Carrier AQUAFORCE 30XA280 Controls, Start-Up, Operation, Service And Troubleshooting Instructions
Mainos
Mainos
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300091-01 Printed in U.S.A. Form 30XA-4T Pg 1 612 10-11 Replaces: 30XA-3T
Controls, Start-Up, Operation, Service
and Troubleshooting
CONTENTS Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .2,3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Conventions Used in This Manual . . . . . . . . . . . . . . . . 3
Display Module Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• TOUCH PILOT™ DISPLAY
• NAVIGATOR™ DISPLAY MODULE
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor Protection Module (CPM) . . . . . . . . . . . 9
Electronic Expansion Valve (EXV) Board . . . . . . . . . 9
Fan Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Enable-Off-Remote Contact Switch (SW1) . . . . . . . 17
Emergency On/Off Switch (SW2) . . . . . . . . . . . . . . . . 17
Energy Management Module (EMM) . . . . . . . . . . . . . 17
Hot Gas Bypass/Pump Board . . . . . . . . . . . . . . . . . . . 17
Local Equipment Network . . . . . . . . . . . . . . . . . . . . . . . 19
Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Touch Pilot Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Module Communication. . . . . . . . . . . . . . . . . 19
• RED LED
• GREEN LED
• YELLOW LED
Carrier Comfort Network® (CCN) Interface. . . . . . . 20
Remote Alarm and Alert Relays . . . . . . . . . . . . . . . . . 20
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-59
Touch Pilot Operation Configuration Tables . . . . . 21
Machine Control Methods . . . . . . . . . . . . . . . . . . . . . . . 22
Machine On/Off Control . . . . . . . . . . . . . . . . . . . . . . . . . 22
• TOUCH PILOT MACHINE CONTROL
• NAVIGATOR DISPLAY MACHINE CONTROL
Fluid Set Point Control Location . . . . . . . . . . . . . . . . 27
Cooling Set Point Selection . . . . . . . . . . . . . . . . . . . . . 27
• SET POINT OCCUPANCY
Chilled Water Fluid Type Selection . . . . . . . . . . . . . . 28
• FRESH WATER
• BRINE OR GLYCOL OPERATION
Cooler Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
• NO PUMP CONTROL
• SINGLE PUMP CONTROL
• DUAL PUMP AND MANUAL CONTROL
Machine Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit/Compressor Staging and Loading . . . . . . . 31
• CIRCUIT/COMPRESSOR STAGING
• CIRCUIT/COMPRESSOR LOADING
Minimum Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
• DUAL CHILLER CONTROL FOR PARALLEL
APPLICATIONS
• DUAL CHILLER PUMP CONTROL FOR PARALLEL
CHILLER APPLICATIONS
Page
• DUAL CHILLER CONTROL FOR SERIES
APPLICATIONS
• DUAL CHILLER PUMP CONTROL FOR SERIES
CHILLER APPLICATIONS
Night Time/Low Noise Applications . . . . . . . . . . . . . 37
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• RETURN WATER RESET
• OUTSIDE AIR TEMPERATURE RESET
• SPACE TEMPERATURE RESET
• 4-20 mA TEMPERATURE RESET
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• SWITCH CONTROLLED DEMAND LIMIT
• EXTERNALLY POWERED CAPACITY BASED
DEMAND LIMIT
• EXTERNALLY POWERED CURRENT BASED
DEMAND LIMIT
• CCN LOADSHED CONTROLLED DEMAND LIMIT
Ice Storage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Broadcast Configuration . . . . . . . . . . . . . . . . . . . . . . . . 46
• ACTIVATE
• OAT BROADCAST
• BROADCAST ACKNOWLEDGER
Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
• ALARM ROUTING CONTROL
• ALARM EQUIPMENT PRIORITY
• COMMUNICATION FAILURE RETRY TIME
• RE-ALARM TIME
• ALARM SYSTEM NAME
Daylight Saving Time Configuration. . . . . . . . . . . . . 47
Capacity Control Overrides . . . . . . . . . . . . . . . . . . . . . 47
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 50
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPTION
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPERATING INSTRUCTIONS
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-67
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
• TEMPERATURES
• VOLTAGE
• MINIMUM FLUID LOOP VOLUME
• FLOW RATE REQUIREMENTS
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-74
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 67
• ACTUATED BALL VALVE (ABV), FLOODED
COOLER ONLY
Dual Chiller Sequence of Operation . . . . . . . . . . . . . 68
• PUMP OPERATION
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
• THERMISTORS
• TRANSDUCERS
AQUAFORCE®
30XA080-500
Air-Cooled Liquid Chillers
Catalog No. 04-53300091-01 Printed in U.S.A. Form 30XA-4T Pg 1 612 10-11 Replaces: 30XA-3T
Controls, Start-Up, Operation, Service
and Troubleshooting
CONTENTS Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .2,3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Conventions Used in This Manual . . . . . . . . . . . . . . . . 3
Display Module Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• TOUCH PILOT™ DISPLAY
• NAVIGATOR™ DISPLAY MODULE
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor Protection Module (CPM) . . . . . . . . . . . 9
Electronic Expansion Valve (EXV) Board . . . . . . . . . 9
Fan Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Enable-Off-Remote Contact Switch (SW1) . . . . . . . 17
Emergency On/Off Switch (SW2) . . . . . . . . . . . . . . . . 17
Energy Management Module (EMM) . . . . . . . . . . . . . 17
Hot Gas Bypass/Pump Board . . . . . . . . . . . . . . . . . . . 17
Local Equipment Network . . . . . . . . . . . . . . . . . . . . . . . 19
Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Touch Pilot Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Module Communication. . . . . . . . . . . . . . . . . 19
• RED LED
• GREEN LED
• YELLOW LED
Carrier Comfort Network® (CCN) Interface. . . . . . . 20
Remote Alarm and Alert Relays . . . . . . . . . . . . . . . . . 20
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-59
Touch Pilot Operation Configuration Tables . . . . . 21
Machine Control Methods . . . . . . . . . . . . . . . . . . . . . . . 22
Machine On/Off Control . . . . . . . . . . . . . . . . . . . . . . . . . 22
• TOUCH PILOT MACHINE CONTROL
• NAVIGATOR DISPLAY MACHINE CONTROL
Fluid Set Point Control Location . . . . . . . . . . . . . . . . 27
Cooling Set Point Selection . . . . . . . . . . . . . . . . . . . . . 27
• SET POINT OCCUPANCY
Chilled Water Fluid Type Selection . . . . . . . . . . . . . . 28
• FRESH WATER
• BRINE OR GLYCOL OPERATION
Cooler Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
• NO PUMP CONTROL
• SINGLE PUMP CONTROL
• DUAL PUMP AND MANUAL CONTROL
Machine Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit/Compressor Staging and Loading . . . . . . . 31
• CIRCUIT/COMPRESSOR STAGING
• CIRCUIT/COMPRESSOR LOADING
Minimum Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
• DUAL CHILLER CONTROL FOR PARALLEL
APPLICATIONS
• DUAL CHILLER PUMP CONTROL FOR PARALLEL
CHILLER APPLICATIONS
Page
• DUAL CHILLER CONTROL FOR SERIES
APPLICATIONS
• DUAL CHILLER PUMP CONTROL FOR SERIES
CHILLER APPLICATIONS
Night Time/Low Noise Applications . . . . . . . . . . . . . 37
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• RETURN WATER RESET
• OUTSIDE AIR TEMPERATURE RESET
• SPACE TEMPERATURE RESET
• 4-20 mA TEMPERATURE RESET
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• SWITCH CONTROLLED DEMAND LIMIT
• EXTERNALLY POWERED CAPACITY BASED
DEMAND LIMIT
• EXTERNALLY POWERED CURRENT BASED
DEMAND LIMIT
• CCN LOADSHED CONTROLLED DEMAND LIMIT
Ice Storage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Broadcast Configuration . . . . . . . . . . . . . . . . . . . . . . . . 46
• ACTIVATE
• OAT BROADCAST
• BROADCAST ACKNOWLEDGER
Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
• ALARM ROUTING CONTROL
• ALARM EQUIPMENT PRIORITY
• COMMUNICATION FAILURE RETRY TIME
• RE-ALARM TIME
• ALARM SYSTEM NAME
Daylight Saving Time Configuration. . . . . . . . . . . . . 47
Capacity Control Overrides . . . . . . . . . . . . . . . . . . . . . 47
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 50
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPTION
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPERATING INSTRUCTIONS
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-67
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
• TEMPERATURES
• VOLTAGE
• MINIMUM FLUID LOOP VOLUME
• FLOW RATE REQUIREMENTS
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-74
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 67
• ACTUATED BALL VALVE (ABV), FLOODED
COOLER ONLY
Dual Chiller Sequence of Operation . . . . . . . . . . . . . 68
• PUMP OPERATION
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
• THERMISTORS
• TRANSDUCERS
AQUAFORCE®
30XA080-500
Air-Cooled Liquid Chillers
2
CONTENTS (cont)
Page
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-87
Economizer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 74
• FLOODED COOLER MAIN EXV CONTROL
• DX COOLER MAIN EXV CONTROL
• ECONOMIZER EXV CONTROL
• EXV TROUBLESHOOTING PROCEDURE
Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 77
• COMPRESSOR OIL SYSTEM
Flooded Cooler Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
• FLOODED COOLER SUCTION SERVICE VALVE
• FLOODED COOLER FREEZE PROTECTION
• FLOODED COOLER LOW FLUID TEMPERATURE
• FLOODED COOLER LOSS OF FLUID FLOW
PROTECTION
• FLOODED COOLER TUBE PLUGGING
• FLOODED COOLER RETUBING
• FLOODED COOLER TIGHTENING COOLER HEAD
BOLTS
• FLOODED COOLER INSPECTING/CLEANING
HEAT EXHANGERS
• FLOODED COOLER WATER TREATMENT
DX Cooler Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• DX COOLER SUCTION SERVICE VALVE
• DX COOLER FREEZE PROTECTION
• DX COOLER LIQUID FLUID TEMPERATURE
• DX COOLER LOSS OF FLUID FLOW PROTECTION
• DX COOLER TUBE PLUGGING
• DX COOLER RETUBING
• DX COOLER TIGHTENING COOLER HEAD BOLTS
• DX COOLER CHILLED WATER FLOW SWITCH
DX Cooler and Flooded Cooler Units . . . . . . . . . . . . 84
• PREPARATION FOR WINTER SHUTDOWN
Microchannel Heat Exchanger (MCHX) Condenser
Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RTPF Condenser Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
• REMOVE SURFACE LOADED FIBERS
• PERIODIC CLEAN WATER RINSE
• ROUTINE CLEANING OF RTPF COIL SURFACES
Condenser Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Refrigerant Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
• LEAK TESTING
• REFRIGERANT CHARGE
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• COMPRESSOR PROTECTION
• OIL SEPARATOR HEATERS
• COOLER PROTECTION
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• PRESSURE RELIEF VALVES
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87,88
Recommended Maintenance Schedule . . . . . . . . . . 87
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . 88-109
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
• DIAGNOSTIC ALARM CODES AND POSSIBLE
CAUSES
Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
APPENDIX A — TOUCH PILOT™
DISPLAY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . 110-127
APPENDIX B — NAVIGATOR™
DISPLAY TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . 128-141
APPENDIX C — CCN TABLES . . . . . . . . . . . . . . 142-156
APPENDIX D — 30XA080-500 CPM
DIP SWITCH ADDRESSES. . . . . . . . . . . . . . . . 157-160
APPENDIX E — PIPING AND
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . 161-164
Page
APPENDIX F — MAINTENANCE SUMMARY
AND LOG SHEETS. . . . . . . . . . . . . . . . . . . . . . . . . . 165-167
APPENDIX G — BACNET COMMUNICATONS
OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168-178
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
START-UP CHECKLIST
FOR 30XA LIQUID CHILLERS . . . . . . . . CL-1 to CL-8
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, etc.). Only
trained, qualified installers and service technicians should
install, start up, and service this equipment. When working on
this equipment, observe precautions in the literature, on tags,
stickers, and labels attached to the equipment, and any other
safety precautions that apply. Follow all safety codes. Wear
safety glasses and work gloves. Use care in handling, rigging,
and setting this equipment, and in handling all electrical
components.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
WARNING
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented in accordance
with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigerating and Air Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and
cause asphyxiation. Provide adequate ventilation in
enclosed or low overhead areas. Inhalation of high concen-
trations of vapor is harmful and may cause heart irregulari-
ties, unconsciousness or death. Misuse can be fatal. Vapor
is heavier than air and reduces the amount of oxygen avail-
able for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.
WARNING
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig-
erant in contact with an open flame produces toxic
gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal
injury or death.
612
CONTENTS (cont)
Page
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-87
Economizer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 74
• FLOODED COOLER MAIN EXV CONTROL
• DX COOLER MAIN EXV CONTROL
• ECONOMIZER EXV CONTROL
• EXV TROUBLESHOOTING PROCEDURE
Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 77
• COMPRESSOR OIL SYSTEM
Flooded Cooler Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
• FLOODED COOLER SUCTION SERVICE VALVE
• FLOODED COOLER FREEZE PROTECTION
• FLOODED COOLER LOW FLUID TEMPERATURE
• FLOODED COOLER LOSS OF FLUID FLOW
PROTECTION
• FLOODED COOLER TUBE PLUGGING
• FLOODED COOLER RETUBING
• FLOODED COOLER TIGHTENING COOLER HEAD
BOLTS
• FLOODED COOLER INSPECTING/CLEANING
HEAT EXHANGERS
• FLOODED COOLER WATER TREATMENT
DX Cooler Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• DX COOLER SUCTION SERVICE VALVE
• DX COOLER FREEZE PROTECTION
• DX COOLER LIQUID FLUID TEMPERATURE
• DX COOLER LOSS OF FLUID FLOW PROTECTION
• DX COOLER TUBE PLUGGING
• DX COOLER RETUBING
• DX COOLER TIGHTENING COOLER HEAD BOLTS
• DX COOLER CHILLED WATER FLOW SWITCH
DX Cooler and Flooded Cooler Units . . . . . . . . . . . . 84
• PREPARATION FOR WINTER SHUTDOWN
Microchannel Heat Exchanger (MCHX) Condenser
Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RTPF Condenser Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
• REMOVE SURFACE LOADED FIBERS
• PERIODIC CLEAN WATER RINSE
• ROUTINE CLEANING OF RTPF COIL SURFACES
Condenser Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Refrigerant Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
• LEAK TESTING
• REFRIGERANT CHARGE
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• COMPRESSOR PROTECTION
• OIL SEPARATOR HEATERS
• COOLER PROTECTION
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• PRESSURE RELIEF VALVES
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87,88
Recommended Maintenance Schedule . . . . . . . . . . 87
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . 88-109
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
• DIAGNOSTIC ALARM CODES AND POSSIBLE
CAUSES
Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
APPENDIX A — TOUCH PILOT™
DISPLAY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . 110-127
APPENDIX B — NAVIGATOR™
DISPLAY TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . 128-141
APPENDIX C — CCN TABLES . . . . . . . . . . . . . . 142-156
APPENDIX D — 30XA080-500 CPM
DIP SWITCH ADDRESSES. . . . . . . . . . . . . . . . 157-160
APPENDIX E — PIPING AND
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . 161-164
Page
APPENDIX F — MAINTENANCE SUMMARY
AND LOG SHEETS. . . . . . . . . . . . . . . . . . . . . . . . . . 165-167
APPENDIX G — BACNET COMMUNICATONS
OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168-178
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
START-UP CHECKLIST
FOR 30XA LIQUID CHILLERS . . . . . . . . CL-1 to CL-8
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, etc.). Only
trained, qualified installers and service technicians should
install, start up, and service this equipment. When working on
this equipment, observe precautions in the literature, on tags,
stickers, and labels attached to the equipment, and any other
safety precautions that apply. Follow all safety codes. Wear
safety glasses and work gloves. Use care in handling, rigging,
and setting this equipment, and in handling all electrical
components.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
WARNING
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented in accordance
with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigerating and Air Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and
cause asphyxiation. Provide adequate ventilation in
enclosed or low overhead areas. Inhalation of high concen-
trations of vapor is harmful and may cause heart irregulari-
ties, unconsciousness or death. Misuse can be fatal. Vapor
is heavier than air and reduces the amount of oxygen avail-
able for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.
WARNING
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig-
erant in contact with an open flame produces toxic
gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal
injury or death.
612
3
GENERAL
This publication contains Controls, Operation, Start-Up,
Service and Troubleshooting information for the 30XA080-
500 air-cooled liquid chillers with electronic controls. The
30XA chillers are equipped with ComfortLink™ controls and
electronic expansion valves. The AquaForce® 30XA chillers
offer two different user interface devices, the Touch Pilot™
display and the Navigator ™ display.
Conventions Used in This Manual — The follow-
ing conventions for discussing configuration points for the
Navigator module and Touch Pilot display will be used in this
manual.
Point names for the Touch Pilot display will be shown in
bold. See Appendix A for a complete list of point names. Item
names for the Navigator module will be shown in bold italics.
See Appendix B for the complete path name preceeding the
item name. The point and item names in Appendices A and B
will be listed in alphabetical order and the path name for each
will be written with the mode name first, then any sub-modes,
each separated by an arrow symbol (.
This path name will show the user how to navigate through the
Navigator module or the Touch Pilot display to reach the desired
configuration. The user would scroll through the modes and
sub-modes using the and keys on the Navigator display.
For the Touch Pilot display, the user would simply touch the menu
item on the screen. The arrow symbol in the path name represents
pressing to move into the next level of the menu struc-
ture for the Navigator module, or touching the menu item on the
screen for the Touch Pilot display.
When a value is included as part of the point name, it will be
shown after the point name after an equals sign. If the value
represents a configuration setting, an explanation will be
shown in parentheses after the value. The Touch Pilot name
will be shown first with the Navigator name following. As an
example,
(Staged Loading Sequence = 1, LLCS = Circuit A leads).
Press the and keys simultaneously on
the Navigator module to display an expanded text description of
the point name or value. The expanded description is shown in the
Navigator display tables (Appendix B) but will not be shown with
the path names in text. The Touch Pilot display will show an
expanded description of the point name. To view the expanded
point name for the Touch Pilot display go to Appendix A.
The Touch Pilot display configures the unit via the CCN
(Carrier Comfort Network®) Tables, which are located in Ap-
pendix C of this manual.
Display Module Usage
TOUCH PILOT DISPLAY — The Touch Pilot display is the
standard user interface for the AquaForce 30XA chillers with
the ComfortLink control system. The display includes a large
LCD (liquid crystal display) touch screen for display and user
configuration, a Start/Stop button, and an Alarm Indicator LED
(light-emitting diode). See Fig. 1.
The Touch Pilot display can be used to access various
Carrier Comfort Network® devices. For operation under these
circumstances, contact your Carrier representative.
Operation of the Touch Pilot display is driven from the
displays on the touch screen. The Touch Pilot display uses the
following screen “buttons” to allow the user to operate the dis-
play and navigate within and between screens.
“BACK” Returns to the next higher screen in the
hierarchy.
“HOME” Displays the Default Group Display screen
for Touch Pilot display. The Default Screen is a user-
configured display of up to 9 points on each of 8 screens. This
allows for quick access to various, frequently viewed points,
without navigating through the Main Menu structure. This but-
ton is available at all menu levels and returns the user to the
first Default Group Display screen.
CAUTION
This unit uses a microprocessor-based electronic control
system. Do not use jumpers or other tools to short out com-
ponents, or to bypass or otherwise depart from recom-
mended procedures. Any short-to-ground of the control
board or accompanying wiring may destroy the electronic
modules or electrical components.
CAUTION
To prevent potential damage to heat exchanger tubes,
always run fluid through heat exchanger when adding or
removing refrigerant charge. Use appropriate antifreeze
solutions in cooler fluid loop to prevent the freezing of heat
exchanger or interconnecting piping when the equipment is
exposed to temperatures below 32 F (0° C). Proof of flow
switch is factory installed on all models. Do NOT remove
power from this chiller during winter shut down periods
without taking precaution to remove all water from heat
exchanger. Failure to properly protect the system from
freezing may constitute abuse and may void warranty.
CAUTION
Compressors require specific rotation. Test condenser
fan(s) first to ensure proper phasing. Swap any two incom-
ing power leads to correct condenser fan rotation before
starting compressors. Operating the unit without testing the
condenser fan(s) for proper phasing could result in equip-
ment damage.
CAUTION
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations. DO NOT leave refrigerant system open to
air any longer than the actual time required to service the
equipment. Seal circuits being serviced and charge with
dry nitrogen to prevent oil contamination when timely
repairs cannot be completed. Failure to follow these proce-
dures may result in damage to equipment.
ENTER
ESCAPE ENTER
START-STOP
BUTTON
LCD TOUCH SCREEN
ALARM
INDICATOR
LIGHT
Fig. 1 — Touch Pilot™ Display
Figure-1
612
GENERAL
This publication contains Controls, Operation, Start-Up,
Service and Troubleshooting information for the 30XA080-
500 air-cooled liquid chillers with electronic controls. The
30XA chillers are equipped with ComfortLink™ controls and
electronic expansion valves. The AquaForce® 30XA chillers
offer two different user interface devices, the Touch Pilot™
display and the Navigator ™ display.
Conventions Used in This Manual — The follow-
ing conventions for discussing configuration points for the
Navigator module and Touch Pilot display will be used in this
manual.
Point names for the Touch Pilot display will be shown in
bold. See Appendix A for a complete list of point names. Item
names for the Navigator module will be shown in bold italics.
See Appendix B for the complete path name preceeding the
item name. The point and item names in Appendices A and B
will be listed in alphabetical order and the path name for each
will be written with the mode name first, then any sub-modes,
each separated by an arrow symbol (.
This path name will show the user how to navigate through the
Navigator module or the Touch Pilot display to reach the desired
configuration. The user would scroll through the modes and
sub-modes using the and keys on the Navigator display.
For the Touch Pilot display, the user would simply touch the menu
item on the screen. The arrow symbol in the path name represents
pressing to move into the next level of the menu struc-
ture for the Navigator module, or touching the menu item on the
screen for the Touch Pilot display.
When a value is included as part of the point name, it will be
shown after the point name after an equals sign. If the value
represents a configuration setting, an explanation will be
shown in parentheses after the value. The Touch Pilot name
will be shown first with the Navigator name following. As an
example,
(Staged Loading Sequence = 1, LLCS = Circuit A leads).
Press the and keys simultaneously on
the Navigator module to display an expanded text description of
the point name or value. The expanded description is shown in the
Navigator display tables (Appendix B) but will not be shown with
the path names in text. The Touch Pilot display will show an
expanded description of the point name. To view the expanded
point name for the Touch Pilot display go to Appendix A.
The Touch Pilot display configures the unit via the CCN
(Carrier Comfort Network®) Tables, which are located in Ap-
pendix C of this manual.
Display Module Usage
TOUCH PILOT DISPLAY — The Touch Pilot display is the
standard user interface for the AquaForce 30XA chillers with
the ComfortLink control system. The display includes a large
LCD (liquid crystal display) touch screen for display and user
configuration, a Start/Stop button, and an Alarm Indicator LED
(light-emitting diode). See Fig. 1.
The Touch Pilot display can be used to access various
Carrier Comfort Network® devices. For operation under these
circumstances, contact your Carrier representative.
Operation of the Touch Pilot display is driven from the
displays on the touch screen. The Touch Pilot display uses the
following screen “buttons” to allow the user to operate the dis-
play and navigate within and between screens.
“BACK” Returns to the next higher screen in the
hierarchy.
“HOME” Displays the Default Group Display screen
for Touch Pilot display. The Default Screen is a user-
configured display of up to 9 points on each of 8 screens. This
allows for quick access to various, frequently viewed points,
without navigating through the Main Menu structure. This but-
ton is available at all menu levels and returns the user to the
first Default Group Display screen.
CAUTION
This unit uses a microprocessor-based electronic control
system. Do not use jumpers or other tools to short out com-
ponents, or to bypass or otherwise depart from recom-
mended procedures. Any short-to-ground of the control
board or accompanying wiring may destroy the electronic
modules or electrical components.
CAUTION
To prevent potential damage to heat exchanger tubes,
always run fluid through heat exchanger when adding or
removing refrigerant charge. Use appropriate antifreeze
solutions in cooler fluid loop to prevent the freezing of heat
exchanger or interconnecting piping when the equipment is
exposed to temperatures below 32 F (0° C). Proof of flow
switch is factory installed on all models. Do NOT remove
power from this chiller during winter shut down periods
without taking precaution to remove all water from heat
exchanger. Failure to properly protect the system from
freezing may constitute abuse and may void warranty.
CAUTION
Compressors require specific rotation. Test condenser
fan(s) first to ensure proper phasing. Swap any two incom-
ing power leads to correct condenser fan rotation before
starting compressors. Operating the unit without testing the
condenser fan(s) for proper phasing could result in equip-
ment damage.
CAUTION
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations. DO NOT leave refrigerant system open to
air any longer than the actual time required to service the
equipment. Seal circuits being serviced and charge with
dry nitrogen to prevent oil contamination when timely
repairs cannot be completed. Failure to follow these proce-
dures may result in damage to equipment.
ENTER
ESCAPE ENTER
START-STOP
BUTTON
LCD TOUCH SCREEN
ALARM
INDICATOR
LIGHT
Fig. 1 — Touch Pilot™ Display
Figure-1
612
4
“MAIN MENU” Displays the Main Menu screen.
This allows access for viewing and configuration,
where possible, of all points supported by the controller. This
includes points such as set point and operational configuration.
This button is available at all menu levels and returns the user
to the Main Menu screen.
“PREVIOUS” In a group of sequential screens of the
same type, pressing this button moves the user to the
next earlier screen in the group.
“NEXT” In a group of sequential screens of the same
type, pressing this button advances the user to the next
screen in the group.
“OK” Agrees with, or says “yes” to a prompt and per-
forms the appropriate processing.
“NO” Rejects, or says “no” to a prompt and performs
the appropriate processing.
“CANCEL” Terminates an ongoing action and returns
to the current screen without any other processing.
“CLEAR DATA” Clears the data value in a data entry
dialog box. This button is used to clear incorrect data.
“RESET DATA” Zeros the data value in a data entry
dialog box.
“ADD” Adds the active point to a Group Display
screen.
“REMOVE” Deletes a point from a Group Display
screen.
“INCREASE” Modifies the value of a field within its
defined limits or “SCROLL UP” and shifts the screen
view up by one item.
“DECREASE” Modifies the value of a field within its
defined limits or “SCROLL DOWN” and shifts the
screen view down by one item.
“PAGE DOWN” If the current table or list has more
data than will fit on the screen, pressing this button
will replace the items currently on the screen with the next
group of items.
“PAGE UP” If the current table or list has more data
than will fit on the screen, pressing this button will
replace the items currently on the screen with the previous
group of items.
“FORCE” Begins the process of forcing or overriding
the value of a point.
“AUTO” Begins the process of removing a force from
a point.
“MODIFY” Begins the process of modifying a con-
figuration value.
“ALARM INDICATOR LIGHT” An LED alarm
indicator light is activated when a new alarm condi-
tion occurs. The alarm indicator light, located on the
right side of the display, remains activated until it is manually
reset using the Reset button on the Main menu.
“START/STOP BUTTON” The Touch Pilot™ dis-
play includes an equipment Start/Stop Button that
enables the user to start or stop the chiller from the
display. See Enable-Off-Remote Contact Switch (SW1) on
page 17 for additional information.
Several items are password protected. When required, a
Password dialog box will be displayed for field input of the
password. The default password is 3333. The password can be
changed if desired.
Power-Up Display — When the Touch Pilot display is pow-
ered up, it displays an initialization progress bar and attaches
(initiates communication) to the Main Base Board. The Touch
Pilot display then shows that controller’s default Group Dis-
play screen. See Fig. 2. This is a user-configured display screen
with up to 9 points on 8 separate screens. For more information
on adding or removing points from the Group Display screen,
see the Group Display Screens section on page 6.
Touch any of the screen point buttons and Point Data Dialog
box will be displayed with expanded information. In the exam-
ple shown below, the CTRL_PNT button in the bottom left
corner was selected. See Fig. 2 and 3.
To exit the box, press .
Main Menu Display — The default screen for the Touch Pilot
controller is the Group Display screen. To access the Main
Menu, press the button. The screen shown in Fig. 4 will be
displayed. Selecting a button will display the screens associat-
ed with that category. The user can also access the login screen
from the Main Menu if needed.
Touch Pilot Menu Structure — The user can navigate through
the Touch Pilot display screens by selecting the buttons that ap-
pear on the screen. When a button is selected, either a sub-
menu or a list of point names and values will be shown. Sub-
menus will display a list of associated point names. See Fig. 5
for the Touch Pilot menu structure.
If the list of point names and values are shown, the top line
of the display is the table name. The line and total line counter
is displayed in the upper right corner of the display. Selecting
an item will cause a Point Data dialog box to appear.
Setup Menu Screen — The Setup Menu screen, shown in
Fig. 6, is accessed by pressing the Setup button from the Main
Menu. This configuration allows the user to configure the basic
operation and look of the display. Table 1 summarizes the Set-
up Menu functions.
Fig. 2 — Group Display Screen
Fig. 3 — Point Data Dialog Box
a30-4470
a30-4471
“MAIN MENU” Displays the Main Menu screen.
This allows access for viewing and configuration,
where possible, of all points supported by the controller. This
includes points such as set point and operational configuration.
This button is available at all menu levels and returns the user
to the Main Menu screen.
“PREVIOUS” In a group of sequential screens of the
same type, pressing this button moves the user to the
next earlier screen in the group.
“NEXT” In a group of sequential screens of the same
type, pressing this button advances the user to the next
screen in the group.
“OK” Agrees with, or says “yes” to a prompt and per-
forms the appropriate processing.
“NO” Rejects, or says “no” to a prompt and performs
the appropriate processing.
“CANCEL” Terminates an ongoing action and returns
to the current screen without any other processing.
“CLEAR DATA” Clears the data value in a data entry
dialog box. This button is used to clear incorrect data.
“RESET DATA” Zeros the data value in a data entry
dialog box.
“ADD” Adds the active point to a Group Display
screen.
“REMOVE” Deletes a point from a Group Display
screen.
“INCREASE” Modifies the value of a field within its
defined limits or “SCROLL UP” and shifts the screen
view up by one item.
“DECREASE” Modifies the value of a field within its
defined limits or “SCROLL DOWN” and shifts the
screen view down by one item.
“PAGE DOWN” If the current table or list has more
data than will fit on the screen, pressing this button
will replace the items currently on the screen with the next
group of items.
“PAGE UP” If the current table or list has more data
than will fit on the screen, pressing this button will
replace the items currently on the screen with the previous
group of items.
“FORCE” Begins the process of forcing or overriding
the value of a point.
“AUTO” Begins the process of removing a force from
a point.
“MODIFY” Begins the process of modifying a con-
figuration value.
“ALARM INDICATOR LIGHT” An LED alarm
indicator light is activated when a new alarm condi-
tion occurs. The alarm indicator light, located on the
right side of the display, remains activated until it is manually
reset using the Reset button on the Main menu.
“START/STOP BUTTON” The Touch Pilot™ dis-
play includes an equipment Start/Stop Button that
enables the user to start or stop the chiller from the
display. See Enable-Off-Remote Contact Switch (SW1) on
page 17 for additional information.
Several items are password protected. When required, a
Password dialog box will be displayed for field input of the
password. The default password is 3333. The password can be
changed if desired.
Power-Up Display — When the Touch Pilot display is pow-
ered up, it displays an initialization progress bar and attaches
(initiates communication) to the Main Base Board. The Touch
Pilot display then shows that controller’s default Group Dis-
play screen. See Fig. 2. This is a user-configured display screen
with up to 9 points on 8 separate screens. For more information
on adding or removing points from the Group Display screen,
see the Group Display Screens section on page 6.
Touch any of the screen point buttons and Point Data Dialog
box will be displayed with expanded information. In the exam-
ple shown below, the CTRL_PNT button in the bottom left
corner was selected. See Fig. 2 and 3.
To exit the box, press .
Main Menu Display — The default screen for the Touch Pilot
controller is the Group Display screen. To access the Main
Menu, press the button. The screen shown in Fig. 4 will be
displayed. Selecting a button will display the screens associat-
ed with that category. The user can also access the login screen
from the Main Menu if needed.
Touch Pilot Menu Structure — The user can navigate through
the Touch Pilot display screens by selecting the buttons that ap-
pear on the screen. When a button is selected, either a sub-
menu or a list of point names and values will be shown. Sub-
menus will display a list of associated point names. See Fig. 5
for the Touch Pilot menu structure.
If the list of point names and values are shown, the top line
of the display is the table name. The line and total line counter
is displayed in the upper right corner of the display. Selecting
an item will cause a Point Data dialog box to appear.
Setup Menu Screen — The Setup Menu screen, shown in
Fig. 6, is accessed by pressing the Setup button from the Main
Menu. This configuration allows the user to configure the basic
operation and look of the display. Table 1 summarizes the Set-
up Menu functions.
Fig. 2 — Group Display Screen
Fig. 3 — Point Data Dialog Box
a30-4470
a30-4471
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Carrier 30XA 080-500 Air-Cooled Liquid Chillers User Manual
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Carrier Air-Cooled Liquid Chillers 30XA 080-500 User Manual
