below. The alarm descriptions are
displayed on the HSIO II when the <1> <STAT> subfunction is
entered.
Following is a detailed description of each alarm and alert code
error and possible cause. Manual reset is accomplished by entering
<1> <STAT> from the HSIO II and pressing <1> <ENTR> or
moving the LOCAL/OFF/REMOTE switch to the OFF position,
then back to LOCAL or REMOTE position (if Alarm Reset Select
is enabled). See Table below for listing of each alarm and alert
code.
51
Alarms and alerts codes table
Alarm/Alert
code
Alarm
or Alert
Description
Why was this
alarm generated ?
Action taken
by control
Reset
method
Probable
cause
–
0
–
No alarms or alerts exist
–
–
1.xx
Alert
Compressor A1 failure
See CPM subcodes below
See CPM subcodes below
Manual
2.xx
Compressor A2 failure
See CPM subcodes below
See CPM subcodes below
Manual
5.xx
Compressor B1 failure
See CPM subcodes below
See CPM subcodes below
Manual
6.xx
Compressor B2 failure
See CPM subcodes below
See CPM subcodes below
Manual
CPM Subcodes
All are alarm codes
(xx)
0
–
–
–
1
–
No error
High pressure switch trip
HPS input to CPM module open
Comp. shut down
Manual
Loss of condenser water flow.
Operation beyond chiller capability.
Liquid valve not open.
2
No motor current
CPM module reads less than
10 % of MTA on all legs
for > 3 seconds
Comp. shut down
Manual
Power supply disconnected, blown
fuse(s), wiring error, contactor not
energized, faulty current toroid.
25
Current imbalance
> 10 % (Alarm)
CPM measures current
balance between phases
greater than 10 %
Circuit shut down
Manual
Loose terminals on power wires.
Poor power supply. Displayed only
if alarm feature is enabled in
<3> <SRVC>
27
Current imbalance
> 10 % (Warning)
CPM measures current
balance between phases
greater than 10 %
None
3
Current imbalance
> 18 % (Alarm)
CPM measures current
balance between phases
greater than 18 % for
25 minutes
Circuit shut down
Manual
Loose terminals on power wires.
Poor power supply.
35
Single phase current loss
CPM measures current
balance between phases
greater than 20 %
Circuit shut down
Manual
Blown fuse, wiring error.
4
High motor current
CPM detects high current
compared to MTA setting
Comp. shut down
Manual
Operation beyond chiller capability,
improperly punched configuration header,
blown fuse.
5
Ground fault
CPM detects ground
current (2.5 ± 2.0 amps)
Comp. shut down
Manual
Motor winding(s) gone to ground,
wiring error.
55
Voltage imbalance
> 3 % (Alarm)
CPM measures voltage
balance between phases
greater than 3 %
Circuit shut down
Manual
Compressor fault, local utility.
supply imbalance. Poor power supply.
Displayed only if alarm feature is enabled
in <3> <SRVC>
57
Voltage imbalance
> 3 % (Warning)
CPM measures voltage
balance between phases
greater than 3 %
None
6
Voltage imbalance
>7%
CPM measures voltage
balance between phases
greater than 7 % for
25 minutes
Circuit shut down
Manual
Compressor fault, local utility.
supply imbalance.
65
Single phase Volts loss
CPM measures current
balance between phases
greater than 20 %
Circuit shut down
Manual
Blown fuse, wiring error.
7
Volt phase reversal
CPM detects incoming
power supply out of phase
Manual
Supply power not in phase.
Interchange any two incoming leads.
75
Contactor failure
CPM detects min. 10 % of
MTA for 10 seconds after
shutting off compressor
contactor. Oil solenoid is
energized.
Chiller shut down
Manual
Faulty contactor, contactor welded,
wiring error.
8
Current phase reversal
CPM detects phase reversal
from toroid reading
Circuit shut down
Manual
Multiple terminal block power supply
leads not in phase. Interchange any two
leads at ONE of the terminal blocks.
85
Motor over temperature
CPM detects high motor
temperature
Comp. shut down
Manual
Solenoid failure, low refrigerant charge.
9
Open thermistor
CPM detects open circuit
in motor temp. thermistor
Comp. shut down
Manual
Wiring error or faulty thermistor*
95
Config header fault
CPM finds error with MTA
value punched out in header
Comp. shut down
Manual
Header on CPM board improperly
punched out, header not fully seated in
CPM board.
10
Shorted thermistor
CPM detects short circuit
in motor temp. thermistor
Comp. shut down
Manual
Wiring error or faulty thermistor*
Loose terminals on power wires.
Poor power supply. Displayed only
if alarm feature is disabled in
<3> <SRVC>
Compressor fault, local utility.
supply imbalance. Poor power supply.
Displayed only if alarm feature is disabled
in <3> <SRVC>
7
Alert
Cir. A discharge gas
Thermistor failure
Thermistor outside range of
of -40 to 118°C or DGT
> 98.9°C
Circuit A shut down
Manual
Thermistor failure, motor cooling
solenoid failure or wiring error.
8
Alert
Cir. B discharge gas
Thermistor failure
Thermistor outside range of
of -10 to 118°C or DGT
> 98.9°C
Circuit B shut down
Manual
Thermistor failure, motor cooling
solenoid failure or wiring error.
9
Alarm
Cooler leaving fluid
Thermistor failure
Thermistor outside range of
of -40 to 118°C
Chiller shut down
Uses 0.1°F/% total
capacity as rise/ton.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
10
Alarm
Cooler entering fluid
Thermistor failure
Thermistor outside range of
of -40 to 118°C
Chiller shut down
Uses 0.1°F/% total
capacity as rise/ton.
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
52
Alarms and alerts codes table (cont.)
Alarm/Alert
code
Alarm
or Alert
Description
Why was this
alarm generated ?
Action taken
by control
Reset
method
Probable
cause
11
Alert
Condenser leaving fluid
Thermistor failure
Thermistor outside range of
of -40 to 118°C
None. Chiller continues to run
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
12
Alert
Condenser entering fluid
Thermistor failure
Thermistor outside range of
of -40 to 118°C
None. Chiller continues to run
Automatic
Thermistor failure, damaged
cable/wire or wiring error.
15
Alert
Compressor A1 high
motor temperature
Thermistor outside range of
-39.9 to 118°C for five
consecutive readings.
Compressor A1 shut down
Manual
Thermistor failure, faulty motor
cooling solenoid.
16
Alert
Compressor A2 high
motor temperature
Thermistor outside range of
-39.9 to 118°C for five
consecutive readings.
Compressor A2 shut down
Manual
Thermistor failure, faulty motor
cooling solenoid.
17
Alert
Compressor B1 high
motor temperature
Thermistor outside range of
-39.9 to 118°C for five
consecutive readings.
Compressor B1 shut down
Manual
Thermistor failure, faulty motor
cooling solenoid.
18
Alert
Compressor B2 high
motor temperature
Thermistor outside range of
-39.9 to 118°C for five
consecutive readings.
Compressor B2 shut down
Manual
Thermistor failure, faulty motor
cooling solenoid.
19
Alert
Circuit A low oil
temp. at start-up
DGT/oil temp. less than
SCT + oil rise
Air-cooled chillers not
allowed to start
Automatic
Failed oil heater
20
Alert
Circuit B low oil
temp. at start-up
DGT/oil temp. less than
SCT + oil rise
Air-cooled chillers not
allowed to start
Automatic
Failed oil heater
21
Alert
External reset
temperature
thermistor failure
Thermistor outside range
of -40 to 118°C
Reset disabled.
Runs under normal
control/setpoints
Automatic
Thermistor failure or wiring error
22
Alert
Circuit A discharge
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Circuit A shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
23
Alert
Circuit B discharge
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Circuit B shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
24
Alert
Circuit A suction
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Circuit A shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
25
Alert
Circuit B suction
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Circuit B shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
26
Alert
Comp. A1 oil
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Comp. A1 shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
27
Alert
Comp. A2 oil
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Comp. A2 shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
28
Alert
Comp. B1 oil
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Comp. B1 shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
29
Alert
Comp. B2 oil
pressure transducer
failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Comp. B2 shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
30
Alert
Circuit A economizer
transducer failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Circuit A shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
31
Alert
Circuit B economizer
transducer failure
Calibration offset more than
41 kPa or voltage ratio (volts
read/ref. voltage) more than
99.9 % or less than 0.5 %.
Circuit B shut down
Automatic
Transducer failure, power supply failure
or wiring damage/error.
32
Alarm
Transducer supply
outside 4.5 to 5.5 Volts
Reference voltage measured
at PSIO-1, less than 4.5 V
or greater than 5.5 V.
Chiller shut down
Automatic
Power supply failure or wiring error.
Low transformer voltage.
34
Alert
4-20 mA reset input
out of range
If configured and input signal
less than 2 mA or greater
than 20 mA.
Reset function disabled.
Normal setpoint used.
Automatic
Faulty signal generator, wiring error.
35
Alert
4-20 mA demand limit input
out of range
If configured and input signal
less than 2 mA or greater
than 20 mA.
Demand limit ignored.
Runs under normal control
base on 100 % demand limit
Automatic
Faulty signal generator, wiring error.
36
Alarm
Loss of communication
with “Hardware point”
PSIO has lost communication
with one of the points in
Table 18.
Automatic
Failed module, wiring error, failed
transformer, loose connection plug,
wrong address.
37
Alert
Circuit A low saturated
suction temperature
SST reads 3.3°C or more below
the freeze point for 3 minutes.
Point is 1.1°C for water, setpoint
minus 4.4°C for brines.
Circuit A shut down
Manual
Low refrigerant charge, plugged strainer,
faulty expansion valve.
Low water flow.
38
Alert
Circuit B low saturated
suction temperature
SST reads 3.3°C or more below
the freeze point for 3 minutes.
Point is 1.1°C for water, setpoint
minus 4.4°C for brines.
Circuit B shut down
Manual
Low refrigerant charge, plugged strainer,
faulty expansion valve.
Low water flow.
53
Alarms and alerts codes table (cont.)
Alarm/Alert
code
Alarm
or Alert
Description
Why was this
alarm generated ?
Action taken
by control
Reset
method
Probable
cause
40
Alert
Compressor A1 low
oil pressure
Oil pressure differential
below oil Setpoint 1 or 2
(see low oil pressure Alert
Criteria and Setpoints)
Comp. A1 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
41
Alert
Compressor A2 low
oil pressure
Oil pressure differential
below oil Setpoint 1 or 2
(see low oil pressure Alert
Criteria and Setpoints)
Comp. A2 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
42
Alert
Compressor B1 low
oil pressure
Oil pressure differential
below oil Setpoint 1 or 2
(see low oil pressure Alert
Criteria and Setpoints)
Comp. B1 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
43
Alert
Compressor B2 low
oil pressure
Oil pressure differential
below oil Setpoint 1 or 2
(see low oil pressure Alert
Criteria and Setpoints)
Comp. B2 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
44
Alarm
Circuit A condenser
freeze protection
For W/C chillers only, if
SCT < 1.1°C
Chiller shut down.
Turn cond. pump on if
chiller is off
Automatic
Failed/bad discharge pressure
transducer, refrigerant leak
45
Alarm
Circuit B condenser
freeze protection
For W/C chillers only, if
SCT < 1.1°C
Chiller shut down.
Turn cond. pump on if
chiller is off
Automatic
Failed/bad discharge pressure
transducer, refrigerant leak
46
Alarm
Cooler freeze protection
Cooler EWT or LWT less
than freeze point. Freeze point
is 1.1°C for water, cooling
setpoint minus 4.4°C for brines
Chiller shut down.
Leave cond. pump on.
Turn cond. pump on if chiller
is off.
Automatic
Faulty thermistor, low water flow.
47
Alert
Circuit A high saturated
suction temperature
After first 90 seconds
SST > 12.8°C and EXV < 1 %.
Circuit A shut down.
Manual
Faulty expansion valve, liquid level
sensor or transducer
48
Alert
Circuit B high saturated
suction temperature
After first 90 seconds
SST > 12.8°C and EXV < 1 %.
Circuit B shut down.
Manual
Faulty expansion valve, liquid level
sensor or transducer
49
Alarm
Loss of condenser flow
Flow switch not closed
within 1 minute after pump
is started
Chiller shut down.
Manual
Low condenser water flow condenser
pump.
50
Alarm
Illegal configuration
x
Illegal configuration has been
entered. Correction needed
Chiller cannot start.
Manual
Configuration error.
51
Alarm
Initial configuration
required
No configuration has been
entered.
Chiller cannot start.
Manual
Configuration omitted.
52
Alarm
Unit is in emergency stop
CCN command received
to shut unit down.
Chiller shut down.
CCN/Automatic
Network command.
53
Alarm
Cooler pump interlock
failed at start-up
Interlock did not close
within 1 minute after transition
Chiller shut down.
Pump turned off.
Automatic
Failure of cooler pump or controls.
54
Alarm
Cooler pump interlock
opened unexpectedly
Interlock opened for at least
5 seconds during operation
Chiller shut down.
Pump turned off.
Automatic
Failure of cooler pump or controls.
55
Alarm
Cooler pump interlock
closed when pump off
Interlock closed when pump
relay is off
Cooler pump remains off.
Unit prevented from starting.
Manual
Failure of cooler pump relay or
interlock, welded contacts.
56
Alert
Loss of communication
with WSM
No communications have
been received by PSIO
within 5 minutes of last
transmission.
WSM forces removed.
Runs under own control.
Automatic
Failed module, wiring error, failed
transformer, loose connection plug,
wrong address.
57
Alert
Circuit A liquid level
sensor failure
Sensor reads 118°C or -40°C
with SST > -12.8°C.
Runs, but controls EXV
based on discharge superheat
Automatic
Thermistor circuit open, faulty
liquid level sensor, wiring error.
58
Alert
Circuit B liquid level
sensor failure
Sensor reads 118°C or -40°C
with SST > -12.8°C.
Runs, but controls EXV
based on discharge superheat
Automatic
Thermistor circuit open, faulty
liquid level sensor, wiring error.
59
Alarm
Compressor A1
Prestart oil pressure
Oil pump did not build
sufficient pressure during
pre-lube cycle.
Circuit cannot start.
Manual
Low oil, oil pump failure, oil solenoid
failure, oil transducer failure.
60
Alarm
Compressor A2
Prestart oil pressure
Oil pump did not build
sufficient pressure during
pre-lube cycle.
Circuit cannot start.
Manual
Low oil, oil pump failure, oil solenoid
failure, oil transducer failure.
61
Alarm
Compressor B1
Prestart oil pressure
Oil pump did not build
sufficient pressure during
pre-lube cycle.
Circuit cannot start.
Manual
Low oil, oil pump failure, oil solenoid
failure, oil transducer failure.
62
Alarm
Compressor B2
Prestart oil pressure
Oil pump did not build
sufficient pressure during
pre-lube cycle.
Circuit cannot start.
Manual
Low oil, oil pump failure, oil solenoid
failure, oil transducer failure.
63
Alarm
Circuits A&B off for alerts
Unit down
Control has shut down
both circuits due to alerts.
None.
Automatic
Check individual alarms.
64
Alert
Circuit A loss of charge
Discharge pressure reading
< 69 kPa for 30 seconds
Circuit A shut down.
Manual
Refrigerant leak or transducer failure.
65
Alert
Circuit B loss of charge
Discharge pressure reading
< 69 kPa for 30 seconds
Circuit B shut down.
Manual
Refrigerant leak or transducer failure.
66
Alarm
Loss of communication
with FSM
No communications have been
received by PSIO within
5 minutes of last transmission.
FSM forces removed.
Runs under own control.
Automatic
Wiring faulty or module failure.
54
Alarms and alerts codes table (cont.)
Alarm/Alert
code
Alarm
or Alert
Description
Why was this
alarm generated ?
Action taken
by control
Reset
method
Probable
cause
67
Alert
Circuit A high
discharge pressure
SCT > MCT_SP + 2.8°C
Circuit A shut down
Automatic
Faulty transducer/high pressure switch,
restricted condenser water flow.
68
Alert
Circuit B high
discharge pressure
SCT > MCT_SP + 2.8°C
Circuit B shut down
Automatic
Faulty transducer/high pressure switch,
restricted condenser water flow.
70
Alert
High leaving chilled
water temperature
LCW read > LCW Delta
alarm limit and total capacity is
100 % and current LCW > LCW
reading 1 minute ago.
Alert only. None
Automatic
Building load greater than capacity,
low water/brine flow, or compressor fault.
Check for other alarms or alerts.
71
Alert
Circuit A low oil level/flow
Level switch input open.
Circuit A shut down
Manual
Low oil level, failed switch, wiring error.
72
Alert
Circuit B low oil level/flow
Level switch input open.
Circuit B shut down
Manual
Low oil level, failed switch, wiring error.
73
Alert
Circuit A low discharge
superheat
Superheat < 2.8°C
for 10 minutes
Circuit A shut down
Manual
Faulty thermistor, transducer or EXV.
74
Alert
Circuit B low discharge
superheat
Superheat < 2.8°C
for 10 minutes
Circuit B shut down
Manual
Faulty thermistor, transducer or EXV.
75
Alarm
Compressor A1 max. oil
Delta P, check oil line
(Discharge pressure - oil
pressure) > 680 kPa for more
than 5 seconds
Comp. A1 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
76
Alarm
Compressor A2 max. oil
Delta P, check oil line
(Discharge pressure - oil
pressure) > 680 kPa for more
than 5 seconds
Comp. A2 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
77
Alarm
Compressor B1 max. oil
Delta P, check oil line
(Discharge pressure - oil
pressure) > 680 kPa for more
than 5 seconds
Comp. B1 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
78
Alarm
Compressor B2 max. oil
Delta P, check oil line
(Discharge pressure - oil
pressure) > 680 kPa for more
than 5 seconds
Comp. B2 shut down
Manual
Low water temperature, plugged oil filter,
closed oil valve, bad oil solenoid,
compressor oil check valve stuck,
plugged oil strainer
79
Alarm
Compressor A1 failed oil
solenoid
Diff. oil pressure > 17 kPa
during period after oil pump
starts and before oil solenoid
opens
Comp. A1 not allowed
to start
Manual
Faulty oil solenoid valve.
80
Alarm
Compressor A2 failed oil
solenoid
Diff. oil pressure > 17 kPa
during period after oil pump
starts and before oil solenoid
opens
Comp. A2 not allowed
to start
Manual
Faulty oil solenoid valve.
81
Alarm
Compressor B1 failed oil
solenoid
Diff. oil pressure > 17 kPa
during period after oil pump
starts and before oil solenoid
opens
Comp. B1 not allowed
to start
Manual
Faulty oil solenoid valve.
82
Alarm
Compressor B2 failed oil
solenoid
Diff. oil pressure > 17 kPa
during period after oil pump
starts and before oil solenoid
opens
Comp. B2 not allowed
to start
Manual
Faulty oil solenoid valve.
Legend:
CPM: Compressor Protection Module
FSM: Flotronic™ System Manager
PS: Power supply
WSM: Water System Manager
MTA: Compressor Must Trip Amps.
55
Low oil pressure alert criteria and setpoints
(Alert 40 to 43)
Two oil pressure setpoints are used. Oil setpoint 1 and oil setpoint 2.
Oil setpoint 1 (oil pressure differential Po - Pe) is calculated as
follows:
30HXC
Oil setpoint 1 = 70 kPa if saturated suction pressure ≤ 240 kPa
Oil setpoint 1 = 86 kPa if saturated suction pressure > 240 kPa
but < 450 kPa
Oil setpoint 1 = 100 kPa if saturated suction pressure > 450 kPa.
30GX
Oil setpoint 1 = 70 kPa for all saturated suction pressure
Oil setpoint 2 (oil pressure differential Po - Ps) changes as a
function of the operating conditions (compressor pressure
differential).
The curve below gives the minimum oil pressure differential
corresponding to oil setpoint 2.
The two setpoints are used by the control for the low oil pressure
alert trip criteria below:
1. Oil Pressure is ignored during the first five seconds after a
compressor is started.
2. In period between 5 and 30 seconds after starting, the alert
will be generated if (Po - Pe) < [(Oil Setpoint 1)/30]* (Compressor
run time in seconds) for 3 consecutive readings.
3. After 30 seconds run time, the alert will be generated if:
a. (Po - Pe) < oil setpoint 1 fot 15 seconds OR
b. (Po - Ps) < oil setpoint 2 fot 15 seconds
Where Pd = Discharge pressure, Ps = Suction pressure, Po = Oil
pressure and Pe = Economizer pressure
NOTE
(Po - Pe) is the Oil pressure differential displayed in <3>
<STAT> for Circuit A and <5> <STAT> for circuit B.
Minimum oil pressure vs compressor pressure differential
OIL SETPOINT 2
OIL PRESSURE DIFFERENTIAL, Po - Ps (kPa)
1400
1200
1000
800
600
400
200
0
500
1000
1500
COMPRESSOR PRESSURE DIFFERENTIAL, Pd - Ps (kPa)
56
2000
MAINTENANCE
To add charge to the 30HXC systems
Refrigerant Charging - Adding Charge
1. Make sure that the unit is running at full-load, and that the cooler
leaving fluid temperature is in the range of 5.6 - 7.8 °C.
IMPORTANT
These units are designed for use with R-134a only. DO NOT
USE ANY OTHER refrigerant in these units.
CAUTION
When adding or removing charge, circulate water through the
condenser (HX) and cooler at all times to prevent freezing.
Freezing damage is considered abuse and may void the Carrier
warranty.
CAUTION
DO NOT OVERCHARGE system. Overcharging results in
higher discharge pressure with higher cooling fluid
consumption, possible compressor damage and higher power
consumption.
Indication of low charge on a 30HXC system
NOTE
To check for low refrigerant charge on a 30HXC, several factors
must be considered. A flashing liquid-line sightglass is not
necessarily an indication of inadequate charge. There are many
system conditions where a flashing sightglass occurs under
normal operation. The 30HXC metering device is designed to
work properly under these conditions.
1. Make sure that the circuit is running at a full-load condition.
To check whether circuit A is fully loaded, enter <3> <STAT>
on the HSIO keypad. The display will read “CIRCUIT A
ANALOGUE VALUES”. Using the down arrow key on the
keypad, scroll down once to “Total Capacity”. If this value is
100 %, the circuit is at full-load. To check circuit B, follow
the same procedure, but enter <5> <STAT> on the keypad.
2. It may be necessary to use the Manual Control feature to force
the circuit into a full-load condition. If this is the case, see the
instructions for using the Manual Control feature (Keypad
Directory) <8> <SRVC>.
3. With the circuit running at full-load, verify that the cooler
leaving fluid temperature is in the range of 5.6 - 7.8 °C.
4. At this condition, observe the refrigerant in the liquid line
sightglass. If there is a clear sightglass, and no signs of
flashing, then the circuit is adequately charged. Skip the
remaining steps.
5. If the refrigerant appears to be flashing, the circuit is probably
low on charge. Verify this by checking the EXV Percent Open.
This information can be accessed by entering <3> <STAT>
on the HSIO keypad for circuit A, or <5> <STAT> for circuit
B. Scroll down using the down arrow key on the keypad, until
EXV Percent Open is displayed.
6. If the EXV Percent Open is greater than 60 %, and the liquidline sightglas is flashing, then the circuit is low on charge.
Follow the procedure for adding charge.
2. At these operating conditions, check the liquid-line sightglass.
If there is a clear sightglass, then the unit has sufficient charge.
If the sightglass is flashing, then check the EXV Percent Open.
If this is greater than 60 %, then begin adding charge.
NOTE
A flashing liquid-line sightglass at operating conditions other
than those mentioned above is not necessarily an indication of
low refrigerant charge.
3. Add 2.5 kg of liquid charge into the cooler using the charging
valve located on the top of the cooler.
4. Observe the EXV Percent Open value. The EXV should begin
closing as charge is being added. Allow the unit to stabilize. If
the EXV Percent Open remains above 60 %, and the sightglass
continues flashing, add an additional 2.5 kg of liquid charge.
5. Allow the unit to stabilize, and again check the EXV Percent
Open. Continue adding 2.5 kg of liquid refrigerant charge at
a time, and allow the unit to stabilize before checking the
EXV position.
6. When the EXV Percent Open is in the range of 40 - 60 %,
check the liquid line sightglass. Slowly add enough additional
liquid charge to ensure a clear sightglass. This should be done
slowly to avoid overcharging the unit.
7. Verify adequate charge by continuing to run at full-load with
5.6 - 7.8 °C cooler leaving fluid temperature. Check that the
refrigerant is not flashing in the liquid-line sightglass. The
EXV Percent Open should be between 40 and 60 %. The cooler
level indicator should be in the range of 1.5 - 2.5.
Indication of low charge on 30GX systems
1. Make sure that the circuit is running at a full-load condition
and all condenser fans are energized and running at full speed.
To check whether circuit A is fully-loaded, enter <3> <STAT>
on the HSIO keypad. The display will read “CIRCUIT A
ANALOGUE VALUES”. Using the down arrow key on the
keypad, scroll down once to “Total Capacity”. If this value is
100 %, the circuit is at full-load. To check circuit B, follow
the same procedure, but enter <5> <STAT> on the keypad.
2. It may be necessary to use the Manual Control feature to force
the circuit into a full-load condition. If this is the case, see the
instructions for using the Manual Control feature (Keypad
Directory) <8> <SRVC>.
3. With the circuit running at full-load, verify that the cooler
leaving fluid temperature is in the range of 5.6 - 7.8 °C.
4. Measure the air temperature entering the condenser coils.
Measure the liquid temperature after the tee where the two
coil liquid lines join. The liquid temperature should be 8.3°C
above the air temperature entering the coils. If the difference
is more than this and the sightglass is flashing, the circuit is
uncharged. Proceed to step 5.
57
5. Add 2.5 kg of liquid charge into the cooler using charging
valve located in the top of the cooler.
6. Allow the system to stabilize and then recheck the liquid
temperature. Repeat step 5 as needed allowing the system to
stabilize between each charge addition. Slowly add charge as
the sightglass begins to clear to avoid overcharging.
Oll Charging - Low oil recharging
Addition of oil charge to 30HX/GX systems
1. If the 30HXC/GX unit shuts-off repeatedly on Low oil Level
(alarm number 71 or 72), this may be an indication of
inadequate oil charge. It could also mean simply that oil is in
the process of being reclaimed from the low-side of the system.
2. Begin by running the unit at full-load for an hour and a half.
It is recommended to use the Manual Control feature of the
software if the unit does not normally run at full load.
3. After running for 1-1/2 hours allow the unit to re-start and
run normally. If the Low Oil Level alarms persist, continue
following this procedure.
4. Stop the unit, and jumper the oil level safety switch. This is
done by placing a jumper wire between channel 14 (J9) for
circuit A, or channel 15 (J9) for circuit B on the basic board.
5. Close the liquid-line service valve, and place a pressure gauge
on top of the cooler. Enable the manual control feature using
the HSIO keypad, and turn the LOR switch to local. Start the
desired compressor by pressing <1> <ENTER> on the keypad,
at the appropriate line on the display.
6. Before starting the compressor, the unit will go through its normal
pre-lube pump routine. If there is an insufficient level of oil in
the oil separator, the compressor will not start, and a Pre-start
oil pressure alarm will be posted. Skip to step number 9.
7. If the compressor starts successfully, keep an eye on the cooler
pressure gauge. When this gauge reads approximately 70 kPa,
press <0> <ENTER> on the HSIO keypad, and move the LOR
switch to the off position.
8. Open the liquid-line service valve and allow the unit to restart and run normally: if the Low Oil Level alarms persist,
continue following this procedure.
9. If none of the previous steps were successful, the unit is low
on oil charge. Add oil to the oil separator using the oil charging
valve on the top of the condenser (30HXC) or on the top of
the oil separator (30GX).
CAUTION
Do NOT add oil at any other location as improper unit operation
may result.
10. Make sure that the unit is not running when adding oil, as this
will make the oil charging process easier. Because the system
is under pressure even when the unit is not running, it will be
necessary to use a suitable pump (hand or electric pump) to
add oil to the system.
58
11. Using a suitable pump, add 2 liters of Polyolester oil to the
system (CARRIER SPEC: PP47-32). Make sure that the oil
level safety switch is NOT jumpered, and allow the unit to restart and run normally.
12. If low oil level problems persist, add another 2 liters of oil.
Continue adding oil in 2 l increments until the problem is
resolved. If it is necessary to add more than 6 liters of oil to
the system, then contact your Carrier distributor service
department.
Integral oil filter change
An integral oil filter in the 06N screw compressor is specified to
provide a high level of filtration (3 µ) required for long bearing
life. As system cleanliness is critical to reliable system operation,
there is also a prefilter (12 µ) in the oil line just before entering
the integral compressor filter.
The replacement integral oil filter element part number is:
Carlyle part number:
8TB0320
Parker part number:
932777Q
An alternate filter element is:
Carrier part number:
KH39MG001
Parker part number:
931984
Filter Change-Out schedule
The filter should be checked after the first 1000 hours of operation,
and every subsequent 4000 hours. The filter should be replaced
at any time when the pressure differential across the filter exceeds
2.1 bar.
The pressure drop across the filter can be determined by measuring
the pressure at the filter service port and the oil pressure port.
The difference in these two pressures will be the pressure drop
across the filter, check valve, and solenoid valve. The pressure
drop across the check valve and solenoid valve is approximately
0.4 bar, which should be subtracted from the two oil pressure
measurements to give the oil filter pressure drop. The oil filter
pressure drop should be checked after any occasion that the
compressor is shut down on a low oil pressure safety.
Filter Change-Out Procedure
The following steps outline the proper method of changing the
integral oil filter.
1. Shutdown and lockout the compressor.
2. Close the oil filter service valve. Bleed pressure from the filter
cavity through the filter service port.
3. Remove the oil filter plug. Remove the old oil filter.
4. Prior to installing the new oil filter, “wet” the o-ring with oil.
Install the filter and replace the plug.
Before closing up the lube oil system, take the opportunity to
replace the prefilter, as well.
5. When complete, evacuate the filter cavity through the filter
service port. Open the filter service valve. Remove any
compressor lockout devices, the compressor is ready to return
to operation.
The replacement pre-filter element part number is:
Carrier part number: XW12EA015
Service replacement compressor
EXV Troubleshooting Procedure
Compressor rotation control
Follow steps below to diagnose and correct EXV/
Economizer problems.
Correct compressor rotation is one of the most critical application
considerations. Reverse rotation, even for a very short duration,
can seriously affect the reliability of the compressor.
The reverse rotation protection scheme must be capable of
determining the direction of rotation and stopping the compressor
within 300 milliseconds.
Reverse rotation is most likely to occur whenever the wiring to
the compressor terminals is disturbed.
To minimize the opportunity for reverse rotation, the following
procedure must be applied. Rewire the power cables to the
compressor terminal pin as originally wired.
For service replacement compressor, a low pressure switch is
included with the compressor. This low pressure switch should
be temporarily installed as a hard safety on the high pressure part
of the compressor. The purpose of this switch is to protect the
compressor against any wiring errors at the compressor terminal
pin. The electrical contact of the switch would be wired in series
with the high pressure switch. The switch will remain in place
until the compressor has been started and direction of rotation
has been verified; at this point, the switch will be removed and
discarded.
On 30HXC/GX units with economizers, verify that the valve for
the bubbler tube (bottom of Economizer) is open. Check EXV
motor operation first. Press <4> <TEST> on the HSIO keypad
and select the appropriate EXV. Press <1> <ENTER> to move
the valve to 25 %. You should be able to feel the actuator moving
by placing your hand on the EXV or economizer body (the
actuator is located about one-half to two-thirds of the way up
from the bottom of the economizer shell). Repeat pressing <1>
<ENTER> three more times until the display reads 100 % for a
target percent (waiting until actuator stops each time). You should
feel a hard knocking come from the actuator when it reaches the
top of its stroke (can be heard if surroundings are relatively quiet).
Press <1> <ENTER> again if necessary to confirm this. Press
<0> <ENTER> four times to step the actuator closed in 25 %
increments, waiting again in between each move. The actuator
should knock when it reaches the bottom of its stroke. If it is
believed that the valve is not working properly, contact your
Carrier service department for further checks on:
• output signals on EXV module
• wire connections (continuity and tight connection at all pin
terminals)
• resistance of the EXV motor windings.
The switch that has been selected for detecting reverse rotation is
Carrier part number HK01CB001. This switch opens the contacts
when the pressure falls below 50 mm of vacuum. The switch is a
manual reset type that can be reset after the pressure has once
again risen above 70 kPa. It is critical that the switch be a manual
reset type to preclude the compressor from short cycling in the
reverse direction.
59
START-UP CKECKLIST FOR 30HXC/GX LIQUID CHILLERS (USE FOR JOB FILE)
Preliminary information
Job name: ................................................................................................................................................................................................
Location: .................................................................................................................................................................................................
Installing contractor: ...............................................................................................................................................................................
Distributor:..............................................................................................................................................................................................
Start-up preformed by: ...........................................................................................................................................................................
Equipment
Model: ............................................................................................. S/N ..............................................................................................
Compressors
Circuit A
1. Model # ......................................................................................
S/N .............................................................................................
Mtr # ...........................................................................................
Circuit B
1. Model # .................................................................................
S/N ..............................................................................................
Mtr # ...........................................................................................
2. Model # ...................................................................................... 2. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
Mtr # ........................................................................................... Mtr # ...........................................................................................
Cooler
Model # ........................................................................................... Manufactured by .........................................................................
S/N .................................................................................................. Date .............................................................................................
Condenser (30HXC)
Model # ........................................................................................... Manufactured by .........................................................................
S/N .................................................................................................. Date .............................................................................................
Air handling equipment
Manufacturer ..........................................................................................................................................................................................
Model # ........................................................................................... S/N ..............................................................................................
Additional air handling units and accessories ........................................................................................................................................
................................................................................................................................................................................................................
Preliminary equipment check
Is there any shipping damage ?....................................................... If so, where ? ...............................................................................
................................................................................................................................................................................................................
Will this damage prevent unit start-up ? .................................................................................................................................................
Unit is level in its installation
Power supply agrees with the unit nameplate
Electrical circuit wiring has been sized and installed properly
Unit ground wire has been connected
Electrical circuit protection has been sized and installed properly
All terminals are tight
All cables and thermistors have been inspected for crossed wires
All plug assemblies are tight
Check air handling systems
All air handlers are operating
All chilled water valves are open
All fluid piping is connected properly
All air has been vented from the system
Chilled water pump (CWP) is operating with the correct rotation. CWP amperage: Rated: ............. Actual ...............
60
Check condenser system (30HXC)
All condenser water valves are open
All condenser piping is connected properly
All air has been vented from the system
Condenser water pump (CWP) is operating with the correct rotation.
Condenser water pump amperage: Rated: ................... Actual ........................
Unit start-up
CWP starter has been properly interlocked with the chiller
Oil heaters have been energized for at least 24 hours (30GX)
Oil level is correct
All discharge and liquid valves are open
All suction valves are open, if equipped
All oil line valves and economizer discharge bubbler valves (30HXC only if equipped) are open
Unit has been leak checked (including swagelock fittings)
Locate, repair, and report any refrigerant leaks
................................................................................................................................................................................................................
................................................................................................................................................................................................................
................................................................................................................................................................................................................
Check voltage imbalance: AB ..................
Average voltage = .....................................
Maximum deviation = ..............................
Voltage imbalance = .................................
AC ................. BC .................
(see installation instructions)
(see installation instructions)
(see installation instructions)
Voltage imbalance is less than 2 %
WARNING
Do not start chiller if voltage imbalance is greater than 2 %. Contact local power company for assistance.
All incoming power voltage is within rated voltage range
Check cooler water loop
Water loop volume = ................................ (liters)
Calculated volume = ................................. (liters)
3.25 liters/nominal kW capacity for air conditioning
6.5 liters/nominal kW capacity for process cooling
Proper loop volume established
Proper loop corrosion inhibitor included .............. liters of ...........................
Proper loop freeze protection included (if required) .........................liters of .............................
Piping includes electric heater tape, if exposed to the outside
Inlet piping to cooler includes a 40 mesh strainer
Check pressure drop across the cooler
Entering cooler = ...................................... (kPa)
Leaving cooler = ....................................... (kPa)
(Leaving - entering) = ............................... (kPa)
WARNING
Plot cooler pressure drop on performance data chart (in product data literature) to determine total liters per second (l/s) and find
unit's minimum flow rate.
Total l/s = ..................................................
l/s / nominal kW = ....................................
Total l/s is greater than unit's minimum flow rate
Total l/s meets job specified requirement of .......................................... (l/s)
Check condenser water loop
Proper loop corrosion inhibitor included .............. liters of ...........................
Inlet piping to condenser includes a 40 mesh strainer
61
Check pressure drop across the condenser (30HXC only)
Entering condenser = ................................ (kPa)
Leaving condenser = ................................. (kPa)
(Leaving - entering) = ............................... (kPa)
WARNING
Plot condenser pressure drop on performance data chart (in product data literature) to determine total liters per second (l/s) and
find unit's minimum flow rate.
Total l/s = ..................................................
l/s / nominal kW = ....................................
Total l/s is greater than unit's minimum flow rate
Total l/s meets job specified requirement of .......................................... (l/s)
Perform TEST function (indicate positive result):
WARNING
Once power is supplied to the unit, check the display for any alarms, such as phase reversal. Follow the TEST function instructions
in the Controls and Troubleshooting literature.
Be sure all service valves are open before beginning the compressor test section. Items marked with"†" will indicate "ABSENT"
unless A2 or B2 compressors are present.
<1> <TEST/ALRM>
Loader A1
Loader A2
Minimum load valve A (FIOP)
Circuit A oil heater (30GX only)
A1 motor cooling solenoid
A2 motor cooling solenoid †
Circuit A oil pump
Oil solenoid A1
Oil solenoid A2 †
<3> <TEST/ALRM>
Fan 1 (30GX only)
Fan 2 (30GX only)
Fan 3 (30GX only)
Cooler pump
Condenser pump
Cooler heater (30GX only)
Alarm relay
<2> <TEST/ALRM>
Loader B1
Loader B2
Minimum load valve B (FIOP)
Circuit B oil heater (30GX only)
B1 motor cooling solenoid
B2 motor cooling solenoid †
Circuit B oil pump
Oil solenoid B1
Oil solenoid B2 †
Fan 4 (30GX only)
Fan 5 (30GX only)
Fan 6 (30GX only)
<4> <TEST/ALRM>
Circuit A EXV valve
Circuit B EXV valve
Circuit A water valve (if installed, 30HXC only)
Circuit A % fan speed (if installed, 30GX only)
Circuit B % fan speed (if installed, 30GX only)
Check for communicating modules (blinking red and green lights)
Correct fluid set points are entered
<1> <SET>
Cool setpoint 1
Cool setpoint 2
Correct date and time is set (<4> <SET>)
Review and record factory/service configuration codes
<5> <SRVC>
Configuration code 1: ......................................
Configuration code 2: ......................................
Configuration code 3: ......................................
Configuration code 4: ......................................
Configuration code 5: ......................................
Review and record software version, <1> <SRVC>
Software version CESR500100 version
62
Review and record field configuration, <2> <SRVC>
External reset sensor ...................................................................
Cooler pump interlock ................................................................
Cooler pump control ...................................................................
Condenser pump control* ...........................................................
Condenser flow switch* ..............................................................
Condenser water sensors* ...........................................................
Cooler fluid select ...........................................................................
Minimum load select ......................................................................
Loading sequence select .................................................................
Lead/lag sequence select ................................................................
Head pressure control .....................................................................
Motormaster select* ....................................................................... *If installed
Water valve type* ...........................................................................
To start the chiller
WARNING
Be sure that all service valves are open, and all pumps are on before attempting to start this machine. Once all checks have been
made, move the switch to "LOCAL" or "REMOTE" from "OFF".
Unit starts and operates properly
Temperatures and pressures
WARNING
Once the machine has been operating for a while and the temperatures and pressures have stabilized, record the following
Cooler EWT .................................................................................... Ambient temperature (GX) .........................................................
Cooler LWT .................................................................................... Condenser EWT ..........................................................................
Condenser LWT ..........................................................................
Circuit A oil pressure ......................................................................
Circuit A suction pressure ..............................................................
Circuit A discharge temperature .....................................................
Circuit A suction temperature .........................................................
Circuit A discharge pressure ...........................................................
Circuit A liquid line temperature ....................................................
Circuit B oil pressure ..................................................................
Circuit B suction pressure ...........................................................
Circuit B suction temperature .....................................................
Circuit B discharge pressure .......................................................
Circuit B discharge temperature .................................................
Circuit B liquid line temperature ................................................
NOTES:
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63
BP 49 Route de Thil
01122 MONTLUEL - FRANCE
Tel: 04 72 25 21 21
Telex: 900386
Fax: 04 72 25 22 51
Order No: 13173-76, March 1997 - Supersedes No: 13173-76, November 1996
Printed in the Netherlands on chlorine-free paper.
Manufacturer reserves the right to change any product specifications without notice.
Manufacturer: Carrier s.a., Montluel, France.