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Carrier 30RAP010-060 Air Conditioner User Manual

1. LOCATED OVER EMM AND i o TRAN E lo is J erig xs 8 Ao s DISCONNECT OPTION TB SP MS MS 220 CWP2 mI COMPRESSOR oa ru r EL USU CONTROL BOX ZE T n Q m H nci 5 eee e e EMM ee ccsa e
2. OPTIONAL CH A1 DISCONNECT TERMINAL Ee BLOCK 380 460 515 BLK CBIA 1 NL 1 1 Tm ack BLK 796 bu TH Hz0 7 TT 095 1 21 YEL 19679 00 vt COMP 1 LK Say 8 735 Sas Hai au cao iom YEL YEL YEL age Lolo Hi CH A2 292 E TE BLK BLU BLU BLK 8LU e 58 a 8LK 9 nav 2 BLU mE V C 1 t 1 BLU BLK a TH BLK TT 3 i BKL Ln 80 26 7 794 18 12 COMP 2 3 BLU C034 H13 T3 dm BLU GAN YEL EQUIP GND 208 2300 ONL zii i 8LU e su rd Mcd PEN ccg 290 480v 515 sce ONLY csp gi 1 RED BLK BLK BLK 7 TT 1 m YEL mKa ver 1 rp COMP B1 82 e BLU G34Hz3 Bl 3 Sin TRAN3 SECONDARY BLU BLK BLU e WHT 115V ME BLK e 4 CSB 82 1 BLK AN Fer BLK TT 5 GFI CO BLK gu coa a FIOP ACCESSORYE YEL G26 2 2 1 124 H22 YEL TA COMP B2 BLU 131 23 BLU T 3j EINE B
3. J10 J8 Fig 8 Main Base Board SN e QOOOOOQOOOQOOOO rw C7 CD I gt UU CONTOL amp sw S OFF ENABLE 2 OFF amp S eO Fig 9 Enable Off Remote Contact Switch and Emergency On Off Switch Locations SPT T10 PART NO See ISP pommes ees Bey pee j h ura 5 2 22 E mu Fig 10 Typical Space Temperature Sensor Wiring 28 T 55 SPACE SENSOR 6 CCN TO CCN CCN GND COMM 1 BUS PLUG AT UNIT CCN A O O QD Oli Fig 11 CCN Communications Bus Wiring to Optional Space Sensor RJ11 Connector Energy Management Module Fig 12 This factory installed option FIOP or field installed accessory is used for the following types of temperature reset demand limit and or ice features 4 t
4. D ea _ m uu afl bog 18 5 aa NEUE 792 WO FH loooloog ad Bg 3 5 a 5 SN SW 5 a B HSS val T B WE Se B oan 28852 o o o o o o 18 852 L 0 0 0 w ics 9 k 9 9 elelele elelo 82 dit eszme ey WW3 11 3 J fe SO O 23 OPTIONAL STANDARD DISCONNECT TERMINAL WA BLK e 380V 4607 5757 BlA CCB 1 ONLY 1 T BLK i K oT64 1 zx BLK 01H F20 BL
5. CEPL130351 01 TEST 1 GREEN LED LEN LOCAL EQUIPMENT NETWORK RED LED STATUS ADDRESS DIP SWITCH Fig 12 Energy Management Module LEAD LAG DETERMINATION This is a configurable choice and is factory set to be automatic for all units unless the unit is equipped with a digital scroll compressor or minimum load then circuit A is lead Configuration gt OPT2 gt LLCS The value can be changed to Circuit A or Cir
6. 110 113 START UP CHECKLIST FOR 30RAP LIQUID to CL 10 SAFETY CONSIDERATIONS Installing starting up and servicing this equipment can be hazardous due to system pressures electrical components and equipment location roof elevated structures mechanical rooms etc Only trained qualified installers and service mechanics should install start up and service this equipment When working on this equipment observe precautions in the literature and on tags stickers and labels attached to the equipment and any other safety precautions that apply 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 A WARNING Electrical shock can cause personal injury and death Shut off all power to this equipment during installation There may be more than one disconnect switch Tag all discon nect locations to alert others not to restore power until work is completed A WARNING DO NOT VENT refrigerant relief valves within a building Outlet from relief valves must be vented outdoors in accordance with the latest edition of ANSI ASHRAE American National Standards Institute American Society of Heating Refrigeration and Air Conditioning Engineers 15 Safety Code for Mechanical Refrigeration The accumulation of refrigerant in an enclosed space can displace oxygen and c
7. 04 P06 01 P08 01 P09 01 P10 01 P11 01 P12 01 P13 01 P14 01 P15 02 P16 02 P17 01 P19 10 P20 10 P21 DC brake time 0 0 o 0 22 DC BRAKE VOLTAGE 0 120 0 0 23 Min 8 Hz 100 160 8 8 8 8 24 Maxtrea 6 60 55 5 25 110 26 100 27 Base freq 60 or50Hz 50 5 P28 0 5 P29 Accel boost P30 Slip compensation 0 P31 47 P32 Presetspa 2 0 0 J 0 P33 Presetspa 3 0 0 j 0 P35 r t aan R134a set point 12 6 12 6 P36 Preset spd 6 defaut 0 0 7 o o o o P38 Skip bandwidth 0 J 0 0 39 Speedscaling 0 J P40 Frequency scaling 50 6 6 50 5 P41 200 p42 2 default notusedsoNA 77 460 6 60 60 P43 P44 111 mode is disabled and 4 20mA input is at 4 mA P46 Speed at max feedback 60 or 50 Hz Used 6 6 s 50 when PID disabled and 4 20mA input is at 20 mA P47 Clear history 01 maintain set to 02 to clear 01 P48 Program selection Program 1 12 0 o P61 01 P62 Min feedback 0 0v 10 2 P63 50 P64 4 P65 2 P66 5 P67 0 0 P68 MMaxalam LEGEND NA Not Applicable PID Proportional Integral Derivative TB Terminal Block 62 ANWARNING Electrical shock can cause pe
8. 1 1 cl cdown 1 aiunitme 1 tmp rgta 1 tmp rgtb 1 k a1 fbk 1 k a1 rly 1 hr a1 1 cy a1 1 k a2 fbk 1 k a2 rly 1 hr a2 1 cy a2 1 k b1 fbk 1 k b1 rly 1 hr b1 1 b1 1 k b2 fbk 1 k b2 rly 1 hr b2 1 cy b2 1 stat msv 1 pnt 1 cool ewt 1 coolflow 1 mode 16 1 cool 1 Iwt sp 1 1 fbk 1 pmp2 fbk 1 coolpmp1 1 coolpmp2 1 pmp slct 1 pump dly 1 cool 1 cramp 1 1 APPENDIX D OPTIONAL BACNET COMMUNICATIONS WIRING cont Table G Network Points List cont BACNET OBJECT ID 20 70 54 POINT DESCRIPTION Cooling Setpoint 2 CSM Controlling Chiller Demand Level 1 Demand Level 2 Demand Level 3 Demand Limit Switch 1 Demand Limit Switch 2 Demand Sound Limited Discharge Gas Temp Discharge Pressure Discharge Pressure Dual Setpoint Dual Setpoint Switch Element Comm Status Element Communications Alarm Emergency Stop Entering Fluid Temp EXV Open EXV Open Fan 1 Relay Fan 2 Relay Head Setpoint Heat Request High SCT Circuit A High SCT Circuit B High Temperature Cooling Ice Done Ice Setpoint Lead Lag Circuit Select Lead Lag Circuit Select Lead Lag Leaving Fluid Leadpump Leaving Fluid Temp Prime Variable Loading Sequence Select Local Schedule Low Cooler Suction Temp A Low Cooler Suction Temp B Low Sound Active Low Sound Mode Low Temperature Cooling Machine Operating Hours Machine Starts Making ICE Master Sl
9. o o Ave ste Rotate Cooler Pumps New ROT PUMP RW Bvi2 pump 1 Saturated Condensing Tmp TMP scra R 6 mosa Saturated Condensing Tmp TMP scere R _ wa 1 Saturated Suction Temp TMP ssa R Saturated Suction Temp TMP sse R 6 Slow Change Override _ MODE9 R mode 9i Space Temperature 8760 40 0 245 AV 35 1 Storing ICE MODE20 R J BV46 mode 20 1 Strainer Maint Done ST MANT Rw 3 BV55 st maint 1 Strainer Srvc Countdown ST CDOWN R mn 20 C AV 52 st cdown 1 Strainer Srvc Interval STRNR 8760 0 65535 AV 51 si_strnr_1 Suction Pressure sPA RB psig Suction Pressure sPB R po sp bi aE _ A4 sh_a_1 Suction Superheat Temp 45 sh_b_1 Suction Superheat Temp System Demand Limiting JU 001 Bv57 dem Imt act 1 Temperature Reset MODE 14 U 40 mode 14 1 Timed Override In Effect MODE 6 U 25900 mode_6_1 User Defined Analog 1 y ya O AV 2901 user_analog_1_1 User Defined Analog 2 User Defined Analog 3 User Defined Analog 4 l AV 2903 user_analog_3_1 User Defined Analog 5 y u T ____________ 2904 user_analog_4_1 _____________ 2905 user_analog_5_1 User Defined Binary 1 C BV291 user_binary_1_1 User Defin
10. 0 HOT FHOPTACCESSORY vio 1 Des FIOP lt oJ e MTS MBB Be m LSS EMM 14 AUX Hvo KE 2 J2 2 s 0 BRN 1 3 VIO e BRA K WS H 8LU e BRI Fig 6A Typical Wiring Schematic 30RAP018 030 Units Power Wiring 24 J10A RLY RLY RLY J10B RLY RLY RLY RLY RLY RLY RLY 3 2 AMPS E RED 4 TRANI 181 2 TBA RED BRN MBB J1 2 MBB 184 5 2 AMPS ORN RED LTEL ar X SECONDARY 24V BRN _ upc ser a 2 Sion O O ORN 1 5 emn i BRN CWFS 3 SEE WOTE 10 o T qg em an2 ao enora w u R 8LK BRN LVT J12 5 oa c BRN amp 2 CHC 3 RED L CA BRN L IG GRA e rat L e BRN BRN Q2 CWP1 23 4 MLV A a MLV ACCSY BRN RED 6 1 6 PNK PNK MX sm A 1 SEE NOTE 1 BRN Q 2 FC2 8 o gt 9 10 495 ORN ORN O m 9 rci my BRN 2 FC3 2 5 HHD 2 gt 4 6 4 9 5 184 423 RED 4 LOAD 5VA SEALED Dn LVT 10VA INRUSH LVT 7 RED m F 602 RED 1 18 poe E BIEILGY S 88 HEC 181 Y Pid STORAG
11. Coil Cleaning Maint Date mmWdyyhhmm Coil Cleaning Maint Date mm dyyhhmm Coil Cleaning Maint Date mm dyyhhmm Coil Cleaning Maint Date mmddyy hrm Coil Cleaning Maint Date mmdyhhmm CCN MAINTENANCE TABLES TESTMODE DESCRIPTION Service Test Mode Compressor At Relay x senem 7 Compressor A2 Relay Compressor B1 Relay o oo Compressor B2 Relay Fan 1 Relay Fan 2 Relay Cooler Pump Relay 1 Cooler Pump Relay 2 Comp A1 Unload Time Minimum Load Valve Relay Remote Alarm Relay EXV Open EXV Open 98 POINT NAME SI_PUMPS P1_CDOWN P1_MAINT P2_CDOWN 2 1 1 1 1 2 1 1 4 2 2 1 PMP2_PM2 PMP2_PM3 PMP2_PM4 POINT NAME SI_STRNR ST_CDOWN 5 STRN_PMO STRN_PM1 STRN_PM2 STRN_PM3 STRN_PM4 POINT NAME SI CL_CDOWN CL_MAINT COIL_PMO COIL_PM1 COIL_PM2 COIL_PM3 COIL_PM4 POINT NAME NET_CTRL S_A1_RLY S_A2_RLY S B1 RLY S B2 RLY S FAN 1 S FAN 2 S S CLPMP2 S A1ULTM S MLV 5 5 5 DESCRIPTION Percent Total Capacity Percent Available Cap Discharge Pressure Suction Pressure Head Setpoint Saturated Condensing Tmp Saturated Suction Temp Compr Return Gas Temp Discharge Gas Temp Suction Superheat Temp Compressor A1 Relay Compressor A2 R
12. Circuit A shut down Circuit B shut down Temperature reset disabled Chiller runs under normal control set points When capacity reaches 0 cooler pump heaters are energized Temperature reset disabled Chiller runs under normal control set points Circuit A shutdown after pumpdown complete Circuit B shutdown after pumpdown complete Chiller runs as a stand alone machine METHOD RESET Manual Manual Manual Manual Manual Manual Manual Manual Automatic Automatic Automatic Automatic Automatic Automati Automatic Automatic Au Au Au Au Au Hi omatic PROBABLE CAUSE High pressure switch open faulty CSB loss of condenser air filter drier plugged non condensables operation beyond capability Welded compressor contac tor CSB wiring error High pressure switch open faulty CSB loss of condenser air filter drier plugged non condensables operation beyond capability Welded compressor contac tor CSB wiring error High pressure switch open faulty CSB loss of condenser air filter drier plugged non condensables operation beyond capability Welded compressor contac tor CSB wiring error High pressure switch open faulty CSB loss of condenser air filter drier plugged non condensables operation beyond capability Welded compressor contac tor CSB wiring error Thermistor failure damaged
13. 29 Capacity Control 29 MINUTES LEFT FOR START MINUTES OFF TIME LEAD LAG DETERMINATION CAPACITY CONTROL OVERRIDES Head Pressure 32 Operation of Machine Based on Control Method and Cooling Set Point Selection Settings 32 Cooling Set Point 33 Low Sound Mode 34 Heating 34 Service Test 34 Optional Factory Installed Hydronic Package 34 Cooler Pump 34 Cooler Pump Sequence of Operation 35 Configuring and Operating Dual Chiller Control 36 Temperature 38 Demand 42 DEMAND LIMIT 2 Stage Switch Controlled EXTERNALLY POWERED DEMAND LIMIT 4 to 20 mA Controlled DEMAND LIMIT CCN Loadshed Controlled Cooling Set Point 4 to 20 43 Digital Scroll 44 DIGITAL SCROLL OPERATION DIGITAL COMPRESSOR CONFIGURATION 5 44 45 Page System 44 START UP AND OPERATION 45 46 Actual
14. 45 Check Refrigerant 45 Operating Limitations 46 TEMPERATURES LOW AMBIENT OPERATION VOLTAGE ALL UNITS OPERATION SEQUENCE 46 47 SERVICE errem 47 63 Electronic Components 47 CONTROL COMPONENTS Electronic Expansion Valve 47 EXV Troubleshooting Procedure 47 FIELD SERVICING INSTRUCTIONS VALVE REPLACEMENT VALVE REASSEMBLY Compressor Replacement 49 5 Duss muy kozes kaha ka 49 BRAZED PLATE COOLER HEAT EXCHANGER REPLACEMENT BRAZED PLATE COOLER HEAT EXCHANGER CLEANING Oil 50 Microchannel Heat Exchanger Condenser Coil Maintenance and Cleaning Recommendations 50 Check Refrigerant Feed Components 50 FILTER DRIER MOISTURE LIQUID INDICATOR MINIMUM LOAD VALVE PRESSURE RELIEF DEVICES Check Unit Safeties 52 HIGH PRESSURE SWITCH PRESSURE TRANSDUCERS COOLER FREEZE UP PROTECTION HEATER CABLE WINTER SHUTDOWN Thermistors 52 Pressure Transducers 53 Chilled Water Flow Switch 53 U 53 Condenser Fans
15. DESCRIPTION VALUE DEFAULT UNITS Control Method 0 Switch 2 Occupancy 3 CON Loading Sequence Select 1 Equal Loading 1 2 Staged Loading Lead Lag Circuit Select 1 Automatic 1 2 Circuit A Leads 3 Circuit B Leads Cooling Setpoint Select 0 Single 1 Dual remote switch controlled 2 Dual CCN occupancy 3 4 20 mA input Ramp Load Select Enable Dsable Heat Cool Select Cool Heat High LCW Alert Limit 200 60 Minutes off time Deadband Multiplier 1 0 to 4 0 Ice Mode Enable Enable Dsable Low Sound Mode Select 0 Disabled 1 Fan only 2 Capacity Fans Low Sound Start Time 00 00 to 23 59 00 00 Low Sound End Time 00 00 to 23 59 00 00 Low Sound Capacity Limit 0 to 100 CCN CONFIGURATION TABLES SCHEDOVR Timed Override Setup VALUE DEFAULT UNITS 009 1 24 ___0 hs DESCRIPTION Schedule Number Override Time Limit Timed Override Hours Timed Override 0004 hows Noyes POINT NAME CONTROL SEQ_TYP LEAD_TYP CLSP_TYP RAMP_EBL HEATCOOL LCW_LMT DELAY Z_GAIN ICE_CNFG LS_MODE LS_START LS_END LS_LIMIT POINT NAME SCHEDNUM OTL OVR_EXT CCN CONFIGURATION TABLES RESETCON Temperature Reset and Demand Limit DESCRIPTION COOLING RESET Cooling Reset Type 4 20 MA RESET 4 20 Degrees Reset REMOTE RESET Remote No Reset Temp Remote Full Reset Temp Remote Degrees Reset RETURN TEMPERATURE RESET
16. EN BRN A2 REDE RED T2 KaR eme 11 437 GRA GRA 8 GRA BRN BRN BRNA SEE NOTE 13 12 7 PL2 8 1 MLV A ato lt eo T2 _wP 82 Kr smoo sm o L MLV ACCSY BRN 6 49 PNK PNK n Oc m 1 T SEE NOTE 8 BRN FC2 8 RLY 10 4 ORN FC3 108 HPS B J m o gt TB1 PL2 1 MP B1 PL2 2 eren a S MMC CAN E i n 3 SEE MOTE 1 AUX AUXILIARY 4 055 060 OL BR BOILER RELAY PL2 5 WP B2 PL2 6 CONTACTOR COMPRESSOR 6 HD PNK vimo oN v10 PNK ND BRN cpi CIRCUIT BREAKER us m mI po E gaa 4 RED 14 COCTRE CD COOLER PUMP HEATER CONTACTOR i MAX LOAD 5VA SEALED CONVENIENCE OUTLET gt gt LVT INRUSH LVT COMP COMPRESSOR did COL gt CHES CHILLED WATER FLOW SWITCH eo l l omal ACCESSORY ep Um Grm om 181 CWP CHILLED WATER PUMP T STORAGE TANK CWPI CHILLED WATER PUMP INTERLOCK meen nT in E M Mu mO RN RED DPT DISCHARGE PRESSURE TRANSDUCER 10 RED DIT DISCHARGE TEMPERATURE THERMISTOR IL U AL UNLOAI LEM nye Cae D s lo Mo URE 0 BLK e epe BLK e BLK BRN 1 EXV EXPANSION VALVE CONTROL BOARD 12 PLI 2 FUSE BLOCK RLY 1 11 61 ORN lt 10 2 10 5 ORN G QD BRN FC FAN CONTACTOR 13 SEE NOTE 1 Vio BRN FCB FAN CIRCUIT BREAKER gt 0 FIOP FACTORY INSTALLED OPTION 14
17. figuration RM NO Configuration RM F and Configuration gt eRT DG must be properly set See Table 26A Configuring Outdoor Air and Space Temperature Reset The outdoor air reset example pro vides 0 F 0 C chilled water set point reset at 85 0 F 29 4 C outdoor air temperature and 15 0 F 8 3 C reset at 55 0 F 12 8 C outdoor air temperature The space temperature reset example provides 0 F 0 C chilled water set point reset at 72 0 F 22 2 C space temperature and 6 0 F 3 3 C reset at 68 0 F 20 0 C space temperature The variable CRST should 40 be configured for the type of reset desired The variable RM NO should be set to the temperature that no reset should occur The variable RM F should be set to the temperature that maximum reset is to occur The variable RM DG should be set to the maximum amount of reset desired Figures 18 and 19 are examples of outdoor air and space temperature resets To use return reset four variables must be configured In the Configuration mode under the sub mode RSET items CRST RT NO RT F and RT DG must be properly set See Table 26B Configuring Return Temperature Reset This example pro vides 5 0 F 2 8 C chilled water set point reset at 2 0 F 1 1 C cooler AT and 0 F 0 C reset at 10 0 F 5 6 C cooler AT The variable RT NO should be set to the cooler temperature differ ence AT where no chilled water temperature reset should oc cu
18. After power is restored restart is automatic through normal MBB start up UNIT ENABLE OFF REMOTE CONTACT SWITCH IS OFF When the switch is OFF the unit will stop immediate ly Place the switch in the ENABLE position for local switch control or in the REMOTE CONTACT position for control through remote contact closure CHILLED FLUID PROOF OF FLOW SWITCH OPEN After the problem causing the loss of flow has been corrected reset is manual by resetting the alarm with the scrolling mar quee as shown in Table 42 OPEN 24 V CONTROL CIRCUIT BREAKER S De termine the cause of the failure and correct Reset circuit break er s Restart is automatic after MBB start up cycle is complete COOLING LOAD SATISFIED Unit shuts down when cooling load has been satisfied Unit restarts when required to satisfy leaving fluid temperature set point THERMISTOR FAILURE If a thermistor fails in either an open or shorted condition the unit will be shut down Replace EWT LWT or OAT as required Unit restarts automatically but must be reset manually by resetting the alarm with the scrolling marquee as shown in Table 42 CAUTION If unit stoppage occurs more than once as a result of any of the safety devices listed determine and correct cause before attempting another restart LOW SATURATED SUCTION Several conditions can lead to low saturated suction alarms and the chiller controls have several override modes built in wh
19. Bl ccB 2 FB 3 a 22 23 LE a gg 09 09 Ss 9 9 18908 0 CSB A2 O 4 S 000 000 1 Bs e o vem DISCONNECT i sooo J MS MS E OPTION TB 2 looooogo HOUQHO 580 2 2 C A2 13 o oolooo 2 2 2 949249 1 TE 6 6 3 i3 00000 T paaa 4 Fig 4 Typical Control Box for 30RAP018 030 22 090 SE0dVHOE 101 1041409 je2id Bly WOULNOD esae 2000 58055494 02 LINN e
20. FEL e Dee meses er Dese Loser Dese esee __ rm Dee se Dee emen x eni Dee LRL recover Repeats for Occupancy Periods 2 through 8 16 Table 11 Time Clock Mode Sub Mode Directory cont KEYPAD ITEM SUB MODE DISPLAY 5 DISPLAY OVR SCHEDULE OVERRIDE OVERRIDE OVR T i TIMED OVERRIDE HOURS Default 0 Range 0 4 hours OVR L w OVERRIDE TIME LIMIT Default 0 Range 0 4 hours T OVR YES NO TIMED OVERRIDE User Entry Table 12 Operating Mode and Sub Mode Directory KEYPAD ITEM SUB MODE ear ITEM DISPLAY EXPANSION COMMENT MODE MODES CONTROLLING UNIT Eg owe sem Lu ee _ Co see LEGEND CSM Chillervisor System Manager SCT Saturated Condensing Temperature WSM Water System Manager Table 13 Alarms Mode and Sub Mode Directory KEYPAD ITEM SUB MODE ENTRY ITEM EXPANSION COMMENT CRNT AXXX OR TXXX CURRENTLY ACTIVE ALARMS Alarms are shown as AXXX Alerts are shown as TXXX RCRN YES NO RESET ALL CURRENT ALARMS Alarms are shown as AXXX HIST ALARM HISTORY Alerts are shown as TXXX 17 MODE NO 01 02 03 05 06 07 08 09 10 13 14 15 16
21. High Pressure Switch LON Local Operating Network LVT Low Voltage Terminal Block MBB Main Base Board MLV Minimum Load Valve MM Motormaster MP Motor Protector MS Manual Starter NEC National Electrical Code OAT Outdoor Air Thermistor OFM Outdoor Fan Motor RGT Return Gas Thermistor SCCR Short Circuit Current Rating SPT Suction Pressure Transducer SW Switch TB Terminal Block TNKR Storage Tank Heater Relay TRAN Transformer UPC Unitary Protocol Converter Terminal Unmarked Terminal Marked Splice Factory Wiring Field Wiring Accessory or Option Wiring To indicate common potential only not to represent wiring Terminal Block O lt gt o cil 21
22. PM P S must be set to YES This option is set to NO as the factory default With this feature enabled if the pump is not op erating it will be started and operated for 2 seconds starting at 14 00 hours If the pump is operating this routine 1s skipped If the pump has failed and an Alarm Alert condition is active the pump will not start that day DUAL INTEGRAL PUMP CONTROL With a dual inte gral pump package the following options must be configured Cooler Pump Control Configuration gt 1 gt ON e Cooler Pump 1 Enable Configuration PMIE YES e Cooler Pump 2 Enable Configuration PM2E YES Pump Start Selection is a field configurable choice Cooler Pump Select Configuration PM SL is factory defaulted to 0 Automatic This value can be changed to 1 Pump 1 Starts First or 2 Pump 2 Starts First If PM SL is 0 Automatic the pump selection is based on two criteria the alert status of a pump and the operational hours on the pump If a pump has an active Alert condition it will not be considered for the lead pump The pump with the lowest operational hours will be the lead pump A pump is selected by the control to start and continues to be the lead pump until the Pump Changeover Hours Configuration gt OPT1 PM DT is reached The Lead Pump Run Status VIEW LD PM indicates the pump that has been selected as the lead pump 1 Pump 1 2 Pump 2 3 No Pu
23. SF Single phase Fault Single phase input power has been Check input power phasing applied to a three phase drive F1 EPM Fault The EPM is missing or damaged F2 F9 Fo Internal Faults The control board has sensed a problem Consult factory Drive display 60 0 even though it Feedback signal is above set point Check for proper set point is cold outside and it should be run Check liquid line pressure ning slower Drive display even though Start jumper is missing Replace start jumper See section above drive should be running Drive display 8 0 even though fan Feedback signal is below set point and fan is at minimum Check for proper set point should be running faster speed Check liquid line pressure VFD flashes 57 and LCS Feedback or speed signal lost Drive will operate at 57 Hz In stand alone mode Check transducer wiring until reset or loss of start command Resetting requires and feedback voltage Feedback voltage dis cycling start command or power played on P 69 Pin 6 should be 5 v output Pin 5 feedback should be somewhere between 0 and 5 v LEGEND EPM Electronic Programming Module LCS Lost Control Signal OEM Outside Equipment Manufacturer VFD Variable Frequency Drive 61 Table 39 Motormaster V Program Parameters for Operating Modes PARAMETERS DESCRIPTION MODE MODE P01 02 P02 01 P03 Startup mode flying o P04 01
24. male PASS Metric Display Language Selection 0 ENGLISH LANGUAGE 1 FRANCAIS 2 ESPANOL 3 PORTUGUES CCN CONFIGURATION TABLES EXV Circuit A Configuration DESCRIPTION POINT NAME EXV Circ A Start Pos EXVASTRT EXV Circ A Min Position nnn 80 EXVAMINP EXVA Steps in Range EVXARANG EXVA Steps Per Second EXVARATE EXVA Fail Position in mmm ____ EXVAPOSF EXVA Minimum Steps nmm EXVAMINS EXVA Maximum Steps EXVAMAXS EXVA Overrun Steps EXVAOVRS EXVA Stepper Type mn EXVATYPE High SCT Threshold HIGH_SCT Open EXV X on 2nd Comp EXV_HSCT Open EXV X on DISCRSOL EXVDISCR Pre Open Fan Adding EXV_AFAN EXV Fan Sub Pre Close EXV Lag Shut EXV_SLAG Lag Start Delay DELAYLAG CCN CONFIGURATION TABLES EXVBCONF EXV Circuit B Configuration DESCRIPTION POINT NAME EXV Circ B Start Pos EXVBSTRT EXV Circ B Min Position mnn 80 EXVBMINP EXVB Steps in Range EVXBRANG EXVB Steps Per Second EXVBRATE EXVB Fail Position in 96 mmm 0 EXVBPOSF EXVB Minimum Steps mmn o se EXVB Maximum Steps EXVBMAXS EXVB Overrun Steps EXVBOVRS EXVB Stepper Type nm Biar EXVBTYPE CCN CONFIGURATION TABLES MM CONF Motormaster Configuration DESCRIPTION POINT NAME Motormaster Select Head Pressure P Gain mnn 10
25. 10 Os Port e RED 9x o 12 093 Ler Fig 7B Typical Wiring Schematic 30RAP035 060 Units Control Wiring 27 RED LED STATUS GREEN LED CEPL130346 01 6 LEN LOCAL EQUIPMENT NETWORK YELLOW LED INSTANCE JUMPER CCN CARRIER COMFORT NETWORK K11 K10 K9 K7 K6 K5 K4 K3 K2 K1 Bu
26. 2 Put on personal protective equipment including safety glasses and or face shield waterproof clothing and gloves It is recommended to use full coverage clothing 3 Start high pressure water sprayer and purge any soap or industrial cleaners from sprayer before cleaning condens er coils Only clean potable water is authorized for clean ing condenser coils 4 Clean condenser face by spraying the core steady and uniformly from top to bottom while directing the spray straight toward the core Do not exceed 900 psig or 30 de gree angle The nozzle must be at least 12 in from the core face Reduce pressure and use caution to prevent damage to air centers A CAUTION Excessive water pressure will fracture the braze between air centers and refrigerant tubes Check Refrigerant Feed Components FILTER DRIER The function of the filter drier is to main tain a clean dry system The moisture indicator described below indicates any need to change the filter drier The filter drier is sealed type drier When the drier needs to be changed the entire filter drier must be replaced NOTE Dual circuit 035 060 sizes units have 1 filter drier per circuit MOISTURE LIQUID INDICATOR The indicator is located immediately ahead of the TXV to provide an indication of the refrigerant moisture content It also provides a sight glass for refrigerant liquid Clear flow of liquid refrigerant at full unit loading indicates sufficie
27. Alert with Master Chiller Master and Slave Chiller Alert with Same Address High Leaving Chilled Alert Water Temperature Cooler Freeze Alarm Protection EWT or LWT Alarm Thermistor failure Cooler Pump 1 Scheduled Maintenance Due Alert Cooler Pump 2 Scheduled Maintenance Due Alert WHY WAS THIS ALARM GENERATED Cooler flow switch contacts open for 3 seconds after initially made Pump 1 Auxiliary Contacts closed for 26 seconds when pump state is off Pump 2 Auxiliary Contacts closed for 26 seconds when pump state is off Cooler flow switch contacts failed to close within 1 minute if cooler pump control is enabled or within 5 minutes if cooler pump control is not enabled after start up Flow switch opens for at least 3 seconds after being initially closed If configured for cooler pump control and flow Switch input is closed for 5 minutes while pump output s are off Master chiller MBB loses communication with slave chiller MBB Slave chiller MBB loses communication with master chiller MBB Master and slave chiller have the same CCN address CCN A LWT read is greater than LCW Alert Limit Total capacity is 100 and LWT is greater than LWT reading one minute ago Cooler EWT or LWT is less than Brine Freeze BR FZ Cooler EWT is less than LWT by 3 F 1 7 C for 1 minute after a circuit is started Pump 1 Service Countdown P 1 DN expired Complete pump 1 maintenan
28. Check all refrigerant joints and valves for refrigerant leaks repair as necessary Check chilled water flow switch operation Check all condenser fans for proper operation e Check compressor oil level Every 12 months for all machines e Check all electrical connections tighten as necessary Inspect all contactors and relays replace as necessary Check accuracy of thermistors replace if greater than x 2 F 1 2 C variance from calibrated thermometer Obtain and test an oil sample Change oil only if necessary Check to be sure that the proper concentration of anti freeze is present in the chilled water loop if applicable Verify that the chilled water loop is properly treated Check refrigerant filter driers for excessive pressure drop replace as necessary Check chilled water strainers clean as necessary Check cooler heater operation if equipped Check condition of condenser fan blades and that they are securely fastened to the motor shaft Perform Service Test to confirm operation of all components Check for excessive cooler approach Leaving Chilled Water Temperature Saturated Suction Temperature which may indicate fouling Clean cooler vessel if necessary Microchannel Heat Exchanger MCHX Con denser Coil Maintenance and Cleaning Recommendations A CAUTION Do not apply any chemical cleaners to MCHX condenser coils These cleaners can accelerate corrosion and da
29. HOLIDAY SCHEDULE 12 Holiday Start Month Duration days HOLIDAY SCHEDULE 13 Duration days HOLIDAY SCHEDULE 14 Duration days HOLIDAY SCHEDULE 15 Duration days HOLIDAY SCHEDULE 16 Duration days HOLIDAY SCHEDULE 17 Duration days HOLIDAY SCHEDULE 18 Duration days HOLIDAY SCHEDULE 19 Duration days 85 COMMENT 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 SUB MODE HD 20 HD 21 HD 22 HD 23 HD 24 HD 25 HD 26 HD 27 HD 28 HD 29 HD 30 APPENDIX A DISPLAY TABLES cont Time Clock Mode and Sub Mode Directory cont ITEM DISPLAY ITEM DESCRIPTION HOLIDAY SCHEDULE 20 Duration days HOLIDAY SCHEDULE 21 XX Duration days HOLIDAY SCHEDULE 22 Duration days HOLIDAY SCHEDULE 23 Duration days HOLIDAY SCHEDULE 24 Duration days HOLIDAY SCHEDULE 25 Duration days HOLIDAY SCHEDULE 26 Duration days HOLIDAY SCHE
30. TT YEL 124 K22 YEL 2 1 z 28 oo gu uer d Ng GRN YE 589 oo G 125 Hi EK EL 0 gt R 8 BLK BLU BLU e Ae fed 2 gm e M a H A o 0 13 takes BLK CSB A2 Vy ED pu latae 2 226 0 42 T 124 H22 YEL us COMP A2 3 BLU K eQ 1 2 BLU T3 2 d ay 78 GRN YEL EQUIP GND 208 230V ONLY pup dS pup CHILLED WATER PUMP FIOP RED MS CWP1 1 BLK 1 BLK gt LD T x 2 W l 00 02579 Gb 1 Kp ax WATER PUMP TRAN3 BLU 73 091 BLK 19 aveg l MS CWP2 1 16 BLK 7 L1 WATER 2 GFI CO ati 026 912 424 HID BLK V t2 ME FIOP ACCESSORYE BLU 36 7909 09 HD BLK gt 13 GRNIYEL UL BRASS SCREW Lnd emm er m I TT T PRIMARY SIDE SECONDARY SIDE BK a BLR BEN f mra RT 2 E 29 146 ad Nt GBR EL 12782 YEL 24 H22 8LK 2 orn z E 298 388 500 icu UEH K _ 3 460 3 60 XF X2 BLU 13 23 18 0 423 BLU 134 KZ BLK 3 X GRN YEL FC2 E ge BLK ZG 8LK 1 1 VEL AD KD BLK 2 2 2 a nm UNIT VOLTAGE BLU 134 BLK 3 GRNIYEL 2087230 3 80 FHO R 3 5 ait 1 man ru am 1 3153 60 WORS BLK BLU
31. When fluid velocity is high more heat will be carried away from the heated thermistor and the temperature differential will be small As fluid velocity decreases less heat will be taken from the heated thermistor and there will be an increase in tem perature differential When unit flow rate is above the minimum flow rate then the output is switched on sending 24 vac to the MBB to prove flow has been established For recommended maintenance check the sensor tip for build up every 6 months Clean the tip with a soft cloth If re al 9 lt 6 MINIMUM CLEARANCE FOR THERMISTOR REMOVAL necessary build up e g lime can be removed with a common vinegar cleansing agent The flow sensor cable is provided with 3 LEDs that indi cate if 24 vac power is present and also status of the switch contacts The LEDs are as follows Green LED 24 vac present One Yellow LED ON Flow sensor switch OPEN Two Yellow LED ON Flow sensor switch CLOSED If nuisance trips of the sensor are occurring follow the steps below to correct the situation 1 Check to confirm that the factory installed strainer is clean Use the blow down valve provided or remove the screen and clean it For the case of VFD controlled pumps ensure that the minimum speed setting has not been changed 2 Measure the pressure drop across the cooler or cooler pump system and compare this to the system requirements 3 Verify that cable connect
32. lt vo RED ori 150 4 11213141516 118 SWITCH LOCATION lt w G2 au aret LG aa EVAPORATOR ENTERING FLUID TEMP EVAPORATOR LEAVING FLUID TEMP 63355 em gt BLK a RED gt om B DPTA D B SPTA gt ax n 1 a ACCSY EL ea SPACE TDPERATURE ACCESSOR DUAL CHILLER LWT ACCESSORY cora TP restr 4 20mA i Fig 6 Typical Wiring Schematic 30RAP018 030 Units Control Wiring 25 STANDARD
33. 030 050 060 may be disassembled for cleaning inspection or motor assembly replacement VALVE REPLACEMENT The valve may be replaced by unsoldering or cutting the piping A tubing cutter must be used to prevent creating contaminants in the piping VALVE REASSEMBLY Perform the following procedure to reassemble the EXV valve 1 Use Service Test to open the EXV to 100 This will re tract the white polyester driver piston fully into the driver guide Remove power from the valve or controller 2 Lightly oil the threads and gasket or knife edge on the new motor adaptor Carefully seat the adaptor on the valve body or engage and tighten the lock nut if used Lock nuts should be torqued to approximately 45 ft lb One eighth turn more than hand tight is sufficient to achieve a leak proof seal on knife edge joints 3 After the motor is tightened the cable should be replaced on the valve Care should be taken to ensure engagement of the alignment key Snap on the cable retainer 4 Pressurize the system and check for leaks 5 Reapply power to the ComfortLink controller Since during service valve position as calculated by the con troller will be lost the controller should be initialized at least twice In some instances cycling power to the con troller will accomplish this 49 CAUTION If the existing motor has been removed for inspection or cleaning be sure that the piston is fully retracted into the moto
34. 500 ANY FIELD MODIFICATIONS OR ADDITIONS MUST BE IN REMOVE JUMPER FROM TERMINAL 11 TO 17 AND 460 3 60 600 COMPLIANCE WITH ALL APPLICABLE CODES WIRE INTERLOCK CONTACT ACROSS TERMINALS 11 amp 17 2 USE 75 C MIN WIRE FOR FIELD POWER SUPPLY 9 NOT USED IN THE FOLLOWING UNITS 3 ALL FIELD INTERLOCK CONTACTS MUST HAVE A MIN RATING OF 018 020 ALL UNITS FUTb 8LK 2 AMPS 6 2AVAC SEALED SEE FIELD INTERLOCK WIRING 025 030 460V UNITS WITHOUT DIGITAL SCROLL 4 COMPRESSOR AND FAN MOTORS ARE THERMALLY PROTECTED 10 MP A2 NOT USED THE FOLLOWING UNITS YEL THREE PHASE MOTORS PROTECTED AGAINST PRIMARY SINGLE 018 020 ALL UNITS PHASE CONDITIONS 025 030 460V UNITS APPROPRIATE 5 TERMINALS 138 14 OF LVT ARE FOR FIELD CONNECTION 11 JUMPER PLUG REQUIRED WHEN MP NOT USED PRIMARY VOLTAG OF REMOTE ON OFF THE CONTACT MUST BE RATED FOR DRY SEE TABLE 1 CIRCUIT APPLICATION CAPABLE OF HANDLING A 5VDC TRAN1 1 MA TO 20 MA LOAD PRIMARY 6 FOR 500 SERIES UNIT OPERATION AT 208 3 60V LINE VOLTAGE 62 4 42 TRANI PRIMARY CONNECTIONS MUST BE MOVED TO TERMINALS amp H4 7 FOR UNITS WITH LOW AMBIENT MOTOR MASTER V FIOP ACCESSORY TBI FAN CONTACTOR IS REPLACED WITH MOTORMASTER RELAY MMR TB4 SECONDARY 24V 1 F RED D dT RED RED BRN A swe BRN 34 T81 3 3 Oo 2 vio upc Flop aan 160 or RED K amp D 3 2 AMPS 1B4 6
35. 9 PUMP SERVICE INTERVAL Default 8760 p BEN xxi PUMP 2 SERVICE COUNTDOWN vso PUMP 1 DONE User Entry j Pu PUMP 2 DONE User Entry NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed 6 KEYPAD SUB MODE ENTRY VERS Table 3 Run Status Mode and Sub Mode Directory cont __ PUMP MAINTENANCE DATES STRAINER SRVC INTERVAL xs STRAINER SRVC COUNTDOWN ___ COIL SERVICE COUNTDOWN __ COIL MAINTENANCE DATES Press and simultaneously to obtain version number COMMENT Default 8760 User Entry Default 8760 User Entry is Version number is Version number is Version number is Version number is Version number is Version number Table 4 Service Test Mode and Sub Mode Directory KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION COMMENT TEST ON OFF SERVICE TEST MODE To Enable Service Test Mode move Enable Off Remote Contact switch to OFF Change TEST to ON Move switch to ENABLE OUTS _ O OUTPUTS AND PUMPS FAN3 ON OFF FAN 3 RELAY FAN5 ON OFF FAN 5 RELAY FANG ON OFF FAN 6
36. COMPLIANCE WITH ALL APPLICABLE CODES WIRE INTERLOCK CONTACT ACROSS TERMINALS 11 amp 17 5 2 USE 75 C MIN WIRE FOR FIELD POWER SUPPLY 10 NOT USED IN THE FOLLOWING UNITS SHY EL 026 29 2 YEL 424 8LK 2 OFM 3 ALL FIELD INTERLOCK CONTACTS MUST HAVE A MIN RATING OF 035 045 ALL UNITS 2 AMPS 0 24VAC SEALED SEE FIELD INTERLOCK WIRING 050 060 460 UNITS WITHOUT DIGITAL SCROLL Neo na 3 lt 4 COMPRESSOR AND FAN MOTORS ARE THERMALLY PROTECTED 11 MP AZ NOT USED IN THE FOLLOWING UNITS D THREE PHASE MOTORS PROTECTED AGAINST PRIMARY SINGLE 035 045 ALL UNITS T PHASE CONDITIONS 050 060 460 UNITS 1 5 5 TERMINALS 138 14 OF LVT ARE FOR FIELD CONNECTION 12 MP Bi NOT USED IN THE FOLLOWING UNITS OF REMOTE ON OFF THE CONTACT MUST BE RATED FOR DRY 935 00 ALL UNITS BLK 2 2 oru CIRCUIT APPLICATION CAPABLE OF HANDLING A 5VDC 045 060 460 UNITS 1 MA 20 LOAD 13 MP B2 NOT USED N THE FOLLOWING UNITS YEL 3 6 FOR 500 SERIES UNIT OPERATION AT 208 3 60V LINE VOLTAGE 163 6 GRNIYEL TRANI PRIMARY CONNECTIONS MUST BE MOVED TO TERMINALS 8 HA PLUG REOUIRED WHEN MP NOT USED BLK BLU FC3 1 1 FOR 575 3 60V UNITS FAN CIRCUIT BREAKER FCB2 BLK 1 1 IS REPLACED WITH FUSE BLOCK 82 m 8 FOR UNITS WITH LOW AMBIENT MOTOR MASTER V FIOP ACCESSORY BLK 030 050 FAN CONTACTOR FCI IS REPLACED WITH MOTORMASTER RELAY MMR 2 055 060 FAN CONTACTO
37. Default 60 minutes Range 0 to 120 minutes Default 80 Range 0 to 100 Default 50 Range 0 to 100 Default Disable Cooling Reset Type 4 20 Degrees Reset Remote No Reset Temp Remote Full Reset Temp Remote Degrees Reset Return No Reset Temp Return Full Reset Temp Return Degrees Reset Demand Limit Select Demand Limit at 20 mA Loadshed Group Number Loadshed Demand Delta Maximum Loadshed Time Demand Limit Switch 1 Demand Limit Switch 2 Lead Lag Chiller Enable Default Master Default 2 Range 0 to 239 Default Master Leads 0 Master Leads 1 Slave Leads 2 Automatic Default 168 hours Range 40 to 400 hours Default 5 minutes Range 0 to 30 minutes Default YES CANNOT BE CHANGED Master Slave Select Slave Address Lead Lag Balance Select Lead Lag Balance Delta Lag Start Delay Parallel Configuration APPENDIX DISPLAY TABLES cont Configuration Mode and Sub Mode Directory cont SUB MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT SETPOINT AND RAMP LOAD Default Single 0 Single 1 Dual Switch CLSP x Cooling Set Point Select 2 Dual CCN Occupied 3 410 20 Input requires SLCT ENBL DSBL Ramp Load Select Default Enable CRMP ENBL DSBL Cooling Ramp Loading 5 SCHD Schedule Number Gange d 99 SERVICE CONFIGURATION SERV BROADCAST CONFIGURATION BCST 83 APPENDIX DISPLAY TABLES cont Time Clock Mod
38. FON equals Head Set Point Set Points gt H DP except after a fan stage increase when the Head Set Point is increased by Fan Stage Delta Set Points gt HEAD gt F DLT fan stage is decreased when the SCTs of both circuits are less than the Fan Off Set Point Set Points HEAD K OFF for two minutes Table 20 shows the number of fan stages contac tors energized and the fans that are during the fan stage Unit sizes 035 to 060 have common fan control Figure 14 shows the location of each fan and compressor within the unit MOTORMASTER V OPTION Motormaster V is stan dard on 30 010 and 015 size units For all other units that need low ambient operation the lead fan on a circuit can be equipped with the Motormaster V head pressure controller op tion or accessory The controller is energized with the first fan stage and adjusts fan speed to maintain a SCT of 72 F 22 2 C The first stage of fan operation is controlled by the Motormas ter V controller Refer to Fig 15 for condenser fan layout infor mation The Motormaster is configured in the Motormaster Se lect Configuration MMR 5S Operation of Machine Based on Control Method and Cooling Set Point Selection Set tings Machine On Off control is determined by the configuration of the Control Method Configura tion OPT2 CTRL and Cooling Set Point Select Config uration SLCT CLSP variables units are factory configured with Coolin
39. Manual restart thereafter 30 sec If the compressors are off and discharge pressure reading is lt 26 psig for 30 sec Circuit not allowed to Alert start Circuit B Loss of Charge Circuit saturated suction temperature pressure transducer gt 70 F 21 1 C for 5 minutes Circuit A High Saturated Alert Suction Temperature Circuit shut down Circuit saturated suction temperature pressure transducer gt 70 F 21 1 C for 5 minutes Circuit B High Saturated Alert Suction Temperature Circuit shut down Suction superheat is less than 5 F 2 8 C for 5 minutes Circuit A Low Suction Alert Superheat Circuit A shut down Automatic restart after first daily occurrence Manual restart thereafter Suction superheat is less than 5 F 2 8 C for 5 minutes Circuit B Low Suction Alert Superheat Circuit B shut down Mode 7 caused the com pressor to unload 6 consecu tive times with less than a 30 minute interval between each circuit shutdown Circuit A Low Cooler Alert Suction Temperature Manual Manual Compressor A1 shut Automatic only after first 3 daily occurrences Manual reset thereafter Read ing from OAT sen sor must drop 5 F 2 8 C before restart Circuit shut down Mode 8 caused the com pressor to unload 6 consecu tive times with less than a 30 minute interval between each circuit shutdown Circuit B Low Cooler Suction Temperature Disch
40. OPT1 OPT2 CCN RSET NOTES 1 Slave Control Method CTRL must be configured for 0 2 Slave CCN Address CCNA 3 Slave CCN Bus Number CCNB must be the same as Master 4 Slave does not require SLVA LLBL LLBD or LLDY to be configured Table 23 Dual Chiller Configuration Slave Chiller Example ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION CTRL CONTROL METHOD CTRL SWITCH CCNA CCN ADDRESS CCNA CCN ADDRESS CCNB CCN BUS NUMBER must be different than Master COOLING RESET TYPE LEAD LAG CHILLER ENABLE m m m z 9 z 9 z z p z lt 5 9 5 9 5 5 9 FI m gt gt gt 2 a 2 2 LLEN m z 5 m 2 LLEN LEAD LAG CHILLER ENABLE m 2 2 m 8 gt D m MASTER SLAVE SELECT MSSL m z 2 z gt 2 MSSL MASTER SLAVE SELECT m 2 5 m 2 gt gt D D m m COMMENTS DEFAULT 0 SCROLLING STOPS VALUE FLASHES SELECT 2 SEE NOTE 1 CHANGE ACCEPTED DEFAULT 0 SEE NOTE 2 PROCEED TO SUBMODE RSET 15 ITEMS SCROLLING STOPS VALUE FLASHES SELECT ENBL CHANGE ACCEPTED SCROLLING STOPS VALUE FLASHES SELECT SLVE CHANGE ACCEPTED SLAVE COMPLETE Table 24 4 to 20 mA Reset SUB MODE RSET TT MA DG 5 0 F DEGREES COOL Default 0 F 0 C Reset at 20 mA i 2 8 C RESET Ran
41. Return No Reset Temp Return Full Reset Temp Return Degrees Reset DEMAND LIMIT Demand Limit Select Demand Limit at 20 mA Loadshed Group Number Loadshed Demand Delta Maximum Loadshed Time Demand Limit Switch 1 Demand Limit Switch 2 VALUE DEFAULT UNITS 0 No Reset 1 4 20 mA input 2 External temp OAT 3 Return Fluid 4 External temp SPT 80 to 30 Qo 010 125 125 0 010 125 00 80 to 30 o oo ____ 010 125 010125 oo o oo 30 to 30 00 2 4 20 mA input pues o c Oto60 1 o 092 miues Oto 4 93 0 None 1 External switch input POINT NAME CRST_TYP 420_DEG REM_NO REM_FULL REM_DEG RTN_NO RTN_FULL RTN_DEG DMD_CTRL DMT20MA SHED_NUM SHED_DEL SHED_TIM DLSWSP1 DLSWSP2 APPENDIX CCN TABLES cont CCN CONFIGURATION TABLES DUALCHIL Dual Chiller Configuration Settings DESCRIPTION POINT NAME EADILAG Lead Lag Ghiller Enable Emabesabe ___ Master Slave Select ms Slave Address Lead Lag Balance Select ozn 0 Balance Delta LL BAL D Lag Start Delay LL DELAY Parallel Configuration Yes w PARLE CCN CONFIGURATION TABLES DISPLAY Marquee Display SETUP DESCRIPTION POINT NAME Password nm 10 54 1221 PASSWORD Password Enable EnsbeDisabe
42. and the Sat urated Suction Temperature is not increasing greater than 1 1 F 0 6 C in 10 seconds If the saturated suction temperature is less than the Brine Freeze Point Set gt 2 BR FZ minus 6 F 3 4 and less than the leaving fluid temperature minus 14 F 7 8 C for 2 minutes a stage of capacity will be removed from the circuit Or If the satu rated suction temperature is less than the Brine Freeze Point minus 14 F 7 8 C for 90 seconds a stage of capacity will be removed from the circuit The control will continue to decrease capacity as long as either condition exists Circuit B cooler Freeze Protection mode At least one compressor must be on and the Sat urated Suction Temperature is not increasing greater than 1 1 F 0 6 C in 10 seconds If the saturated suction temperature is less than the Brine Freeze Point Set Points FRZ BR FZ minus 6 F 3 4 and less than the leaving fluid temperature minus 14 F 7 8 C for 2 minutes a stage of capacity will be removed from the circuit Or If the satu rated suction temperature is less than the Brine Freeze Point minus 14 F 7 8 C for 90 seconds a stage of capacity will be removed from the circuit The control will continue to decrease capacity as long as either condition exists Slow change override is in effect The leaving fluid temperature is close to and moving towards the control point Chiller is being held off by Mi
43. gt G RED w MAIN CD wo OEA T as a ca pee _ BASE Gro em m 8 gt BRN ui gt RED BOARD De 6 AUX J2 m a sin OS lt 7 ENABLE 1 a DAY RE qu Dex eg OFF ts 52 lt 0 J9 Or AO 19 16 wen Ce m SWITCH RED OS ORN BLK 60 Ss E su SEE sort BRN mTLD DGS OR me ox RED RED K amp D MM 6 OS ORN J4 1 MA J7 025 3 aaa a a D gt wr 94 9o J 5 No EG SETPOINT 2 OY 820 104 3 RGTB GP st EE y 3 lt Lo lt 2 O gt aza 4 o 29 aa m as 29 WPT gt SPACE TEMPERATURE 1 E gt arre A 1 DUAL CHILLER LWT ECD Ody Er Pe GO sui 3 TS 4 D BLU lt 1 v gt Dr Km EVAPORATOR ENTERING 4 Cw FLUID TEMP lt D 2 ox BRN EXD Di EG 1 18 3 5 EVAPORATOR LEAVING TED J4 95 lt ee CD Q7 RED gt su Boe 9 5 gt gt reo 7465 O 5 EB FIOP 49 s lt D ACCESSORY mH om or 530 4 or lt 0957 05 vio lt aco ET O on P sre 9 s 5 o gt usi mas O ORN 1 ae gt L lt 6235 can DPTA Dr lt a rx OX IO
44. num P zi e BACview UPC OPEN gt LOGIN gt UserPw 03 05 2010 01 39 28 pm NETWORK wClockSet BACnet gt C CN ber and CCN Bus number The factory default settings for CCN Element and CCN Bus number are 1 and 0 respectively If modifications to the default Element and Bus number are required both the ComfortLink and UPC Open configurations must be changed The following configurations are used to set the CCN Ad dress and Bus number in the ComfortLink control These con figurations can be changed using the scrolling marquee display or accessory Navigator handheld device Configuration CCN gt CCN A CCN Address Configuration CCN gt CCN B CCN Bus Number The following configurations are used to set the CCN Ad dress and Bus Number in the UPC Open controller These con figurations can be changed using the accessory BACview dis play Navigation BACview CCN Home Element Comm Stat Element 1 Bus 0 Fig F BACview Device Connection 105 APPENDIX D OPTIONAL BACNET COMMUNICATIONS WIRING cont If the UPC Open is used with the chiller application of Lead Lag Standby all chillers and UPC Open s CCN element numbers must be changed to a unique number in order to fol low CCN specifications In this application there can only be a maximum of 3 UPC Open controllers on a CCN bus For the CCN Alarm Acknowledger configuration the UPC Open defaults to CCN Ac
45. tem For size 010 030 units access to the controls is through the upper latched outer door above the compressor access door Similarly the upper center latched door on sizes 035 060 gives access to the controls Inner panels are secured in place and should not be removed unless all power to the chiller is off Electronic Expansion Valve EXV See Fig 24 for a cutaway view of the EXV High pressure liquid refriger ant enters valve through the top As refrigerant passes through the orifice pressure drops and refrigerant changes to a 2 phase condition liquid and vapor The electronic expansion valve operates through an electronically controlled activation of a stepper motor The stepper motor stays in position unless power pulses initiate the two discrete sets of motor stator wind ings for rotation in either direction The direction depends on the phase relationship of the power pulses The motor directly operates the spindle which has rotating movements that are transformed into linear motion by the transmission in the cage assembly The valve includes a posi tive shut off when closed There are two different EXVs See Table 30 for number of steps The EXV motor moves at 200 steps per second Com manding the valve to either 0 or 100 will add extra steps to the move to ensure the value is open or closed completely Table 30 EXV Steps UNIT SIZE 30RAP EXV STEPS 010 020 1596 025 030 2500 035 045 1596 050 060 2500 T
46. 162 1 625 114 236 77 10 000 163 1 594 110 549 78 9 762 164 1 565 107 006 79 9 526 165 11536 103 558 80 9 300 166 11508 100 287 81 9 078 167 1 480 97 060 82 8 862 168 1453 94 020 83 8 653 169 1 426 91 019 84 8 448 170 1400 88 171 85 8 251 171 1 375 85 396 86 8 056 172 1 350 82 729 87 7 869 173 1 326 80 162 88 7 685 174 1 302 77 662 89 7 507 175 1278 75 286 90 7 383 176 1 255 721940 91 7 165 177 1233 70 727 92 6 999 178 1211 68 542 93 6 838 179 1 190 66 465 94 6 683 180 1 169 64 439 95 6 530 181 11148 62 491 96 6 383 182 11128 60 612 97 6 238 183 1 108 58 781 98 6 098 184 1 089 57 039 99 5 961 185 1070 55 319 100 5 827 186 1 052 53 693 101 5 698 187 1033 52 086 102 5 571 188 1016 50 557 103 5 449 189 998 49 065 104 5 327 190 981 47 627 105 5 210 191 964 46 240 106 5 095 192 947 44 888 107 4 984 193 931 43 598 108 41876 194 915 42324 109 4 769 195 900 41118 110 4 666 196 885 39 926 111 4 564 197 870 38 790 112 4467 198 855 37 681 113 4 370 199 841 36 610 114 4 277 200 827 35 577 115 4185 201 814 34 569 116 4 096 202 800 33 606 117 4 008 203 787 32 654 118 3 923 204 774 31 752 119 3 840 205 762 30 860 120 3 759 206 749 30 009 121 3 681 207 737 29 177 122 3 603 208 725 28 373 123 3 529 209 714 27597 124 3 455 210 702 26 838 125 3 383 211 691 26 113 126 3 313 212 680 25 396 127 3 244 213 670 24 715 128 3 178 214 659 24 042 129 3 112 215 649 23 399 130 3 049 216 639 22 770 131 2986 217 629 22161 132 2 926 218 620 21 573 133 2
47. 4 20 MA INPUTS 77 Default Default Default Default Default Default Default Default Default 44 F 44 F 32 F 95 95 72 F 23 F 15 F 34 COMMENT APPENDIX DISPLAY TABLES cont Outputs Mode and Sub Mode Directory SUB MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT GENERAL OUTPUTS GEN O OUTPUTS CIRCUIT A EXV EXV Open Reset at UnkDig DigeadtoStat SH RST SR AmeuntofSHReset OUTPUTS CIRCUIT A EXV EXV Open 221 OUTPUTS CIRCUIT A s x DER ONOF Comp At Load Percent OUTPUTS CIRCUIT B 78 SUB MODE DISP UNIT OPT1 APPENDIX A DISPLAY TABLES cont Configuration Mode and Sub Mode Directory COMMENT DISPLAY CONFIGURATION English On Metric Default 0 0 English LANG x Language Selection 1 Espanol 2 Francais 3 Portuguese UNIT CONFIGURATION SE Default 5 Default No Default 7 MAX T XX Maximum A1 Unload Time Max 12 010 015 Max 10 018 060 UNIT OPTIONS 1 HARDWARE FLUD X Cooler Fluid Default Water 1 Water 2 Medium Temperature Brine MLV S YES NO Minimum Load Valve Select CSB E ENBL DSBL Csb Boards Enable Default Enable ON OFF Cooler Pump Control Default Off PM1E YES NO Cooler Pump 1 Enable PM2E YES NO Cooler Pump 2 Enable PM P S YES NO Cooler Pmp Periodic Strt Default No PM SL X Cooler Pump Select Def
48. 5 N s Foo gt APPENDIX D OPTIONAL BACNET COMMUNICATIONS WIRING Optional BACnet Communications Wiring The following section is used to configure the UPC Open con troller which is used when the BACnet communications option is selected UPC Open controller is mounted in the main control box per unit components arrangement diagrams TO ADDRESS THE UPC OPEN CONTROLLER The user must give the UPC Open controller an address that is unique on the BACnet network Perform the following proce dure to assign an address 1 Ifthe UPC Open controller is powered pull the screw ter minal connector from the controller s power terminals la beled Gnd and HOT The controller reads the address each time power is applied to it Using the rotary switches see Fig A and B set the con troller s address Set the Tens 10 s switch to the tens dig it of the address and set the Ones 1 s switch to the ones digit As an example in Fig B if the controller s address is 25 point the arrow on the Tens 10 s switch to 2 and the arrow on the Ones 1 s switch to 5 10 s 18 G Fig B Address Rotary Switches BACNET DEVICE INSTANCE ADDRESS The UPC Open controller also has a BACnet Device Instance address This Device Instance MUST be unique for the complete BAC net system in which the UPC Open controller is installed The
49. 8 Heat Enabled 9 Pump Delay sanso ooo J o i oe ows omm 1 OpevGoss MPLFBK Open close PMPZFBK OpevGose Heat Cool PSL CCN DISPLAY TABLES CIRCA_AN Circuit A Analog Parameters DESCRIPTION CIRCUIT A ANALOG VALUES Percent Total Capacity Percent Available Cap Discharge Pressure Suction Pressure Head Setpoint Saturated Condensing Tmp Saturated Suction Temp EXV Open Var Head Press Output Compr Return Gas Temp Discharge Gas Temp Suction Superheat Temp Spare 1 Temperature smn TPS smn TPS nnn EXV mmn 90 z lt Z Z lt Z 2 2 2 lt 2 z lt 2 lt lt z z Z Z Z Z Z Z Z Z Z Z Z Z FORCIBLE FORCIBLE APPENDIX CCN TABLES cont CCN DISPLAY TABLES CIRCADIO Circuit A Discrete Inputs Outputs DESCRIPTION FORCIBLE CIRC A DISCRETE OUTPUTS Compressor A1 Relay ovo KATRIN Compressor A2 Relay Ovot KA2RY Minimum Load Valve Relay On Off 22221 MLV_RLY N CIRC A DISCRETE INPUTS Compressor A1 Feedback Ovo KALFBK N Compressor 2 Feedback Ovot CCN DISPLAY TABLES CIRCB AN Circuit B Analog Parameters DESCRIPTION FORCIBLE CIRCUIT
50. 866 219 610 20 998 134 2 809 220 601 20 447 135 2 752 221 592 19 903 136 2697 222 583 19 386 137 2 643 223 574 18 874 138 2590 224 566 18 384 139 2539 225 557 17 904 140 2488 17 441 141 2 439 16 991 142 2 301 16 552 143 2343 16 131 144 2297 15 714 145 2 253 15 317 146 2209 56 Table 36 10K Thermistor Temperature C vs Resistance Voltage Drop For SPT VOLVAGE RESISTANCE Temp VOLTAGE RESISTANCE TEMP VOLTAGE RESISTANCE Ohms C Ohms Ohms V V V 200 510 15 15 714 62 2 815 188 340 16 15 000 63 2 235 177 000 17 14 323 64 2 157 166 342 18 13 681 65 2 083 156 404 19 13 071 66 2 011 147 134 20 12 493 67 1 943 138 482 21 11 942 68 1 876 130 402 22 11 418 69 1 813 122 807 23 10 921 70 1 752 115 710 24 10 449 71 1 693 109 075 25 10 000 72 1 637 102 868 26 9 571 73 1 582 97 060 27 9 164 74 1 530 91 588 28 8 776 75 1 480 86 463 29 8 407 76 1 431 81 662 30 8 056 77 1 385 77 162 31 7 720 78 1 340 72 940 32 7 401 79 1 297 68 957 33 7 096 80 1 255 65 219 34 6 806 81 1 215 61 711 35 6 530 82 1 177 58 415 36 6 266 83 1 140 55 319 37 6 014 84 1 104 52 392 38 5 774 85 1 070 49 640 39 5 546 86 1 037 47 052 40 5 327 87 1 005 44 617 41 5 117 88 974 42 324 42 4 918 89 944 40 153 43 4 727 90 915 38 109 44 4 544 91 889 36 182 45 4 370 92 861 34 367 46 4 203 93 836 32 654 47 4 042 94 811 31 030 48 3 889 95 787 29 498 49 3 743 96 764 28 052 50 3 603 97 742 26 686 51 3 469 98 721 25 396 52 3 340 99 700
51. At ambient temperatures above 110 F MOP is bypassed at start up to prevent charge backup in the condenser If it appears that the EXV module is not properly control ling circuit operation to maintain correct superheat there are a number of checks that can be made using test functions and initialization features built into the microprocessor control See the EXV Troubleshooting Procedure section to test EXVs EXV Troubleshooting Procedure Follow steps below to diagnose and correct EXV economizer problems Check EXV motor operation first Switch the Enable Off Remote Contact EOR switch to the Off position Press on the Navigator display until Select a menu item appears on the display Use the arrow keys to select the Service Test mode Press The display will be gt TEST OFF OUTS COMP Press password entry may be required and use to change OFF to ON Switch the switch to Enable The Service Test mode is now enabled Move the pointer down to the OUTS sub mode and press Move the pointer to item or as needed Press and the valve position will flash Use to select 100 valve position hold for quick movement and press technician should able to feel the actuator moving placing a hand on the EXV A sight glass is located on the valve body to verify that the sleeve is moving to expose cover slots in the orifice A hard kn
52. B ANALOG VALUES Percent Total Capacity N Percent Available Cap N Discharge Pressure N Suction Pressure N Head Setpoint N Saturated Condensing Tmp N Saturated Suction Temp N EXV Open N Var Head Press Output N Compr Return Gas Temp N Suction Superheat Temp N Spare 2 Temperature N CCN DISPLAY TABLES CIRCBDIO Circuit B Discrete Inputs Outputs DESCRIPTION FORCIBLE CIRC B DISCRETE OUTPUTS Compressor B Relay Compressor B2 Relay N Minimum Load Valve Relay Compressor B1 Feedback On Off Compressor 2 Feedback On Off 2211 K B2 FBK N CIRC B DISCRETE INPUTS 91 DESCRIPTION FANS Fan 1 Relay Fan 2 Relay Cooler Pump Heater UNIT ANALOG VALUES Cooler Entering Fluid Cooler Leaving Fluid Lead Lag Leaving Fluid TEMPERATURE RESET 4 20 mA Reset Signal Outside Air Temperature Space Temperature DEMAND LIMIT 4 20 mA Demand Signal Demand Limit Switch 1 Demand Limit Switch 2 CCN Loadshed Signal MISCELLANEOUS Heat Request Dual Setpoint Switch Cooler LWT Setpoint Ice Done APPENDIX B CCN TABLES cont CCN DISPLAY TABLES OPTIONS Unit Parameters Off On FAN Off On FN2 Of n COOL_EWT COOL_LWT DUAL LWT RST VA DMDSWi Of n DMDSW __ 1 Redline 2 Loadshed 42 Off On ________________ _ __ Oo ______ CEDONE CC
53. Close at Start Up Alarm will be generated and chiller will not be al lowed to start If the chilled water flow switch opens for at least 3 seconds after initially being closed a T196 Flow Lost While Pump 1 Running Alert and an A201 Cooler Flow Interlock Contacts Opened During Normal Operation Alarm will be generated and the machine will stop If the control detects the chilled water pump interlock open for 25 seconds after initially being closed T194 Cooler Pump 1 Contacts Opened During Normal Operation Alert is generated and the unit is shut down If the control detects the chilled water flow switch circuit closed for at least 5 minutes with the pump output OFF an A202 Cooler Pump Interlock Closed When Pump is Off Alarm will be generated and the unit will not be allowed to start If the control detects that the chilled water pump auxiliary contacts are closed for at least 25 seconds while the pump is OFF a T198 Cooler Pump 1 Aux Contacts Closed While Pump Off Alert is generated The chiller will not be allowed to start If the control starts a pump and the wrong interlock circuit closes for at least 20 seconds an A189 Cooler Pump and Aux Contact Input Miswire Alarm will be generated The unit will be prevented from starting As part of a pump maintenance routine the pump can be started to maintain lubrication of the pump seal To utilize this function Cooler Pmp Periodic Start Configuration OPT1
54. Device Instance is auto generated by default and is derived by adding the MAC address to the end of the Network Number The Network Number of a new UPC Open controller is 16101 but it can be changed using i Vu Tools or BAC View device By default a MAC address of 20 will result in a Device In stance of 16101 20 which would be a Device Instance of 1610120 BT485 TERMINATOR OPN UPC JI ey EU 24V ac gt 7 D BACNET 1 vocc Nu k Power CONNECTION oe FTN POWER LED BAS PORT zm 274 gt m Tx1 LED n e7 con Port E UR Owen 1 mon CR2032 p x E T9009 8768 5 MSTP 3 0001 LED 29 oy V oo od 20 Modbus 0100 100 8 H ao Signal 5940 BAS PORT Tx2 LED EIA485 MODE 4 B Boe gt O CI 3 Rx2 LED rr O E BAUD EIA 485 IPM C DIP SWITCHES JUMPE
55. KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION po RESET COOL TEMP RSET SLCT SERV pem me meme L E me eer e LE om _ LE me wer p c mumeweeswer LT pee ome LE pe om Cp LE pes ome ENTER 0 LLBD LEAD LAG BALANCE DELTA LLDY LAG START DELAY PARA ves PARALLEL CONFIGURATION SETPOINT AND RAMP LOAD COOLING SETPOINT SELECT ws ENBL DSBL RAMP LOAD SELECT CRMP COOLING RAMP LOADING SCHD SCHEDULE NUMBER DEADBAND MULTIPLIER Table 10 Configuration Mode and Sub Mode Directory cont MEN E pep ENTER 1 SERVICE CONFIGURATION COOLING RESET TYPE DEMAND LIMIT SELECT LEAD LAG BALANCE SELECT Default Reset 0 No Reset 1 4 to 20 mA Input 2 Outdoor Air Temperature 3 Return Fluid 4 Space Temperature Default 0 0 AF Range 30 to 30 Default 125 F 51 7 C Range 0 to 125 F Default 0 0 F 17 8 C Range 0 to 125 F Default 0 0 F Range 30 to 30 F Default 10 0 AF 5 6 AC Range 0 to 125 COOLER AT Default 0 0 AF 0 0 AC Range 0 to 125 F COOLER AT Default 0 0 F Range 30 to 30 F 34 4 to 1 1 Default None 0 None 1 Switch 2 4 to 20 mA Input 3 Loadshed Default 100 Range Oto 100 Default 0 Range 0109
56. LWT Leaving Water Fluid Temperature Fig 19 Space Temperature Reset 12 2 w E 89 5 n ger 5 a 2 67 5 T SET POINT 44 DESIGN RISE IOF 5 6 O 10 20 30 40 50 60 70 80 90 100 UNIT LOADING LEGEND EWT Entering Water Fluid Temperature LWT Leaving Water Fluid Temperature Fig 20 Standard Chilled Fluid Temperature Control No Reset To use demand limit select the type of demand limiting to use Then configure the demand limit set points based on the type selected DEMAND LIMIT 2 Stage Switch Controlled To con figure demand limit for 2 stage switch control set the Demand Limit Select Configuration 3RSET DMDO to 1 Then configure the 2 Demand Limit Switch points Configura tion 2RSET DLSI and Configuration gt RSET DLS2 to the desired capacity limit See Table 27 Capacity steps are controlled by 2 relay switch inputs field wired to TB6 as shown in Fig 6 and 7 For demand limit by 2 stage switch control closing the first stage demand limit contact will put the unit on the first demand limit level The unit will not exceed the percentage of capacity entered as Demand Limit Switch 1 set point DLST Closing contacts on the second demand limit switch prevents the unit from exceeding the capacity entered as Demand Limit Switch 2 set point The demand limit stage that is set to the lowest
57. RELAY V HPA 0 to 100 VAR HEAD PRESS CL HT ON OFF COOLER PUMP HEATER RMT A ON OFF REMOTE ALARM RELAY CMPA CIRCUITACOMPRESSORTEST CMPB CIRCUITB COMPRESSOR TEST See Note ON OFF COMPRESSOR B1 RELAY ON OFF COMPRESSOR B2 RELAY CC B3 ON OFF COMPRESSOR B3 RELAY ON OFF COMPRESSOR B4 RELAY NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed Tab KEYPAD SUB MODE LR UNIT ENTER le 5 Temperature Mode and Sub Mode Directory ITEM ITEM DISPLAY EXPANSION CU ENT AND LEAVE UNIT TEMPS CEWT XXX X F COOLER ENTERING FLUID TEMPERATURES CIRCUIT A SCT A XXX X F SATURATED CONDENSING TMP CIR A ENTER CIR B ENTER ee TEMPERATURES CIRCUIT B SCT B XXX X F SATURATED CONDENSING TMP NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed SSTB XXX X F SATURATED SUCTION TEMP RGTB XXX X F COMPR RETURN GAS TEMP XXX X F SUCTION SUPERHEAT TEMP Table 6 Pressure Mode and Sub Mode Directory KEYPAD SUB MODE PRC A ENTER ITEM ITEM DISPLAY PRESSURESCIRCUITA CIRCUIT A FE ee XXX X PSIG DISCHARGE PRESSURE PRC B NOTE If the unit has a single circuit the Circuit B items will not app
58. RR TS cone 460 3 60 575 3 60 FNO R 2 5 ATERS Fus 4 Fue 208 230 3 60 230 3 60 Sheva FNO R 3 5 CHC 2 508 830 230V Fa noL SESSA neg YEL GHEG 460 3 80 575 3 8 NO 208 230 3 60 ABD 360 575 THO HER WITH MM 208 230 3 60 KTK R 20 r b m T x D T 89 P iy Ti ae 1 MIS 1 66 20 LOW AMBIENT OPERATION MOTORMASTER V FIOP ACCESSORY m wot incen FB1 MM A BLK npa lt YEL 12 T2 LK 2 2 OFM1 3 BLU 13 73 LK 3 amp GRN YEL I 2 EL 2 MMR 4 SIGNAL CONNECTION FED T VOLTAGE W 1 p mareststrsms 60 25 RED FROM 134 380 60 Blr AUX FB2 FC2 BLK BLK AD QD BLK 1 2 VEL AID BLK 2 XE OFM2 2 Bud BLU OH HD aix 3 el3 sme CHC COH BLK 1 BLK 1 BLK 3 09080 5180 CH HE BLK TABLE 1 TERMINAL VOLTAGE SERIES CONNECTIONS FOR PRIMARY SIDE 575 30 100 380 3 60 700 NH NOTES 230 3 60 500 xu FACTORY WIRING IS IN ACCORDANCE WITH UL 1995 STANDARDS 8 IF CHILLED WATER PUMP INTERLOCK S USED 2083 60
59. WORD will alternate on the display when required The default password is 0111 Press and the 1111 password will be displayed Press again and the first digit will begin to flash Use the arrow keys to change the number and press to accept the digit Continue with the remaining digits of the password The password can only be changed through CCN operator in terface software such as ComfortWORKS ComfortVIEWTM and Service Tool See Tables 2 14 and Appendix A for further details ACCESSORY NAVIGATOR DISPLAY MODULE The Navigator module provides a mobile user interface to the ComfortLink control system which is only available as a field installed accessory The display has up and down arrow keys an key and an key These keys are used to navigate through the different levels of the display structure Press the key until Select a Menu Item is displayed to move through the top 11 mode levels indicated by LEDs on the left side of the display See Fig 2 Once within a Mode or sub mode a gt indicates the cur rently selected item on the display screen Pressing the and keys simultaneously will put the Nav igator module into expanded text mode where the full meaning of all sub modes items and their values can be displayed Press ing the and keys when the display says Select Menu Item Mode LED level will return the Navigator module to its default menu of rotating display items those items in Run Status V
60. additional information on CCN point name Table E LED Status Indicators LED STATUS Lights when power is being supplied to the controller The UPC Open controller is protected by internal solid state polyswitches on Power the incoming power and network connections These polyswitches are not replaceable and will reset themselves if the condition that caused the fault returns to normal Rx Lights when the controller receives data from the network segment there is an Rx LED for Ports 1 and 2 Tx Lights when the controller transmits data to the network segment there is an Rx LED for Ports 1 and 2 Run Lights based on controller status See Table F Error Lights based on controller status See Table F Table F Run and Error LEDs Controller and Network Status Indication RUN LED STATUS 2 flashes per second Normal 2 flashes per second Five minute auto restart delay after system error 2 flashes per second Controller has just been formatted 2 flashes per second Controller is alone on the network 2 flashes per second Exec halted after frequent system errors or control programs halted 5 flashes per second Exec start up aborted Boot is running 5 flashes per second Firmware transfer in progress Boot is running 7 flashes per second 7 flashes per second alternating with Run LED Ten second recovery period after brownout 14 flashes per second 14 flashes per second alternating with Run LED Brownout 106 APPENDIX D OPTIONAL BACNET COMMU
61. before operation Use Service Test function to test operation of pumps Verify that the flow switch input is made when the pump is running For dual pump hydronic systems the control only uses one pump at a time Consult the Installation Instructions supplied with this chiller and use the circuit setter balancing valve installed in hydronic package to adjust fluid flow rate Cooler Pump Control The AquaSnap 30RAP ma chines equipped with a factory installed pump package are configured with the Cooler Pump Control Configura tion CPC ON Machines not equipped with a pump package are config ured with the cooler pump control OFF It is recommended that the machine control the chilled water pump If not a 5 minute time delay is required after the command to shut the machine down is sent before the chilled water pump is turned off This is required to maintain water flow during the shutdown period of the machine With or without this option enabled the cooler pump relay will be energized when the machine enters an ON status 1 On Local On CCN On Time An A207 Cooler Freeze Protection Alarm will energize the cooler pump relay also as an override The cooler pump relay will remain energized if the machine is in MODE 10 Minimum Off Time Cooler Pump Sequence of Operation At any time the unit is in an ON status as defined by the one of the following conditions the cooler pump relay will be enabl
62. cable wire or wiring error Thermistor failure damaged cable wire or wiring error Thermistor failure damaged cable wire or wiring error Thermistor failure damaged cable wire or wiring error Thermistor failure damaged cable wire or wiring error Thermistor failure damaged cable wire or wiring error Faulty expansion valve or suction pressure transducer or leaving fluid thermistor Faulty expansion valve or suction pressure transducer or leaving fluid thermistor Dual LWT thermistor failure damaged cable wire or wiring error Transducer failure poor connection to MBB or wiring damage error Transducer failure poor omatic connection to MBB or wiring damage error Transducer failure poor omatic connection to MBB or wiring damage error Transducer failure poor omatic connection to MBB or wiring omatic damage error Thermistor failure damaged cable wire or wiring error ALARM ALERT CODE T110 T111 T112 T113 T114 T115 T116 T117 T118 A118 T126 T127 T133 T134 A140 A150 A151 A152 Table 42 Alarm and Alert Codes cont ALARM WHY WAS THIS ACTION TAKEN RESET OR DESCRIPTION ALARM UY CONTROL ALERT GENERATED If the compressors are off and discharge pressure reading is lt 26 psig for Circuit not allowed to Alert start Circuit A Loss of Charge Automatic restart after first daily occurrence
63. de mand takes priority if both demand limit inputs are closed If the demand limit percentage does not match unit staging the unit will limit capacity to the closest capacity stage To disable demand limit configure DMDC to 0 See Table 27 EXTERNALLY POWERED DEMAND LIMIT 4 to 20 mA Controlled To configure demand limit for 4 to 20 mA control set the Demand Limit Select Configura tion RSET DMD O to 2 Then configure the Demand Limit at 20 mA Configuration 2ORSET DM20 to the maximum loadshed value desired Connect the output from an externally powered 4 to 20 mA signal to terminal block TB6 terminals 1 and 5 Refer to the unit wiring diagram for these connections to the optional accessory energy management module and terminal block The control will reduce allowable capacity to this level for the 20 mA signal See Table 27 and Fig 21 A CAUTION Care should be taken when interfacing with other manufac turer s control systems due to possible power supply differences full wave bridge versus half wave rectification The two different power supplies cannot be mixed ComfortLink controls use half wave rectification A sig nal isolation device should be utilized if a full wave bridge signal generating device is used DEMAND LIMIT CCN Loadshed Controlled To con figure Demand Limit for CCN Loadshed control set the De mand Limit Select Configuration 3RSET DMDOC to 3 Then configure the Loadshed Group Numbe
64. filter drier Reverse any two incoming power leads to correct Check for correct fan rotation first CCN Network command Configuration error Check unit settings Alarm notifies user that chiller is 100 down ALARM ALERT CODE T153 A154 T155 A156 A157 A172 T173 T174 T175 T176 T177 A189 T190 T191 T192 T193 T194 T195 T196 Table 42 Alarm and Alert Codes cont ALARM OR DESCRIPTION ALERT Alert Real Time Clock Serial EEPROM Chiller is unable Critical Serial EEPROM Configuration storage Chiller is not allowed Hardware failure with Chiller is not allowed a Alert Alarm Alert Alert Alert Alert Alert Alarm Alert Alert Alert Alert Alert Alert Alert Hardware Failure Serial EEPROM Storage Failure Loss of Communication with EXV Board Loss of Communication with EMM 4 to 20 mA Cooling Set Point Input Failure Loss of Communication with the AUX Board 4 to 20 mA Temperature Reset Input Failure 4 to 20 mA Demand Limit Input Failure Cooler Pump Auxiliary Contact Inputs Miswired Cooler Pump 1 Aux Contacts Failed to Close at Start Up Cooler Pump 2 Aux Contacts Failed to Close at Start Up Cooler Pump 1 Failed to Provide Flow at Start Up Cooler Pump 2 Failed to Provide Flow at Start Up Cooler Pump 1 Aux Contacts Opened During Normal Operation Cooler Pump 2 Aux Con
65. inhibited ethylene or propylene glycol 52 HEATER CABLE Optional factory installed cooler and or hydronic package heaters are cycled based on the input from the outside air temperature sensor These heaters when in stalled are designed to protect the cooler and or hydronic pack age from freezing down to 20 F 29 Power for these heat ers is supplied from the main unit power The input from the low pressure transducer provides a back up cooler freeze protection package The MBB shuts down the unit when a low pressure condition exists that could cause the cooler to freeze up A CAUTION Do not disconnect main unit power when servicing com pressor s 1f ambient temperature is below 40 F 4 4 C compressors have either a single circuit breaker or multiple circuit breakers which can be used to shut off power to the compressors If power to the unit must be off for a prolonged period drain the cooler hydronic package if installed and internal piping Add glycol according to Winter Shutdown Step 2 below WINTER SHUTDOWN At the end of the cooling season 1 Drain the fluid from the cooler hydronic package if in stalled and internal piping 2 Fill the cooler and hydronic package with at least 2 gal lons 7 6 L of inhibited propylene glycol or other suit able inhibited antifreeze solution to prevent any residual water in the cooler and hydronic package piping from freezing 3 At the beginnin
66. mA signal produced by the ComfortLink con trols The MMV output speed is displayed in Hz The ComfortLink controls must be configured for MMV operation in order for it to operate This is configured under the Configuration menu Configuration gt MM MMR S and selecting YES This configuration menu also contains the gains and minimum speed for the Motormaster control logic CONFIGURATION The MMV is configured for 1 of 12 operation modes based on the inputs to the control terminal block The 30RAP units use operating modes 5 8 In these con figurations the MMV follows a 4 to 20 mA speed reference signal present on terminals 25 and 2 One additional jumper is required to configure the drive for 50 60 Hz opera tion and input voltage See Table 39 for proper inputs Once the drive is powered it will change to the mode selected according to the inputs See Fig 33 DRIVE PROGRAMMING A CAUTION It is strongly recommended that the user NOT change any programming without consulting Carrier service personnel Unit damage may occur from improper programming To enter password and change program values 1 Press Mode 2 Upper right decimal point blinks 3 Display reads 00 To enter the PROGRAM mode to ac cess the parameters press the Mode button This will ac tivate the PASSWORD prompt if the password has not been disabled The display will read 00 and the upper right hand decimal point will be
67. rotation clockwise when viewed from above If necessary switch any 2 power leads to reverse fan rotation Fig 28 Thermistor Well Table 33 5K Thermistor Temperatures F Resistance Voltage Drop VOLTAGE DROP V Voltage Drop for EWT LWT RGT and OAT RESISTANCE Ohms VOLTAGE DROP V 54 RESISTANCE Ohms 5 929 TEMP F 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 VOLTAGE DROP RESISTANCE V Ohms Table 34 5K Thermistor Temperatures C Resistance Voltage Drop Voltage Drop for EWT LWT RGT and VOLTAGE VOLTAGE TEMP VOLTAGE RESISTANCE TEMP RESISTANCE RESISTANCE Ohms C Kod Ohms C DROP Ohms 100 260 15 7 855 62 1 158 94 165 16 7 499 63 1 118 88 480 17 7 161 64 1 079 83 170 18 6 840 65 1 041 78 125 19 6 536 66 1 006 73 580 20 6 246 67 971 69 250 21 5 971 68 938 65 205 22 5 710 69 906 61 420 23 5 461 70 876 57 875 24 5 225 71 836 54 555 25 5 000 72 805 51 450 26 4 786 73 77
68. shutting a circuit down due to low saturated suction conditions by removing stages of capacity These circuit alert conditions T116 T117 compare saturated suction tempera ture to the configured Brine Freeze Point Set Points 9FRZBR FZ The Brine Freeze point is a user configurable value that must be left at 34 F 1 1 C for 100 water systems A lower value may be entered for systems with brine solutions but this value should be set according to the freeze protection level of the brine mixture Failure to properly set this brine freeze point value may permanently damage the brazed plate heat exchanger The control will initiate Mode 7 Circuit A or Mode 8 Circuit B to indicate a circuit s capaci ty is limited and that eventually the circuit may shut down Head Pressure Control The main base board MBB controls the condenser fans to maintain the lowest condensing temperature possible and thus the highest unit efficiency The MBB uses the saturated condensing tempera ture input from the discharge pressure transducer and outside air temperature sensor to control the fans If OAT is greater than 70 F before a circuit is starting then all condenser fan stages will be energized A fan stage is increased based on SCT saturated condensing temperature When the highest SCT 18 greater than the Fan On Set Point Set Points gt HEAD gt F ON then an additional stage of fan will be added to the current fan stage Fan On Set Point
69. that it be entered again before changes can be made to password protect ed items Press the key to exit out of the expanded text mode NOTE When the Language Selection Configuration gt DISP LANG variable is changed all appropriate display expansions will immediately change to the new language No power off or control reset is required when reconfiguring languages When a specific item is located the item name alternates with the value Press the key at a changeable item and the value will be displayed Press again and the value will begin to flash indicating that the value can be changed Use the up and down arrow keys to change the value and confirm the value by pressing the ENTER key MODE status Q senice Test Temperature Pressures setpoints Alarm Status Outputs ESCAPE ENTER Time Clock Operating Modes Alarms Fig 1 Scrolling Marquee Display Changing item values or testing outputs is accomplished in the same manner Locate and display the desired item Press so that the item value flashes Use the arrow keys to change the value or state and press the key to accept it Press the key to return to the next higher level of structure Repeat the process as required for other items Items in the Configuration and Service Test modes are pass word protected The words PASS and
70. the expansion valve to protect it from excess heat 7 Reconnect the water brine lines 8 Dehydrate and recharge the unit Check for leaks BRAZED PLATE COOLER HEAT EXCHANGER CLEANING Brazed plate heat exchangers must be cleaned chemically A professional cleaning service skilled in chemical cleaning should be used Use a weak acid 5 phos phoric acid or if the heat exchanger is cleaned frequently 5 oxalic acid Pump the cleaning solution through the exchanger preferably in a backflush mode After cleaning rinse with large amounts of fresh water to dispose of all the acid Cleaning materials must be disposed of properly The factory installed strainer screen in front of the water brine inlets of the heat exchangers should be cleaned periodi cally depending on condition of the chiller water brine Oil Charge CAUTION The compressor in a Puron refigerant R 410A system uses a polyol ester POE oil This is extremely hygro scopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precau tions to avoid exposure of the oil to the atmosphere Failure to do so could result in possible equipment damage Puron refrigerant systems use a polyol ester POE oil Use only Carrier approved compressor oil Oil should be visible in compressor oil sight glass An acceptable oil level is from to 3 g of sight glass All comp
71. the chilled water flow switch The Cooler Pump Relay will be energized when the machine is On The chilled water pump interlock circuit consists of a chilled water flow switch and a field installed chilled water pump interlock If the chilled water pump inter lock circuit does not close within five 5 minutes of starting an A200 Cooler Flow Interlock Failed to Close at Start Up Alarm will be generated and chiller will not be allowed to start If the chilled water pump interlock or chilled water flow switch opens for at least three 3 seconds after initially being closed an A201 Cooler Flow Interlock Contacts Opened During Normal Operation Alarm will be generated and the ma chine will stop NO INTEGRAL PUMP DUAL EXTERNAL PUMP CONTROL With two external pumps the following options must be configured Cooler Pump Control Configuration gt 1 gt ON e Cooler Pump 1 Enable Configuration gt PMIE YES e Cooler Pump 2 Enable Configuration PM2E YES The maximum load allowed for the Chilled Water Pump Starters is 5 VA sealed 10 VA inrush at 24 volts The starter coil is powered from the chiller control system The starter for Chilled Water Pump 1 should be wired between LVT 25 and LVT 21 The starter for Chilled Water Pump 2 should be wired between LVT 24 and LVT 21 A field installed chilled water pump interlock for each pump must be connected to each pump s interlo
72. thermostat would be in the conditioned space where it will not be sub jected to either a cooling or heating source or direct exposure to sunlight and 4 to 5 ft above the floor Space temperature sensor wires are to be connected to terminals in the unit main control box The space temperature sensor includes a terminal block SEN and a RJ11 female connector The RJ11 connector is used access into the Carrier Comfort Network CCN at the sensor To connect the space temperature sensor Fig 10 1 Using 20 AWG twisted pair conductor cable rated for the application connect 1 wire of the twisted pair to one SEN terminal and connect the other wire to the other SEN terminal located under the cover of the space temperature sensor 2 Connect the other ends of the wires to terminals 5 and 6 on 5 located the unit control box Units on the CCN be monitored from the space at the 3 Insert and secure the white ground wire to terminal 4 of sensor through the RJ11 connector if desired To wire the RJ11 the space temperature sensor connector into the CCN Fig 11 4 Insert and secure the black wire to terminal 2 of the IMPORTANT The cable selected for the RJ11 connector space temperature sensor wiring MUST be identical to the CCN communication bus 5 Connect the other end of the communication bus cable to wire used for the entire network Refer to Table 18 for the remainder of the CCN communication bus accept
73. to be below 32 F 0 a brine of sufficient concentra tion must be used to prevent freeze up at anticipated suction temperatures See Table 28 Check tightness of all electrical connections Oil should be visible in the compressor sightglass es See Fig 23 An acceptable oil level in the compressors is from to 3 of sight glass Adjust the oil level as re quired See Oil Charge section on page 50 for Carrier ap proved oils Electrical power source must agree with unit nameplate All condenser fan and factory installed hydronic package pump motors are three phase Check for proper rotation of condenser fans first BEFORE attempting to start pumps or compressors To reverse rotation interchange any two of the main incoming power leads Be sure system is fully charged with refrigerant see Check Refrigerant Charge section on this page If unit is a brine unit check to ensure proper brine con centration is used to prevent freezing Verify proper operation of cooler and hydronic package heaters if installed Heaters operate at the same voltage as the main incoming power supply and are single phase Heater current is approximately 0 4 amps for 460 and 575 v units Heater current is approximately 0 8 amps for 230 v units OIL SIGHTGLASS Fig 23 Sight Glass Location START UP AND OPERATION NOTE Refer to Start Up Checklist on pages CL 1 to CL 10 Actual Start Up Actual start up should be done only under
74. used by the slave chiller SUB MODE DISP UNIT OPT1 OPT2 CCN RSET Table 22 Dual Chiller Configuration Master Chiller Example ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION CONTROL METHOD GIRL SWITCH CCNA CCN ADDRESS CCNB CCN BUS NUMBER COOLING RESET LEAD LAG CHILLER ENABLE 8 lt 5 4 9 FI 4 9 gt m m gt m 2 2 nu Q 2 wW LLEN m z 5 m 2 LEAD LAG CHILLER ENABLE MASTER SLAVE SELECT MSSL MASTER SLAVE SELECT m g 2 9 m SLAVE ADDRESS SLVA ENTER ENTER SLVA SLAVE ADDRESS m z 5 m 2 EE EN 9 LEAD LAG BALANCE SELECT m lt 8 gt D LLBL m 2 5 m 2 2 2 5 DEFAULT 0 DEFAULT 1 DEFAULT 0 PROCEED SUBMODE RESET 15 ITEMS SCROLLING STOPS VALUE FLASHES SELECT ENBL CHANGE ACCEPTED DEFAULT MAST SCROLLING STOPS VALUE FLASHES SELECT 2 CHANGE ACCEPTED SCROLLING STOPS VALUE FLASHES SELECT 2 Automatic Table 22 Dual Chiller Configuration Master Chiller Example cont ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION LEAD LAG BALANCE SELECT x E LEAD LAG BALANCE DELTA COMMENTS CHANGE ACCEPTED DEFAULT 168 SUB MODE LLBL EN
75. will be generated and the pump shut down The unit will not be allowed to start If the chilled water flow switch does not close within one 1 minute two alarms will be generated A T193 Cooler Pump 2 Failed to Provide Flow at Start Up Alert and an A200 Cooler Flow Interlock Failed to Close at Start Up Alarm will be generated and chiller will not be allowed to start In either fault case listed above Pump 1 will be commanded to start once Pump 2 has failed If the chilled water flow switch opens for at least 3 seconds after initially being closed a T196 Flow Lost While Pump 1 Running Alert or T197 Flow Lost While Pump 2 Running Alert for the appropriate pump and an A201 Cooler Flow Interlock Contacts Opened During Normal Operation Alarm will be generated and the machine will stop If available the other pump will be started If flow is proven the machine will be allowed to restart If the chilled water pump interlock opens for 25 seconds after initially being closed is detected by the control the appro priate T194 Cooler Pump 1 Contacts Opened During Nor mal Operation Alert or 7195 Cooler Pump 2 Contacts Opened During Normal Operation Alert is generated and the unit is shut down If available the other pump will be started If flow 1s proven the machine will be allowed to restart If the control detects that the chilled water flow switch circuit is closed for at least 5 minutes with the pump output OFF a
76. 12 SUB MODE OPT2 CCN HP A HP B Table 10 Configuration Mode and Sub Mode Directory cont KEYPAD ITEM ENTRY DISPLAY EXPANSION po UNIT OPTIONS 2 CONTROLS CTRL CONTROL METHOD ENBL DSBL ICE MODE ENABLE LS ST 00 00 LOW SOUND START TIME o LS ND 00 00 LOW SOUND END TIME Lat LS LT XXX LOW SOUND CAPACITY LIMIT CCN NETWORK CONFIGURATION Ip p HEAD PRESSURE CMP DELTA A1 DT SCT DELTA FOR COMP A1 A2 DT SCT DELTA FOR 2 HEAD PRESSURE DELTA 13 Default Switch 0 Enable Off Remote Switch 2 Occupancy 3 CCN Control Default Equal Equal 2 Staged Default Automatic 1 Automatic 2 Circuit A Leads 3 Circuit B Leads Default 60 Range 2 to 60 F Default 0 Minutes Range 0 to 15 Minutes Default Disable Default 0 0 Mode Disable 1 Fan Noise Only 2 Fan Compressor Noise Default 00 00 Default 00 00 Default 100 Range 0 to 100 Default 1 Range 1 to 239 Default 0 Range 0 to 239 Default 9600 1 2400 2 4800 3 9600 4 19 200 5 38 400 Range 0 50 Default 12 Range 0 50 Default 12 Range 0 50 Default 12 Range 0 50 Default 12 Table 10 Configuration Mode Sub Mode Directory cont KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION EXV A __ CONFIGU
77. 17 18 19 20 21 22 23 24 25 ITEM EXPANSION CSM CONTROLLING CHILLER WSM CONTROLLING CHILLER MASTER SLAVE CONTROL RAMP LOAD LIMITED TIMED OVERRIDE IN EFFECT LOW COOLER SUCTION TEMPA LOW COOLER SUCTION TEMPB SLOW CHANGE OVERRIDE MINIMUM OFF TIME ACTIVE DUAL SETPOINT TEMPERATURE RESET DEMAND SOUND LIMITED COOLER FREEZE PROTECTION LOW TEMPERATURE COOLING HIGH TEMPERATURE COOLING MAKING ICE STORING ICE HIGH SCT CIRCUIT A HIGH SCT CIRCUIT B MINIMUM COMP ON TIME PUMP OFF DELAY TIME LOW SOUND MODE Table 14 Operating Modes DESCRIPTION Chillervisor System Manager CSM is controlling the chiller Water System Manager WSM is controlling the chiller Dual Chiller control is enabled Ramp load pull down limiting in effect In this mode the rate at which leaving fluid temperature is droppedis limited to a predetermined value to prevent compressor overloading See Cooling Ramp Loading Configuration gt SLCT gt CRMP The pull down limit can be modified if desired to any rate from 0 2 F to 2 F 0 1 to 1 C minute Timed override is in effect This is a 1 to 4 hour temporary override of the programmed schedule forcing unit to Occupied mode Override can be implemented with unit under Local Enable or CCN Carrier Comfort Network control Override expires after each use Circuit A cooler Freeze Protection mode At least one compressor must be on
78. 1s required weigh in the appropriate charge for the circuit as shown on the unit nameplate If partial charging is required operate circuit at full load and use an accurate tem perature sensor on the liquid line as it enters the EX V Use the Temperatures mode on the scrolling marquee display to show the circuit saturated condensing temperature Tempera tures 2CIR A SCT A Or Temperatures gt CIR B SCT B Charging is most accurate at saturated discharge temperatures of 120 to 125 F 49 to 52 C Block condenser air flow as required to reach this temperature range Add refriger ant until the system subcooling SCT A or SCT B minus liquid line temperature entering EXV is approximately 15 to 17 F 9 4 to 8 3 Refrigerant VAPOR only may be added to a circuit through the in suction Schraeder connection on the suction line Table 28 Minimum Cooler Flow Rates and Minimum Loop Volume SEE MAXIMURATE Ve SIZE RATE gpm RATE gpm RATE 1 5 RATE 1 5 3 OT gt o T o 32 i i 6 t 42 018 20 25 020 57 025 030 84 035 103 040 117 045 132 050 14 4 055 158 6 2 4 17 0 CAUTION Never charge liquid into low pressure side of system Do not overcharge Overcharging results in higher discharge pressure possible compressor damage and higher power consumption During charging or removal of refrigerant be sure water is continuously circulating through the cooler to pre
79. 227 25160PV CLPO520LC MS TP specifications Network RS 485 24 AWG single twisted shielded pair low capacitance CL2P TC foam plenum rated See MS TP Installation Guide W241P 2000F 82841 25120 OR for specifications Rnet 4 conductor unshielded CMP 18 AWG plenum rated W184C 2099BLB 6302UE 21450 CLP0442 LEGEND American Wire Gage CL2P Class 2 Plenum Cable CMP Communications Plenum Rated FEP Fluorinated Ethylene Polymer TC Tinned Copper LOCAL ACCESS TO THE UPC OPEN CONTROL LER The user can use a BACview handheld keypad dis play unit or the Virtual BACview software as a local user inter face to an Open controller These items let the user access the controller network information These are accessory items and do not come with the UPC Open controller The BACview unit connects to the local access port on the UPC Open controller See Fig F The BACview software must be running on a laptop computer that is connected to the local access port on the UPC Open controller The laptop will re quire an additional USB link cable for connection See the BACview Installation and User Guide for instruc tions on connecting and using the BACview device To order a BACview Handheld BV6H consult Commer cial Products 1 Open Control System Master Prices CONFIGURING THE UPC OPEN CONTROLLER S PROPERTIES The UPC Open device and ComfortLink control must be set to the same CCN Address Element
80. 24 171 53 3 217 100 680 23 013 54 3 099 101 661 21 918 55 2 986 102 643 20 883 56 2 878 103 626 19 903 57 2 774 104 609 18 972 58 2 675 105 592 18 090 59 2 579 106 576 17 255 60 2 488 107 561 16 464 61 2 400 Table 37 86K Thermistor vs Resistance DTT TEMP RESISTANCE TEMP RESISTANCE C Ohms C Ohms 40 2 889 600 75 12 730 35 2 087 220 80 10 790 30 1 522 200 85 9 200 25 1 121 440 90 7 870 20 834 720 95 6 770 15 627 280 100 5 850 10 475 740 105 5 090 5 363 990 110 4 450 0 280 820 115 3 870 5 218 410 120 3 350 10 171 170 125 2 920 15 135 140 130 2 580 20 107 440 135 2 280 25 86 000 140 2 020 30 69 280 145 1 800 35 56 160 150 1 590 40 45 810 155 1 390 45 37 580 160 1 250 50 30 990 165 1 120 55 25 680 170 1 010 60 21 400 175 920 70 15 070 180 830 57 SPACE TEMPERATURE ACCESSORY OR DUAL CHILLER LWT C piti rm 2 oo Ce Rpg wes 8 a e 489 ase yn 20 ak gt gt ai ce GP 63 10 B 99 ex SPTA s LEGEND ACCSY Accessory DPT Discharge Pressure Transducer LWT Leaving Water Temperature Sensor LVT Low Voltage Terminal OAT Outdoor Air Temperature Sensor RGT Return Gas Temperature Sensor SEN Sensor Terminal Block SPT Space Temperature Sensor Fig 29 Thermistor Connections to Main Base Board J8 Connector Fig 30 Chilled Water Flow Switch 0
81. 30RAP010 060 AQUASNAPS Air Cooled Chillers with COMFORTLINK Controls Controls Start Up Operation Service and Troubleshooting CONTENTS Page SAFETY CONSIDERATIONS 2 GENERAL ere 3 18 Conventions Used in this Manual 3 Basic Controls Usage 3 CONTROLS 19 44 General sores 19 Main Base Board 19 Energy Management Module 19 Current Sensor Board CSB 19 AUX Board 19 Expansion Valve Board 19 Enable Off Remote Contact Switch 19 Emergency On Off Switch 19 Board 19 Control Module Communication 19 Carrier Comfort Network CCN Interface 19 SONSOMS TTA 20 COOLER LEAVING FLUID SENSOR COOLER ENTERING FLUID SENSOR COMPRESSOR RETURN GAS TEMPERATURE SENSOR OUTDOOR AIR TEMPERATURE SENSOR OAT DISCHARGE TEMPERATURE THERMISTOR DTT REMOTE SPACE TEMPERATURE SENSOR OR DUAL LEAVING WATER TEMPERATURE SENSOR Energy Management Module 29 Loss of Cooler Flow Protection 29 Electronic Expansion Valves
82. 32 0 12 MEASURE FROM FAN WEB OF FAN DECK ORIFICE Fig 31 Mounted Fan Position 58 LOW SOUND FAN A shroud and a wire guard provide protection from the rotating fan The exposed end of the fan motor shaft is protected from weather by grease If fan motor must be removed for service or replacement be sure to re grease fan shaft and reinstall fan guard The fan motor has a step in the motor shaft For proper performance fan should be positioned such that it is securely seated on this step Tighten the bolt to 15 1 ft lb 20 1 3 IMPORTANT Check for proper fan rotation counter clockwise when viewed from above If necessary switch any 2 power leads to reverse fan rotation Motormaster V Controller The Motormaster V controller is standard on size 010 and 015 units For other sizes the optional or accessory Motormaster V controller uses an in put signal from the AUX board See Fig 32 The controller is factory configured and requires no field programming Ifa situ ation arises where the drive does not function properly the in formation provided below and in Table 38 can be used to trou bleshoot the drive A WARNING Hazard of electrical shock Wait three minutes after discon necting incoming power before servicing drive Capacitors retain charge after power is removed Drive assembly includes externally mounted current limiting resistors Use ext
83. 4 to 20 mA signal input which will re duce the maximum capacity linearly between 100 at a 4 mA input signal no reduction down to the user configurable level at a 20 mA input signal The third type uses the CCN Loadshed module and has the ability to limit the current operating capaci ty to maximum and further reduce the capacity if required NOTE The 2 stage switch control and 4 to 20 mA input sig nal types of demand limiting require the energy management module EMM 21 70 18 3 65 5 CHANGE i RESET TEMPERATURE T 156 60 lt lt 55 T H 50 E 72 5 45 CHILLED FLUID SET POINT SET S 44 40 40 45 50 55 60 65 70 75 80 85 90 OUTSIDE TEMPERATURE F t 1 1 1 1 1 44 72 100 12 8 15 6 183 211 239 267 294 322 OUTSIDE TEMPERATURE LEGEND LWT Leaving Water Fluid Temperature Fig 18 Outdoor Air Temperature Reset 12 2 54 TN 52 5 E CHANGE IN m RESET TEMPERATURE W loop u 50 trt B 5 89r amp 48 MAXIMUM RESET B zer 46 5 67 44R CHILLED FLUID SET POINT 5 6 42 RESET SET POINT 65 66 67 68 69 70 72 13 74 SPACE TEMPERATURE F 3 1 1 1 1 ae ae oe 183 189 194 200 206 21 217 222 22 8 23 3 SPACE TEMPERATURE LEGEND
84. 5 48 536 27 4 583 74 747 45 807 28 4 389 75 719 43 247 29 4 204 76 693 40 845 30 4 028 77 669 38 592 31 3 861 78 645 38 476 32 3 701 79 623 34 489 33 3 549 80 602 32 621 34 3 404 81 583 30 866 35 3 266 82 564 29 216 36 3 134 83 547 27 633 37 3 008 84 531 26 202 38 2 888 85 516 24 827 39 2 773 86 502 23 532 40 2 663 87 489 22 313 41 2 559 88 477 21 163 42 2 459 89 466 20 079 43 2 363 90 456 19 058 44 2 272 91 446 18 094 45 2 184 92 436 17 184 46 2 101 93 427 16 325 47 2 021 94 419 15 515 48 1 944 95 410 14 749 49 1 871 96 402 14 026 50 1 801 97 393 13 342 51 1 734 98 385 12 696 52 1 670 99 376 12 085 53 1 609 100 367 11 506 54 1 550 101 357 10 959 55 1 493 102 346 10 441 56 1 439 103 335 9 949 57 1 387 104 324 9 485 58 1 337 105 312 9 044 59 1 290 106 299 8 627 60 1 244 107 285 8 231 61 1 200 55 Table 35 10K Thermistor Temperature F Resistance Voltage Drop 5 CORE RESISTANCE TEMP RESISTANCE TEMP NEO RESISTANCE Ohms F Ohms F Ohms V V V 196 453 61 14 925 147 2166 189 692 62 14 549 148 2 124 183 300 63 14 180 149 2 083 177 000 64 13 824 150 2 043 171 079 65 13 478 151 2 003 165 238 66 13 139 152 1 966 159 717 67 12 814 153 1 928 154 344 68 12 493 154 11891 149 194 69 12 187 155 1 855 144 250 70 11 884 156 1 820 139 443 7i 11 593 157 1 786 134 891 72 11 308 158 1752 130 402 73 11 031 159 1719 126 183 74 10 764 160 1 687 122 018 75 10 501 161 1 656 118 076 76 10 249
85. 53 Motormaster V Controller 58 GENERAL OPERATION CONFIGURATION DRIVE PROGRAMMING EPM CHIP LOSS OF CCN COMMUNICATIONS REPLACING DEFECTIVE MODULES Hydronic 63 MAINTENANCE 63 64 Recommended Maintenance Schedule 63 Microchannel Heat Exchanger MCHX Condenser Coil Maintenance and Cleaning Recommendations 64 TROUBLESHOOTING 64 73 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53300067 01 Printed in U S A Form 30RAP 2T Pg 1 12 10 Replaces 30RAP 1T CONTENTS cont Page complete Unit Stoppage and Restart 64 GENERAL POWER FAILURE UNIT ENABLE OFF REMOTE CONTACT SWITCH IS OFF CHILLED FLUID PROOF OF FLOW SWITCH OPEN OPEN 24 V CONTROL CIRCUIT BREAKERS COOLING LOAD SATISFIED THERMISTOR FAILURE LOW SATURATED SUCTION COMPRESSOR SAFETIES Alarms and 5 65 APPENDIX A DISPLAY TABLES 74 89 APPENDIX B CCN TABLES 90 100 APPENDIX C FACTORY SETTINGS FOR PUMP AND MANUAL STARTERS 101 APPENDIX D OPTIONAL BACNET COMMUNICATONS WIRING 102 109 APPENDIX E MAINTENANCE SUMMARY AND LOG 5 5
86. 9 Outputs Mode and Sub Mode Directory KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION COMMENT GEN O o Se j GENERAL OUTPUTS ENTERI FAN1 ON OFF FAN 1 RELAY FAN SPEED CIRCUIT A FAN SPEED CIRCUIT B COOLER PUMP RELAY 1 COOLER PUMP RELAY 2 COOLER PUMP HEATER MINIMUM LOAD VALVE RELAY 10 Table 9 Outputs Mode and Sub Mode Directory cont KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION COMMENT A EXV peccemus OUTPUTS CIRCUIT A EXV n Lows p o meer ANN B EXV x _ OUTPUTS CIRCUIT B EXV 9m meme m owes ACTIVE MOP SETPT POSITION LIMIT SPARE 2 TEMPERATURE e CIR A COMPRESSOR A1 RELAY m 2 OUTPUTS CIRCUIT A COMP A1 LOAD PERCENT COMPRESSOR A2 RELAY COMPRESSOR A3 RELAY CIR B OUTPUTS CIRCUIT B See Note NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed Table 10 Configuration Mode and Sub Mode Directory KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION COMMENT DISP f DISPLAY CONFIGURATION TEST ON OFF TEST DISPLAY LEDS METR ON OFF METRIC DISPLAY Off English On Metric Default 0 LANG x LANGUAGE SELECTION 0 E
87. 9 Default 0 Range 0 to 60 Default 60 minutes Range 0 120 minutes Default 80 Range 0 to 100 Default 50 Range 0 to 100 Default Disable Default Master Default 0 Range 0 to 239 Default Master Leads 0 Master Leads 1 Slave Leads 2 Automatic Default 168 hours Range 40 to 400 hours Default 5 minutes Range 0 to 30 minutes Default YES CANNOT BE CHANGED Default Single 0 Single 1 Dual Switch 2 Dual CCN Occupied 3 4 to 20 mA Input requires EMM Default Enable Default 1 0 Range 0 2 to 2 0 Default Range Default Range 7 1 to 99 1 1 oo to 4 0 Table 10 Configuration Mode Sub Mode Directory cont KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION Best 1 BROADCAST CONFIGURATION Fe T D BC ON OFF CCN TIME DATE BROADCAST ese ON OFF GLOBAL SCHEDULE BROADCAST Table 11 Time Clock Mode and Sub Mode Directory KEYPAD ITEM SUB MODE DISPLAY SUB ITEM DISPLAY COMMENT TIME ______ Tl Lm HOUR AND MINUTE Military 00 00 23 59 DATE MONTH DATE DAY AND YEAR ee eee DST DAYLIGHT SAVINGS TIME HOL L LOCALHOLIDAY SCHEDULES HD 01 through HD 30 SCH L LOCAL OCCUPANCY SCHEDULE OCCUPANCY SCHEDULE FERT 11 sememmer Lp ew Dee eem
88. ABLE LOAD 0 2 4 6 8 12 14 16 18 20 DEMAND LIMIT SIGNAL 4 20 mA INPUT Fig 21 4 to 20 mA Demand Limiting MAXIMUM SET POINT 70 F 21 1 SET POINT F C FLUD 1 MINIMUM SET POINT 38 F 3 3 C FLUD 2 MINIMUM SET POINT 14 10 C 13 1 15 4 17 7 20 4 TO 20 mA SIGNAL TO EMM EMM Energy Management Module Fig 22 Cooling Set Point 4 to 20 mA Table 27 Configuring Demand Limit Ew re em Ed x mena Tie em oem pom j pes EL we EE X cesar _ Default 0 0 None Demand Limit Select 1 Switch 2 410 20 mA Input 3 CCN Loadshed L LE pee pee semen NN M sss Lm pee s 1 Fm eee moss xe Cum ER e Seven items skipped in this example Digital Scroll Option The 30RAP units have a DTT is installed along with the AUX board for control of the factory installed option for a digital scroll compressor which DUS provides additional stages of unloading for the unit The digital DIGITAL COMPRESSOR CONFIGURATION When a compressor is always installed in the A1 compressor location digital compressor is installed the configuration parameter When a digital com
89. BRN 2 GND 1 I v10 1 BLK 1 Dem 2 2 one 3 3 K 3 Lo 3 81 3 GRN YEL 247 MBB O s 260 arn lt AUX FCI 1 I vio 2 E m J2 rr rase ur 7 810 1 YEL 34624 Kea 2 2 SN 035 60 ONLY BRN BLU 4 34 8LC 3 4 amp GRN YEL 1 3 055 060 ONLY V10 e BRN amp CW gt gt CIT CY T Fig 7A Typical Wiring Schematic 30RAP035 060 Units Power Wiring 26 3 2 AMPS 4 RED 4 TRANI 1 ato R m RED BRN MBB 21 2 gy MBB 5 2 AMPS ORN RED Ti RED SECONDARY 24V 2 BRN LBRN UPC GND REDE RED TD wen D sma ORN O A O ORN 1 c BRN CWFS 3 SEWE J10A 1 BRN QD CB1 hut PLI 8 at Se ek C2 TD 2 BLK SEE WOTE 12 L QG 3 PBRN A2Q CHC PL2 3 PL2 4 3 RED BLU L
90. C The high saturated suction alert is generated and the circuit is shut down T114 Circuit A Low Superheat T115 Circuit B Low Superheat Alert codes 114 and 115 occur when the superheat of a circuit 15 less than 5 F 2 8 C for 5 continuous minutes The low superheat alert is generated and the circuit is shut down T116 Circuit A Low Cooler Suction Temperature T117 Circuit B Low Cooler Suction Temperature Alert codes 116 and 117 are for circuits A and B respectively These alerts are generated if the capacity stages are reduced three times without a 30 minute interval between capacity reductions due to operating mode 7 or mode 8 T118 High Discharge Gas Temperature Alert 118 High Discharge Gas Temperature Alarm This alert or alarm occurs for units which have the digital compres sor installed on circuit A If discharge gas temperature 18 great er than 268 F 131 1 C the circuit will be shut off The alert will reset itself when discharge temperature is less than 250 F 121 1 C If this alert occurs 3 times within a day the A118 alarm will be generated and the alarm must be reset manually The cause of the alert is usually low refrigerant charge or a faulty thermistor T126 Circuit A High Head Pressure T127 Circuit B High Head Pressure Alert codes 126 and 127 are for circuits A and B respectively These alerts occur when the appropriate saturated condensing temperature is greater than the operatin
91. CCUPANCY PERIOD 7 Military 00 00 25 58 Military 00 00 23 59 PERT OCCUPANCY PERIOD 8 Miltary 06 00 25 8 Miltary 00 00 23 59 PERS SCHEDULE OVERRIDE OUR OVR T Timed Override Hours Default 0 Range 0 4 hours OVR L Override Time Limit Default 0 Range 0 4 hours T OVR YES NO Timed Override User Entry 88 APPENDIX DISPLAY TABLES cont Operating Mode and Sub Mode Directory SUB MODE COMMENT MODES CONTROLLING UNIT MODE Alarms Mode and Sub Mode Directory SUB MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT CURRENTLY ACTIVE ALARMS RNT AXXX 5 TXXX Current Alarms 1 25 RCRN YES NO ResetAl Current Alarms ALARM HISTORY HIST AXXX Alarms shown as ix Alarm History 1 20 Alerts are shown as TXXX 89 DESCRIPTION Control Mode Occupied CCN Chiller Low Sound Active Alarm State Active Demand Limit Override Modes in Effect Percent Total Capacity Requested Stage Active Set Point Control Point Entering Fluid Temp Leaving Fluid Temp Emergency Stop Minutes Left for Start PUMPS Cooler Pump Relay 1 Cooler Pump Relay 2 Cooler Pump 1 Interlock Cooler Pump 2 Interlock Cooler Flow Switch Lead Pump Rotate Cooler Pumps Now Heat Cool Select APPENDIX B CCN TABLES CCN DISPLAY TABLES A_UNIT General Unit Parameters VALUE UNITS POINT NAME 0 Test 1 Local 2 CCN Off 3 Clock Off STAT 4 Emergency Stop 5 Local On 6 CCN On 7 Clock On
92. CN BUS NUMBER PRESS ESCAPE KEY TO DISPLAY OPT2 PRESS DOWN ARROW KEY TO DISPLAY CCN PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW CCN CCN Network Configuration SUB MODE ENTRY Wx O CONBUSNUMBER x BAD OONBADDRME x PRESS ESCAPE KEY DISPLAY CCN PRESS DOWN ARROW KEY TO DISPLAY HPA PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW HP A Head Pressure Cmp Delta Configuration SUB MODE ITEM ITEM EXPANSION DISPLAY ENTRY A1 DT SCT DELTA FOR COMP A1 A2 DT SCT DELTA FOR COMP A2 PRESS ESCAPE KEY TO DISPLAY PRESS DOWN ARROW KEY TO DISPLAY HPB PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW HP B Head Pressure Cmp Delta Configuration SUB MODE ITEM ITEM EXPANSION DISPLAY ENTRY B1 DT SCT DELTA FOR COMP B1 HP B B2 DT SCT DELTA FOR COMP B2 CL 6 CUT ALONG DOTTED LINE ALONG DOTTED LINE Unit Start Up cont PRESS ESCAPE KEY TO DISPLAY HP B PRESS DOWN ARROW KEY TO DISPLAY EXV A PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW EXV A Circuit A EXV Configuration SUB MODE ENTRY Se OPEN EXV ON 2ND MOVE EXV ON DISCRSOL PRESS ESCAPE KEY TO DISPLAY EXV A PRESS DOWN ARROW KEY TO DISPLAY EXV B PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW EXV B Circuit B EXV Configuration SUB MODE ENTRY EX
93. DT is not satisfied the changeover will not occur With the machine at Capacity Stage 0 the pumps would rotate automatically as part of the normal routine With Cooler Pump Select PM SL set to 1 Pump 1 Starts First or 2 Pump 2 Starts First a manual changeover can be ac complished by changing PM SL only The machine Remote Off Enable Switch must be in the OFF position to change this variable The Rotate Cooler Pump Now ROT P feature does not work for these configuration options As part of a pump maintenance routine the pumps can be started to maintain lubrication to the pump seal To utilize this function Cooler Pmp Periodic Start Configuration gt OPT1 PM PS must be set to YES This option is set to NO as the factory default If feature is enabled and the pump s not operating then the pumps will be operated every other day for 2 seconds starting at 14 00 hours If a pump has failed and has an active Alert condition it will not be started that day Configuring and Operating Dual Chiller Con trol The dual chiller routine is available for the control of two units supplying chilled fluid on a common loop This control algorithm is designed for parallel fluid flow arrangement only One chiller must be configured as the master chiller the other as the slave An additional leaving fluid temperature thermistor Dual Chiller LWT must be installed as shown in Fig 16 and 17 and connected to the master chiller Refer
94. DULE 27 Duration days HOLIDAY SCHEDULE 28 Duration days HOLIDAY SCHEDULE 29 Duration days HOLIDAY SCHEDULE 30 Duration days 86 COMMENT 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 1 12 1 January 2 February etc 01 31 APPENDIX A DISPLAY TABLES cont Time Clock Mode and Sub Mode Directory cont SUB MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT SCH N 1 Schedule Number 0 SCH L LOCAL OCCUPANCY SCHEDULE OCCUPANCY PERIOD 1 Military 00 00 239 Military 00 00 23 59 PER OCCUPANCY PERIOD 2 Military 00 00 23 59 Military 00 00 25 55 PER2 OCCUPANCY PERIOD 3 Military 00 00 23 8 Military 00 00 23 59 PERS OCCUPANCY PERIOD 4 Military 00 00 25 8 Miltary 00 00 23 59 PERA OCCUPANCY PERIOD 5 Military 00 00 23 8 Miltary 00 00 28 50 PERS 87 APPENDIX DISPLAY TABLES cont Time Clock Mode and Sub Mode Directory cont SUB MODE COMMENT OCCUPANCY PERIOD 6 Miltary 0000 2559 Miltary 00 00 25 55 PERG O
95. E TANK D 4 HEATER RELAY ORN RED A 10 8 HHD ORN BRN 11 HPS A 520 BLK e BLK BLK BLK 1 407 ORN i RN C BRN TBI stt wort 1 14 PLI 5 MP A2 PLI 6 2 039 GRA lt 10 2 1020 6 DO BRN 2 15 SEE NOTE 11 VIO 29 m 3 11 297 vIO p BRN 781 gt BRN amp 2 18 4 1 7 RED BRN 2 CWP1 J6 ALUR lf e 20 Frey T BRN lt INSTALLED WIRING a WFS 2 rarer e wee DUAL SETPOINT oio Bel as J3 ORN K2 14 gt MAIN BASE BOARD To S 1 lt O irten J9 JT REDD HIRED D 2 7 10 44H HE3 v10 amp D 8 J5 KS SIGNAL PORT 1A 2 KS SHIEL UPC OPT RGTA FIELD INSTALLED FIELD INSTALLED MAX LOAD 5VA SEALED 10VA INRUSH O RED BLK lt Or lt BLK RED CD D DL wo reo KED ME 360 KO QD or lt WHT lt gt 9 CD ODE RED AO OSE C sm SEE NOTES ON PAGE 24 PL EXVA D su gt GE DS w 4 gt om 5 RID or lt EXV A DARE 1 25 1
96. Head Pressure Gain mnn HPIGAN Head Pressure D Gain mnn f HP DGAN Minimum Fan Speed MIN VHP 94 DESCRIPTION SERVICE Brine Freeze Point Pump Service Interval COMPRESSOR ENABLE Enable Compressor A1 Enable Compressor A2 Enable Compressor B1 Enable Compressor B2 DESCRIPTION COOLING Cooling Setpoint 1 Cooling Setpoint 2 ICE Setpoint RAMP LOADING Cooling Ramp Loading Brine Freeze Point Head Setpoint Fan On Set Point Fan Off Set Point Fan Stage Delta Base Fan Off Delta Temp DESCRIPTION EXV Open Circuit A Approach Approach Setpoint EXVA Override Suction Superheat Temp Active Superheat Setpt Active MOP Setpt Cir A EXV Position Limit APPENDIX B CCN TABLES cont CCN SERVICE TABLES SERVICE nnn n La e hours Disablelenable Disable Enable Disable Enable Disabe Enabe 7 CCN SETPOINT TABLES SETPOINT 20 to 70 20 to 70 2201032 0 21020 gu o o o 20 to 34 ____ ________ CCN MAINTENANCE TABLES CIRA EXV Chr mm mn anni ta FY 1 95 POINT NAME BRN_FRZ SI PUMPS ENABLEA1 ENABLEA2 ENABLEB1 ENABLEB2 POINT NAME CSP1 CSP2 CSP3 CRAMP BRN_FRZ HSP FANONSP FANOFFSP FSTGDLTA B_FANOFF POINT NAME EXV_A CIRA_APP APPRA_SP EXVAOVRR SH_A ACTSH_SP ACMOP_SP PLMA APPENDIX CCN TABLES cont CCN MAI
97. IEW In addition the password will be dis abled requiring that it be entered again before changes can be made to password protected items Press the key to exit out of the expanded text mode NOTE When the Language Selection Configuration DISP LANG variable is changed all appropriate display expansions will immediately change to the new language No power off or control reset is required when reconfiguring languages When a specific item is located the item name appears on the left of the display the value will appear near the middle of the display and the units 1f any will appear on the far right of the display Press the key at a changeable item and the val ue will begin to flash Use the up and down arrow keys to change the value and confirm the value by pressing the key Changing item values or testing outputs is accomplished in the same manner Locate and display the desired item Press so that the item value flashes Use the arrow keys to change the value or state and press the key to accept it Press the key to return to the next higher level of structure Repeat the process as required for other items Items in the Configuration and Service Test modes are pass word protected The words Enter Password will be displayed when required with 1111 also being displayed The default password is 1111 Use the arrow keys to change the number and press to enter the digit Continue with the re maining digits of the password The
98. LU 208 230 ONLY BRASS SCREW umm m TOR PRIMARY SIDE SECONDARY SIDE MS CWP1 3153 60 100 WI H2 XF X7 BLK 3 HIT BLK L1 2301 80 CWP1 208 3 60 500 H3 H4 XF Y2 aoe pepe pe DOE wc cus ie BLU 9413 01 BLK L3 GRN YEL MS CWP2 7 01 gt 7 17 UNIT VOLTAGE Ta un YEL 426 902 214 HID BLK L2 RATER 2087230 3 60 THO R 3 5 man Bern LEES 8LU 4 35 9 3 34 HO BLK 13 GRNIYEL 4650 3 60 FNO R 2 515 3 THO R 1 5 LQ la i n a a bhau a pim Tua Ww 460 3 80 575 3 8 soova ENO R 2 5 B3 FB1 1 208 230 3 60 230 3 60 FNO R 3 5 BLATT ee k Gk BL HKI BLK 1 lt SOES __ 2 T7 11412 X12 YEL 2 8LK 2 OFM3 EET Ton wr i ie X d EN TBI 380 3 80 460 3 60 575 3 80 TRS BLU 8LK 3 wo 2087230 3 60 rr GRN YEL FB2 515 3 60 NONE LP CC 20 CHC 360 3 60 460 360 3575 3 60 m 208 230 3 60 BLDH HZ BLK 1 BLK e wT 3 BLK cooLER Pup 2 gpr 208 230 230V YEL GOH KE BLK NOTES FCB2 FB2 SEE NOTE 7 FACTORY WIRING IS IN ACCORDANCE WITH UL 1995 STANDARDS 9 IF CHILLED WATER PUMP NTERLOCK IS USED 1 ANY FIELD MODIFICATIONS OR ADDITIONS MUST BE IN REMOVE JUMPER FROM TERMINAL 11 TO 17 AND BLK Q36 e 81 1
99. MMDDYYHHMM x SIM 1 o MWDDYYHHMM COIL MAINTENANCE User Entry COIL MAINTENANCE DATES imo MWDDYYHHMM Pim MWDDYYHHMM CLM2 cims 1 MWDDYYHHMM cim O MMWDDYYHHMM SOFTWARE VERSION NUMBERS CESR131460 XXXXX_ 172 5 _ 5 131333 EM CESR13174XO0 __ MARO CESR131171 XXXXX NV CESRIS0227XXX 75 APPENDIX DISPLAY TABLES cont Service Test Mode and Sub Mode Directory SUB MODE COMMENT To enable Service Test mode move Move switch to ENABLE OUTPUTS EXV Open EXV Open dus CIRCUIT A COMPRESSOR TEST CIRCUIT COMPRESSOR TEST cupa Temperature Mode and Sub Mode Directory SUB MODE COMMENT ENTERING AND LEAVING UNIT TEMPERATURES ae TEMPERATURES CIRCUIT A TEMPERATURES CIRCUIT B Pressures Mode Sub Mode Directory SUB MODE COMMENT PRESSURES CIRCUIT A PRC A PRESSURES CIRCUIT B PRC B 76 SUB MODE COOL HEAD FRZ SUB MODE GEN I CRCT 4 20 APPENDIX A DISPLAY TABLES cont Set Points Mode and Sub Mode Directory mem DISPLAY ITEMDESCRIPTION RANGE COOLING SET POINTS HEAD PRESSURE SET POINTS ____ __ ocr FanOnSetPin FO cr Fan Off SetPoint BRINE FREEZE SET POINT 2201034 Inputs Mode Sub Mode Directory ITEM DISPLAY ITEM DESCRIPTION GENERAL INPUTS CIRCUIT INPUTS
100. MODE_14 Demand Sound Limited MODE_15 Cooler Freeze Protection MODE_16 Low Temperature Cooling MODE_17 High Temperature Cooling MODE_18 Making ICE MODE_19 Storing ICE MODE 20 High SCT Circuit A MODE 21 High SCT Circuit B MODE 22 Minimum Comp On Time MODE 23 Pump Off Delay Time 24 Owo ON APPENDIX B CCN TABLES cont CCN MAINTENANCE TABLES ALARMS DESCRIPTION POINT NAME Relive Alarm 1 ALARMO1C Active Alarm 2 ALARMO2C Active Alarm 3 ALARMOSC Active Alarm 4 ALARMO4C Active Alarm 45 ALARM05C Active Alarm 46 ALARM06C Active Alarm 7 ALARMO7G Active Alarm 8 Active Alarm 9 ALARMOSC Active Alarm 10 Active Alarm 11 ALARMTIC Active Alarm 12 ALARMI2C Active Alarm 13 ALARMI3C Active Alarm 14 ALARM14C Active Alarm 15 15 Active Alarm 16 ALARMI6C Active Alarm 17 ALARM17C Active Alarm 18 18 Active Alarm 19 ALARM19C Active Alarm 20 2 Active Alarm 21 ALARMZIC Active Alarm 22 ALARM22C Active Alarm 23 23 Active Alarm 24 ALARM24C Active Alarm 25 ALARM25C CCN MAINTENANCE TABLES VERSIONS DESCRIPTION VALUE EXV AUX MBB nn nn EMM MARQUEE NAVIGATOR CCN MAINTENANCE TABLES LOADFACT DESCRIPTION POINT NAME CAPACITY CONTROL Load Unload Factor Control Point CTRL_PNT Entering Fluid Temp EWT Leaving Fluid Temp LWT 21452201 Ramp Load Li
101. N Baud Rate 3 9600 4 219 200 5 38 400 HEAD PRESSURE CMP DELTA Default 12 SCT Delta For Comp A1 Range 0 to 50 Default 12 SCT Delta For Comp A2 Range 0 to 50 HEAD PRESSURE CMP DELTA SCT Delta For Comp B1 Default 12 Range 0 to 50 Default 12 SCT Delta For Comp B2 Range 0 to 50 APPENDIX A DISPLAY TABLES cont Configuration Mode and Sub Mode Directory cont SUB MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT CIR A EXV CONFIGURATION Default 50 i Default 8 010100 RNG A XXXXX EXVA Steps In Range 0 to 65535 Default 200 SPD A XXXXX EXVA STeps Per Second 0 to 65535 m Default 0 POF A EXVA Fail Position In 0 to 100 m Default 0 MIN A XXXXX EXVA Minimum Steps 0 to 65535 MAX A XXXXX EXVA Maximum Steps 0 to 65535 OVR A EXVA Overrun Steps abend EXV A Default 1 EXVA Stepper 0 UNIPOLAR 1 BIPOLAR H SCT EE OD High High SCT Threshold Threshold p tg X PCT ENSE Open EXV On 2nd Comp rud X PER Move EXV On DISCRSOL aD A PCT Pre open EXV Fan Adding pore M PCT Pre close EXV Fan Sub pod S PCT Pre close EXV Lag Shut eee DELY Lag Start Delay CONFIGURATION Default 50 1 m Default 8 MIN B EXV Circ B Min Position 0 to 100 RNG B XXXXX EXVB Steps In Range 0 to 65535 Default 200 SPD B XXXXX EXVB STeps Per Second 0 to 65535 i Default 0 EXV B POFB EXVB Fail Position In 0 to 100 E Default 0 MIN B XXXXX EXVB Minim
102. N CONFIGURATION TABLES UNIT Unit Configuration DESCRIPTION Unit Size Compressor A1 Size Compressor A2 Size Compressor B1 Size Compressor B2 Size Suction Superheat Setpt Number of Fans Compressor A1 Digital Maximum A1 Unload Time CCN CONFIGURATION TABLES OPTIONS 1 Options 1 Configuration DESCRIPTION Cooler Fluid Minimum Load Select CSB Board Enable Cooler Pump Control Cooler Pump 1 Enable Cooler Pump 2 Enable Cooler Pmp Periodic Strt Cooler Pump Select Cooler Pump Shutdown Dly Pump Changeover Hours EMM Module Installed HX Typ 0 1 EXV MOP Set Point Config Approach Setpoint m mm 1 m m m m 1 tons m 1 mn 1 38 E bhe e Jo VALUE DEFAULT UNITS 2 Med Brine Dsabe Enabe Enable olo O Ot 1 Nows f N 1 NOT NoYes No ___ 0 Pump 1 2 Pump 2 NoYes No p il Eire i 1 man u nn s 92 FORCIBLE POINT NAME SIZE SIZE_A1 SIZE_A2 SIZE_B1 SIZE_B2 SH_SP FAN_TYPE CPA1TYPE MAXULTME POINT NAME FLUIDTYP MLV_FLG CSB_ENA CPC PMP1_ENA PMP2_ENA PUMP_PST PMP SLCT PUMP DLY PMP DLTA EMM BRD COILTYPE MOP SP IAPPROSP APPENDIX B CCN TABLES cont CCN CONFIGURATION TABLES 52 Options 2 Configuration
103. NICATIONS WIRING cont Table G Network Points List ET ERE SRE NAME WRITE VALUE OBJECT ID mtma R m Av R Av SP R ET C A4 POINT DESCRIPTION 4 20 ma Demand Signal 4 20 ma Reset Signal Active Demand Limit Active Setpoint Alarm State CCN Chiller CCN Loadshed Signal Circuit A Run Hours Circuit A Starts Circuit B Run Hours Circuit B Starts Coil Cleaning Maint Done Coil Cleaning Srvc Inter Coil Service Countdown Comp A1 Unload Time Compr Return Gas Temp Compr Return Gas Temp Compressor A1 Feedback Compressor A1 Relay Compressor A1 Run Hours Compressor A1 Starts Compressor A2 Feedback Compressor A2 Relay Compressor A2 Run Hours Compressor A2 Starts Compressor B1 Feedback Compressor B1 Relay Compressor B1 Run Hours Compressor B1 Starts Compressor B2 Feedback Compressor B2 Relay Compressor B2 Run Hours Compressor B2 Starts Control Mode Control Point Cooler Entering Fluid Cooler Flow Switch Cooler Freeze Protection Cooler Leaving Fluid Cooler LWT Setpoint Cooler Pump 1 Interlock Cooler Pump 2 Interlock Cooler Pump Relay 1 Cooler Pump Relay 2 Cooler Pump Select Cooler Pump Shutdown Dly Cooler Pump Heater Cooling Ramp Loading Cooling Setpoint 1 LEGEND R Read w Write 1 Normal 2 Alert 3 Alarm MSV 1 SS Rw S Sr a BR n As ovo
104. NOTE Conductors and drain wire must be 20 AWG Ameri can Wire Gage minimum stranded tinned copper Individual conductors must be insulated with PVC PVC nylon vinyl Teflon or polyethylene An aluminum polyester 100 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operating temperature range of 20 C to 60 C is required Wire manufactured by Alpha 2413 or 5463 American A22503 Belden 8772 or Columbia 02525 meets the above mentioned requirements It is important when connecting to a CCN communication bus that a color coding scheme be used for the entire network to simplify the installation It is recommended that red be used for the signal positive black for the signal negative and white for the signal ground Use a similar scheme for cables contain ing different colored wires At each system element the shields of its communication bus cables must be tied together If the communication bus is entirely within one building the resulting continuous shield must be connected to a ground at one point only If the commu nication bus cable exits from one building and enters another the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building one point per building only To connect the unit to the network 1 Turn off power to the control box 2 Cutthe CCN wire and strip the ends of the red white ground an
105. NTENANCE TABLES CIRB_EXV DESCRIPTION POINT NAME EXV Open Circuit Approach Approach Setpoint APPRB SP EXVB Override nmmn Suction Superheat Temp mn CF SHB Active Superheat Seipt TSS Active Seipt mn ACMOP SP Cir B EXV Position Limit nm p PB CCN MAINTENANCE TABLES STRTHOUR DESCRIPTION POINT NAME Machine Operating Hours HR MACH Machine Starts mmn MACH x a ae Circuit A Run Hours HR CIRA Compressor A1 Run Hours HRAT Compressor A2 Run Hours HR A2 Circuit B Run Hours HR CIRB Compressor B1 Run Hours HR BT Compressor B2 Run Hours HR_B2 Circuit A Stars Compressor Starts mmm GA Compressor A2 Start mmm Circuit B Starts yem Compressor BT Starts mmm Xi Compressor B2 Start mmm 7 E C PUMP HOURS Pump 1 Run Hours Pump 2 Run Hours HR_PUMP2 CCN MAINTENANCE TABLES CURRMODS Low Sound Mode On Off MODE_25 DESCRIPTION POINT NAME CSM controlling Chiller MODE_1 WSM controlling Chiller MODE_2 Master Slave control MODE_3 Ramp Load Limited MODE_5 Timed Override in effect MODE 6 Low Cooler Suction TempA 7 Low Cooler Suction MODE_8 Slow Change Override MODE_9 Minimum OFF time active MODE_10 Dual Setpoint MODE_13 Temperature Reset
106. ODE T051 A051 T052 A052 T055 A055 T056 A056 A060 A061 T068 T069 T073 T074 T077 T078 T079 T090 T091 T092 T093 T094 Alert Failure Alarm Alert Failure Alarm Failure Alert Failure Alarm Alert Failure Alarm Failure Alarm Alarm None Alert Failure gt A gt Thermistor Failure Circuit A Saturated Circuit B Saturated gt Fluid Temperature Circuit B Suction Failure Circuit A Compressor 1 Failure Circuit A Compressor 2 Circuit A Compressor 2 Circuit B Compressor 1 Circuit B Compressor 1 Failure Circuit B Compressor 2 Circuit B Compressor 2 Cooler Leaving Fluid Thermistor Failure Cooler Entering Fluid Thermistor Failure Circuit A Return Gas Thermistor Failure Circuit B Return Gas Thermistor Failure Outside Air Thermistor Space Temperature Dual Chiller Suction Temperature exceeds Cooler Leaving Fluid Temperature Suction Temperature exceeds Cooler Leaving Outside of range 0 to 420 psig Circuit shut down Discharge Gas Discharge thermistor DTT is Digital compressor shut Thermistor Failure either open or shorted down Pressure Transducer WHY WAS THIS ALARM GENERATED Compressor feedback signal does not match relay state Respective current sensor board CSB feedback signal is ON when the compressor should be off Compre
107. OLER PUMP 2 380 460 515V HEATERS YELX8 4H6 2 e BLK 3 CHC 2 208 230 2 300 L LEGEND CONFIGURATION TABLE Auxiliary Fuse Block CONTROL INPUT Z Motormaste NOMINAL VOLTAGE PINS 25 2 START JUMPER Outdoor Fan Motor 208 230 460 575 60 External control 4 20 mA TB1 TB2 Terminal Block 208 380 60 External control 4 20 mA TB13A TB2 208 v can run in mode 5 or 6 Fig 32 Typical Motormaster Wiring m 11 L2 L3 HL ILI mmm 000000000000000000k INAL nunnunnnunnmunmnn BLOCK 1 T2 T8 B B x O BUTTONS DISPLAY Mode O Fig 33 Motormaster V Mode Buttons and Mode Display 60 Table 38 Fault Codes FAULT CODE SOLUTION AF High Temperature Fault Ambient temperature is too high Check cooling fan operation Cooling fan has failed if equipped CF Control Fault A blank EPM or an EPM with corrupted data Perform a factory reset using Parameter 48 has been installed PROGRAM SELECTION cF Incompatibility Fault An EPM with an incompatible parame Either remove the EPM or perform a factory ter version has been installed reset Parameter 48 to change the parameter version of the EPM to match the parameter version of the drive CL CURRENT LIMIT The outpu
108. On Off LVT 13 14 Cooler Flow Switch J7 9 10 Compressor Fault Signal A1 J9 11 12 Compressor Fault Signal A2 J9 5 6 Compressor Fault Signal B1 J9 8 9 Compressor Fault Signal B2 J9 2 3 RELAY NO K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 Table 17 Output Relays DESCRIPTION Energize Compressor A1 010 030 Energize Compressor A1 and Condenser Fan Contac tor 3 055 060 Energize Compressor A2 all but 010 015 60 Hz Energize Chilled Water Pump 1 Output Energize Chilled Water Pump 2 Output Energize Compressor B1 035 050 Energize Compressor B1 and Condenser Fan Contac tor 3 055 060 Energize Compressor B2 035 060 Alarm Relay Cooler Pump Heater Energize Condenser Fan Contactor 1 018 060 Energize Condenser Fan Contactor 2 018 060 Minimum Load Valve 20 Table 18 CCN Communication Bus Wiring PART NO MANUFACTURER Plenum Wiring Alpha American A48301 Belden 884421 Columbia Manhattan M64430 Quabik Sensors The electronic control uses 4 to 7 thermistors to sense temperatures for controlling chiller operation See Table 15 These sensors are outlined below Thermistors RG TA RGTB EWT LWT and OAT are identical in temperature versus resistance and voltage drop performance The dual chill er thermistor is 5 at 77 F 25 C thermistor Space tempera ture thermistor is a 10 at 77 F 25 C The DTT thermistor is an 86 kQ at 77 F 25 C thermistor See Thermistors sectio
109. P 1 COOLER PUMP 2 L1 L2 L1 L2 L1 L2 CL 3 CIRCUIT B DP B SP B SCT B 55 RGT B Dual Chiller Control Only L3 L3 L3 Record Software Versions MODE RUN STATUS SUB MODE ITEM DISPLAY ITEM EXPANSION VERS MBB CESR 1314600 AUX1 CESR 313332 __ __ MARQUEE CESR 131171 __ __ NAVIGATOR CESR 131227 __ __ PRESS ENTER AND ESCAPE SIMULTANEOUSLY TO OBTAIN SOFTWARE VERSIONS CUT ALONG DOTTED LINE 0000 COMMENTS SIGNATURES START UP CUSTOMER TECHNICIAN REPRESENTATIVE DATE DATE CL 4 CUTALONGDOTTEDUINE lll Unit Start Up cont RECORD CONFIGURATION SETTINGS SUBMODE UNIT UNIT Configuration Settings 1 UNTCONFGURATON PRESS ESCAPE KEY TO DISPLAY UNIT PRESS DOWN ARROW KEY TO DISPLAY OPT1 PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW SUBMODE OPT1 OPTIONS Options Configuration UNTOPTIONBTHARDWARE CL 5 ENTRY ENTRY Unit Start Up cont PRESS ESCAPE KEY TO DISPLAY OPT1 PRESS DOWN ARROW KEY DISPLAY OPT2 PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW OPTIONS2 Options Configuration SUBMODE ENTRY uioprions2controts O cm covmoweHO x Low LOADING SEQUENCE ucs LewwGCROUTSEECT ADDRESS XXX CCNB C
110. PLI 5 MP A2 PLI 6 055 060 ONLY R RLY 2 mE GRA 10 2 10 2 ea BRN 2 CA1 GND GROUND 15 SEE oe vio HPS HIGH PRESSURE SWITCH LOW VOLTAGE TERMINAL I 2555 vio LWT LEAVING WATER TEMPERATURE LVT VIO C MBB MAIN BASE BOARD m es ES m G 23 BRN MMR MOTORMASTER RELAY RLY 4 eT RED 2 04 RED m BRN 2 CwP1 ene OAT OUTDOOR AIR THERMISTOR FIOP OR OFM OUTDOOR FAN MOTOR HE FIELD INSTALLED PLUG N 055 060 ONLY RGT RETURN GAS TEMPERATURE TO saa is WAX LORD SVA SEALED Sat SUPPLY AIR TEMPERATURE 5 TOVA INRUSH SCCR SHORT CIRCUIT CURRENT RATING gt lt orf 0 ser SUCTION PRESSURE TRANSDUCER D PNK W H x J6 n 78 TERMINAL BLOCK ALMR HR 09 INKR STORAGE TANK HEATER RELAY 1 KE gt TRAN TRANSFORMER 8 XD 055 060 ONLY pli UPC UNITARY PROTOCOL CONVERTER TALES WIRING TAN FRI A2 BRN 2 FC2 a WFS 055 060 ONLY 055 060 ONLY 2 8u exem SEE NOTE 8 PL EXVB EXV gt BE YEL or RED BLK O J3 Ox ERE SEE J3 o WHT ED N ll sta EXV B NOTE 9 La GO RED L amp D 9 6 9 d QD KOD DL Da Or w BLK lt J4 D gt BLK gt a J4 Oy ED 16 tice RED 1 gt o o BRN o 9 5
111. R FC3 15 REPLACED WITH MOTORMASTER RELAY MMR BLK BLU DIKE 3 GRN E y N YEL YEL V 055 060 ONLY 7 TABLE 1 TABLE 2 LOW AMBIENT OPERATION MOTORMASTER V FIOP ACCESSORY TERMI TERMI emm 575358 100 5558 10 cow i 575 TY AAD 7 380 3 60 700 380 3 60 200 COM 380 2 FM3 035 050 230 360 500 230 3 60 500 1 230 EL YEL4L2 T2 2 6 kin Ma dl 208 360 500 208 360 500 08 208 3 460 3 60 600 460 3 60 600 COM 4 460 Pesca 63 8 041343 BLUL3 13 LK 3 4 EI m l K SIGNAL CONNECTION BL BLK 78 VOLTAGE WI 2400 iw 1 208 230 460 575 60 CONNECT FOR TELS 25 RED prou T AUK APPROPRIATE CONNECT FOR 2 BLK PRIMARY VOLTAGI APPROPRIATE SEE TABLE 1 TRANT PRIMARY VOLTAGE TRAN2 Mod CHC PRIMARY SEE TABLE 2 PRIMARY BLK COH EZ BLK 1 BLK T m WHT 3 BLK r UMP 2 T SECONDARY 24V 7 380 460 575v HEATERS TBA SECONDARY 24V 3 2 AMPS o SECONDARY 24V 208 230 230 T RED KP dIU3b GD 4 RED D m AEG WB swe Brn RED FCB2 FB2 SEE NOTE 7 d in BLK MT 0 Hai BLK IE 7 61 4 3 YEL G26 3 A Gz YEL 124 HED 2 amp 2 OFM1 UPC FIOP 2 Go 3 OS BLU THK 8 3 lt
112. RATION x E p o eem L E pom om L E oem x om ow o wem L E ee om mese esr sm NN EXV B CIR B EXV CIRBEXVCONFIGURATION EP se o eem L E ome en ee L E ome cem L E oem om Ce NE NE MM ____ ______ _____________ MOTORMASTER CONFIGURATION wes Sizes 010 020 and 035 045 default is 1596 Sizes 025 030 and 050 060 default is 2500 14 Range Range Range Range Range Range Range Range 0 100 Default 30 0 100 Default 8 0 65535 Default 0 65535 Default 200 0 100 Default 0 0 65535 Default 0 0 65535 Default 0 65535 Default 167 0 UNIPOLAR 1 BIPOLAR Default 1 Range Range Range Range Range Range Range Range Range Range Range Range Range Range Range 50 140 Default 115 0 30 Default 10 0 30 Default 5 0 100 Default 10 0 100 Default 10 0 100 Default 10 0 100 Default 10 0 100 Default 50 0 100 Default 8 0 65535 Default 0 65535 Default 200 0 100 Default 0 0 65535 Default 0 0 65535 Default 0 65535 Default 167 0 UNIPOLAR 1 BIPOLAR Default 1 Range Range Range Range 20 20 Default 1 0 20 20 Default 0 1 20 20 Default 0 0 0 100 Default 5 0
113. ROVIDED ______ ANTIFREEZE TYPE CONCENTRATION IF OUTDOOR AMBIENT IS BELOW 32 F 0 C THEN ITEMS 9 11 HAVE TO BE COMPLETED TO PROVIDE COOLER FREEZE PROTECTION TO 20 F 29 C REFER TO WINTER SHUTDOWN FOR PROPER COOLER WINTERIZATION PROCEDURE 9 OUTDOOR PIPING WRAPPED WITH ELECTRIC HEATER TAPE INSULATED AND OPERATIONAL 10 COOLER HEATERS INSTALLED AND OPERATIONAL 11 CHILLED WATER PUMP CONTROLLED BY CHILLER Unit Start Up 1 COMPRESSOR OIL LEVEL IS CORRECT 2 VERIFY COMPRESSOR MOUNTING BOLT TORQUE IS 7 10 FT LB 9 5 13 5 3 LEAK CHECK UNIT LOCATE REPAIR AND REPORT ANY REFRIGERANT LEAKS 4 VOLTAGE IS WITHIN UNIT NAMEPLATE RANGE 5 CONTROL TRANSFORMER PRIMARY CONNECTION SET FOR PROPER VOLTAGE 6 CONTROL TRANSFORMER SECONDARY VOLTAGE 7 CHECK VOLTAGE IMBALANCE A B A C B C AVERAGE VOLTAGE A C 3 MAXIMUM DEVIATION FROM AVERAGE VOLTAGE VOLTAGE IMBALANCE MAX DEVIATION AVERAGE VOLTAGE X 100 VOLTAGE IMBALANCE LESS THAN 2 DO NOT START CHILLER IF VOLTAGE IMBALANCE IS GREATER THAN 2 CONTACT LOCAL UTILITY FOR ASSISTANCE 8 VERIFY COOLER FLOW RATE PRESSURE ENTERING COOLER psig kPa PRESSURE LEAVING COOLER psig kPa COOLER PRESSURE DROP psig kPa Psig X 2 31 ft psi ft of water kPa X 0 334 m psi m of water COOLER FLOW RATE gpm 1 5 See Cooler Pressure Drop Curves from Installation Instructions Start and Operate Machine Complete the Fol
114. RS 1912 zx O ADDRESS h S o 5 ROTARY aS ar SWITCHES 12 LISTED 002106 Made in USA Enclosed Energy Management Equipment RUN LED ERROR LED Fig A UPC Open Controller Sponsored by ASHRAE American Society of Heating Refrigerat ing and Air Conditioning Engineers 102 APPENDIX D OPTIONAL BACNET COMMUNICATIONS WIRING cont CONFIGURING THE BAS PORT FOR BACNET MS TP Use the same baud rate and communication settings for all controllers on the network segment The UPC Open con troller is fixed at 8 data bits No Parity and 1 Stop bit for this protocol s communications If the UPC Open controller has been wired for power pull the screw terminal connector from the controller s power termi nals labeled Gnd and HOT The controller reads the DIP Switches and jumpers each time power is applied to it Set the BAS Port DIP switch DS3 to enable Set the BAS Port DIP switch DS4 to E1 485 Set the BMS Protocol DIP switches DS8 through 055 to MSTP See Table A Table A SW3 Protocol Switch Settings for MS TP 058 057 056 055 054 053 Off Off Verify that the EIA 485 jumpers below the CCN Port are set to EIA 485 and 2W The example in Fig C shows the BAS Port DIP Switches set for 76 8k Carrier default and MS TP Set t
115. TALLING CONTRACTOR SALES OFFICE START UP PERFORMED BY Design Information CAPACITY CEAT FLUID TYPE FLOW RATE P D UNIT MODEL SERIAL ll Preliminary Equipment Check IS THERE ANY PHYSICAL DAMAGE OYES ONO DESCRIPTION 1 UNIT IS INSTALLED LEVEL AS PER THE INSTALLATION INSTRUCTIONS OYES ONO 2 POWER SUPPLY AGREES WITH THE UNIT NAMEPLATE OYES ONO 3 ELECTRICAL POWER WIRING IS INSTALLED PROPERLY OYES ONO 4 UNIT IS PROPERLY GROUNDED OYES ONO 5 ELECTRICAL CIRCUIT PROTECTION HAS BEEN SIZED AND INSTALLED PROPERLY OYES ONO 6 ALL TERMINALS ARE TIGHT OYES ONO 7 ALL PLUG ASSEMBLIES ARE TIGHT OYES ONO 8 ALL CABLES AND THERMISTORS HAVE BEEN INSPECTED FOR CROSSED WIRES OYES ONO 9 ALL THERMISTORS ARE FULLY INSERTED INTO WELLS OYES ONO Chilled Water System Check 1 ALL CHILLED WATER VALVES ARE OPEN OYES ONO 2 ALL PIPING IS CONNECTED PROPERLY OYES ONO 3 ALL AIR HAS BEEN PURGED FROM THE SYSTEM OYES ONO 4 CHILLED WATER PUMP IS OPERATING WITH THE CORRECT ROTATION OYES ONO Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53300067 01 Printed in U S A Form 30RAP 2T Pg CL 1 12 10 Replaces 30RAP 1T 5 CHILLED WATER PUMP STARTER INTERLOCKED WITH CHILLER 6 CHILLED WATER FLOW SWITCH IS OPERATIONAL 7 WATER LOOP VOLUME GREATER THAN MINIMUM REQUIREMENTS See Table 40 8 PROPER LOOP FREEZE PROTECTION P
116. TE ALARM RELAY CIRCUIT A COMPRESSOR TEST CMPA MLV ON OFF MINIMUM LOAD VALVE RELAY CC B1 ON OFF COMPRESSOR B1 RELAY See Note ON OFF COMPRESSOR B4 RELAY See Note NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed NTE CIRCUIT B COMPRESSOR TEST Copyright 2010 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53300067 01 Printed in U S A Form 2 Pg CL 10 12 10 Replaces 30RAP 1T CUT ALONG DOTTED LINE 1 ALONG DOTTED LINE
117. TER 2 E NOTES gt LAG START DELAY SCROLLING STOPS VALUE FLASHES SELECT 10 LAG START DELAY CHANGE ACCEPTED MASTER COMPLETE 1 Master Control Method CTRL be configured as 0 Switch 2 Occupancy or 3 CCN 2 Parallel Configuration PARA cannot be changed Dual chiller start stop control is determined by configura tion of Control Method Configuration of the Master chiller The Slave chiller should always be config ured for CTRL 0 Switch If the chillers are to be controlled by Remote Contacts both Master and Slave chillers should be enabled together Two separate relays or one relay with two sets of contacts may control the chillers The Enable Off Remote Contact switch should be in the Remote Contact position on both the Master and Slave chillers The Enable Off Remote Contact switch should be in the Enable position for CTRL 2 Occupancy CTRL 3 CCN Control Both chillers will stop if the Master chiller Enable Off Remote Contact switch is in the Off position If the Emergency Stop switch is turned off or an alarm is generated on the Master chiller the Slave chiller will operate in a Stand Alone mode If the Emergency Stop switch is turned off or an alarm is generated on the Slave chiller the Master chiller will operate in a Stand Alone mode The master chiller controls the slave chiller by changing its Contr
118. TO ILLUMINATE CONFIGURATION LED PRESS ENTER TO DISPLAY DISP PRESS ENTER AGAIN TO DISPLAY TEST FOLLOWED BY OFF PRESS ENTER TO STOP DISPLAY AT OFF AND ENTER AGAIN SO OFF DISPLAY FLASHES PASS AND WORD WILL FLASH IF PASSWORD NEEDS TO BE ENTERED PRESS ENTER TO DISPLAY PASSWORD FIELD AND USE THE ENTER KEY FOR EACH OF THE FOUR PASSWORD DIGITS USE ARROW KEYS IF PASSWORD IS OTHER THAN STANDARD AT FLASHING OFF DISPLAY PRESS THE UP ARROW KEY TO DISPLAY ON AND PRESS ENTER ALL LED SEGMENTS AND MODE LEDS WILL LIGHT UP PRESS ESCAPE TO STOP THE TEST PRESS ESCAPE TO RETURN TO THE DISP DISPLAY PRESS THE ESCAPE KEY AGAIN AND USE THE ARROW KEYS TO ILLU MINATE THE SERVICE TEST LED PRESS ENTER TO DISPLAY TEST PRESS ENTER TO STOP DISPLAY AT OFF AND ENTER AGAIN SO OFF FLASHES PRESS THE UP ARROW KEY AND ENTER TO ENABLE THE MANUAL MODE PRESS ESCAPE AND DISPLAY NOW SAYS TEST ON REFER TO THE TABLE BELOW Service Test Mode and Sub Mode Directory KEYPAD ITEM Completed SUB MODE ENTRY ITEM DISPLAY EXPANSION COMMENT Yes No ON OFF SERVICE TEST MODE To Enable Service Test Mode move Enable Off Remote OUTPUTS AND PUMPS XXX VAR HEAD PRESS p ON OFF COOLER PUMP 1 RELAY cure ON OFF COOLER PUMP 2 RELAY TEST Contact switch to OFF Change TEST to ON Move switch to ENABLE CL HT ON OFF COOLER PUMP HEATER RMT A ON OFF REMO
119. V B PRESS ESCAPE KEY TO DISPLAY EXV B PRESS DOWN ARROW KEY TO DISPLAY PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW MM Motormaster Configuration Settings SUB MODE ITEM ITEM EXPANSION DISPLAY ENTRY MMR S MOTORMASTER SELECT YES NO PGAN HEAD PRESSURE P GAIN MM HEAD PRESSURE GAIN D GAN HEAD PRESSURE D GAIN MIN S MINIMUM FAN SPEED CL 7 Unit Start Up cont PRESS ESCAPE KEY TO DISPLAY MM PRESS DOWN ARROW KEY TO DISPLAY RSET PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW RSET Reset Configuration Settings SUBMODE mesrCOLTEMP PRESS ESCAPE KEY TO DISPLAY RSET PRESS DOWN ARROW KEY TO DISPLAY SLCT PRESS ENTER KEY RECORD CONFIGURATION INFORMATION BELOW SLCT Setpoint and Ramp Load Configuration SUBMODE ITEM ITEM EXPANSION DISPLAY SLCT SETPOINT AND RAMP LOAD CLSP COOLING SETPOINT SELECT x CL 8 ENTRY ENTRY CUT ALONG DOTTED LINE CUT ALONG DOTTED Unit Start Up cont PRESS ESCAPE KEY SEVERAL TIMES TO GET TO THE MODE LEVEL BLANK DISPLAY USE THE ARROW KEYS TO SCROLL TO THE SET POINT LED PRESS ENTER TO DISPLAY SETPOINTS RECORD CONFIGURATION INFORMATION BELOW SETPOINT SUBMODE ENTRY con eapPRESSURESETTONS ids 1 smwEFREEZESETPPONT J o dis CL 9 Unit Start Up cont COMPONENT TEST USE ESCAPE ARROW KEYS
120. a Override Head Pressure Comp Delta HP B Cir Configuration EXV A EXV Configuration EXV B Motormaster Configuration Reset Cool Temp RSET Set Point and Ramp Load SLCT Service Configuration SERV Broadcast Configuration BCST LEGEND Ckt Circuit Throughout this text the location of items in the menu structure will be described in the following format Item Expansion Mode Name Sub mode Name ITEM For example using the language selection item Language Selection Configuration DISP LANG Current CRNT Reset Alarms RCRN Alarm History HIST Table 3 Run Status Mode and Sub Mode Directory VIEW prox ENTERING FLUID TEMP LOAD UNLOAD FACTOR STAT CONTROL MODE 0 Service Test 1 Local 2 Off CCN 3 Off Time 4 Off Emrgcy 5 On Local 6 On CCN 7 On Time 8 Ht Enabled 9 Pump Delay 1 MONTH OF YEAR 1 January 2 February etc RUN MACHINE OPERATING HOURS HOUR HRS A A poo HRs CIRCUIT A RUN HOURS CIRCUIT B RUN HOURS See Note i COMPRESSOR B1 RUN HOURS See Note a COMPRESSOR B2 RUN HOURS See Note STRT fe jeep COMPRESSOR B1 STARTS See Note fa jew x COMPRESSOR B2 STARTS See Note
121. a faulty thermistor a shorted or open thermistor caused by a wiring er ror or a loose connection Failure of this thermistor will shut down the entire unit 068 T69 Circuit A B Compressor Return Gas Tempera ture Thermistor Failure This alert occurs when the com pressor return gas temperature sensor is outside the range of 40 to 240 F 40 to 116 C Failure of this thermistor will shut down the appropriate circuit T073 Outside Air Temperature Thermistor Failure This alert occurs when the outside air temperature sensor 1s outside the range of 40 to 240 40 to 116 C Failure of this therm istor will disable any elements of the control which requires its use T074 Space Temperature Thermistor Failure This alert occurs when the space temperature sensor is outside the range 72 of 40 to 245 40 to 118 C Failure of this thermistor will disable any elements of the control which requires its use The cause of the alert is usually a faulty thermistor in the T55 or T58 device a shorted or open thermistor caused by a wiring er ror or a loose connection T090 Circuit A Discharge Pressure Transducer Failure T091 Circuit B Discharge Pressure Transducer Failure Alert codes 090 and 091 are for circuits A and B respectively These alerts occur when the pressure is outside the range of 0 0 to 667 0 psig A circuit cannot run when this alert is active Use the scrolling marque
122. able Conductor 22 or 24 AWG stranded copper tin plated Insulation Foamed FEP 0 015 in 0 381 mm wall 0 060 in 1 524 mm O D Color Code Black White Twist Lay 2 in 50 8 mm lay on pair 6 twists foot 20 twists meter nominal Shielding Aluminum Mylar shield with 24 AWG TC drain wire Jacket SmokeGard Jacket SmokeGard PVC 0 021 in 0 5334 mm wall 0 175 in 4 445 mm O D Halar Jacket E CTFE 0 010 in 0 254 mm wall 0 144 in 3 6576 mm O D DC Resistance 15 2 Ohms 1000 feet 50 Ohms km nominal Capacitance 12 5 pF ft 41 pF meter nominal conductor to conductor Characteristic Impedance 100 Ohms nominal Weight 12 16 1000 feet 17 9 kg km UL Temperature Rating SmokeGard 167 F 75 C Voltage 300 Vac power limited Listing UL CL2P or better LEGEND AWG American Wire Gage CL2P Class 2 Plenum Cable DC Direct Current FEP Fluorinated Ethylene Polymer NEC National Electrical Code O D Outside Diameter TC Tinned Copper UL Underwriters Laboratories 104 Halar 40 to 302 F 40 to 150 C APPENDIX D OPTIONAL COMMUNICATIONS WIRING cont Table D Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS Wire Type Description RMCORP w Contractors 22 AWG single twisted shielded pair low capacitance CL2P TC foam FEP plenum rated See MS TP Installation Guide for W221P 22
123. able wiring Dual Leaving Water Temperature Sensor For dual chiller applications parallel only are supported connect the dual chiller leaving fluid temperature sensor refer to Configuring and Operating Dual Chiller Control section on page 36 to the space temperature input of the Master chiller If space tempera ture is required for reset applications connect the sensor to the 1 Cut the CCN wire and strip ends of the red white ground and black conductors If another wire color scheme is used strip ends of appropriate wires 2 Insert and secure the red wire to terminal 5 of the Slave chiller and configure the slave chiller to broadcast the space temperature sensor terminal block value to the Master chiller LEGEND FOR FIG 3 7 ALMR Alarm Relay AUX Auxilliary BR Boiler Relay Contactor Compressor CB Circuit Breaker CCB Compressor Circuit Breaker CH Crankcase Heater CHC Cooler Pump Heater Contactor COMP Compressor CSB Current Sensor Board CWFS Chilled Water Flow Switch CWP Chilled Water Pump DGS Digital Scroll Compressor DPT Discharge Pressure Transducer DTT Discharge Temperature Thermistor DUS Digital Unloader Solenoid EMM Energy Management EXV Electronic Expansion Valve FB Fuse Block FC Fan Contactor FCB Fan Circuit Breaker FIOP factory Installed Option FR Fan Relay GND Ground HPS
124. addition if a compressor stuck failure occurs and the cur rent sensor board reports the compressor and the request off certain diagnostics will take place as follows 1 If any of the compressors are diagnosed as stuck on and the current sensor board is on and the request is off the control will command the condenser fans to maintain normal head pressure 2 The control will shut off all other compressors The possible causes include welded contactor or frozen compressor relay on the MBB To check out alarms A051 A056 1 Place the unit in Service Test mode All compressors should be off 2 Verify that there is not 24 v at the contactor coil If there is 24 v at the contactor check relay on MBB and wiring 3 Check for welded contactor 4 Verify CSB wiring 5 Return to Normal mode and observe compressor opera tion to verify that compressor current sensor is working and condenser fans are energized A060 Cooler Leaving Fluid Thermistor Failure sensor reading is outside the range of 40 to 245 40 to 118 C then the alarm will occur The cause of the alarm is usu ally a faulty thermistor a shorted or open thermistor caused by a wiring error or a loose connection Failure of this thermistor will shut down the entire unit A061 Cooler Entering Thermistor Failure If the sensor reading is outside the range of 40 to 240 40 10116 C then the alarm will occur The cause of the alarm is usually
125. age imbalance is satisfactory as it is below the maximum allowable of 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Do not operate unit until imbalance condition is corrected Control Circuit Power Power for the control circuit is supplied from the main incoming power through a factory installed control power transformer TRAN1 for all models Field wiring connections are made to the LVT OPERATION SEQUENCE During unit off cycle the control monitors the outdoor air temperature If the ambient temperature drops below 40 F 4 4 C cooler and hydronic system heaters if either are facto ry installed are energized If power is maintained to the chiller and the EMERGENCY ON OFF switch is left in the OFF po sition these heaters are also energized The unit is started by putting the ENABLE OFF REMOTE CONTACT switch in the ENABLE or REMOTE CONTACT position When the unit receives a call for cooling either from the internal control or CCN network command or remote con tact closure the unit stages up in capacity to maintain the leav ing fluid set point The first compressor starts 11 to 3 minutes after the call for cooling The lead circuit can be specifically designated on all models or selected based on compressor run hours and starts depend ing on field configuration The unit control will override this selection under certain starting c
126. ainer T302 Alert Scheduled pirecs p None Automatic maintenance Maintenance Due blowdown and enter YES required for Strainer Maintenance q Done S T MN item Coil Service Countdown C L DN expired Routi d Condenser Coil Complete condenser coil outine condenser 303 Alert Maintenance Due cleaning and enter YES Automatic coi maintenance for Coil Maintenance Done 4 C L MN item Current Sensor Board Alert occurs when CSB out Compressor A1 shut CSB failure T500 1 Failure put is a constant high value Automatic Wiring error Current Sensor Board Alert occurs when CSB out Compressor A2 shut CSB failure 501 2 Failure put is constant high value Automatic Wiring error Current Sensor Board Alert occurs when CSB out Compressor A3 shut CSB failure 502 Failure put is constant high value Automatic Wiring error Current Sensor Board Alert occurs when CSB out Compressor B1 shut CSB failure 503 1 Failure put is constant high value Automatic Wiring error Current Sensor Board Alert occurs when CSB out Compressor B2 shut CSB failure 504 B2 Failure put is a constant high value Automatic Wiring error Current Sensor Board Alert occurs when CSB out Compressor B3 shut CSB failure T505 B3 Failure put is a constant high value Automatic Wiring error T950 Alert Loss of Communication No communications have WSM forces removed Automatic Failed module wiring with Water System been received by the MBB Chiller runs un
127. alve controller Dis connect the valve wires from the controller 3 Ifthe motor fails to operate properly check the resistance of each motor phase Resistance between black and white leads or between the red and green leads should be ap proximately 100 ohms Differences of more than 1096 be tween phases indicate a defective motor Resistance be tween black and red or any lead and piping should be in finite or open Any resistance reading will indicate a shorted winding and the valve will need to be replaced 4 The output of the controller to the valve can be tested with the following procedure a Disconnect supply voltage to the controller PL EXVB BLK gt WHT EXV B GRN gt PL EXVA BLK gt WHT gt EXV A GRN RED gt Fig 25 EXV Cable Connections to EXV Module b Place a digital voltmeter on 20 volt AC scale across the black and white terminals on the con troller Restore power to the controller For at least 7 seconds the voltmeter should read approxi mately 12 to 14 volts Significant differences mean the controller is defective or not properly config ured for the EXV valve c Repeat the procedure in Step b above using the red and green terminals on the controller If the con troller responds properly then the wiring may be damaged or the valve may be plugged with debris or otherwise obstructed d The EXV valves on sizes 025
128. are off due to alerts and or alarms Reset is automatic when all alarms are cleared This alarm indicates the unit is at 0 capacity 73 T153 Real Time Clock Hardware Failure problem has been detected with MBB real time clock hardware Try re setting the power and check the indicator lights If the alarm continues the board should be replaced A154 Serial EEPROM Hardware Failure problem has been detected with the EEPROM on the MBB Try resetting the power and check the indicator lights If the alarm continues the board should be replaced T155 Serial EEPROM Storage Failure Error A problem has been detected with the EEPROM storage on the MBB Try resetting the power and check the indicator lights If the alert continues the board should be replaced A156 Critical Serial EEPROM Storage Failure Error A problem has been detected with the EEPROM storage on the MBB Try resetting the power and check the indicator lights If the alarm continues the board should be replaced A157 A D Hardware Failure A problem has been detect ed with A D conversion on the boards Try resetting the power and check the indicator lights If the alarm continues the board should be replaced A172 Loss of Communication with the EXV Board This alarm indicates that there are communications problems with the EXV board The alarm will automatically reset T173 Energy Management Module Communication Fa
129. arge Thermistor DTT Compressor A1 shut High Discharge Gas i i Temperature Alert reading is greater than 250 F down 3 Discharge Gas Tempera High Discharge Gas Circuit High Discharge Pressure Alert Circuit shut down Alert Alarm Compressor operation out Alert side of operating envelope Circuit shut down Automatic only after first 3 daily occurrences Man ual reset thereafter Reading from OAT sensor must drop 5 F 2 8 before restart Circuit B High Discharge Pressure Compressor operation out Alert side of operating envelope Circuit shut down Automatic restart after first daily occurrence Manual restart thereafter Suction pressure below 34 psig for 8 seconds or below 23 psig Circuit A Low Suction Alert Pressure Circuit shut down Automatic restart after first daily occurrence Manual restart thereafter Reverse Rotation Incoming chiller power leads Chiller not allowed to Manual Detected not phased correctly start Automatic once Chiller shutdown without going through CCN command for pumpdown Suction pressure below 34 psig for 8 seconds or below 23 psig Circuit B Low Suction Alert Pressure Circuit shut down Alert CCN emergency stop Alarm Emergency Stop command received EMSTOP returns to normal lar i Manual once One more illegal Chiller is not allowed to Alarm Illegal Configuration d configu
130. art the chiller The contacts must be capable of handling 24 vac 50 mA load In the Enable and Remote Contact dry contacts closed positions the chiller is allowed to operate and respond to the scheduling configuration CCN configuration and set point data See Fig 9 Emergency On Off Switch The Emergency On Off switch should only be used when it is required to shut the chiller off immediately Power to the MBB EMM and marquee display is interrupted when this switch is off and all outputs from these modules will be turned off Board Addresses The main base board MBB has a 3 position instance jumper that must be set to 1 The elec tronic expansion valve board EXV and energy management board EMM have 4 position DIP switches switches are 19 set to On for these boards The auxiliary board AUX has an 8 position DIP switch Switches 2 5 and 7 are set to On Control Module Communication RED LED Proper operation of the control boards can be visually checked by looking at the red status LEDs light emitting diodes When operating correctly the red status LEDs should be blinking in unison at a rate of once every 2 seconds If the red LEDs are not blinking in unison verify that correct power is being supplied to all modules Be sure that the main base board MBB is supplied with the current soft ware If necessary reload current software If the problem still persists replace the MBB A
131. ault Automatic 0 Automatic 1 Pump 1 Starts first 2 Pump 2 Starts first PM DY XX MIN Cooler Pump Shutdown Dly 0 to 10 minutes Default 1 min PM DT XXXX HRS Pump Changeover Hours Default 500 hours ROT P YES NO Rotate Cooler Pumps Now User Entry 79 SUB MODE OPT2 CCN HP A HP B APPENDIX A DISPLAY TABLES cont Configuration Mode and Sub Mode Directory cont ITEM DISPLAY ITEM DESCRIPTION CTRL COMMENT UNIT OPTIONS 2 CONTROLS Default 0 0 Enable Off Remote Switch 2 Occupancy 3 CCN Control Control Method Default 1 LOAD X Loading Sequence Select 1 Equal 2 Staged Default 1 P 1 Automatic LLCS X Lead Lag Circuit Select 2 Circuit A Leads 3 Circuit B Leads NT Default 60 LCWT XX High LCW Alert Limit Range 2 to 60 F Default O Minutes DELY XX Minutes Off Time Range 0 to 15 Minutes ICE M ENBL DSBL Ice Mode Enable Default Disable LS MD X Low Sound Mode Select Default 0 0 Mode Disable 1 Fan Noise Only 2 Fan Compressor Noise LS ST 00 00 Low Sound Start Time Default 00 00 LS ND 00 00 Low Sound End Time Default 00 00 LS LT XXX Low Sound Capacity Limit Default 100 Range 0 to 100 CCNB BAUD A1 DT A2 DT B1 DT B2 DT XXX gt gt X XX XX XX XX CCN NETWORK CONFIGS Default 1 CCN Address Range 0 to 239 CCN Bus Number Default 1 Range 0 to 239 Default 3 1 2400 2 4800 CC
132. ause asphyxiation Provide adequate ventilation in enclosed or low overhead areas 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 A WARNING DO NOT attempt to unbraze factory joints when servicing this equipment Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrigerant lines Cut lines with a tubing cutter as required when performing service 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 system DO NOT re use compressor oil CAUTION This unit uses a microprocessor based electronic control system Do not use jumpers or other tools to short out components 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 A CAUTION To prevent potential damage to heat exchanger always run fluid through heat exchanger when adding or removing refrigerant charge Use appropriate brine solutions in cooler fluid loop to prevent the freezing of brazed plate heat exchanger optional hydronic section and or interconnecting piping when the equipment is exposed to temperatures b
133. ave Control Minimum Comp On Time Minimum Load Valve Relay Minimum OFF Time Active Minutes Off Time Occupied Outside Air Temperature Override Modes in Effect Percent Available Cap Percent Available Cap LEGEND Read R w Write POINT NAM MODE 1 E DMD SW1 DMD_SW2 MODE_15 DISGAS T MODE_13 DUAL_IN EMSTOP Ew R W RW R R ES S R R LR R R R E R F F sig F DEFAULT VALUE Enabled Enabled Emstop __ av Av EB R j 1 R8 svsb gt rane R Bv jJ js REQ R v8 vo 2 Bv4 MODE22 R Bv MODE18 BV4 CEDONE Bv LEAD TY R d MSV6 DIALIWT LEADPUMPP MSV9 pow same 8 o ova prece gt R R o BV36 isere 8 sv R R Bv HR MACH R m A R Ass R i L Bv moves R SS Bv R n o io R 2 R Emp l R R 108 1 Automatic 2 Circuit A Leads 3 Circuit B Leads AV 43 BACNET OBJECT NAME csp2 1 mode 1 1 lvl 1 pe
134. band Avoid rapidly removing system load Compressor Shuts Down on Replace control MAG tense Control Evacuate and recharge Condenser dirty Clean condenser Repair or replace if defective Reduce charge Unit Operates Too Long Add refrigerant Replace control Clean or replace as needed Replace or repair as needed Check compressor and replace if necessary Unusual or Loud System Piping vibration Support piping as required Noises PS Check for loose pipe connections or damaged compressor Replace compressor worn bearings Check for loose compressor holddown bolts Compressor Loses Oil Repair leak Replace compressor Check piping for oil traps Hot Liquid Line Shortage of refrigerant due to leak Repair leak and recharge Frosted Liquid Line Restricted filter drier Replace filter drier Frosted Suction Line Expansion valve admitting excess refrigerant note this is Replace valve if defective normal condition for brine applications Stuck EXV Replace valve if defective Freeze Up Improper charging Make sure a full quantity of fluid is flowing through the cooler while charging and suction pressure in cooler is equal to or greater than pressure corresponding to 32 F 0 C System not drained for winter shutdown Recommended that system be filled with an appropriate gly col mixture to prevent freezing of pumps and fluid tubing Loose Thermistor Verify thermistors are fully inserted in wells 66 ALARM ALERT C
135. blinking See Fig 33 4 Use the buttons to scroll to password value the factory default password is 1111 and press the Mode button Once the correct password value is entered the display will read P01 which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu 01 is the first parameter NOTE If the display flashes Er the password was incorrect and the process to enter the password must be repeated 5 Press Mode to display present parameter number Upper right decimal point blinks Use the vi buttons to scroll to the desired parameter number Once the desired parameter number is found press the Mode button to display the present parameter setting The up per right hand decimal point will begin blinking indicating that the present parameter setting is being displayed and that it can be changed by using the up and down buttons Use and Ivi to change setting Press Mode to store new setting Pressing the Mode will store the new setting and also exit the PROGRAM mode To change another parameter press the Mode key again to re enter the PROGRAM mode the param eter menu will be accessed at the parameter that was last viewed or changed before exiting If the Mode key is pressed within two minutes of exiting the PROGRAM mode the pass word is not required to access the parameters After two min utes the password must be entered in order to a
136. ccess the pa rameters again To change password first enter the current password then change parameter P44 to the desired password To disable automatic control mode and enter manual speed control mode 1 Change 05 to 01 keypad 2 Push UP and DOWN arrow key to set manual speed 3 Set POS to 04 4 20mA control to restore 4 to 20 mA control EPM CHIP The drive uses a electronic programming mod ule EPM chip to store the program parameters This is an EEPROM memory chip and is accessible from the front of the 59 VFD It should not be removed with power applied to the VFD LOSS OF CCN COMMUNICATIONS Carrier Comfort Network CCN communications with external control systems can be affected by high frequency electrical noise gen erated by the Motormaster V control Ensure unit is well grounded to eliminate ground currents along communication lines If communications are lost only while Motormaster V con trol 1s in operation order a signal isolator CEAS420876 2 and power supplies CEAS221045 01 2 required for the CCN communication line Fault Codes The drive is programmed to automatically re start after a fault and will attempt to restart three times after a fault the drive will not restart after CF cF GF F1 F2 F9 or Fo faults If all three restart attempts are unsuccessful the drive will trip into FAULT LOCKOUT LC which requires a manual reset Manual Reset If fault conditi
137. ce and enter YES for Pump 1 Maintenance Done P 1 MN item Pump 2 Service Countdown P 2 DN expired Complete pump 2 maintenance and enter YES for Pump 1 Maintenance Done P 2 MN item 70 ACTION TAKEN BY CONTROL All compressors shut down Pump 2 turned off Pump 1 will be started if available Chiller allowed to run if Pump 1 successfully starts and flow switch is closed Chiller not allowed to start Chiller not allowed to start Chiller not allowed to start For models with dual pumps the second pump will be started if available All compressors shut down For models with dual pumps the second pump will be started if available Chiller shut down Dual chiller control disabled Chiller runs as a stand alone machine Dual chiller control disabled Chiller runs as a stand alone machine Dual chiller routine disabled Master slave run as stand alone chillers Alert only No action taken Chiller shutdown without going through pumpdown Cooler pump continues to run a minimum of 5 minutes if control enabled Chiller shutdown Cooler pump shut off if control enabled None None RESET METHOD Manual Automatic when aux contacts open Automatic when aux contacts open Manual Manual Automatic when aux contacts open Automatic Automatic Automatic Automatic Both EWT and LWT must be at least 6 F 3 3 C above Brine Freeze point BR FZ Aut
138. ck points on the main base board The chilled water pump 1 interlock CWP1 must be connected to MBB J7 1 and 2 The chilled water pump 2 interlock CWP2 must be connected to MBB J7 3 and 4 The chilled water pump 35 interlock contacts should be rated for dry circuit application capable of handling 5 vdc at 2 mA SINGLE INTEGRAL PUMP CONTROL With a single pump the following options must be configured Cooler Pump Control Configuration gt 1 gt ON e Cooler Pump 1 Enable Configuration gt YES e Cooler Pump 2 Enable Configuration DOPTI 2 NO With a single integral pump the Cooler Pump Starter will be energized when the machine is occupied As part of the factory installed package an auxiliary set of contacts 1s wired to the MBB to serve as Chilled Water Pump Interlock When the mechanical cooling is called for the pump interlock and flow switch is checked If the circuits are closed the machine starts its capacity routine If the auxiliary contact interlock does not close within 25 seconds of the ON command a T190 Cooler Pump 1 Aux Contacts Failed to Close at Start Up Alert will be generated and the pump shut down The unit will not be allowed to start If the chilled water flow switch does not close within one 1 minute two alarms will be generated A T192 Cooler Pump 1 Failed to Provide Flow at Start Up Alert and an A200 Cooler Flow Interlock Failed to
139. cted 5 Verify communication with the network by viewing a module status report To perform a module status report using the BACview keypad display unit press and hold the FN key then press the Key BT485 Terminator Fig D Network Wiring 103 APPENDIX D OPTIONAL BACNET COMMUNICATIONS WIRING cont BACnet Shield 2 2 Port S1 BACnet MS TP EIA 485 4 485 2 Fig E BT485 Terminator Installation To install a BT485 terminator push the BT485 terminator on to the BT485 connector located near the BACnet connector NOTE The BT485 terminator has no polarity associated with it To order a BT485 terminator consult Commercial Products i Vu Open Control System Master Prices MS TP WIRING RECOMMENDATIONS Recommen dations are shown in Tables C and D The wire jacket and UL temperature rating specifications list two acceptable alterna tives The Halar specification has a higher temperature rating and a tougher outer jacket than the SmokeGard specification and it is appropriate for use in applications where the user is concerned about abrasion The Halar jacket is also less likely to crack in extremely low temperatures NOTE Use the specified type of wire and cable for maximum signal integrity Table C MS TP Wiring Recommendations SPECIFICATION RECOMMMENDATION Cable Single twisted pair low capacitance CL2P 22 AWG 7x30 TC foam FEP plenum rated c
140. cuit B leading as desired Set at automatic the control will sum the current num ber of logged circuit starts and one quarter of the current oper ating hours for each circuit The circuit with the lowest sum is started first Changes to which circuit is the lead circuit and which is the lag are also made when total machine capacity is at 100 or when there is a change in the direction of capacity increase or decrease and each circuit s capacity is equal CAPACITY CONTROL OVERRIDES The following over rides will modify the normal operation of the routine Deadband Multiplier The user configurable Deadband Multiplier Configuration SLCT Z GN has default val ue of 1 0 The range is from 1 0 to 4 0 When set to other than 1 0 this factor is applied to the capacity Load Unload Factor The larger this value is set the longer the control will delay be tween adding or removing stages of capacity Figure 13 shows how compressor starts can be reduced over time if the leaving water temperature is allowed to drift a larger amount above and below the set point This value should be set in the range of 3 0 to 4 0 for systems with small loop volumes First Stage Override If the current capacity stage is zero the control will modify the routine with a 1 2 factor on adding the first stage to reduce cycling This factor is also applied 30 when the control is attempting to remove the last stage of capacity Slow Change Ov
141. d black conductors Substitute appropri ate colors for different colored cables 3 Connect the red wire to terminal LVT of the plug the white wire to COM terminal and the black wire to the terminal 4 The RJ14 CCN connector on can also be used but is only intended for temporary connection for example a laptop computer running Service Tool IMPORTANT A shorted CCN bus cable will prevent some routines from running and may prevent the unit from start ing If abnormal conditions occur unplug the connector If conditions return to normal check the CCN connector and cable Run new cable if necessary A short in one section of the bus can cause problems with all system elements on the bus Table 15 Thermistor Designations THERMISTOR LWT EWT RGTA RGTB OAT SPT DTT PIN CONNECTION THERMISTOR INPUT POINT J8 13 14 MBB Cooler Leaving Fluid J8 11 12 MBB Cooler Entering Fluid J8 1 2 MBB Circuit A Return Gas Temperature J8 3 4 MBB Circuit B 035 060 only Return Gas Temperature MBB Outdoor Air Temperature Sensor J8 7 8 J8 5 6 Accessory Remote Space TB5 5 6 Temperature Sensor or Dual LWT Sensor 1 2 Discharge Temperature Thermistor J6 AUX LEGEND LWT Leaving Water Temperature MBB Main Base Board STATUS SWITCH Table 16 Status Inputs PIN CONNECTION POINT Chilled Water Pump 1 J7 1 2 Chilled Water Pump 2 J7 3 4 Remote
142. der own error failed Manager within 5 minutes of last control transformer loose transmission connection plug wrong address T951 Alert Loss of Communication No communications have CSM forces removed Automatic Failed module wiring with Chillervisor System been received by the MBB Chiller runs under own error failed Manager within 5 minutes of last control transformer loose transmission connection plug wrong address T952 Alert Loss of Communication No communications have HSM forces removed Automatic Failed module wiring with Hydronic System been received by the MBB Chiller runs under own error failed Manager within 5 minutes of last control transformer loose transmission connection plug wrong address LEGEND FOR TABLE 42 CCN Carrier Comfort Network CSB Current Sensor Board EEPROM Electronic Eraseable Programmable Read Only Memory EMM Energy Management Module EWT Entering Fluid Temperature EXV Electronic Expansion Valve HSM Hydronic System Manager LCW Leaving Chilled Water LWT Leaving Fluid Temperature MBB Main Base Board OAT Outdoor Air Temperature SCT Saturated Condensing Temperature WSM Water System Manager COMPRESSOR FAILURE ALERTS 051 052 Circuit A Compresser Failures T055 T056 Circuit B Compressor Failures Alert codes 051 052 055 and 056 are for compressors 1 A2 and B2 respectively These alerts occur when the current sensor CS does not detect co
143. e and Sub Mode Directory SUB MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT mm TIME OF DAY HH MM XX XX Military 00 00 23 59 DATE ray fonts 01 31 gt Mondays DAYLIGHT SAVINGS TIME Deiauit 4 Range 1 12 Default T Range 1 5 Default 7 Range 1 7 DST Default 60 Range 0 59 Default 10 Range 1 12 Default 5 Range 1 5 Default 7 Range 1 7 Default 60 Range 0 59 HOL L LOCAL HOLIDAY SCHEDULES HOLIDAY SCHEDULE 01 HD 01 Holiday Start Month EM _________ ____ XX Duration days HOLIDAY SCHEDULE 02 s mum 01 31 Duration days HOLIDAY SCHEDULE 03 a en 01 34 Barton day HD 02 HD 03 HOLIDAY SCHEDULE 04 1 12 1 January 01 31 HD 04 Duration days HOLIDAY SCHEDULE 05 01 31 Xx 71 Duration days HOLIDAY SCHEDULE 06 HD 05 01 34 Barton day HOLIDAY SCHEDULE 07 ae 01 31 E Duration days HOLIDAY SCHEDULE 08 1 12 1 January 01 31 Duration days HD 06 HD 07 84 SUB MODE HD 09 HD 10 HD 11 HD 12 HD 13 HD 14 HD 15 HD 16 HD 17 HD 18 HD 19 APPENDIX A DISPLAY TABLES cont Time Clock Mode and Sub Mode Directory cont ITEM DISPLAY ITEM DESCRIPTION HOLIDAY SCHEDULE 09 Duration days HOLIDAY SCHEDULE 10 XX Duration days HOLIDAY SCHEDULE 11 Holiday Start Month Duration days
144. e pump curve See base unit installation instruc tions This can be done in a variety of ways 1 Ifpump impeller diameter is known a Connect a differential pressure gage across the pump at the ports provided on the pump volutes b Read GPM from applicable impeller curve 2 Ifpump impeller diameter is not known If pump impeller diameter has been trimmed and the size is not known it is necessary to determine which impeller curve to read The easiest way to confirm pump performance is to dead head the pump and read the differential pressure across the pressure ports on the pump Dead heading can be done by shutting the circuit setter valve on the dis charge side of the pump NOTE Although not all pumps can be safely dead headed centrifugal pumps such as on the 30RAP units be dead headed for short amounts of time It is rec ommended to keep the time short due to excessive heat build up in the pump Since the dead head condition is a no flow condition the head will correspond to the intersection of an impel ler curve with the vertical axis of the pump chart The correct impeller diameter is that which corresponds to the measured head 3 Once the impeller diameter is known proceed as in Step 1 4 Water flow rate can be determined by using a differential pressure gage with the Bell amp Gossett circuit setter bal ance valve calculator This information is also provided in the installat
145. e to reset the alert The cause of the alert is usually a faulty transducer faulty 5 v power supply or a loose connection T092 Circuit A Suction Pressure Transducer Failure 1093 Circuit B Suction Pressure Transducer Failure Alert codes 092 and 093 are for circuits A and B respectively These alerts occur when the pressure is outside the range of 0 0 to 420 0 psig A circuit cannot run when this alert is active Use the scrolling marquee to reset the alert The cause of the alert is usually a faulty transducer faulty 5 v power supply or a loose connection T094 Discharge Gas Thermistor Failure This alert oc curs for units which have the digital compressor installed on circuit A If discharge gas temperature is open or shorted the circuit will be shutoff The alert will reset itself when discharge temperature is less than 250 F 121 1 C The cause of the alert is usually low refrigerant charge or a faulty thermistor T110 Circuit A Loss of Charge T111 Circuit B Loss of Charge Alert codes 110 and 111 are for circuits A and B respectively These alerts occur when the compressor is OFF and the discharge pressure is less than 26 psig T112 Circuit A High Saturated Suction Temperature T113 Circuit B High Saturated Suction Temperature Alert codes 112 and 113 occur when compressors in a circuit have been running for at least 5 minutes and the circuit saturat ed suction temperature is greater than 70 F 21 1
146. ear in the display except the ability to configure circuit B will be displayed Ta KEYPAD SUB MODE 8 COOL ENTER XXX X PSIG SUCTION PRESSURE PRESsURESCICUTB CIRCUIT B 7 PSIG DISCHARGE PRESSURE XXX X PSIG SUCTION PRESSURE ble 7 Set Points Mode and Sub Mode Directory ITEM DISPLAY COOLINGSETPOINTS SETPOINTS ENTER HEAD FRZ XXX X F COOLING SETPOINT 2 CSP 3 XXX X F ICE SETPOINT HEAD PRESSURE SETPOINTS BRINE FREEZE SETPOINT BR FZ XXX X F BRINE FREEZE POINT COMMENT See Note See Note See Note See Note See Note COMMENT See Note See Note See Note COMMENT Default Default Default Default Default Default Default Default Default 44 F 44 F 32 F 95 F 95 F 72 23 F 34 F Table 8 Inputs Mode Sub Mode Directory KEYPAD ITEM SUB MODE ENTRY ITEM DISPLAY EXPANSION COMMENT GEN I GENERAL INPUTS p ee 2 7 DLS2 DEMAND LIMIT SWITCH 2 DUAL ON OFF DUAL SETPOINT SWITCH CRCT PY CIRCUITS INPUTS 1 COMPRESSOR 1 FEEDBACK 4 20 DMND XX X MA 4 20 MA DEMAND SIGNAL EI RSET XX X MA 4 20 MA RESET SIGNAL XX X MA 4 20 MA COOLING SETPOINT NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed Table
147. eat exchanger The unit insulation covers the manufacturer s part number Make sure the depths of the replacement and original cooler heat exchangers are the same 2 Disconnect the liquid in and connections at the heat exchanger 3 Recover the refrigerant from the system and unsolder the refrigerant in refrigerant out connections 4 Remove the old heat exchanger The replacement heat ex changer is supplied fully insulated It also includes a cool er heater Use of the heater is not required unless the orig inal cooler contained a factory installed heater 5 Install the replacement heat exchanger in the unit and at tach the mounting bracket hardware to the fan uprights sizes 010 030 or to the bottom bracket sizes 035 060 using the hardware removed in Step 4 Reconnect the cooler heater if required For sizes 010 025 torque the bolts to 7 10 ft lb For sizes 030 060 torque the bolts to 30 50 ft lb 6 Carefully braze the refrigerant lines to the connections on the heat exchanger Lines should be soldered using silver as the soldering material with a minimum of 45 silver Keep the temperature below 1472 F 800 C under nor mal soldering conditions no vacuum to prevent the cop per solder of the brazed plate heat exchanger from chang ing its structure Failure to do so can result in internal or external leakage at the connections which cannot be re paired Braze the liquid lines with a heat sink around
148. ed 1 The Enable Off Remote Switch in ENABLE CTRL 0 2 Enable Off Remote Switch in REMOTE with a Start Stop remote contact closure CTRL 0 3 An Occupied Time Period from an Occupancy Schedule in combination with items 1 or 2 CTRL 2 4 A CCN Start Stop Command to Start in combination with items 1 or 2 CTRL 3 As stated before there are certain alarm conditions and Operating Modes that will turn the cooler pump relay ON This sequence will describe the normal operation of the pump control algorithm When the unit cycles from an state to an Off state the cooler pump output will remain energized for the Cooler Pump Shutdown Delay Configuration gt 1 gt This is configurable from 0 to 10 minutes The factory default is 1 minute NO INTEGRAL PUMP SINGLE EXTERNAL PUMP CONTROL With a single external pump the following options must be configured Cooler Pump Control Configuration gt 1 gt OFF e Cooler Pump 1 Enable Configuration gt NO e Cooler Pump 2 Enable PM2E NO The maximum load allowed for the Chilled Water Pump Starter is 5 sealed 10 VA inrush at 24 volts The starter coil is powered from the chiller control system The starter should be wired between LVT 25 and LVT 21 If equipped the field installed chilled water pump starter auxiliary contacts should be connected in series with
149. ed Binary 2 2912 user_binary_2_1 User Defined Binary 3 qa BVv2913 user binary 3 1 User Defined Binary 4 cqa Bv2914 user binary 4 1 User Defined Binary 5 RW sam 2015 user 5 1 Var Head Press Output m WSM Controlling Chiller MODE2 R mode 2 1 LEGEND R Read w Write n I k RW _ 2965 useranalog 2 TI LI 109 Compressor Cooler Condenser Compressor Cooler Condenser Compressor Cooler Condenser Compressor Cooler Condenser APPENDIX E MAINTENANCE SUMMARY AND LOG SHEETS 30RAP Maintenance Interval Requirements WEEKLY Check oil level Economizer None MONTHLY Check oil level Economizer None QUARTERLY Check oil level Economizer None Check refrigerant charge Check all connec Controls Perform an Automated Controls test Run all compressors tions for leaks and ensure proper operation ANNUALLY Level Obtain test Economizer Verify proper operation of EXVs TXVs Check refrigerant charge Check all connec tions for leaks Check approach on unit to Perform an Automated Controls test Run all compressors determine if tubes need cleaning Check for Controls and ensure proper operation Ensure operation of unit flow temperature drop across filter drier t
150. elay Minimum Load Valve Relay Compressor A1 Feedback Compressor A2 Feedback Percent Total Capacity Percent Available Cap Discharge Pressure Suction Pressure Head Setpoint Saturated Condensing Tmp Saturated Suction Temp Compr Return Gas Temp Suction Superheat Temp Compressor B1 Relay Compressor B2 Relay Minimum Load Valve Relay Compressor B1 Feedback Compressor B2 Feedback Fan 1 Relay Fan 2 Relay Outside Air Temperature Space Temperature Cooler Pump Relay 1 Cooler Pump Relay 2 Cooler Pump 1 Interlock Cooler Pump 2 Interlock Cooler Entering Fluid Cooler Leaving Fluid Compressor A1 Size Compressor A2 Size Compressor B1 Size Compressor B2 Size Cooler Flow Switch APPENDIX B CCN TABLES cont CCN MAINTENANCE TABLES RUNTEST VALUE UNITS mna s E ono pL ws LS onto _ ovo 99 POINT NAME CAPA T CAPA A DP A SPA HSP SCTA SSTA DISGAS SH_A K_A1_RLY K_A2_RLY MLV_RLY K_A1_FBK K_A2_FBK CAPB_T CAPB_A DP_B SP_B HSP TMP_SCTB TMP_SSTB TMP_RGTB SH_B K_B1_RLY K_B2_RLY MLV_RLY K_B1_FBK K_B2_FBK FAN_1 FAN_2 OAT SPT COOLPMP1 COOLPMP2 PMP1_FBK PMP2_FBK COOL_EWT COOL_LWT SIZE_A1 SIZE_A2 SIZE_B1 SIZE_B2 COOLFLOW DESCRIPTION Dual Chiller Link Good Master Chiller Role Slave Chiller Role Lead Chil
151. elow 32 F 0 C Proof of flow switch and strainer are factory installed on all models Do NOT remove power from this chiller during winter shutdown periods without taking precaution to remove all water from heat exchanger and optional hydronic system Failure to properly protect the system from freezing may constitute abuse and may vold warranty A CAUTION Compressors and optional hydronic system pumps require specific rotation Test condenser fan s first to ensure proper phasing Swap any two incoming power leads to correct condenser fan rotation before starting any other motors N CAUTION Refrigerant charge must be removed slowly to prevent loss of compressor oil that could result in compressor failure CAUTION Puron refrigerant R 410A systems operate at higher pressures than standard R 22 systems Do not use R 22 ser vice equipment or components on Puron refrigerant equip ment If service equipment is not rated for Puron refrigerant equipment damage or personal injury may result GENERAL This publication contains Controls Start Up Operation Service and Troubleshooting information for the 30RAP AquaSnap air cooled chillers See Table 1 These chillers are equipped with ComfortLink controls and electronic expan sion valves 5 ANWARNING This unit uses a microprocessor based electronic control system Do not use jumpers or other tools to short out or bypass components or otherwise depart f
152. en open in ternal protection circuit breaker trip incorrect safety wir ing or incorrect compressor wiring 2 Ifthe compressor does start verify it 1s rotating in the cor rect direction IMPORTANT Prolonged operation in the wrong direction can damage the compressor Correct rotation can be veri fied by a gage set and looking for a differential pressure rise on start up IMPORTANT If the CS is always detecting current verify that the compressor is on If the compressor is on check the contactor and the relay on the MBB If the compressor is off and there is no current verify the CSB wiring and replace if necessary IMPORTANT Return to Normal mode and observe com pressor operation to verify that compressor current sensor 18 working and condenser fans are energized COMPRESSOR STUCK ON FAILURE ALARMS Circuit A A051 A052 Circuit A055 A056 Alarm codes 051 052 055 and 056 are for compressors Al A2 and B2 These alarms cur when the CSB detects current when the compressor should be off When this occurs the control turns off the compressor If the current sensor board reads ON while the compressor relay has been commanded OFF for a period of 4 continuous seconds an alarm is generated These alarms are only moni tored for a period of 10 seconds after the compressor relay has been commanded OFF This is done to facilitate a service tech nician forcing a relay to test a compressor In
153. erature reset disabled Demand Limit set to 10096 4 to 20 mA set point disabled Set point function disabled Chiller controls to CSP1 Reset function disabled Chiller returns to normal set point control Demand limit function disabled Chiller returns to 10096 demand limit control Both pump outputs are turned off Pump 1 turned off Pump 2 will be started if available Pump 2 turned off Pump 1 will be started if available Pump 1 turned off Pump 2 will be started if available Pump 1 turned off Pump 2 will be started if available Pump 2 will be started if available Chiller allowed to run if Pump 2 successfully starts Pump 1 will be started if available Chiller allowed to run if Pump 1 successfully starts All compressors shut down Pump 1 turned off Pump 2 will be started if available Chiller allowed to run if Pump 2 successfully starts and flow switch is closed ACTION TAKEN RESET BY CONTROL METHOD Automatic when correct clock control restarts Automatic Automatic Automatic Automatic Automatic gt omatic Manual Manual Manual Manual Manual Manual Manual Manual PROBABLE CAUSE Time Date Month Day Year not properly set Main Base Board failure Potential failure of MBB Download current operating software Replace MBB if error occurs again Main Base Board failure Main Base Board fail
154. ercent Displacement Standard Units with Minimum Load Valve CONTROL CAPACITY STEPS CAPACITY 30RAP UNIT SIZE STEPS Displacement Circuit A Circuit B 010 100 100 015 100 100 1 100 018 2 50 100 3 20 1 100 020 2 50 100 3 24 1 100 025 2 50 100 3 29 1 100 030 2 50 100 3 1 2 035 3 46 4 5 1 2 040 3 53 4 5 1 2 045 3 53 4 5 1 2 050 3 50 4 5 1 2 055 3 54 4 5 1 2 060 3 50 4 5 Minimum Load Valve energized NOTE These capacity steps may vary due to different capacity staging sequences DEADBAND EXAMPLE zd dn 47 8 46 45 S 7 44 6 5 43 42 5 41 400 600 TIME SECONDS 3 STARTS SN LEGEND MODIFIED LWT Leaving Water Temperature DEADBAND Fig 13 Deadband Multiplier 31 Cooler Freeze Protection control will try to prevent shutting the chiller down on a Cooler Freeze Protection alarm by removing stages of capacity If the cooler fluid selected is Water the freeze point is 34 F 1 1 C If the cooler fluid selected is Brine the freeze point is the Brine Freeze Point Set Points gt FRZ BR FZ This alarm condition A207 only references leaving fluid temperature and NOT Brine Freeze point If the cooler leaving fluid temperature is less than the freeze point plus 2 0 F 1 1 C the control will immediately remove one stage of capacity This can be repeated once every 30 seconds Low Saturated Suction Protection The control will try to prevent
155. erride The control prevents the capacity stages from being changed when the leaving fluid temperature is close to the set point within an adjustable deadband and moving towards the set point Ramp Loading Ramp loading Configura gt gt limits the rate of change of leaving fluid temperature If the unit is in a Cooling mode and config ured for Ramp Loading the control makes 2 comparisons be fore deciding to change stages of capacity The control calcu lates a temperature difference between the control point and leaving fluid temperature If the difference is greater than 4 F 2 2 C and the rate of change F or C per minute is more than the configured Cooling Ramp Loading value CRMP the control does not allow any changes to the current stage of capacity Low Entering Fluid Temperature Unloading When the entering fluid temperature is below the control point the control will attempt to remove 25 of the current stages being used If exactly 2596 cannot be removed the control removes an amount greater than 2596 but no more than necessary The lowest stage will not be removed Minimum Load Control If equipped the minimum load control valve is energized only when one compressor is run ning on circuit A If the close control feature 1s enabled the minimum load control valve may be used as needed to obtain leaving fluid temperature close to set point Table 19 Part Load Data P
156. es and the leaving fluid temperature is greater than the saturated condensing temperature the wear factor is still used to determine which compressor to start next If the leaving fluid temperature is less than the saturated con densing temperature then the control will start either compres sor Al or compressor first depending on the user configu rable circuit lead lag value For units with the minimum load control valve the A circuit with the minimum load valve is al ways the lead circuit The A circuit is also always the lead for units with the digital compressor option On units with the dig ital scroll option the Al compressor operates continuously providing close leaving chilled water control For this reason on off cycling of the unit s compressors is dramatically re duced which in turn reduces wear associated with compressor start stop cycles The EXVs will provide a controlled start up During start up the low pressure logic will be bypassed for 2 minutes to allow for the transient changes during start up As additional stages of compression are required the processor control will add them See Table 19 If a circuit is to be stopped the compressor with the lowest wear factor will be shut off first except when a digital compres sor is used The digital compressor is always the last compres sor to shut off The capacity control algorithm runs every 30 seconds The algorithm attempts to maintain the Control Po
157. f the machine should be running and none of the above are true a minimum off time DELY see below may be in effect The machine should start normally once the time limit has expired MINUTES OFF TIME Configuration 2OPT2 DELY This user configurable time period is used by the control to determine how long unit operation is delayed after power is applied restored to the unit Typically this time period is configured when multiple machines are located on a single site For example this gives the user the ability to prevent all the units from restarting at once after a power failure A value of zero for this variable does not mean that the unit should be running CEBD430351 0396 01C J1 J2 6 D
158. factory installed option or as a field installed accessory The EMM module receives 4 to 20 mA inputs for the leaving fluid temperature reset cooling set point and demand limit functions The EMM module also receives the switch inputs for the field installed 2 stage demand limit and ice done functions The EMM module communicates the status of all inputs with the MBB and the MBB adjusts the control point capacity limit and other functions according to the inputs received Current Sensor Board CSB The CSB is used to monitor the status of the compressors by measuring current and providing an analog input to the main base board MBB or compressor expansion module CXB AUX Board AUX The AUX is used with the digital scroll option and the low ambient head pressure option It pro vides additional inputs and outputs for digital scroll control along with analog outputs to control head pressure control fan speeds Expansion Valve Board EXV The EXV board communicates with the MBB and directly controls the expan sion valves to maintain the correct compressor superheat Enable Off Remote Contact Switch The Enable Off Remote Contact switch is 3 position switch used to control the chiller When switched to the Enable position the chiller is under its own control Move the switch to the Off position to shut the chiller down Move the switch to the Remote Contact position and a field installed dry contact can be used to st
159. g Set Point Select set to 0 single set point With the control method set to 0 simply switching the Enable Off Remote Contact switch to the Enable or Remote Contact position external contacts closed will put the chiller in an occupied state The control mode Operating Modes MODE will be 1 OFF LOCAL when the switch is Off and will be 5 ON LOCAL when in the Enable position or Remote Contact position with external contacts closed 170 160 150 140 130 120 110 9 100 iss 90 80 70 60 50 40 30 1 30 20 10 0 10 20 30 40 50 60 70 80 SST F LEGEND SCT Saturated Condensing Temperature SST Saturated Suction Temperature Fig 14 Operating Envelope for R 410A Compressor 32 View Sizes 010 015 CONTROL BOX CONTROL BOX Top View Sizes 018 030 m m EST E E o o i Top View Top View Sizes 035 050 Sizes 055 060 Fig 15 30RAP Condenser Fan Layout Table 20 Fan Stages FAN STAGES 30RAP UNIT SIZE Contactor Energized Fans Operating 010 015 Stgei OFM1 Stage 1 FC1 OFM1 Stage 1 FC1 OFM3 035 050 Stage 2 FC2 OFM1 2 Stage 3 FC1 2 OFM1 2 3 Stage 1 FC3 OFM4 Stage 2 FC1 3 OFM4 3 055 060 Stage 3 2 OFM4 1 2 Stage 4 FC1 2 3 OFM1 2 3 4 Two other control methods are available for Machine On Off contr
160. g envelope shown in Fig 14 Prior to the alert the control will shut down one compressor on a circuit if that circuit s saturated condensing temperature is greater than the maximum SCT minus 5 F 2 7 C If SCT continues to rise to greater than the maximum SCT the alert will occur the circuit s remaining compressor will shut down The cause of the alarm is usually an overcharged system high outdoor ambient temperature coupled with dirty outdoor coil plugged filter drier or a faulty high pressure switch T133 Circuit A Low Suction Pressure 134 Circuit Low Suction Pressure Alert codes 133 and 134 are for circuits A and B respectively These alerts are generated if one of the two following conditions is satisfied the circuit suction pressure is below 34 psig 234 4 kPa for 8 seconds or the suction pressure is below 23 psig 158 6 kPa The cause of this alert may be low refrigerant charge plugged liquid line filter drier or sticking EXV Check head pressure operation If not equipped consider adding low ambient tem perature head pressure control Add wind baffles if required A140 Reverse Rotation Detected A test is made once on power up for suction pressure change on the first activated cir cuit The unit control determines failure as follows 1 The suction pressure of both circuits is sampled 5 seconds before the compressor is brought on right when the c
161. g of the next cooling season refill the cooler and add the recommended inhibitor Thermistors Electronic control uses up to five 5 thermistors to sense temperatures used to control operation of the chiller Thermistors EWT LWT RGTA RGTB and are identical in their temperature and voltage drop perfor mance SPT space temperature thermistor has a 10 in put channel and it has a different set of temperature vs resis tance and voltage drop performance Resistance at various tem peratures are listed in Tables 33 37 For dual chiller operation a dual chiller sensor is required which is a 5 kO thermistor When a digital compressor is used a DTT digital temperature thermistor is used The DTT is an 86 thermistor REPLACING THERMISTORS EWT LWT RGT Add a small amount of thermal conductive grease to the thermistor well and end of probe For all probes tighten the retaining nut 1 4 turn past finger tight See Fig 28 THERMISTOR TEMPERATURE SENSOR CHECK A high quality digital volt ohmmeter is required to perform this check 1 Connect the digital voltmeter across the appropriate the mistor terminals at the J8 terminal strip on the Main Base Board see Fig 29 2 Using the voltage reading obtained read the sensor tem perature from Tables 33 37 3 To check thermistor accuracy measure temperature at probe location with an accurate thermocouple type tem perature measuring instrument In
162. g temperatures can go as low as 20 29 C on size 010 and 015 units as standard Installa tion of wind baffles is also required Refer to separate installa tion instructions for operation using this accessory Contact your Carrier representative for details A CAUTION Brine duty application below 40 F 4 4 C LCWT for 44 chiller normally requires factory modification Contact your Carrier representative for applicable LCWT range for standard water cooled chiller in a specific application VOLTAGE ALL UNITS Main Power Supply Minimum and maximum acceptable supply voltages are listed in the Installation Instructions 46 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance between phases is greater than 2 To determine percent voltage imbalance max voltage deviation from avg voltage average voltage The maximum voltage deviation is the largest difference between a voltage measurement across 2 legs and the average across all 3 legs Example Supply voltage is 240 3 60 Voltage Imbalance 100 x B C 243 BC 236 v AC 238 1 Determine average voltage 243 236 238 Average voltage NE 3 239 2 Determine maximum deviation from average voltage AB 243 239 4 v 239 236 2 3v AC 239 238 1 Maximum deviation is 4 v 3 Determine percent voltage imbalance Voltage Imbalance 100 x A 1 7 This volt
163. ge 30 to 30 F 16 7 to 16 7 C NOTE The example above shows how to configure the chiller for 4 to 20 mA reset No reset will occur at 4 0 mA input and a 5 0 F reset will occur at 20 0 mA An EMM is required KEYPAD ITEM ENTRY ITEM DISPLAY EXPANSION COOLING RESET TYPE COMMENT 0 no reset 1 4 to 20 mA input 2 Outdoor air temp 3 Return Fluid 4 Space Temperature Table 25 Menu Configuration of 4 to 20 mA Cooling Set Point Control MODE RED LED ERE KEYPAD KEYPAD ITEM ENTRY SUB MODE Entry ITEM DISPLAY Lu EUCH NN NEN 2 ee 2 CONFIGURATION m rn 202 n 02 w J ENTER ENTER ENTER CLSP ER COOLING SETPOINT SELECT ENTER IMPORTANT Care should be taken when interfacing with other control systems due to possible power supply differ ences full wave bridge versus half wave rectification Con nection of control devices with different power supplies may result in permanent damage ComfortLinkTM controls incorporate power supplies with half wave rectification A signal isolation device should be utilized if the signal gen erator incorporates a full wave bridge rectifier To use outdoor air or space temperature reset four variables must be configured In the Configuration mode under the sub mode RSET items Configuration OPTI CRST
164. hange OFF to ON Pressing will illuminate all LEDs and display all pixels in the view screen Pressing the up and down arrow keys simultane ously allows the user to adjust the display brightness Use the up or down arrow keys to adjust screen brightness Press to accept the change The Navigator module will keep this setting as long as it is plugged in to the LEN bus Fig 2 Accessory Navigator Display Module Table 2 Scrolling Marquee Display Menu Structure RUN SERVICE SET TIME OPERATING MODE STATUS TEST TEMPERATURES PRESSURES POINTS INPUTS OUTPUTS CONFIGURATION CLOCK MODES ALARMS E Service Ent and Leave Unit Pressures Cooling General General Display Time of Run Status Test Mode Temps Ckt A Setpoints Inputs Outputs Configuration VIEW TEST UNIT PRC A COOL GEN I GEN O DISP Unit Run Head Hour and Outputs Pressures Pressure Circuit Circui and Pumps Ckt B Inputs Configuration tart t t EXV RUM PRC B EAD CRCT UNIT irui Brine EUER Daylight Compressor Ciruit A Comp Temperatures Unit Options 1 Hours Ckt B Freeze Hardware Savings HOUR CMPA CIR B rot OPT1 zu Outputs Compressor CiruitB Comp Starts Test STRT CMPB Unit Options 2 Holiday rr Schedules Preventive Maintenance PM CCN Network Configuration CCN Schedule Software Version sup MopE _ VERS Head Pressure Schedule Comp Delt
165. has been changed use the arrow keys to change each individu al character Toggle the display to YES and press ENTER The alarms will be reset E P 5 10 20 30 50 60 70 80 90 Compressor Unloaded Run Time Minutes Times are approximate NOTE Various factors including high humidity high ambient temperature and the presence of a sound blanket will increase cool down times Fig 35 Recommended Minimum Cool Down Time After Compressor is Stopped Table 41 Troubleshooting SYMPTOMS REMEDY Cooler Circulating Pump Does Power line open Reset circuit breaker Not Run Control fuse or circuit breaker open Check control circuit for ground or short Reset breaker and replace fuse Tripped power breaker Check the controls Find the cause of trip and reset breaker Loose terminal connection Check connections Improperly wired controls Check wiring and rewire if necessary Low line voltage Check line voltage determine location of voltage drop and remedy deficiency Pump motor defective Check motor winding for open or short Replace compressor if necessary Replace pump Compressor Cycles Repair leak and recharge Off on Loss of Charge Compressor Cycles Off on Cooler Replace thermistor Freeze Protection Unit will restart after fluid temperature rises back into the remove stages control
166. he BAS Port DIP Switches DS2 and DS1 for the appro priate communications speed of the MS TP network 9600 19 2k 38 4k or 76 8k bps See Fig D and Table B Table B Baud Selection Table BAUD RATE DS1 9 600 Off 19 200 Off 38 400 On 76 800 On WIRING THE UPC OPEN CONTROLLER TO THE MS TP NETWORK The UPC Open controller communicates using BACnet on an MS TP network segment communications at 9600 bps 19 2 kbps 38 4 kbps or 76 8 kbps Terminator BACnet MS TP m 485 Enable 76 8k baud rate Fig C DIP Switches Wire the controllers on an MS TP network segment in a dai sy chain configuration Wire specifications for the cable are 22 AWG American Wire Gage or 24 AWG low capacitance twisted stranded shielded copper wire The maximum length is 2000 ft Install a BT485 terminator on the first and last controller on a network segment to add bias and prevent signal distortions due to echoing See Fig A D and E To wire the UPC Open controller to the BAS network 1 Pull the screw terminal connector from the controller s BAS Port 2 Check the communications wiring for shorts and grounds 3 Connect the communications wiring to the BAS port s screw terminals labeled Net Net and Shield NOTE Use the same polarity throughout the network segment 4 Insert the power screw terminal connector into the UPC Open controller s power terminals if they are not current ly conne
167. he EXV board controls the valve Each circuit has a thermistor located in a well in the suction manifold before the compressor Suction pressure as measured by the suction pres sure transducer is converted to a saturated suction temperature The thermistor measures the temperature of the superheated gas entering the compressor and the pressure transducer 47 determines the saturated temperature of suction gas differ ence between the temperature of the superheated gas and the saturated suction temperature is the superheat The EX V board controls the position of the electronic expansion valve stepper motor to maintain superheat set point The MBB controls the superheat leaving cooler to approxi mately 9 F 5 C Because EXV status is communicated to the main base board MBB and is controlled by the EXV boards it is possible to track the valve position The unit is then protected against loss of charge and a faulty valve Just prior to compressor start the EXV will open At low ambient tempera tures the is closed at start up After initialization period valve position is tracked by the EXV board by constantly mon itoring the amount of valve movement The is also used to limit cooler saturated suction tem perature to 50 F 10 C This makes it possible for the chiller to start at higher cooler fluid temperatures without overloading the compressor This is commonly referred to as MOP maxi mum operating pressure
168. higher condensing temperature and or reduced capacity to minimize overall unit noise during evening night hours Configuration gt OPT2 gt LS MD 18 CONTROLS General The 30RAP air cooled scroll chillers contain the ComfortLinkTM electronic control system that controls and monitors all operations of the chiller The control system is composed of several components as listed in the sections below See Fig 3 5 for typical control box drawings See Fig 6 and 7 for control schematics Main Base Board MBB See Fig 8 The MBB is the heart of the ComfortLink control system It contains the major portion of operating software and controls the operation of the machine The MBB continuously monitors input output channel information received from its inputs and from all other modules The MBB receives inputs from the discharge and suction pressure transducers and thermistors See Table 15 The MBB also receives the feedback inputs from each compressor current sensor board and other status switches See Table 16 The MBB also controls several outputs Relay outputs con trolled by the MBB are shown in Table 17 Information is transmitted between modules via a 3 wire communication bus or LEN Local Equipment Network The CCN Carrier Com fort Network bus is also supported Connections to both LEN and CCN buses are made at the LVT low voltage terminal See Fig 8 Energy Management Module EMM The EMM module is available as a
169. hort cycle delay built into the unit control module expires PRESSURE TRANSDUCERS Each refrigerant circuit is equipped with a suction and discharge pressure transducer These inputs to the MBB are not only used to monitor the sta tus of the unit but to also maintain operation of the chiller within the compressor manufacturer s specified limits The in put to the MBB from the suction pressure transducer is also used to protect the compressor from operating at low pressure conditions and low superheat conditions In some cases the unit may not be able to run at full capacity The control module will automatically reduce the capacity of a circuit as needed to maintain specified maximum minimum operating pressures COOLER FREEZE UP PROTECTION A WARNING On medium temperature brine units the anti freeze solu tion must be properly mixed to prevent freezing at a tem perature of at least 15 F 8 3 C below the leaving fluid temperature set point Failure to provide the proper anti freeze solution mixture is considered abuse and may impair or otherwise negatively impact the Carrier warranty The main base board MBB monitors leaving fluid temper ature at all times The MBB will rapidly remove stages of ca pacity as necessary to prevent freezing conditions due to the rapid loss of load or low cooler fluid flow When the cooler is exposed to lower ambient temperatures 34 F 1 C or below freeze up protection is required using
170. ich will attempt to keep the chiller from shutting down Low fluid flow low refrigerant charge and plugged filter driers are the main causes for this condition To avoid permanent damage and potential freezing of the system do NOT repeatedly reset these alert and or alarm conditions without identifying and correcting the cause s COMPRESSOR SAFETIES The 30RAP units with Com fortLink controls include a compressor protection board that protects the operation of each of the compressors Each board senses the presence or absence of current to each compressor If there is a command for a compressor to run and there is no current then one of the following safeties or conditions have turned the compressor off Compressor Overcurrent All compressors have internal line breaks or a motor protection device located in the com pressor electrical box Compressor Short Circuit There will not be current if the compressor circuit breaker that provides short circuit protection has tripped Compressor Motor Over Temperature The internal line break or over temperature switch has opened High Pressure Switch Trip high pressure switch has opened Below are the factory settings for the fixed high pres sure switch 30RAP UNIT CUTOUT CUT IN size psig k kPa 010 060 3447 ASTP Protection Trip non digital Copeland compres sors are equipped with an advanced scroll temperature protec tion ASTP A
171. id 4 Space Temperature Connect to TB5 5 6 RETURNFLUID NO Default 10 0 AF 5 6 AC RESET Range 0 1010 F COOLER RETURN FLUID FULL Default 0 AF 17 8 RESET TEMP Range 0 to 30 F COOLER AT RETURN DEGREES Default 0 0 21 proa rooar 0 167101670 4 items skipped in this example 41 Under normal operation the chiller will maintain a constant leaving fluid temperature approximately equal to the chilled fluid set point As the cooler load varies the entering cooler fluid will change in proportion to the load as shown in Fig 20 Usually the chiller size and leaving fluid temperature set point are selected based on a full load condition At part load the flu id temperature set point may be colder than required If the leaving fluid temperature was allowed to increase at part load the efficiency of the machine would increase Return temperature reset allows for the leaving temperature set point to be reset upward as a function of the return fluid temperature or in effect the building load Demand Limit Demand limit is a feature that allows the unit capacity to be limited during periods of peak energy us age There are 3 types of demand limiting that can be config ured The first type is through 2 stage switch control which will reduce the maximum capacity to 2 user configurable percentag es The second type is by
172. il ure This alert indicates that there are communications problems with the energy management All functions per formed by the EMM will stop which include demand lim it reset and capacity input The alarm will automatically reset 1174 4 to 20 mA Cooling Set Point Input Failure This alert indicates a problem has been detected with cooling set point 4 to 20 mA input The input value is either less than 2 mA or greater than 22 mA T175 Loss of Communication with the AUX Board This alarm indicates that there are communications problems with the AUX board functions performed by the AUX board will stop which can include digital scroll unloader oper ation and low ambient head pressure control The alarm will automatically reset 1176 4 to 20 mA Reset Input Failure This alert indi cates a problem has been detected with reset 4 to 20 mA input The input value is either less than 2 mA or greater than 22 mA The reset function will be disabled when this occurs T177 4 to 20 mA Demand Limit Input Failure This alert indicates a problem has been detected with demand limit 4 to 20 mA input The input value is either less than 2 mA or greater than 22 mA The reset function will be disabled when this occurs T500 T501 Current Sensor Board Failure A xx Circuit A T503 T504 Current Sensor Board Failure B xx Circuit B Alert codes 500 501 503 and 504 are f
173. int at the desired set point Each time it runs the control reads the entering and leaving fluid temperatures The control determines the rate at which conditions are changing and calculates 2 variables based on these conditions Next a capacity ratio is calculated using the 2 variables to determine whether or not to make any changes to the current stages of capacity This ratio value ranges from 100 to 100 If the next stage of capacity is a compressor the control starts stops a compressor when the ratio reaches 100 100 If installed the minimum load valve solenoid will be energized with the first stage of capacity Minimum load valve value is a fixed 30 in the total capacity calculation The control will also use the minimum load valve solenoid as the last stage of capacity before turning off the last compressor A delay of 90 seconds occurs after each capacity step change Refer to Table 19 MINUTES LEFT FOR START This value is displayed only in the network display tables using Service Tool ComfortVIEWTM ComfortWORKS software represents the amount of time to elapse before the unit will start its initialization routine This value can be zero without the machine running in many situations This can include being unoccupied ENABLE OFF REMOTE CONTACT switch in the OFF position CCN not allowing unit to start Demand Limit in effect no call for cooling due to no load and alarm or alert conditions present I
174. ion instructions This method will not di rectly measure pressure differential seen by the pump but be used to double check the pump measurement 5 Verify that cable connections at the switch and at the ter minal block are secure 6 For factory installed hydronic system verify that Allair has been purged from the system Circuit setter balance valve has been correctly set 7 Pump impeller has been improperly trimmed and is not providing sufficient flow 8 Wrong pump motor rotation Pump must rotate clockwise when viewed from motor end of pump PUMP MODIFICATIONS AND IMPELLER TRIMMING See applicable section in the Installation instructions RESET OF CHILLER WATER FLOW See applicable sec tion in the Installation instructions CHANGING OF PUMP SEALS See Bell amp Gossett ser vice instruction manual provided with the hydronic package MAINTENANCE Recommended Maintenance Schedule The fol lowing are only recommended guidelines Jobsite conditions may dictate that maintenance schedule is performed more often than recommended Routine For machines with e coat condenser coils Periodic clean water rinse especially in coastal and industrial applications Check condenser coils for debris clean as necessary Every month e Check moisture indicating sight glass for possible refrig erant loss and presence of moisture Every 3 months for all machines Check refrigerant charge
175. ions at the switch and at the ter minal block are secure 4 For factory installed hydronic systems verify that All air has been purged from the system Circuit setter balance valve has been correctly set 5 Pump impeller has been improperly trimmed and is not providing sufficient flow 6 Wrong pump motor rotation Pump must rotate clockwise when viewed from motor end of pump Strainer Periodic factory installed strainer cleaning is required Pressure drop across strainer in excess of 3 psi 21 kPa indicates the need for cleaning Normal clean pres sure drop is approximately 1 psi 6 9 kPa Open the factory installed blowdown valve to clean the strainer If required shut the chiller down and remove the strainer screen to clean When strainer has been cleaned enter YES for Strainer Mainte nance Done Run Status PM S T MN Condenser Fans Each fan is supported by a formed wire mount bolted to a fan deck and covered with a wire guard METAL FANS The exposed end of fan motor shaft is pro tected from weather by grease and a rubber boot If fan motor must be removed for service or replacement be sure to re grease fan shaft and reinstall fan guard For proper perfor mance with the value sound fan option fan web should be 0 32 in 8 mm below top of orifice on the fan deck to top of the fan hub See Fig 31 Tighten set screws to 15 1 ft Ib 20 1 3 N m IMPORTANT Check for proper fan
176. ixed amount Control will automatically load the chiller if necessary to better match the increasing load Chiller is in an unoccupied mode and is using Cooling Set Point 3 Set Points COOL gt CSP 3 to make ice The ice done input to the Energy Management Module EMM is open Chiller is unoccupied mode andis controlling to Cooling Set Point 2 Set Points COOL CSP 2 ice done input to the Energy Management Module EMM is closed Chiller is in a Cooling mode and the Saturated Condensing Temperature SCT is greater than the calculated maximum limit No additional stages of capacity will be added Chiller capacity may be reduced if SCT continues to rise to avoid high pressure switch trips by reducing con densing temperature Chiller is in a Cooling mode and the Saturated Condensing Temperature SCT is greater than the calculated maximum limit No additional stages of capacity will be added Chiller capacity may be reduced if SCT continues to rise to avoid high pressure switch trips by reducing con densing temperature Cooling load may be satisfied however control continues to operate compressor to ensure proper oil return May be an indication of oversized application low fluid flow rate or low loop volume Cooling load is satisfied however cooler pump continues to run for the number of minutes set by the configuration variable Cooler Pump Shutdown Delay Configuration OPT1 Chiller operates at
177. knowledger If a Chiller Lead Lag Standby application is being used then the Carrier technician must change the configuration to only one CCN Acknowledger on the CCN bus For the CCN Time Broadcaster configuration the UPC Open defaults to CCN Time Broadcaster If the Chiller Lead Lag Standby application is used then the Carrier technician must change the configuration to only one CCN Time Broad caster on the CCN bus TROUBLESHOOTING If there are problems wiring or addressing the UPC Open controller contact Carrier Technical Support COMMUNICATION LEDS The LEDs indicate if the controller is communicating with the devices on the network See Tables E and F The LEDs should reflect communication traffic based on the baud rate set The higher the baud rate the more solid the LEDs become See Fig A for location of LEDs on UPC Open module REPLACING THE UPC OPEN BATTERY The UPC Open controller s 10 year lithium CR2032 battery provides a minimum of 10 000 hours of data retention during power out ages IMPORTANT Power must be ON to the UPC Open when replacing the battery or the date time and trend data will be lost Remove the battery from the controller making note of the battery s polarity Insert the new battery matching the battery s polarity with the polarity indicated on the UPC Open controller NETWORK POINTS LIST The points list for the control ler is shown in Table G Refer to Appendix B for
178. label located above the terminal box identifies models that contain this technology See Fig 34 serou Advanced Scroll Temperature Protection Compressor May Stop Pumping With Motor Running Turn Off And Wait Until Cool May Need More Than 1 Hour To Reset 052 1272 00 www EmersonClimateContractor com ASTP Fig 34 Advanced Scroll Temperature Protection Label Advanced scroll temperature protection is a form of inter nal discharge temperature protection that unloads the scroll compressor when the internal temperature reaches approxi mately 300 F At this temperature an internal bi metal disk valve opens and causes the scroll elements to separate which stops compression Suction and discharge pressures balance while the motor continues to run The longer the compressor runs unloaded the longer it must cool before the bi metal disk resets See Fig 35 for approximate reset times To manually reset ASTP the compressor should be stopped and allowed to cool Ifthe compressor is not stopped the motor will run until the motor protector trips which occurs up to 90 minutes later Advanced scroll temperature protection will reset automatically before the motor protector resets which may take up to 2 hours High Discharge Gas Temperature Protection Units equipped with digital compressors have an additional thermis tor located on the discharge line If discharge temperature ex ceeds 265 F 129 4 C the digital c
179. ld be within 15 psig If the two readings are not reasonably close replace the pressure transducer Chilled Water Flow Switch factory installed flow switch is installed in the leaving fluid piping for all units without the factory installed hydronic package See Fig 30 Units with the optional hydronic package have the flow switch installed in the entering fluid piping This is thermal disper sion flow switch with no field adjustments The switch is set for approximately 0 5 ft sec of flow The sensor tip houses two thermistors and a heater element One thermistor is located in the sensor tip closest to the flowing fluid This thermistor is used to detect changes in the flow velocity of the liquid The second thermistor is bonded to the cylindrical wall and is af fected only by changes in the temperature of the liquid The thermistors are positioned to be in close contact with the wall of the sensor probe and at the same time to be kept separated from each other within the confines of the probe In order to sense flow it is necessary to heat one of the thermistors in the probe When power is applied the tip of the probe is heated As the fluid starts to flow heat will be carried away from the sensor tip Cooling of the first thermistor is a function of how fast heat is conducted away by the flowing liquid The difference in temperature between the two thermistors provides a measurement of fluid velocity past the sensor probe
180. ler Ctrl Point Lag Chiller Ctrl Point Control Point Cool EnteringFluid Slave Cool Leaving Fluid Slave Cooler Entering Fluid Cooler Leaving Fluid Lead Lag Leaving Fluid Percent Avail Capacity Percent Avail Cap Slave Lag Start Delay Time Load Unload Factor Load Unload Factor Slave Lead SMZ Clear Commanded Lag SMZ Clear Commanded Lag Commanded Dual Chill Lead CapLimit Dual Chill Lag CapLimit APPENDIX B CCN TABLES cont CCN MAINTENANCE TABLES DUALCHIL VALUE UNITS Stand Alone Lead Chiller Lag Chiller Stand Alone Lead Chiller Lag Chiller O omn e x sm Oo e j _ _ ee 100 POINT NAME DC_LINK MC_ROLE SC_ROLE LEAD_CP LAG_CP CTRL_PNT COOLEWTS COOLLWTS COOL_EWT COOL_LWT DUAL_LWT CAP_A CAP_A_S LAGDELAY SMZ SMZSLAVE LEADSMZC LAG SMZC LAG OFF DCLDCAPL DCLGCAPL APPENDIX C FACTORY SETTINGS FOR PUMP AND MANUAL STARTERS PUMP OPTION 1 8 2 9 4 C 5 6 D F 7 G 1 0 HP 1 5 HP 2 0 HP 3 0 HP 5 0 HP 7 5 HP UNIT VOLTAGE V Hz 3 Ph 101 208 230 60 380 60 460 60 575 60 208 230 60 380 60 460 60 575 60 208 230 60 380 60 460 60 575 60 208 230 60 380 60 460 60 575 60 208 230 60 380 60 460 60 575 60 208 230 60 380 60 460 60 575 60 OVERLOAD SETTING o
181. lowing 1 COMPLETE COMPONENT TEST 2 CHECK REFRIGERANT AND OIL CHARGE 3 RECORD COMPRESSOR MOTOR CURRENT 4 RECORD CONFIGURATION SETTINGS 5 RECORD OPERATING TEMPERATURES AND PRESSURES 6 PROVIDE OPERATING INSTRUCTIONS TO OWNER S PERSONNEL Instruction Time CL 2 O YES YES YES YES YES YES YES YES YES O YES YES YES YES YES YES O YES O YES YES YES ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO ONO hours CUT ALONG DOTTED LINE 0000 CUTALONGDOTTEDUNE OPERATING DATA RECORD THE FOLLOWING INFORMATION FROM THE PRESSURES AND TEMPERATURES MODES WHEN MACHINE IS IN A STABLE OPERATING CONDITION PRESSURE TEMPERATURE DISCHARGE PRESSURE SUCTION PRESSURE SATURATED CONDENSING TEMP SATURATED SUCTION TEMP RETURN GAS TEMPERATURE LIQUID LINE TEMPERATURE DISCHARGE LINE TEMPERATURE Readings taken with a digital thermometer COOLER EWT COOLER LWT OUTDOOR AIR TEMPERATURE CONTROL POINT PERCENT TOTAL CAPACITY LEAD LAG LEAVING FLUID CIRCUIT A DPA SPA SCT A SSTA RGT A EWT LWT OAT CTPT CAP DLWT Compressor Running Current All readings taken at full load COMPRESSOR MOTOR CURRENT COMPRESSOR A1 COMPRESSOR A2 COMPRESSOR B1 COMPRESSOR B2 CONDENSER FAN MOTOR CURRENT FAN MOTOR 1 FAN MOTOR 2 FAN MOTOR 3 FAN MOTOR 4 COOLER PUMP MOTOR CURRENT COOLER PUM
182. m mom R8 m cvom R A Ne BV54 R m 7779 R TwPRGm R F Av R ka rk R Bv KALA s HA R n T L A LA a kark R Bv R Bvu mae R mn A R A Kstr R R i T Bv R mn o A R A R oo i T ova Kg Rv R B Huge R A cm n CTRLPNT RW 440 1 Test 2 Local 3 CCN Off 4 Clock 5 Emergency Stop 6 Local On 7 CCN On 8 Clock On 9 Heat Enabled 10 Pump Delay MSV 2 20 70 R F A R R COOLIWT R 107 ___ iwrsp R AV38 PMPISEBK R iu Te Bv PMP2FBK _ _____ jcooPMP R B cootpmp2 R _ R Avo R cramp RW 10 02 20 OBJECT Imt ma 1 rst ma 1 dem lim 1 sp 1 alm msv 1 chil s s 1 dl stat 1 hr cira 1 Cy cira 1 hr cirb 1 Cy cirb 1
183. mage the coil Routine cleaning of coil surfaces is essential to maintain proper operation of the unit Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit The following steps should be taken to clean MCHX condenser coils 1 Remove any foreign objects or debris attached to the coreface or trapped within the mounting frame and brackets 2 Put on personal protective equipment including safety glasses and or face shield waterproof clothing and gloves It is recommended to use full coverage clothing 3 Start high pressure water sprayer and purge any soap or industrial cleaners from sprayer before cleaning condens er coils Only clean potable water is authorized for clean ing condenser coils 4 Clean condenser face by spraying the core steady and uniformly from top to bottom while directing the spray straight toward the core Do not exceed 900 psig or 30 de gree angle The nozzle must be at least 12 in from the 64 core face Reduce pressure and use caution to prevent damage to air centers A CAUTION Excessive water pressure will fracture the braze between air centers and refrigerant tubes TROUBLESHOOTING Complete Unit Stoppage and Restart Possi ble causes for unit stoppage and reset methods are shown be low and in Table 41 Refer to Fig 3 7 for component arrange ment and control wiring diagrams GENERAL POWER FAILURE
184. mited _____ Slow Change Override 9 Cooler Freeze Protection Low Temperature Cooling 17 High Temperature Cooling Minimum Comp On Time 2 97 APPENDIX B CCN TABLES cont CCN MAINTENANCE TABLES PM PUMP DESCRIPTION Pump Service Interval Pump 1 Service Countdown Pump 1 Maintenance Done x WN Pump 2 Service Countdown Pump 2 Maintenance Done WN S SS Pump 1 Maintenance Date mmddyy phim _ Pump 1 Maintenance Date S Pump 1 Maintenance Date mm dyhmm Pump 1 Maintenance Date mm dyhmm Pump 1 Maintenance Date mm dyhmm Pump 2 Maintenance Dale mmddyy him Pump 2 Maintenance Date mmddyy him Pump 2 Maintenance Date mmddyy phim S Pump 2 Maintenance Date mm dyhmm Pump 2 Maintenance Date CCN MAINTENANCE TABLES PM STRN DESCRIPTION Strainer Interval Strainer Countdown Strainer Maint Done Strainer Maint Date mmddyy him Strainer Maint Date mmddyy him Strainer Maint Date mmWdyhimm Strainer Maint Date mmWdyhimm SS Strainer Maint Date CCN MAINTENANCE TABLES PM COIL DESCRIPTION Col Cleaning Srvc inter Coil Service Countdown Coil Cleaning Maint Done YeNo
185. mp The Pump Changeover Hours is facto ry defaulted to 500 hours Regardless of the Cooler Pump Se lection any pump that has an active alert will not be allowed to start With the dual integral pump package the Cooler Pump Starter will be energized when the machine is in an occupied period As part of the factory installed package an auxiliary set of contacts is wired to the MBB to serve as Chilled Water Pump Interlock one set for each pump to individual channels on the MBB With a call for mechanical cooling the specific pump interlock and flow switch are checked If the circuits are closed the machine starts its capacity routine If Pump 1 starts and the auxiliary contact interlock does not close within 25 seconds of the ON command a T190 Cooler Pump 1 Aux Contacts Failed to Close at Start Up Alert will be generated and the pump shut down The unit will not be allowed to start If the chilled water flow switch does not close within 1 minute two alarms will be generated A T192 Cooler Pump 1 Failed to Provide Flow at Start Up Alert and an A200 Cooler Flow Interlock Failed to Close at Start Up Alarm will be generated and chiller will not be allowed to start In either fault case listed above Pump 2 will be commanded to start once Pump 1 has failed If Pump 2 starts and the auxiliary contact interlock does not close within 25 seconds of the ON command a T191 Cooler Pump 2 Aux Contacts Failed to Close at Start Up Alert
186. mpressor current during compressor op eration When this occurs the control turns off the compressor If the current sensor board reads OFF while the compressor relay has been commanded ON an alert is generated POSSIBLE CAUSES Compressor Overload Either the compressor internal over load protector 1s open or the external overload protector Kri wan module has activated The external overload protector modules are mounted in the compressor wiring junction box Temperature sensors embedded in the compressor motor wind ings are the inputs to the module The module is powered with 24 vac from the units main control box The module output is a normally closed contact that is wired in series with the com pressor contactor coil In a compressor motor overload condi tion contact opens deenergizing the compressor contactor 71 Low Refrigerant Charge If the compressor operates for an extended period of time with low refrigerant charge the com pressor ASTP device will open which will cause the compres sor to trip on its overload protection device Circuit Breaker Trip The compressors are protected from short circuit by a breaker in the control box Wiring Error A wiring error might not allow the compres sor to start To check out alerts T051 T056 Turn on the compressor in question using Service Test mode If the compressor does not start then most likely the problem is one of the following HPS op
187. n for temperature resistance voltage drop characteristics COOLER LEAVING FLUID SENSOR The thermistor is installed in a well in the factory installed leaving fluid piping coming from the bottom of the brazed plate heat exchanger COOLER ENTERING FLUID SENSOR The thermistor is installed in a well in the factory installed entering fluid piping coming from the top of the brazed plate heat exchanger COMPRESSOR RETURN GAS TEMPERATURE SEN SOR These thermistors are installed in a well located in the suction line of each circuit OUTDOOR AIR TEMPERATURE SENSOR OAT This sensor is factory installed on a bracket which is inserted through the base pan of the unit DISCHARGE TEMPERATURE THERMISTOR DTT This sensor is only used on units with a digital compressor The sensor is mounted on the discharge line close to the discharge of the digital compressor It attaches to the dis charge line using a spring clip and protects the system from high discharge gas temperature when the digital compressor is used This sensor is a connected to the AUX board REMOTE SPACE TEMPERATURE SENSOR OR DUAL LEAVING WATER TEMPERATURE SENSOR One of two inputs can be connected to the LVT See appropriate sen sor below Remote Space Temperature Sensor Sensor part no 33ZCTSSSPT is an accessory sensor that is remotely mounted in the controlled space and used for space temperature reset The sensor should be installed as a wall mounted
188. n A202 Cooler Pump Interlock Closed When Pump is Off Alarm will be generated and the unit will not be allowed to start If the control detects that the chilled water pump auxiliary contacts are closed for at least 25 seconds while the pump is OFF the appropriate T198 Cooler Pump 1 Aux Contacts Closed While Pump Off or Alert T199 Cooler Pump 2 Aux Contacts Closed While Pump Off Alert is generated The chiller will not be allowed to start 36 If the control starts a pump and the wrong interlock circuit closes for at least 20 seconds an A189 Cooler Pump and Aux Contact Input Miswire Alarm will be generated The unit will be prevented from starting The control will allow for pump changeover Two methods will change the pump sequence Before the changeover can occur the unit must be at Capacity Stage 0 During changeover the chilled water flow switch input is ignored for 10 seconds to avoid a nuisance alarm With Cooler Pump Select Configuration DOPT1 PM SL set to 0 Automatic and when the differential time limit Pump Changeover Hours Configuration PM DT is reached the lead pump will be turned OFF Ap proximately one 1 second later the lag pump will start Manu al changeover can be accomplished by changing Rotate Cooler Pump Now Configuration ROT P to YES only if the machine is at Capacity Stage 0 and the differential time limit Pump Changeover Hours PM DT is reached If the PM
189. nglish 1 Espanol 2 Francais 3 Portuguese PAS E ENBL DSBL PASSWORD ENABLE Default Enable NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed 11 SUB MODE UNIT OPT1 Table 10 Configuration Mode and Sub Mode Directory ee FAN S NUMBER OF FANS 1 One Fan 2 Two Fans 3 Three Fans 4 Four Fans Default A1 TY YES NO COMPRESSOR A1 DIGITAL Yes 1 Compressor is Digital crol Default 7 MAX T 01012 1 UNLOAD TIME 12 010 015 10 018 060 1 INIT OPTIONS t HARDWARE Default Water 1 Water FLUD X COOLER FLUID 2 Medium Temperature Brine MLV S YES NO MINIMUM LOAD VALVE SELECT Default No D G EN ENBL DSBL DISCHARGE GAS TEMP ENABLE CSB E ENBL DSBL CSB BOARDS ENABLE ON OFF COOLER PUMP CONTROL Default Off PM1E YES NO COOLER PUMP 1 ENABLE 2 YES NO COOLER PUMP 2 ENABLE PM PS YES NO COOLER PERIODIC STRT Default No PM SL COOLER PUMP SELECT Default Automatic 0 Automatic 1 Pump 1 Starts first 2 Pump 2 Starts first PM DY XX MIN COOLER PUMP SHUTDOWN 010 10 minutes Default 1 PM DT XXXX HRS PUMP CHANGEOVER HOURS Default 500 hours ROT P YES NO ROTATE COOLER PUMPS NOW User Entry 0 RTPF MOPS EXV MOP SET POINT Range 40 80 Default 50 APPR CONFIG APPROACH SETPOINT Range 5 40 Default 9 0
190. nt charge in the system Bubbles in the sight glass at full unit loading indicate an undercharged system or the presence of noncondensables Moisture in the system measured in parts per million ppm changes the color of the indicator as follows Green safe Moisture is below 75 ppm Yellow Green caution 75 to 150 ppm Yellow wet above 150 ppm The unit must be in operation at least 12 hours before the moisture indicator gives an accurate reading and must be in contact with iquid refrigerant At the first sign of moisture in the system change the corresponding filter drier NOTE Dual circuit 035 060 sizes units have one indicator per circuit DPT HPS pr 5 SUCTION ACCESS FLOW SWITCH Compressor Location 30RAP010 030 EWT VALVE Fig 26 SPT RGT SUCTION RGT SPT ACCESS DISCHARGE ACCESS VALVE OIL SIGHTGLASS DISCHARGE ACCESS Fig 27 Compressor Location 30RAP035 060 LEGEND FOR FIG 26 AND 27 2 0 85 5 ees 5 999 5 9 ESE FSESESG SOLE oge 20 lt gt 2 a HFL Les oo o 6 o SGo o o gt zr TERT z 5 51 MINIMUM LOAD VALVE On units equipped with the factory installed capacity reduction option a solenoid valve and discharge bypass valve minimum load valve are loca
191. nting grommets single compressor circuits or steel spacers dual compressor circuits Remove the old com pressor from the unit Slide the new compressor in place on the basepan Lifting one side of the compressor at a time replace all of the compres sor mounting grommets Using new tubing as required recon nect compressor suction and discharge lines Using hardware saved reinstall the mounting bolts and washers through the compressor feet Using proper techniques braze suction and discharge lines and check for leaks Reconnect oil equalization line on dual compressor circuit models Reconnect the compressor power connections and high pressure switch wiring as on the old compressor Refer to Fig 26 and 27 Following the installation of the new compres sor tighten all hardware to the following specifications See Table 31 Table 31 Unit Torque Specification FASTENER Compressor Mounting Bolts Compressor Power Connections Compressor Ground Terminal Connections RECOMMENDED TORQUE 7 to 10 ft lb 9 5 to 13 5 N m 24 to 28 in Ib 2 7 to 3 2 N m 14 to 18 in Ib 1 6 to 2 0 N m Cooler BRAZED PLATE COOLER HEAT EXCHANGER RE PLACEMENT Brazed plate heat exchangers cannot be repaired if they develop a leak If a leak refrigerant or water develops the heat exchanger must be replaced To replace a brazed plate heat exchanger 1 Check that the replacement heat exchanger is the same as the original h
192. nutes Off Time Configuration gt OPT2 DELY Dual Set Point mode is in effect Chiller controls to Cooling Set Point 1 Set Points COOL 1 during occupied periods and Cooling Set Point 2 Set Points COOL CSP 2 during unoccupied periods Temperature reset is in effect In this mode chiller is using temperature reset to adjust leav ing fluid set point upward and is currently controlling to the modified set point The set point can be modified based on return fluid outdoor air temperature space temperature or 4 to 20 mA signal Demand limit is in effect This indicates that the capacity of the chiller is being limited by demand limit control option Because of this limitation the chiller may not be able to pro duce the desired leaving fluid temperature Demand limit can be controlled by switch inputs or a 4 to 20 mA signal Cooler fluid temperatures are approaching the Freeze point see Alarms and Alerts section for definition The chiller will be shut down when either fluid temperature falls below the Freeze point Chiller is in Cooling mode and the rate of change of the leaving fluid is negative and decreasing faster than 0 5 F per minute Error between leaving fluid and control point exceeds fixed amount Control will automatically unload the chiller if necessary Chiller is in Cooling mode and the rate of change of the leaving fluid is positive and increasing Error between leaving fluid and control point exceeds f
193. o 20 mA leaving fluid temperature reset requires field supplied 4 to 20 mA generator 4 to 20 mA cooling set point reset requires field supplied 4 to 20 mA generator Discrete inputs for 2 step demand limit requires field supplied dry contacts capable of handling a 24 vac 50 mA load 4 to 20 mA demand limit requires field supplied 4 to 20 mA generator Discrete input for Ice Done switch requires field supplied dry contacts capable of handling a 24 vac 50 mA load See Demand Limit and Temperature Reset sections on pages 41 and 37 for further details A CAUTION Care should be taken when interfacing with other manufac turer s control systems due to possible power supply differences full wave bridge versus half wave rectification The two different power supplies cannot be mixed ComfortLink controls use half wave rectification A signal isolation device should be utilized if a full wave bridge signal generating device is used Loss of Cooler Flow Protection proof of cooler flow device is factory installed in all chillers It is recom mended that proper operation of the switch be verified on a reg ular basis Electronic Expansion Valves EXV All units are equipped from the factory with EXVs Each refrigeration cir cuit is also supplied with a factory installed liquid line filter drier and sight glass The is set at the factory to maintain 9 F 5 0 suc tion superheat lea
194. o deter switch mine if filter needs replacement Inspect all coils and clean Check condenser Inspect all electrical connections and tighten as needed approach to determine if tubes need to be Measure current to each compressor and inspect contac cleaned tors NOTE Equipment failures caused by lack of adherence to the Main tenance Interval Requirements are not covered under warranty 110 APPENDIX E SUMMARY AND LOG SHEETS cont 30RAP Weekly Maintenance Log Plant Machine Model No CHECKALARMS OPERATOR DATE OIL LEVEL 7 FAULTS INITIALS REMARKS NOTE Equipment failures caused by lack of adherence to the Main tenance Interval Requirements are not covered under warranty 111 TII APPENDIX E MAINTENANCE SUMMARY AND LOG SHEETS cont 30RAP Monthly Maintenance Log Month Date Operator UNIT SECTION ENTRY Check OilLevel yes __ S I 141444 Compressor Annually LeakTest pm 41144444 Every 8 5 Years Inspect Cooler Heater ams T L Cooler j O j j j Record Water Pressure Differential PSI Pi j T oo j os inspectWaterPumps T j J L Condenser eit I S ff j 1 1 Annually General Cleaning and Tightening Connections yes no Annually Controls Check Pressure Transducers ysn T T C
195. ocking should be felt from the actuator when it reaches the top of its stroke can be heard if surround ings are relatively quiet Press ess again twice if necessary to confirm this To close the valve press select 0 with and press ves The actuator should knock when it reaches the bottom of its stroke If it is believed that the valve is not working properly continue with the checkout procedure below Check the EXV output signals at appropriate terminals on the EXV module see Fig 25 Connect positive test lead to red wire EXV J6 terminal 3 for Circuit A EXV J7 terminal 3 for Circuit B Set meter to approximately 20 vdc Using the Service Test procedure above move the valve output under test to 100 DO NOT short meter leads together or pin 3 to any other pin as board damage will occur INCLUDED CABLE KIT CABLE CABLE RETAINER MOTOR AND ADAPTER ASSEMBLY MOTOR ADAPTER ASSEMBLY CABLE RETAINER MOTOR ADAPTER ASSEMBLY NORMAL FLOW DIRECTION DIRECTION E m 9 z Fig 24 Electronic Expansion Valve Details During the next several seconds carefully connect the nega tive test lead to pins 1 2 4 and 5 in succession plug J6 for Cir cuit A plug J7 for Circuit B Digital voltmeters will average this signal and display approximately 6 vdc If it remains con stan
196. ol OCCUPANCY SCHEDULE Configuration gt 2 CTRL 2 The main base board will use the operating schedules as defined under the Time Clock mode in the scroll ing marquee display These schedules are identical The sched ule number must be set to 1 for local schedule The schedule number can be set anywhere from 65 to 99 for operation under a CCN global schedule The Enable Off Remote Contact must be in the Enable or Remote Contact posi tion The control mode Operating Modes MODE will be when the switch is Off The control mode will be 3 when the Enable Off Remote Contact switch input is On and the time of day is during an unoccupied period Similarly the control mode will be 7 when the time of day is during an occupied period CCN CONTROL Configuration 2OPT2 3 An external CCN device such as Chillervisor System Manager controls the On Off state of the machine This CCN device forces the variable CHIL S S between Start Stop to control the chiller The control mode Operating Modes gt will be 1 when the switch 15 Off The control mode will be 2 when the Enable Off Remote Contact switch input is On and 33 the CHIL S S variable is Stop Similarly the control mode will be 6 when the CHIL S S variable is Start Table 20 illustrates how the control method and cooling set point select variables direct the operation of the chiller and the set point to which it controls The illus
197. ol Mode Run Status VIEW STAT and its operat ing setpoint or Control Point Run Status VIEW CT PT THERMISTOR WIRING RETURN gt LEAVING FLUID FLUID MASTER CHILLER SLAVE CHILLER INSTALL DUAL CHILLER LWT LEAVING FLUID TEMPERATURE THERMISTOR T10 HERE Depending on piping sizes use either e HH79NZ014 sensor 10HB50106801 well 3 in sensor well HH79NZ029 sensor 10HB50106802 well 4 in sensor well Fig 16 Dual Chiller Thermistor Location 38 PART DIMENSIONS in mm NUMBER _ 10HB50106801 3 10 78 7 1 55 39 4 10HB50106802 4 10 104 1 1 28 32 5 0 505 0 495 0 61 DIA 6 MINIMUM CLEARANCE FOR Ust THERMISTOR REMOVAL Fig 17 Dual Leaving Water Thermistor Well Temperature Reset The control system is capable of handling leaving fluid temperature reset based on return cooler fluid temperature Because the change in temperature through the cooler is a measure of the building load the return tempera ture reset is in effect an average building load reset method The control system is also capable of temperature reset based on outdoor air temperature OAT space temperature SPT or from an externally powered 4 to 20 mA signal Accessory sen sors must be used for SPT reset 33ZCTSSSPT The energy management module EMM must be used for temperature reset using a 4 to 20 mA signal See Tables 24 and 25 SUB MODE DISP UNIT
198. om pressor is brought on and 5 seconds afterwards 2 The rate of suction pressure change from 5 seconds be fore the compressor is brought on to when the compres sor is brought on is calculated 3 The rate of suction pressure change from when the compressor is brought on to 5 seconds afterwards is calculated 4 With the above information the test for reverse rotation is made If the suction pressure change 5 seconds after com pression is greater than the suction pressure change 5 sec onds before compression 1 25 then there is a reverse rotation error This alarm will disable mechanical cooling and will require manual reset A150 Unit is in Emergency Stop If the CCN emergency stop command is received the alarm is generated and the unit will be immediately stopped Ifthe CCN point name EMSTOP in the system table is set to emergency stop the unit will shut down immediately and broadcast an alarm back to the CCN indicating that the unit is down This alarm will clear when the variable is set back to enable A151 Illegal Configuration An A151 alarm indicates an invalid configuration has been entered The following are ille gal configurations Invalid unit size has been entered Dual thermostat configured for single circuit unit Dual thermostat and switch demand limit configure AUX board incorrect revision Unit configuration set to invalid type A152 Unit Down Due to Failure Both circuits
199. omatic for first Manual reset thereaf ter Manual Automatic Automatic PROBABLE CAUSE Wiring error pump circuit breaker tripped contactor failure Wiring error faulty pump contactor welded contacts Wiring error faulty pump contactor welded contacts Wiring error pump circuit breaker tripped contactor failure faulty flow Switch or interlock Cooler pump failure faulty flow switch or interlock pump circuit breaker tripped Wiring error faulty pump contactor welded contacts Wiring error faulty wiring failed Slave chiller MBB module power loss at slave chiller wrong slave address Wiring error faulty wiring failed master chiller MBB module power loss at Master chiller CCN Address for both chillers is the same Must be different Check CCN A under the OPT2 sub mode in Configuration at both chillers Building load greater than unit capacity low water brine flow or compressor fault Check for other alarms alerts Faulty thermistor low water flow Faulty cooler pump low water flow plugged fluid strainer Routine pump maintenance required Routine pump maintenance required Table 42 Alarm and Alert Codes cont ALARM ALARM WHY WAS THIS ACTION TAKEN RESET PROBABLE ALERT OR DESCRIPTION ALARM CODE ALERT pesompmon GENERATED BY CONTROL METHOD CAUSE Strainer Service Strainer Blowdown Fuere S TDN NIME Routine str
200. ompressor will be shut off Alarms will also occur if the current sensor board malfunc tions or is not properly connected to its assigned digital input If the compressor is commanded OFF and the current sensor reads ON an alert is generated This will indicate that a com pressor contactor has failed closed In this case a special mode Compressor Stuck on Control will be enabled and all other compressors will be turned off An alarm will then be enabled to indicate that service is required Outdoor fans will continue to operate The first outdoor fan stage is turned on immediately The other stages of fan will be turned on as required by SCT Alarms and Alerts 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 in Table 42 Automatic alarms will reset without operator intervention if the condition corrects itself The following method must be used to reset manual alarms Before resetting any alarm first determine the cause of the alarm and correct it Enter the Alarms mode indicated by the LED on the side of the scrolling marquee display Press ENTER and Ivi until the sub menu item RCRN RESET ALL CURRENT ALARMS is displayed Press ENTER The control will prompt the user for a password by displaying PASS and WORD Press ENTER to display the default pass word 1111 Press ENTER for each character If the password
201. on has been removed cycle power to the chiller to reset the VFD Troubleshooting Troubleshooting the Motormaster V control requires a combination of observing system operation and VFD information The drive provides 2 kinds of trouble shooting modes a status matrix using the 3 digit display P57 P58 and real time monitoring of key inputs and outputs The collective group is displayed through parameters 50 60 and all values are read only P50 FAULT HISTORY Last 8 faults P51 SOFTWARE version P52 DC BUS VOLTAGE in percent of nominal Usually rated input voltage x 1 4 P53 MOTOR VOLAGE in percent of rated output voltage P54 LOAD in percent of drives rated output current rating P55 VDC INPUT in percent of maximum input 100 will indicate full scale which is 5 v P56 4 20 mA INPUT in percent of maximum input 20 4 mA 100 20 mA Manual Starter Trip If the VFD manual starter MS FC HS MS FC Al or MS FC B1 depending on model trips locate the inrush current protectors 3 round black disks per motor and verify their resistance For units operating at 208 v or 230 v these devices should measure approximately 7 ohms For all other voltages they should measure approximately 20 ohms Check value with mating plug disconnected power to chiller off and at ambient temperature not hot immediately after stopping VFD These are standard resistances at 77 F 25 C Re
202. onditions to properly maintain oil return to the compressors In general on dual compressor circuits the control will most often start the Al or B1 compres sor first especially after long off periods The MBB controls fan stages to maintain the head pressure set point and will auto matically adjust unit capacity as required to keep compressors from operating outside of the specified envelope There are no pumpout or pumpdown sequences on these chillers For all units iftemperature reset is being used the unit con trols to a higher leaving fluid temperature as the building load reduces If demand limit is used the unit may temporarily be unable to maintain the desired leaving fluid temperature be cause of imposed power limitations SERVICE A WARNING Electrical shock can cause personal injury and death Shut off all power to this equipment during service There may be more than one disconnect switch Tag all disconnect locations to alert others not to restore power until work is completed Electronic Components CONTROL COMPONENTS Unit uses an advanced elec tronic control system that normally does not require service For details on controls refer to Operating Data section Access to the compressors is through latched panels from beneath the control box on all models or from opposite the coil side sizes 010 030 only The front door s provide access to the compressor s and all components of the refrigeration sys
203. onfiguration OPTN LLCS 1 Circuit A leads Pressing the ESCAPE and ENTER keys simultaneously will scroll an expanded text description of the point name or value across the display The expanded description is shown in the local display tables but will not be shown with the path names in text The CCN Carrier Comfort Network point names are also referenced in the local display tables for users configuring the unit with CCN software instead of the local display The CCN tables are located in Appendix B of the manual Basic Controls Usage SCROLLING MARQUEE DISPLAY The scrolling mar quee display is the standard interface display to the ComfortLink Control System for 30RAP units The display has up and down arrow keys an key and an key These keys are used to navigate through the different levels of the display structure Press the key until the highest operating level is displayed to move through the top 11 mode levels indicated by LEDs on the left side of the display See Fig 1 and Tables 2 14 Once within a mode or sub mode pressing the and keys simultaneously will put the scrolling marquee display into expanded text mode where the full mean ing of all sub modes items and their values can be displayed for the current selection Press the and keys to return the scrolling marquee display to its default menu of rotating display items those items in Run Status VIEW In addition the password will be disabled requiring
204. onfirm Accuracy of Thermistors __ um cunt Inspect All Contactos yemo P j J Check RefrigerantCharge yemo P System _ Verify Operation Of EXVs And Record Position 040 1 Record SystemSuperHeat deF T 1 NOTE Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty ell APPENDIX E MAINTENANCE SUMMARY AND LOG SHEETS cont 30RAP Seasonal Shutdown Log Month 12 Date UNIT SECTION Cooler solate and Drain Cooler 22 2 xp j j j Add Glycol for Freeze Protection j Controls Do Not Disconnect Control Power 1 1 1 NOTE Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty Copyright 2010 Carrier Corporation Manufacturer reserves the right to discontinue or change at time specifications or designs without notice and without incurring obligations Catalog No 04 53300067 01 Printed in U S A Form 30RAP 2T Pg 114 12 10 Replaces 30RAP 1T START UP CHECKLIST FOR 30RAP LIQUID CHILLER Remove and use for Job File Project Information JOB NAME ADDRESS CITY STATE ZIP INS
205. or compressors Al A2 and B2 respectively These alerts occur when the output of the CSB is a constant high value These alerts reset automatically If the problem cannot be resolved the CSB must be replaced APPENDIX A DISPLAY TABLES Run Status Mode and Sub Mode Directory SUB MODE COMMENT AUTO VIEW OF RUN STATUS Trac Factor O Service Test 1 Local 2 Off CCN 3 Off Time STAT Control Mode 4 Off Emrgcy 5 On Local 6 On CCN VIEW 7 On Time LD PM e Lead Pump occ Total Capacity L see x ReesedSuge _ 00 00 25 58 MNTH Month of Year ESI 0123 UNIT RUN HOUR AND START RUN CIRC AND COMP RUN HOURS HOUR 74 APPENDIX A DISPLAY TABLES cont Run Status Mode Sub Mode Directory cont SUB MODE COMMENT COMPRESSOR STARTS STRT PREVENTIVE MAINTENANCE PUMP MAINTENANCE P 1 DN Pump 1 Service Countdown P 2 DN Pump 2 Service Countdown User Entry User Entry PUMP MAINTENANCE DATES O PO MWDDOYYHHMM PRIM MWDDYYHHMM PM MWDD YYHHMM MWDD YYHHMM O PA Pemo PPM MWBDYYHHMM PP MWeDYYHHMM MWBDYYHHMM aM4 MWBDYYHHMM P STRAINER MAINTENANCE User Entry STRAINER MAINTENANCE DATES STMO 1 1 MWDDYYHH VM SMS 1 MWDDYYHHMM 1
206. password can only be changed through CCN operator interface software such as ComfortWORKS ComfortVIEW and Service Tool Adjusting the Contrast The contrast of the display can be adjusted to suit ambient conditions To adjust the contrast of the Navigator module press the key until the dis play reads Select a menu item Using the arrow keys move to the Configuration mode Press to obtain access to this mode The display will read gt TEST OFF METR OFF LANG ENGLISH Pressing will cause the OFF to flash Use the up or down arrow to change OFF to ON Pressing will illuminate all LEDs and display all pixels in the view screen Pressing and simultaneously allows the user to adjust the display contrast Use the up or down arrows to adjust the contrast The screen s contrast will change with the adjustment Press to accept the change The Navigator module will keep this setting as long as it is plugged in to the LEN bus Adjusting the Backlight Brightness The backlight of the display can be adjusted to suit ambient conditions The factory default 15 set to the highest level To adjust the backlight of the Navigator module press the key until the display reads Select a menu item Using the arrow keys move to the Configuration mode Press to obtain access to this mode The display will read gt TEST OFF METR OFF LANG ENGLISH Pressing will cause the OFF to flash Use the up or down arrow keys to c
207. pressor is installed a digital unloader sole Configuration 2UNIT A1TY is configured to YES noid DUS is used on the digital compressor There is also a maximum unload time configuration Config DIGITAL SCROLL OPERATION A digital scroll oper uration UNIT MAX T that is set to 7 seconds which in ates in two stages the loaded state when the solenoid valve dicates the maximum unloading for the digital compressor is is normally closed and the unloaded state when the solenoid 47 This is done to optimize efficiency ofthe system valve is open During the loaded state the compressor operates like a standard scroll and delivers full capacity and mass flow PRE START UP However during the unloaded state there is no capacity and no mass flow through the compressor The capacity of the IMPORTANT Before beginning Pre Start Up or Start Up system is varied by varying the time the compressor operates complete Start Up Checklist for 30RAP Liquid Chiller at in an unloaded and loaded state during a 15 second period If end of this publication pages CL 1 to CL 10 The check the DUS is energized for 7 seconds the compressor will be list assures proper start up of a unit and provides a record operating at 47 capacity If the DUS is energized for 10 sec of unit condition application requirements system infor onds the compressor will be operating at approximately 33 mation and operation at initial start up of its capacity Capacity i
208. r Configura tion RSET SHNM Loadshed Demand Delta Configu ration gt RSET SHDL and Maximum Loadshed Time Configuration gt RSET SHTM See Table 27 The Loadshed Group number is established by the CCN system designer The ComfortLink controls will respond to a Redline command from the Loadshed control When the Redline command is received the current stage of capacity is set to the maximum stages available Should the loadshed con trol send a Loadshed command the ComfortLink controls will reduce the current stages by the value entered for Loadshed Demand delta The Maximum Loadshed Time is the maximum length of time that a loadshed condition is allowed to exist The control will disable the Redline Loadshed command if no Cancel command has been received within the configured maximum loadshed time limit Cooling Set Point 4 to 20 mA A field supplied and generated externally powered 4 to 20 mA signal can be used to provide the leaving fluid temperature set point Connect the signal to LVT7 8 See Table 27 for instructions to enable the function Figure 22 shows how the 4 to 20 mA sig nal is linearly calculated on an overall 10 F to 80 F range for fluid types Configuration gt OPT1 FLUD 1 or 2 The set point will be limited by the fluid FLUD type Be sure that the chilled water loop is protected at the lowest temperature 50 CAPACITY AT 20 75 CAPACITY AT 12 mA ALLOW
209. r The variable RT F should be set to the cooler temperature difference where the maximum chilled water temperature reset should occur The variable RM DG should be set to the maxi mum amount of reset desired To verify that reset 1s functioning correctly proceed to Run Status mode sub mode VIEW and subtract the active set point Run Status VIEW SETP from the control point Run Status VIEW gt CTPT to determine the degrees reset Table 26 Configuring Outdoor Air Space Temperature Reset DISPLAY i jom i fore x e e ER Lie el o ee MMST sss Outdoor Air Temperature RSET CRST Md 4 5 5 6 REMOTE Default 125 0 F 51 7 55 F PR TM FULL Default 0 0 F 17 7 C PR TM Range 0 to 125 F Default 0 F 0 C RM DG 15 F REMOTE DEGREES Range 30 to 30 F 34 4 to 1 1 C 4 items skipped in this example Table 26B Configuring Return Temperature Reset RED LED ENTRY SUB MODE ITEM DISPLAY DISP E TEST ON OFF TESTDISPLAYLEDs DISPLAY LEDs EZE FLUD COOLER FLUID m m CONFIGURATION 0 No Reset 1 4 to 20 mA Input EMM required Connect to EMM TB6 2 3 3 Return Flu
210. r assembly before installation on the valve Failure to do so will permanently damage the drive and motor Replacement motor assemblies are shipped in the retracted position and may be installed as received Compressor Replacement Refer to Fig 26 and 27 All models contain scroll compressors and have from one to four compressors The size 010 030 units are a sin gle refrigeration circuit while sizes 035 060 are dual circuit A compressor is most easily removed from the front of the unit depending on where clearance space was allowed during unit installation Remove the junction box cover bolts and disconnect the compressor power and ground connections Remove the cable from the compressor junction box Remove the connections from the high pressure switch Knock the same holes out of the new compressor junction box and install the cable connectors from the old compressor The compressors are bolted to rails which are in turn bolted to the unit basepan for all sizes except 010 and 015 which are directly bolted to the basepan Remove the 4 bolts holding the compressor to the rail on the basepan Save the mounting hard ware for use with the new compressor Carefully cut the com pressor suction and discharge lines with a tubing cutter as close to the compressor as feasible Remove high pressure switch and pressure transducer s if required for compressor removal Lift one corner of the compressor at a time and remove all the rubber mou
211. ration errors corrected Automatic once alarms alerts are cleared that pre vent the chiller from starting Chiller is unable to run Both circuits are down due to alarms alerts Unit Down Due to Alarm Failure 68 PROBABLE CAUSE Refrigerant leak or transducer failure Refrigerant leak or transducer failure Faulty Expansion valve faulty suction pressure transducer or high entering fluid temperature Faulty Expansion valve faulty suction pressure transducer or high entering fluid temperature Faulty expansion valve faulty suction pressure transducer faulty suction gas thermistor circuit overcharged Faulty expansion valve faulty suction pressure transducer faulty suction gas thermistor circuit overcharged Faulty expansion valve low refrigerant charge plugged filter drier faulty suction pressure transducer low cooler fluid flow Faulty expansion valve low refrigerant charge plugged filter drier faulty suction pressure transducer low cooler fluid flow Refrigerant charge plugged filter drier head pressure control Refrigerant charge plugged filter drier head pressure control Faulty transducer high pressure switch low restricted condenser airflow Faulty transducer high pressure switch low restricted condenser airflow Faulty or sticking EXV low refrigerant charge plugged filter drier Faulty or sticking EXV low refrigerant charge plugged
212. rct 1 lvl 2 perct 1 3 perct 1 sw1 1 sw2 1 mode 15 1 disgas 1 dp a 1 dp b 1 mode 13 1 dual in 1 element stat 1 comm lost alm 1 emstop 1 ewt 1 exv a 1 b 1 fan 1 1 fan 2 1 1 heat req 1 mode 21 1 mode 22 1 mode 18 1 ice done 1 csp3 1 lead typ 1 lead typ 1 dual lwt 1 leadpump msv 1 Iwt_1 seq_type_1 schedule_1 mode_7_1 mode 8 1 Isactive 1 mode 25 1 mode 17 1 hr mach 1 cy mach 1 mode 19 1 mode 3 1 mode 23 1 rly 1 mode 10 1 delay 1 occ 1 oat 1 mode 1 capa a 1 capb a 1 APPENDIX D OPTIONAL BACNET COMMUNICATIONS WIRING cont Table G Network Points List cont Percent Total Capacity CAPT R Percent Total Capacity R Percent Total Capacity caset R Pump 1 Maintenance Pi MANT RW veso Bv52 Pump 1 Run Hours R m AV ppt PumpiSericeCountdoun P1 CDOWN R n J Pump 2 Maintenance Done P2 MANT RW vemo BVs3 P2 meint Pump 2 Run Hours R m hr pump 1 Pump 2 Service Countdown P2 CDOWN R n poomi Pump Changeover Hours dita 1 Pump DelayTime MODE24 R __ mode 24 Pump Service Interval si pumps 1 Ramp Load Limited Moves R 5 1 Requested Stage sms
213. red LED that is lit continuously or blinking at a rate of once per second or faster indicates that the board should be replaced GREEN LED The MBB has one green LED The Local Equipment Network LEN LED should always be blinking whenever power is on All other boards have a LEN LED which should be blinking whenever power is on Check LEN connections for potential communication errors at the board J3 and or J4 connectors Communication between modules is accomplished by a 3 wire sensor bus These 3 wires run in parallel from module to module The J4 connector on the MBB provides both power and communication directly to the marquee display only YELLOW LED The MBB has one yellow LED The Carrier Comfort Network CCN LED will blink during times of network communication Carrier Comfort Network CCN Interface The 30RAP chiller units can be connected to the CCN if desired The communication bus wiring is a shielded 3 conductor cable with drain wire and is supplied and installed in the field See Table 18 The system elements are connected to the communication bus in a daisy chain arrangement The positive pin of each system element communication connector must be wired to the positive pins of the system elements on either side of it This is also required for the negative and signal ground pins of each system element Wiring connections for CCN should be made at LVT Consult the CCN Contrac tor s Manual for further information
214. relay and alarm relay con tacts Factory installed BOILER connections exist in the con trol panel near LVT for these applications Alarms and alerts A189 through A202 are active during heating operation Service Test See Table 4 Both main power and control circuit power must be on The Service Test function should be used to verify proper operation of condenser fan s compressors minimum load valve solenoid if installed cooler pump s EXVs and re mote alarm relay To use the Service Test mode the Enable Off Remote Contact switch must be in the OFF position Use the display keys and Table 4 to enter the mode and display TEST Press twice so that OFF flashes Enter the password if required Use either arrow key to change the TEST value to the ON position and press ENTER Press ESCAPE and the wr button to enter the OUTS or COMP sub mode Test the condenser fans cooler pump s and alarm relay by changing the item values from OFF to ON These discrete outputs are then turned off if there is no keypad activity for 10 minutes Use the arrow keys to select the desired percentage when testing expansion valves and Motormaster V controller When testing compressors lead compressor must be started first All compressor outputs can be turned on but the control will limit the rate by staging one compressor per minute Com pressor unloaders and hot gas bypass relays solenoids if in stalled can be tested with the compresso
215. reme caution when servicing the drive Failure to com ply could result in possible personal injury ANWARNING When configured as shown in this literature this equip ment is designed to start when it receives line power Ensure that all personnel are clear of fans and guards are installed before applying power Failure to comply could result in possible personal injury CAUTION DO NOT connect incoming AC power to output terminals T2 and Severe damage to the drive will result Do not continuously cycle input power to the drive more than once every two minutes Damage to the drive will result CAUTION If input power has not been applied to the drive for a period of time exceeding three years due to storage etc the electrolytic DC bus capacitors within the drive can change internally resulting in excessive leakage current This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage In order to reform the capacitors and prepare the drive for operation after a long period of inactivity apply input power to the drive for 8 hours prior to actually operating the motor Before attempting to operate the drive motor and driven equipment be sure all procedures pertaining to installation and wiring have been properly followed Fail ure to comply could result in equipment damage GENERAL OPERATION The speed varies in proportion to a 4 to 20
216. ressors must be off when checking oil level Recommended oil level adjustment method is as follows ADD OIL Recover charge from the unit Add oil to suction line Schrader valve on tandem compressors sets and the com pressor Schrader on the trio s and single compressor circuits See Fig 26 and 27 When oil can be seen at the bottom of the sight glass add oil in 5 oz increments which is approximately 1 in oil level Run all compressors for 20 minutes then shut off to check oil level Repeat procedure until acceptable oil level is present NOTE Use only Carrier approved compressor oil Approved sources are oppi RERO nek 903 1601 50 RL32 3MAF Do not reuse oil that has been drained out or oil that has been exposed to atmosphere Microchannel Heat Exchanger MCHX Con denser Coil Maintenance and Cleaning Recommendations CAUTION Do not apply any chemical cleaners to MCHX condenser coils These cleaners can accelerate corrosion and damage the coil Routine cleaning of coil surfaces is essential to maintain proper operation of the unit Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit The following steps should be taken to clean MCHX condenser coils 1 Remove any foreign objects or debris attached to the coreface or trapped within the mounting frame and brackets
217. rom recom mended procedures Any short to ground of the control board or accompanying wiring may destroy the board or electrical component Table 1 Unit Sizes UNIT NOMINAL CAPACITY TONS 30RAP010 10 30RAP015 14 30RAP018 16 30RAP020 19 30RAP025 24 30RAP030 28 30RAP035 34 30RAP040 39 30RAP045 43 30RAP050 48 30RAP055 53 30RAPO060 56 Conventions Used in This Manual The follow ing conventions for discussing configuration points for the local display scrolling marquee or Navigator accessory will be used in this manual Point names will be written with the mode name first then any sub modes then the point name each separated by an arrow symbol Names will also be shown in bold and italics As an example the Lead Lag Circuit Select Point which is located in the Configuration mode Option sub mode would be written as Configuration OPTN gt LLCS This path name will show the user how to navigate through the local display to reach the desired configuration The user would scroll through the modes and sub modes using the and fw keys The arrow symbol in the path name repre sents pressing ENTER to move into the next level of the menu structure When a value is included as part of the path name it will be shown at the end of the path name after an equals sign If the value represents a configuration setting an explanation will be shown in parenthesis after the value As an example C
218. rs on or off The relays 34 under the COMP mode will stay on for 10 minutes if there is no keypad activity Compressors will stay on until they are turned off by the operator The Service Test mode will remain enabled for as long as there is one or more compressors run ning All safeties are monitored during this test and will turn a compressor circuit or the machine off if required Any other mode or sub mode can be accessed viewed or changed during the TEST mode The MODE item Run Status gt VIEW will display 0 as long as the Service mode is enabled The TEST sub mode value must be changed back to OFF before the chill er can be switched to Enable or Remote contact for normal operation Optional Factory Installed Hydronic Pack age If the chiller has factory installed chilled fluid pumps specific steps should be followed for proper operation The pump s in the hydronic package come factory pre wired into the main unit power supply starter In order to check proper pump rotation use the Service Test function to test the condenser fans and observe them for proper rotation If fans turn correctly the pumps will rotate correctly Clockwise rotation of the pump motor cooling fans can also be used to de termine that pumps are rotating correctly CAUTION Operation of pump in wrong direction even for a few seconds can cause irreversible damage to pump impeller and housing Always verify correct wiring pump rotation
219. rsonal injury and death Shut off all power to this equipment during installation There may be more than one disconnect switch Tag all discon nect locations to alert others not to restore power until work is completed 1 Check that all power to unit is off Carefully disconnect all wires from the defective module by unplugging its connectors 2 Remove the defective module by removing its mounting screws with a Phillips screwdriver and removing the module from the control box Save the screws later use 3 Verify that the instance jumper MBB or address switch es all other modules exactly match the settings of the defective module NOTE Handle boards by mounting standoffs only to avoid electrostatic discharge 4 Package the defective module in the carton of the new module for return to Carrier 5 Mount the new module in the unit s control box using a Phillips screwdriver and the screws saved in Step 2 6 Reinstall all module connectors For accessory Navigator replacement make sure the plug is installed at TB3 in the LEN connector 7 Carefully check all wiring connections before restoring power 8 Verify the ENABLE OFF REMOTE CONTACT switch is in the OFF position 9 Restore control power Verify that all module red LEDs blink in unison Verify that all green LEDs are blinking and that the scrolling marquee or Navigator display is communicating correctly 10 Verify all configuration information settings se
220. s the time averaged summation of loaded and unloaded states and range is continuous from Do not attempt to start the chiller until following checks the minimum configured capacity to 100 Regardless of have been completed capacity the compressor always rotates with constant speed As the compressor transitions from a loaded to unloaded state System Check 2 the discharge and suction pressures will fluctuate and the com 1 Check all auxiliary components such as chilled fluid pressor sound will change pumps air handling equipment or other equipment to which the chiller supplies liquid Consult manufacturer s instructions Verify that any pump interlock contacts have been properly installed If the unit If the unit has field installed accessories be sure all are properly in stalled and wired correctly Refer to unit wiring diagrams The ComfortLink controller controls and integrates the op eration of the DUS into the compressor staging routine to maintain temperature control When a digital compressor is in stalled an additional discharge gas temperature thermistor 44 Use the scrolling marquee display to adjust the Cooling Set Point Fill chilled fluid circuit with clean water with recom mended inhibitor added or other non corrosive fluid to be cooled Bleed all air out of the high points of the sys tem If chilled water is to be maintained at a temperature below 40 F 4 4 O or outdoor temperatures are expected
221. sistance values decrease at higher temperatures and increase at lower temperatures REPLACING DEFECTIVE MODULES The Comfort Link replacement modules are shown in Table 40 If the main base board MBB has been replaced verify that all configura tion data is correct Follow the Configuration mode table and verify that all items under sub modes UNIT OPTI and OPT2 are correct Any additional field installed accessories or op tions RSET SLCT sub modes should also be verified as well as any specific time and maintenance schedules Refer to the Start Up Checklist for 30RAP Liquid Chillers completed at time of original start up found in the job folder This information is needed later in this procedure If the check list does not exist fill out the current information in the Config uration mode on a new checklist Tailor the various options and configurations as needed for this particular installation LOW AMBIENT OPERATION MOTORMASTER V FIOP ACCESSORY 8L 1 4 BLK 2 2 m BLK 3 GRN YEL w HIGH SCCR ONLY MMR MM SIGNAL CONNECTION KA TB VOLTAGE HZ 2400 1744 1 208 230 460 515 60 E RED FROM 13 380 60 BLK BLK 1 7 BLK 2 4 OFM2 a i oe GRN YEL O 2 BLK TEL WHT 3 BLK CO
222. ssor feedback signal does not match relay state Respective current sensor board CSB feedback signal is ON when the compressor should be off Compressor feedback signal does not match relay state Respective current sensor board CSB feedback signal is ON when the compressor should be off Compressor feedback signal does not match relay state Respective current sensor board CSB feedback signal is ON when the compressor should be off Thermistor outside range of 40 to 245 F 40 to 118 C Thermistor outside range of 40 to 245 F 40 to 118 C If return gas sensors are enabled RG EN and thermistor is outside range of 40 to 245 F 40 to 118 C If return gas sensors are enabled RG EN and thermistor is outside range of 40 to 245 F 40 to 118 C Thermistor outside range of 40 to 245 F 40 to 118 C Thermistor outside range of 40 to 245 F 40 to 118 C Faulty expansion valve suction pressure transducer or leaving fluid thermistor Faulty expansion valve suction pressure transducer or leaving fluid thermistor Thermistor outside range of 40 to 245 F 40 to 118 C 67 Table 42 Alarm and Alert Codes ALARM OR DESCRIPTION ALERT Circuit A Compressor 1 ACTION TAKEN BY CONTROL Compressor A1 shut down Compressor A2 shut down Compressor B1 shut down Compressor B2 shut down Chiller shut down immediately Chiller shut down immediately
223. sulate thermocouple to avoid ambient temperatures from influencing reading Temperature measured by thermocouple and temperature determined from thermistor voltage reading should be close 5 F 3 C if care was taken in applying thermo couple and taking readings Ifa more accurate check is required unit must be shut down and thermistor removed and checked at a known temperature freezing point or boiling point of water using either voltage drop measured across thermistor at the J8 terminal by deter mining the resistance with chiller shut down and thermistor disconnected from J8 Compare the values determined with the value read by the control in the Temperatures mode using the scrolling marquee display Pressure Transducers The suction and discharge transducers are different part numbers and can be distinguished by the color of the transducer body suction yellow and dis charge red No pressure transducer calibration is required The transducers operate on a 5 vde supply which is generated by the main base board MBB See Fig 29 for transducer con nections to the J8 connector on the MBB TROUBLESHOOTING Ifa transducer is suspected of be ing faulty first check supply voltage to the transducer Supply voltage should be 5 vdc 0 2 v If supply voltage is correct compare pressure reading displayed on the scrolling marquee display module against pressure shown on a calibrated pressure gauge Pressure readings shou
224. supervision of a qualified refrigeration mechanic 1 Be sure all service valves are open 2 Using the scrolling marquee display set leaving fluid set point Set Points gt COOL CSP 1 No cooling range adjustment is necessary 3 Start chilled fluid pump if not configured for cooler pump control 4 Turn ENABLE OFF REMOTE CONTACT switch to ENABLE position 5 Allow unit to operate and confirm that everything is func tioning properly Check to see that leaving fluid tempera ture agrees with leaving set point Set Points gt COOL CSP 1 or Set Points gt COOL CSP 2 or if reset is used with the control point Run Status gt VIEW CTPT 6 Check the cooler leaving chilled water temperature to see that it remains well above 32 F 0 C or the brine freez ing point if the unit is a medium temperature brine unit 7 Recheck compressor oil level see Oil Charge section Check Refrigerant Charge 30RAP units are shipped with a complete operating charge of R 410A and should be under sufficient pressure to conduct a leak test after installation If there is no system pressure admit nitrogen until a pressure is observed and then proceed to test for leaks After leaks are repaired the system must be dehydrated refrigerant charging should be done through the V4 in Schraeder connection on the liquid line Do NOT add refriger ant charge through the low pressure side of the system If com plete charging
225. t at a voltage other than 6 VDC or shows 0 volts remove the connector to the valve and recheck Press and select 0 to close the valve Check the 4 po sition DIP switch on the board all switches should be set to On If a problem still exists replace the EXV module If the reading is correct the expansion valve and EXV wiring should be checked Check the EXV terminal strip and interconnecting wiring 1 Check color coding and wire connections Make sure they are connected to the correct terminals at the EXV driver and EXV plug and that the cables are not crossed 2 Check for continuity and tight connection at all pin terminals 3 Check the resistance of the EXV motor windings Re move the EXV module plug J6 for Circuit A J7 for Cir cuit B and check the resistance of the two windings be tween pins 1 and 2 for one winding and pins 4 and 5 for the other winding see Fig 25 The resistance should be 100 ohms 10 ohms 48 FIELD SERVICING INSTRUCTIONS The EXV valves on sizes 025 030 050 060 can be serviced The EXV valves on all other sizes are hermetic and cannot be disassembled for installation or during service however the cable and retainer may be replaced if necessary Motor kits for the EXV valve are available as replacement parts To remove the valve from the system perform the follow ing procedure 1 Be sure the refrigerant has been recovered from the circuit 2 Disconnect the line voltage to the v
226. t current has exceeded the Check for loose electrical connections CURRENT LIMIT setting Parameter 25 and the drive is Check for faulty condenser fan motor reducing the output frequency to reduce the output current Check Parameter P25 from Table 39 is set If the drive remains in CURRENT LIMIT too long it can trip correctly into a CURRENT OVERLOAD fault PF GF Data Fault User data and OEM defaults in the EPM are Restore factory defaults P48 see section corrupted above If that does not work replace EPM HF High DC Bus Voltage Fault Line voltage is too high Decel Check line voltage set P01 appropriately eration rate is too fast Overhauling load JF Serial Fault The watchdog timer has timed out indicating Check serial connection computer that the serial link has been lost Check settings for PXX Check settings in communication software to match PXX LF Low DC Bus Voltage Fault Line voltage is too low Check line voltage set appropriately OF Output Transistor Fault Phase to phase or phase to ground Reduce boost or increase acceleration values short circuit on the output Failed output transistor Boost If unsuccessful replace drive settings are too high Acceleration rate is too fast PF Current Overload Fault VFD is undersized for the applica Check line voltage set PO1 appropriately tion Mechanical problem with the driven equipment Check for dirty coils Check for motor bearing failure
227. t points and schedules Return the ENABLE OFF REMOTE CONTACT switch to its previous position Table 40 Replacement Modules REPLACEMENT REPLACEMENT PART MODULE PART NO with Software NO without Software Main Base Board MBB 30RA502134 HK50AA029 Scrolling Marquee HK50AA031 HK50AA030 Display Energy Management Module 30GT515218 HK50AA028 EMM Navigator Display HK50AA033 N A EXV 30GT515217 HK50AA026 AUX 32GB500442E N A Hydronic Package If the unit is equipped with a factory installed hydronic package consult the information be low for proper maintenance and service In addition to this information each factory installed hydronic package is sup plied with a packet of information supplied by the manufactur er Bell amp Gossett Carrier Corporation strongly recommends that this information be thoroughly reviewed prior to operation of the chiller PUMP PERFORMANCE CHECK The factory installed pumps in the 30RAP units are shipped with a single impeller size available for that pump The pump was selected based on the flow and head requirements as provided to Carrier It is not 63 uncommon for actual pump duty to be different than what was anticipated at time of selection In many cases it may be desir able to make some field modifications to obtain optimum pump performance Before any pump modifications are made it is recommend ed that actual pump performance be verified and compared to the applicabl
228. tacts Opened During Normal Operation Flow Lost While Pump 1 Running WHY WAS THIS ALARM GENERATED Internal clock on MBB fails Configuration storage failure with MBB MBB loses communication with EXV board MBB loses communication with EMM If configured with EMM and input less than 2 mA or greater than 22 mA MBB loses communication with AUX Board If configured with EMM and input less than 2 mA or greater than 22 mA If configured with EMM and input less than 2 mA or greater than 22 mA Pump 1 Auxiliary Contact are closed when Pump 2 output is energized or if Pump 2 Auxiliary Contact are closed when Pump 1 output is energized Pump 1 Auxiliary Contac did not close within 26 seconds after pump was started Pump 2 Auxiliary Contac did not close within 26 seconds after pump was started Pump 1 did not provide flow to close flow switch within 60 seconds Pump 2 did not provide flow to close flow switch within 60 seconds Pump 1 Auxiliary Contacts open for 26 seconds after initially made All compressors shut down Pump 1 turned off Pump 2 Auxiliary Contacts open for 26 seconds after initially made All compressors shut down Pump 2 turned off Cooler flow switch contacts open for 3 seconds after initially made 69 Occupancy schedule will not be used Chiller defaults to Local On mode Chiller is not allowed to run 4 to 20 mA temp
229. ted between the discharge line and the cooler entering refrigerant line The MBB cycles the solenoid to perform minimum load valve function and the discharge bypass valve modulates to the suction pressure set point and the valve The amount of capacity reduction achieved by the mini mum load valve is not adjustable The total unit capacity with the minimum load valve is shown in Table 19 PRESSURE RELIEF DEVICES All units have one pres sure relief device per circuit located in the liquid line which re lieves at 210 F 100 C Check Unit Safeties HIGH PRESSURE SWITCH A high pressure switch is provided to protect each compressor and refrigeration system from unsafe high pressure conditions See Table 32 for high pressure switch settings The high pressure switch is mounted in the discharge line of each circuit If an unsafe high pressure condition should exist the switch opens and shuts off the affected circuit The CSB senses the compressor feedback signal and generates an appro priate alarm The MBB prevents the circuit from restarting un til the alert condition is reset The switch should open at the pressure corresponding to the appropriate switch setting as shown in Table 32 Table 32 Factory Settings High Pressure Switch Fixed E Psg 30RA 3407 Clear the alarm using the scrolling marquee display as de scribed on page 63 The unit should restart after the compressor anti s
230. to Sen sors section page 20 for wiring The CCN communication bus must be connected between the two chillers Connections can be made to the CCN screw terminals on LVT Refer to Carrier Comfort Network Interface section page 19 for wiring infor mation Configuration examples are shown in Tables 22 and 23 Refer to Table 22 for dual chiller configuration In this example the master chiller will be configured at address 1 and the slave chiller at address 2 The master and slave chillers must reside on the same CCN bus Configuration gt CCNB but cannot have the same CCN address Configu ration gt CCN gt CCNA Both master and slave chillers must Lead Lag Chiller Enable Configuration gt RSET LLEN configured to ENBL Master Slave Select Config uration GRSET MSSL must be configured to MAST for the master chiller and SLVE for the slave Also in this example the master chiller will be configured to use Lead Lag Balance Select Configuration gt RSET gt LLBL and Lead Lag Bal ance Delta Configuration gt RSET LLBD to even out the chiller run times weekly The Lag Start Delay Configura tion RSET LLDY feature will be set to 10 minutes This will prevent the lag chiller from starting until the lead chiller has been at 100 capacity for the length of the delay time allel configuration Configuration gt 5 gt only be configured to YES The variables LLBL LLBD and LLDY are not
231. tration also shows the ON OFF state of the machine for the given combinations Cooling Set Point Select SINGLE Unit operation is based on Cooling Set Point 1 Set Points COOL CSP 1 DUAL SWITCH Unit operation is based on Cooling Set Point 1 Set Points 2COOL CSP 1 when the Dual Set Point switch contacts are open and Cooling Set Point 2 Set Points COOL CSP 2 when they are closed DUAL CCN OCCUPIED Unit operation is based on Cooling Set Point 1 Set Points gt COOL during the Occupied mode and Cooling Set Point 2 Set Points 29COOL CSP 2 during the Unoccupied mode as configured under the local occupancy schedule accessible only from CCN Schedule Number in Table SCHEDOVR See Ap pendix B must be configured to 1 If the Schedule Number is set to 0 the unit will operate in a continuous 24 hr Occupied mode Control method must be configured to 0 switch See Table 21 Table 21 Control Methods Cooling Set Points CONTROL OCCUPANCY z COOLING SET POINT SELECT CLSP CTRL 41030 ma Tuum ON ON ON 2 Occupaney oe o pum ONG ON Dual set point switch input used CSP1 used when switch input is open CSP2 used when switch input is closed TCooling set point determined from 4 to 20 mA input to energy management module EMM to terminals 6 3 5 4 TO 20 mA INPUT Unit operation is based on an e
232. um Steps 0 to 65535 MAX B XXXXX EXVB Maximum Steps 0 to 65535 OVR B EXVB Overrun Steps Default 1 0 1 EXVB Stepper 0 UNIPOLAR 1 BIPOLAR 81 SUB MODE RSET APPENDIX A DISPLAY TABLES cont Configuration Mode and Sub Mode Directory cont ITEM DISPLAY MMR S YES NO P GAN XX XX X D GAN XX X MIN S XX CRST x MA DG XX XAF RM NO XXX X F RM F XXX X F RM DG XX X F RT F XXX XAF RT DG XX X F DMDC DM20 XXX SHNM XXX SHTM XXX DLS1 XXX DLS2 XXX LLEN ENBL DSBL MSSL SLVE MAST SLVA XXX LLBL gt gt LLBD x LLDY XXX PARA YES ITEM DESCRIPTION COMMENT MOTORMASTER Motormaster Select Default NO Default 1 Head Pressure P Gain Range 1 to 4 Default 0 1 Head Pressure Gain Range 20 to 20 Default 0 0 Head Pressure D Gain Range 20 to 20 Minimum Fan Speed Default 5 RESET COOL TEMP Default 0 0 No Reset 1 410 20 mA Input 2 Outdoor Air Temperature 3 Return Fluid 4 Space Temperature Default 0 0 AF Range 30 to 30 AF Default 125 F Range 0 to125 F Default 0 F Range 0 to125 F Default 0 0 AF Range 30 to 30 AF Default 10 0 AF Range 0 to125 F Default 0 AF Range 0 to125 F Default 0 0 AF Range 30 to 30 AF Default 0 0 None 1 Switch 2 4 to 20 mA Input 3 CCN Loadshed Default 100 Range 0 to 100 Default 0 Range 0 to 99 Default 0 Range 0 to 60
233. ure Wiring error faulty wiring or failed EXV board Wiring error faulty wiring or failed Energy Manage ment Module EMM Faulty signal generator wiring error or faulty EMM Wiring error faulty wiring or failed AUX board Faulty signal generator wiring error or faulty EMM Faulty signal generator wiring error or faulty EMM Wiring error faulty pump contactor auxiliary contacts Wiring error faulty contacts on pump contactor Wiring error faulty contacts on pump contactor Wiring error pump circuit breaker tripped contactor failure Wiring error pump circuit breaker tripped contactor failure Wiring error faulty contacts on pump contactor Wiring error faulty contacts on pump contactor Wiring error pump circuit breaker tripped contactor failure ALARM ALERT CODE T197 T198 T199 T200 A201 A202 T203 T204 T205 T206 A207 A208 T300 T301 Table 42 Alarm and Alert Codes cont ALARM OR DESCRIPTION ALERT Alert Flow Lost While Pump 2 Running Cooler Pump 1 Aux Contacts Closed While Pump Off Cooler Pump 2 Aux Contacts Closed While Pump Off Alert Cooler Flow Interlock Contacts Failed to Close at Start Up Cooler Flow Interlock Contacts Opened During Normal Operation Alarm Cooler Pump Interlock Closed When Pump is Off Alarm Loss of Communication Alert with Slave Chiller Loss of Communication
234. vent freezing Operating Limitations TEMPERATURES See Table 29 for 30RAP standard tem perature limits A CAUTION Do not operate with cooler leaving chiller water fluid temperature LCWT below 40 F 4 4 C for the standard units or below 15 9 4 C for units factory built for medium temperature brine High Cooler Leaving Chilled Water Fluid Temperatures LCWT During start up with cooler LCWT above approx imately 60 F 16 C the unit expansion valve will limit suction pressure to approximately 90 psig 620 kPa to avoid overload ing the compressor Low Cooler LCWT For standard units the LCWT must be no lower than 40 F 4 4 C If the unit is the factory installed optional medium temperature brine unit the cooler LCWT can go down to 15 F 9 4 C Table 29 Temperature Limits for Standard 30RAP Units UNIT SIZE 30RA 010 030 035 060 Temperature Maximum Ambient 49 Temperature Minimum Ambient 0 Temperature Maximum Cooler EWT 35 Maximum Cooler LWT 21 Minimum Cooler LWTT LEGEND EWT Entering Fluid Water Temperature LWT Leaving Fluid Water Temperature For sustained operation EWT should not exceed 85 F 29 4 C TUnit requires modification below this temperature LOW AMBIENT OPERATION If operating temperatures below 45 F 7 C on size 018 030 units and 32 F 0 C on size 035 060 units are expected accessory Motormaster amp V con trol must be installed Operatin
235. ving the cooler by metering the proper amount of refrigerant into the cooler The superheat set point is adjustable but should not be adjusted unless absolutely necessary The is designed to limit the cooler saturated suction temperature to 50 F 12 8 C This makes it possible for unit to start at high cooler fluid temperatures without overloading the compressor Capacity Control The control system cycles com pressors digital scroll modulting solenoid if equipped and minimum load valve solenoids if equipped to maintain the user configured leaving chilled fluid temperature set point En tering fluid temperature is used by the main base board MBB to determine the temperature drop across the cooler and is used in determining the optimum time to add or subtract capacity stages The chilled fluid temperature set point can be automati cally reset by the return fluid temperature space or outdoor air temperature reset features It can also be reset from an external 4 to 20 mA signal requires energy management module FIOP or accessory The standard control has an automatic lead lag feature built in which determines the wear factor combination of starts and run hours for each compressor If all compressors are off and less than 30 minutes has elapsed since the last compressor was turned off the wear factor is used to determine which 29 compressor to start next If no compressors have been running for more than 30 minut
236. xternal 4 to 20 mA signal input to the Energy Management Module EMM Low Sound Mode Operation All models are fac tory configured with the Low Sound Mode disabled In the Configuration mode under sub mode 2 items for Low Sound Mode Select Configuration gt OPT2 gt LS MD Low Sound Start Time Configuration gt OPT2 gt LS ST Low Sound End Time Configuration gt 2 LS ND and Low Sound Capacity Limit Configuration gt OPT2 gt LS LT factory configured so that the chiller always runs as quietly as possible This results in operation at increased saturated con densing temperature As a result some models may not be able to achieve rated efficiency For chiller operation at rated effi ciency disable the low sound mode or adjust the low sound mode start and stop times accordingly or set both times to 00 00 for rated efficiency operation 24 hours per day In addi tion the low sound capacity limit can be used to reduce overall chiller capacity if required by limiting the maximum to a user configured percentage Heating Operation The chiller can be used for pump outputs or optional factory installed hydronic system operation can be utilized for heating applications The heating mode is activated when the control sees a field supplied closed switch input to terminal block LVT 19 20 The control locks out cool ing when the heat relay input is seen A field supplied boiler re lay connection is made using heat

Carrier 30RAP010-060 Air Conditioner User Manual

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