Contents

Carrier 30RAP011-060 v3 Installation Instructions PDF

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Summary of Content for Carrier 30RAP011-060 v3 Installation Instructions PDF

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300221-01 Printed in U.S.A. Form 30RAP-7T Rev. A Pg 1 5-21 Replaces: 30RAP-6T

Controls, Start-Up, Operation, Service, and Troubleshooting CONTENTS

Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Conventions Used in This Manual . . . . . . . . . . . . . . . 3 Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . 4 SCROLLING MARQUEE DISPLAY ACCESSORY NAVIGATOR DISPLAY MODULE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . 26 Energy Management Module (EMM) . . . . . . . . . . . . 27 Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . 27 Auxiliary (AUX) Board . . . . . . . . . . . . . . . . . . . . . . . . 27 Electronic Expansion Valve (EXV) Board . . . . . . . . 27 Compressor Expansion Board (CXB) . . . . . . . . . . . 27 Enable/Off/Remote Control Switch . . . . . . . . . . . . . 27 Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . 27 Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Control Module Communication . . . . . . . . . . . . . . . 27 RED LED GREEN LED YELLOW LED Carrier Comfort Network (CCN) Interface . . . . . . . 28 Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ALARM ROUTING CONTROL ALARM EQUIPMENT PRIORITY COMMUNICATION FAILURE RETRY TIME RE-ALARM TIME ALARM SYSTEM NAME Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 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 . . . . . . . . . . . . . . . . . . 30 Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . 31 Electronic Expansion Valves (EXVs) . . . . . . . . . . . . 31 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 MINUTES LEFT FOR START MINUTES OFF TIME LEAD/LAG DETERMINATION LOADING SEQUENCE SELECT LOW AMBIENT LOCKOUT CAPACITY CONTROL OVERRIDES

SLOW CHANGE OVERRIDE Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . .34 MOTORMASTER V OPTION High-Efficiency Variable Condenser Fans . . . . . . . .37 30RAP011-060 WITH GREENSPEED INTELLIGENCE FAN DRIVE OPERATION Operation of Machine Based on Control Method and

Cooling Set Point Selection Settings . . . . . . . . .38 OCCUPANCY SCHEDULE CCN CONTROL Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . .39 SINGLE DUAL SWITCH DUAL CCN OCCUPIED 4 TO 20 MA INPUT CONFIGURATION SET POINT LIMITS Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . .39 Low Sound Mode Operation . . . . . . . . . . . . . . . . . . .40 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Optional Factory-Installed Hydronic Package . . . .41 Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . .41 Cooler Pump Operation . . . . . . . . . . . . . . . . . . . . . . .41 Cooler Pump Sequence of Operation . . . . . . . . . . .41 NO INTEGRAL PUMP SINGLE EXTERNAL PUMP

CONTROL NO INTEGRAL PUMP DUAL EXTERNAL PUMP

CONTROL SINGLE INTEGRAL PUMP CONTROL DUAL INTEGRAL PUMP CONTROL Configuring and Operating Dual Chiller Control . .43 Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . .43 Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 DEMAND LIMIT (2-STAGE SWITCH CONTROLLED) EXTERNALLY POWERED DEMAND LIMIT (4 TO 20

MA CONTROLLED) DEMAND LIMIT (CCN LOADSHED CONTROLLED) Digital Scroll Option . . . . . . . . . . . . . . . . . . . . . . . . .49 DIGITAL SCROLL OPERATION DIGITAL COMPRESSOR CONFIGURATION PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 START-UP AND OPERATION . . . . . . . . . . . . . . . . . .51 Crankcase Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Check Refrigerant Charge . . . . . . . . . . . . . . . . . . . . .52 Charge Adjustment for Brine Operation . . . . . . . . .52 Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . .52

AquaSnap 30RAP010-150 Air-Cooled Chillers and 30RAP011-060 Air-Cooled Chillers with

Greenspeed Intelligence with Puron Refrigerant (R-410A)

50/60 Hz

2

COOLER FLOW RATES AND LOOP VOLUMES LOW-AMBIENT OPERATION VOLTAGE ALL UNITS OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . 54 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Electronic Components . . . . . . . . . . . . . . . . . . . . . . 54 CONTROL COMPONENTS Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . 54 EXV Troubleshooting Procedure . . . . . . . . . . . . . . . 55 FIELD SERVICING INSTRUCTIONS EXV REPLACEMENT (ALL SIZES) VALVE MOTOR REPLACEMENT Compressor Replacement (Fig. 45-47) . . . . . . . . . . 57 Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 BRAZED-PLATE COOLER HEAT EXCHANGER RE-

PLACEMENT BRAZED-PLATE COOLER HEAT EXCHANGER

CLEANING Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ADD OIL MICROCHANNEL Heat EXCHANGER CONDENSER

COIL MAINTENANCE AND CLEANING Recommendations . . . . . . . . . . . . . . . . . . . . . . . . 61

Round Tube Plate Fin (RTPF) Condenser Coil Maintenance and Cleaning Recommendations . 61

REMOVE SURFACE LOADED FIBERS PERIODIC CLEAN WATER RINSE ROUTINE CLEANING OF COIL SURFACES Check Refrigerant Feed Components . . . . . . . . . . . 61 FILTER DRIER MOISTURE-LIQUID INDICATOR MINIMUM LOAD VALVE PRESSURE RELIEF DEVICES Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . 62 HIGH-PRESSURE SWITCH PRESSURE TRANSDUCERS COOLER FREEZE-UP PROTECTION HEATER CABLE WINTER SHUTDOWN Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 REPLACING THERMISTORS (EWT, LWT, RGT) THERMISTOR/TEMPERATURE SENSOR CHECK Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . 67 TROUBLESHOOTING Chilled Water Flow Switch . . . . . . . . . . . . . . . . . . . . 67 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Condenser Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 METAL (VALUE SOUND) FANS AEROACOUSTIC (LOW SOUND) FANS Motormaster V Controller . . . . . . . . . . . . . . . . . . . . 69 GENERAL OPERATION CONFIGURATION DRIVE PROGRAMMING EPM CHIP LOSS OF CCN COMMUNICATIONS REPLACING DEFECTIVE MODULES Hydronic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 PUMP PERFORMANCE CHECK PUMP MODIFICATIONS AND IMPELLER TRIMMING RESET OF CHILLER WATER FLOW CHANGING OF PUMP SEALS VFD OPERATION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Recommended Maintenance Schedule . . . . . . . . . . 75

ROUTINE: EVERY MONTH: EVERY 3 MONTHS (FOR ALL MACHINES): EVERY 6 MONTHS: EVERY 12 MONTHS (FOR ALL MACHINES): CONDENSER COIL MAINTENANCE AND CLEANING

RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . 75 Control Box Maintenance . . . . . . . . . . . . . . . . . . . . 75 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 75 Complete Unit Stoppage and Restart . . . . . . . . . . . 75 GENERAL POWER FAILURE UNIT ENABLE-OFF-REMOTE CONTROL SWITCH IS

OFF CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN OPEN 24-V CONTROL CIRCUIT BREAKER(S) COOLING LOAD SATISFIED THERMISTOR FAILURE LOW SATURATED SUCTION COMPRESSOR SAFETIES Motor Overload Protection . . . . . . . . . . . . . . . . . . . 86 COPELAND COMPRESSORS MODELS WITH

ELECTRICAL CODE TF (010-090) COPELAND COMPRESSORS MODELS WITH

ELECTRICAL CODE TW OR TE (010-090) OR DANFOSS COMPRESSOR (100-150)

Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . 92 COMPRESSOR FAILURE ALERTS POSSIBLE CAUSES POSSIBLE CAUSES APPENDIX A DISPLAY TABLES . . . . . . . . . . . . . 97 APPENDIX B CCN TABLES . . . . . . . . . . . . . . . 114 APPENDIX C FACTORY SETTINGS FOR PUMP

AND MANUAL STARTERS . . . . . . . . . . . . . . . . 126 APPENDIX D BACNET COMMUNICATION . . . 127 TO ADDRESS THE UPC OPEN CONTROLLER BACNET DEVICE INSTANCE ADDRESS APPENDIX E MAINTENANCE SUMMARY AND LOG

SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 30RAP WEEKLY MAINTENANCE LOG . . . . . . . . . 136 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 START-UP CHECKLIST FOR 30RAP LIQUID

CHILLER. . . . . . . . . . . . . . . . . . . . . CL-1 TO CL-12

SAFETY CONSIDERATIONS Installing, starting up, and servicing this equipment can be hazard- ous due to system pressures, electrical components, and equip- ment location (roof, elevated structures, mechanical rooms, etc.). Only trained, qualified installers and service mechanics should in- stall, start up, and service this equipment. When working on this equipment, observe precautions in the liter- ature, 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.

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 disconnect locations to alert others not to restore power until work is completed.

3

GENERAL This publication contains Controls, Start-Up, Operation, Service, and Troubleshooting information for the AquaSnap 30RAP air- cooled chillers. See Table 1. These chillers are equipped with ComfortLink controls and electronic expansion valves (EXVs).

Conventions Used in This Manual The following 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 sym- bol (. Names will also be shown in bold and italics. As an ex- ample, the Lead/Lag Circuit Select Point, which is located in the

WARNING

DO NOT VENT refrigerant relief valves within a building. Outlet from relief valves must be vented outdoors in accor- dance 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 cause 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.

WARNING

DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective gloves and goggles and proceed as follows: a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from system

using both high-pressure and low pressure ports. c. Traces of vapor should be displaced with nitrogen and

the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.

d. Cut component connection tubing with tubing cutter and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.

e. Carefully unsweat remaining tubing stubs when neces- sary. Oil can ignite when exposed to torch flame.

Failure to follow these procedures may result in personal injury or death.

CAUTION

DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations. DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be com- pleted. Failure to follow these procedures may result in dam- age to equipment.

CAUTION

Compressors and optional hydronic system pumps require specific rotation. For non-HEVCF (high-efficiency variable condenser fan) units, test condenser fan(s) first to ensure proper phasing. Swap any two incoming power leads to cor- rect condenser fan rotation before starting any other motors. For HEVCF units, check to ensure the supply power phase rotation is clockwise A-B-C (L1-L2-L3).

CAUTION

Refrigerant charge must be removed slowly to prevent loss of compressor oil that could result in compressor failure.

CAUTION

This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result. Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module con- nections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center. Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections. This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to International Standard in North America EN61000-2/3 which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference. Always store and transport replacement or defective boards in anti-static shipping bag.

CAUTION

To prevent potential damage to heat exchanger, always run fluid through heat exchanger when adding or removing refrig- erant 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 below 32F (0C). 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. Fail- ure to properly protect the system from freezing may constitute abuse and may void warranty.

CAUTION

Puron refrigerant (R-410A) systems operate at higher pres- sures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment. If service equipment is not rated for Puron refrigerant, equipment damage or personal injury may result.

4

Configuration mode, Option sub-mode, would be written as Con- figuration OPT2LLCS. This path name will show the user how to navigate through the lo- cal display to reach the desired configuration. The user would scroll through the modes and sub-modes using the and keys. The arrow symbol in the path name represents pressing

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 rep- resents a configuration setting, an explanation will be shown in pa- rentheses after the value. As an example, Configura- tionOPT2LLCS = 1 (Automatic). Pressing the and 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 refer- enced in the local display tables for users configuring the unit with CCN software instead of the local display. The CCN tables are lo- cated in Appendix B of the manual.

Table 1 Unit Sizes

Basic Controls Usage SCROLLING MARQUEE DISPLAY The scrolling marquee 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 op- erating level is displayed to move through the top 11 mode levels indicated by LEDs (light-emitting diodes) on the left side of the display. See Fig. 1 and Table 2.

Fig. 1 Scrolling Marquee Display

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 meaning of all sub-modes and items and their values can be displayed for the cur- rent selection. Press the and keys to return the scrolling marquee display to its default menu of rotating dis- play items (those items in Run StatusVIEW). In addition, the password will be disabled, 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 DISPLANG), variable is changed, all appropriate display ex- pansions will immediately change to the new language. No pow- er-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 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 struc- ture. Repeat the process as required for other items. Items in the Configuration and Service Test modes are password protected. The words PASS and WORD will alternate on the display when required. The default password is 1111. Press

and the 1111 password will be displayed. Press again and the first digit will begin to flash. Use the ar-

row 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 interface software such as ComfortWORKS, ComfortVIEW, and Ser- vice Tool. Configuration value cannot be changed while the unit is enabled. Remote Control-Off-Enable must be in the Off position in order to change any configuration mode. See Table 2 and Appendix A for further details. See Table 3 for a description of operating modes.

UNIT NOMINAL CAPACITY (TONS) 30RAP010 10 30RAP011 10 30RAP015 14 30RAP016 14 30RAP018 16 30RAP020 19 30RAP025 24 30RAP030 28 30RAP035 34 30RAP040 39 30RAP045 43 30RAP050 48 30RAP055 52 30RAP060 56 30RAP070 69 30RAP080 77 30RAP090 85 30RAP100 99 30RAP115 112 30RAP130 126 30RAP150 140

ENTER

ESCAPE ENTER

ENTER ESCAPE

ESCAPE

Run Status

Service Test

Temperature

Pressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

Operating Modes

Alarms

Alarm Status

ENTER

MODE

ESCAPE

ENTER ESCAPE

ENTER ESCAPE

ESCAPE

ENTER ENTER

ENTER

ENTER ENTER

ESCAPE

ENTER ENTER

ENTER

5

Table 2 Scrolling Marquee Display Menu Structure*

LEGEND Ckt Circuit *Throughout this text, the location of items in the menu structure will be described in the following format: Item Expansion (Mode NameSub-mode NameITEM) For example, using the language selection item: Language Selection (ConfigurationDISPLANG)

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the dis- play, except the ability to configure circuit B will be displayed.

MODE RUN STATUS

SERVICE TEST TEMPERATURES PRESSURES SET

POINTS INPUTS OUTPUTS CONFIGURATION TIME CLOCK

OPERATING MODES ALARMS

SUB-MODE

Auto View of

Run Status (VIEW)

Service Test Mode

(TEST)

Ent and Leave Unit Temps (UNIT)

Pressures Ckt A

(PRC.A)

Cooling Setpoints (COOL)

General Inputs

(GEN.I)

General Outputs (GEN.O)

Display Configuration

(DISP)

Time of Day (TIME)

Modes (MODE)

Current (CRNT)

Unit Run Hour and Start

(RUN)

Outputs and Pumps

(OUTS)

Temperatures Ckt A

(CIR.A)

Pressures Ckt B

(PRC.B)

Head Pressure Setpoint (HEAD)

Circuit Inputs

(CRCT)

Outputs Circuit A

EXV (A.EXV)

Unit Configuration

(UNIT)

Month, Date, Day, and Year (DATE)

Reset Alarms (RCRN)

Compressor Run Hours

(HOUR)

Circuit A Comp Test

(CMPA)

Temperatures Ckt B

(CIR.B)

Brine Freeze Setpoint (FRZ)

4-20mA Inputs (4-20)

Outputs Circuit B

EXV (B.EXV)

Unit Options 1 Hardware (OPT1)

Daylight Savings

Time (DST)

Alarm History (HIST)

Local Holiday

Schedules (HOL.L)

Compressor Starts

(STRT)

Circuit B Comp Test

(CMPB)

Outputs Circuit A (CIR.A)

Unit Options 2 Controls (OPT2)

Preventive Maintenance

(PM)

Outputs Circuit B (CIR.B)

CCN Network Configuration

(CCN)

Schedule Number (SCH.N)

Software Version (VERS)

Cir. A EXV Configuration

(EXV.A)

Local Occupancy Schedule (SCH.L)

Cir. B EXV Configuration

(EXV.B)

Schedule Override (OVR)

Motormaster Configuration

(MM)

Reset Cool Temp (RSET)

Set Point and Ramp Load

(SLCT)

Service Configuration

(SERV)

Broadcast Configuration

(BCST)

6

Table 3 Operating Modes MODE

NO. ITEM EXPANSION DESCRIPTION

01 CSM CONTROLLING CHILLER Chillervisor System Manager (CSM) is controlling the chiller. 02 WSM CONTROLLING CHILLER Water System Manager (WSM) is controlling the chiller. 03 MASTER/SLAVE CONTROL Dual Chiller control is enabled.

05

RAMP LOAD LIMITED Ramp load (pull-down) limiting in effect. In this mode, the rate at which leaving fluid temperature is dropped is limited to a predetermined value to prevent compressor overloading. See Cooling Ramp Loading (ConfigurationSLCTCRMP). 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.

06 TIMED OVERRIDE IN EFFECT Timed override is in effect. This is a 1 to 4 hour temporary override of the programmed sched-

ule, 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.

07

LOW COOLER SUCTION TEMPA Circuit A cooler Freeze Protection mode. At least one compressor must be on, and the Satu- rated 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 PointsFRZ BR.FZ) minus 6 F (3.4 C) 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 saturated 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.

08

LOW COOLER SUCTION TEMPB Circuit B cooler Freeze Protection mode. At least one compressor must be on, and the Satu- rated 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 PointsFRZ BR.FZ) minus 6 F (3.4 C) 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. If the saturated suction tem- perature 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.

09 SLOW CHANGE OVERRIDE Slow change override is in effect. The leaving fluid temperature is close to and moving towards the control point.

10 MINIMUM OFF TIME ACTIVE Chiller is being held off by Minutes Off Time (ConfigurationOPT2DELY).

13 DUAL SETPOINT Dual Set Point mode is in effect. Chiller controls to Cooling Set Point 1 (Set PointsCOOL

CSP.1) during occupied periods and Cooling Set Point 2 (Set PointsCOOLCSP.2) during unoccupied periods.

14

TEMPERATURE RESET Temperature reset is in effect. In this mode, chiller is using temperature reset to adjust leaving 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.

15

DEMAND/SOUND LIMITED 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 produce the desired leaving fluid temperature. Demand limit can be controlled by switch inputs or a 4 to 20 mA signal.

16 COOLER FREEZE PROTECTION 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.

17 LOW TEMPERATURE COOLING Chiller is in Cooling mode and the rate of change of the leaving fluid is negative and decreas-

ing 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.

18 HIGH TEMPERATURE COOLING 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 fixed amount. Control will automatically load the chiller if necessary to better match the increasing load.

19 MAKING ICE Chiller is in an unoccupied mode and is using Cooling Set Point 3 (Set PointsCOOLCSP.3) to make ice. The ice done input to the Energy Management Module (EMM) is open.

20 STORING ICE Chiller is in an unoccupied mode and is controlling to Cooling Set Point 2 (Set PointsCOOL CSP.2). The ice done input to the Energy Management Module (EMM) is closed.

21

HIGH SCT CIRCUIT A 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 condensing temperature.

22

HIGH SCT CIRCUIT B 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 condensing temperature.

23 MINIMUM COMP ON TIME 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.

24 PUMP OFF DELAY TIME Cooling load is satisfied, however cooler pump continues to run for the number of minutes set by the configuration variable Cooler Pump Shutdown Delay (ConfigurationOPT1PM.DY).

25 LOW SOUND MODE Chiller operates at higher condensing temperature and/or reduced capacity to minimize overall unit noise during evening/night hours (ConfigurationOPT2LS.MD).

AO CIRCUIT A TRIO OIL MGMT Additional stage of capacity is added if circuit operates with only one compressor for an accu- mulated time of 60 minutes.BO CIRCUIT B TRIO OIL MGMT

OL OAT LOCKOUT IN EFFECT Chiller will not start due to OAT less than OAT lockout temperature set point (Set PointsCOOLOAT.L).

7

ACCESSORY NAVIGATOR DISPLAY MODULE The Navigator module provides a mobile user interface to the ComfortLink control system, which is only available as a field-in- stalled accessory. The display has up and down arrow keys, an

key, and an key. These keys are used to nav- igate 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 > indicates the currently se- lected item on the display screen. Pressing the and

keys simultaneously will put the Navigator module into expanded text mode where the full meaning of all sub-modes and items and their values can be displayed. Pressing 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 StatusVIEW). In addition, the password will be disabled, re- quiring 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 DISPLANG) variable is changed, all appropriate display ex- pansions will immediately change to the new language. No pow- er-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 (if any) will appear on the far right of the display. Press the key at a changeable item and the value will be- gin 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. Re- peat the process as required for other items. Items in the Configuration and Service Test modes are password protected. The words Enter Password will be displayed when re- quired, 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 remaining digits of the password. The password can only be changed through CCN operator interface software such as ComfortWORKS, Comfort- VIEW, and Service Tool. Adjusting the Contrast The contrast of the display can be adjusted to suit ambient condi- tions. To adjust the contrast of the Navigator module, press the

key until the display reads, Select a menu item. Us- ing the arrow keys move to the Configuration mode. Press

to obtain access to this mode. The display will read: > 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 il- luminate all LEDs and display all pixels in the view screen. Press- ing and simultaneously allows the user to adjust the display contrast. Use the up or down arrows to adjust the contrast. The screens contrast will change with the adjust- ment. Press to accept the change. The Navigator module will keep this setting as long as it is plugged in to the LEN (local equipment network) bus. Adjusting the Backlight Brightness The backlight of the display can be adjusted to suit ambient condi- tions. The factory default is 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:

> TEST OFF METR OFF LANG ENGLISH

Pressing will cause the OFF to flash. Use the up or down arrow keys to change OFF to ON. Pressing will illuminate all LEDs and display all pixels in the view screen. Pressing the up and down arrow keys simultaneously 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

CONTROLS

General The 30RAP air-cooled scroll chillers contain the ComfortLink electronic control system that controls and monitors all operations of the chiller. The control system is composed of several components as listed in sections starting on page 26. See Fig. 3-5 for typical control box drawings. See Fig. 6-19 for wiring. Table 4 lists the drawings by unit size.

ENTER ESCAPE

ESCAPE

ENTER ESCAPE

ENTER ESCAPE

ESCAPE

ENTER

ENTER

ENTER

ENTER ESCAPE

ENTER

ESCAPE

ENTER

ENTER ENTER

ENTER ESCAPE

ENTER

ESCAPE

ENTER

ENTER ENTER

ENTER

Run Status Service TestTemperaturesPressures

Setpoints Inputs

Outputs ConfigurationTime Clock

Operating ModesAlarms

ENTER

ESC

MODE Alarm Status

ComfortLink

8

Table 4 Component, Power, and Control Drawings

UNIT DESCRIPTION LOCATION

30RAP010 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 6, page 12 Control Wiring Schematic Fig. 7, page 13

30RAP011 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 8, page 14 Control Wiring Schematic Fig. 9, page 15

30RAP015 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 6, page 12 Control Wiring Schematic Fig. 7, page 13

30RAP016 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 8, page 14 Control Wiring Schematic Fig. 9, page 15

30RAP018 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 10, page 16 Control Wiring Schematic Fig. 11, page 17

30RAP020 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 10, page 16 Control Wiring Schematic Fig. 11, page 17

30RAP025 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 10, page 16 Control Wiring Schematic Fig. 11, page 17

30RAP030 Typical Control Box Fig. 3, page 9

Power Wiring Schematic Fig. 10, page 16 Control Wiring Schematic Fig. 11, page 17

30RAP035 Typical Control Box Fig. 4, page 10

Power Wiring Schematic Fig. 12, page 18 Control Wiring Schematic Fig. 13, page 19

30RAP040 Typical Control Box Fig. 4, page 10

Power Wiring Schematic Fig. 12, page 18 Control Wiring Schematic Fig. 13, page 19

30RAP045 Typical Control Box Fig. 4, page 10

Power Wiring Schematic Fig. 12, page 18 Control Wiring Schematic Fig. 13, page 19

30RAP050 Typical Control Box Fig. 4, page 10

Power Wiring Schematic Fig. 12, page 18 Control Wiring Schematic Fig. 13, page 19

30RAP055 Typical Control Box Fig. 4, page 10

Power Wiring Schematic Fig. 12, page 18 Control Wiring Schematic Fig. 13, page 19

30RAP060 Typical Control Box Fig. 4, page 10

Power Wiring Schematic Fig. 12, page 18 Control Wiring Schematic Fig. 13, page 19

30RAP070 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 14, page 20 Control Wiring Schematic Fig. 15, page 21

30RAP080 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 14, page 20 Control Wiring Schematic Fig. 15, page 21

30RAP090 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 14, page 20 Control Wiring Schematic Fig. 15, page 21

30RAP100 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 16, page 22 Control Wiring Schematic Fig. 17, page 23

30RAP115 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 16, page 22 Control Wiring Schematic Fig. 17, page 23

30RAP130 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 18, page 24 Control Wiring Schematic Fig. 19, page 25

30RAP150 Typical Control Box Fig. 5, page 11

Power Wiring Schematic Fig. 18, page 24 Control Wiring Schematic Fig. 19, page 25

9

N O

T E

1 :

F C

1, F

C 2

A R

E U

S E

D O

N 0

18 -0

30 O

N LY

. F

O R

H E

V C

F O

P T

IO N

, T

B 2

W IL

L R

E P

LA C

E F

C 1,

F C

2. T

B 2

W IL

L B

E L

O C

AT E

D A

T T

H E

B O

T TO

M O

F C

O N

T R

O L

B O

X .

F ig

. 3

T yp

ic al

C o

n tr

o l B

o x

fo r

30 R

A P

01 0-

03 0

10

F ig

. 4

T yp

ic al

C o

n tr

o l B

o x

fo r

30 R

A P

03 5-

06 0

11

F ig

. 5

T yp

ic al

C o

n tr

o l B

o x

fo r

30 R

A P

07 0-

15 0

a30-5713

12

Fig. 6 Typical Wiring Schematic, 30RAP010,015 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

13

Fig. 7 Typical Wiring Schematic, 30RAP010,015 Units Control Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

14

Fig. 8 Typical Wiring Schematic, 30RAP011,016 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

15

Fig. 9 Typical Wiring Schematic, 30RAP011,016 Units Control Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

16

TO COOLER, PUMP HEATER SEE STANDARD OPERTION HEATER DETAIL

Fig. 10 Typical Wiring Schematic, 30RAP018-030 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

17

Fig. 11 Typical Wiring Schematic, 30RAP018-030 Units Control Wiring

18

Fig. 12 Typical Wiring Schematic, 30RAP035-060 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

19

Fig. 13 Typical Wiring Schematic, 30RAP035-060 Units Control Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

20

Fig. 14 Typical Wiring Schematic, 30RAP070-090 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

21

Fig. 15 Typical Wiring Schematic, 30RAP070-090 Units Control Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

22

Fig. 16 Typical Wiring Schematic, 30RAP100,115 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

23

Fig. 17 Typical Wiring Schematic, 30RAP100,115 Units Control Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

24

Fig. 18 Typical Wiring Schematic, 30RAP130-150 Units Power Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

25

Fig. 19 Typical Wiring Schematic, 30RAP130-150 Units Control Wiring

NOTE: Typical drawing shown. Refer to unit wiring diagram label for specific unit.

26

LEGEND FOR FIG. 3-19

Main Base Board (MBB) See Fig. 20. The MBB is the heart of the ComfortLink control sys- tem. It contains the major portion of operating software and con- trols the operation of the machine. The MBB continuously moni- tors input/output channel information received from its inputs and from all other modules. The MBB receives inputs from the dis- charge and suction pressure transducers and thermistors. See Table 5. The MBB also receives the feedback inputs from each

compressor current sensor board and other status switches. See Tables 6 and 7. The MBB also controls several outputs. Relay out- puts controlled by the MBB are shown in Tables 8 and 9. Informa- tion 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. 20 and 21.

Fig. 20 Main Base Board

ALMR Alarm Relay FCB Fan Circuit Breaker SW Switch AUX Auxiliary FIOP Factory-Installed Option TB Terminal Block BR Boiler Relay FR Fan Relay TNKR Storage Tank Heater Relay C Contactor, Compressor FU Fuse TRAN Transformer CB Circuit Breaker FVFD Fan Variable Frequency Drive UPC Unitary Protocol Converter CCB Compressor Circuit Breaker GND Ground VFD Variable Frequency Drive CH Crankcase Heater HPS High-Pressure Switch Terminal Block CHC Cooler/Pump Heater Contactor HR Heat Relay COMP Compressor LON Local Operating Network Terminal (Unmarked) CSB Current Sensor Board LVT Low Voltage Terminal Block CWFS Chilled Water Flow Switch LWT Leaving Water Temperature Terminal (Marked) CWP Chilled Water Pump MBB Main Base Board CXB Compressor Expansion Board MLV Minimum Load Valve Splice DGS Digital Scroll Compressor MM Motormaster DPT Discharge Pressure Transducer MP Motor Protector Factory Wiring DTT Discharge Temperature Thermistor MS Manual Starter DUS Digital Unloader Solenoid NEC National Electrical Code Field Wiring EMM Energy Management OAT Outdoor-Air Thermistor EWT Entering Water Temperature OFM Outdoor Fan Motor Accessory or Option Wiring EXV Electronic Expansion Valve RGT Return Gas Thermistor FB Fuse Block SCCR Short Circuit Current Rating To indicate common potential

only; not to represent wiring.FC Fan Contactor SPT Suction Pressure Transducer

CEPL130346-01

STATUS

LEN

J1 J2

J4 J3

J5

J6

J7 J8 J9

J10

CCN

RED LED - STATUS GREEN LED - LEN (LOCAL EQUIPMENT NETWORK)

YELLOW LED - CCN (CARRIER COMFORT NETWORK)

INSTANCE JUMPER

K11 K10 K9

K8 K7 K6 K5

K4 K3 K2 K1

2 1

27

Fig. 21 CCN Wiring Diagram

Energy Management Module (EMM) EMM is available as a factory-installed option or as a field-in- stalled accessory. The EMM module receives 4 to 20 mA inputs for the leaving fluid temperature reset, cooling set point and de- mand 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 in- puts with the MBB, and the MBB adjusts the control point, capac- ity 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 mea- suring current and providing an analog input to the main base board (MBB) or compressor expansion module (CXB).

Auxiliary (AUX) Board The AUX board is used with the digital scroll option and the low ambient head pressure option. It provides additional inputs and outputs for digital scroll control along with analog outputs to con- trol head pressure control fan speeds. See Tables 10 and 11.

Electronic Expansion Valve (EXV) Board The EXV board communicates with the MBB and directly con- trols the expansion valves to maintain the correct compressor su- perheat.

Compressor Expansion Board (CXB) The CXB communicates with the MBB and directly controls addi- tional compressors for contactors, cooler/pump heaters, and com- pressor crankcase heater relays for sizes 070-150.

Enable/Off/Remote Control Switch The Enable/Off/Remote Control switch (SW1) is a 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 Re- mote Control position and a field-installed dry contact can be used to start the chiller. The contacts must be capable of handling a 24 vac, 50-mA load. In the Enable and Remote Control (dry con- tacts closed) positions, the chiller is allowed to operate and re- spond to the scheduling configuration, CCN configuration, and set point data. See Fig. 22.

Emergency On/Off Switch The Emergency On/Off switch (SW2) 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. The cooler and pump heaters are energized.

Fig. 22 Enable/Off/Remote Control Switch, and Emergency On/Off Switch Locations

Board Addresses The main base board (MBB) has a 3-position instance jumper that must be set to 1. The electronic expansion valve (EXV) board, compressor expansion board (CXB), and energy management module (EMM) board have 4-position DIP switches. All switches are 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 bevisually checked by looking at the red status LEDs. During initial power-up the LED will signal a 1/2-second blink 3 times, followed by a pause. This indicates that the processor is booting. If this pattern repeats, it is an indication that the control board is in a continuous reboot loop and the board should be replaced. When operating correctly, the red status LEDs should be blinking in unison at a rate of once ev- ery 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 control is supplied with the current software. If neces- sary, reload current software. If the problem still persists, replace the control board. A red LED that is lit continuously or blinking at a rate of once per second or faster indicates that the control board should be replaced.

28

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 whenev- er power is on. Check LEN connections for potential communica- tion 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 scrolling marquee display only. YELLOW LED The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication.

Table 5 Thermistor Designations (MBB)

Table 6 Status Inputs (MBB)

Table 7 Status Inputs (CXB)

Table 8 Output Relays (MBB)

Table 9 Output Relays (CXB)

Table 10 Inputs (AUX)

Table 11 Outputs (AUX)

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 12. The system elements are connected to the communica- tion 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 sys- tem element. Wiring connections for CCN should be made at LVT. Consult the CCN Contractors Manual for further informa- tion. Refer to Fig. 21. NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conduc- tors must be insulated with PVC, PVC/nylon, vinyl, Teflon1, 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 20C to 60C is re- quired. 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 containing different col- ored wires. At each system element, the shields of its communication bus ca- bles must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be con- nected to a ground at one point only. If the communication bus ca- ble exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building

THERMISTOR PIN

CONNECTION POINT

THERMISTOR INPUT REF. VOLTAGE

LWT J8-13,14 (MBB) Cooler Leaving Fluid Temperature 4 vdc

EWT J8-11,12 (MBB) Cooler Entering Fluid Temperature 4 vdc

RGTA J8-1,2 (MBB) Circuit A Return Gas Temperature 4 vdc

RGTB J8-3,4 (MBB) Circuit B (035-150 only) Return Gas Temperature

4 vdc

OAT J8-7,8 (MBB) Outdoor-Air Temperature Sensor

4 vdc

SPT/DLWT J8-5,6 (MBB) LVT-22,23

Accessory Remote Space Temperature Sensor or Dual LWT Sensor

4 vdc

STATUS SWITCH PIN

CONNECTION POINT

REF. VOLTAGE

CHILLED WATER PUMP 1, PM.F.1 J7-1,2 24 vac CHILLED WATER PUMP 2, PM.F.2 J7-3,4 24 vac

REMOTE ON/OFF LVT-13,14 24 vac COOLER FLOW SWITCH J7-9,10 24 vac

COMPRESSOR FAULT SIGNAL, A1 J9-11,12 5 vdc COMPRESSOR FAULT SIGNAL, A2 J9-5,6 5 vdc COMPRESSOR FAULT SIGNAL, B1 J9-8,9 5 vdc COMPRESSOR FAULT SIGNAL, B2 J9-2,3 5 vdc

STATUS SWITCH PIN

CONNECTION POINT

REF. VOLTAGE

COMPRESSOR FAULT SIGNAL, A3 (080,090,115,130,150) J5-11,12 5 vdc

COMPRESSOR FAULT SIGNAL, B3 (070-150) J5-8,9 5 vdc

RELAY NO. DESCRIPTION

K1 Energize Compressor A1 (010-050, 070-150) Energize Compressor A1 and Condenser Fan Contactor 3 (055,060)

K2 Energize Compressor A2 (all but 010, 015 60 Hz) K3 Energize Chilled Water Pump 1 Output K4 Energize Chilled Water Pump 2 Output

K5 Energize Compressor B1 (035-050, 070-150) Energize Compressor B1 and Condenser Fan Contactor 3 (055,060)

K6 Energize Compressor B2 (035-150) K7 Alarm Relay

K8 Cooler/Pump Heater (010-060), Energize Condenser Fan Con- tactor 3 (070-150)

K9 Energize Condenser Fan Contactor 1 (018-150) K10 Energize Condenser Fan Contactor 2 (018-150) K11 Minimum Load Valve (010-060)

RELAY NO. DESCRIPTION

K1 Energize Compressor Fan Contactor 4 K2 Crankcase Heater Relay Output, Circuit A K3 Cooler / Pump Heater K4 Crankcase Heater Relay Output, Circuit B K5 Energize Compressor B3 (070-150) K6 Energize Compressor A3 (080,090,115,130,150)

NAME DESCRIPTION PIN

CONNECTION POINT

REF. VOLTAGE

DTT Discharge

Temperature Thermistor

J6-1,2 5 vdc

NAME DESCRIPTION PIN

CONNECTION POINT

REF. VOLTAGE

MLV-A Minimum Load Valve (070-150) J2-3,4 24 vac

MLV-B Minimum Load Valve (070-150) J2-5,6 24 vac

DUS Digital Unloader Solenoid J2-7,8 24 vac

FC-5 Fan Contactor (070-150) J3-1,2 24 vac

FC-6 Fan Contactor (080-150) J3-3,4 24 vac

MM-A Motormaster Ckt A J4-1,2 2-10 vdc MM-B Motormaster Ckt B J5-1,2 2-10 vdc

1. Teflon is a registered trademark of Dupont.

29

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. Cut the CCN wire and strip the ends of the red (+), white

(ground), and black () conductors. (Substitute appropriate colors for different colored cables.)

3. Connect the red wire to (+) terminal on LVT of the plug, the white wire to COM terminal, and the black wire to the () ter- minal.

4. The RJ14 CCN connector on LVT can also be used, but is only intended for temporary connection (for example, a lap- top computer running Service Tool).

Table 12 CCN Communication Bus Wiring

Alarm Control ALARM ROUTING CONTROL Alarms recorded on the chiller can be routed through the CCN. To configure this option, the ComfortLink control must be configured to determine which CCN elements will receive and process alarms. Input for the decision consists of eight digits, each of which can be set to either 0 or 1. Setting a digit to 1 specifies that alarms will be sent to the system element that corresponds to that digit. Setting all digits to 0 disables alarm processing. The factory default is 00000000. See Fig. 23. The default setting is based on the assumption that the unit will not be connected to a network. If the network does not contain a ComfortVIEW, Comfort- WORKS, TeLink, DataLINK, or BAClink module, enabling this feature will only add unnecessary activity to the CCN com- munication bus. This option can be modified with Network Service Tool. It cannot be modified with the scrolling marquee display. Typical configuration of the Alarm Routing variable is 11010000. This Alarm Routing status will transmit alarms to ComfortVIEW software, TeLink, BAClink, and DataLINK.

ALARM EQUIPMENT PRIORITY The ComfortVIEW software uses the equipment priority value when sorting alarms by level. The purpose of the equipment prior- ity value is to determine the order in which to sort alarms that have the same level. A priority of 0 is the highest and would appear first when sorted. A priority of 7 would appear last when sorted. For example, if two chillers send out identical alarms, the chiller with the higher priority would be listed first. The default is 4. This vari- able can only be changed when using ComfortVIEW software or Network Service Tool. This variable cannot be changed with the scrolling marquee display. COMMUNICATION FAILURE RETRY TIME This variable specifies the amount of time that will be allowed to elapse between alarm retries. Retries occur when an alarm is not acknowledged by a network alarm acknowledger, which may be either a ComfortVIEW software or TeLink. If acknowledgment is not received, the alarm will be re-transmitted after the number of minutes specified in this decision. This variable can only be changed with ComfortVIEW software or Network Service Tool. This variable cannot be changed with the scrolling marquee display. RE-ALARM TIME This variable specifies the amount of time that will be allowed to elapse between re-alarms. A re-alarm occurs when the conditions that caused the initial alarm continue to persist for the number of minutes specified in this decision. Re-alarming will continue to occur at the specified interval until the condition causing the alarm is corrected. This variable can only be changed with Comfort- VIEW software or Network Service Tool. This variable cannot be changed with the scrolling marquee display. ALARM SYSTEM NAME This variable specifies the system element name that will appear in the alarms generated by the unit control. The name can be up to 8 alphanumeric characters in length. This variable can only be changed with ComfortVIEW software or Network Service Tool. This variable cannot be changed with the scrolling marquee display.

Sensors The electronic control uses 4 to 7 thermistors to sense tempera- tures for controlling chiller operation. See Table 5. These sensors are outlined below. Thermistors RGTA, RGTB, EWT, LWT, and OAT are 5 kat 77F (25C) thermistors and are identical in tem- perature versus resistance and voltage drop performance. The dual chiller thermistor is 5 kat 77F (25C)thermistor. Space tem- perature thermistor is a 10 kat 77F (25C). The DTT thermis- tor is an 86 kat 77F (25C)thermistor. See Thermistors section for temperature-resistance-voltage drop characteristics.

Fig. 23 Alarm Routing Control

IMPORTANT: A shorted CCN bus cable will prevent some rou- tines from running and may prevent the unit from starting. 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.

MANUFACTURER PART NO.

REGULAR WIRING PLENUM WIRING Alpha 1895 American A21451 A48301 Belden 8205 884421 Columbia D6451 Manhattan M13402 M64430 Quabik 6130

DESCRIPTION STATUS POINT Alarm Routing 0 0 0 0 0 0 0 0 ALRM_CNT

ComfortVIEW or ComfortWORKS

TeLink

Unused

BACLink or DataLINK

Unused

30

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 SENSOR 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 the digital compressor op- tion. The sensor is mounted on the discharge line close to the dis- charge of the digital compressor. It attaches to the discharge line using a spring clip and protects the system from high discharge gas temperature when the digital compressor is used. This sensor is 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 sensor below. Remote Space Temperature Sensor Sensor (part no. 33ZCT55SPT) is an accessory sensor that is remotely mounted in the controlled space and used for space tem- perature reset. The sensor should be installed as a wall-mounted thermostat would be (in the conditioned space where it will not be subjected 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. 24): 1. Using a 20 AWG twisted pair conductor cable rated for the

application, connect 1 wire of the twisted pair to one SEN ter- minal 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 LVT-22,23 located in the unit control box.

3. Units on the CCN can be monitored from the space at the sen- sor through the RJ11 connector, if desired. To wire the RJ11 connector into the CCN (Fig. 25):

4. 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.)

5. Insert and secure the red (+) wire to terminal 5 of the space temperature sensor terminal block.

6. Insert and secure the white (ground) wire to terminal 4 of the space temperature sensor.

7. Insert and secure the black () wire to terminal 2 of the space temperature sensor.

8. Connect the other end of the communication bus cable to the remainder of the CCN communication bus.

Fig. 24 Typical Space Temperature Sensor Wiring

Fig. 25 CCN Communications Bus Wiring to Optional Space Sensor RJ11 Connector

Dual Leaving Water Temperature Sensor For dual chiller applications (parallel only are supported), connect the dual chiller leaving fluid temperature sensor (refer to Config- uring and Operating Dual Chiller Control section on page 43) to the space temperature input of the Master chiller. If space tempera- ture is required for reset applications, connect the sensor to the Slave chiller and configure the slave chiller to broadcast the value to the Master chiller. The sensor wire must not be routed with any power wire.

Energy Management Module This factory-installed option (FIOP) or field-installed accessory is used for the following types of temperature reset, demand limit, and/or ice features: (See Fig. 26.) 4 to 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-sup-

plied 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 Temperature Reset and Demand Limit sections on pages 43 and 49 for further details.

IMPORTANT: The cable selected for the RJ11 connector wir- ing MUST be identical to the CCN communication bus wire used for the entire network. Refer to Table 12 for acceptable wiring.

SPT (T10) PART NO. 33ZCT55SPT

SENSOR

SEN SEN LVT

22

23

a30-4968

T-55 SPACE SENSOR

CCN+

CCN GND

CCN-

TO CCN COMM 1 BUS (PLUG) AT UNIT

1

2

3

4

5

6

31

Loss-of-Cooler Flow Protection A proof-of-cooler flow device is factory installed in all chillers. It is recommended that proper operation of the switch be verified on a regular basis.

Electronic Expansion Valves (EXVs) All units are equipped from the factory with EXVs. Each refriger- ation circuit is also supplied with a factory-installed liquid line fil- ter drier and sight glass. The EXV is set at the factory to maintain 9F (5.0C) suction su- perheat leaving the cooler by metering the proper amount of re- frigerant into the cooler. The superheat set point is adjustable, but should not be adjusted unless absolutely necessary. The EXV is designed to limit the cooler saturated suction temperature to 50F (12.8C). This makes it possible for unit to start at high cooler fluid temperatures without overloading the compressor.

Capacity Control The control system cycles compressors, digital scroll modulating solenoid (if equipped), and minimum load valve solenoids (if equipped) to maintain the user-configured leaving chilled fluid temperature set point. Entering 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 automatically 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 mod- ule 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 compressor to start next. If no compressors have been running for more than 30 min- utes 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 condensing temperature, then the control will start either compressor A1 or compressor B1 first, depending on the user-configurable circuit lead-lag value. For units with the minimum load control valve, the A circuit with the minimum load valve is always the lead circuit. The A circuit is also always the lead for units with the digital compressor option. On units with the digital scroll option, the A1 compressor operates continuously, providing close leaving chilled water control. For this reason, on/ off cycling of the units compressors is dramatically reduced, which in turn reduces wear associated with compressor start/stop cycles.

Fig. 26 Energy Management Module

CAUTION

Care should be taken when interfacing with other manufac- turers control systems due to possible power supply differ- ences, full wave bridge versus half wave rectification. The two different power supplies cannot be mixed. ComfortLink con- trols use half wave rectification. A signal isolation device should be utilized if a full wave bridge signal generating device is used.

CEBD430351-0396-01C

T E

S T

1

C E

P L1

30 35

1- 01

P W

R

TEST 2

J1 J2

J4 J3

J5

J6 J7

LEN

STATUS

RED LED - STATUS GREEN LED - LEN (LOCAL EQUIPMENT NETWORK)

ADDRESS DIP SWITCH

32

The EXVs will provide a controlled start-up. During start-up, the low pressure logic will be bypassed for 2-1/2 minutes to allow for the transient changes during start-up. As additional stages of com- pression are required, the processor control will add them. See Ta- ble 13. If a circuit is to be stopped, the compressor with the lowest wear factor will be shut off first except when a digital compressor is used. The digital compressor is always the last compressor to shut off. The capacity control algorithm runs every 30 seconds. The algo- rithm attempts to maintain the Control Point 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 con- ditions are changing and calculates 2 variables based on these con- ditions. Next, a capacity ratio is calculated using the 2 variables to determine whether or not to make any changes to the current stag- es 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 ca- pacity step change. Refer to Table 14. MINUTES LEFT FOR START This value is displayed only in the network display tables (using Service Tool, ComfortVIEW or ComfortWORKS software) and 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 unoc- cupied, Enable/Off/Remote Control 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. If the machine should be running and none of the above are true, a mini- mum off time (DELY, see below) may be in effect. The machine should start normally once the time limit has expired. MINUTES OFF TIME (ConfigurationOPT2 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. LEAD/LAG DETERMINATION This is a configurable choice and is factory set to be automatic for all units. The 30RAP units offer an optional digital compressor. When the unit is equipped with a digital scroll compressor and en- abled (ConfigurationUNITA1.TY=YES), or minimum load, then circuit A is lead (ConfigurationOPT2LLCS). If the unit is equipped with Minimum Load Valve (MLV) and op- tion has been enabled, Circuit A will be the last circuit on as ca- pacity is decreasing for the MLV to be active for the last stage of capacity.

The value can be changed to Circuit A or Circuit B leading as de- sired. Set at automatic, the control will sum the current number of logged circuit starts and one-quarter of the current operating 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. LOADING SEQUENCE SELECT This is configurable as equal circuit loading or staged circuit load- ing with the default set at equal (Configuration OPT2LOAD). The control determines the order in which the steps of capacity for each circuit are changed. Set to equal, the unit will alternate starting compressors in each circuit as the require- ment increases. Set to staged, one circuit will load completely be- fore the second circuit is started. This control choice does NOT have any impact on machines with only one circuit or units with 2 compressors - one in each circuit. LOW AMBIENT LOCKOUT The control software has a feature that allows the user to select an outdoor air temperature (OAT) at which mechanical cooling will be disabled. To use this feature, set OAT Lockout Temperature (Set Points COOLOAT.L) to a value between 19 and 120F (28.3 and 48.9C). This value should be set to the desired tem- perature at which no mechanical cooling is required. Any time the feature is active due to the outdoor air temperature being below the field programmed value, the machine will indicate OAT Be- low Lockout Temp (Operating ModesMODE MD.OL= ON). Mechanical cooling will be enabled once the Outdoor Ambi- ent is 3F (1.6C) above the OAT.L set point. The factory default is 20F (28.9C) and indicates that this feature is disabled. If an Outdoor Air Temperature Sensor failure is declared, this feature must be disabled by setting the OAT.L to 20F (28.9C), to al- low the unit to operate. CAPACITY CONTROL OVERRIDES The following overrides will modify the normal operation of the routine. Deadband Multiplier The user configurable Deadband Multiplier (Configuration SLCTZ.GN) has a default value 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 capaci- ty Load/Unload Factor. The larger this value is set, the longer the control will delay between adding or removing stages of capacity. Fig. 27 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 when the control is attempting to re- move the last stage of capacity. SLOW CHANGE OVERRIDE The control prevents the capacity stages from being changed when the leaving fluid temperature is close to the set point (within an ad- justable deadband) and moving towards the set point.

33

Table 13 Part Load Data Percent Displacement, Standard Units with Minimum Load Valve

*Minimum Load Valve energized. NOTE: These capacity steps may vary due to different capacity staging sequences.

30RAP UNIT SIZE CONTROL STEPS

CAPACITY STEPS CAPACITY % % DISPLACEMENT CIRCUIT A CIRCUIT B

010 1 100 100

011 1 2 3

40 60

100 100

015 1 100 100

016 1 2 3

40 60

100 100

018 1 2 3

*20 50

100 100

020 1 2 3

*24 50

100 100

025 1 2 3

*29 50

100 100

030 1 2 3

*32 50

100 100

035

1 2 3 4 5

*9 23

50 77

100

54 46

040

1 2 3 4 5

*11 23 50 73

100

47 53

045

1 2 3 4 5

*12 24 50 74

100

47 53

050

1 2 3 4 5

*14 25 50 75

100

50 50

055

1 2 3 4 5

*13 23 50 73

100

46 54

060

1 2 3 4 5

*16 25 50 75

100

50 50

070

1 2 3 4 5 6

*13 20 40 60 80

100

40 60

080

1 2 3 4 5 6 7

*9 15 31 46 64 82

100

46 54

090

1 2 3 4 5 6 7

*11 17 33 50 67 83

100

50 50

100

1 2 3 4 5 6

*13 19 38 57 76

100

43 57

115

1 2 3 4 5 6 7

*11 17 33 50 67 83

100

50 50

130

1 2 3 4 5 6 7

*9 15 30 44 63 81

100

44 56

150

1 2 3 4 5 6 7

*11 17 33 50 67 83

100

50 50

34

Fig. 27 Deadband Multiplier Ramp Loading Ramp loading (ConfigurationSLCTCRMP) limits the rate of change of leaving fluid temperature. If the unit is in a Cooling mode and configured for Ramp Loading, the control makes 2 comparisons before deciding to change stages of capacity. The control calculates a temperature difference between the control point and leaving fluid temperature. If the difference is greater than 4F (2.2C) 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 25% cannot be removed, the control removes an amount greater than 25% 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 running on Circuit A and capacity is de- creasing, provided that the minimum run time for Circuit B com- pressors has been satisfied. Cooler Freeze Protection The control will try to prevent shutting the chiller down on a Cool- er Freeze Protection alarm by removing stages of capacity. If the cooler fluid selected is Water, the freeze point is 34F (1.1C). If the cooler fluid selected is Brine, the freeze point is the Brine Freeze Point (Set PointsFRZBR.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 2.0F (1.1C), the control will immediately re- move one stage of capacity. This can be repeated once every 30 seconds. Low Saturated Suction Protection The control will try to prevent shutting a circuit down due to low saturated suction conditions by removing stages of capacity. These

circuit alert conditions (T116, T117) compare saturated suction temperature to the configured Brine Freeze Point (Set Points FRZBR.FZ). The Brine Freeze point is a user-configurable value that must be left at 34F (1.1C) 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 circuits capacity is limited and that eventually the circuit may shut down. Head Pressure Control The main base board (MBB) controls the condenser fans to main- tain the lowest condensing temperature possible, and thus the highest unit efficiency. The MBB uses the saturated condensing temperature input from the discharge pressure transducer and out- side air temperature sensor to control the fans. Head pressure con- trol is maintained through a calculated set point which is automat- ically adjusted based on actual saturated condensing and saturated suction temperatures so that the compressor(s) are always operat- ing within the manufacturers specified envelope (Fig. 28 and 29). If OAT is greater than 70F 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 is greater than the Fan On Set Point (Set PointsHEADF.ON), then an additional stage of fan will be added to the current fan stage. Fan On Set Point (F.ON) equals Head Set Point (Set PointsHEADH.DP) except after a fan stage increase when the Head Set Point is increased by Fan Stage Delta (Set PointsHEADF.DLT). A fan stage is decreased when the SCTs of both circuits are less than the Fan Off Set Point (Set PointsHEAD F.OFF) for two minutes. Table 14 shows the number of fan stages, contactors energized and the fans that are on during the fan stage. Unit sizes 035 to 060 have common fan control. Figure 30 shows the location of each fan and control box within the unit.

47

46

45

44

43

42

41 0 200 400 600 800 1000

TIME (SECONDS)

2 STARTS

3 STARTS

DEADBAND EXAMPLE

LW T

( F

)

MODIFIED DEADBAND

STANDARD DEADBAND

8

7

6

5

LW T

( C

)

LEGEND LWT Leaving Water Temperature

35

Fig. 28 30RAP010-090 Operating Envelope for R-410A Compressor Fig. 29 30RAP100-150 Operating Envelope

for R-410A Compressor

Fig. 30 30RAP Condenser Fan Layout

706050403020100-10-20-30 Evaporating Temperature (F)

80

60

70

80

90

100

110

120

130

140

150

160 C

o n

d en

si n

g T

em p

er at

u re

( F

)

30

40

50

170

706050403020100-10-20-30 Evaporating Temperature (F)

60

70

80

90

100

110

120

130

140

150

160

C on

de ns

in g

Te m

pe ra

tu re

( F)

TOP VIEW

TOP VIEW TOP VIEW

SIZES 010, 011, 015, 016

SIZES 035-050 SIZES 055,060

C O

N TR

O L

BO X

C O

N TR

O L

BO X

C O

N TR

O L

BO X

OFM1

OFM2

OFM3

OFM3

OFM4OFM2

OFM1 OFM1

TOP VIEW SIZES 018-030

C O

N TR

O L

BO X

OFM1

OFM2

TOP VIEW SIZES 070-150

C O

N TR

O L

BO X OFM3

OFM4OFM2

OFM1 OFM5

OFM6

080-150 ONLY

OFM7

OFM8

OFM9

OFM10

100-150 ONLY

130-150 ONLY

NOT ON 100,130

a30-5459

36

Table 14 Fan Stages, Standard Unit

LEGEND

30RAP UNIT SIZE FAN STAGES

FAN STAGE CONTACTOR ENERGIZED FANS OPERATING 010,015 STAGE 1 MMR OFM1

018-030 STAGE 1 STAGE 2

FC1 FC1,2

OFM1 OFM1,2

035-050 STAGE 1 STAGE 2 STAGE 3

FC1 FC2

FC1,2

OFM3 OFM1,2

OFM1,2,3

055,060

STAGE 1 STAGE 2 STAGE 3 STAGE 4

FC3 FC1,3 FC3,2

FC1,2,3

OFM4 OFM4,3

OFM4,1,2 OFM1,2,3,4

070

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B)

FC1 FC1,3 FC2

FC2,4 FC2,4,5

OFM5 OFM5,6 OFM1

OFM1,3 OFM1,3,2

080-090 (PSN 2214)

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 3 (CKT A) STAGE 4 (CKT A) STAGE 5 (CKT A) STAGE 6 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B) STAGE 4 (CKT B) STAGE 5 (CKT B) STAGE 6 (CKT B)

FC4 FC1

FC1,4 FC3,4 FC1,3

FC1,3,4 FC4 FC2

FC2,4 FC3,4 FC2,3

FC2,3,4

OFM3 OFM5

OFM3,5 OFM2,3,4,6 OFM2,5,4,6

OFM2,3,4,5,6 OFM3 OFM1

OFM1,3 OFM2,3,4,6 OFM1,2,4,6

OFM1,2,3,4,6

080-090 (SSN 2214)

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 3 (CKT A) STAGE 4 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B) STAGE 4 (CKT B)

FC1 FC1,6

FC1,6,3 FC1,6,3,4

FC2 FC2,6

FC2,6,5 FC2,6,5,4

OFM5 OFM5,4

OFM5,4,6 OFM5,4,6,3

OFM1 OFM1,4

OFM1,4,2 OFM1,4,2,3

100

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 3 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B) STAGE 4 (CKT B)

FC1 FC1,5

FC1,5,6 FC2

FC2,4 FC2,3

FC2,3,4

OFM7 OFM7,5

OFM7,5,8 OFM1

OFM1,3 OFM1,2,4

ORM1,2,3,4

115

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 3 (CKT A) STAGE 4 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B) STAGE 4 (CKT B)

FC1 FC1,5 FC1,6

FC1,5,6 FC2

FC2,4 FC2,3

FC2,3,4

OFM7 OFM7,5

OFM7,6,8 OFM7,5,6,8

OFM1 OFM1,3

OFM1,2,4 OFM1,2,3,4

130

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 3 (CKT A) STAGE 4 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B) STAGE 4 (CKT B) STAGE 5 (CKT B)

FC1 FC1,5 FC1,6

FC1,6,5 FC2

FC2,4 FC2,4,7 FC2,7,3

FC2,7,3,4

OFM9 OFM9,7

OFM9,8,10 OFM9,8,10,7

OFM1 OFM1,3

OFM1,3,5 OFM1,5,2,4

OFM1,5,2,4,3

150

STAGE 1 (CKT A) STAGE 2 (CKT A) STAGE 3 (CKT A) STAGE 4 (CKT A) STAGE 5 (CKT A) STAGE 6 (CKT A) STAGE 1 (CKT B) STAGE 2 (CKT B) STAGE 3 (CKT B) STAGE 4 (CKT B) STAGE 5 (CKT B) STAGE 6 (CKT B)

FC1 FC1,8

FC1,8,5 FC1,8,6

FC1,8,6,7 FC1,8,6,7,5

FC2 FC2,8

FC2,8,4 FC2,8,3

FC2,8,3,7 FC2,8,3,7,4

OFM9 OFM9,6

OFM9,6,7 OFM9,6,8,10

OFM9,6,8,10,5 OFM9,6,8,10,5,7

OFM1 OFM1,6

OFM1,6,3 OFM1,6,2,4

OFM1,6,2,4,5 OFM1,6,2,4,5,3

PSN Prior serial number SSN Start serial number

37

MOTORMASTER V OPTION The Motormaster V controller is standard on 30RAP010 and 015 size units. For all other standard (non-Greenspeed/HEVCF) units that need low-ambient operation, the lead fan on a circuit can be equipped with the Motormaster V head pressure controller option or accessory. The controller is energized with the first fan stage and adjusts fan speed to maintain a SCT of 72F (22.2C). The first stage of fan operation is controlled by the Motormaster V controller. Refer to Fig. 30 for condenser fan layout information. The Motormaster is configured in Motormaster Select (Configu- rationMMMMR.S=1(LOW AMBIENT)).

High-Efficiency Variable Condenser Fans 30RAP011-060 WITH GREENSPEED INTELLIGENCE This option controls the speed of all fans for improvement in part load efficiency and sound levels. All fans run at the same speed. High-Efficiency Variable Condenser Fans (HEVCF) is standard on 30RAP011 and 016 size units; it is not available on sizes 30RAP010 and 015. HEVCF is configured in Motormaster Select (ConfigurationMMMMR.S=2 (GREENSPEED)). For the HEVCF option, the following parameters should also be configured from the factory exactly as shown in Table 15.

Table 15 HECVF Configuration

FAN DRIVE OPERATION The HEVCF option uses Danfoss VLT 102 variable frequency drives. Drives are connected to the LEN communication bus. Fan speed is determined by the chiller controller and communi- cated to the drive. The drive must be set at Auto On mode. Fan speed is controlled to maintain SCT set point. The set point is calculated from conditions and adjusted to the most efficient oper- ating point. Drive parameters are set by the chiller control each time the unit power is cycled with the exception of the drive address. The drive address is set at the factory to 184 at Drive Parameter 8-31, but will have to be configured in case of drive replacement. If the drive address is not set correctly, the control would display Alarm A179. The address is configured using the display on the drive. See drive manual for detailed instructions. Once the address is set, the power is cycled to reset all other parameters in the drive. Other parame- ters are listed in Tables 16 and 17 for reference. Drive must be in Auto mode to operate. Push the Auto button at the bottom of the drive; the light above it will be on. The drive front cover is secured by a T-20 screw; the nominal torque is 18 inch-pounds (2 Nm). Refer to the power and control wiring diagrams for all wiring requirements. Note the shield from the LEN cable shall be attached to VFD ground.

Fan motor troubleshooting should be done at the main control box. Disconnect power from unit. All fan motors are connected to Terminal Block 2. Disconnect each fan cable and check resistance of motor. An open or short reading between phases or a phase and ground could signify a failed fan motor. Verify reading at motor before replacing. Reconnect wires using label coding L1, L2, and L3. Replace main control box cover, and power up the unit to test fan operation. Drive alarms are shown on the chiller controls as A179, A412, and A413. Refer to Alarms and Alerts section starting on page 92 for a complete list of alarms and the common alarms with possible causes. For more details see the drive manual supplied with the chiller. Drives and motors are protected by fuses for short circuit protec- tion. See the Service Test section for details. Fan motor overload protection is provided by an overload device internal to the motor. The motor overload responds to a combination of temperature and current. On overload condition, the device breaks all 3 phases to the motor. It will reset automatically once the motor temperature cools.

Table 16 High-Efficiency Fan Drive Parameters

UNIT VOLTAGE VOLTS (ConfigurationUnitVLTS) 575-3-60 575 380-3-60 380

208/230-3-60 208 or 230 460-3-60 460

380/415-3-50 400

Unit Fan Type Fan Poles (ConfigurationUnitF.POL) Low Sound Fan 8

Metal Fan 6

PARAMETER DESCRIPTION SETTING 0-02 Motor Speed Unit 1 = Hz 1-03 Torque characteristic 1 = Variable Torque 1-73 Flying Restart 1 = Yes 1-80 Function at Stop 0 = Coast 1-90 Motor Temp Protection 0 = No 1-91 Motor External Fan 0 = No 1-93 Thermistor SRC 0 = No 3-02 Min Reference [Hz] 1 3-03 Max Reference [Hz] 60 3-13 Type Reference 0 3-15 SRC REF#1 1 = AI#53 3-16 SRC REF#2 0 = No 3-41 Ramp Up 10 = 10s 3-42 Ramp Down 10 = 10s 4-10 Motor Speed Direction 2 = Both 4-12 Motor Speed Low Limit [Hz] 5 4-14 Motor Speed High Limit [Hz] 61 4-16 Torque Limit [%] 150 4-18 Current Limit [%] 110 4-19 Max Output [Hz] 61 5-12 Digital Input 27 0 = No Operation 14-01 Switching Frequency [4KHz] 6 = 4KHz 14-03 OverModulation 1 = Yes 14-40 VT Level Zero Mag Level 66 14-60 Function at Overtemp 1 = Derate 14-61 Function at Inverter Overload 1 = Derate 8-01 Control Site 2 = Digital and Control Word 8-02 Control Source 1 = FC port=RS485 8-03 Control Timeout 20S 8-04 Control Timeout Function 2 = Stop 8-05 Function at Timeout End 1= Resume setup 8-10 Control Profile 0=FC Profile 8-30 Protocol 20=LEN 8-31 Address 184 8-32 Baud Rate 4=38400 8-33 Parity/Stop Bit 2=No parity, 1 stop bit 8-34 Estimated Cycle Time 0 msec 8-37 Max Intercharacter delay 5 msec

38

Table 17 HEVCF Parameters Reset at Chiller Power Cycle

Operation of Machine Based on Control Method and Cooling Set Point Selection Settings Machine On/Off control is determined by the configuration of the Control Method (ConfigurationOPT2CTRL) and Cooling Set Point Select (ConfigurationSLCTCLSP) variables. All units are factory configured with Cooling Set Point Select set to 0 (single set point). With the control method set to 0, simply switch- ing the Enable/Off/Remote Control switch to the Enable or Re- mote Control position (external contacts closed) will put the chiller in an occupied state. The control mode (Operating ModesMODE) will be 1 (OFF LOCAL) when the switch is Off and will be 5 (ON LOCAL) when in the Enable position or Re- mote Control position with external contacts closed. Two other control methods are available for Machine On/Off control: OCCUPANCY SCHEDULE (ConfigurationOPT2CTRL = 2) The main base board will use the operating schedules as defined under the Time Clock mode in the scrolling marquee display. These schedules are identical. The schedule number must be set to 1 for local schedule.

The schedule number can be set anywhere from 65 to 99 for oper- ation under a CCN global schedule. The Enable/Off/Remote Con- trol switch must be in the Enable or Remote Control position. The control mode (Operating ModesMODE) will be 1 when the switch is Off. The control mode will be 3 when the Enable/Off/ Remote Control 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 (ConfigurationOPT2CTRL = 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 ModesMODE) will be 1 when the Enable/Off/Remote Control switch is Off. The control mode will be 2 when the Enable/Off/Remote Control switch input is On and the CHIL_S_S variable is Stop. Similarly, the control mode will be 6 when the CHIL_S_S variable is Start. Table 18 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 illustration also shows the ON/OFF state of the machine for the given combinations.

NO. FANS PARAMETER

1-20 1-22 1-23 1-24 1-25 Motor Power (kW) Motor Volts Motor Frequency Motor Amps (A) Motor Speed (RPM)

1 2.3

208

60

6.5

1140 380 3.9 460 2.9 575 2.4 400 50 2.9 950

2 4.6

208

60

13

1140 380 7.8 460 5.8 575 4.8 400 50 5.8 950

3 6.9

208

60

19.5

1140 380 11.7 460 8.7 575 7.2 400 50 8.7 950

4 9.2

208

60

26

1140 380 15.6 460 11.6 575 9.6 400 50 11.6 950

1 1.6

208

60

6

850 380 3.9 460 2.9 575 2.4 400 50 2.9 710

2 4.6

208

60

12

850 380 7.8 460 5.8 575 4.8 400 50 5.8 710

3 6.9

208

60

18

850 380 11.7 460 8.7 575 7.2 400 50 8.7 710

4 9.2

208

60

24

850 380 15.6 460 11.6 575 9.6 400 50 11.6 710

39

Table 18 Control Methods and Cooling Set Points

*Dual set point switch input used. CSP1 used when switch input is open. CSP2 used when switch input is closed. Cooling set point determined from 4 to 20 mA input to energy management module (EMM) to terminals LVT-10,8.

Cooling Set Point Select Table 19 lists cooling set point limits.

Table 19 Cooling Set Point Limits

SINGLE Unit operation is based on Cooling Set Point 1 (Set Points COOLCSP.1). DUAL SWITCH Unit operation is based on Cooling Set Point 1 (Set PointsCOOLCSP.1) when the Dual Set Point switch con- tacts are open and Cooling Set Point 2 (Set PointsCOOL CSP.2) when they are closed. DUAL CCN OCCUPIED Unit operation is based on Cooling Set Point 1 (Set PointsCOOLCSP.1) during the Occupied mode and Cool- ing Set Point 2 (Set PointsCOOLCSP.2) during the Unoc- cupied mode as configured under the local occupancy schedule accessible only from CCN. Schedule Number in Table SCHE- DOVR (See Appendix B) must be configured to 1. If the Schedule Number is set to 0, the unit will operate in a continuous 24-hr Oc- cupied mode. Control method must be configured to 0 (switch). See Table 18. 4 TO 20 MA INPUT Unit operation is based on an external 4 to 20 mA signal input to the Energy Management Module (EMM). Refer to page 30. CONFIGURATION SET POINT LIMITS Table 20 lists configuration set point limits.

Table 20 Configuration Set Point Limits

Ice Mode When Ice Mode is enabled (Configuration OPT2ICE.M), Cooling Setpoint Select (ConfigurationSLCTCLSP) must be set to Dual Switch or Dual CCN Occupied. The Energy Man- agement Module (EMM) must be installed. Unit operation is based on Cooling Setpoint 1 (CSP.1) during the Occupied mode, Ice Setpoint (CSP.3) during the Unoccupied mode with the Ice Done contacts open, and Cooling Setpoint 2 (CSP.2) during the Unoccupied mode with the Ice Done contacts closed. These 3 set points can be utilized to develop your specific control strategy.

Cooling Set Point (4 to 20 mA) A field supplied and generated, externally powered 4 to 20 mA signal input to the Energy Management Module (EMM) can be used to provide the leaving fluid temperature set point. Connect the signal to LVT10,8 (+,). Figure 31 shows how the 4 to 20 mA signal is linearly calculated on an overall 10F to 80F (12.2 to 26.7C) range for fluid types (ConfigurationOPT1FLUD) 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 tempera- ture. See Table 21.

Fig. 31 Cooling Set Point (4 to 20 mA)

CONTROL TYPE

(CTRL)

OCCUPANCY STATE

COOLING SET POINT SELECT (CLSP) 0

(SINGLE) 1

(DUAL, SWITCH) 2

(DUAL, OCC) 3

(4 TO 20 MA)

0 (switch) Occupied ON,CSP1 ON* ON,CSP1 ON Unoccupied ON,CSP1 ON* ON,CSP2 ON

2 (Occupancy) Occupied ON,CSP1 ON* Illegal ON Unoccupied OFF OFF Illegal OFF

3 (CCN) Occupied ON,CSP1 ON* ON,CSP1 ON Unoccupied ON,CSP1 ON* ON,CSP2 ON

SET POINT LIMIT COOLER FLUID TYPE, FLUD

1 = WATER 2 = MEDIUM BRINE MINIMUM 40 F (4.4 C) 14 F (10.0 C) MAXIMUM 70 F (21.1 C)

SET POINT LIMIT COOLER FLUID TYPE (FLUD) 1 = WATER 2 = BRINE

MINIMUM 40F (4.4C) 14F (10.0C) MAXIMUM 60F (15.5C)

EMM Energy Management Module

MAXIMUM SETPOINT 70F(21.1C)

(FLUD=1) MINIMUM SETPOINT 40F(4.4C)

80 (27)

60 (15)

40 (4.4)

20 (-7)

0 (-17)

90 (32)

70 (21)

50 (10)

30 (-1)

10 (-12)

S E

T P

O IN

T F

( C

)

0 2 4 6 8 10 12 14 16 18 20

4 to 20 mA Signal to EMM

22

(FLUD=2) MINIMUM SETPOINT 14F(-10.0C)

40

Table 21 Menu Configuration of 4 to 20 mA Cooling Set Point Control

Low Sound Mode Operation All models are factory configured with the Low Sound Mode dis- abled. In the Configuration mode under sub-mode OPT2, items for Low Sound Mode Select (ConfigurationOPT2LS.MD), Low Sound Start Time (ConfigurationOPT2LS.ST), Low Sound End Time (ConfigurationOPT2LS.ND) and Low Sound Capacity Limit (ConfigurationOPT2LS.LT) are fac- tory configured so that the chiller always runs as quietly as possi- ble. This results in operation at increased saturated condensing temperature. As a result, some models may not be able to achieve rated efficiency. For chiller operation at rated efficiency, 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 addition, 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-in- stalled hydronic system operation can be utilized for heating appli- cations. 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 cooling when the heat relay input is seen. A field-supplied boiler relay connection is made using heat relay and alarm relay contacts. Factory-installed BOILER connections exist in the control panel near LVT for these applications. Alarms and alerts A189 through A202 are active during heating operation.

Service Test Both main power and control circuit power must be on. The Service Test function should be used to verify proper opera- tion of condenser fan(s), compressors, minimum load valve sole- noid (if installed), cooler pump(s), EXVs, and remote alarm relay. To use the Service Test mode, the Enable/Off/Remote Control switch must be in the Off position. Use the Service Test Mode and Sub-Mode Directory table in Appendix A 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 . Press and the 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 compres- sor outputs can be turned on, but the control will limit the rate by staging one compressor per minute. Compressor unloaders and hot gas bypass relays/solenoids (if installed) can be tested with the compressors on or off. The relays 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 com- pressors running. All safeties are monitored during this test and will turn a compressor, a 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 StatusVIEW) will display 0 as long as the Service mode is enabled. The TEST sub-mode value must be changed back to OFF before the chiller can be switched to Enable or Remote Control for normal opera- tion. 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 determine that pumps are rotating correctly. 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.

MODE (RED LED)

KEYPAD ENTRY SUB-MODE KEYPAD

ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT

CONFIGURATION

DISP

UNIT

OPT1

OPT2

HP.A

HP.B

EXV.A

EXV.B

M.MST

RSET

DMDC

SLCT CLSP 0 COOLING SETPOINT SELECT

0 Scrolling Stops

0 Flashing 0

3 Select 3

3 Change Accepted

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER ESCAPE

41

Optional Factory-Installed Hydronic Package If the chiller has factory-installed chilled fluid pumps, specific steps should be followed for proper operation.

Cooler Pump Control The AquaSnap 30RAP machines equipped with a factory-in- stalled pump package are configured with the Cooler Pump Con- trol (ConfigurationOPT1CPC) = ON. Machines not equipped with a pump package are configured 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 re- quired after command to shut machine down is sent before chilled water pump is turned off. This is required to maintain water flow during 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 (i.e., On Local, On CCN, On Time). An A207 Cooler Freeze Protection Alarm will energize the cooler pump relay also, as an override. The cool- er pump relay will remain energized if the machine is in MODE 10 Minimum Off Time.

Cooler Pump Operation Two options of pump operation are available with 30RAP units (ConfigurationOPT1PMP.O). The factory default for PMP.O is 0 (Auto) for automatic. In this mode, the pump will be energized any time the unit is enabled, or for a freeze condition. The pump will be de-energized in any alarm other than A207 Cooler Freeze Protection alarm. If PMP.O is set to 1 (Continuous), the chilled water pump will be energized any time the unit is enabled. If the unit is in an alarm condition, the pump will remain energized. Because of this fea- ture, a High Temperature Cut-Off variable, Configuration OPT1PM.HT has been added for field configuration. If the leaving chilled water temperature exceeds the configured value, the pump will shut off to avoid overheating the chilled loop. The factory default is 95F (35C) and has a range of 95 to 125F (35 to 52C). This variable is only active when PMP.O is set to 1.

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 enabled. 1. Enable-Off-Remote Switch in ENABLE, (CTRL=0). 2. Enable-Off-Remote Switch in REMOTE with a Start-Stop

Remote Control 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 On state to an Off state, the cooler pump output will remain energized for the Cooler Pump Shutdown Delay (ConfigurationOPT1PM.DY). 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 con- figured: Cooler Pump Control (ConfigurationOPT1CPC) =

OFF. Cooler Pump 1 Enable (ConfigurationOPT1 PM1E)

= NO. Cooler Pump 2 Enable (ConfigurationOPT1 PM2E)

= NO.

The maximum load allowed for the Chilled Water Pump Starter is 5 VA sealed, 10 VA inrush at 24 volts. The starter coil is powered from the chiller control system. The starter should be wired be- tween LVT-25 and LVT-21. If equipped, the field-installed chilled water pump starter auxiliary contacts should be connected in se- ries with 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 interlock circuit does not close within five (5) minutes of starting, an A200 Cooler Flow/Inter- lock 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 machine will stop. NO INTEGRAL PUMP DUAL EXTERNAL PUMP CON- TROL With two external pumps, the following options must be config- ured: Cooler Pump Control (ConfigurationOPT1CPC) =

ON. Cooler Pump 1 Enable (ConfigurationOPT1 PM1E)

= YES. Cooler Pump 2 Enable (ConfigurationOPT1 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 pow- ered 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 pumps interlock 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 interlock contacts should be rated for dry cir- cuit 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 (ConfigurationOPT1CPC) =

ON. Cooler Pump 1 Enable (ConfigurationOPT1 PM1E)

= YES. Cooler Pump 2 Enable (ConfigurationOPT1 PM2E)

= NO. With a single integral pump, the Cooler Pump Starter will be ener- gized when the machine is occupied. As part of the factory-in- stalled package, an auxiliary set of contacts is 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/In- terlock Failed to Close at Start-Up Alarm will be generated and chiller will not be allowed 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 Run- ning Alert and an A201 Cooler Flow/Interlock Contacts

42

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, a 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 (ConfigurationOPT1 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 operating, it will be started and operated for 2 seconds starting at 14:00 hours. If the pump is operating, this routine is 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 integral pump package, the following options must be configured: Cooler Pump Control (ConfigurationOPT1CPC) =

ON. Cooler Pump 1 Enable (ConfigurationOPT1 PM1E)

= YES. Cooler Pump 2 Enable (ConfigurationOPT1 PM2E)

= YES. Pump Start Selection is a field-configurable choice. Cooler Pump Select (ConfigurationOPT1PM.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 (Configura- tionOPT1PM.DT) is reached. The Lead Pump (Run StatusVIEWLD.PM) indicates the pump that has been selected as the lead pump: 1 (Pump 1), 2 (Pump 2), 3 (No Pump). The Pump Changeover Hours is factory defaulted to 500 hours. Regardless of the Cooler Pump Selection, 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 inter- lock 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 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/In- terlock 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 Run- ning Alert or T197 Flow Lost While Pump 2 Running Alert for the appropriate pump and an A201 Cooler Flow/Interlock Con- tacts 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 a chilled water pump interlock that opens for 25 seconds after initially being closed is detected by the control, the appropriate T194 Cooler Pump 1 Contacts Opened During Normal Opera- tion Alert or T195 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 is proven, the ma- chine 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, 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, the ap- propriate 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 al- lowed 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. 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 nui- sance alarm. With Cooler Pump Select (ConfigurationOPT1 PM.SL) set to 0 (Automatic) and when the differential time limit Pump Changeover Hours (ConfigurationOPT1PM.DT) is reached, the lead pump will be turned OFF. Approximately one (1) second later, the lag pump will start. Manual changeover can be accomplished by changing Rotate Cooler Pump Now (Config- urationOPT1ROT.P) to YES only if the machine is at Ca- pacity Stage 0 and the differential time limit Pump Changeover Hours (PM.DT) is reached. If the PM.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 rou- tine. With Cooler Pump Select (PM.SL) set to 1 (Pump 1 Starts First) or 2 (Pump 2 Starts First), a manual changeover can be accom- plished by changing PM.SL only. The machine Remote-Off-En- able 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 (ConfigurationOPT1 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) are not operating, then the

43

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 condi- tion, it will not be started that day.

Configuring and Operating Dual Chiller Control 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. 32 and 33 and connected to the master chiller. Refer to Sensors section, page 29, 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 28, for wiring information. Configuration examples are shown in Tables 22 and 23.

Refer to Tables 22 and 23 for dual chiller configuration. In this ex- ample 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 (ConfigurationCCN CCNB) but can- not have the same CCN address (ConfigurationCCN CCNA). Both master and slave chillers must have Lead/Lag Chiller Enable (ConfigurationRSET LLEN) configured to

ENBL. Master/Slave Select (ConfigurationRSETMSSL) must be configured to MAST for the master chiller and SLVE for the slave. Also in this example, the master chiller will be config- ured to use Lead/Lag Balance Select (Configura- tionRSETLLBL) and Lead/Lag Balance Delta (Configura- tionRSETLLBD) to even out the chiller run-times weekly. The Lag Start Delay (ConfigurationRSETLLDY) 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. Parallel configuration (Configura- tionRSETPARA) can only be configured to YES. The vari- ables LLBL, LLBD, and LLDY are not used by the slave chiller. Dual chiller start/stop control is determined by configuration of Control Method (ConfigurationOPT1CTRL) of the Master chiller. The Slave chiller should always be configured for CTRL=0 (Switch). If the chillers are to be controlled by Remote Controls, both Master and Slave chillers should be enabled togeth- er. Two separate relays or one relay with two sets of contacts may control the chillers. The Enable/Off/Remote Control switch should be in the Remote Control position on both the Master and Slave chillers. The Enable/Off/Remote Control switch should be in the Enable position for CTRL=2 (Occupancy) or CTRL=3 (CCN Control). Both chillers will stop if the Master chiller Enable/Off/Remote Control 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 Emergen- cy 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 Con- trol Mode (Run StatusVIEWSTAT) and its operating set- point or Control Point (Run StatusVIEWCT.PT).

Temperature Reset The control system is capable of handling leaving-fluid tempera- ture reset based on return cooler fluid temperature. Because change in temperature through the cooler is a measure of the building load, the return temperature 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), on space temperature (SPT), or from an externally powered 4 to 20 mA signal. Accessory sensors must be used for SPT reset (33ZCT55SPT). The energy management module (EMM) must be used for temperature reset using a 4 to 20 mA signal. See Table 24.

MASTER CHILLER

SLAVE CHILLER

LEAVING FLUID

RETURN FLUID

THERMISTOR WIRING

INSTALL DUAL CHILLER LWT LEAVING FLUID TEMPERATURE THERMISTOR (T10) HERE*

*Depending on piping sizes, use either: HH79NZ014 sensor/10HB50106801 well (3-in. sensor/well) HH79NZ029 sensor/10HB50106802 well (4-in. sensor/well)

Fig. 32 Dual Chiller Thermistor Location

A

B

1/4 N.P.T.

0.505/0.495 0.61 DIA

6 MINIMUM CLEARANCE FOR

THERMISTOR REMOVAL

Fig. 33 Dual Leaving Water Thermistor Well

PART NUMBER

DIMENSIONS IN. (MM) A B

10HB50106801 3.10 (78.7) 1.55 (39.4) 10HB50106802 4.10 (104.1) 1.28 (32.5)

IMPORTANT: Care should be taken when interfacing with other control systems due to possible power supply differences: full wave bridge versus half wave rectification. Connection of control devices with different power supplies may result in per- manent damage. ComfortLink controls incorporate power sup- plies with half wave rectification. A signal isolation device should be utilized if the signal generator incorporates a full wave bridge rectifier.

44

Table 22 Dual Chiller Configuration (Master Chiller Example)

SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS

DISP

UNIT

OPT1

OPT2

CTRL CONTROL METHOD

CTRL 0 SWITCH DEFAULT 0

OPT2

CCN

CCN

CCNA 1 CCN ADDRESS DEFAULT 1

CCNB

CCNB 0 CCN BUS NUMBER DEFAULT 0

CCN

RSET PROCEED TO SUBMODE RESET

RSET

CRST COOLING RESET TYPE

LLEN LEAD/LAG CHILLER ENABLE 15 ITEMS

LLEN DSBL SCROLLING STOPS

DSBL VALUE FLASHES

ENBL SELECT ENBL

LLEN ENBL LEAD/LAG CHILLER ENABLE CHANGE ACCEPTED

LLEN

MSSL MASTER /SLAVE SELECT

MSSL MAST MASTER /SLAVE SELECT DEFAULT MAST

MSSL

SLVA SLAVE ADDRESS

SLVA 0 SCROLLING STOPS

0 VALUE FLASHES

2 SELECT 2

SLVA 2 SLAVE ADDRESS CHANGE ACCEPTED

SLVA

LLBL LEAD/LAG BALANCE SELECT

ENTER

ENTER

ESCAPE

ENTER

ENTER

ESCAPE

ENTER

ENTER

ENTER

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ENTER

ENTER

ESCAPE

45

Table 22 Dual Chiller Configuration (Master Chiller Example) (cont)

NOTES: 1. Master Control Method (CTRL) can be configured as 0-Switch, 2-Occu-

pancy or 3-CCN. 2. Parallel Configuration (PARA) cannot be changed.

SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS

RSET (CONT)

LLBL 0 SCROLLING STOPS

0 VALUE FLASHES

2 SELECT 2 - Automatic

LLBL 2 LEAD/LAG BALANCE SELECT CHANGE ACCEPTED

LLBL

LLBD LEAD/LAG BALANCE DELTA

LLBD 168 LEAD/LAG BALANCE DELTA DEFAULT 168

LLBD

LLDY LAG START DELAY

LLDY 5 SCROLLING STOPS

5 VALUE FLASHES

10 SELECT 10

LLDY 10 LAG START DELAY CHANGE ACCEPTED

LLDY

RSET

PARA YES MASTER COMPLETE

ENTER

ENTER

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ENTER

ENTER

ESCAPE

ESCAPE

ENTER

46

Table 23 Dual Chiller Configuration (Slave Chiller Example)

NOTES: 1. Slave Control Method (CTRL) must be configured for 0. 2. Slave CCN Address (CCNA) must be different than Master.

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.

SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS

DISP

UNIT

OPT1

OPT2

CTRL CONTROL METHOD

CTRL 0 SWITCH DEFAULT 0 (SEE NOTE 1)

OPT2

CCN

CCN

CCNA

CCNA 1 CCN ADDRESS SCROLLING STOPS

1 VALUE FLASHES

2 SELECT 2 (SEE NOTE 2)

CCNA 2 CCN ADDRESS CHANGE ACCEPTED

CCN

CCNB 0 CCN BUS NUMBER DEFAULT 0 (SEE NOTE 3)

CCN

RSET PROCEED TO SUBMODE RSET

RSET

CRST COOLING RESET TYPE

LLEN LEAD/LAG CHILLER ENABLE 15 ITEMS

LLEN DSBL SCROLLING STOPS

DSBL VALUE FLASHES

ENBL SELECT ENBL

LLEN ENBL LEAD/LAG CHILLER ENABLE CHANGE ACCEPTED

LLEN

MSSL MASTER /SLAVE SELECT

MSSL MAST SCROLLING STOPS

MAST VALUE FLASHES

SLVE SELECT SLVE

MSSL SLVE MASTER /SLAVE SELECT CHANGE ACCEPTED

MSSL

RSET SLAVE COMPLETE (SEE NOTE 4)

ENTER

ESCAPE

ENTER

ENTER

ENTER

ESCAPE

ENTER

ESCAPE

ENTER

ENTER

ENTER

ENTER

ESCAPE

ENTER

ENTER

ENTER

ESCAPE

ESCAPE

47

To use outdoor air or space temperature reset, four variables must be configured. In the Configuration mode under the sub-mode RSET, items (ConfigurationRSETCRST), (Configura- tionRSETRM.NO), (ConfigurationRSETRM.F), and (ConfigurationRSETRT.DG) must be properly set. See Table 25. The outdoor air reset example provides 0F (0C) chilled water set point reset at 85.0F (29.4C) outdoor-air tem- perature and 15.0F (8.3C) reset at 55.0F (12.8C) outdoor-air temperature. The space temperature reset example provides 0F (0C) chilled water set point reset at 72.0F (22.2C) space tem- perature and 6.0F (3.3C) reset at 68.0F (20.0C) space tempera- ture. The variable CRST should 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 tem- perature that maximum reset is to occur. The variable RM.DG should be set to the maximum amount of reset desired.

To use return reset, four variables must be configured. In the Con- figuration mode under the sub-mode RSET, items CRST, RT.NO, RT.F and RT.DG must be properly set. See Table 26. This exam- ple provides 5.0F (2.8C) chilled water set point reset at 2.0F (1.1C) cooler T and 0F (0C) reset at 10.0F (5.6C) cooler T. The variable RT.NO should be set to the cooler temperature differ- ence (T) where no chilled water temperature reset should occur. The variable RT.F should be set to the cooler temperature differ- ence where the maximum chilled water temperature reset should occur. The variable RM.DG should be set to the maximum amount of reset desired. To verify that reset is functioning correctly proceed to Run Status mode, sub-mode VIEW, and subtract the active set point (Run StatusVIEWSETP) from the control point (Run Sta- tusVIEWCTPT) to determine the degrees reset. Figures 34- 36 are examples of space, outdoor air, and water temperature re- sets.

Table 24 4 to 20 mA Reset

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 5.0F reset will occur at 20.0 mA. An EMM is required.

Table 25 Configuring Outdoor Air and Space Temperature Reset

*One item skipped in this example.

SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM

EXPANSION COMMENT

RSET CRST 1 COOLING RESET

TYPE

0 = no reset 1 = 4 to 20 mA input 2 = Outdoor air temp 3 = Return Fluid 4 = Space Temperature

MA.DG 5.0 F (2.8 C)

DEGREES COOL RESET

Default: 0F (0C) Reset at 20 mA Range: 30 to 30F (16.7 to 16.7C)

ENTER

MODE (RED LED)

KEYPAD ENTRY

SUB- MODE

KEYPAD ENTRY ITEM

DISPLAY ITEM

EXPANSION COMMENTOUTDOOR AIR SPACE

CONFIGURATION

DISP

UNIT

OPT1

OPT2

CCN

EXV.A

EXV.B

MM

RSET CRST 2 4 COOLING RESET TYPE 2 = Outdoor-Air Temperature 4 = Space Temperature (Connect to LVT-22,23)

RM.NO* 85 F 72 F REMOTE - NO RESET TEMP

Default: 125.0 F (51.7 C) Range: 0 to125 F (17.8 to 51.7 C)

RM.F 55 F 68 F REMOTE - FULL RESET TEMP

Default: 0.0 F (17.8 C) Range: 0 to 125 F (17.8 to 51.7 C)

RM.DG 15 F 6 F REMOTE - DEGREES RESET

Default: 0 F (0 C) Range: 30 to 30 F (16.7 to 16.7 C)

ENTER

ENTER

48

Table 26 Configuring Return Fluid Temperature Reset

*4 items skipped in this example.

MODE (RED LED)

KEYPAD ENTRY SUB-MODE KEYPAD

ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT

CONFIGURATION

DISP

UNIT

OPT1

OPT2

CCN

EXV.A

EXV.B

MM

RSET CRST 3 COOLING RESET TYPE

0 = No Reset 1 = 4 to 20 mA Input (EMM required)

(Connect to LVT-9,8) 2 = Outdoor-Air Temperature 3 = Return Fluid 4 = Space Temperature (Connect to LVT-22,23)

RT.NO* 10.0 F RETURN FLUID - NO RESET TEMP

Default: 10.0 F (5.6 C) Range: 0 to10 F COOLER T (0 to 5.6 C)

RT.F 2.0 F RETURN FLUID - FULL RESET TEMP

Default: 0 F (0 C) Range: 0 to 30 F COOLER T (0 to 16.7 C)

RT.DG 5.0 F RETURN - DEGREES RESET

Default: 0 F (0 C) Range: 30 to 30F (16.7 to 16.7 C)

ENTER ENTER

ENTER

ENTER

ENTER

ENTER

LEGEND LWT Leaving Water (Fluid) Temperature

Fig. 34 Space Temperature Reset

LEGEND LWT Leaving Water (Fluid) Temperature

Fig. 35 Outdoor-Air Temperature Reset

49

LEGEND

Fig. 36 Standard Chilled Fluid Temperature Control No Reset

Under normal operation, the chiller will maintain a constant leav- ing 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. 36. Usually the chiller size and leaving-fluid temperature set point are selected based on a full-load condition. At part load, the fluid temperature set point may be colder than required. If the leaving fluid tempera- ture was allowed to increase at part load, the efficiency of the ma- chine would increase. Return temperature reset allows for the leaving temperature set point to be reset upward as a function of the return fluid tempera- ture or, in effect, the building load (see Fig. 37).

Demand Limit Demand limit is a feature that allows the unit capacity to be limit- ed during periods of peak energy usage. There are 3 types of de- mand limiting that can be configured. The first type is through 2- stage switch control, which will reduce the maximum capacity to 2 user-configurable percentages. The second type is by 4 to 20 mA signal input which will reduce the maximum capacity linearly be- tween 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 capacity to maximum and further reduce the ca- pacity if required. NOTE: The 2-stage switch control and 4 to 20 mA input signal types of demand limiting require the energy management module (EMM).

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 configure demand limit for 2-stage switch control set the De- mand Limit Select (ConfigurationRSETDMDC) to 1. Then configure the 2 Demand Limit Switch points (Configura- tionRSETDLS1) and (ConfigurationRSETDLS2) to the desired capacity limit. See Table 27. Capacity steps are con- trolled by 2 relay switch inputs field wired to LVT as shown in Fig. 6-19. 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 (DLS1). Closing contacts on the second demand limit switch prevents the unit from exceeding the capacity entered as Demand Limit Switch 2 set point. The de- mand limit stage that is set to the lowest demand takes priority if both demand limit inputs are closed. If the demand limit percent- age 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 (ConfigurationRSET DMDC) to 2. Then con- figure the Demand Limit at 20 mA (Configuration RSETDM20) to the maximum loadshed value desired. Con- nect the output from an externally powered 4 to 20 mA signal to terminal block LVT-7,8. 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 Fig. 38 and Table 27.

DEMAND LIMIT (CCN LOADSHED CONTROLLED) To configure Demand Limit for CCN Loadshed control set the Demand Limit Select (ConfigurationRSETDMDC) to 3. Then configure the Loadshed Group Number (Configura- tionRSETSHNM), Loadshed Demand Delta (Configura- tionRSETSHDL), and Maximum Loadshed Time (Config- urationRSETSHTM). 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 com- mand is received, the current stage of capacity is set to the maxi- mum stages available. Should the loadshed control send a Load- shed command, the ComfortLink controls will reduce the current stages by the value entered for Loadshed Demand delta. The Max- imum Loadshed Time is the maximum length of time that a load- shed condition is allowed to exist. The control will disable the Redline/Loadshed command if no Cancel command has been re- ceived within the configured maximum loadshed time limit.

Digital Scroll Option The 30RAP010-090 units have a factory-installed option for a dig- ital scroll compressor which provides additional stages of unload- ing for the unit. The digital compressor is always installed in the

EWT Entering Water (Fluid) Temperature LWT Leaving Water (Fluid) Temperature

0

1

2

3

4

5

6

7

8

9

10

0 1 2 3 4 5 6 7 8 9 10

Reset Amount RT.DG = 5

Design Rise

RT.F = 2

RT.NO = 10

R es

et A

m o

u n

t (

F )

T (F), Entering Fluid Temperature - Leaving Fluid Temperature

0

1

2

3

4

5

6

7

8

9

10

0 1 2 3 4 5 6 7 8 9 10

Reset Amount RT.DG = 5

Design Rise

RT.F = 2

RT.NO = 10

R es

et A

m o

u n

t (

F )

T (F), Entering Fluid Temperature - Leaving Fluid Temperature

Fig. 37 Reset Amount

CAUTION

Care should be taken when interfacing with other manufac- turers control systems, due to possible power supply differ- ences, full wave bridge versus half wave rectification. The two different power supplies cannot be mixed. ComfortLink con- trols use half wave rectification. A signal isolation device should be utilized if a full wave bridge signal generating device is used.

50

A1 compressor location. When a digital compressor is installed, a digital unloader solenoid (DUS) is used on the digital compressor. DIGITAL SCROLL OPERATION A digital scroll operates in two stages the loaded state when the solenoid valve is deenergized and the unloaded state when the solenoid valve is energized. During the loaded state, the com- pressor operates like a standard scroll and delivers full capacity and mass flow. However, during the unloaded state, there is no capacity and no mass flow through the compressor. The capacity of the system is varied by varying the time the compressor operates in an unloaded and loaded state during a 15-second period. If the DUS is ener- gized for 7 seconds, the compressor will be operating at 47% ca- pacity. If the DUS is energized for 10 seconds, the compressor will be operating at approximately 33% of its capacity. Capacity is the time averaged summation of loaded and unloaded states, and its range is continuous from the minimum configured capacity to

100%. Regardless of capacity, the compressor always rotates with constant speed. As the compressor transitions from a loaded to un- loaded state, the discharge and suction pressures will fluctuate and the compressor sound will change. The ComfortLink controller controls and integrates the operation of the DUS into the compressor staging routine to maintain tem- perature control. When a digital compressor is installed, an addi- tional discharge gas temperature thermistor (DTT) is installed along with the AUX board for control of the DUS. DIGITAL COMPRESSOR CONFIGURATION When a digital compressor is installed, the configuration parame- ter (ConfigurationUNITA1.TY) is configured to YES. There is also a maximum unload time configuration (Configura- tionUNITMAX.T) that is set to 7 seconds, which indicates the maximum unloading for the digital compressor is 47%. This is done to optimize efficiency of the system.

Table 27 Configuring Demand Limit

*Seven items skipped in this example.

MODE KEYPAD ENTRY SUB-MODE KEYPAD

ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT

CONFIGURATION DISP

UNIT

OPT1

OPT2

CCN

EXV.A

EXV.B

MM

RSET CRST X Cooling Reset Type

DMDC* X Demand Limit Select

Default: 0 0 = None 1 = Switch 2 = 4 to 20 mA Input 3 = CCN Loadshed

DM20 XXX % Demand Limit at 20 mA Default: 100% Range: 0 to 100

SHNM XXX Loadshed Group Number

Default: 0 Range: 0 to 99

SHDL XXX% Loadshed Demand Delta

Default: 0% Range: 0 to 60%

SHTM XXX MIN Maximum Loadshed Time

Default: 60 min. Range: 0 to 120 min.

DLS1 XXX % Demand Limit Switch 1

Default: 80% Range: 0 to 100%

DLS2 XXX % Demand Limit Switch 2

Default: 50% Range: 0 to 100%

ENTER ENTER

ENTER

ENTER

ENTER

ENTER

51

PRE-START-UP

Do not attempt to start the chiller until the following checks have been completed.

System Check 1. Check all auxiliary components, such as chilled fluid 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 has field-installed accessories, be sure all are properly installed and wired correctly. Refer to unit wiring diagrams.

2. Use the scrolling marquee display to adjust the Cooling Set Point.

3. 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 system. If chilled water is to be maintained at a temperature below 40F (4.4C) or outdoor temperatures are expected to be below 32F (0C), an antifreeze of sufficient concentration must be used to prevent freeze-up at anticipated suction temperatures. The chilled water loop must be cleaned before the unit is connected. NOTE: On units with digital scroll option do not check re- frigerant charge if compressor is operating at less than 100% capacity, digital operation can be disabled by configuring A1.TY = NO (ConfigurationUNITA1.TY)

4. Check tightness of all electrical connections. 5. Oil should be visible in the compressor sight glass(es). See

Fig. 39. For unit sizes 010-090, an acceptable oil level is from 1/8 to 3/8 of sight glass. For unit sizes 100-150, an acceptable oil level is from 3/4 to 7/8 of sight glass. No oil should be removed unless the crankcase heater, if equipped, has been energized for at least 24 hours. Adjust the oil level as required. See Oil Charge section on page 60 for Carrier approved oils.

6. Electrical power source must agree with unit nameplate. 7. All condenser fan and factory-installed hydronic package

pump motors are phase. For non-HEVCF units, check for

proper rotation of condenser fans first BEFORE attempting to start pumps or compressors. For HEVCF units, check the phase to ensure the supply power phase rotation is clockwise A-B-C (L1-L2-L3). To reverse rota- tion, interchange any two of the main incoming power leads.

8. Be sure system is fully charged with refrigerant (see Check Refrigerant Charge section on page 52).

9. 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.

START-UP AND OPERATION NOTE: Refer to Start-Up Checklist on pages CL-1 to CL-12.

50% CAPACITY AT 20 mA

75% CAPACITY AT 12 mA

100% CAPACITY AT 4 mA

0 2 4 6 8 10 12 14 16 18 20 DEMAND LIMIT SIGNAL 4 - 20 mA INPUT

100

80

60

40

20

0

M A

X . A

LL O

W A

B LE

L O

A D

( %

)

Fig. 38 4 to 20-mA Demand Limiting

IMPORTANT: Before beginning Pre-Start-Up or Start-Up, complete Start-Up Checklist for 30RAP Liquid Chiller at end of this publication (pages CL-1 to CL-12). The checklist assures proper start-up of a unit, and provides a record of unit condition, application requirements, system information, and operation at initial start-up.

CAUTION

Crankcase heaters, if equipped, are wired into the control cir- cuit, so they are always operable as long as the main power supply disconnect is on (closed), even if any safety device is open. Compressor heaters must be on for 24 hours prior to the start-up of any compressor. Equipment damage could result if heaters are not energized for at least 24 hours prior to com- pressor start-up.

OIL SIGHT GLASS

Fig. 39 Sight Glass Location

a30-5515

52

Crankcase Heaters Unit sizes 070-150 are equipped with crankcase heaters. Unit sizes 010-060 require field-installed crankcase heater(s) if remote cool- er accessory is utilized. Compressor crankcase heaters, if equipped, must be on for 24 hours before start-up. To energize the crankcase heaters, close the field disconnect and turn on the fan circuit breakers. Leave the compressor circuit breakers off/open. The crankcase heaters are now energized.

Actual Start-Up Actual start-up should be done only under supervision of a quali- fied refrigeration mechanic. 1. Be sure all service valves are open. 2. Using the scrolling marquee display, set leaving-fluid set

point (Set PointsCOOLCSP.1). No cooling range adjustment is necessary.

3. Start chilled fluid pump (if not configured for cooler pump control).

4. Turn Enable/Off/Remote Control 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 PointsCOOL CSP.1) or (Set PointsCOOLCSP.2), or if reset is used, with the control point (Run StatusVIEW CTPT).

6. Check the cooler leaving chilled water temperature to see that it remains well above 32F (0C), or the brine freezing point if the unit is a medium temperature brine unit.

7. Recheck compressor oil level (see Oil Charge section).

Check Refrigerant Charge All 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. Af- ter leaks are repaired, the system must be dehydrated. All refrigerant charging should be done through the 1/4 in. Schrad- er connection on the liquid line. Do NOT add refrigerant charge through the low-pressure side of the system. If complete charging is required, weigh in the appropriate charge for the circuit as shown on the unit nameplate. If partial charging is required, oper- ate circuit at full load and use an accurate temperature sensor on the liquid line as it enters the filter drier. Use the Temperatures mode on the scrolling marquee display to show the circuit saturat- ed condensing temperature (TemperaturesCIR.ASCT.A) or (TemperaturesCIR.BSCT.B). Charging is most accurate at saturated discharge temperatures of 120 to 125F (49 to 52C). Block condenser airflow as required to reach this temperature range. Add refrigerant until the system subcooling (SCT.A or SCT.B minus liquid line temperature entering EXV) is

approximately 15 to 17F (9.4 to 8.3C). Refrigerant VAPOR only may be added to a circuit through the 1/4 in. suction Schrader connection on the suction line.

Charge Adjustment for Brine Operation For 30RAP010-060 units, the 30RAP chiller does not require a medium temperature brine modification at any temperature within the chiller application range which is as low as 14F (10C) leav- ing fluid temperature. For 30RAP070-150 units with MCHX condenser, see Table 28 for proper charge adjustment. For 30RAP070-150 units with RTPF condenser, no charge adjustment is needed.

Operating Limitations COOLER FLOW RATES AND LOOP VOLUMES Refer to Table 29 for minimum and maximum cooler flow rates, and to Table 30 for minimum fluid volume requirements. TEMPERATURES (See Table 31 for 30RAP standard tempera- ture limits.)

High Cooler Leaving Chilled Water (Fluid) Temperatures (LCWT) During start-up with cooler LCWT above approximately 60F (16C), the unit expansion valve will limit suction pressure to ap- proximately 142 psig (929 kPa) to avoid overloading the compres- sor. Low Cooler LCWT For standard units, the LCWT must be no lower than 40F (4.4C). If the unit is the factory-installed optional medium tem- perature brine unit, the cooler LCWT can go down to 15F (9.4C).

Table 28 Charge Adjustment for Brine Operation

CAUTION

Never charge liquid into low-pressure side of system. Do not overcharge. Overcharging results in higher discharge pres- sure, possible compressor damage, and higher power con- sumption. During charging or removal of refrigerant, be sure water is continuously circulating through the cooler to prevent freezing.

CAUTION

Do not operate with cooler leaving chiller water (fluid) tem- perature (LCWT) below 40F (4.4C) without an appropriate concentration of an inhibited antifreeze solution. Units should not be operated below 15F (9.4C) when configured for medium temperature brine. Damage to the cooler and/or com- pressor(s) may result.

CHARGE TO BE REMOVED FROM BRINE OPERATION (LB) 30RAP UNIT SIZE 070 080 090 100 115 130 150

LEAVING BRINE TEMPERATURE Ckt A

Ckt B

Ckt A

Ckt B

Ckt A

Ckt B

Ckt A

Ckt B

Ckt A

Ckt B

Ckt A

Ckt B

Ckt A

Ckt B

44F-35F No Change is Needed 34F-15F 0.8 1.1 1.1 1.1 1.1 1.1 1.1 2.0 2.0 2.0 2.0 3.0 3.0 3.0

53

Table 29 Minimum Cooler Flow Rates

Table 30 Minimum Fluid Volume in Circulation

LEGEND

Table 31 Temperature Limits for Standard 30RAP Units

LEGEND

*For sustained operation, EWT should not exceed 85 F (29.4 C).

LOW-AMBIENT OPERATION If operating temperatures below 45F (7C) on size 018-030 units, and 32F (0C) on size 035-150 units are expected, accessory Mo- tormaster V control must be installed. Operating temperatures can go as low as 20F (29C) on size 010-016 units, as standard, and all Greenspeed units. Installation of wind baffles is also re- quired. Refer to separate installation instructions for operation us- ing this accessory. Contact your Carrier representative for details.

VOLTAGE ALL UNITS Main Power Supply Minimum and maximum acceptable supply voltages are listed in the Installation Instructions. Unbalanced 3-Phase Supply Voltage Never operate a motor where a phase imbalance between phases is greater than 2%. To determine percent voltage imbalance:

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.

AB = 243 v BC = 236 v AC = 238 v

1. Determine average voltage:

30RAP UNIT SIZE

MINIMUM COOLER FLOW RATE (GPM)

MAXIMUM COOLER FLOW RATE (GPM)

MINIMUM COOLER FLOW RATE (L/S)

MAXIMUM COOLER FLOW RATE (L/S)

010 13 50 0.8 3.2 011 13 45 0.8 2.8 015 17 66 1.1 4.2 016 20 63 1.3 3.9 018 20 78 1.3 4.9 020 23 91 1.5 5.7 025 28 112 1.8 7.1 030 33 133 2.1 8.4 035 41 164 2.6 10.3 040 47 186 3.0 11.7 045 53 209 3.3 13.2 050 57 228 3.6 14.4 055 63 251 4.0 15.8 060 68 270 4.3 17.0 070 86 310 5.4 19.6 080 98 355 6.2 22.4 090 107 387 6.8 24.4 100 123 444 7.8 28.0 115 140 503 8.8 31.7 130 158 569 10.0 35.8 150 175 629 11.0 39.6

30RAP UNIT SIZE

NORMAL AIR CONDITIONING APPLICATION

GAL/TON (L PER kW)

PROCESS COOLING, LOW AMBIENT OPERATION, OR MEDIUM TEMPERATURE BRINE

APPLICATIONS GAL/TON (L PER kW)

STD UNIT HGBP DIGITAL STD UNIT HGBP DIGITAL 010-016 12 (13) N/A 3 (3.3) 12 (13) N/A 6 (6.5) 018-030 6 (6.5) 4 (4.3) 3 (3.3) 10 (10.8) 10 (10.8) 6 (6.5) 035-150 3 (3.3) 3 (3.3) 3 (3.3) 6 (6.5) 6 (6.5) 6 (6.5)

HGBP Hot Gas Bypass

30RAP UNIT SIZE 010-030 035-150 Temperature F C F C Maximum Ambient Temperature 120 49 120 49

Minimum Ambient Temperature 45 7 32 0

Maximum Cooler EWT* 95 35 95 35 Maximum Cooler LWT 70 21 70 21 Minimum Cooler LWT 40 4.4 40 4.4

EWT Entering Fluid (Water) Temperature LWT Leaving Fluid (Water) Temperature

CAUTION

Brine duty application (below 40F [4.4C] LCWT) requires an appropriate concentration of an inhibited antifreeze solution and may require low ambient head pressure control and wind baffles for proper operation. Contact your Carrier representa- tive for additional information for the specific application.

% Voltage Imbalance = 100 x max voltage deviation

from avg voltage average voltage

Average voltage = 243 + 236 + 238 3

= 717 3

= 239

54

2. Determine maximum deviation from average voltage: (AB) 243 239 = 4 v (BC) 239 236 = 3 v (AC) 239 238 = 1 v Maximum deviation is 4 v.

3. Determine percent voltage imbalance:

This voltage imbalance is satisfactory as it is below the maximum allowable of 2%.

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 tem- perature. If the ambient temperature drops below 40F (4.4C), cooler and hydronic system heaters (if either are factory installed) are energized. The unit is started by putting the Enable/Off/Remote Control switch in the ENABLE or Remote Control position. When the unit receives a call for cooling (either from the internal control or CCN network command or Remote Control closure), the unit stages up in capacity to maintain the leaving fluid set point. The first compressor starts 1-1/2 to 3 minutes after the call for cooling. The lead circuit can be specifically designated on all models or se- lected based on compressor run hours and starts depending on field configuration. The unit control will override this selection under certain starting conditions to properly maintain oil return to the compressors. In general, on dual compressor circuits, the con- trol will most often start the A1 or B1 compressor first, especially after long off periods. The MBB controls fan stages to maintain the head pressure set point and will automatically adjust unit ca- pacity as required to keep compressors from operating outside of the specified envelope. There are no pumpout or pumpdown se- quences on these chillers. For all units, if temperature reset is being used, the unit controls to a higher leaving-fluid temperature as the building load reduces. If demand limit is used, the unit may temporarily be unable to main- tain the desired leaving-fluid temperature because of imposed power limitations.

SERVICE

Electronic Components CONTROL COMPONENTS Unit uses an advanced electronic control system that normally does not require service.

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 compres- sor(s) and all components of the refrigeration system. 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 035-150 gives access to the controls. Inner panels are secured in place and should not be removed un- less all power to the chiller is off.

Electronic Expansion Valve (EXV) See Fig. 40 for a cutaway view of the EXV. High-pressure liquid refrigerant 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 windings for rotation in either direction. The direction depends on the phase relationship of the power pulses. As the stepper motor rotates, its motion is transferred to linear movement by a lead screw. Refrigerant flow is modulated by ei- ther opening or closing the port. The valve includes a positive shut-off when closed.

There are four different EXVs. Table 32 shows the number of steps, by unit size, for each type of EXV. The EXV motor moves at 200 or 150 steps per second, respectively, for sizes 010-060 or sizes 070-150. Commanding the valve to either 0% or 100% will add extra steps to the move, to ensure the value is open or closed completely.

Table 32 EXV Steps

The 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 pressure transducer is

% Voltage Imbalance = 100 x 4 239

= 1.7%

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediate- ly. Do not operate unit until imbalance condition is corrected.

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.

UNIT SIZE 30RAP EXV STEPS 010-020 1596 025,030 2500 035-045 1596 050-060 2500

070-090, 100 CKT A 2785 100 CKT B, 110-150 3690

1. Cable 2. Glass Seal 3. Motor Housing 4. Stepper Motor 5. Bearing 6. Lead Screw 7. Insert 8. Valve Piston 9. Valve Seat 10. Valve Port

Fig. 40 Cutaway View of the Electronic Expansion Valve (Size 070-150 Shown)

55

converted to a saturated suction temperature. The thermistor mea- sures the temperature of the superheated gas entering the compressor and the pressure transducer determines the saturated temperature of suction gas. The difference between the tempera- ture of the superheated gas and the saturated suction temperature is the superheat. The EXV board controls the position of the elec- tronic expansion valve stepper motor to maintain superheat set point. The MBB controls the superheat leaving cooler to approximate- ly 9F (5C). 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 temperatures the EXV is closed at start-up. After initialization period, valve position is tracked by the EXV board by constantly monitoring the amount of valve movement. The EXV is also used to limit cooler saturated suction temperature to 50F (10C). This makes it possible for the chiller to start at higher cooler fluid temperatures without overloading the compres- sor. This is commonly referred to as MOP (maximum operating pressure). At ambient temperatures above 110F (43C), MOP is bypassed at start-up to prevent charge backup in the condenser. If it appears that the EXV module is not properly controlling cir- cuit operation to maintain correct superheat, there are a number of checks that can be made using test functions and initialization fea- tures built into the microprocessor control. See the EXV Trouble- shooting Procedure section to test EXVs.

EXV Troubleshooting Procedure Follow steps below to diagnose and correct EXV problems. Check EXV motor operation first. Switch the Enable/Off/Remote Control (EOR) switch to the Off position. Press on the scrolling marquee until the display is blank or on Navigator dis- play until Select a menu item appears on the display. Use the ar- row keys to select the Service Test mode. Press . The display will be:

> TEST OFF OUTS COMP

Press (password entry may be required) and use to change OFF to ON. Switch the EOR 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 EXV.A or EXV.B as needed. Press and the valve position will flash. Use to select 100% valve position (hold for quick move- ment) and press . The technician should be able to feel the actuator moving by plac- ing a hand on the EXV. A sight glass is located on the valve body to verify that the actuator is moving. A hard knocking should be felt from the actuator when it reaches the top of its stroke (can be heard if surroundings are relatively quiet). Press again twice if necessary to confirm this. To close the valve, press , select 0% with and press . 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 be- low. Check the EXV output signals at appropriate terminals on the EXV board (see Fig. 41 or 42). Do not disconnect EXV connector with power applied to the board. Damage to the board may result if disconnected while under power. Connect positive test lead to EXV-J6 terminal 3 for Circuit A, EXV-J7 terminal 3 for Circuit B. Set meter to approximately 20 vdc. Using the Service Test proce- dure above, move the valve output under test to 100%. DO NOT short meter leads together or pin 3 to any other pin as board dam- age will occur.

During the next several seconds, carefully connect the negative test lead to pins 1,2,4 and 5 in succession (plug J6 for Circuit A, plug J7 for Circuit B). Digital voltmeters will average this signal and display approximately 6 vdc. If it remains constant at a volt- age 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-position DIP switch on the board (all switches should be set to On). If a problem still exists, replace the EXV board. If the reading is cor- rect, the expansion valve and EXV wiring should be checked. 1. Check color coding and wire connections. Make sure they

are connected to the correct terminals at the EXV board and EXV plug and that the cables are not crossed.

2. Check for continuity and tight connection at all pin terminals. 3. If the motor fails to operate properly, check the resistance of

each motor phase. Remove the EXV Board connector (J6 for Circuit A, J7 for Circuit B). Check the resistance of the two windings. Resistance between pins 1 and 2 for one winding or between pins 4 and 5 for the other winding should be approximately 100 10 ohms (sizes 010-060) or 52 5.2 ohms (sizes 070-150). Differences of more than 10% between windings indicate a defective motor. Resistance between any lead and ground should be infinite or open. Any resistance reading will indicate a shorted winding and the valve will need to be replaced.

FIELD SERVICING INSTRUCTIONS EXVs on sizes 025, 030, and 050-150 can be serviced. See Fig. 40 for a cutaway view of the EXV for sizes 070-150. Motor kits for the EXVs on sizes 025, 030, and 050-150 are available as replace- ment parts. The EXVs on sizes 010-020 and 035-045 are hermetic and cannot be disassembled for installation or during service. EXV REPLACEMENT (ALL SIZES) To replace the valve, perform the following procedure: 1. Be sure the refrigerant has been recovered from the circuit. 2. Disconnect the EXV cable from the EXV. For sizes 010-

060, refer to Fig. 41 or 42 and remove the EXV retainer clip, taking care not to damage the clip as it will be required for installation later.

3. The valve may be replaced by cutting the piping. A tubing cutter must be used to prevent creating contaminants in the piping.

4. The EXVs have copper connections and any brazing alloy can be used to install the valve. During installation the torch flame should be directed away from the valve body and cable. The valve body should be wrapped with a wet cloth during the brazing operation. Be sure to use a nitro- gen purge while brazing the valve in place.

5. Check for refrigerant leaks. 6. Once the valve body has cooled, reconnect the EXV cable.

Care should be taken to ensure engagement of the align- ment key. On sizes 010-060, install the EXV cable retainer clip.

7. Check the operation of the valve using the EXV Trouble- shooting Procedure on page 55.

ESCAPE

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER

ENTER

CAUTION

Do not disconnect EXV connector with power applied to the board. Damage to the board may result if disconnected while under power. DO NOT short meter leads together or pin 3 to any other pin as board damage will occur.

ENTER

56

VALVE MOTOR REPLACEMENT Sizes 025, 030, and 050-060

Perform the following procedure to replace the EXV motor: 1. Be sure the refrigerant has been recovered from the circuit. 2. Remove power from the EXV board. 3. Refer to Fig. 43 and remove the EXV retainer clip, taking

care not to damage the clip as it will be required for installa- tion later.

4. Using a wrench and back-up wrench, remove the motor assembly from the EXV body by placing the back-up wrench on the valve body.

5. To install the motor, be sure to use a new gasket. Connect the EXV cable to the EXV motor assembly.

6. Use Service Test as described on page 40 to open the EXV to 100%. This will retract the piston fully. Remove power from the EXV board prior to removing the EXV cable. Remove the EXV cable from the motor prior to installation. For 025, 030, 050-060 sizes, replacement motors are shipped in the

retracted position and may be installed as received; therefore, this step may be skipped if installing a new motor.

7. Lightly oil the threads and gasket on the new motor. Carefully seat the motor on the valve body. Using a wrench and back- up wrench as described above, tighten the motor assembly as follows: one eighth turn more than hand tight is sufficient to achieve a leak proof seal.

8. After the motor is tightened, the cable should be replaced on the valve. Care should be taken to ensure engagement of the alignment key. Install the EXV cable retainer clip (see Fig. 43).

9. Pressurize the system and check for leaks. 10. Reapply control power and test the operation using Service

Test. Sizes 070-150

Perform the following procedure to replace the EXV motor: 1. Be sure the refrigerant has been recovered from the circuit. 2. On sizes 070-150, use Service Test as described on page

40 to open the EXV to 100%. This will retract the piston fully.

3. Remove power from the EXV board and then disconnect the EXV cable from the EXV.

4. Using a wrench and back-up wrench, remove the motor assembly from the EXV body. Be sure to place the back- up wrench on the adapter to remove the motor as shown in Fig. 44.

5. To install the motor, be sure to use a new gasket. 6. Manually depress the valve piston before installing the

motor assembly. This will allow for the lead screw to engage the piston as the motor is installed.

7. Lightly oil the threads and gasket on the new motor. Care- fully seat the motor on the valve body. Using a wrench and back-up wrench as described above, tighten the motor assembly as follows: Tighten the motor to 36 ft-lb (50 Nm) and then tighten an additional 30 degrees as indicated in Fig. 44.

8. After tightening the motor, replace the cable on the valve. Care should be taken to ensure engagement of the align- ment key. Pressurize the system and check for leaks.

9. Reapply control power and test the operation using Ser- vice Test.

IMPORTANT: Obtain replacement gasket before opening EXV. Do not re-use gaskets.

BLK WHT

GRN

RED

BLK WHT

GRN

RED

Fig. 41 30RAP010-060 EXV Cable Connections to EXV Module

a30-4972

Fig. 42 30RAP070-150 EXV Cable Connections to EXV Module

WHT BRN

BLK

BLU

WHT BRN

BLK

BLU

CAUTION

If the existing motor has been removed for inspection or clean- ing, be sure that the piston is fully retracted into the motor 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.

IMPORTANT: Obtain replacement gasket before opening EXV. Do not re-use gaskets.

57

Compressor Replacement (Fig. 45-47) All models contain scroll compressors and have from one to six compressors. The size 010-030 units are a single refrigeration cir- cuit while sizes 035-150 are dual circuit. Disconnect power to unit using lockout tagout procedures. Remove the junction box cover bolts (Danfoss compressors only) and disconnect the compressor power and ground connections. Remove the cable from the compressor junction box. 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 hardware for use with the new compressor. Carefully cut the compressor suction and discharge lines with a tubing cutter as close to the compressor

SPORLAN

MOTOR AND ADAPTER ASSEMBLY

CABLE

CABLE

CABLE RETAINER

CABLE RETAINER CLIP

MOTOR ADAPTER ASSEMBLY

MOTOR ADAPTER ASSEMBLY

INCLUDED IN CABLE KIT

GASKET

SIGHTGLASS

FLOW DIRECTION

NORMAL FLOW DIRECTION

Fig. 43 Electronic Expansion Valve Details (010-060)a30-4971

CLOSED

OPEN

CLOSED

OPEN

GASKET

OPEN VALVE IN QUICK TEST SUB-MODE BEFORE DISASSEMBLING

EF05BD271 NV 32.5mm EF05BD331 NV 36mm

50Nm (36 ft-lb)+ 30 27mm / 11/16''

27mm / 11/16''

ADAPTER

DISASSEMBLY

ASSEMBLY

NOTES: 1. Push down on valve piston to close valve before assembling. 2. After valve is assembled close valve in Quick Test sub-mode or cycle power before opening service valve.

Fig. 44 Disassembly and Assembly of EXV Motor (070-150)

NOTE: Open valve in Quick Test sub-mode before disassembling.

a30-4072ef

58

as feasible. Remove high-pressure switch and pressure transduc- er(s) if required for compressor removal. Lift one corner of the compressor at a time and remove all the rubber mounting grom- mets (single compressor circuits) or steel spacers (dual compres- sor circuits). Remove the old compressor 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 compressor mount- ing grommets. Using new tubing as required, reconnect compres- sor suction and discharge lines. Using hardware saved, reinstall

the mounting bolts and washers through the compressor feet. Us- ing proper techniques, braze suction and discharge lines and check for leaks. Reconnect oil equalization line on dual compressor cir- cuit models. Reconnect the compressor power connections and high-pressure switch wiring as on the old compressor. Refer to Fig. 45-47. Fol- lowing the installation of the new compressor, tighten all hardware to the following specifications. (See Table 33.)

SUCTION ACCESS VALVE

FLOW SWITCH

LWT DTT

EWT

RGT

SPT

HPSDPT

COMPRESSOR A1

COMPRESSOR A2

Fig. 45 Component Location 30RAP010-030

a30-4973

LEGEND DPT Discharge Pressure Thermostat DTT Discharge Temperature Thermistor EWT Entering Water Thermistor HPS High Pressure Switch LWT Leaving Water Thermistor RGT Return Gas Thermistor SPT Suction Pressure Transducer

A1

A2

B1

B2 OIL SIGHT GLASS

DISCHARGE ACCESS VALVE

FLOW SWITCH

LWT

DTT

DISCHARGE ACCESS VALVE

DPT HPS

RGT SPT SUCTION ACCESS VALVE

RGTSPT

DPT HPS

EWT

LEGEND DPT Discharge Pressure Thermostat DTT Discharge Temperature Thermistor EWT Entering Water Thermistor HPS High Pressure Switch LWT Leaving Water Thermistor RGT Return Gas Thermistor SPT Suction Pressure Transducer

Fig. 46 Component Location 30RAP035-060

a30-4974

59

Table 33 Unit Torque Specification Crankcase Heater The 30RAP070-150 units are equipped with crankcase heaters. 30RAP070-090 units utilize a 90-watt heater on each compressor. See Fig. 48. 30RAP100-150 units utilize a 56-watt heater secured to the bottom of each compressor (see Fig. 49). The 30RAP010- 060 units are not equipped with crankcase heaters because the sys- tem refrigerant charge is less than the compressor manufacturers requirement. Crankcase heaters are required on all units installed with remote coolers. Refer to remote cooler installation instructions for more information.

A1 A2

A3

B1 B2

B3

ONLY ON SIZE 080,090,115,130,150 UNITS

DTT RGT

SPT

DPT

HPS

DISCHARGE ACCESS VALVE

OIL SIGHT GLASS

DPT, HPS (NOT SHOWN

LOCATED BEHIND A1)

Fig. 47 Component Location 30RAP070-150

a30-5373

LEGEND DPT Discharge Pressure Thermostat DTT Discharge Temperature Thermistor HPS High Pressure Switch RGT Return Gas Thermistor SPT Suction Pressure Transducer

FASTENER RECOMMENDED TORQUE Compressor Mounting Bolts

7 to 10 ft-lb (9.5 to 13.5 Nm)

Compressor Power Connections

24 to 28 in.-lb (2.7- to 3.2 Nm)

Compressor Ground Terminal Connections

14 to 18 in.-lb (1.6 to 2.0 Nm)

Fig. 48 Crankcase Heater Location, 30RAP070-090

A = 9/16 in. 15/16 in. B = 1/2 in. 11/16 in.

A B

a30-5736

60

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 heat exchanger. The unit insulation covers the manufacturers part number. Make sure the depths of the replacement and original cooler heat exchangers are the same.

2. Disconnect the liquid-in and liquid-out connections at the heat exchanger.

3. Recover the refrigerant from the system, and unsolder the refrigerant-in and refrigerant-out connections.

4. Remove the old heat exchanger. Save the mounting hard- ware for use with the replacement heat exchanger. The replacement heat exchanger is supplied fully insulated. It also includes a cooler heater. Use of the heater is not required unless the original cooler contained a factory- installed heater.

5. Install the replacement heat exchanger in the unit and attach the mounting bracket hardware to the fan uprights (sizes 010-030) or to the bottom bracket (sizes 035-150) using the hardware removed in Step 4. Reconnect the cooler heater if required. For sizes 010-025, torque the bolts to 7 to 10 ft-lb (9.5 to 13.5 Nm). For sizes 030-150, torque the bolts to 30 to 50 ft-lb (40.6 to 67.7 Nm).

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 1472F (800C) under nor- mal soldering conditions (no vacuum) to prevent the cop- per solder of the brazed plate heat exchanger from changing its structure. Failure to do so can result in inter- nal or external leakage at the connections which cannot be repaired. Braze the liquid lines with a heat sink around 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 CLEAN- ING Brazed-plate heat exchangers must be cleaned chemically. A pro- fessional cleaning service skilled in chemical cleaning should be

used. Use a weak acid (5% phosphoric acid, or if the heat ex- changer 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 in- lets of the heat exchangers should be cleaned periodically, depend- ing on condition of the chiller water/brine.

Oil Charge

Puron refrigerant systems use a polyolester (POE) oil. Use only Carrier-approved compressor oil. Oil should be visible in com- pressor oil sight glass. An acceptable oil level is from 1/8 to 3/8 of sight glass for unit size 010-090, and 3/4 to 7/8 of sight glass for unit size 100-150. All compressors 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 compressor Schrader on the three-compressor circuits and single-compressor circuits. (See Fig. 45-47.) When oil can be seen at the bottom of the sight glass, add oil in 5 oz increments which is approximately 1/8 of 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. Oil Type. . . . . . . . . . . . . . . . . Inhibited polyolester-based

synthetic compressor lubricant. ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Approved sources are: UNIT SIZES 010-090 MANUFACTURER OIL Totaline . . . . . . . . . . . . . . . . . . . . . . 3MAF POE, P903-1601 Mobil . . . . . . . . . . . . . . . . . . . . . . . . . . .EAL Arctic 32-3MA Uniqema (ICI) . . . . . . . . . . . . . . . Emkarate RL32-3MAF

HEATER PAD

INSULATION

RETAINING CLIPS

Fig. 49 Crankcase Heater Detail Under Compressor, 30RAP100-150

a30-5737

CAUTION

The compressor in a Puron refrigerant (R-410A) system uses a polyolester (POE) oil. This is extremely hygroscopic, mean- ing it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refriger- ants. Take all necessary precautions to avoid exposure of the oil to the atmosphere. Failure to do so could result in possible equipment damage.

61

UNIT SIZES 100-150 MANUFACTURER OIL Totaline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P903-2401 Uniqema (ICI) . . . . . . . . . . . . . . . . . . . Emkarate RL 32H

Do not reuse drained oil or any oil that has been exposed to the atmosphere.

Microchannel Heat Exchanger Condenser Coil Maintenance and Cleaning Recommendations

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 ex- tend 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 coil

face 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 condenser coils. Only clean, potable water is authorized for cleaning condenser coils.

4. Clean condenser face by spraying the coil steadily and uni- formly from top to bottom while directing the spray straight toward the coil. Do not exceed 900 psig or 30 degree angle. The nozzle must be at least 12 in. from the coil face. Reduce pressure and use caution to prevent damage to air centers.

Round Tube Plate Fin (RTPF) Condenser Coil Maintenance and Cleaning Recommendations 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 ex- tend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil. REMOVE SURFACE LOADED FIBERS Surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be ap- plied in the direction of the fins. Coil surfaces can be easily dam- aged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins. NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse. PERIODIC CLEAN WATER RINSE A periodic clean water rinse is very beneficial for coils that are ap- plied in coastal or industrial environments. However, it is very im- portant that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning is rec- ommended. ROUTINE CLEANING OF COIL SURFACES Routine cleaning with Totaline environmentally balanced coil cleaner is essential to extend the life of coils. This cleaner is avail- able from Carrier Replacement parts division as part number

P902-0301 for a one-gallon container, and part number P902-0305 for a 5-gallon container. It is recommended that all coils, including the standard copper tube aluminum fin, pre-coated fin, copper fin, or e-coated coils be cleaned with the Totaline environmentally bal- anced coil cleaner as described below. Coil cleaning should be part of the units regularly scheduled maintenance procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment. Avoid the use of: coil brighteners acid cleaning prior to painting high pressure washers poor quality water for cleaning Totaline environmentally balanced coil cleaner is non-flammable, hypoallergenic, nonbacterial, and a USDA accepted biodegrad- able agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

Check Refrigerant Feed Components FILTER DRIER The function of the filter drier is to maintain a clean, dry system. The moisture indicator (described below) indicates any need to change the filter drier. The filter drier is a sealed-type drier. When the drier needs to be changed, the entire filter drier must be replaced. NOTE: Dual circuit (035-150 sizes) units have 1 filter drier per circuit. MOISTURE-LIQUID INDICATOR The indicator is located immediately ahead of the EXV 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 sufficient charge in the system. Bubbles in the sight glass (at full unit loading) indicate an undercharged sys- tem or the presence of noncondensables. Moisture in the system, measured in parts per million (ppm), changes the color of the indi- cator 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 liquid refrigerant. At the first sign of moisture in the system, change the corresponding filter drier. NOTE: Dual circuit (035-150 sizes) units have one indicator per circuit. MINIMUM LOAD VALVE On units equipped with the factory-installed capacity reduction option, a solenoid valve and discharge bypass valve (minimum load valve) are located 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 minimum load valve is not adjustable. The total unit capacity with the minimum load valve is shown in Table 13. PRESSURE RELIEF DEVICES All units have one pressure relief device per circuit located in the liquid line which relieves at 210F (100C).

CAUTION

Do not apply any chemical cleaners to MCHX condenser coils. These cleaners can accelerate corrosion and damage the coil.

CAUTION

Excessive water pressure will fracture the braze between air centers and refrigerant tubes.

62

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 Ta- ble 34 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 appropriate alarm. The MBB prevents the circuit from restarting until the alert condi- tion is reset. The switch should open at the pressure corresponding to the appropriate switch setting as shown in Table 34. Table 34 Factory Settings, High-Pressure Switch

(Fixed)

Clear the alarm using the scrolling marquee display. The unit should restart after the compressor anti-short-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 status of the unit, but to also maintain operation of the chiller within the compressor manufacturer's specified limits. The input to the MBB from the suction pressure transducer is also used to protect the compressor from operating at low pressure condi- tions and low superheat conditions. In some cases, the unit may not be able to run at full capacity. The control module will auto- matically reduce the capacity of a circuit as needed to maintain specified maximum/minimum operating pressures. COOLER FREEZE-UP PROTECTION

The main base board (MBB) monitors leaving fluid temperature at all times. The MBB will rapidly remove stages of capacity as nec- essary 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 (34F [1C] or below), freeze-up protection is required using inhibited ethylene or propylene glycol. The input from the low pressure transducer provides additional cooler freeze protection. The MBB shuts down the unit when a low pressure condition exists that could cause the cooler to freeze up. HEATER CABLE Optional factory-installed cooler and/or hydronic package heaters are cycled based on the input from the outside-air temperature sen- sor. These heaters, when installed, are designed to protect the cool- er and/or hydronic package from freezing down to 20F (29C). Power for these heaters is supplied from the main unit power.

WINTER SHUTDOWN Do not shut off power disconnect during off-season shutdown. At end of the cooling season: 1. Drain water from system. 2. Replace drain plug(s) and add sufficient inhibited ethylene

glycol (or other suitable inhibited antifreeze) to cooler, pump, and piping to prevent freezing of residual water.

3. At the beginning of the next cooling season, refill the cooler and add the recommended inhibitor.

Thermistors Electronic control uses up to five 5 kthermistors to sense tem- peratures used to control operation of the chiller. Thermistors EWT, LWT, RGTA, RGTB, and OAT are identical in their tem- perature and voltage drop performance. The SPT space tempera- ture thermistor has a 10 k input channel and it has a different set of temperature vs. resistance and voltage drop performance. Resis- tance at various temperatures are listed in Tables 35-39. For dual chiller operation, a dual chiller sensor is required which is a 5 k thermistor. When a digital compressor is used, a DTT (digital tem- perature thermistor) is used. The DTT is an 86 k thermistor. REPLACING THERMISTORS (EWT, LWT, RGT) Add a small amount of thermal conductive grease to the thermis- tor well and end of probe. For all probes, tighten the retaining nut 1/4 turn past finger tight. See Fig. 50 and 51. Insulate the thermistor with cork tape or other appropriate insulating material. THERMISTOR/TEMPERATURE SENSOR CHECK A high quality digital volt-ohmmeter is required to perform this check. 1. Connect the digital voltmeter across the appropriate

thermistor terminals at the J8 terminal strip on the Main Base Board (see Fig. 51).

2. Using the voltage reading obtained, read the sensor tem- perature from Tables 35-39. Supply voltage to the thermis- tor should be 4 vdc 0.2 v with the thermistor disconnected from the MBB.

3. To check thermistor accuracy, measure temperature at probe location with an accurate thermocouple-type tem- perature measuring instrument. Insulate thermocouple to avoid ambient temperatures from influencing reading. Temperature measured by thermocouple and temperature determined from thermistor voltage reading should be close, 5F (3C) if care was taken in applying thermo- couple and taking readings.

If a 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 determining the resistance with chiller shut down and thermistor disconnected from J8. Com- pare the values determined with the value read by the control in the Temperatures mode using the scrolling marquee display.

UNIT CUTOUT CUT-IN

PSIG KPA PSIG KPA 30RAP 650 4482 500 3447

CAUTION

On medium temperature brine units, the anti-freeze solution must be properly mixed to prevent freezing at a temperature of at least 15F (8.3C) below the leaving-fluid temperature set point. Failure to provide the proper anti-freeze solution mixture may damage the cooler, water piping, and/or hydronic package and is considered abuse and may impair or otherwise negatively impact the Carrier warranty.

CAUTION

Do not disconnect main unit power when servicing compres- sor(s) if ambient temperature is below 40F (4.4C) if the chilled water loop is not protected with an appropriate concen- tration of an inhibited antifreeze solution. The compressors have a circuit breaker that can be used to shut off power to the compressors. If the chilled water loop is not protected with an appropriate concentration of an inhibited antifreeze solution and 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. Fail- ure to do so may damage the cooler, water piping, and/or hydronic package.

63

Table 35 5K Thermistor Temperatures (F) vs. Resistance/Voltage Drop (Voltage Drop for EWT, LWT, DLWT, RGT, and OAT)

TEMP (F)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

25 3.699 98,010 24 3.689 94,707 23 3.679 91,522 22 3.668 88,449 21 3.658 85,486 20 3.647 82,627 19 3.636 79,871 18 3.624 77,212 17 3.613 74,648 16 3.601 72,175 15 3.588 69,790 14 3.576 67,490 13 3.563 65,272 12 3.550 63,133 11 3.536 61,070 10 3.523 59,081 9 3.509 57,162 8 3.494 55,311 7 3.480 53,526 6 3.465 51,804 5 3.450 50,143 4 3.434 48,541 3 3.418 46,996 2 3.402 45,505 1 3.386 44,066 0 3.369 42,679 1 3.352 41,339 2 3.335 40,047 3 3.317 38,800 4 3.299 37,596 5 3.281 36,435 6 3.262 35,313 7 3.243 34,231 8 3.224 33,185 9 3.205 32,176

10 3.185 31,202 11 3.165 30,260 12 3.145 29,351 13 3.124 28,473 14 3.103 27,624 15 3.082 26,804 16 3.060 26,011 17 3.038 25,245 18 3.016 24,505 19 2.994 23,789 20 2.972 23,096 21 2.949 22,427 22 2.926 21,779 23 2.903 21,153 24 2.879 20,547 25 2.856 19,960 26 2.832 19,393 27 2.808 18,843 28 2.784 18,311 29 2.759 17,796 30 2.735 17,297 31 2.710 16,814 32 2.685 16,346 33 2.660 15,892 34 2.634 15,453 35 2.609 15,027 36 2.583 14,614 37 2.558 14,214 38 2.532 13,826 39 2.506 13,449 40 2.480 13,084 41 2.454 12,730 42 2.428 12,387 43 2.402 12,053 44 2.376 11,730 45 2.349 11,416 46 2.323 11,112 47 2.296 10,816 48 2.270 10,529 49 2.244 10,250 50 2.217 9,979 51 2.191 9,717 52 2.165 9,461 53 2.138 9,213 54 2.112 8,973 55 2.086 8,739 56 2.060 8,511 57 2.034 8,291 58 2.008 8,076

TEMP (F)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

59 1.982 7,686 60 1.956 7,665 61 1.930 7,468 62 1.905 7,277 63 1.879 7,091 64 1.854 6,911 65 1.829 6,735 66 1.804 6,564 67 1.779 6,399 68 1.754 6,238 69 1.729 6,081 70 1.705 5,929 71 1.681 5,781 72 1.656 5,637 73 1.632 5,497 74 1.609 5,361 75 1.585 5,229 76 1.562 5,101 77 1.538 4,976 78 1.516 4,855 79 1.493 4,737 80 1.470 4,622 81 1.448 4,511 82 1.426 4,403 83 1.404 4,298 84 1.382 4,196 85 1.361 4,096 86 1.340 4,000 87 1.319 3,906 88 1.298 3,814 89 1.278 3,726 90 1.257 3,640 91 1.237 3,556 92 1.217 3,474 93 1.198 3,395 94 1.179 3,318 95 1.160 3,243 96 1.141 3,170 97 1.122 3,099 98 1.104 3,031 99 1.086 2,964

100 1.068 2,898 101 1.051 2,835 102 1.033 2,773 103 1.016 2,713 104 0.999 2,655 105 0.983 2,597 106 0.966 2,542 107 0.950 2,488 108 0.934 2,436 109 0.918 2,385 110 0.903 2,335 111 0.888 2,286 112 0.873 2,239 113 0.858 2,192 114 0.843 2,147 115 0.829 2,103 116 0.815 2,060 117 0.801 2,018 118 0.787 1,977 119 0.774 1,937 120 0.761 1,898 121 0.748 1,860 122 0.735 1,822 123 0.723 1,786 124 0.710 1,750 125 0.698 1,715 126 0.686 1,680 127 0.674 1,647 128 0.663 1,614 129 0.651 1,582 130 0.640 1,550 131 0.629 1,519 132 0.618 1,489 133 0.608 1,459 134 0.597 1,430 135 0.587 1,401 136 0.577 1,373 137 0.567 1,345 138 0.557 1,318 139 0.548 1,291 140 0.538 1,265 141 0.529 1,240 142 0.520 1,214

TEMP (F)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

143 0.511 1,190 144 0.502 1,165 145 0.494 1,141 146 0.485 1,118 147 0.477 1,095 148 0.469 1,072 149 0.461 1,050 150 0.453 1,029 151 0.445 1,007 152 0.438 986 153 0.430 965 154 0.423 945 155 0.416 925 156 0.408 906 157 0.402 887 158 0.395 868 159 0.388 850 160 0.381 832 161 0.375 815 162 0.369 798 163 0.362 782 164 0.356 765 165 0.350 750 166 0.344 734 167 0.339 719 168 0.333 705 169 0.327 690 170 0.322 677 171 0.317 663 172 0.311 650 173 0.306 638 174 0.301 626 175 0.296 614 176 0.291 602 177 0.286 591 178 0.282 581 179 0.277 570 180 0.272 561 181 0.268 551 182 0.264 542 183 0.259 533 184 0.255 524 185 0.251 516 186 0.247 508 187 0.243 501 188 0.239 494 189 0.235 487 190 0.231 480 191 0.228 473 192 0.224 467 193 0.220 461 194 0.217 456 195 0.213 450 196 0.210 445 197 0.206 439 198 0.203 434 199 0.200 429 200 0.197 424 201 0.194 419 202 0.191 415 203 0.188 410 204 0.185 405 205 0.182 401 206 0.179 396 207 0.176 391 208 0.173 386 209 0.171 382 210 0.168 377 211 0.165 372 212 0.163 367 213 0.160 361 214 0.158 356 215 0.155 350 216 0.153 344 217 0.151 338 218 0.148 332 219 0.146 325 220 0.144 318 221 0.142 311 222 0.140 304 223 0.138 297 224 0.135 289 225 0.133 282

64

Table 36 5K Thermistor Temperatures (C) vs. Resistance/Voltage Drop (Voltage Drop for EWT, LWT, DLWT, RGT, and OAT)

TEMP (C)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

32 3.705 100,260 31 3.687 94,165 30 3.668 88,480 29 3.649 83,170 28 3.629 78,125 27 3.608 73,580 26 3.586 69,250 25 3.563 65,205 24 3.539 61,420 23 3.514 57,875 22 3.489 54,555 21 3.462 51,450 20 3.434 48,536 19 3.406 45,807 18 3.376 43,247 17 3.345 40,845 16 3.313 38,592 15 3.281 38,476 14 3.247 34,489 13 3.212 32,621 12 3.177 30,866 11 3.140 29,216 10 3.103 27,633

9 3.065 26,202 8 3.025 24,827 7 2.985 23,532 6 2.945 22,313 5 2.903 21,163 4 2.860 20,079 3 2.817 19,058 2 2.774 18,094 1 2.730 17,184 0 2.685 16,325 1 2.639 15,515 2 2.593 14,749 3 2.547 14,026 4 2.500 13,342 5 2.454 12,696 6 2.407 12,085 7 2.360 11,506 8 2.312 10,959 9 2.265 10,441

10 2.217 9,949 11 2.170 9,485 12 2.123 9,044 13 2.076 8,627 14 2.029 8,231

TEMP (C)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

15 1.982 7,855 16 1.935 7,499 17 1.889 7,161 18 1.844 6,840 19 1.799 6,536 20 1.754 6,246 21 1.710 5,971 22 1.666 5,710 23 1.623 5,461 24 1.580 5,225 25 1.538 5,000 26 1.497 4,786 27 1.457 4,583 28 1.417 4,389 29 1.378 4,204 30 1.340 4,028 31 1.302 3,861 32 1.265 3,701 33 1.229 3,549 34 1.194 3,404 35 1.160 3,266 36 1.126 3,134 37 1.093 3,008 38 1.061 2,888 39 1.030 2,773 40 0.999 2,663 41 0.969 2,559 42 0.940 2,459 43 0.912 2,363 44 0.885 2,272 45 0.858 2,184 46 0.832 2,101 47 0.807 2,021 48 0.782 1,944 49 0.758 1,871 50 0.735 1,801 51 0.713 1,734 52 0.691 1,670 53 0.669 1,609 54 0.649 1,550 55 0.629 1,493 56 0.610 1,439 57 0.591 1,387 58 0.573 1,337 59 0.555 1,290 60 0.538 1,244 61 0.522 1,200

TEMP (C)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

62 0.506 1,158 63 0.490 1,118 64 0.475 1,079 65 0.461 1,041 66 0.447 1,006 67 0.433 971 68 0.420 938 69 0.407 906 70 0.395 876 71 0.383 836 72 0.371 805 73 0.360 775 74 0.349 747 75 0.339 719 76 0.329 693 77 0.319 669 78 0.309 645 79 0.300 623 80 0.291 602 81 0.283 583 82 0.274 564 83 0.266 547 84 0.258 531 85 0.251 516 86 0.244 502 87 0.237 489 88 0.230 477 89 0.223 466 90 0.217 456 91 0.211 446 92 0.204 436 93 0.199 427 94 0.193 419 95 0.188 410 96 0.182 402 97 0.177 393 98 0.172 385 99 0.168 376

100 0.163 367 101 0.158 357 102 0.154 346 103 0.150 335 104 0.146 324 105 0.142 312 106 0.138 299 107 0.134 285

65

Table 37 10K Thermistor Temperature (F) vs. Resistance/Voltage Drop (For SPT)

TEMP (F)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

25 4.758 196,453 24 4.750 189,692 23 4.741 183,300 22 4.733 177,000 21 4.724 171,079 20 4.715 165,238 19 4.705 159,717 18 4.696 154,344 17 4.686 149,194 16 4.676 144,250 15 4.665 139,443 14 4.655 134,891 13 4.644 130,402 12 4.633 126,183 11 4.621 122,018 10 4.609 118,076 9 4.597 114,236 8 4.585 110,549 7 4.572 107,006 6 4.560 103,558 5 4.546 100,287 4 4.533 97,060 3 4.519 94,020 2 4.505 91,019 1 4.490 88,171 0 4.476 85,396 1 4.461 82,729 2 4.445 80,162 3 4.429 77,662 4 4.413 75,286 5 4.397 72,940 6 4.380 70,727 7 4.363 68,542 8 4.346 66,465 9 4.328 64,439

10 4.310 62,491 11 4.292 60,612 12 4.273 58,781 13 4.254 57,039 14 4.235 55,319 15 4.215 53,693 16 4.195 52,086 17 4.174 50,557 18 4.153 49,065 19 4.132 47,627 20 4.111 46,240 21 4.089 44,888 22 4.067 43,598 23 4.044 42,324 24 4.021 41,118 25 3.998 39,926 26 3.975 38,790 27 3.951 37,681 28 3.927 36,610 29 3.903 35,577 30 3.878 34,569 31 3.853 33,606 32 3.828 32,654 33 3.802 31,752 34 3.776 30,860 35 3.750 30,009 36 3.723 29,177 37 3.697 28,373 38 3.670 27,597 39 3.654 26,838 40 3.615 26,113 41 3.587 25,396 42 3.559 24,715 43 3.531 24,042 44 3.503 23,399 45 3.474 22,770 46 3.445 22,161 47 3.416 21,573 48 3.387 20,998 49 3.357 20,447 50 3.328 19,903 51 3.298 19,386 52 3.268 18,874 53 3.238 18,384 54 3.208 17,904 55 3.178 17,441 56 3.147 16,991 57 3.117 16,552 58 3.086 16,131 59 3.056 15,714 60 3.025 15,317

TEMP (F)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

61 2.994 14,925 62 2.963 14,549 63 2.932 14,180 64 2.901 13,824 65 2.870 13,478 66 2.839 13,139 67 2.808 12,814 68 2.777 12,493 69 2.746 12,187 70 2.715 11,884 71 2.684 11,593 72 2.653 11,308 73 2.622 11,031 74 2.592 10,764 75 2.561 10,501 76 2.530 10,249 77 2.500 10,000 78 2.470 9,762 79 2.439 9,526 80 2.409 9,300 81 2.379 9,078 82 2.349 8,862 83 2.319 8,653 84 2.290 8,448 85 2.260 8,251 86 2.231 8,056 87 2.202 7,869 88 2.173 7,685 89 2.144 7,507 90 2.115 7,333 91 2.087 7,165 92 2.059 6,999 93 2.030 6,838 94 2.003 6,683 95 1.975 6,530 96 1.948 6,383 97 1.921 6,238 98 1.894 6,098 99 1.867 5,961

100 1.841 5,827 101 1.815 5,698 102 1.789 5,571 103 1.763 5,449 104 1.738 5,327 105 1.713 5,210 106 1.688 5,095 107 1.663 4,984 108 1.639 4,876 109 1.615 4,769 110 1.591 4,666 111 1.567 4,564 112 1.544 4,467 113 1.521 4,370 114 1.498 4,277 115 1.475 4,185 116 1.453 4,096 117 1.431 4,008 118 1.409 3,923 119 1.387 3,840 120 1.366 3,759 121 1.345 3,681 122 1.324 3,603 123 1.304 3,529 124 1.284 3,455 125 1.264 3,383 126 1.244 3,313 127 1.225 3,244 128 1.206 3,178 129 1.187 3,112 130 1.168 3,049 131 1.150 2,986 132 1.132 2,926 133 1.114 2,866 134 1.096 2,809 135 1.079 2,752 136 1.062 2,697 137 1.045 2,643 138 1.028 2,590 139 1.012 2,539 140 0.996 2,488 141 0.980 2,439 142 0.965 2,391 143 0.949 2,343 144 0.934 2,297 145 0.919 2,253 146 0.905 2,209

TEMP (F)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

147 0.890 2,166 148 0.876 2,124 149 0.862 2,083 150 0.848 2,043 151 0.835 2,003 152 0.821 1,966 153 0.808 1,928 154 0.795 1,891 155 0.782 1,855 156 0.770 1,820 157 0.758 1,786 158 0.745 1,752 159 0.733 1,719 160 0.722 1,687 161 0.710 1,656 162 0.699 1,625 163 0.687 1,594 164 0.676 1,565 165 0.666 1,536 166 0.655 1,508 167 0.645 1,480 168 0.634 1,453 169 0.624 1,426 170 0.614 1,400 171 0.604 1,375 172 0.595 1,350 173 0.585 1,326 174 0.576 1,302 175 0.567 1,278 176 0.558 1,255 177 0.549 1,233 178 0.540 1,211 179 0.532 1,190 180 0.523 1,169 181 0.515 1,148 182 0.507 1,128 183 0.499 1,108 184 0.491 1,089 185 0.483 1,070 186 0.476 1,052 187 0.468 1,033 188 0.461 1,016 189 0.454 998 190 0.447 981 191 0.440 964 192 0.433 947 193 0.426 931 194 0.419 915 195 0.413 900 196 0.407 885 197 0.400 870 198 0.394 855 199 0.388 841 200 0.382 827 201 0.376 814 202 0.370 800 203 0.365 787 204 0.359 774 205 0.354 762 206 0.349 749 207 0.343 737 208 0.338 725 209 0.333 714 210 0.328 702 211 0.323 691 212 0.318 680 213 0.314 670 214 0.309 659 215 0.305 649 216 0.300 639 217 0.296 629 218 0.292 620 219 0.288 610 220 0.284 601 221 0.279 592 222 0.275 583 223 0.272 574 224 0.268 566 225 0.264 557

66

Table 38 10K Thermistor Temperature (C) vs. Resistance/Voltage Drop (For SPT)

Table 39 86K Thermistor vs Resistance (DTT)

TEMP (C)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

32 4.762 200,510 31 4.748 188,340 30 4.733 177,000 29 4.716 166,342 28 4.700 156,404 27 4.682 147,134 26 4.663 138,482 25 4.644 130,402 24 4.624 122,807 23 4.602 115,710 22 4.580 109,075 21 4.557 102,868 20 4.533 97,060 19 4.508 91,588 18 4.482 86,463 17 4.455 81,662 16 4.426 77,162 15 4.397 72,940 14 4.367 68,957 13 4.335 65,219 12 4.303 61,711 11 4.269 58,415 10 4.235 55,319

9 4.199 52,392 8 4.162 49,640 7 4.124 47,052 6 4.085 44,617 5 4.044 42,324 4 4.003 40,153 3 3.961 38,109 2 3.917 36,182 1 3.873 34,367 0 3.828 32,654 1 3.781 31,030 2 3.734 29,498 3 3.686 28,052 4 3.637 26,686 5 3.587 25,396 6 3.537 24,171 7 3.485 23,013 8 3.433 21,918 9 3.381 20,883

10 3.328 19,903 11 3.274 18,972 12 3.220 18,090 13 3.165 17,255 14 3.111 16,464

TEMP (C)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

15 3.056 15,714 16 3.000 15,000 17 2.944 14,323 18 2.889 13,681 19 2.833 13,071 20 2.777 12,493 21 2.721 11,942 22 2.666 11,418 23 2.610 10,921 24 2.555 10,449 25 2.500 10,000 26 2.445 9,571 27 2.391 9,164 28 2.337 8,776 29 2.284 8,407 30 2.231 8,056 31 2.178 7,720 32 2.127 7,401 33 2.075 7,096 34 2.025 6,806 35 1.975 6,530 36 1.926 6,266 37 1.878 6,014 38 1.830 5,774 39 1.784 5,546 40 1.738 5,327 41 1.692 5,117 42 1.648 4,918 43 1.605 4,727 44 1.562 4,544 45 1.521 4,370 46 1.480 4,203 47 1.439 4,042 48 1.400 3,889 49 1.362 3,743 50 1.324 3,603 51 1.288 3,469 52 1.252 3,340 53 1.217 3,217 54 1.183 3,099 55 1.150 2,986 56 1.117 2,878 57 1.086 2,774 58 1.055 2,675 59 1.025 2,579 60 0.996 2,488 61 0.968 2,400

TEMP (C)

VOLTAGE DROP

(V)

RESISTANCE (OHMS)

62 0.940 2,315 63 0.913 2,235 64 0.887 2,157 65 0.862 2,083 66 0.837 2,011 67 0.813 1,943 68 0.790 1,876 69 0.767 1,813 70 0.745 1,752 71 0.724 1,693 72 0.703 1,637 73 0.683 1,582 74 0.663 1,530 75 0.645 1,480 76 0.626 1,431 77 0.608 1,385 78 0.591 1,340 79 0.574 1,297 80 0.558 1,255 81 0.542 1,215 82 0.527 1,177 83 0.512 1,140 84 0.497 1,104 85 0.483 1,070 86 0.470 1,037 87 0.457 1,005 88 0.444 974 89 0.431 944 90 0.419 915 91 0.408 889 92 0.396 861 93 0.386 836 94 0.375 811 95 0.365 787 96 0.355 764 97 0.345 742 98 0.336 721 99 0.327 700

100 0.318 680 101 0.310 661 102 0.302 643 103 0.294 626 104 0.287 609 105 0.279 592 106 0.272 576 107 0.265 561

TEMP (C)

TEMP (F)

RESISTANCE (OHMS)

-40 -40 2,889,600 -35 -31 2,087,220 -30 -22 1,522,200 -25 -13 1,121,440 -20 -4 834,720 -15 5 627,280 -10 14 475,740 -5 23 363,990 0 32 280,820 5 41 218,410

10 50 171,170 15 59 135,140 20 68 107,440 25 77 86,000 30 86 69,280 35 95 56,160 40 104 45,810 45 113 37,580 50 122 30,990 55 131 25,680 60 140 21,400 70 158 15,070

TEMP (C)

TEMP (F)

RESISTANCE (OHMS)

75 167 12,730 80 176 10,790 85 185 9,200 90 194 7,870 95 203 6,770 100 212 5,850 105 221 5,090 110 230 4,450 115 239 3,870 120 248 3,350 125 257 2,920 130 266 2,580 135 275 2,280 140 284 2,020 145 293 1,800 150 302 1,590 155 311 1,390 160 320 1,250 165 329 1,120 170 338 1,010 175 347 920 180 356 830

67

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 discharge (red). No pressure transducer calibration is required. The transducers operate on a 5 vdc supply, which is generated by the main base board (MBB). See Fig. 51 for transducer connections to the J8 connector on the MBB. TROUBLESHOOTING If a transducer is suspected of being faulty, first check supply volt- age to the transducer. Supply voltage should be 5 vdc 0.2 v. If supply voltage is correct, compare the pressure reading displayed on the scrolling marquee display module against pressure shown on a calibrated pressure gauge. Pressure readings should be within 15 psig. If the two readings are not reasonably close, replace the pressure transducer.

Chilled Water Flow Switch A factory-installed flow switch is installed in the leaving fluid pip- ing for all units without the factory-installed hydronic package. See Fig. 52. Units with the optional hydronic package have the flow switch installed in the entering fluid piping. This is a thermal- dispersion 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 affected only by changes in the temperature of the liquid. The thermistors are posi- tioned 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.

Fig. 50 Thermistor Well and Return Gas Thermistor (RGT) Mounting

INSTALL NUT AND SEAL ON THERMISTOR. APPLY THERMAL CONDUCTIVE

GREASE TO THERMISTOR AND WELL. INSERT

THERMISTOR INTO WELL.

LOOP WIRE HARNESS AND SECURE WITH WIRE TIE TO FORM STRAIN RELIEF.

INSULATE WITH CORK TAPE INSULATION.

5/8 in. HEX

6" MINIMUM CLEARANCE FOR

THERMISTOR REMOVAL

1/4-18 NPT

26

25

24

23

22

17

16

15

14

13

12

11

10

9

8

7

6

3

1

3

1

3

1

6

2

4

2

4

2

12

11

21

20

19

18

10

9

8

7

6

5

4

5

4

3

2

1

4

2

1

3

5

J8

BLK

RED

LVT

4

3

22

23 T-55 ACCSY

SEN

OAT

BLU

BLU

BLK

RED RGTB

BLK

RED RGTA

SPTB

-

+

DPTB

-

+

A

C

B

A

C

B

GRN

RED

BLK

GRN

RED

BLK

SPTA

-

+

DPTA

-

+

A

C

B

A

C

B

GRN

RED

BLK

GRN

RED

BLK

BLK

RED EVAPORATOR ENTERING FLUID TEMP

BLK

RED EVAPORATOR LEAVING FLUID TEMP

SPACE TEMPERATURE ACCESSORY OR DUAL CHILLER LWT

J12 T55

Fig. 51 Thermistor Connections to Main Base Board, J8 Connector

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

a30-4975

68

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 sen- sor 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 pro- vides a measurement of fluid velocity past the sensor probe. 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 temperature differential. When unit flow rate is above the minimum flow rate, then the out- put 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 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 indicate if 24 vac power is present and also status of the switch contacts. The LEDs are as follows: Green LED ON 24 vac present One Yellow LED ON Flow sensor switch OPEN Two Yellow LEDs 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 blowdown valve provided or remove the screen and clean it. In 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 connections at the switch and at the terminal block are secure.

4. For factory-installed hydronic systems, verify that: a. All air has been purged from the system. b. Circuit setter balance valve has been correctly set.

5. Pump impeller has been improperly trimmed and is not pro- viding 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) pressure 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 Maintenance Done (Run StatusPMS.T.MN).

Condenser Fans Two types of condenser fans are offered in the 30RAP units: metal (value sound) fans, and AeroAcoustic (low sound) fans. Each fan is supported by a formed wire mount bolted to a fan deck and covered with a wire guard. METAL (VALUE SOUND) FANS The exposed end of fan motor shaft is protected from weather by grease and a rubber boot. If fan motor must be removed for service or replacement, when reinstalling the motor be sure to mount the motor band in the proper location, re-grease fan shaft, and reinstall fan guard. The fan hub must be facing up. For proper performance 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. Tighten set screws to 15 2 ft-lb (20 2.7 Nm). Fig. 53 shows the proper position of mounted fan.

4.2 in. (107 mm)

0.87 in. (22 mm)

0.30 in. (7.7 mm)

M 12

x1

1/ 4-

in . N

P T

TORQUE WITH WRENCH (SIZE 22 mm)

a30-5238

Fig. 52 Chilled Water Flow Switch

IMPORTANT: Check for proper fan rotation (clockwise when viewed from above). If necessary, switch any 2 power leads to reverse fan rotation. The anti-rotation tab must be located to the left and adjacent to the motor mounting rod.

0.32 0.12 in. (8 3 mm) MEASURE FROM FAN WEB TOP TO TOP OF FAN DECK ORIFICE.

7.00 in. (178 mm) MIN.

a38-7325

FAN DECK

Fig. 53 Metal (Value Sound) Fan Mounted Position

69

AEROACOUSTIC (LOW SOUND) FANS Two designs have been used for this option and can be distin- guished by the mounting bolt color. Two separate processes are used depending on the design revision. A shroud and a wire guard provide protection from the rotating fan.

Gray Bolt The fan motor shaft is protected from weather by grease and the fan cover. If fan motor must be removed for service or replace- ment, when reinstalling the motor be sure to mount the motor band in the proper location. Re-grease fan shaft and reinstall fan cover. The fan motor has a step in the motor shaft. For proper per- formance, fan should be positioned such that it is securely seated on this step. See Fig. 54. Tighten bolt to 15 2 ft-lb (20 2.7 Nm). Figure 54 shows the proper position of mounted fan. Black Bolt To remove the fan, a fan puller will likely be needed. The fan mo- tor shaft is protected from weather by the fan cover. If fan motor must be removed for service or replacement, when reinstalling the motor be sure to mount the motor band in the proper location. Do not use grease on the shaft or key. 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. Apply Loctite 680 Re- taining Compound to the hub and motor keyway only just prior to installing the key. See Fig. 55 and 56. Tighten bolt to 24 2 ft-lb (32.5 2.7 Nm). Fig. 57 shows the proper position of mounted fan.

.

Motormaster V Controller The Motormaster V (MMV) controller is standard on size 010 and 015 units. For other sizes, the optional or accessory Motormaster V controller uses an input signal from the AUX board. See Fig. 58. The controller is factory configured and requires no field programming. If a situation arises where the drive does not func- tion properly, the information provided below and in Table 40 can be used to troubleshoot the drive.

IMPORTANT: Check for proper fan rotation (counter- clockwise when viewed from above). If necessary, switch any 2 power leads to reverse fan rotation.

7.00 in. (178 mm) MIN.

FAN DECK

TORQUE BOLTS 15 2 ft-lb (20 2.6 N-m)

FAN CAP

Fig. 54 AeroAcoustic Fan (Gray Bolt) Mounted Position

a38-7326

680

Fig. 55 AeroAcoustic Fan (Black Bolt) Fan Hub Keyway

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 extreme caution when servicing the drive. Failure to comply may result in personal injury.

WARNING

When configured as shown in this literature, this equipment 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 may result in personal injury.

WARNING

The opening of a branch-circuit protective device may be an indication that a fault has been interrupted. To reduce the risk of fire or electric shock, current carrying parts and other com- ponents of the controller should be examined and replaced if damaged.

a38-7327

680

Fig. 56 AeroAcoustic Fan (Black Bolt) Fan Motor Keyway

TORQUE BOLTS 24 2 ft-lb (32.5 2.7 N-m)

FAN DECK

7.00 in. (178 mm) MIN.

a38-7328

Fig. 57 AeroAcoustic Fan (Black Bolt) Mounted Position

70

CAUTION

DO NOT connect incoming AC power to output terminals T1, T2, and T3. 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 electro- lytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in pre- mature 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. Failure to comply may result in equipment damage.

Fig. 58 Typical Motormaster Wiring

CONFIGURATION TABLE

*208-v can run in mode 5 or 6.

MODE NOMINAL VOLTAGE Hz CONTROL INPUT (PINS 25, 2)

START JUMPER

5 208/230/460/575* 60 External control 4-20 mA TB1-TB2

6 208/380 60 External control 4-20 mA TB13A-TB2

380/415-50 50 External control 4-20 mA TB13C-TB2

LEGEND AUX Auxiliary FB Fuse Block MM Motormaster MMR Motormaster Relay OFM Outdoor Fan Motor SCCR Short Circuit Current Rating TB Terminal Block

LOW AMBIENT OPERATION (MOTORMASTER V) FIOP/ACCESSORY

* MM SIGNAL CONNECTION

VOLTAGE ZHBT

208/230/460/575 061

380 06A31

GRN/YEL

1

2

3

BLK-1

BLK-2

BLK-3

L1 T1

L2 T2

L3 T3

MMR 11 14*1

2 YEL

VIO

MM-A

FC2 11 21

12 22

13 23 GRN/YEL

OFM2

1

2

3

BLK-1

BLK-2

BLK-3

BLK

YEL

BLU

BLK

YEL

BLU

BLK

25

2

RED FROM AUX-J4

OFM1

BLK

YEL

BLU

BLK

YEL

BLU

BLK

YEL

BLU

FB3

11

12

13

21

22

23

HIGH SCCR ONLY

FB1

11

12

13

21

22

23

11

12

13

21

22

23

FB2

240 1/4W

TO COOLER HEATER/ PUMP HEATER

71

Table 40 Fault Codes

LEGEND

GENERAL OPERATION The speed varies in proportion to a 0 to 10 vdc signal produced by the ComfortLink controls. The MMV output speed is displayed in Hz. The ComfortLink controls must be configured for MMV opera- tion in order for it to operate. This is configured under the Config- uration menu (ConfigurationMMMMR.S) and selecting 1=LOW AMBIENT. 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 operat- ing modes 5-8. In these configurations, the MMV follows a 4 to 20 mA speed reference signal present on terminals 25 (+) and 2 (-). The Aux board generates a 2 to 10 vdc signal that is converted to a 4 to 20 mA signal by means of a 240 1/4 w resistor in series with the positive (+) signal wire. One additional jumper is re- quired to configure the drive for 50/60 Hz operation and input voltage. See Table 41 for proper inputs. Once the drive is pow- ered, it will change to the mode selected according to the inputs. See Fig. 59.

FAULT CODE DESCRIPTION SOLUTION AF High Temperature Fault: Ambient temperature is too high;

Cooling fan has failed (if equipped). Check cooling fan operation

CF Control Fault: A blank EPM, or an EPM with corrupted data has been installed.

Perform a factory reset using Parameter 48 PROGRAM SELECTION.

cF Incompatibility Fault: An EPM with an incompatible param- eter version has been installed.

Either remove the EPM or perform a factory reset (Parameter 48) to change the parameter version of the EPM to match the parameter version of the drive.

CL CURRENT LIMIT: The output current has exceeded the CURRENT LIMIT setting (Parameter 25) and the drive is reducing the output frequency to reduce the output current. If the drive remains in CURRENT LIMIT too long, it can trip into a CURRENT OVERLOAD fault (PF).

Check for loose electrical connections. Check for faulty condenser fan motor. Check Parameter P25 from Table 41 is set correctly.

ER ERROR: Invalid data has been entered or an invalid com- mand was attempted.

GF Data Fault: User data and OEM defaults in the EPM are corrupted.

Restore factory defaults P48, see section above. If that does not work, replace EPM.

HF High DC Bus Voltage Fault: Line voltage is too high; Decel- eration rate is too fast; Overhauling load.

Check line voltage set P01 appropriately.

JF Serial Fault: The watchdog timer has timed out, indicating that the serial link has been lost.

Check serial connection (computer). Check settings for P15. Check settings in communication software to match P15.

LC FAULT LOCKOUT: The drive has failed three restart attempts and requires a manual reset.

LF Low DC Bus Voltage Fault: Line voltage is too low. Check line voltage set P01 appropriately. OF Output Transistor Fault: Phase to phase or phase to ground

short circuit on the output; Failed output transistor; Boost settings are too high; Acceleration rate is too fast.

Reduce boost or increase acceleration val- ues. If unsuccessful, replace drive.

PF Current Overload Fault: VFD is undersized for the applica- tion; Mechanical problem with the driven equipment.

Check line voltage set P01 appropriately. Check for dirty coils. Check for motor bearing failure.

SF Single-phase Fault: Single-phase input power has been applied to a three-phase drive.

Check input power phasing.

SP START PENDING: SP blinks during the interval between restart attempts.

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 is cold outside and it should be running slower

Feedback signal is above set point. Check for proper set point. Check liquid line pressure.

Drive display = --- even though drive should be running

Start jumper is missing. Replace start jumper. See section above.

Drive display = 8.0 even though fan should be running faster

Feedback signal is below set point and fan is at minimum speed.

Check for proper set point. Check liquid line pressure.

VFD flashes 57 and LCS Feedback or speed signal lost. Drive will operate at 57 Hz until reset or loss of start command. Resetting requires cycling start command (or power).

In stand alone mode: Check transducer wiring and feedback voltage. Feedback voltage dis- played on P-69. Pin 6 should be 5 v output. Pin 5 (feedback) should be somewhere between 0 and 5 v.

EPM Electronic Programming Module LCS Lost Control Signal OEM Original Equipment Manufacturer VFD Variable Frequency Drive

72

Table 41 Motormaster V Program Parameters for Operating Modes

LEGEND

PARAMETERS DESCRIPTION MODE 5 MODE 6 MODE 7 MODE 8 P01 Line Voltage: 01 = low line, 02 = high line 01 02 01 02 P02 Carrier Freq: 01 = 4 kHz, 02 = 6 kHz, 03 = 8 kHz 01 01 01 01 P03 Startup mode: flying restart 06 06 06 06 P04 Stop mode: coast to stop 01 01 01 01

P05 Standard Speed source: 01= keypad, 04=4-20mA (NO PI), 05= R22, 06=R134a 04 04 04 04

P06 TB-14 output: 01 = none 01 01 01 01 P08 TB-30 output: 01 = none 01 01 01 01 P09 TB-31 Output: 01 = none 01 01 01 01 P10 TB-13A function sel: 01 = none 01 01 01 01 P11 TB-13B function sel: 01 = none 01 01 01 01 P12 TB-13C function sel: 01 = none 01 01 01 01 P13 TB-15 output: 01 = none 01 01 01 01 P14 Control: 01 = Terminal strip 01 01 01 01 P15 Serial link: 02 = enabled 9600,8,N,2 with timer 02 02 02 02 P16 Units editing: 02 = whole units 02 02 02 02 P17 Rotation: 01 = forward only, 03 = reverse only 01 01 01 01 P19 Acceleration time: 10 sec 10 10 10 10 P20 Deceleration time: 10 sec 10 10 10 10 P21 DC brake time: 0 0 0 0 0 P22 DC BRAKE VOLTAGE 0% 0 0 0 0 P23 Min freq = 8 Hz ~ 100 160 rpm 8 8 8 8 P24 Max freq 60 60 50 50 P25 Current limit: (%) 125 110 125 110 P26 Motor overload: 100 100 100 100 100 P27 Base freq: 60 or 50 Hz 60 60 50 50 P28 Fixed boost: 0.5% at low frequencies 0.5 0.5 0.5 0.5 P29 Accel boost: 0% 0 0 0 0 P30 Slip compensation: 0% 0 0 0 0 P31 Preset spd #1: speed if loss of control signal 57 57 47 47 P32 Preset spd #2: 0 0 0 0 0 P33 Preset spd #3: 0 0 0 0 0

P34 Preset spd 4 default R22 set point. TB12-2 open 18.0 18.0 18.0 18.0

P35 Preset spd 5 default R134a set point. TB12-2 closed 12.6 12.6 12.6 12.6

P36 Preset spd 6 default 0 0 0 0 P37 Preset spd 7 default 0 0 0 0 P38 Skip bandwidth 0 0 0 0 P39 Speed scaling 0 0 0 0 P40 Frequency scaling 50 or 60 Hz 60 60 50 50 P41 Load scaling: default (not used so NA) 200 200 200 200 P42 Accel/decel #2: default (not used so NA) 60 60 60 60 P43 Serial address 1 1 1 1 P44 Password:111 111 111 111 111

P45 Speed at min signal: 8 Hz; used when PID mode is disabled and 4-20mA input is at 4 mA 8 8 8 8

P46 Speed at max feedback: 60 or 50 Hz. Used when PID disabled and 4-20mA input is at 20 mA 60 60 50 50

P47 Clear history? 01 = maintain. (set to 02 to clear) 01 01 01 01 P48 Program selection: Program 1 12 05 06 07 08 P61 PI Mode: 05= reverse, 0-5V, 01 = no PID 01 01 01 01 P62 Min feedback = 0 (0V *10) 0 0 0 0 P63 Max feedback = 50 (5V * 10) 50 50 50 50 P64 Proportional gain = 4% 4 4 4 4 P65 Integral gain = .2 .2 .2 .2 .2 P66 PI accel/decel (set point change filter) = 5 5 5 5 5 P67 Min alarm 0 0 0 0 P68 Max alarm 0 0 0 0 P69 0 - 10 VDC Feedback NA NA NA NA

NA Not Applicable PID Proportional Integral Derivative TB Terminal Block

73

DRIVE PROGRAMMING

To change parameter values of the Motormaster V controller: 1. To enter the PROGRAM mode to access the parameters,

press the Mode button. This will activate the password prompt (if the password has not been disabled). The dis- play will read 00 and the upper right-hand decimal point will be blinking. See Fig. 59.

2. Use the up and down arrow buttons to scroll to the password value (the factory default password is 111) and press the Mode button to accept the value.

3. Once the correct password value is entered, the display will read P01, which indicates that the PROGRAM mode has been accessed. P01 is the first parameter. NOTE: If the display flashes Er, the password was incor- rect and the process to enter the password must be repeated.

4. Use the up and down arrow buttons to scroll to the desired parameter number.

5. Once the desired parameter number is found, press the Mode button to display the present parameter setting. The upper 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 the up and down arrow buttons to change setting. Press Mode to store the new setting and exit the PROGRAM mode.

6. To change another parameter, press the Mode button again to re-enter the PROGRAM mode (the parameter menu will be accessed at the parameter that was last viewed or changed before exiting). If the Mode button is pressed within two min- utes of exiting the PROGRAM mode, the password is not required to access the parameters. After two minutes, the password must be entered in order to access the parameters again.

The drive uses an electronic programming module (EPM) chip to store the program parameters. This is an EPROM memory chip and is accessible from the front of the Motormaster V. It should not be removed with power applied to the VFD. See Fig. 59. Motormaster V Drive Password Configuration Changing the password is not recommended. Once the password is changed, there is no means to retrieve the new password if it is lost. A new EPM chip must be installed. To change password, follow the parameter changing instructions in the section Changing Motormaster V Parameters above. Change parameter P44 to the desired password. Setting P44 to 000 disables the password function. Valid range for the password is 000 to 999. EPM CHIP The drive uses a electronic programming module (EPM) chip to store the program parameters. This is an EEPROM memory chip and is accessible from the front of the VFD. It should not be re- moved 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 generated by the Motormaster V controller. Ensure unit is well grounded to eliminate ground currents along communication lines.

Fig. 59 Motormaster V Mode Buttons and Mode Display

L1 L2 L3

Mode

DANGER

T1 T2 T3 B+B-

DISPLAYBUTTONS

Mode

MMV TERMINAL BLOCK

EPM

LEGEND EPM Electronic Programming Module MMV Motormaster V

CAUTION

It is strongly recommended that the user NOT change any pro- gramming without consulting Carrier service personnel. Unit damage may occur from improper programming.

74

Fault Codes The drive is programmed to automatically restart after a fault and will attempt to restart three times after a fault (the drive will not re- start after CF, cF, GF, F1, F2-F9, or Fo faults). If all three restart at- tempts are unsuccessful, the drive will trip into FAULT LOCK- OUT (LC), which requires a manual reset. Manual Reset If fault condition has been removed, cycle power to the chiller to reset the VFD. Troubleshooting Troubleshooting the Motormaster V control requires a combina- tion of observing system operation and VFD information. The drive provides 2 kinds of troubleshooting 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 to 60 and all values are read-only. P50: FAULT HISTORY Last 8 faults P51: SOFTWARE version P52: DC BUS VOLTAGE in percent of nominal. Usu-

ally rated input voltage x 1.4 P53: MOTOR VOLTAGE 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-A1 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 approx- imately 7 ohms. For all other voltages, they should measure ap- proximately 20 ohms. Check value with mating plug disconnect- ed, power to chiller off and at ambient temperature (not hot imme- diately after stopping VFD). These are standard resistances at 77F (25C). Resistance values decrease at higher temperatures and increase at lower temperatures. REPLACING DEFECTIVE MODULES The ComfortLink replacement modules are shown in Table 42. If the main base board (MBB) has been replaced, verify that all con- figuration data is correct. Follow the Configuration mode table and verify that all items under sub-modes UNIT, OPT1 and OPT2 are correct. Any additional field-installed accessories or options (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 Chiller (com- pleted at time of original start-up) found in the job folder. This in- formation is needed later in this procedure. If the checklist does not exist, fill out the current information in the Configuration mode on a new checklist. Tailor the various options and configura- tions as needed for this particular installation.

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 for later use.

3. Verify that the instance jumper (MBB) or address switches (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 mod- ule for return to Carrier.

5. Mount the new module in the units control box using a Phil- lips screwdriver and the screws saved in Step 2. See Table 42 for replacement module part numbers.

6. Reinstall all module connectors. For accessory Navigator display 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 Control 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, set points, and schedules. Return the Enable/Off/Remote Control switch to its previous position.

Table 42 Replacement Modules

Hydronic Package If the unit is equipped with a factory-installed hydronic package, consult the information below for proper maintenance and service. In addition to this information, each factory-installed hydronic package is supplied with a packet of information supplied by the manufacturer, Bell & Gossett. Carrier 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 select- ed based on the flow and head requirements as provided to Carrier. It is not uncommon for actual pump duty to be different than what was anticipated at time of selection. In many cases, it may be de- sirable to make some field modifications to obtain optimum pump performance. Before any pump modifications are made, it is recommended that actual pump performance be verified and compared to the

applicable pump curve. See base unit installation instructions. This can be done in a variety of ways:

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 disconnect locations to alert others not to restore power until work is completed.

MODULE REPLACEMENT PART NO. (WITH

SOFTWARE)

REPLACEMENT PART NO. (WITHOUT

SOFTWARE) MAIN BASE

BOARD (MBB) 30RA502134 HK50AA029

SCROLLING MARQUEE DISPLAY

HK50AA031 HK50AA030

ENERGY MANAGEMENT MODULE (EMM)

30GT515218 HK50AA028

NAVIGATOR DISPLAY HK50AA033 N/A

EXV 30GT515217 HK50AA026 AUX 32GB500442E N/A CXB 30GT515219 HK50AA027

75

1. If pump 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. If pump 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 discharge side of the pump. NOTE: Although not all pumps can be safely dead-headed, centrifugal pumps (such as on the 30RAP units) can be dead-headed for short amounts of time. It is recommended 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 impeller 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 & Gossett circuit setter balance valve calculator or Armstrong Circuit Balancing Valve Slide Rule. (This information is also provided in the installation instructions.) This method will not directly measure pressure differential seen by the pump, but can be used to double- check the pump measurement.

5. Verify that cable connections at the switch and at the terminal block are secure.

6. For factory-installed hydronic system, verify that: a. All air has been purged from the system. b. Circuit setter balance valve has been correctly set.

7. Pump impeller has been improperly trimmed and is not pro- viding 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 section in the Installation instructions. CHANGING OF PUMP SEALS See service instruction manual provided with the hydronic package. VFD OPERATION For units with factory-installed VFD (variable frequency drive) option, see service instruction manual provided with the hydronic package. Default password is 00002323.

MAINTENANCE

Recommended Maintenance Schedule The following are only recommended guidelines. Jobsite condi- tions may dictate that maintenance schedule is performed more of- ten than recommended.

ROUTINE: Periodic clean water rinse, especially in coastal and indus-

trial applications. Check condenser coils for debris, clean as necessary.

EVERY MONTH: Check moisture indicating sight glass for possible refriger-

ant loss and presence of moisture. EVERY 3 MONTHS (FOR ALL MACHINES): Check refrigerant charge. 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. Check compressor oil level. Check crankcase heater operation if equipped.

EVERY 6 MONTHS: Check chilled water flow switch sensor tip for buildup.

Clean if necessary. See page page 67. EVERY 12 MONTHS (FOR ALL MACHINES): Check all electrical connections, tighten as necessary. Inspect all contactors and relays, replace as necessary. Check accuracy of thermistors, replace if greater than

2F (1.2C) variance from calibrated thermometer. 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 Wa-

ter Temperature Saturated Suction Temperature) which may indicate fouling. Clean cooler vessel if necessary.

Condenser Coil Maintenance and Cleaning Recommendations Routine cleaning of coil surfaces is essential to maintain proper operation of the unit. See the following sections: MCHX condenser coils See page 61. RTPF condenser coils See page 61.

Control Box Maintenance The control panel for 30RAP100-150 208/230 v and 380 v units has two 24-v fans installed at the right side of the panel to modu- late the inside temperature of the control box. These two fans are controlled by a temperature switch. The temperature switch closes at 120F and opens at 105F. The inlet filter is located at the left side of the control box. Inspect the inlet filter and fan outlet screen every three months, clean as needed.

TROUBLESHOOTING

Complete Unit Stoppage and Restart Possible causes for unit stoppage and reset methods are shown be- low and in Table 43. Refer to Fig. 3-19 for component arrange- ment and control wiring diagrams.

76

GENERAL POWER FAILURE After power is restored, restart is automatic through normal MBB start-up. UNIT ENABLE-OFF-REMOTE CONTROL SWITCH IS OFF When the switch is OFF, the unit will stop immediately. Place the switch in the ENABLE position for local switch control or in the Remote Control position for control through Remote Control clo- sure. CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN After the problem causing the loss of flow has been corrected, re- set is manual by resetting the alarm with the scrolling marquee as shown in Table 44. OPEN 24-V CONTROL CIRCUIT BREAKER(S) Determine 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 re- starts 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 44.

Table 43 Troubleshooting

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.

SYMPTOMS CAUSE REMEDY Cooler Circulating Pump Does Not Run

Power line open Reset circuit breaker. 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. Pump seized Replace pump.

Compressor Cycles Off on Loss of Charge

Low refrigerant charge Repair leak and recharge.

Compressor Cycles Off on Cooler Freeze Protection

Thermistor failure Replace thermistor. System load was reduced faster than controller could remove stages

Unit will restart after fluid temperature rises back into the control band. Avoid rapidly removing system load.

Compressor Shuts Down on High-Pressure Control

High-pressure control acting erratically Replace control. Noncondensables in system Evacuate and recharge. Condenser dirty Clean condenser. Fans not operating Repair or replace if defective. System overcharged with refrigerant Reduce charge.

Unit Operates Too Long or Continuously

Low refrigerant charge Add refrigerant. Control contacts fused Replace control. Partially plugged or plugged expansion valve or filter drier Clean or replace as needed. Defective insulation Replace or repair as needed. Damaged compressor Check compressor and replace if necessary.

Unusual or Loud System Noises

Piping vibration Support piping as required. Check for loose pipe connections or damaged compressor.

Compressor noisy Replace compressor (worn bearings). Check for loose compressor holddown bolts.

Compressor Loses Oil Leak in system Repair leak. Mechanical damage (Failed seals or broken scrolls) Replace compressor. Oil trapped in line 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 a

normal condition for brine applications) Replace valve if defective.

Stuck EXV (electronic expansion valve) 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 32F (0C).

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.

77

Table 44 Alarm and Alert Codes

See Legend on page 82.

ALARM/ ALERT CODE

ALARM OR

ALERT DESCRIPTION

WHY WAS THIS ALARM

GENERATED?

ACTION TAKEN BY CONTROL

RESET METHOD

PROBABLE CAUSE

P051 Pre-Alert Circuit A, Compressor 1 Failure Compressor feedback sig- nal does not match relay state

Compressor A1 Shut down for 5 minutes Automatic

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

P052 Pre-Alert Circuit A, Compressor 2 Failure Compressor feedback sig- nal does not match relay state

Compressor A2 Shut down for 5 minutes Automatic

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

P053 Pre-Alert Circuit A, Compressor 3 Failure Compressor feedback sig- nal does not match relay state

Compressor A3 Shut down for 5 minutes Automatic

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

P055 Pre-Alert Circuit B, Compressor 1 Failure Compressor feedback sig- nal does not match relay state

Compressor B1 Shut down for 5 minutes Automatic

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

P056 Pre-Alert Circuit B, Compressor 2 Failure Compressor feedback sig- nal does not match relay state

Compressor B2 Shut down for 5 minutes Automatic

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

P057 Pre-Alert Circuit B, Compressor 3 Failure Compressor feedback sig- nal does not match relay state

Compressor B3 Shut down for 5 minutes Automatic

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

T051 Alert Circuit A, Compressor 1 Failure

3 consecutive P051 Pre- Alerts without compressor feedback signal matching relay state.

Compressor A1 shut down. Manual

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

A051

Alarm Circuit A, Compressor 1 Stuck On Failure

CSB reads ON while the compressor relay has been commanded OFF

Compressor A1 shut down Manual

Welded compressor contac- tor, welded relay output on MBB or CXB, failed CSB or wiring error.

Alarm Circuit A, Compressor 1 Chattering Contactor

CSB reads current/no cur- rent/current/no current cycling in any 16 second win- dow.

Compressor A1 shut down Manual

Refrigerant charge, wiring error, plugged condenser coil, condenser fan motor failure.

T052 Alert Circuit A, Compressor 2 Failure

3 consecutive P052 Pre- Alerts without compressor feedback signal matching relay state.

Compressor A2 shut down. Manual

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

A052

Alarm Circuit A, Compressor 2 Stuck On Failure

CSB reads ON while the compressor relay has been commanded OFF

Compressor A2 shut down Manual

Welded compressor contac- tor, welded relay output on MBB or CXB, failed CSB or wiring error.

Alarm Circuit A, Compressor 2 Chattering Contactor

CSB reads current/no cur- rent/current/no current cycling in any 16 second win- dow.

Compressor A2 shut down Manual

Refrigerant charge, wiring error, plugged condenser coil, condenser fan motor failure.

T053 Alert Circuit A, Compressor 3 Failure

3 consecutive P053 Pre- Alerts without compressor feedback signal matching relay state.

Compressor A3 shut down. Manual

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of condenser air, filter drier plugged, non-condensables, operation beyond capability.

A053

Alarm Circuit A, Compressor 3 Stuck On Failure

CSB reads ON while the compressor relay has been commanded OFF

Compressor A3 shut down Manual

Welded compressor contac- tor, welded relay output on MBB or CXB, failed CSB or wiring error.

Alarm Circuit A, Compressor 3 Chattering Contactor

CSB reads current/no cur- rent/current/no current cycling in any 16 second win- dow.

Compressor A3 shut down Manual

Refrigerant charge, wiring error, plugged condenser coil, condenser fan motor failure.

78

Table 44 Alarm and Alert Codes (cont)

See Legend on page 82.

ALARM/ ALERT CODE

ALARM OR

ALERT DESCRIPTION

WHY WAS THIS ALARM

GENERATED?

ACTION TAKEN BY CONTROL

RESET METHOD

PROBABLE CAUSE

T055 Alert Circuit B, Compressor 1 Failure

3 consecutive P055 Pre-Alerts without compressor feedback signal matching relay state.

Compressor B1 shut down. Manual

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of con- denser air, filter drier plugged, non-condensables, operation beyond capability.

A055

Alarm Circuit B, Compressor 1 Stuck On Failure

CSB reads ON while the com- pressor relay has been com- manded OFF

Compressor B1 shut down Manual

Welded compressor contac- tor, welded relay output on MBB or CXB, failed CSB or wiring error.

Alarm Circuit B, Compressor 1 Chattering Contactor

CSB reads current/no current/ current/no current cycling in any 16 second window.

Compressor B1 shut down Manual

Refrigerant charge, wiring error, plugged condenser coil, condenser fan motor failure.

T056 Alert Circuit B, Compressor 2 Failure

3 consecutive P056 Pre-Alerts without compressor feedback signal matching relay state.

Compressor B2 shut down. Manual

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of con- denser air, filter drier plugged, non-condensables, operation beyond capability.

A056

Alarm Circuit B, Compressor 2 Stuck On Failure

CSB reads ON while the com- pressor relay has been com- manded OFF

Compressor B2 shut down Manual

Welded compressor contac- tor, welded relay output on MBB or CXB, failed CSB or wiring error.

Alarm Circuit B, Compressor 2 Chattering Contactor

CSB reads current/no current/ current/no current cycling in any 16 second window.

Compressor B2 shut down Manual

Refrigerant charge, wiring error, plugged condenser coil, condenser fan motor failure.

T057 Alert Circuit B, Compressor 3 Failure

3 consecutive P057 Pre-Alerts without compressor feedback signal matching relay state.

Compressor B3 shut down. Manual

High-pressure switch open, solid-state motor protection module, internal overload open, faulty CSB, loss of con- denser air, filter drier plugged, non-condensables, operation beyond capability.

A057

Alarm Circuit B, Compressor 3 Stuck On Failure

CSB reads ON while the com- pressor relay has been com- manded OFF

Compressor B3 shut down Manual

Welded compressor contac- tor, welded relay output on MBB or CXB, failed CSB or wiring error.

Alarm Circuit B, Compressor 3 Chattering Contactor

CSB reads current/no current/ current/no current cycling in any 16 second window.

Compressor B3 shut down Manual

Refrigerant charge, wiring error, plugged condenser coil, condenser fan motor failure.

A060 Alarm Cooler Leaving Fluid Thermistor Failure

Thermistor outside range of 40 to 245F (40 to 118C)

Chiller shut down immediately Automatic Thermistor failure, damaged

cable/wire or wiring error.

A061 Alarm Cooler Entering Fluid Thermistor Failure

Thermistor outside range of 40 to 245F (40 to 118C)

Chiller shut down immediately Automatic Thermistor failure, damaged

cable/wire or wiring error.

T068 Alert Circuit A Return Gas Thermistor Failure

Return gas thermistor is out- side range of 40 to 245F (40 to 118C)

Circuit A shut down Automatic Thermistor failure, damaged cable/wire or wiring error.

T069 Alert Circuit B Return Gas Thermistor Failure

Return gas thermistor is out- side range of 40 to 245F (40 to 118C)

Circuit B shut down Automatic Thermistor failure, damaged cable/wire or wiring error.

T073 Alert Outside Air Thermistor Failure

Thermistor outside range of 40 to 245F (40 to 118C)

Temperature reset disabled. Chiller runs under normal control/set points. When capacity reaches 0, cooler/pump heaters are energized.

Automatic Thermistor failure, damaged cable/wire or wiring error.

T074 Alert Space Temperature/ Dual Chiller Thermis- tor Failure

Thermistor outside range of 40 to 245F (40 to 118C)

Temperature reset dis- abled. Chiller runs under normal control/set points.

Automatic Thermistor failure, damaged cable/wire or wiring error.

T077 Alert

Circuit A Saturated Suction Temperature exceeds Cooler Leav- ing Fluid Temperature

Saturated suction temperature is greater than leaving fluid temperature for 5 minutes.

Circuit A shutdown Manual Faulty expansion valve or suction pressure transducer or leaving fluid thermistor.

T078 Alert

Circuit B Saturated Suction Temperature exceeds Cooler Leav- ing Fluid Temperature

Saturated suction temperature is greater than leaving fluid temperature for 5 minutes.

Circuit B shutdown Manual Faulty expansion valve or suction pressure transducer or leaving fluid thermistor.

T079 Alert Lead/Lag LWT Thermistor Failure

Thermistor outside range of 40 to 245F (40 to 118C)

Chiller runs as a stand alone machine Automatic

Dual LWT thermistor failure, damaged cable/wire or wiring error.

T090 Alert Circuit A Discharge Pressure Transducer Failure

Outside of range (0 to 667 psig) Circuit A shut down Automatic

Transducer failure, poor connection to MBB, or wiring damage/error.

T091 Alert Circuit B Discharge Pressure Transducer Failure

Outside of range (0 to 667 psig) Circuit B shut down Automatic

Transducer failure, poor connection to MBB, or wiring damage/error.

T092 Alert Circuit A Suction Pressure Transducer Failure

Outside of range (0 to 420 psig) Circuit A shut down Automatic

Transducer failure, poor connection to MBB, or wiring damage/error.

79

Table 44 Alarm and Alert Codes (cont)

See Legend on page 82.

ALARM/ ALERT CODE

ALARM OR

ALERT DESCRIPTION

WHY WAS THIS ALARM

GENERATED?

ACTION TAKEN BY CONTROL

RESET METHOD

PROBABLE CAUSE

T093 Alert Circuit B Suction Pressure Transducer Failure

Outside of range (0 to 420 psig) Circuit B shut down Automatic

Transducer failure, poor connection to MBB, or wiring damage/error.

T094 Alert Discharge Gas Thermistor Failure

Discharge thermistor (DTT) is either open or shorted

Size 010,015 chiller shut down. Digital com- pressor shut down.

Automatic Thermistor failure, damaged cable/wire or wiring error.

T110 Alert Circuit A Loss of Charge

If the compressors are off and discharge pressure reading is < 26 psig for 30 sec.

Circuit not allowed to start. Manual Refrigerant leak or

transducer failure

T111 Alert Circuit B Loss of Charge

If the compressors are off and discharge pressure reading is < 26 psig for 30 sec.

Circuit not allowed to start. Manual Refrigerant leak or

transducer failure

T112 Alert Circuit A High Saturated Suction Temperature

Circuit saturated suction temperature pressure transducer > 70F (21.1C) for 5 minutes

Circuit shut down Manual

Faulty Expansion valve, faulty suction pressure transducer or high entering fluid temperature.

T113 Alert Circuit B High Saturated Suction Temperature

Circuit saturated suction temperature pressure transducer > 70F (21.1C) for 5 minutes

Circuit shut down Manual

Faulty Expansion valve, faulty suction pressure transducer or high entering fluid temperature.

T114 Alert Circuit A Low Suction Superheat

Suction superheat is less than 3F (1.7C) for 5 minutes.

Circuit A shut down.

Automatic restart after first daily occurrence. Manual restart thereafter.

Faulty expansion valve, faulty suction pressure transducer, faulty suction gas thermistor, circuit overcharged

T115 Alert Circuit B Low Suction Superheat

Suction superheat is less than 3F (1.7C) for 5 minutes.

Circuit B shut down.

Automatic restart after first daily occurrence. Manual restart thereafter.

Faulty expansion valve, faulty suction pressure transducer, faulty suction gas thermistor, circuit overcharged

T116 Alert Circuit A Low Cooler Suction Temperature

Mode 7 caused the com- pressor to unload 3 consecu- tive times with less than a 30-minute interval between each circuit shutdown.

Circuit shut down Manual

Faulty expansion valve, low refrigerant charge, plugged filter drier, faulty suction pressure transducer, low cooler fluid flow, improper brine freeze set point

T117 Alert Circuit B Low Cooler Suction Temperature

Mode 8 caused the com- pressor to unload 3 consecu- tive times with less than a 30-minute interval between each circuit shutdown.

Circuit shut down Manual

Faulty expansion valve, low refrigerant charge, plugged filter drier, faulty suction pressure transducer, low cooler fluid flow, improper brine freeze set point

P118 Pre-Alert High Discharge Gas Temperature

Discharge Thermistor (DTT) reading is greater than 250F

Compressor A1 shut down Automatic

Refrigerant charge, plugged filter drier, head pressure control.

T118/ A118 Alert High Discharge Gas

Temperature

3 Discharge Gas Tempera- ture alerts occur within a day

Compressor A1 shut down Manual

Refrigerant charge, plugged filter drier, head pressure control.

T126 Alert Circuit A High Head Pressure

Compressor operation out- side of operating envelope. Circuit shut down

Automatic, only after first 3 daily occur- rences. Manual reset thereaf- ter. Reading from OAT sensor must drop 5F (2.8C) before restart

Faulty transducer, low/restricted con- denser airflow, incor- rect refrigerant charge, non-con- densables, faulty condenser fan motor, faulty EXV.

T127 Alert Circuit B High Head Pressure

Compressor operation out- side of operating envelope. Circuit shut down

Automatic, only after first 3 daily occurrences. Manual reset thereafter. Reading from OAT sensor must drop 5F (2.8C) before restart

Faulty transducer/ restricted condenser airflow, incorrect refrigerant charge, non-condensables, faulty condenser fan motor, faulty EXV.

T133 Alert Circuit A Low Suction Pressure

Suction pressure below 34 psig for 8 seconds or below 23 psig

Circuit shut down

Automatic restart after first daily occurrence. Manual restart thereafter.

Faulty or sticking EXV, low refrigerant charge, plugged filter drier.

80

Table 44 Alarm and Alert Codes (cont)

See Legend on page 82.

ALARM/ ALERT CODE

ALARM OR

ALERT DESCRIPTION

WHY WAS THIS ALARM

GENERATED?

ACTION TAKEN BY CONTROL

RESET METHOD

PROBABLE CAUSE

T134 Alert Circuit B Low Suction Pressure

Suction pressure below 34 psig for 8 seconds or below 23 psig

Circuit shut down

Automatic restart after first daily occurrence. Manual restart thereafter.

Faulty or sticking EXV, low refrigerant charge, plugged filter drier.

A140 Alarm Reverse Rotation Detected

Suction pressure failed to drop when compressor is energized

Chiller not allowed to start. Manual

Verify correct com- pressor rotation. Check for correct fan rotation first.

A150 Alarm Unit is in Emergency Stop

CCN emergency stop command received Chiller shutdown

Automatic once CCN command for EMSTOP returns to normal

CCN Network command.

A151 Alarm Illegal Configuration One or more illegal configurations exists.

Chiller is not allowed to start.

Manual once configuration errors are corrected

Configuration error. Check unit settings.

A152 Alarm Unit Down Due to Failure

Both circuits are down due to alarms/alerts.

Chiller is unable to run.

Automatic once alarms/alerts are cleared that prevent the chiller from starting.

Alarm notifies user that chiller is 100% down.

T153 Alert Real Time Clock Hardware Failure Internal clock on MBB fails

Occupancy schedule will not be used. Chiller defaults to Local On mode.

Automatic when correct clock control restarts.

Time/Date/Month/ Day/Year not properly set.

A154 Alarm Serial EEPROM Hardware Failure Hardware failure with MBB Chiller is unable

to run. Manual Main Base Board failure.

T155 Alert Serial EEPROM Storage Failure

Configuration/storage failure with MBB No Action Manual

Potential failure of MBB. Download current operating software. Replace MBB if error occurs again.

A156 Alarm Critical Serial EEPROM Storage Failure

Configuration/storage failure with MBB

Chiller is not allowed to run. Manual Main Base Board

failure.

A157 Alarm A/D Hardware Failure Hardware failure with peripheral device

Chiller is not allowed to run. Manual Main Base Board

failure.

T170 Alert Loss of communication with the Compressor Expansion Module

MBB cannot communicate with CXB

Compressor A1 shut down Automatic

Wiring error, faulty wiring or failed CXB. Incorrect configura- tion.

A172 Alarm Loss of Communication with EXV board

MBB loses communication with EXV board

Chiller is not allowed to run. Automatic

Wiring error, faulty wiring or failed EXV board.

T173 Alert Loss of Communication with EMM

MBB loses communication with EMM

4 to 20 mA temperature reset disabled. Demand Limit set to 100%. 4 to 20 mA set point disabled.

Automatic

Wiring error, faulty wiring or failed Energy Management Module (EMM).

T174 Alert 4 to 20 mA Cooling Set Point Input Failure

If configured with EMM and input less than 2 mA or greater than 22 mA

Set point function disabled. Chiller controls to CSP1.

Automatic Faulty signal generator, wiring error, or faulty EMM.

T175 Alert Loss of Communication with the AUX Board

MBB loses communication with AUX Board.

Chiller is not allowed to run. Automatic

Wiring error, faulty wiring or failed AUX board, incorrect configuration.

T176 Alert 4 to 20 mA Temperature Reset Input Failure

If configured with EMM and input less than 2 mA or greater than 22 mA

Reset function disabled. Chiller returns to normal set point control.

Automatic Faulty signal generator, wiring error, or faulty EMM.

T177 Alert 4 to 20 mA Demand Limit Input Failure

If configured with EMM and input less than 2 mA or greater than 22 mA

Demand limit function disabled. Chiller returns to 100% demand limit control.

Automatic Faulty signal generator, wiring error, or faulty EMM.

A179 Alarm Fan VFD Communica- tion Failure

The MBB lost communica- tion with the Danfoss VFD1 module.

Chiller shut down. Automatic

Wrong VFD address, damaged communi- cation cable, wiring error, no power to VFD, unresponsive VFD.

A189 Alarm Cooler Pump Auxiliary Contact Inputs Miswired

Pump 1 Auxiliary Contacts are closed when Pump 2 output is energized or if Pump 2 Auxiliary Contacts are closed when Pump 1 output is energized.

Both pump outputs are turned off. Automatic

Wiring error, faulty pump contactor auxiliary contacts.

T190 ALERT Cooler Pump 1 Aux Contacts Failed to Close at Start-Up

Pump 1 Auxiliary Contacts did not close within 26 seconds after pump was started

Pump 1 turned off. Pump 2 will be started if available. Manual

Wiring error, faulty contacts on pump contactor

81

Table 44 Alarm and Alert Codes (cont)

See Legend on page 82.

ALARM/ ALERT CODE

ALARM OR

ALERT DESCRIPTION

WHY WAS THIS ALARM

GENERATED?

ACTION TAKEN BY CONTROL

RESET METHOD

PROBABLE CAUSE

T191 ALERT Cooler Pump 2 Aux Contacts Failed to Close at Start-Up

Pump 2 Auxiliary Contacts did not close within 26 seconds after pump was started

Pump 2 turned off. Pump 1 will be started if available. Manual

Wiring error, faulty contacts on pump contactor

T192 Alert Cooler Pump 1 Failed to Provide Flow at Start-Up

Pump 1 did not provide flow to close flow switch within 60 seconds

Pump 1 turned off. Pump 2 will be started if available.

Manual

Wiring error, pump circuit breaker tripped, contactor failure

T193 Alert Cooler Pump 2 Failed to Provide Flow at Start-Up

Pump 2 did not provide flow to close flow switch within 60 seconds

Pump 1 turned off. Pump 2 will be started if available.

Manual

Wiring error, pump circuit breaker tripped, contactor fail- ure

T194 Alert

Cooler Pump 1 Aux Contacts Opened During Normal Operation

Pump 1 Auxiliary Contacts open for 26 seconds after initially made. All compressors shut down. Pump 1 turned off.

Pump 2 will be started if available. Chiller allowed to run if Pump 2 successfully starts.

Manual Wiring error, faulty contacts on pump contactor

T195 Alert

Cooler Pump 2 Aux Contacts Opened During Normal Operation

Pump 2 Auxiliary Contacts open for 26 seconds after initially made. All compressors shut down. Pump 2 turned off.

Pump 1 will be started if available. Chiller allowed to run if Pump 1 successfully starts.

Manual Wiring error, faulty contacts on pump contactor

T196 Alert Flow Lost While Pump 1 Running

Cooler flow switch contacts open for 3 seconds after initially made

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.

Manual

Wiring error, pump circuit breaker tripped, contactor fail- ure

T197 Alert Flow Lost While Pump 2 Running

Cooler flow switch contacts open for 3 seconds after initially made

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.

Manual

Wiring error, pump circuit breaker tripped, contactor failure

A198 Alarm Cooler Pump 1 Aux Contacts Closed While Pump Off

Pump 1 Auxiliary Contacts closed for 2 minutes when pump state is off

Chiller not allowed to start

Manual when aux contacts open

Wiring error, faulty pump contactor (welded contacts), pump in hand position

A199 Alert Cooler Pump 2 Aux Contacts Closed While Pump Off

Pump 2 Auxiliary Contacts closed for 2 minutes when pump state is off

Chiller not allowed to start

Manual when aux contacts open

Wiring error, faulty pump contactor (welded contacts), pump in hand position

P200 /A200

Pre- Alert/ Alarm

Cooler Flow/Interlock Contacts Failed to Close at Start-Up

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

Chiller not allowed to start. For models with dual pumps, the second pump will be started if available

Manual

Wiring error, pump circuit breaker tripped, contactor failure, faulty flow switch or interlock

P201 /A201

Pre- Alert/ Alarm

Cooler Flow/Interlock Contacts Opened During Normal Operation

Flow switch opens for at least 3 seconds after being initially closed

All compressors shut down. For models with dual pumps, the second pump will be started if available

Automatic (P201) or Manual (A201)

Cooler pump failure, faulty flow switch or interlock, pump circuit breaker tripped

A202 Alarm Cooler Pump Interlock Closed When Pump is Off

If configured for cooler pump control and flow switch input is closed for 5 minutes while pump output(s) are off

Chiller not allowed to start

Automatic when aux contacts open

Wiring error, faulty pump contactor (welded contacts)

T203 Alert Loss of Communication with Slave Chiller

Master chiller MBB loses communication with slave chiller MBB

Dual chiller control disabled. Chiller runs as a stand-alone machine.

Automatic

Wiring error, faulty wiring, failed Slave chiller MBB module, power loss at slave chiller, wrong slave address.

T204 Alert Loss of Communication with Master Chiller

Slave chiller MBB loses communication with master chiller MBB

Dual chiller control disabled. Chiller runs as a stand-alone machine

Automatic

Wiring error, faulty wiring, failed master chiller MBB module, power loss at Master chiller.

T205 Alert Master and Slave Chiller with Same Address

Master and slave chiller have the same CCN address (CCN.A)

Dual chiller routine disabled. Master/slave run as stand-alone chillers.

Automatic

CCN Address for both chillers is the same. Must be different. Check CCN.A under the OPT2 sub-mode in Configuration at both chillers.

82

Table 44 Alarm and Alert Codes (cont)

LEGEND

ALARM/ ALERT CODE

ALARM OR

ALERT DESCRIPTION

WHY WAS THIS ALARM

GENERATED?

ACTION TAKEN BY CONTROL

RESET METHOD

PROBABLE CAUSE

A207 Alarm Cooler Freeze Protection

Cooler EWT or LWT is less than Brine Freeze (BR.FZ)

Chiller shutdown. Cooler pump continues to run a minimum of 5 minutes (if control enabled).

Both EWT and LWT must be at least 6 F (3.3 C) above Brine Freeze point (BR.FZ). Automatic for first, Manual reset thereaf- ter.

Faulty thermistor, low water flow, faulty cooler water.

T206 Alert High Leaving Chilled Water Temperature

LWT is greater than control point and LCW Alert Limit, and capacity is at 100% for one minute.

Alert only. No action taken. Automatic

Building load greater than unit capacity, or compressor fault. Check for other alarms/alerts.

A208 Alarm EWT or LWT Thermistor failure

Cooler EWT is less than LWT by 3 F (1.7 C) for 1 minute after a circuit is started

Chiller shutdown. Cooler pump shut off (if control enabled).

Manual

Faulty cooler pump, low water flow, plugged fluid strainer, faulty thermistor.

T300 Alert Cooler Pump 1 Scheduled Maintenance Due

Pump 1 Service Countdown (P.1.DN) expired. Complete pump 1 maintenance and enter 'YES' for Pump 1 Maintenance Done (P.1.MN) item.

None Automatic Routine pump maintenance required

T301 Alert Cooler Pump 2 Scheduled Maintenance Due

Pump 2 Service Countdown (P.2.DN) expired. Complete pump 2 maintenance and enter 'YES' for Pump 1 Maintenance Done (P.2.MN) item.

None Automatic Routine pump maintenance required

T302 Alert Strainer Blowdown Scheduled Maintenance Due

Strainer Service Countdown (S.T.DN) expired. Complete strainer blowdown and enter 'YES' for Strainer Maintenance Done (S.T.MN) item.

None Automatic Routine strainer maintenance required

T303 Alert Condenser Coil Maintenance Due

Coil Service Countdown (C.L.DN) expired. Complete condenser coil cleaning and enter 'YES' for Coil Maintenance Done (C.L.MN) item.

None Automatic Routine condenser coil maintenance required

A412 Alarm Variable Speed Fan Motor/Drive Failure Alarm See Table 45 and Table 46 Chiller shut down Automatic

See Table 45 - HEVCF Common Alarms and Table 46 - HEVCF Alarm/Alert Details, Danfoss Drive

T413 Alert Variable Speed Fan Motor/Drive Failure Alert See Table 45 and Table 46 None Automatic

See Table 45 - HEVCF Common Alarms and Table 46 - HEVCF Alarm/Alert Details, Danfoss Drive

T501 Alert Current Sensor Board A1 Failure

Alert occurs when CSB out- put is a constant high value

Compressor A1 shut down Automatic CSB failure.

Wiring error.

T502 Alert Current Sensor Board A2 Failure

Alert occurs when CSB out- put is a constant high value

Compressor A2 shut down Automatic CSB failure.

Wiring error.

T503 Alert Current Sensor Board A3 Failure

Alert occurs when CSB out- put is a constant high value

Compressor A3 shut down Automatic CSB failure.

Wiring error.

T505 Alert Current Sensor Board B1 Failure

Alert occurs when CSB out- put is a constant high value

Compressor B1 shut down Automatic CSB failure.

Wiring error.

T506 Alert Current Sensor Board B2 Failure

Alert occurs when CSB out- put is a constant high value

Compressor B2 shut down Automatic CSB failure.

Wiring error.

T507 Alert Current Sensor Board B3 Failure

Alert occurs when CSB out- put is a constant high value

Compressor B3 shut down Automatic CSB failure.

Wiring error. T950 Alert Loss of Communication

with Water System Manager

No communications have been received by the MBB within 5 minutes of last transmission

WSM forces removed. Chiller runs under own control

Automatic Failed module, wiring error, failed transformer, loose connection plug, wrong address

A951 Alert Loss of Communication with Chillervisor System Manager

No communications have been received by the MBB within 5 minutes of last transmission

CSM forces removed. Chiller runs under own control

Automatic Failed module, wiring error, failed transformer, loose connection plug, wrong address

CCN Carrier Comfort Network CSB Current Sensor Board CSM Chillervisor System Manager CXB Current Sensor Board EEPROM Electronic Erasable 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

83

Table 45 HEVCF Common Alarms

*Danfoss Drive Alarm Code.

ALARM DESCRIPTION PROBABLE CAUSE

A179 Loss of communication with the Danfoss VFD module Wrong VFD address, damaged communication cable, wiring error, no power to VFD, unrespon- sive VFD.

A412 Mains phase loss(A4)* Phase is missing or imbalance is too high on supply side. Check incoming wiring, drive fuses,

and incoming power to unit. This is also used for a fault in the input rectifier on the frequency con- verter.

A412 Inverter Overload(A9)* Frequency converter has cut out due to excessive current and temperature over a certain time period. Check motors for locked rotor or shorts.

A412 Torque Limit(A12)* Motor torque limit has been exceeded. Check motor for locked rotor or fan restrictions. A412 Over Current(A13)* Inverter peak current limit is exceeded. Check motor for locked rotor or fan restrictions.

A412 Earth (ground) Fault(A14)* Current exists between output phases and ground. Check motors for short to ground. Check wir- ing connections at fan motor terminal block at drive.

A412 Short Circuit(A16)* There is a short circuit in the motor wiring. Find the short circuit and repair.

A412 Control Word Timeout(A17)* Drive is not communicating with chiller. Check LEN bus wiring connections. Ensure address is set properly.

A412 Heatsink Temp(A29)* Heatsink has exceeded max temperature. Check drive fan operation and blockage of air-flow to heatsink fins.

A412 Motor Phase U Missing(A30)* Check load side wiring to motor for missing phase. A412 Motor Phase V Missing(A31)* Check load side wiring to motor for missing phase. A412 Motor Phase W Missing(A32)* Check load side wiring to motor for missing phase. A412 Fieldbus Communication Fault(A34)* Fieldbus on communication card in drive is not working.

84

Table 46 HEVCF Alarm/Alert Details, Danfoss Drive

NOTE: (X) = Dependent on parameter.

ALARM NO./ WARNING NO. ALARM DESCRIPTION WARNING ALARM/TRIP ALARM/

TRIP LOCK PARAMETER

1 T413 10V Low X 2 T413,A412 Live Zero Error (X) (X) 6-01 3 T413 No Motor (X) 1-80 4 T413,A412 Mains phase Loss (X) (X) (X) 14-12 5 T413 DC Voltage High X 6 T413 DC Voltage Low X 7 T413,A412 DC over Volt X X 8 T413,A412 DC under Volt X X 9 T413,A412 Inverter Overld X X

10 T413,A412 Motor ETR Over (X) (X) 1-90 11 T413,A412 Motor Thermistor Over (X) (X) 1-90 12 T413,A412 Torque Limit X X 13 T413,A412 Over Current X X X 14 T413,A412 Earth Fault X X X 16 A412 Short Circuit X X 17 T413,A412 Ctrl Word TO (X) (X) 8-04 23 T413,A412 Fans Warn X X 25 T413,A412 Brake Resistor X X 26 T413,A412 Brake Overload (X) (X) 2-13 28 T413,A412 Brake Check (X) (X) 2-15 29 A412 Pwr Card Temp X X 30 A412 U phase Loss (X) (X) 4-58 31 A412 V phase Loss (X) (X) 4-58 32 A412 W phase Loss (X) (X) 4-58 33 A412 Inrush Fault X X 34 T413,A412 Fieldbus Fault X X 36 T413,A412 Mains Failure X X 38 A412 Internal Fault X X 47 T413,A412 24V Supply Low X X X 48 A412 1.8V Supply Low X X 49 T413 Speed Limit (X) 1-86 57 A412 AMA Not OK X 59 T413 Current Limit X 61 T413 Encoder Loss X 62 T413 Output freq limit X 64 T413 Voltage Limit X 65 T413,A412 Ctrl Card Temp X X X 66 T413 Low Temp X 67 A412 Option Change X 68 A412 Safe Stop X 71 T413,A412 PTC1 Safe Stop X X 72 T413,A412 Dangerous Failure X X X 80 A412 Drive Initialized X 94 T413,A412 End of curve (X) (X) 22-50 95 T413,A412 Broken Belt (X) (X) 22-60 96 T413 Start delayed (X) 22-76 97 T413 Stop delayed (X) 22-76 98 T413 Clock Failure (X) 0-70

203 T413 Missing Motor X 204 T413 Locked Rotor X 243 T413,A412 Brake IGBT X X 247 T413 Pwr Card Temp X 251 A412 Service Trip X

85

LOW SATURATED SUCTION Several conditions can lead to low saturated suction alarms and the chiller controls have several override modes built in which will attempt to keep the chiller from shutting down. Low fluid flow, low refrigerant charge and plugged filter driers are the main caus- es 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 ComfortLink controls include a compres- sor protection board that protects the operation of each of the com- pressors. 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 cur- rent, 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 compressor electrical box. Compressor Short Circuit There will not be current if the 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 The high-pressure switch has opened. Below are the factory set- tings for the fixed high-pressure switch.

ASTP Protection Trip All non-digital Copeland compressors are equipped with an ad- vanced scroll temperature protection (ASTP). A label located above the terminal box identifies models that contain this technol- ogy. See Fig. 60.

Advanced scroll temperature protection is a form of internal dis- charge temperature protection that unloads the scroll compressor when the internal temperature reaches approximately 300F. 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. 61 for approximate reset times. To manually reset ASTP, the compressor should be stopped and allowed to cool. If the 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 automati- cally before the motor protector resets, which may take up to 2 hours.

30RAP UNIT SIZE

CUTOUT CUT-IN PSIG KPA PSIG KPA

010-150 650 4482 500 3447

Fig. 60 Advanced Scroll Temperature Protection Label (010-090)

Fig. 61 Recommended Minimum Cool Down Time After Compressor Is Stopped*

0 10 20 30 40 50 60 70 80 90 100 110 120

0 10 20 30 40 50 60 70 80 90

R ec

om m

en de

d C

oo lin

g T

im e

(M in

ut es

)

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.

86

Motor Overload Protection COPELAND COMPRESSORS MODELS WITH ELECTRI- CAL CODE TF (010-090) Models with a TF in the electrical code (i.e., ZP120KCE-TFD) have an internal line break motor overload located in the center of the Y of the motor windings. This overload disconnects all three legs of the motor from power in case of an over-current or over- temperature condition. The overload reacts to a combination of motor current and motor winding temperature. The internal over- load protects against single phasing. Time must be allowed for the motor to cool down before the overload will reset. If current mon- itoring to the compressor is available, the system controller can take advantage of the compressor internal overload operation. The controller can lock out the compressor if current draw is not coin- cident with contactor energizing, implying that the compressor has shut off on its internal overload. This will prevent unnecessary compressor cycling on a fault condition until corrective action can be taken. COPELAND COMPRESSORS MODELS WITH ELECTRI- CAL CODE TW OR TE (010-090) OR DANFOSS COM- PRESSOR (100-150)

Copeland models with TW or TE in the electrical code (i.e.,ZP182KCE-TWD or ZP182KCE-TED) or Danfoss com- pressor have a motor overload system that consists of an external electronic control module connected to a chain of four thermistors embedded in the motor windings. The module will trip and remain off for a minimum of 30 minutes if the motor temperature exceeds a preset point to allow the scrolls to cool down after the motor temperature limit has been reached. It may take as long as two hours for the motor to cool down before the overload will reset. NOTE: Turning off power to the module resets it immediately.

For this reason, module power must never be switched with the control circuit voltage. Current sensing boards monitor to the compressor current. The ComfortLink control system takes advantage of the compressor overload operation by locking out the compressor if current draw is not detected. This will prevent unnecessary compressor cycling on a fault condition until corrective action can be taken. Kriwan Motor Protection Module Troubleshooting Copeland models with a TW in the electrical code (i.e., ZP182KCE-TWD), have a motor overload system that consists of an external Kriwan electronic control module. These have been re- placed by the CoreSense1 communication module for motor pro- tection. This section is included for reference, and contains in- structions for replacing the Kriwan module with the CoreSense module in the field. Follow the steps listed below to troubleshoot the Kriwan module in the field. See wiring diagram on terminal box cover, or Fig. 62.

1. De-energize control circuit and module power. Remove the control circuit wires from the module (terminals M1 and M2). Connect a jumper across these control circuit wires. This will bypass the control contact of the module.

2. Re-energize the control circuit and module power. If the com- pressor will not operate with the jumper installed, then the problem is external to the solid-state protection system. If the compressor operates with the module bypassed but will not operate when the module is reconnected, then the control cir- cuit relay in the module is open. Remove the temporary jumper installed in Step 1.

3. The thermistor protection chain now needs to be tested to determine if the modules control circuit relay is open due to excessive internal temperatures or a faulty component. Check the thermistor protection chain located in the compres- sor as follows: a. De-energize control circuit and module power. b. Remove the sensor leads from the module (S1 and S2).

CAUTION

The electronic motor protection module is a safety device that must not be bypassed or compressor damage may result.

CAUTION

Restarting the compressor sooner may cause a destructive temperature buildup in the scrolls.

1. CoreSense is a trademark of Emerson Climate Technologies.

WARNING

Do not supply power to unit with compressor cover removed. Failure to follow this warning can cause a fire, resulting in per- sonal injury or death.

WARNING

Exercise extreme caution when reading compressor currents when high-voltage power is on. Correct any of the problems described below before installing and running a replacement compressor. Wear safety glasses and gloves when handling refrigerants. Failure to follow this warning can cause fire, resulting in personal injury or death.

CAUTION

Do not manually operate contactors. Serious damage to the machine may result.

CAUTION

The motor protection system within the compressor is now bypassed. Use this configuration to temporarily test module only.

1 2 3

LEGEND 1 Kriwan Motor Protection Module Power 2 Kriwan Control Circuit Connections 3 Motor Thermal Sensor

Fig. 62 Kriwan Motor Protection Module

87

c. Measure the resistance of the thermistor protection chain through these sensor leads with an ohm meter.

d. The diagnosis of this resistance reading is as follows: 200 to 2250 ohms: Normal operating range 2750 ohms or greater: Compressor overheated. Allow

time to cool. Zero resistance: Shorted sensor circuit. Replace the

compressor. Infinite resistance: Open sensor circuit. Replace the

compressor. 4. If the resistance reading is abnormal, remove the sensor con-

nector plug from the compressor and measure the resistance at the sensor fusite pins. This will determine if the abnormal reading was due to a faulty connector.

5. On initial start-up, and after any module trip, the resistance of the sensor chain must be below the module reset point before the module circuit will close. Reset values are 2250 to 3000 ohms.

6. If the sensor chain has a resistance that is below 2250 ohms, and the compressor will run with the control circuit bypassed, but will not run when connected properly, the solid-state module is defective and should be replaced. The replacement module must have the same supply voltage rating as the orig- inal module.

CoreSense Replacement of Kriwan Motor Protection Module The Kriwan module has been replaced by the CoreSense commu- nication module for motor protection. Minor wiring changes are required as described below.

Removing the Kriwan motor protection module: 1. Disconnect and lock out the high voltage and control voltage

supply to the unit. 2. Using a straight blade screwdriver, carefully depress the tabs

holding the terminal cover to the terminal box to remove the terminal cover. Before proceeding, use a volt meter to verify that the power has been disconnected from the unit.

3. Using wire markers, label the M1, M2, T1, and T2 wires that are connected to the Kriwan module. Using needle nose pli- ers, remove the M1, M2, T1, T2, S1 and S2 wires from the Kriwan motor protector module.

4. Gently bend the holding tabs holding the Kriwan module in the terminal box and remove the Kriwan module from the ter- minal box. See Fig. 63.

5. Take note of the S1-S2 plug orientation on the compressor thermistor fusite. Remove the S1-S2 wire harness and plug from the compressor.

Fig. 63 Kriwan Motor Protection Module Removal

Installing the CoreSense communications module: 1. A new S1-S2 thermistor wiring harness is shipped with the

CoreSense kit and must be used. The wiring harness connec- tor block should be fully inserted on the three pins in the ori- entation shown in Fig. 64 for proper operation.

2. Review the DIP switch settings on the CoreSense module. DIP switch no. 1 should be ON (up position) and all other DIP switches should be OFF (down position). See Fig. 65.

CAUTION

Use an ohmmeter with a maximum of 9 volts to check the sen- sor chain. The sensor chain is sensitive and easily damaged; no attempt should be made to check continuity through it with anything other than an ohmmeter. The application of any external voltage to the sensor chain may cause damage requir- ing the replacement of the compressor.

WARNING

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag all dis- connect locations to alert others not to restore power until work is completed.

WARNING

Do not supply power to unit with compressor cover removed. Failure to follow this warning can cause a fire, resulting in per- sonal injury or death.

HOLDING TAB

HOLDING TAB

a38-7310

INSTALL IN THIS ORIENTATION

A38-7311

Fig. 64 Compressor Motor Sensor Harness Installation

ROCKER DOWN

O F F

ON

OFF OFF OFF OFF OFF OFF OFF OFF

1 2 3 4 5 6 7 8 9

OFF

10

A38-7812

Fig. 65 CoreSense Communication DIP Switch Settings for Kriwan Retrofit

88

3. Install the CoreSense module in the compressor terminal box as shown in Fig. 66, with the tabs holding the module in place. Route the thermistor wire harness as shown and plug the harness into the 2x2 socket on the CoreSense module.

4. Connect the previously labeled M1, M2, T1, and T2 wires to the appropriate terminals on the CoreSense module.

5. Connect the L1, L2, and L3 phase sensing wires to the L1, L2, and L3 compressor terminal block connections. See the compressor terminal cover diagram for identification of the L1, L2, and L3 terminal block connections.

6. Double-check the installation and make sure all connections are secure. Install the compressor terminal cover.

The CoreSense retrofit is complete and the system can be put back into service.

CoreSense Communications Module Troubleshooting Copeland models with a TE in the electrical code (i.e., ZP182KCETED) have a motor overload system that consists of an external CoreSense communication electronic control module. Motor thermistors are connected to the CoreSense communication module via a 2x2 plug (Fig. 67). The CoreSense communications module has field configurable DIP switches for addressing and configuring the module. The DIP switches should be addressed as shown in Table 47. The CoreSense communication module has a green and a red light-emitting diode (LED). A solid green LED indicates the mod- ule is powered and operation is normal. A solid red LED indicates an internal problem with the module. If a solid red LED is encoun- tered, power down the module (interrupt the T1-T2 power) for 30 seconds to reboot the module. If a solid red LED is persistent, change the CoreSense module. The CoreSense module communicates warning codes via a green flashing LED. Warning codes do not result in a trip or lockout

condition. Alert codes are communicated via a red flashing LED. Alert codes will result in a trip condition and possibly a lockout condition. See wiring diagram on terminal box cover, or Fig. 68. The flash code corresponds to the number of LED flashes, fol- lowed by a pause; then the flash code is repeated. A lockout condi- tion produces a red flash, followed by a pause, a solid red, a sec- ond pause, and then repeated. Table 48 lists the flash code infor- mation for Warning and Alert codes along with code reset and troubleshooting information.

Table 47 CoreSense Communication Module DIP Switch Settings

*Settings for Kriwan retrofit. See CoreSense Replacement of Kriwan Motor Protection Module on page 87.

1 2 3 4 5 6 7 8 9 10

T2 T1

L3 L2

L1

RED

BLACK

WHITE

BLUE HOLDING TAB

HOLDING TAB

THERMISTOR WIRE HARNESS PLUGGED INTO 2X2 SOCKETBLACK

WHITE A38-7313

Fig. 66 CoreSense Communication Module Mounting

MOTOR PTC

CIRCUIT

SCROLL NTC CIRCUIT (NOT USED)

FOR FUTURE USE

COMMON CONNECTION a38-7308

Fig. 67 CoreSense Communication Motor Thermistor Plug

1 2 3 4 5 6 7 8 9 10

T2 T1 L3L2L1

M2 M1

JUMPER

COMMUNICATION PORT

DIP SWITCHES LEDS

R

G

MOTOR THERMAL SENSORS

CONTROL CIRCUIT CONNECTIONS

MODULE POWER

COMPRESSOR PHASE SENSING A38-7314

Fig. 68 CoreSense Communication Motor Protection Wiring

COPELAND ELECTRICAL

CODE

DIP SWITCH

1 2 3 4 5 6 7 8 9 10

TE ON OFF OFF OFF OFF OFF OFF OFF ON OFF TW* ON OFF OFF OFF OFF OFF OFF OFF OFF OFF

89

Table 48 CoreSense Communication Module LED Flash Codes

Warning Codes (Green LED Flash Code): Code 1 Loss of Communication: The module will flash the

green Warning LED one time indicating the module has not communicated with the master controller for longer than 5 minutes. Once communication is reinitiated, the Warning will be cleared. The 30RAP units do not support the communica- tion capability of this module.

Code 2 Reserved For Future Use Code 3 Short Cycling: The module will flash the green

Warning LED three times indicating the compressor has short cycled more than 48 times in 24 hours. A short cycle is defined as compressor runtime of less than 1 minute. The Warning will be activated when the Short Cycling DIP Switch (no. 10) is OFF (in the down position). When fewer than 48 short cycles are accumulated in 24 hours the Warn- ing code will be cleared.

Code 4 Open/Shorted Scroll Thermistor: The module will flash the green Warning LED four times, indicating that the scroll NTC thermistor has a resistance value that indicates

an open/shorted thermistor. The Warning will be cleared when the resistance value is in the normal range. The 30RAP units do not utilize a scroll thermistor.

Code 5 Not used. Alert/Lockout Codes (Red LED Flash Code): Code 1 Motor High Temperature: The module will flash

the red Alert LED one time indicating the motor PTC circuit has exceeded 4500 . A Code 1 Alert will open the M2-M1 contacts. The Alert will reset after 30 minutes and the M2- M1 contacts will close if the resistance of the motor PTC circuit is below 2750 . Five consecutive Code 1 Alerts will lock out the compressor. Once the module has locked out the compressor, a power cycle will be required for the lock- out to be cleared.

Code 2 Open/Shorted Motor Thermistor: The module will flash the red Alert LED 2 times indicating the motor PTC thermistor circuit has a resistance value greater than 2200 or less than 100 . that indicates an open/shorted thermistor chain. A Code 2 Alert will open the M2-M1 contacts. The

LED STATUS FAULT CONDITION FAULT CODE DESCRIPTION FAULT CODE RESET TROUBLESHOOTING

INFORMATION

SOLID GREEN None, normal operation Module is powered and under normal operation

Not applicable None

SOLID RED Module malfunction Module has an internal fault Not applicable 1. Reset module by removing

power from T1-T2. 2. Replace module.

WARNING LED FLASH

GREEN FLASH CODE 1

Loss of communication Module and Master Control- ler have lost communica- tions with each other for more than 5 minutes

Automatic when communi- cations are re-established

Not Supported. Check DIP Switch settings.

GREEN FLASH CODE 2 Not used Not applicable Not applicable Not applicable

GREEN FLASH CODE 3

Short cycling Run time of less than 1 min- ute. Number of short cycles exceeds 48 in a 24-hour period.

Fewer than 48 short cycles in 24 hours

30RAP controls do not allow this operation normally. Con- firm proper wiring and DIP switch settings.

GREEN FLASH CODE 4 Open/Shorted Scroll Thermistor

Not applicable Not applicable Not applicable

GREEN FLASH CODE 5 Not used Not applicable Not applicable Not applicable ALERT/LOCKOUT LED FLASH

RED FLASH CODE 1

High motor temperature Thermistor resistance greater than 4500 . Lock- out occurs after 5 alerts.

Thermistor resistance less than 2750 and 30 min- utes have elapsed

1. Check power supply. 2. Check system charge and

superheat. 3. Check compressor

contactor.

RED FLASH CODE 2

Open/shorted motor thermistor

Thermistor resistance greater than 4500 , or less than 100 . Lockout occurs after 6 hours.

Thermistor resistance is between 100 and 2750 and 30 minutes have elapsed

1. Check for poor connec- tions at module and therm- istor fusite.

2. Check continuity of therm- istor wiring harness.

3. Check for an open thermis- tor circuit.

RED FLASH CODE 3

Short cycling Run time of less than 1 min- ute. Lockout if the number of alerts exceeds the num- ber configured by the user in 24 hours.

Interrupt power to T2-T1 30RAP controls do not allow this operation normally. Con- firm proper wiring.

RED FLASH CODE 4 Scroll high temperature Not applicable Not applicable Not applicable RED FLASH CODE 5 Not used Not applicable Not applicable Not applicable

RED FLASH CODE 6

Missing phase Missing phase detected. Lockout after 10 consecu- tive alerts.

After 5 minutes and missing phase condition is not pres- ent

1. Check incoming power. 2. Check fuses or circuit

breakers. 3. Check compressor contactor.

RED FLASH CODE 7

Reverse phase Reverse phase detected. Lockout after 1 alert.

Interrupt power to T2-T1 1. Check incoming power phase sequence

2. Check compressor contactor 3. Check module phase wir-

ing A-B-C. RED FLASH CODE 8 Not used Not applicable Not applicable Not applicable

RED FLASH CODE 9

Module low voltage Less than 18 vac supplied to module

After 5 minutes and voltage is between 18 and 30 vac

This alert does not result in a lockout fault. 1. Verify correct 24 vac mod-

ule is installed. 2. Check for a wiring error.

90

Alert will reset after 30 minutes and the M2-M1 contacts will close if the resistance of the motor PTC circuit is back in the normal range. The module will lock out the compressor if the trip condition exists for longer than 6 hours. Once the module has locked out the compressor, a power cycle will be required to clear the lockout.

Code 3 Short Cycling: The module will flash the red Alert LED 3 times indicating the compressor is locked out due to short cycling. A Code 3 Alert will open the M2-M1 con- tacts. Code 3 will be enabled when the Short Cycling DIP switch (no. 10) is ON (in the up position) and the compres- sor has exceeded the number of short cycles configured by the user in a 24-hour period. Once the module has locked out the compressor, a power cycle will be required to clear the lockout.

Code 4 Scroll High Temperature: The module will flash the red Alert LED 4 times indicating the scroll NTC circuit is less than 2400 . A Code 4 Alert will open the M2-M1 contacts. The Alert will reset after 30 minutes and the M2- M1 contacts will close if the resistance of the scroll NTC circuit is higher than 5100 . The module will lock out the compressor if the number of Code 4 Alerts exceeds the user configurable number of Code 4 events within a 24-hour period. Once the module has locked out the compressor, a power cycle will be required to clear the lockout.

Code 5 Not used. Code 6 Missing Phase: The module will flash the red

Alert LED 6 times indicating a missing phase in one of the three leads to the compressor. A Code 6 Alert will open the M2-M1 contacts. The Alert will reset after 5 minutes and the M2-M1 contacts will close if the missing phase condi- tion is not present. The module will lock out the compressor after 10 consecutive Code 6 Alerts. Once the module has locked out the compressor, a power cycle will be required to clear the lockout.

Code 7 Reverse Phase: The module will flash the red Alert LED 7 times indicating a reverse phase in two of the three leads to the compressor. A Code 7 Alert will open the M2-M1 contacts. The module will lock out the compressor after one Code 7 Alert. A power cycle will be required to clear the lockout.

Code 8 Not used. Code 9 Module Low Voltage: The module will flash the

red Alert LED 9 times indicating low module voltage, less than 18 vac on the T2-T1 terminals for more than 5 seconds. A Code 9 Alert will open the M2-M1 contacts. The Alert will reset after 5 minutes and the M2-M1 contacts will close if the T2-T1 voltage is above the reset value in 18 to 30 vac.

Resetting Alert codes can be accomplished manually by cycling power to the module (disconnect T2 or T1 for 5 seconds). If the fault that initiated the Alert code is absent after the reset is per- formed, the Alert code will be cleared and CoreSense module will allow normal operation. If the fault is still present after the reset is performed, the fault code will continue to be displayed via the green or red flashing LED. Troubleshooting procedures described for the Kriwan module sec- tion (page 86) are applicable to the CoreSense communication module. Copeland replacement compressors are shipped with two solid- stage motor protection modules. A 120/240-volt module is in- stalled and a 24-volt module is shipped with the compressor. The 30RAP units require the 24-volt module be field installed. Failure to install the 24-volt module will result in a compressor failure alarm. See Fig. 69.

Danfoss Electronic Module Replacement of Kriwan Motor Protection Module The Kriwan module has been replaced by the Danfoss communi- cation module for motor protection on all Danfoss compressors. Motor Overheating and Overloading The motor protector comprises a control module and PTC sensors embedded in the motor winding. The close contact between thermistors and wind- ings ensures a very low level of thermal inertia. The motor temperature is constantly measured by a PTC thermis- tor loop connected on S1-S2. If the thermistor exceeds its response temperature, its resistance increases above the trip level (4,500 ) and the output relay then trips; i.e., contacts M1-M2 are open. Af- ter cooling to below the response temperature (resistance < 2,750 ), a 5-minute time delay is activated. After this delay has elapsed, the relay is once again pulled in; i.e., contacts M1-M2 are closed. The time delay may be canceled by means of resetting the mains (L-N-disconnect) for approximately 5 seconds. A red/green twin LED is visible on the module. A solid green LED denotes a fault-free condition. A blinking red LED indicates an identifiable fault condition. See Fig. 70 and 71.

Fig. 69 Solid-State Motor Protection Module

1 2 3 4 5 6 7 8 9 10

T2 T1 L3L2L1

M2 M1

JUMPER

COMMUNICATION PORT

DIP SWITCHES LEDS

R

G

MOTOR THERMAL SENSORS

CONTROL CIRCUIT CONNECTIONS

MODULE POWER

COMPRESSOR PHASE SENSING A38-7314

Fig. 70 PTC Overheat

91

Phase Loss, Phase Sequence The electronic module pro- vides protection against phase reversal and phase loss at start- up. The circuit should be thoroughly checked in order to determine the cause of the phase problem before re-energizing the control circuit. The phase sequencing and phase loss monitoring functions are active during a 5-second window 1 second after the compres- sor start-up (power on L1-L2-L3). See Fig. 72.

Should one of these parameters be incorrect, the relay would lock out (contact M1-M2 [or 11-14] open). The red LED on the module will show the following blink code (Fig. 73 and 74).

The lockout may be canceled by resetting the power mains (dis- connect L-N) for approximately 5 seconds. Internal Module Failure Protection An internal microproces- sor fault leads to trip; relay contacts M1-M2 open. Fault Diagnosis If the relay contacts M1-M2 are open, carry out the following steps: 1. Check all electrical connections (wiring, drawing conformi-

ty, connection tightness, etc.) 2. Try to reset by interrupting mains supply to the module for at

least 5 seconds. If, after reset, the relay contacts M1-M2 are closed, a fault in motor power supply or high motor temperature caused a trip condition (missing phase, wrong phase sequence, operating outside of the compressor operating envelope, etc.). If the relay contacts M1-M2 remain open:

a. Disconnect the PTC thermistor leads and measure the resistance value at this point (max measurement voltage 3V). R=: PTC loop opened; remove compressor. R>2750: wait until compressor motor winding

temperature has cooled down, then reconnect PTC and try to reset; check root causes of motor over- heating (operation outside of working envelope, etc.).

150 <1250: normal resistance value for PTC at ambient temperature; continue with step 2.b.

R=0: PTC loop in short circuit; replace the compressor.

b. Test the module itself within the terminal box: Disconnect L-N. Disconnect S1-S2. Disconnect M1-M2. Reconnect mains supply L-N. Bridge S1-S2. Try to reset by interrupting mains supply to the

module for at least 5 seconds. Check relay contacts M1-M2 with ohmmeter.

If the relay contacts M1-M2 are closed, module is okay.

Fig. 71 PTC Reset Delay Active (after PTC Overheat)

Fig. 72 Phase Sequence Module Logic

Fig. 73 In Case of Phase Loss Error

Fig. 74 In Case of Phase Reverse Error

92

If the relay contacts M1-M2 are still open, replace the module.

High Discharge Gas Temperature Protection Units equipped with digital compressors have an additional therm- istor located on the discharge line. If discharge temperature ex- ceeds 265F (129.4C), the digital compressor will be shut off. Alarms will also occur if the current sensor board malfunctions or is not properly connected to its assigned digital input. If the com- pressor is commanded OFF and the current sensor reads ON, an alert is generated. This will indicate that a compressor 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 44. If the unit is in alarm and unable to operate, Control Mode (STAT) = 4 (Off Emrgcy). Automatic alarms will reset without operator intervention if the condition corrects itself. The following method must be used to re- set 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 and un- til the sub-menu item RCRN RESET ALL CURRENT ALARMS is displayed. Press . The control will prompt the user for a password, by displaying PASS and WORD. Press

to display the default password, 1111. Press for each character. If the password has been changed, use the arrow keys to change each individual character. Toggle the display to YES and press . The alarms will be reset. COMPRESSOR FAILURE ALERTS T051, T052, T053 (Circuit A Compressor Failures) T055, T056, T057 (Circuit B Compressor Failures) Alert codes T051-T053 are for compressors A1-A3, respectively, and T055-T057 are for compressors B1-B3, respectively. These alerts occur when the current sensor (CS) does not detect com- pressor current during compressor operation. 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 overload protector is open or the external overload protector (Kriwan module) has activated. The external overload protector modules are mounted in the compres- sor wiring junction box. Temperature sensors embedded in the compressor motor windings 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 se- ries with the compressor contactor coil. In a compressor motor overload condition, contact opens, deenergizing the compressor contactor. Low Refrigerant Charge If the compressor operates for an extended period of time with low refrigerant charge, the compressor ASTP device will open, which will cause the compressor 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 compressor to start. To check out alerts T051-T057: 1. 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 open, open internal protection, circuit breaker trip, incorrect safety wiring, or incorrect com- pressor wiring.

2. If the compressor does start, verify it is rotating in the correct direction.

COMPRESSOR STUCK ON FAILURE ALARMS Circuit A A051, A052, A053 Circuit B A055, A056, A057 Alarm codes A051, A052, A053, A055, A056, and A057 are for compressors A1, A2, A3, B1, B2, and B3. These alarms occur 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 monitored for a peri- od of 10 seconds after the compressor relay has been commanded OFF. This is done to facilitate a service technician forcing a relay to test a compressor. In addition, if a compressor stuck failure occurs and the current sensor board reports the compressor and the request off, certain di- agnostics 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 com- pressor relay on the MBB.

To check out alarms A051-A057: 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 operation

to verify that compressor current sensor is working and con- denser fans are energized.

Circuit A A051, A052, A053 (Chattering Failure) Circuit B A055, A056, A057 (Chattering Failure) Alarm codes A051, A052, A053 are for compressors A1, A2, and A3: A055, A056, and A057 are for compressors B1, B2, and B3. The compressor is commanded ON. If the compressor feed- back indicates a feedback regular expression of 11*00*11*0 during any given 16-sec. time period, the alert is tripped. In

ENTER

ENTER

ENTER ENTER

ENTER

IMPORTANT: Prolonged operation in the wrong direction can damage the compressor. Correct rotation can be verified 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 contac- tor 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 compres- sor operation to verify that compressor current sensor is work- ing and condenser fans are energized.

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regular expression notation X* means any number of occur- rences of X (including 0 occurrences). For the expression 11*00*11*0, read as at least 1 ON state, followed by at least 1 OFF state, followed by at least one ON state, followed by one OFF state. (In the given expression, 1 is ON, 0 is OFF.) When this occurs, the control turns off the compressor and a manual reset is required. POSSIBLE CAUSES Typically this failure will indicate that the high pressure switch (HPS) is chattering. The HPS is in series with the 24 VAC that is providing power to the on-board relay (which in turn is powering the coil of the compressor contactor). It is possible for the HPS to reset faster than the control can detect it reliably (without experi- encing nuisance trips), thus the need for chattering compressor logic. Note that the HPS also has chattering logic applied to it. A060 (Cooler Leaving Fluid Thermistor Failure) If the sen- sor reading is outside the range of 40 to 245F (40 to 118C) then the alarm will occur. The cause of the alarm is usually 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 240F (40 to116C) then the alarm will occur. The cause of the alarm is usually 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. T068, T069 (Circuit A,B Compressor Return Gas Temperature Thermistor Failure) This alert occurs when the compressor re- turn gas temperature sensor is outside the range of 40 to 240F (40 to 116C). Failure of this thermistor will shut down the ap- propriate circuit. T073 (Outside Air Temperature Thermistor Failure) This alert occurs when the outside air temperature sensor is outside the range of 40 to 240F (40 to 116C). Failure of this thermistor will disable any elements of the control which require its use. T074 (Space Temperature Thermistor Failure) This alert oc- curs when the space temperature sensor is outside the range of 40 to 245F (40 to 118C). 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 error, or a loose connection. T077 (Circuit A Saturated Suction Temperature exceeds Cooler Leaving Fluid Temperature) T078 (Circuit B Saturated Suction Temperature exceeds Cooler Leaving Fluid Temperature) Alert codes T077 and T078 occur when a compressor in a circuit has been running and the saturated suction temperature is greater than the cooler leaving water temperature for 5 minutes. The alert is generated and the cir- cuit is shut down. The alert automatically resets when the saturat- ed suction temperature is less than the leaving water temperature minus 1F (0.5C). T090 (Circuit A Discharge Pressure Transducer Failure) T091 (Circuit B Discharge Pressure Transducer Failure) Alert codes T090 and T091 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 marquee to reset the alert. The cause of the alert is usual- ly a faulty transducer, faulty 5-v power supply, or a loose connec- tion. T092 (Circuit A Suction Pressure Transducer Failure) T093 (Circuit B Suction Pressure Transducer Failure) Alert codes T092 and T093 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 occurs for units which have the digital compressor installed on circuit A. If discharge gas temperature is open or shorted, the circuit will be shut off. The alert will reset itself when discharge temperature is less than 250 F (121.1 C). The cause of the alert is usually low re- frigerant charge or a faulty thermistor. T110 (Circuit A Loss of Charge) T111 (Circuit B Loss of Charge) Alert codes T110 and T111 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 T112 and T113 occur when compressors in a circuit have been running for at least 5 minutes and the circuit saturated suc- tion temperature is greater than 70 F (21.1 C). The high saturated suction alert is generated and the circuit is shut down. T114 (Circuit A Low Suction Superheat) T115 (Circuit B Low Suction Superheat) Alert codes T114 and T115 occur when the superheat of a circuit is less than 5F (2.8 C) for 5 continuous minutes. The low superheat alert is gener- ated and the circuit is shut down. T116 (Circuit A Low Cooler Suction Temperature) T117 (Circuit B Low Cooler Suction Temperature) Alert codes T116 and T117 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) A118 (High Discharge Gas Temperature Alarm) This alert or alarm occurs for units which have the digital compressor installed on circuit A. If discharge gas temperature is greater than 268F (131.1C), the circuit will be shut off. The alert will reset itself when discharge temperature is less than 250F (121.1C). 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 T126 and T127 are for circuits A and B, respectively. These alerts occur when the appropriate saturated condensing temperature is greater than the operating envelope shown in Fig. 28 or 29. 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 max- imum SCT minus 5F (2.7C). If SCT continues to rise to greater than the maximum SCT, the alert will occur and the circuit's re- maining compressor will shut down. The cause of the alarm is usually an overcharged system, high outdoor ambient temperature coupled with dirty outdoor coil, non-condensables, faulty con- denser fan motor, plugged filter drier, or a faulty high-pressure switch. T133 (Circuit A Low Suction Pressure) T134 (Circuit B Low Suction Pressure) Alert codes T133 and T134 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 temperature head pressure control. Add wind baffles if required. A140 (Reverse Rotation Detected) A test is made once, when compressor is energized, for suction pressure change on the first activated circuit. The unit control determines failure as follows:

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1. The suction pressure of both circuits is sampled 5 seconds before the compressor is brought on, right when the com- pressor is brought on, and 5 seconds afterwards.

2. The rate of suction pressure change from 5 seconds before the compressor is brought on to when the compressor 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 rota- tion error.

This alarm will disable mechanical cooling and will require man- ual 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. If the CCN point name EMSTOP in the system table is set to emergency stop, the unit will shut down immediately and broad- cast 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 in- valid configuration has been entered. The following are illegal configurations. Invalid unit size has been entered. Fluid is water with ICE making configured. Incorrect AUX board installed with Motormaster config-

ured (AUX 1 must be used). Incorrect AUX software version (must be 3.0 or higher). A152 (Unit Down Due to Failure) Both circuits 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. T153 (Real Time Clock Hardware Failure) A problem has been detected with MBB real time clock hardware. Try resetting the power and check the indicator lights. If the alarm continues, the board should be replaced. A154 (Serial EEPROM Hardware Failure) A 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 re- setting the power and check the indicator lights. If the alert contin- ues, 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 detected 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. T170 (Loss of Communication with the Compressor Expan- sion Module) This alert indicates that there are communica- tions problems with the compressor expansion module. All func- tions performed by the CXB will stop. The alarm will automati- cally reset. 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 Failure) This alert indicates that there are communications problems with the energy management. All functions performed by the

EMM will stop, which can include demand limit, reset and capac- ity input. The alarm will automatically reset. T174 (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. All functions performed by the AUX board will stop, which can include digital scroll unloader operation and low ambient head pressure control. The alarm will automatically reset. T176 (4 to 20 mA Reset Input Failure) This alert indicates 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. A179 (Fan VFD Communication Failure) This alarm indi- cates that there are communications problems between MBB and fan VFD. When this alarm occurs, the chiller will shut down. Re- set is automatic when all alarms are cleared. A189 (Cooler Pump Auxiliary Contacts Inputs Miswired) This alarm indicates that Pump 1 auxiliary contacts are closed when Pump 2 output is energized or Pump 2 auxiliary contacts are closed when Pump 1 output is energized. When this alarm occurs, both pump outputs are turned off. Reset is automatic when all alarms are cleared. T190 (Cooler Pump 1 Aux Contacts Failed to Close at Start- Up) This alert indicates that Pump 1 auxiliary contacts did not close within 26 seconds after Pump 1 was started. When this alert occurs, Pump 1 will be turned off. Pump 2 will be started if avail- able. Manual reset is required for this alert. T191 (Cooler Pump 2 Aux Contacts Failed to Close at Start- Up) This alert indicates that Pump 2 auxiliary contacts did not close within 26 seconds after Pump 2 was started. When this alert occurs, Pump 2 will be turned off. Pump 1 will be started if avail- able. Manual reset is required for this alert. T192 (Cooler Pump 1 Failed to Provide Flow at Start-Up) This alert indicates that Pump 1 did not provide flow to close flow switch within 60 seconds after Pump 1 was started. When this alert occurs, Pump 1 will be turned off. Pump 2 will be started if available. Manual reset is required for this alert. T193 (Cooler Pump 2 Failed to Provide Flow at Start-Up) This alert indicates that Pump 2 did not provide flow to close flow switch within 60 seconds after Pump 2 was started. When this alert occurs, Pump 2 will be turned off. Pump 1 will be started if available. Manual reset is required for this alert. T194 (Cooler Pump 1 Aux Contacts Opened During Normal Operation) This alert indicates that Pump 1 auxiliary contacts open for 26 seconds after initially made. When this alert occurs, all compressors shut down and Pump 1 will be turned off. Pump 2 will be started if available. Chiller will be allowed to run if Pump 2 starts successfully. Manual reset is required for this alert. T195 (Cooler Pump 2 Aux Contacts Opened During Normal Operation) This alert indicates that Pump 2 auxiliary contacts open for 26 seconds after initially made. When this alert occurs, all compressors shut down and Pump 2 will be turned off. Pump 1 will be started if available. Chiller will be allowed to run if Pump 1 starts successfully. Manual reset is required for this alert. T196 (Flow Lost While Pump 1 Running) This alert indi- cates that cooler flow switch contacts open for 3 seconds after ini- tially made, when Pump 1 is running. When this alert occurs, all compressors shut down and Pump 1 will be turned off. Pump 2 will be started if available. Chiller will be allowed to run if Pump 2 starts successfully. Manual reset is required for this alert.

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T197 (Flow Lost While Pump 2 Running) This alert indi- cates that cooler flow switch contacts open for 3 seconds after ini- tially made, when Pump 2 is running. When this alert occurs, all compressors shut down and Pump 2 will be turned off. Pump 1 will be started if available. Chiller will be allowed to run if Pump 1 starts successfully. Manual reset is required for this alert. A198 (Cooler Pump 1 Aux Contacts Closed While Pump Off) This alert indicates that Pump 1 auxiliary contacts closed for 2 minutes when pump state is off. When this alarm occurs, chiller is not allowed to start. Manual reset is required for this alarm, when aux contact becomes open. A199 (Cooler Pump 2 Aux Contacts Closed While Pump Off) This alert indicates that Pump 2 auxiliary contacts closed for 2 minutes when pump state is off. When this alarm occurs, Chiller is not allowed to start. Manual reset is required for this alarm, when aux contact becomes open. P200 Cooler Flow/Interlock Contacts Failed to Close at Start-Up Pre-Alert A200 Cooler Flow/Interlock Contacts Failed to Close at Start-Up Alarm These alarms will occur if the cooler flow switch/cooler pump interlock contacts failed to close within 1 minute after start-up, if cooler pump control is enabled; or within 5 minutes after start-up, if cooler pump control is not enabled. If the unit is equipped with dual pumps, the second pump will be started and time allowed to prove flow before the unit is alarmed. When this alarm occurs, the chiller is not allowed to start. The alarm will require manual reset. If this condition is encountered, check the following items: chilled water flow switch, for proper operation flow switch cable, for power and control chilled water loop to be sure that it is completely filled with

water, and all air has been purged chilled water pump interlock circuit, for proper operation pump electrical circuit for power pump circuit breaker pump contactor, for proper operation chilled water pump, for proper operation; look for overload

trips chilled water strainer for a restriction all isolation valves are open completely P201 Cooler Flow/Interlock Contacts Opened During Nor- mal Operation Pre-Alert A201 Cooler Flow/Interlock Contacts Opened During Nor- mal Operation Alarm If the chilled water flow switch opens for at least three (3) seconds after initially being closed, a P201 Cooler Flow/Interlock Contacts Opened During Normal Operation Pre-Alert will be generated for the appropriate pump and the ma- chine will stop. If available, the other pump will be started. If flow is proven, the machine will be allowed to restart. If after 5 minutes, the cooler flow switch/interlock contacts do not close, the alarm will change to an A201 Cooler Flow/Interlock Contacts Opened During Normal Operation Alarm. When this alarm occurs, the chiller will be shut down. The pre- alert (P201) will be reset automatically; the alarm (A201) will re- quire manual reset. Possible Causes: If this condition is encountered, check the following items: chilled water flow switch, for proper operation. flow switch cable, for power and control. chilled water loop to be sure that it is completely filled with

water, and all air has been purged. chilled water pump interlock circuit for proper operation. In units that do not control the chilled water pump, check the Cooler Pump Shutdown Delay (ConfigurationOPT1 PM.DY). The factory default is set to one minute. If the unit is signaled to stop and the pumps are shutdown shortly after the command, this alarm may trigger. Try setting the delay to 0. Look at the system operation sequence to be sure that the unit has

enough time to shut down, before the chilled water flow stops. Check the following items: pump electrical circuit for power. pump circuit breaker. pump contactor, for proper operation. chilled water pump for proper operation; look for overload

trips. chilled water strainer for a restriction. all isolation valves are open completely. A202 (Cooler Pump Interlock Closed When Pump is Off) This alarm indicates that if the chiller is configured for cooler pump control, the flow switch input is closed for 5 minutes while the pump outputs are off. When this alarm occurs, the chiller will shut down. Reset is automatic when auxiliary contact becomes open. T203 (Loss of Communication with Slave Chiller) This alert indicates that the master chiller MBB loses communication with the slave chiller MBB. When this alert occurs, dual chiller routine will be disabled; Master/Slave will run as stand-alone chillers. Re- set is automatic when all alerts are cleared. T204 (Loss of Communication with Master Chiller) This alert indicates that the slave chiller MBB loses communication with the master chiller MBB. When this alert occurs, dual chiller routine will be disabled; Master/Slave will run as stand-alone chillers. Reset is automatic when all alerts are cleared. T205 (Master and Slave Chiller with Same Address) This alert indicates that the master and slave chiller have the same CCN address (CCN.A). When this alert occurs, dual chiller routine will be disabled; Master/Slave will run as stand-alone chillers. Reset is automatic when all alerts are cleared. T206 High Leaving Chilled Water Temperature Alert This alert will be generated if the unit is at 100% capacity for at least 60 seconds and the Leaving Water Temperature, LWT (Run StatusVIEW) is greater than the Control Point, CTPT (Run StatusVIEW) plus the High Leaving Chilled Water Alert Limit, LCWT (ConfigurationOPT2). LWT > CTPT + LCWT LCWT is field selectable from 2 to 60 F (1.1 to 33.3 C) and is defaulted at 60 F (33.3 C). The unit will not generate this alert if Capacity, CAP (Run Sta- tusVIEW) is less than 100%. If the unit's available capacity is less than 100%, this alert will not be generated. No action will be taken; this is an alert only. This alert will reset automatically if one of two conditions is met: 1. If the Leaving Water Temperature, LWT (Run Sta-

tusVIEW) is less than the Control Point, CTPT (Run Sta- tusVIEW) plus the High Leaving Chilled Water Alert Limit, LCWT (ConfigurationOPT2) minus 5F (2.8C). LWT < CTPT + LCWT 5F (2.8C)

2. If the Leaving Water Temperature, LWT (Run Sta- tusVIEW) is less than the Control Point, CTPT (Run Sta- tusVIEW). LWT < CTPT

If this condition is encountered, check to be sure building load does not exceed unit capacity. A207 (Cooler Freeze Protection) This alarm indicates that cooler EWT or LWT is less than Brine Freeze (BR.FZ). When this alarm occurs, chiller will shut down; the cooler pump will continue to run a minimum of 5 minutes if control enabled. Both EWT and LWT must be at least 6F (3.3C) above the brine freeze point (BR.FZ) to clear the alarm. The alarm will be cleared auto- matically for the first time, then manual reset will be required thereafter. A208 (EWT or LWT Thermistor Failure) This alarm indi- cates that cooler EWT is less than LWT by 3F for one minute af- ter a circuit is started. When this alarm occurs, chiller will shut

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down; the cooler pump will shut off if control enabled. Manual re- set will be required for this alarm. T300 (Cooler Pump 1 Scheduled Maintenance Due) This alert indicates that Pump 1 Service Countdown (P.1.DN) expired. Complete Pump 1 maintenance and enter YES for Pump 1 Maintenance Done (P.1.MN) item to clear the alert. Reset is auto- matic when all alerts are cleared. T301 (Cooler Pump 2 Scheduled Maintenance Due) This alert indicates that Pump 2 Service Countdown (P.2.DN) expired. Complete Pump 2 maintenance and enter YES for Pump 2 Maintenance Done (P.2.MN) item to clear the alert. Reset is auto- matic when all alerts are cleared. T302 (Strainer Blowdown Scheduled Maintenance Due) This alert indicates that Strainer Service Countdown (S.T.DN) ex- pired. Complete the strainer blowdown maintenance and enter YES for Strainer Maintenance Done (S.T.MN) item to clear the alert. Reset is automatic when all alerts are cleared. T303 (Condenser Coil Maintenance Due) This alert indicates that Coil Service Countdown (C.L.DN) expired. Complete the condenser coil cleaning and enter YES for Coil Maintenance Done (C.L.MN) item to clear the alert. Reset is automatic when all alerts are cleared. A412 (Variable Speed Fan Motor/Drive Failure) This alarm indicates that there is a variable speed fan motor/VFD related alarm. See Tables 44 and 45 for details. When this alarm occurs,

chiller will shut down, or is not allowed to start. Reset is automatic when all alarms are cleared. T413 (Variable Speed Fan Motor/Drive Failure) This alert indicates that there is a variable speed fan motor/VFD related alert See Tables 44 and 45 for details. When this alert occurs, there is no impact to normal chiller operation. Reset is automatic when all alerts are cleared. T501, T502, T503 (Current Sensor Board Failure A xx Circuit A) T505, T506, T507 (Current Sensor Board Failure B xx Cir- cuit B) Alert codes T501-T503 are for compressors A1-A3, respectively, and T505-T507 are for compressors B1-B3, respec- tively. 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. T950 (Loss of Communication with Water System Manager) This alert indicates that no communications have been received by the MBB within 5 minutes of last transmission. When this alert occurs, WSM forces will be removed and chiller will run under its own control. Reset is automatic when all alerts are cleared. A951 (Loss of Communication with Chillervisor System Man- ager) This alarm indicates that no communications have been received by the MBB within 5 minutes of last transmission. When this alarm occurs, CSM forces will be removed and chiller will run under its own control. Reset is automatic when all alarms are cleared.

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APPENDIX A DISPLAY TABLES Run Status Mode and Sub-Mode Directory

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

VIEW

AUTO VIEW OF RUN STATUS EWT XXX.X F Entering Fluid Temp LWT XXX.X F Leaving Fluid Temp SETP XXX.X F Internal Active Setpoint CTPT XXX.X F Control Point LOD.F XXX Load/Unload Factor

STAT Control Mode

0=Service Test 1=Off 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

LD.PM Lead Pump OCC YES/NO Occupied

LS.AC YES/NO Low Sound Active MODE YES/NO Override Modes in Effect CAP XXX Percent Total Capacity

STGE X Requested Stage ALRM XXX Current Alarms & Alerts TIME XX.XX Time of Day 00:00-23:59

MNTH XX Month of Year 1 - 12 (1 = January, 2 = February, etc.)

DATE XX Day of Month 01-31 YEAR XX Year of Century

C. TON XXX.X TONS Total Available Capacity

RUN

UNIT RUN HOUR AND START HRS.U XXXX HRS Machine Operating Hours STR.U XXXX Machine Starts HR.P1 XXXX HRS Pump 1 Run Hours HR.P2 XXXX HRS Pump 2 Run Hours

HOUR

CIRC AND COMP RUN HOURS HRS.A XXXX HRS Circuit A Run Hours HRS.B XXXX HRS Circuit B Run Hours See Note HR.A1 XXXX HRS Compressor A1 Run Hours HR.A2 XXXX HRS Compressor A2 Run Hours HR.A3 XXXX HRS Compressor A3 Run Hours HR.B1 XXXX HRS Compressor B1 Run Hours See Note HR.B2 XXXX HRS Compressor B2 Run Hours See Note HR.B3 XXXX HRS Compressor B3 Run Hours See Note

STRT

COMPRESSOR STARTS ST.A1 XXXX Compressor A1 Starts ST.A2 XXXX Compressor A2 Starts ST.A3 XXXX Compressor A3 Starts ST.B1 XXXX Compressor B1 Starts See Note ST.B2 XXXX Compressor B2 Starts See Note ST.B3 XXXX Compressor B3 Starts See Note

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APPENDIX A DISPLAY TABLES (cont)

Run Status Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

PM

PREVENTIVE MAINTENANCE PUMP PUMP MAINTENANCE SI.PM XXXX HRS Pump Service Interval Default: 8760 P.1.DN XXXX HRS Pump 1 Service Countdown P.2.DN XXXX HRS Pump 2 Service Countdown P.1.MN YES/NO Pump 1 Maintenance Done User Entry P.2.MN YES/NO Pump 2 Maintenance Done User Entry PMDT PUMP MAINTENANCE DATES P.1.M0 MM/DD/YY HH:MM P.1.M1 MM/DD/YY HH:MM P.1.M2 MM/DD/YY HH:MM P.1.M3 MM/DD/YY HH:MM P.1.M4 MM/DD/YY HH:MM P.2.M0 MM/DD/YY HH:MM P.2.M1 MM/DD/YY HH:MM P.2.M2 MM/DD/YY HH:MM P.2.M3 MM/DD/YY HH:MM P.2.M4 MM/DD/YY HH:MM STRN STRAINER MAINTENANCE SI.ST XXXX HRS Strainer Srvc Interval Default: 8760

S.T.DN XXXX HRS Strainer Srvc Countdown S.T.MN YES/NO Strainer Maint. Done User Entry ST.DT STRAINER MAINTENANCE DATES S.T.M0 MM/DD/YY HH:MM S.T.M1 MM/DD/YY HH:MM S.T.M2 MM/DD/YY HH:MM S.T.M3 MM/DD/YY HH:MM S.T.M4 MM/DD/YY HH:MM COIL COIL MAINTENANCE SI.CL XXXX HRS Coil Cleaning Srvc Int Default: 8760

C.L.DN XXXX HRS Coil Service Countdown C.L.MN YES/NO Coil Cleaning Maint.Done User Entry CL.DT COIL MAINTENANCE DATES C.L.M0 MM/DD/YY HH:MM C.L.M1 MM/DD/YY HH:MM C.L.M2 MM/DD/YY HH:MM C.L.M3 MM/DD/YY HH:MM C.L.M4 MM/DD/YY HH:MM

VERS

SOFTWARE VERSION NUMBERS MBB CESR131460-XX-XX XX-XX is version number EXV CESR131172-XX-XX XX-XX is version number

AUX1 CESR131333-XX-XX XX-XX is version number EMM CESR131174-XX-XX XX-XX is version number

MARQ CESR131171-XX-XX XX-XX is version number NAVI CESR130227-XX-XX XX-XX is version number CXB CESR131173-XX-XX XX-XX is version number

99

APPENDIX A DISPLAY TABLES (cont) Service Test Mode and Sub-Mode Directory

*Refer to Fig. 30 on page 35 for condenser fan layout.

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT*

TEST Service Test Mode

To enable Service Test mode, move Enable/Off/Remote Control switch to

OFF. Change TEST to ON. Move switch to ENABLE

OUTS

OUTPUTS EXV.A XXX% EXV% Open EXV.B XXX% EXV% Open

FAN1 ON/OFF Fan 1 Relay

Size 010-030: Fan 1 Size 035-060: Fan 3 Size 070-090: Fan 5 Size 100-115: Fan 7 Size 130-150: Fan 9

FAN2 ON/OFF Fan 2 Relay Size 018-030: Fan 2

Size 035-060: Fans 1, 2 Size 070-150: Fan 1

FAN3 ON/OFF Fan 3 Relay Size 055, 060: Fan 4 Size 070-090: Fan 6

Size 100-150: Fans 2, 4 FAN4 ON/OFF Fan 4 Relay Size 070-150: Fan 3

FAN5 ON/OFF Fan 5 Relay Size 070-090: Fan 2 Size 100-115: Fan 5 Size 130-150: Fan 7

FAN6 ON/OFF Fan 6 Relay

Size 080-090: Fan 4 Size 100: Fan 8

Size 115: Fans 6,8 Size 130-150: Fans 8, 10

FAN7 ON/OFF Fan 7 Relay Size130-150: Fan 5 FAN8 ON/OFF Fan 8 Relay Size 150: Fan 6 V.HPA XXX% Var Head Press% Circuit A V.HPB XXX% Var Head Press% Circuit B CLP.1 ON/OFF Cooler Pump Relay 1 CLP.2 ON/OFF Cooler Pump Relay 2 DIG.P XXX% Compressor A1 Load Percent Digital Scroll option only CL.HT ON/OFF Cooler/Pump Heater CCH.A ON/OFF Crankcase Heater Circuit A CCH.B ON/OFF Crankcase Heater Circuit B RMT.A ON/OFF Remote Alarm Relay

CMPA

CIRCUIT A COMPRESSOR TEST CC.A1 ON/OFF Compressor A1 Relay DIG.P XXX% Compressor A1 Load Percent Digital Scroll option only CC.A2 ON/OFF Compressor A2 Relay CC.A3 ON/OFF Compressor A3 Relay MLV ON/OFF Minimum Load Valve Relay

CMPB

CIRCUIT B COMPRESSOR TEST CC.B1 ON/OFF Compressor B1 Relay See Note CC.B2 ON/OFF Compressor B2 Relay See Note CC.B3 ON/OFF Compressor B3 Relay See Note

100

APPENDIX A DISPLAY TABLES (cont) Temperature Mode and Sub-Mode Directory

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

Pressures Mode and Sub-Mode Directory

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

Set Points Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

UNIT

ENTERING AND LEAVING UNIT TEMPERATURES CEWT XXX.X F Cooler Entering Fluid CLWT XXX.X F Cooler Leaving Fluid OAT XXX.X F Outside Air Temperature SPT XXX.X F Space Temperature

DLWT XXX.X F Lead/Lag Leaving Fluid

CIR.A

TEMPERATURES CIRCUIT A SCT.A XXX.X F Saturated Condensing Tmp SST.A XXX.X F Saturated Suction Temp RGT.A XXX.X F Compr Return Gas Temp D.GAS XXX.X F Discharge Gas Temp Digital Scroll option only SH.A XXX.X F Suction Superheat Temp

CIR.B

TEMPERATURES CIRCUIT B SCT.B XXX.X F Saturated Condensing Tmp See Note SST.B XXX.X F Saturated Suction Temp See Note RGT.B XXX.X F Compr Return Gas Temp See Note SH.B XXX.X F Suction Superheat Temp See Note

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

PRC.A PRESSURES CIRCUIT A

DP.A XXX.X PSIG Discharge Pressure SP.A XXX.X PSIG Suction Pressure

PRC.B PRESSURES CIRCUIT B

DP.B XXX.X PSIG Discharge Pressure See Note SP.B XXX.X PSIG Suction Pressure See Note

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION RANGE COMMENT

COOL

COOLING SET POINTS CSP.1 XXX.X F Cooling Set Point 1 20 to 70 Default: 44F CSP.2 XXX.X F Cooling Set Point 2 20 to 70 Default: 44F CSP.3 XXX.X F ICE Set Point 20 to 32 Default: 32F OAT.L XXX.X F OAT Lockout Temp 20 to 120 Default: 20F

HEAD

HEAD PRESSURE SET POINTS H.DP XXX.X F Head Set Point 85 to 120 Default: 95F F.ON XXX.X F Fan On Set Point Read Only Default: 95F F.OFF XXX.X F Fan Off Set Point Read Only Default: 72F B.OFF XX.X F Base Fan Off Delta Temp 10 to 50 Default: 23F F.DLT XX.X F Fan Stage Delta 0 to 50 Default: 15F

FRZ BRINE FREEZE SET POINT

BR.FZ XX.X F Brine Freeze Point 20 to 34 Default: 34F

101

APPENDIX A DISPLAY TABLES (cont) Inputs Mode and Sub-Mode Directory

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

GEN.I

GENERAL INPUTS STST STRT/STOP Start/Stop Switch FLOW ON/OFF Cooler Flow Switch PM.F.1 ON/OFF Cooler Pump 1 Interlock PM.F.2 ON/OFF Cooler Pump 2 Interlock HT.RQ ON/OFF Heat Request DLS1 ON/OFF Demand Limit Switch 1 DLS2 ON/OFF Demand Limit Switch 2 ICED ON/OFF Ice Done DUAL ON/OFF Dual Set Point Switch

CRCT

CIRCUIT INPUTS FKA1 ON/OFF Compressor A1 Feedback FKA2 ON/OFF Compressor A2 Feedback FKA3 ON/OFF Compressor A3 Feedback FKB1 ON/OFF Compressor B1 Feedback See Note FKB2 ON/OFF Compressor B2 Feedback See Note FKB3 ON/OFF Compressor B3 Feedback See Note

4-20

4-20 MA INPUTS DMND XX.X mA 4-20 mA Demand Signal RSET XX.X mA 4-20 mA Reset Signal CSP XX.X mA 4-20 mA Cooling Set Point

102

APPENDIX A DISPLAY TABLES (cont) Outputs Mode and Sub-Mode Directory

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

GEN.O

GENERAL OUTPUTS FAN1 ON/OFF Fan 1 Relay FAN2 ON/OFF Fan 2 Relay FAN3 ON/OFF Fan 3 Relay FAN4 ON/OFF Fan 4 Relay FAN5 ON/OFF Fan 5 Relay FAN6 ON/OFF Fan 6 Relay FAN7 ON/OFF Fan 7 Relay FAN8 ON/OFF Fan 8 Relay V.HPA XXX.X% Fan Speed Circuit A V.HPB XXX.X% Fan Speed Circuit B See Note C.WP1 ON/OFF Cooler Pump Relay 1 C.WP2 ON/OFF Cooler Pump Relay 2 CLHT ON/OFF Cooler/Pump Heater MLV.R ON/OFF Minimum Load Valve Relay

A.EXV

OUTPUTS CIRCUIT A EXV EXV.A XXX.X% EXV% Open APPR XX.X F Circuit A Approach AP.SP XX.X F Approach Setpoint X.SH.R XX.X F SH Reset at Max Unl-Dig S.SH.R XXX.X% Digload to Start SH RST SH_R XX.X F Amount of SH Reset OVR.A XX EXVA Override SPH.A XX.X F Suction Superheat Temp ASH.S XX.X F Active Superheat Setpt AMP.S XX.X F Active Mop Setpt PLM.A XXX.X% Cir A EXV Position Limit SPR.1 XXX.X F Spare 1 Temperature

B.EXV

OUTPUTS CIRCUIT A EXV EXV.B XXX.X% EXV% Open APPR XX.X F Circuit B Approach AP.SP XX.X F Approach Setpoint OVR.B XX EXVB Override SPH.B XX.X F Suction Superheat Temp ASH.S XX.X F Active Superheat Setpt AMP.S XX.X F Active Mop Setpt PLM.B XXX.X% Cir B EXV Position Limit SPR.2 XXX.X F Spare 2 Temperature

CIR.A

OUTPUTS CIRCUIT A CC.A1 ON/OFF Compressor A1 Relay DPE.R XXX.X% Comp A1 Load Percent CC.A2 ON/OFF Compressor A2 Relay CC.A3 ON/OFF Compressor A3 Relay CCH.A ON/OFF Crankcase Heater Circ A

CIR.B

OUTPUTS CIRCUIT B CC.B1 ON/OFF Compressor B1 Relay See Note CC.B2 ON/OFF Compressor B2 Relay See Note CC.B3 ON/OFF Compressor B3 Relay See Note CCH.B ON/OFF Crankcase Heater Circ B See Note

103

APPENDIX A DISPLAY TABLES (cont) Configuration Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

DISP

DISPLAY CONFIGURATION TEST ON/OFF Test Display LEDs METR ON/OFF Metric Display Off = English On = Metric

LANG X Language Selection

Default: 0 0 = English 1 = Espanol 2 = Francais

3 = Portuguese PAS.E ENBL/DSBL Password Enable Default: Enable PASS XXXX Service Password Default: 1111

UNIT

UNIT CONFIGURATION SIZE Unit Size SZA.1 XX TONS Compressor A1 Size

Automatically configured dependent on unit size.

SZA.2 XX TONS Compressor A2 Size SZA.3 XX TONS Compressor A3 Size SZB.1 XX TONS Compressor B1 Size SZB.2 XX TONS Compressor B2 Size SZB.3 XX TONS Compressor B3 Size SH.SP XX.X F Suction Superheat Setpt Default: 9 F FAN.S XX Number of Fans Dependent on Unit Size EXV YES/NO EXV Module Installed Default: Yes

A1.TY YES/NO Compressor A1 Digital Default: No

MAX.T XX SEC Maximum A1 Unload Time Default: 7

Max = 12 (010,015) Max = 10 (011,016-150)

FN.SQ YES/NO CONDFAN SEQ for SSN 2214

YES, if unit produced on or after 2214 (WWYY)

NO, if unit produced before 2214 (WWYY)

VLTS XXX Unit Voltage Unit Nameplate Voltage

60 Hz - 208, 230, 380, 460, 575 50 Hz - 400

F.POL X Num Poles in Fan Low Sound Fan = 8 Metal Fan = 6

OPT1

UNIT OPTIONS 1 HARDWARE FLUD X Cooler Fluid Default: Water

1 = Water 2 = Medium Temperature Brine

MLV.S YES/NO Minimum Load Valve Select Default: No CSB.E ENBL/DSBL CSB Boards Enable Default: Enable CPC 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 Default: 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

PMP.O X Cooler Pump Operation Default: 0 0 = Auto

1 = Continuous

PM.HT XX.X F Pump High Temp Cut Off Default: 95F Range: 95 - 125F

EMM YES/NO EMM Module Installed EMM is automatically configured to Yes when an option requiring

the EMM is configured. CND.T X Cnd HX Typ:0=RTPF 1=MCHX

MOPS XX.X F EXV MOP Set Point Default: 50F Range: 40 - 80F

APPR XX.X F Config Approach Set Point Default: 9.0F Range: 5 - 40F

104

APPENDIX A DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

OPT2

UNIT OPTIONS 2 CONTROLS

CTRL X Control Method

Default: 0 0 = Enable/Off/Remote Switch

2 = Occupancy 3 = CCN Control

LOAD X Loading Sequence Select Default: 1 1 = Equal

2 = Staged

LLCS X Lead/Lag Circuit Select

Default: 1 1 = Automatic

2 = Circuit A Leads 3 = Circuit B Leads

LCWT XX.X F High LCW Alert Limit Default: 60 F Range: 2 to 60 F

DELY XX Minutes Off Time Default: 0 Minutes 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%

ALR.C X Alarm Relay Usage 0 = ALTS & ALRMS

1 = Alarms Only 2 = OFF

SER.T ENBL/DSBL Service Trio Enable

CCN

CCN NETWORK CONFIGS

CCNA XXX CCN Address Default: 1 Range: 0 to 239

CCNB XXX CCN Bus Number Default: 0 Range: 0 to 239

BAUD X CCN Baud Rate

Default: 3 1 = 2400 2 = 4800 3 = 9600

4 =19,200 5 =38,400

105

APPENDIX A DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory (cont)

* Sizes 010-020 and 035-045, default is 1596. Sizes 025,030, 050-060, default is 2500, and 070-100 A circuit, default is 2785. 100 B circuit - 150, default is 3690.

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

EXV.A

CIR A EXV CONFIGURATION

EXV.L XX% EXV Opening at Low LWT Default:25% Range:0 to 50%

LWT.L XX F LWT for EXV Min Opening Default:10F Range:-20 to 40F

EXV.H XX% EXV Opening at High LWT Default:50% Range: 0 to 70%

LWT.H XX F LWT for EXV Max Opening Default:35F Range:20 to 70F

MIN.A XXX.X% EXV CIRC.A Min Position Default: 2 Range: 0 - 100

RNG.A XXXXX STEP EXVA Steps in Range Default: * Range: 0 - 65535

SPD.A XXXXX EXVA Steps Per Second Default: 150 Range: 0 - 65535

POF.A X.XX% EXVA Fail Position In% Default: 0 Range: 0 - 100

MIN.A XXXXX STEP EXVA Minimum Steps Default: 0 Range: 0 - 65535

MAX.A XXXXX STEP EXVA Maximum Steps Default: * Range: 0 - 65535

OVR.A XXX.X% EXVA Overrun Steps Default: 167 Range: 0 - 65535

A.ST.P XXX.X% EXV CIRC.A Start Position

TYP.A X EXVA Stepper Type Default: 1

0 = UNIPOLAR 1 = BIPOLAR

H.SCT XXX.X F High SCT Threshold Default: 115 Range: 50 - 140

X.PCT XX.X% Open EXV X% on 2nd COMP Default: 10 Range: 0 - 30

X.PER XX.X% Move EXV X% on DISCRSOL Default: 5 Range: 0 - 30

A.PCT XXX.X% Pre-Open EXV - Fan Adding Default: 10 Range: 0 - 100

M.PCT XXX.X% Pre-Close EXV - Fan Sub Default: 10 Range: 0 - 100

S.PCT XXX SEC Pre-Close EXV - Lag Shut Default: 10 Range: 0 - 100

DELY XXX SEC Lag Start Delay Default: 10 Range: 0 - 100

L.DL.T XXX SEC Low SH Delta T - EXV Move Default: 6 Range: 0 - 240

SHR.T XX.X F EXV Rate Threshold Default: 0.2F Range: 1.0 to 1.0F

L.EX.M X.X% Low SH Override EXV Move Default: 1.0% Range: 0.4 to 3.0%

EXV.B

CIR B EXV CONFIGURATION

MIN.B XXX.X% EXV Circ.B Min Position Default: 2%

Range:0 to 100

RNG.B XXXXX STEP EXVB Steps in Range Default: *

Range: 0 to 65535

SPD.B XXXXX EXVB Steps Per Second Default: 150

Range: 0 to 65535

POF.B XXX.X% EXVB Fail Position in % Default: 0

Range: 0 to 100

MIN.B XXXXX STEP EXVB Minimum Steps Default: 0

Range: 0 to 65535

MAX.B XXXXX STEP EXVB Maximum Steps Default: *

Range: 0 to 65535

OVR.B XXX STEP EXVB Overrun Steps Default: 167

Range: 0 to 65535

TYP.B X EXVB Stepper Type Default: 1

0 = UNIPOLAR 1 = BIPOLAR

106

APPENDIX A DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

MM

MOTORMASTER

MMR.S X Motormaster Select

Default: 0 0 = NONE

1 = LOW AMBIENT 2 = GREENSPEED

P.GAN XX.X Head Pressure P Gain Default: 1 Range: 1 to 4

I.GAN XX.X Head Pressure I Gain Default: 0.1 Range: -20 to 20

D.GAN XX.X Head Pressure D Gain Default: 0.0

GREENSPEED = 1.0 Range: -20 to 20

MIN.S XXX.X% Minimum Fan Speed Default: 5.0 Range: 0 to 100

RSET

RESET COOL TEMP

CRST X Cooling Reset Type

Default: 0 0 = No Reset

1 = 4 to 20 mA Input 2 = Outdoor Air Temperature

3 = Return Fluid 4 = Space Temperature

MA.DG XX.XF 4-20 - Degrees Reset Default: 0.0 F Range: -30 to 30 F

RM.NO XXX.X F Remote - No Reset Temp Default: 125F Range: 0 to125F

RM.F XXX.X F Remote - Full Reset Temp Default: 0F Range: 0 to125F

RM.DG XX.X F Remote - Degrees Reset Default: 0.0 F Range: -30 to 30 F

RT.NO XXX.XF Return - No Reset Temp Default: 10.0 F Range: 0 to125 F

RT.F XXX.XF Return - Full Reset Temp Default: 10.0 F Range: 0 to125 F

RT.DG XX.X F Return - Degrees Reset Default: 0.0 F Range: -30 to 30 F

DMDC X Demand Limit Select

Default: 0 0 = None 1 = Switch

2 - 4 to 20 mA Input 3 = CCN Loadshed

DM20 XXX% Demand Limit at 20 mA Default: 100% Range: 0 to 100%

SHNM XXX Loadshed Group Number Default: 0 Range: 0 to 99

SHDL XXX% Loadshed Demand Delta Default: 0% Range: 0 to 60%

SHTM XXX MIN Maximum Loadshed Time Default: 60 minutes Range: 0 to 120 minutes

DLS1 XXX.X% Demand Limit Switch 1 Default: 80% Range: 0 to 100%

DLS2 XXX.X% Demand Limit Switch 2 Default: 50% Range: 0 to 100%

LLEN ENBL/DSBL Lead/Lag Chiller Enable Default: Disable

MSSL SLVE/MAST Master/Slave Select Default: Master

SLVA XXX Slave Address Default: 0 Range: 0 to 239

LLBL X Lead/Lag Balance Select

Default: Master Leads 0 = Master Leads 1 = Slave Leads

2 = Automatic

LLBD XXX HRS Lead/Lag Balance Delta Default: 168 hours Range: 40 to 400 hours

LLDY XXX MIN Lag Start Delay Default: 5 minutes Range: 0 to 30 minutes

PARA YES Parallel Configuration Default: Yes (cannot be changed)

107

APPENDIX A DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

SLCT

SETPOINT AND RAMP LOAD

CLSP X Cooling Set Point Select

Default: 0 0 = Single

1 = Dual Switch 2 = Dual CCN Occupied

3 = 4 to 20 mA Input (requires EMM)

RL.S ENBL/DSBL Ramp Load Select Default: Enable

CRMP X.X F Cooling Ramp Loading Default: 1.0 Range: 0.2 to 2

SCHD XX Schedule Number Default: 1 Range: 1 to 99

Z.GN X.X Deadband Multiplier Default: 1 Range: 1 to 4

SERV

SERVICE CONFIGURATION EN.A1 ENBL/DSBL Enable Compressor A1 EN.A2 ENBL/DSBL Enable Compressor A2 EN.A3 ENBL/DSBL Enable Compressor A3 EN.B1 ENBL/DSBL Enable Compressor B1 EN.B2 ENBL/DSBL Enable Compressor B2 EN.B3 ENBL/DSBL Enable Compressor B3 REV.R ENBL/DSBL Reverse Rotation Enable Default: Enabled

BCST

BROADCAST CONFIGURATION T.D.BC ON/OFF CCN Time/Date Broadcast Default: Off OAT.B ON/OFF CCN OAT Broadcast Default: Off G.S.BC ON/OFF Global Schedule Broadcst Default: Off BC.AK ON/OFF CCN Broadcast Ack'er Default: Off

108

APPENDIX A DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

TIME TIME OF DAY

HH.MM XX.XX Hour and Minute Military (00:00 - 23:59)

DATE

MONTH, DATE, DAY, AND YEAR

MNTH XX Month of Year 1 - 12 (1 = January, 2 = February, etc.)

DOM XX Day of Month Range: 01 -31

DAY X Day of Week 1 - 7 (1 = Monday, 2 = Tuesday, etc.)

YEAR XXXX Year of Century

DST

DAYLIGHT SAVINGS TIME STR.M XX Month Default: 4 Range 1- 12 STR.W X Week Default: 1 Range 1- 5 STR.D X Day Default: 7 Range 1- 7 MIN.A XX Minutes to Add Default: 60 Range 0 - 99 STP.M XX Month Default: 10 Range 1- 12 STP.W XX Week Default: 5 Range 1- 5 STP.D XX Day Default: 7 Range 1- 7 MIN.S XX Minutes to Subtract Default: 60 Range 0 - 99

HOL.L LOCAL HOLIDAY SCHEDULES

HD.01

HOLIDAY SCHEDULE 01 MON XX Holiday Start Month DAY XX Start Day LEN XX Duration (days)

HD.02

HOLIDAY SCHEDULE 02

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.03

HOLIDAY SCHEDULE 03

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.04

HOLIDAY SCHEDULE 04

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.05

HOLIDAY SCHEDULE 05

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.06

HOLIDAY SCHEDULE 06

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.07

HOLIDAY SCHEDULE 07

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.08

HOLIDAY SCHEDULE 08

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

109

APPENDIX A DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

HD.09

HOLIDAY SCHEDULE 09

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.10

HOLIDAY SCHEDULE 10

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.11

HOLIDAY SCHEDULE 11

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.12

HOLIDAY SCHEDULE 12

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.13

HOLIDAY SCHEDULE 13

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.14

HOLIDAY SCHEDULE 14

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.15

HOLIDAY SCHEDULE 15

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.16

HOLIDAY SCHEDULE 16

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.17

HOLIDAY SCHEDULE 17

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.18

HOLIDAY SCHEDULE 18

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.19

HOLIDAY SCHEDULE 19

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

110

APPENDIX A DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

HD.20

HOLIDAY SCHEDULE 20

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.21

HOLIDAY SCHEDULE 21

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.22

HOLIDAY SCHEDULE 22

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.23

HOLIDAY SCHEDULE 23

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.24

HOLIDAY SCHEDULE 24

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.25

HOLIDAY SCHEDULE 25

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.26

HOLIDAY SCHEDULE 26

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.27

HOLIDAY SCHEDULE 27

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.28

HOLIDAY SCHEDULE 28

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.29

HOLIDAY SCHEDULE 29

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

HD.30

HOLIDAY SCHEDULE 30

MON XX Holiday Start Month 1 - 12 (1 = January, 2 = February, etc.)

DAY XX Start Day 01-31 LEN XX Duration (days)

111

APPENDIX A DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT SCH.N 0 Schedule Number SCH.L LOCAL OCCUPANCY SCHEDULE

PER.1

OCCUPANCY PERIOD 1 OCC.1 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.1 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.1 YES/NO Monday In Period TUE.1 YES/NO Tuesday In Period WED.1 YES/NO Wednesday In Period THU.1 YES/NO Thursday In Period FRI.1 YES/NO Friday In Period SAT.1 YES/NO Saturday In Period SUN.1 YES/NO Sunday In Period HOL.1 YES/NO Holiday In Period

PER.2

OCCUPANCY PERIOD 2 OCC.2 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.2 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.2 YES/NO Monday In Period TUE.2 YES/NO Tuesday In Period WED.2 YES/NO Wednesday In Period THU.2 YES/NO Thursday In Period FRI.2 YES/NO Friday In Period SAT.2 YES/NO Saturday In Period SUN.2 YES/NO Sunday In Period HOL.2 YES/NO Holiday In Period

PER.3

OCCUPANCY PERIOD 3 OCC.3 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.3 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.3 YES/NO Monday In Period TUE.3 YES/NO Tuesday In Period WED.3 YES/NO Wednesday In Period THU.3 YES/NO Thursday In Period FRI.3 YES/NO Friday In Period SAT.3 YES/NO Saturday In Period SUN.3 YES/NO Sunday In Period HOL.3 YES/NO Holiday In Period

PER.4

OCCUPANCY PERIOD 4 OCC.4 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.4 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.4 YES/NO Monday In Period TUE.4 YES/NO Tuesday In Period WED.4 YES/NO Wednesday In Period THU.4 YES/NO Thursday In Period FRI.4 YES/NO Friday In Period SAT.4 YES/NO Saturday In Period SUN.4 YES/NO Sunday In Period HOL.4 YES/NO Holiday In Period

PER.5

OCCUPANCY PERIOD 5 OCC.5 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.5 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.5 YES/NO Monday In Period TUE.5 YES/NO Tuesday In Period WED.5 YES/NO Wednesday In Period THU.5 YES/NO Thursday In Period FRI.5 YES/NO Friday In Period SAT.5 YES/NO Saturday In Period SUN.5 YES/NO Sunday In Period HOL.5 YES/NO Holiday In Period

112

APPENDIX A DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory (cont)

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

PER.6

OCCUPANCY PERIOD 6 OCC.6 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.6 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.6 YES/NO Monday In Period TUE.6 YES/NO Tuesday In Period WED.6 YES/NO Wednesday In Period THU.6 YES/NO Thursday In Period FRI.6 YES/NO Friday In Period SAT.6 YES/NO Saturday In Period SUN.6 YES/NO Sunday In Period HOL.6 YES/NO Holiday In Period

PER.7

OCCUPANCY PERIOD 7 OCC.7 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.7 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.7 YES/NO Monday In Period TUE.7 YES/NO Tuesday In Period WED.7 YES/NO Wednesday In Period THU.7 YES/NO Thursday In Period FRI.7 YES/NO Friday In Period SAT.7 YES/NO Saturday In Period SUN.7 YES/NO Sunday In Period HOL.7 YES/NO Holiday In Period

PER.8

OCCUPANCY PERIOD 8 OCC.8 XX:XX Period Occupied Time Military (00:00 - 23:59) UNC.8 XX:XX Period Unoccupied Time Military (00:00 - 23:59) MON.8 YES/NO Monday In Period TUE.8 YES/NO Tuesday In Period WED.8 YES/NO Wednesday In Period THU.8 YES/NO Thursday In Period FRI.8 YES/NO Friday In Period SAT.8 YES/NO Saturday In Period SUN.8 YES/NO Sunday In Period HOL.8 YES/NO Holiday In Period

OVR

SCHEDULE OVERRIDE OVR.T X HRS Timed Override Hours Default: 0 Range 0-4 hours OVR.L X HRS Override Time Limit Default: 0 Range 0-4 hours T.OVR YES/NO Timed Override User Entry

113

APPENDIX A DISPLAY TABLES (cont) Operating Mode and Sub-Mode Directory

Alarms Mode and Sub-Mode Directory

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

MODE

MODES CONTROLLING UNIT MD01 ON/OFF CSM Controlling Chiller MD02 ON/OFF WSM Controlling Chiller MD03 ON/OFF Master/Slave Control MD05 ON/OFF Ramp Load Limited MD06 ON/OFF Timed Override in effect MD07 ON/OFF Low Cooler Suction TempA MD08 ON/OFF Low Cooler Suction TempB MD09 ON/OFF Slow Change Override MD10 ON/OFF Minimum OFF time active MD13 ON/OFF Dual Set Point MD14 ON/OFF Temperature Reset MD15 ON/OFF Demand/Sound Limited MD16 ON/OFF Cooler Freeze Protection MD17 ON/OFF Low Temperature Cooling MD18 ON/OFF High Temperature Cooling MD19 ON/OFF Making Ice MD20 ON/OFF Storing Ice MD21 ON/OFF High SCT Circuit A MD22 ON/OFF High SCT Circuit B MD23 ON/OFF Minimum Comp. On Time MD24 ON/OFF Pump Off Delay Time MD25 ON/OFF Low Sound Mode MDAO ON/OFF Circuit A Trio Oil MGMT MDBO ON/OFF Circuit B Trio Oil MGMT MD.OL ON/OFF OAT Lockout in effect

SUB-MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT

CRNT

CURRENTLY ACTIVE ALARMS AXXX TXXX PXXX

Current Alarms 1-25 Alarms are shown as AXXX Alerts are shown as TXXX

RCRN YES/NO Reset All Current Alarms

HIST

ALARM HISTORY AXXX TXXX PXXX

Alarm History 1-20 Alarms are shown as AXXX Alerts are shown as TXXX

114

APPENDIX B CCN TABLES CCN DISPLAY TABLES A_UNIT (General Unit Parameters)

CCN DISPLAY TABLES CIRCA_AN (Circuit A Analog Parameters)

DESCRIPTION VALUE UNITS POINT NAME FORCIBLE Control Mode 0 = Test

1 = Local Off 2 = CCN Off 3 = Clock Off 4 = Emergency Stop 5 = Local On 6 = CCN On 7 = Clock On 8 = Heat Enabled 9 = Pump Delay

STAT N

Occupied No/Yes OCC N CCN Chiller Start/Stop CHIL_S_S Y Low Sound Active No/Yes LSACTIVE N Alarm State Normal/Alert/Alarm ALM N Active Demand Limit 0 to 100 % DEM_LIM Y Override Modes in Effect No/Yes MODE N Percent Total Capacity 0 to 100 % CAP_T N Requested Stage 0 to 99 STAGE N Internal Active Set Point 20 to 70 F SP N Control Point 20 to 70 F CTRL_PNT Y Entering Fluid Temp snnn.n F EWT N Leaving Fluid Temp snnn.n F LWT N Emergency Stop Enable/Emstop Enable EMSTOP Y Minutes Left for Start 00:00 to 15:00 minutes MIN_LEFT N PUMPS Cooler Pump Relay 1 Off/On COOLPMP1 N Cooler Pump Relay 2 Off/On COOLPMP2 N Cooler Pump 1 Interlock Open/Close PMP1_FBK N Cooler Pump 2 Interlock Open/Close PMP2_FBK N Cooler Flow Switch Open/Close COOLFLOW N Lead Pump No Pump/Pump 1/Pump

2 LEADPUMP N

Rotate Cooler Pumps Now No/Yes ROT_PUMP Y Heat/Cool Select Heat/Cool HC_SEL N Total Available Capacity 0-200.0 Tons CALCTONS Y

DESCRIPTION VALUE UNITS POINT NAME CIRCUIT A ANALOG VALUES Percent Total Capacity 0-100 % CAPA_T Percent Available Cap. 0-100 % CAPA_A Discharge Pressure nnn.n PSIG DP_A Suction Pressure nnn.n PSIG SP_A Head Setpoint nnn.n F HSP Saturated Condensing Tmp snnn.n F TMP_SCTA Saturated Suction Temp snnn.n F TMP_SSTA Average SST last 15 sec snnn.n F SSTA_AVG Instantaneous SSTA snnn.n F TMPISSTA EXV% Open nnn % EXV_A Var Head Press Output A nnn.n milliamps VHPA_ACT Compr Return Gas Temp nnn.n F TMP_RGTA Discharge Gas Temp nnn.n F DISGAS Suction Superheat Temp nnn.n F SH_A Spare 1 Temperature nnn.n F SPR1_TMP

115

APPENDIX B CCN TABLES (cont) CCN DISPLAY TABLES CIRCADIO (Circuit A Discrete Inputs/Outputs)

CCN DISPLAY TABLES CIRCB_AN (Circuit B Analog Parameters)

CCN DISPLAY TABLES CIRCBDIO (Circuit B Discrete Inputs/Outputs)

DESCRIPTION VALUE UNITS POINT NAME CIRC. A DISCRETE OUTPUTS Compressor A1 Relay Off K_A1_RLY Comp A1 Unload Time 0 sec A1UNLTME Compressor A2 Relay Off K_A2_RLY Compressor A3 Relay Off K_A3_RLY Minimum Load Valve Relay Off MLV_RLY Crankcase Heater Circ A On CCHA CIRC. A DISCRETE INPUTS Compressor A1 Feedback Off K_A1_FBK Compressor A2 Feedback Off K_A2_FBK Compressor A3 Feedback Off K_A3_FBK

DESCRIPTION VALUE UNITS POINT NAME FORCIBLE CIRCUIT B ANALOG VALUES Percent Total Capacity 0-100 % CAPB_T N Percent Available Cap. 0-100 % CAPB_A N Discharge Pressure nnn.n PSIG DP_B N Suction Pressure nnn.n PSIG SP_B N Head Setpoint nnn.n F HSP N Saturated Condensing Tmp snnn.n F TMP_SCTB N Saturated Suction Temp snnn.n F TMP_SSTB N EXV% Open nnn % EXV_B N Var Head Press Output B nnn.n milliamps VHPB_ACT N Compr Return Gas Temp nnn.n F TMP_RGTB N Suction Superheat Temp nnn.n F SH_B N Spare 2 Temperature nnn.n F SPR2_TMP N

DESCRIPTION VALUE UNITS POINT NAME CIRC. B DISCRETE OUTPUTS Compressor B1 Relay Off K_B1_RLY Compressor B2 Relay Off K_B2_RLY Compressor B3 Relay Off K_B3_RLY Minimum Load Valve Relay Off MLV_RLY Crankcase Heater Circ B On CCHB CIRC. B DISCRETE INPUTS Compressor B1 Feedback Off K_B1_FBK Compressor B2 Feedback Off K_B2_FBK Compressor B3 Feedback Off K_B3_FBK

116

APPENDIX B CCN TABLES (cont) CCN DISPLAY TABLES OPTIONS (Unit Parameters)

CCN CONFIGURATION TABLES UNIT (Unit Configuration)

DESCRIPTION VALUE UNITS POINT NAME FANS Fan 1 Relay Off FAN_1 Fan 2 Relay Off FAN_2 Fan 3 Relay Off FAN_3 Fan 4 Relay Off FAN_4 Fan 5 Relay Off FAN_5 Fan 6 Relay Off FAN_6 Fan 7 Relay Off FAN_7 Fan 8 Relay Off FAN_8 Cooler/Pump Heater Off COOL_HTR UNIT ANALOG VALUES Cooler Entering Fluid snnn.n F COOL_EWT Cooler Leaving Fluid snnn.n F COOL_LWT Average Entering Fluid snnn.n F EWTAVG Average Leaving Fluid snnn.n F LWTAVG Lowest LWT in 15 Seconds snnn.n F LWTLOW Lead/Lag Leaving Fluid snnn.n F DUAL_LWT TEMPERATURE RESET 4-20 mA Reset Signal nn.n mA RST_MA Outside Air Temperature snnn.n F OAT Space Temperature snnn.n F SPT DEMAND LIMIT 4-20 mA Demand Signal nn.n mA LMT_MA Demand Limit Switch 1 Off DMD_SW1 Demand Limit Switch 2 Off DMD_SW2 CCN Loadshed Signal 0 = Normal

1 = Redline 2 = Loadshed

DL_STAT

MISCELLANEOUS Heat Request On HEAT_REQ Dual Setpoint Switch On DUAL_IN Cooler LWT Setpoint snnn.n F LWT_SP Ice Done Off ICE_DONE

DESCRIPTION VALUE DEFAULT UNITS POINT NAME Unit Size nnn tons SIZE Compressor A1 Size nnn

Automatically configured dependent on unit size

tons SIZE_A1 Compressor A2 Size nnn tons SIZE_A2 Compressor A3 Size nnn tons SIZE_A3 Compressor B1 Size nnn tons SIZE_B1 Compressor B2 Size nnn tons SIZE_B2 Compressor B3 Size nnn tons SIZE_B3 Suction Superheat Setpt nn.n 9.0 F SH_SP Number of Fans n Dependent on unit size FAN_TYPE Compressor A1 Digital? No/Yes No CPA1TYPE Maximum A1 Unload Time nn 12 sec MAXULTME Unit Produced On or After 2214? No/Yes Yes FAN_SEQ Unit Voltage nnn Unit dependent 200,

230, 380, 400, 460, 575 volts UNITVOLT

Num Poles in Fan Motor 8 8 FANPOLES

117

APPENDIX B CCN TABLES (cont) CCN CONFIGURATION TABLES OPTIONS1 (Options 1 Configuration)

*EMM is automatically configured to Yes when an option requiring the EMM is configured.

CCN CONFIGURATION TABLES OPTIONS2 (Options 2 Configuration)

CCN CONFIGURATION TABLES SCHEDOVR (Timed Override Setup)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME Cooler Fluid 1 = Water

2 = Med. Brine 1 FLUIDTYP

Minimum Load Vlv Select No/Yes No MLV_FLG CSB Board Enable Dsable/Enable Enable CSB_ENA Cooler Pump Control Off/On Off CPC Cooler Pmp Continuous ON No/Yes No PUMPOPER Pump High Temp Cut Off 95 to 125 95.0 F PUMPHTCO Cooler Pump 1 Enable No/Yes No PMP1_ENA Cooler Pump 2 Enable No/Yes No PMP2_ENA Cooler Pmp Periodic Strt No/Yes No PUMP_PST Cooler Pump Select 0 = Automatic, 1 =

Pump 1, 2 = Pump 2

0 PMP_SLCT

Cooler Pump Shutdown Dly 0 to 10 1 minutes PUMP_DLY Pump Changeover Hours 10 to 2000 500 hours PMP_DLTA EMM Module Installed No/Yes* No EMM_BRD Cnd HX Typ: 0=RTPF 1=MCHX 0/1 1 COILTYPE EXV MOP Set Point nn.n 50 F MOP_SP Config Approach Setpoint nn.n 9.0 F IAPPROSP

DESCRIPTION VALUE DEFAULT UNITS POINT NAME Control Method 0 = Switch

2 = Occupancy 3 = CCN

0 CONTROL

Loading Sequence Select 1 = Equal Loading 2 = Staged Loading

1 SEQ_TYP

Lead/Lag Circuit Select 1 = Automatic 2 = Circuit A Leads 3 = Circuit B Leads

1 LEAD_TYP

Cooling Setpoint Select 0 = Single 1 = Dual, remote switch controlled 2 = Dual CCN occupancy 3 = 4-20 mA input

0 CLSP_TYP

Ramp Load Select Enable/Dsable Enable RAMP_EBL Heat Cool Select Cool/Heat Cool HEATCOOL High LCW Alert Limit 2 to 60 60.0 F LCW_LMT Minutes off time 0 to 15 0 min DELAY Deadband Multiplier 1.0 to 4.0 1.0 Z_GAIN Ice Mode Enable Enable/Dsable Dsable ICE_CNFG Low Sound Mode Select 0 = Disabled

1 = Fan only 2 = Capacity/Fans

0 LS_MODE

Low Sound Start Time 00:00 to 23:59 00:00 LS_START Low Sound End Time 00:00 to 23:59 00:00 LS_END Low Sound Capacity Limit 0 to 100 100 % LS_LIMIT Alarm Relay Usage 0 = Alts & Alrms

1 = Alarms Only 2 = Off

0 ALRMCNFG

Service Trio Enable Enable/Dsable Dsable SER_TRIO

DESCRIPTION VALUE DEFAULT UNITS POINT NAME Schedule Number 0 to 99 1 SCHEDNUM Override Time Limit 0 to 4 0 hours OTL Timed Override Hours 0 to 4 0 hours OVR_EXT Timed Override No/Yes No TIMEOVER

118

APPENDIX B CCN TABLES (cont) CCN CONFIGURATION TABLES RESETCON (Temperature Reset and Demand Limit)

CCN CONFIGURATION TABLES DUALCHIL (Dual Chiller Configuration Settings)

CONFIGURATION DISPLAY TABLES

DESCRIPTION VALUE DEFAULT UNITS POINT NAME COOLING RESET Cooling Reset Type 0 = No Reset

1 = 4-20 mA input 2 = External temp OAT 3 = Return Fluid 4 = External temp - SPT

0 CRST_TYP

4-20 MA RESET 4-20 Degrees Reset 30 to 30 0.0 F 420_DEG REMOTE RESET Remote No Reset Temp 0 to 125 125.0 F REM_NO Remote Full Reset Temp 0 to 125 0.0 F REM_FULL Remote Degrees Reset 30 to 30 0.0 F REM_DEG RETURN TEMPERATURE RESET Return No Reset Temp 0 to 125 10.0 F RTN_NO Return Full Reset Temp 0 to 125 0.0 F RTN_FULL Return Degrees Reset 30 to 30 0.0 F RTN_DEG DEMAND LIMIT Demand Limit Select 0 = None

1 = External switch input 2 = 4-20 mA input 3 = Loadshed

0 DMD_CTRL

Demand Limit at 20 mA 0 to 100 100 % DMT20MA Loadshed Group Number 0 to 99 0 SHED_NUM Loadshed Demand Delta 0 to 60 0 % SHED_DEL Maximum Loadshed Time 0 to 120 60 minutes SHED_TIM Demand Limit Switch 1 0 to 100 80 % DLSWSP1 Demand Limit Switch 2 0 to 100 50 % DLSWSP2

DESCRIPTION VALUE DEFAULT UNITS POINT NAME LEAD/LAG Lead/Lag Chiller Enable Enable/Dsable Dsable LL_ENA Master/Slave Select Master/Slave Master MS_SEL Slave Address 0 to 239 2 SLV_ADDR Lead/Lag Balance Select 0 = None 0 LL_BAL Lead/Lag Balance Delta 40 to 400 168 hours LL_BAL_D Lag Start Delay 0 to 30 5 minutes LL_DELAY Parallel Configuration Yes Yes PARALLEL

TABLE DISPLAY NAME RANGE DEFAULT UNITS POINT NAME

ALARMDEF/ ALARMS01

Alarm Routing Control 0 or 1 for each position 00000000 ALRM_CNT Alarm Equipment Priority 0-7 4 EQP_TYP Comm Failure Retry Time 1-240 10 min RETRY_TM Realarm Time 1-255 30 min RE_ALARM Alarm System Name 8 chars CHILLER ALRM_NAM

BRODEFS/ BROCASTS

CCN Time/Date Broadcast Yes/No No CCNBC CCN OAT Broadcast Yes/No No OATBC Global Schedule Broadcast Yes/No No GSBC CCN Broadcast Ack'er Yes/No No CCNBCACK Daylight Savings Start: Month 1 to 12 3 month STARTM Week 1 to 5 2 week STARTW Day 1 to 7 7 day STARTD Minutes to Add 0 to 90 60 min MINADD Daylight Savings Start: Month 1 to 12 11 month STOPM Week 1 to 5 1 week STOPW Day 1 to 7 7 day STOPD Minutes to Add 0 to 90 60 min MINSUB

119

APPENDIX B CCN TABLES (cont) CCN CONFIGURATION TABLES DISPLAY (Marquee Display SETUP)

CCN CONFIGURATION TABLES EXVACONF (EXV Circuit A Configuration)

CCN CONFIGURATION TABLES EXVBCONF (EXV Circuit B Configuration)

CCN CONFIGURATION TABLES MM_CONF (Motormaster Configuration)

DESCRIPTION VALUE DEFAULT UNITS POINT NAME Service Password nnnn 1111 PASSWORD Password Enable Enable/Disable Enable PASS_EBL Metric Display Off/On Off DISPUNIT Language Selection 0 = ENGLISH

1 = FRANCAIS 2 = ESPANOL 3 = PORTUGUES

0 LANGUAGE

DESCRIPTION VALUE DEFAULT UNITS POINT NAME EXV Opening at Low LWT nnn.n 25 % EXV_Y1 LWT for EXV Min Opening nnn.n 10 F LWT_X1 EXV Opening at High LWT nnn.n 50 % EXV_Y2 LWT for EXV Max Opening nnn.n 35 F LWT_X2 EXV Circ. A Min Position nnn.n 2 % EXVAMINP EXVA Steps in Range nnnnn 2500 steps EXVARANG EXVA Steps Per Second nnnnn 150 EXVARATE EXVA Fail Position In % nnnn.nn 0 % EXVAPOSF EXVA Minimum Steps nnnnn 0 steps EXVAMINS EXVA Maximum Steps nnnnn 2500 steps EXVAMAXS EXVA Overrun Steps nnnnn 167 steps EXVAOVRS EXVA Stepper Type nnn 1 EXVATYPE High SCT Threshold nnn.n 115 F HIGH_SCT Open EXV X% on 2nd comp nnn.n 10 % EXV_HSCT Move EXV X% on DISCRSOL nnn.n 5 % EXVDISCR Pre-Open EXV Fan Adding nnn.n 10 % EXV_AFAN Pre-Close EXV Fan Sub nnn.n 10 % EXV_MFAN Pre-Close EXV Lag shut nnn.n 10 % EXV_SLAG Lag Start Delay nnn 10 sec DELAYLAG SH Reset Maximum nnn.n 11 ^F MAXSHRST Cap at SH Offset Maximum nnn.n 25 % SHRSTBGN SH Rate Threshold nnn.n 0.2 ^F SHR_THR Low SH DeltaT EXV Move nnn 60 sec LSH_DL_T Low SH Override EXV Move nnn.n 1 % LSH_EXVM

DESCRIPTION VALUE DEFAULT UNITS POINT NAME EXV Circ. B Min Position nnn.n 2 % EXVBMINP EXVB Steps in Range nnnnn 2500 steps EVXBRANG EXVB Steps Per Second nnnnn 150 EXVBRATE EXVB Fail Position in % nnnn.nn 0 % EXVBPOSF EXVB Minimum Steps nnnnn 0 steps EXVBMINS EXVB Maximum Steps nnnnn 2500 steps EXVBMAXS EXVB Overrun Steps nnnnn 167 steps EXVBOVRS EXVB Stepper Type nnn 1 EXVBTYPE

DESCRIPTION VALUE DEFAULT UNITS POINT NAME Motormaster Select 0 = NONE

1 = LOW AMBIENT 2 = GREENSPEED

0 = NONE MM_SLCT

Head Pressure P Gain nnn.n 1.0 HP_PGAIN Head Pressure I Gain nnn.n 0.1 HP_IGAIN Head Pressure D Gain LOW AMBIENT 0.0

GREENSPEED 1.0 0.0 HP_DGAIN

Minimum Fan Speed nnn.n 5.0 % MIN_VHP

120

APPENDIX B CCN TABLES (cont) CCN SERVICE TABLES SERVICE

CCN SETPOINT TABLES SETPOINT

CCN MAINTENANCE TABLES CIRA_EXV

CCN MAINTENANCE TABLES CIRB_EXV

DESCRIPTION VALUE DEFAULT UNITS POINT NAME SERVICE Brine Freeze Point nnn.n 34.0 F BRN_FRZ Pump Service Interval nnnnn 876.0 hours SI_PUMPS COMPRESSOR ENABLE Enable Compressor A1 Disable/Enable Dependent on unit size ENABLEA1 Enable Compressor A2 Disable/Enable Dependent on unit size ENABLEA2 Enable Compressor A3 Disable/Enable Dependent on unit size ENABLEA3 Enable Compressor B1 Disable/Enable Dependent on unit size ENABLEB1 Enable Compressor B2 Disable/Enable Dependent on unit size ENABLEB2 Enable Compressor B3 Disable/Enable Dependent on unit size ENABLEB3 Reverse Rotation Enable Disable/Enable Enable REVR_VER

DESCRIPTION VALUE DEFAULT UNITS POINT NAME COOLING Cooling Setpoint 1 14 to 70 44.0 F CSP1 Cooling Setpoint 2 14 to 70 44.0 F CSP2 ICE Setpoint 14 to 32 32.0 F CSP3 RAMP LOADING Cooling Ramp Loading 0.2 to 2.0 1.0 CRAMP Brine Freeze Point 20 to 34 34.0 F BRN_FRZ Head Setpoint 85 to 120 95.0 F HSP Fan On Set Point 95.0 F FANONSP Fan Off Set Point 72.0 F FANOFFSP Fan Stage Delta 0 to 50 15.0 F FSTGDLTA Base Fan Off Delta Temp 10 to 50 23.0 F B_FANOFF OAT Lockout Temp 28.9 to 48.9 20 F OAT_LOCK

DESCRIPTION VALUE UNITS POINT NAME EXV % Open nnn % EXV_A Circuit A Approach nnn.n delta F CIRA_APP Approach Setpoint nnn.n delta F APPRA_SP EXVA Override nnnnn EXVAOVRR Suction Superheat Temp nnn.n delta F SH_A Active Superheat Setpt nn.n delta F ACTSH_SP Active MOP Setpt nn.n delta F ACMOP_SP Cir A EXV Position Limit nnn % PLMA

DESCRIPTION VALUE UNITS POINT NAME EXV % Open nnn % EXV_B Circuit B Approach nnn.n delta F CIRB_APP Approach Setpoint nnn.n delta F APPRB_SP EXVB Override nnnnn EXVBOVRR Suction Superheat Temp nnn.n delta F SH_B Active Superheat Setpt nn.n delta F ACTSH_SP Active MOP Setpt nn.n delta F ACMOP_SP Cir B EXV Position Limit nnn % PLMB

121

APPENDIX B CCN TABLES (cont) CCN MAINTENANCE TABLES STRTHOUR

CCN MAINTENANCE TABLES CURRMODS

DESCRIPTION VALUE UNITS POINT NAME Machine Operating Hours nnnnnn hours HR_MACH Machine Starts nnnnnn CY_MACH Circuit A Run Hours nnnnnn hours HR_CIRA

Compressor A1 Run Hours nnnnnn hours HR_A1 Compressor A2 Run Hours nnnnnn hours HR_A2 Compressor A3 Run Hours nnnnnn hours HR_A3

Circuit B Run Hours nnnnnn hours HR_CIRB Compressor B1 Run Hours nnnnnn hours HR_B1 Compressor B2 Run Hours nnnnnn hours HR_B2 Compressor B3 Run Hours nnnnnn hours HR_B3

Circuit A Starts nnnnnn CY_CIRA Compressor A1 Starts nnnnnn CY_A1 Compressor A2 Starts nnnnnn CY_A2 Compressor A3 Starts nnnnnn CY_A3

Circuit B Starts nnnnnn CY_CIRB Compressor B1 Starts nnnnnn CY_B1 Compressor B2 Starts nnnnnn CY_B2 Compressor B3 Starts nnnnnn CY_B3

PUMP HOURS Pump 1 Run Hours nnnnnn hours HR_PUMP1 Pump 2 Run Hours nnnnnn hours HR_PUMP2

DESCRIPTION VALUE POINT NAME CSM controlling Chiller On/Off MODE_1 WSM controlling Chiller On/Off MODE_2 Master/Slave control On/Off MODE_3 Ramp Load Limited On/Off MODE_5 Timed Override in effect On/Off MODE_6 Low Cooler Suction TempA On/Off MODE_7 Low Cooler Suction TempB On/Off MODE_8 Slow Change Override On/Off MODE_9 Minimum OFF time active On/Off MODE_10 Dual Setpoint On/Off MODE_13 Temperature Reset On/Off MODE_14 Demand/Sound Limited On/Off MODE_15 Cooler Freeze Protection On/Off MODE_16 Low Temperature Cooling On/Off MODE_17 High Temperature Cooling On/Off MODE_18 Making ICE On/Off MODE_19 Storing ICE On/Off MODE_20 High SCT Circuit A On/Off MODE_21 High SCT Circuit B On/Off MODE_22 Minimum Comp. On Time On/Off MODE_23 Pump Off Delay Time On/Off MODE_24 Low Sound Mode On/Off MODE_25 Circuit A Trio Oil Mgmt On/Off MD_A_OIL Circuit B Trio Oil Mgmt On/Off MD_B_OIL OAT Lockout in effect On/Off MD_OATL

122

APPENDIX B CCN TABLES (cont)

CCN MAINTENANCE TABLES VFD1

CCN MAINTENANCE TABLES ALARMS

CCN MAINTENANCE TABLES VERSIONS

DESCRIPTION VALUE UNITS POINT NAME Unit Voltage 460 Volts UNITVOLT Num Poles in Fan Motor 8 FANPOLES Fan Control Select 0 MM_SLCT VFD1 Comm Fail Count 0 VF1CFAIL Danfoss VFD Command 0 % VFD1CMD Danfoss VFD Status Word 0 VFD1STAT Danfoss VFD Voltage 0 Volts VFD1VLTS Danfoss VFD Freq HZ 0 VFD1_HZ Danfoss VFD Power 0 kW VFD1_PWR Danfoss VFD Freq Percent 0 % VFD1_PCT Danfoss VFD Speed RPM 0 VFD1_RPM

DESCRIPTION VALUE POINT NAME Active Alarm #1 AXXX or TXXX ALARM01C Active Alarm #2 AXXX or TXXX ALARM02C Active Alarm #3 AXXX or TXXX ALARM03C Active Alarm #4 AXXX or TXXX ALARM04C Active Alarm #5 AXXX or TXXX ALARM05C Active Alarm #6 AXXX or TXXX ALARM06C Active Alarm #7 AXXX or TXXX ALARM07C Active Alarm #8 AXXX or TXXX ALARM08C Active Alarm #9 AXXX or TXXX ALARM09C Active Alarm #10 AXXX or TXXX ALARM10C Active Alarm #11 AXXX or TXXX ALARM11C Active Alarm #12 AXXX or TXXX ALARM12C Active Alarm #13 AXXX or TXXX ALARM13C Active Alarm #14 AXXX or TXXX ALARM14C Active Alarm #15 AXXX or TXXX ALARM15C Active Alarm #16 AXXX or TXXX ALARM16C Active Alarm #17 AXXX or TXXX ALARM17C Active Alarm #18 AXXX or TXXX ALARM18C Active Alarm #19 AXXX or TXXX ALARM19C Active Alarm #20 AXXX or TXXX ALARM20C Active Alarm #21 AXXX or TXXX ALARM21C Active Alarm #22 AXXX or TXXX ALARM22C Active Alarm #23 AXXX or TXXX ALARM23C Active Alarm #24 AXXX or TXXX ALARM24C Active Alarm #25 AXXX or TXXX ALARM25C

DESCRIPTION VERSION VALUE EXV CESR131172- nn-nn AUX CESR131333- nn-nn MBB CESR131460- nn-nn EMM CESR131174- nn-nn MARQUEE CESR131171- nn-nn NAVIGATOR CESR130227- nn-nn CXB CESR131173- nn_nn

123

APPENDIX B CCN TABLES (cont) CCN MAINTENANCE TABLES LOADFACT

CCN MAINTENANCE TABLES PM-PUMP

CCN MAINTENANCE TABLES PM-STRN

CCN MAINTENANCE TABLES PM-COIL

DESCRIPTION VALUE UNITS POINT NAME CAPACITY CONTROL Load/Unload Factor snnn.n SMZ Control Point snnn.n F CTRL_PNT Entering Fluid Temp snnn.n F EWT Leaving Fluid Temp snnn.n F LWT Ramp Load Limited On/Off MODE_5 Slow Change Override On/Off MODE_9 Cooler Freeze Protection On/Off MODE_16 Low Temperature Cooling On/Off MODE_17 High Temperature Cooling On/Off MODE_18 Minimum Comp. On Time On/Off MODE_23

DESCRIPTION VALUE UNITS POINT NAME Pump Service Interval nnnnnn hours SI_PUMPS Pump 1 Service Countdown nnnnnn hours P1_CDOWN Pump 1 Maintenance Done Yes/No P1_MAINT Pump 2 Service Countdown nnnnnn hours P2_CDOWN Pump 2 Maintenance Done Yes/No P2_MAINT Pump 1 Maintenance Date mm/dd/yy hh:mm PMP1_PM0 Pump 1 Maintenance Date mm/dd/yy hh:mm PMP1_PM1 Pump 1 Maintenance Date mm/dd/yy hh:mm PMP1_PM2 Pump 1 Maintenance Date mm/dd/yy hh:mm PMP1_PM3 Pump 1 Maintenance Date mm/dd/yy hh:mm PMP1_PM4 Pump 2 Maintenance Date mm/dd/yy hh:mm PMP2_PM0 Pump 2 Maintenance Date mm/dd/yy hh:mm PMP2_PM1 Pump 2 Maintenance Date mm/dd/yy hh:mm PMP2_PM2 Pump 2 Maintenance Date mm/dd/yy hh:mm PMP2_PM3 Pump 2 Maintenance Date mm/dd/yy hh:mm PMP2_PM4

DESCRIPTION VALUE UNITS POINT NAME Strainer Srvc Interval nnnnnn hours SI_STRNR Strainer Srvc Countdown nnnnnn hours ST_CDOWN Strainer Maint. Done Yes/No ST_MAINT Strainer Maint. Date mm/dd/yy hh:mm STRN_PM0 Strainer Maint. Date mm/dd/yy hh:mm STRN_PM1 Strainer Maint. Date mm/dd/yy hh:mm STRN_PM2 Strainer Maint. Date mm/dd/yy hh:mm STRN_PM3 Strainer Maint. Date mm/dd/yy hh:mm STRN_PM4

DESCRIPTION VALUE UNITS POINT NAME Coil Cleaning Srvc Inter nnnnnn hours SI_COIL Coil Service Countdown nnnnnn hours CL_CDOWN Coil Cleaning Maint.Done Yes/No CL_MAINT Coil Cleaning Maint.Date mm/dd/yy hh:mm COIL_PM0 Coil Cleaning Maint.Date mm/dd/yy hh:mm COIL_PM1 Coil Cleaning Maint.Date mm/dd/yy hh:mm COIL_PM2 Coil Cleaning Maint.Date mm/dd/yy hh:mm COIL_PM3 Coil Cleaning Maint.Date mm/dd/yy hh:mm COIL_PM4

124

APPENDIX B CCN TABLES (cont) CCN MAINTENANCE TABLES TESTMODE

CCN MAINTENANCE TABLES RUNTEST

APPENDIX B CCN TABLES (cont)

DESCRIPTION VALUE UNITS POINT NAME Service Test Mode On/Off NET_CTRL Compressor A1 Relay On/Off S_A1_RLY Compressor A2 Relay On/Off S_A2_RLY Compressor A3 Relay On/Off S_A3_RLY Compressor A4 Relay On/Off S_A4_RLY Compressor B1 Relay On/Off S_B1_RLY Compressor B2 Relay On/Off S_B2_RLY Compressor B3 Relay On/Off S_B3_RLY Compressor B4 Relay On/Off S_B4_RLY Fan 1 Relay On/Off S_FAN_1 Fan 2 Relay On/Off S_FAN_2 Fan 3 Relay On/Off S_FAN_3 Fan 4 Relay On/Off S_FAN_4 Fan 5 Relay On/Off S_FAN_5 Fan 6 Relay On/Off S_FAN_6 Fan 7 Relay On/Off S_FAN_7 Fan 8 Relay On/Off S_FAN_8 Cooler Pump Relay 1 On/Off S_CLPMP1 Cooler Pump Relay 2 On/Off S_CLPMP2 Comp A1 Unload Time nn sec S_A1ULTM Minimum Load Valve Relay On/Off S_MLV Remote Alarm Relay On/Off S_ALM EXV % Open nn % S_EXV_A EXV % Open nn % S_EXV_B

DESCRIPTION VALUE UNITS POINT NAME Percent Total Capacity nnn % CAPA_T Percent Available Cap. nnn % CAPA_A Discharge Pressure nnn.n psig DP_A Suction Pressure nnn.n psig SP_A Head Setpoint nnn.n F HSP Saturated Condensing Tmp nnn.n F TMP_SCTA Saturated Suction Temp nnn.n F TMP_SSTA Compr Return Gas Temp nnn.n F TMP_RGTA Discharge Gas Temp nnn.n F DISGAS Suction Superheat Temp nnn.n ^F SH_A Compressor A1 Relay On/Off K_A1_RLY Compressor A2 Relay On/Off K_A2_RLY Compressor A3 Relay On/Off K_A3_RLY Minimum Load Valve Relay On/Off MLV_RLY Compressor A1 Feedback On/Off K_A1_FBK Compressor A2 Feedback On/Off K_A2_FBK Compressor A3 Feedback On/Off K_A3_FBK Percent Total Capacity nnn % CAPB_T Percent Available Cap. nnn % CAPB_A Discharge Pressure nnn.n psig DP_B Suction Pressure nnn.n psig SP_B Head Setpoint nnn.n F HSP Saturated Condensing Tmp nnn.n F TMP_SCTB Saturated Suction Temp nnn.n F TMP_SSTB Compr Return Gas Temp nnn.n F TMP_RGTB Suction Superheat Temp nnn.n ^F SH_B Compressor B1 Relay On/Off K_B1_RLY Compressor B2 Relay On/Off K_B2_RLY Compressor B3 Relay On/Off K_B3_RLY

125

CCN MAINTENANCE TABLES RUNTEST (cont)

CCN MAINTENANCE TABLES DUALCHIL

DESCRIPTION VALUE UNITS POINT NAME Minimum Load Valve Relay On/Off MLV_RLY Compressor B1 Feedback On/Off K_B1_FBK Compressor B2 Feedback On/Off K_B2_FBK Compressor B3 Feedback On/Off K_B3_FBK Fan 1 Relay On/Off FAN_1 Fan 2 Relay On/Off FAN_2 Fan 3 Relay On/Off FAN_3 Fan 4 Relay On/Off FAN_4 Fan 5 Relay On/Off FAN_5 Fan 6 Relay On/Off FAN_6 Fan 7 Relay On/Off FAN_7 Fan 8 Relay On/Off FAN_8 Outside Air Temperature nnn.n F OAT Space Temperature nnn.n F SPT Cooler Pump Relay 1 On/Off COOLPMP1 Cooler Pump Relay 2 On/Off COOLPMP2 Cooler Pump 1 Interlock Open/Closed PMP1_FBK Cooler Pump 2 Interlock Open/Closed PMP2_FBK Cooler Entering Fluid nnn.n F COOL_EWT Cooler Leaving Fluid nnn.n F COOL_LWT Compressor A1 Size nnn tons SIZE_A1 Compressor A2 Size nnn tons SIZE_A2 Compressor A3 Size nnn tons SIZE_A3 Compressor B1 Size nnn tons SIZE_B1 Compressor B2 Size nnn tons SIZE_B2 Compressor B3 Size nnn tons SIZE_B3 Cooler Flow Switch On/Off COOLFLOW

DESCRIPTION VALUE UNITS POINT NAME Dual Chiller Link Good? Yes/No DC_LINK Master Chiller Role Stand Alone,

Lead Chiller, Lag Chiller

MC_ROLE

Slave Chiller Role Stand Alone, Lead Chiller,

Lag Chiller SC_ROLE

Lead Chiller Ctrl Point snnn.n F LEAD_CP Lag Chiller Ctrl Point snnn.n F LAG_CP Control Point snnn.n F CTRL_PNT Cool EnteringFluid-Slave snnn.n F COOLEWTS Cool Leaving Fluid-Slave snnn.n F COOLLWTS Cooler Entering Fluid snnn.n F COOL_EWT Cooler Leaving Fluid snnn.n F COOL_LWT Lead/Lag Leaving Fluid snnn.n F DUAL_LWT Percent Avail.Capacity 0-100 % CAP_A Percent Avail.Cap.Slave 0-100 % CAP_A_S Lag Start Delay Time hh:mm LAGDELAY Load/Unload Factor snnn.n SMZ Load/Unload Factor-Slave snnn.n SMZSLAVE Lead SMZ Clear Commanded Yes/No LEADSMZC Lag SMZ Clear Commanded Yes/No LAG_SMZC Lag Commanded Off? Yes/No LAG_OFF Dual Chill Lead CapLimit 0-100 % DCLDCAPL Dual Chill Lag CapLimit 0-100 % DCLGCAPL

126

APPENDIX C FACTORY SETTINGS FOR PUMP AND MANUAL STARTERS

*Identified by 12th digit in unit model number.

30RAP UNIT SIZE PUMP SIZE PUMP OPTION* UNIT VOLTAGE OVERLOAD SETTING

010-060

1.5 HP 2, 9

208/230-60 4.6 380-60 2.6 460-60 2.2 575-60 1.7

3 HP 3, 4, B, C

208/230-60 9.1 380-60 5.2 460-60 4.3 575-60 3.3

5 HP 5, 6, D, F

208/230-60 14.5 380-60 8.1 460-60 6.7 575-60 5.3

7.5 HP 7, G

208/230-60 21.3 380-60 12.0 460-60 10.0 575-60 8.1

10 HP Z, H

208/230-60 28.8 380-60 16.1 460-60 13.2 575-60 10.6

070-150

3 HP

1, C

208/230-60 9.1 380-60 5.2 460-60 4.3 575-60 3.3

6, J

208/230-60 10.5 380-60 5.9 460-60 4.8 575-60 3.8

5 HP

2,D (070-130)

208/230-60 14.5

380-60 8.1 460-60 6.7 575-60 5.3

2,D (150-ton only)

208/230-60 17.7 380-60 9.3 460-60 8.2 575-60 6.2

7,K

208/230-60 14.5 380-60 8.1 460-60 6.7 575-60 5.3

7.5 HP

3,F (070-130)

208/230-60 21.3 380-60 12.0 460-60 10.0 575-60 8.1

3,F (150-ton only)

208/230-60 25.3 380-60 14.1 460-60 11.6 575-60 9.3

8,L

208/230-60 21.3 380-60 12.0 460-60 10.0 575-60 8.1

10 HP 4,9,G,M

208/230-60 28.8 380-60 16.1 460-60 13.2 575-60 10.6

15 HP 5,B,H,N

208/230-60 42.2 380-60 24.2 460-60 19.6 575-60 16.1

127

APPENDIX D BACNET COMMUNICATION The following section is used to configure the UPC Open control- ler which is used when the BACnet1 communication option is selected. The 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 procedure to assign an address: 1. If the UPC Open controller is powered, pull the screw termi-

nal connector from the controller's power terminals labeled Gnd and HOT. The controller reads the address each time power is applied to it.

2. Using the rotary switches (see Fig. A and B), set the control- ler's address. Set the Tens (10's) switch to the tens digit of the address, and set the Ones (1's) switch to the ones digit.

As an example in Fig. B, if the controllers 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.

BACNET DEVICE INSTANCE ADDRESS The UPC Open controller also has a BACnet Device Instance ad- dress. This Device Instance MUST be unique for the complete BACnet system in which the UPC Open controller is installed. The 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 BACView device. By de- fault, a MAC address of 20 will result in a Device Instance of 16101 + 20 which would be a Device Instance of 1610120.

1. BACnet is a registered trademark of ASHRAE (American Society of Heating, Refrigerating, and Air-Conditioning Engineers).

10's

1's

1

3

45

2

7 8

9

6

0

1

3

45

2

7 8

9

6

0

Fig. B Address Rotary Switches

Fig. A UPC Open Controller

BACNET BAUD RATE DIP SWITCHES

ADDRESS ROTARY SWITCHES

POWER LED

RUN LED

ERROR LED

BACNET CONNECTION (BAS PORT)

BT485 TERMINATOR

Tx2 LED

Rx2 LED

Tx1 LED

Rx1 LED

EIA-485 JUMPERS

876

5 4 3 21

09

876

5 4 3 21

09

10

1

128

APPENDIX D BACNET COMMUNICATION OPTION (cont) CONFIGURING THE BAS PORT FOR BACNET MS/TP Use the same baud rate and communication settings for all con- trollers on the network segment. The UPC Open controller is fixed at 8 data bits, No Parity, and 1 Stop bit for this protocol's commu- nications. If the UPC Open controller has been wired for power, pull the screw terminal connector from the controller's power terminals la- beled 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 DS5 to MSTP. See Table A.

Table A SW3 Protocol Switch Settings for MS/TP

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 the BAS Port DIP Switches DS2 and DS1 for the appropriate communications speed of the MS/TP network (9600, 19.2k, 38.4k, or 76.8k bps). See Fig. C and Table B.

Table B Baud Selection Table

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.

Wire the controllers on an MS/TP network segment in a daisy- 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 net- work 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 ports 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 currently con- nected.

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.

DS8 DS7 DS6 DS5 DS4 DS3 Off Off Off Off On Off

BAUD RATE DS2 DS1 9,600 Off Off 19,200 On Off 38,400 Off On 76,800 On On

Fig. C DIP Switches

Fig. D Network Wiring

129

APPENDIX D BACNET COMMUNICATION OPTION (cont)

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 Recommendations are shown in Tables C and D. The wire jacket and UL temperature rating specifications list two acceptable alter- natives. The Halar1 specification has a higher temperature rating

and a tougher outer jacket than the SmokeGard2 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 ex- tremely low temperatures. NOTE: Use the specified type of wire and cable for maximum sig- nal integrity.

Table C MS/TP Wiring Recommendations

LEGEND

Fig. E BT485 Terminator Installation

1. Halar is a egistered trademark of Solvay Plastics. 2. SmokeGard is a trademark of AlphaGary-Mexichem Corp.

SPECIFICATION RECOMMENDATION

CABLE Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable

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 lb/1000 feet (17.9 kg/km)

UL TEMPERATURE RATING SmokeGard 167F (75C) Halar -40 to 302F (-40 to 150C)

VOLTAGE 300 Vac, power limited LISTING UL: NEC CL2P, or better

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

130

APPENDIX D BACNET COMMUNICATION OPTION (cont) Table D Open System Wiring Specifications and Recommended Vendors

LEGEND

LOCAL ACCESS TO UPC OPEN CONTROLLER The user can use a BACview6 handheld keypad display unit or the Virtual BACview software as a local user interface 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 BACview6 unit connects to the local access port on the UPC Open controller. See Fig. F. The BACview software must be run- ning on a laptop computer that is connected to the local access port on the UPC Open controller. The laptop will require an additional USB link cable for connection. See the BACview Installation and User Guide for instructions on connecting and using the BACview6 device. To order a BACview6 Handheld (BV6H), consult Commercial Products i-Vu Open Control System Master Prices. CONFIGURING THE UPC OPEN CONTROLLER'S PROP- ERTIES The UPC Open device and ComfortLink controller must be set to the same CCN Address (Element) number and CCN Bus number.

The factory default settings for CCN Element and CCN Bus num- ber are 1 and 0 respectively. If modifications to the default Element and Bus number are re- quired, both the ComfortLink and UPC Open configurations must be changed. The following configurations are used to set the CCN Address and Bus number in the ComfortLink controller. These configurations can be changed using the scrolling marquee display or accessory Navigator handheld device.

ConfigurationCCNCCN.A (CCN Address) ConfigurationCCNCCN.B (CCN Bus Number)

The following configurations are used to set the CCN Address and Bus Number in the UPC Open controller. These configurations can be changed using the accessory BACview6 display.

Navigation: BACviewCCN Home: Element Comm Stat Element: 1 Bus: 0

WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS

WIRE TYPE DESCRIPTION CONNECT AIR INTERNATIONAL BELDEN RMCORP CONTRACTORS

WIRE AND CABLE

MS/TP NETWORK (RS-485)

22 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.

W221P-22227 25160PV CLP0520LC

24 AWG, single twisted shielded pair, low capacitance, CL2P, TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.

W241P-2000F 82841 25120-OR

RNET 4 conductor, unshielded, CMP, 18 AWG, plenum rated. W184C-2099BLB 6302UE 21450 CLP0442

AWG American Wire Gage CL2P Class 2 Plenum Cable CMP Communications Plenum Rated FEP Fluorinated Ethylene Polymer TC Tinned Copper

Fig. F BACview6 Device Connection

131

APPENDIX D BACNET COMMUNICATION OPTION (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 follow CCN specifica- tions. 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 Acknowledger. If a Chiller Lead/Lag/Standby ap- plication 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 de- faults 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 Broadcaster on the CCN bus. TROUBLESHOOTING If there are problems wiring or addressing the UPC Open control- ler, contact Carrier Technical Support. COMMUNICATION LEDS The LEDs indicate if the controller is communicating with the de- vices on the network. See Tables E and F. The LEDs should re-

flect communication traffic based on the baud rate set. The higher the baud rate the more solid the LEDs become. See Fig. A for lo- cation of LEDs on the UPC Open module. REPLACING THE UPC OPEN BATTERY The UPC Open controller's 10-year lithium CR2032 battery pro- vides a minimum of 10,000 hours of data retention during power outages.

Remove the battery from the controller, making note of the bat- tery's polarity. Insert the new battery, matching the battery's polari- ty with the polarity indicated on the UPC Open controller. NETWORK POINTS LIST The points list for the controller is shown in Table G. Refer to Appendix B for additional information on CCN point name.

Table E LED Status Indicators

Table F Run and Error LEDs Controller and Network Status Indication

IMPORTANT: Power must be ON to the UPC Open when replacing the battery, or the date, time, and trend data will be lost.

LED STATUS

POWER Lights when power is being supplied to the controller. The UPC Open controller is protected by internal solid-state polyswitches on 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 a Tx LED for Ports 1 and 2.

RUN Lights based on controller status. See Table F. ERROR Lights based on controller status. See Table F.

RUN LED ERROR LED STATUS 2 flashes per second Off Normal 2 flashes per second 2 flashes, alternating with Run LED Five minute auto-restart delay after system error 2 flashes per second 3 flashes, then off Controller has just been formatted 2 flashes per second 1 flash per second Controller is alone on the network 2 flashes per second On Exec halted after frequent system errors or control programs halted 5 flashes per second On Exec start-up aborted, Boot is running 5 flashes per second Off 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 sec- ond 14 flashes per second, alternating with Run LED Brownout

132

APPENDIX D BACNET COMMUNICATION OPTION (cont) Table G Network Points List

LEGEND

POINT DESCRIPTION CCN POINT NAME

READ/ WRITE UNITS DEFAULT

VALUE RANGE BACNET OBJECT ID

BACNET OBJECT NAME

4-20 mA Demand Signal LMT_MA R mA AV:36 lmt_ma_1 4-20 mA Reset Signal RST_MA R F AV:33 rst_ma_1 Active Demand Limit DEM_LIM R/W % 100 0 - 100 AV:2 dem_lim_1 Active Setpoint SP R F AV:4 sp_1

Alarm State ALM R 1 = Normal 2 = Alert 3 = Alarm

MSV:1 alm_msv_1

Available Cap Nominal Tons CALCTONS R TONS 0 - 200 AV:84 calctons_1 CCN Chiller CHIL_S_S R/W Start Start/Stop BV:4 chil_s_s_1 Circuit A Run Hours HR_CIRA R hr AV:59 hr_cira_1 Circuit A Starts CY_CIRA R AV:67 cy_cira_1 Circuit B Run Hours HR_CIRB R hr AV:63 hr_cirb_1 Circuit B Starts CY_CIRB R AV:71 cy_cirb_1 Coil Cleaning Maint.Done CL_MAINT R/W No Yes/No BV:54 cl_maint_1 Coil Cleaning Srvc Inter SI_COIL R/W hr 8760 0 - 65535 AV:50 si_coil_1 Coil Service Countdown CL_CDOWN R hr AV:49 cl_cdown_1 Comp A1 Unload Time A1UNLTME R AV:78 a1unltme_1 Compr Return Gas Temp TMP_RGTA R F AV:20 tmp_rgta_1 Compr Return Gas Temp TMP_RGTB R F AV:28 tmp_rgtb_1 Compressor A1 Feedback K_A1_FBK R BV:16 k_a1_fbk_1 Compressor A1 Relay K_A1_RLY R BV:13 k_a1_rly_1 Compressor A1 Run Hours HR_A1 R hr AV:60 hr_a1_1 Compressor A1 Starts CY_A1 R AV:68 cy_a1_1 Compressor A2 Feedback K_A2_FBK R BV:17 k_a2_fbk_1 Compressor A2 Relay K_A2_RLY R BV:14 k_a2_rly_1 Compressor A2 Run Hours HR_A2 R hr AV:61 hr_a2_1 Compressor A2 Starts CY_A2 R AV:69 cy_a2_1 Compressor A3 Feedback K_A3_FBK R On/Off BV:18 k_a3_fbk_1 Compressor A3 Relay K_A3_RLY R On/Off BV:15 k_a3_rly_1 Compressor A3 Run Hours HR_A3 R hr 0-9999 AV:62 hr_a3_1 Compressor A3 Starts CY_A3 R 0-9999 AV:70 cy_a3_1 Compressor B1 Feedback K_B1_FBK R BV:22 k_b1_fbk_1 Compressor B1 Relay K_B1_RLY R BV:19 k_b1_rly_1 Compressor B1 Run Hours HR_B1 R hr AV:64 hr_b1_1 Compressor B1 Starts CY_B1 R AV:72 cy_b1_1 Compressor B2 Feedback K_B2_FBK R BV:23 k_b2_fbk_1 Compressor B2 Relay K_B2_RLY R BV:20 k_b2_rly_1 Compressor B2 Run Hours HR_B2 R hr AV:65 hr_b2_1 Compressor B2 Starts CY_B2 R AV:73 cy_b2_1 Compressor B3 Feedback K_B3_FBK R On/Off BV:24 k_b3_fbk_1 Compressor B3 Relay K_B3_RLY R On/Off BV:21 k_b3_rly_1 Compressor B3 Run Hours HR_B3 R hr 0-9999 AV:66 hr_b3_1 Compressor B3 Starts CY_B3 R 0-9999 AV:74 cy_b3_1

Control Method CONTROL R 1 = Switch 3 = Occupancy 4 = CCN

MSV:5 control_msv_1

R Read W Write

133

APPENDIX D BACNET COMMUNICATION OPTION (cont) Table G Network Points List (cont)

LEGEND

POINT DESCRIPTION CCN POINT NAME

READ/ WRITE UNITS DEFAULT

VALUE RANGE BACNET OBJECT ID

BACNET OBJECT NAME

Control Mode STAT R

1 = Test 2 = Local Off 3 = CCN Off 4 = Clock Off 5 = Emergency Stop 6 = Local On 7 = CCN On 8 = Clock On 9 = Heat Enabled 10 = Pump Delay

AV:8 stat_1

Control Point CTRL_PNT R/W F 44.0 -20 - 70 AV:5 ctrl_pnt_1 Cooler Entering Fluid COOL_EWT R F AV:30 cool_ewt_1 Cooler Flow Switch COOLFLOW R BV:11 coolflow_1 Cooler Freeze Protection MODE_16 R BV:42 mode_16_1 Cooler Leaving Fluid COOL_LWT R F AV:31 cool_lwt_1 Cooler LWT Setpoint LWT_SP R F AV:38 lwt_sp_1 Cooler Pump 1 Interlock PMP1_FBK R BV:9 pmp1_fbk_1 Cooler Pump 2 Interlock PMP2_FBK R BV:10 pmp2_fbk_1 Cooler Pump Relay 1 COOLPMP1 R BV:7 coolpmp1_1 Cooler Pump Relay 2 COOLPMP2 R BV:8 coolpmp2_1 Cooler Pump Select PMP_SLCT R/W AV:40 pmp_slct_1 Cooler Pump Shutdown Dly PUMP_DLY R/W min 1 0 - 10 AV:41 pump_dly_1 Cooler/Pump Heater COOL_HTR R BV:59 cool_htr_1 Cooling Ramp Loading CRAMP R/W 1.0 0.2 - 2.0 AV:56 cramp_1

Cooling Reset Type CRST_TYP R

1 = No Reset 2 = 4-20mA Input 3 = External Temp- OAT 4 = Return Fluid 5 = External Temp- SPT

MSV:7 crst_typ1_msv_1

Cooling Setpoint 1 CSP1 R/W F 44.0 -20 - 70 AV:53 csp1_1 Cooling Setpoint 2 CSP2 R/W F 44.0 -20 - 70 AV:54 csp2_1 CSM Controlling Chiller MODE_1 R BV:30 mode_1_1 Demand Level 1 R/W % AV:80 dmv_lvl_1_perct_1 Demand Level 2 R/W % AV:81 dmv_lvl_2_perct_1 Demand Level 3 R/W % AV:82 dmv_lvl_3_perct_1

Demand Limit Select DMD_CTRL R

1 = None 2 = External Sw. Input 3 = 4-20mA Input 4 = Loadshed

MSV:8 dmd_ctrl_msv_1

Demand Limit Switch 1 DMD_SW1 R BV:25 dmd_sw1_1 Demand Limit Switch 2 DMD_SW2 R BV:26 dmd_sw2_1 Demand/Sound Limited MODE_15 R BV:41 mode_15_1 Discharge Gas Temp DISGAS R F AV:15 disgas_1 Discharge Pressure DP_A R psig AV:13 dp_a_1 Discharge Pressure DP_B R psig AV:23 dp_b_1 Dual Setpoint MODE_13 R BV:39 mode_13_1 Dual Setpoint Switch DUAL_IN R BV:29 dual_in_1 Element Comm Status R BV:2999 element_stat_1 Emergency Stop EMSTOP R/W Enabled Enabled/Emstop BV:6 emstop_1 Entering Fluid Temp EWT R F AV:6 ewt_1 EXV% Open EXV_A R % AV:18 exv_a_1 EXV% Open EXV_B R % AV:27 exv_b_1

R Read W Write

134

APPENDIX D BACNET COMMUNICATION OPTION (cont) Table G Network Points List (cont)

LEGEND

POINT DESCRIPTION POINT NAME READ/ WRITE UNITS DEFAULT

VALUE RANGE BACNET OBJECT ID

BACNET OBJECT NAME

Fan Relay 1 FAN_1 R BV:60 fan_1_1 Fan Relay 2 FAN_2 R BV:61 fan_2_1 Fan Relay 3 FAN_3 R BV:62 fan_3_1 Fan Relay 4 FAN_4 R BV:63 fan_4_1 Fan Relay 5 FAN_5 R BV:64 fan_5_1 Fan Relay 6 FAN_6 R BV:65 fan_6_1 Fan Relay 7 FAN_7 R BV:66 fan_7_1 Fan Relay 8 FAN_8 R BV:67 fan_8_1 Head Setpoint HSP R F AV:29 hsp_1 Heat Request HEAT_REQ R BV:28 heat_req_1 High SCT Circuit A MODE_21 R BV:47 mode_21_1 High SCT Circuit B MODE_22 R BV:48 mode_22_1 High Temperature Cooling MODE_18 R BV:44 mode_18_1 Ice Done ICE_DONE R BV:27 ice_done_1 Ice Setpoint CSP3 R/W F 32.0 -20 - 32 AV:55 csp3_1

Lead Pump LEADPUMP R

1 = Automatic 2 = Pump 1 3 = Pump 2 4 = No Configuration

MSV:9 leadpump_msv_1

Lead/Lag Circuit Select LEAD_TYP R 1 1 = Automatic 2 = Circuit A Leads 3 = Circuit B Leads

AV:43 lead_typ_1

Lead/Lag Leaving Fluid DUAL_LWT R F AV:32 dual_lwt_1 Leaving Fluid Temp - Prime Variable LWT R F AV:7 lwt_1

Loading Sequence Select SEQ_TYPE R AV:77 seq_type_1 Low Cooler Suction Temp A MODE_7 R BV:35 mode_7_1 Low Cooler Suction Temp B MODE_8 R BV:36 mode_8_1 Low Sound Active LSACTIVE R BV:2 lsactive_1 Low Sound Mode MODE_25 R BV:51 mode_25_1 Low Temperature Cooling MODE_17 R BV:43 mode_17_1 Machine Operating Hours HR_MACH R hr AV:57 hr_mach_1 Machine Starts CY_MACH R AV:58 cy_mach_1 Making ICE MODE_19 R BV:45 mode_19_1 Master/Slave Control MODE_3 R BV:32 mode_3_1 Minimum Comp. On Time MODE_23 R BV:49 mode_23_1 Minimum Load Valve Relay MLV_RLY R BV:79 mlv_rly_1 Minimum OFF Time Active MODE_10 R BV:38 mode_10_1 Minutes Off Time DELAY R/W min 0 0 - 15 AV:42 delay_1 Minutes Left for Start MIN_LEFT R min 00:00-15:00 AV:34 min_left_1 Occupancy Status OCC R BV:2008 occ_status Outdoor Air Temperature OAT R/W F AV:1003 oat_1 Override Modes in Effect MODE R BV:5 mode_1 Percent Available Cap. CAPA_A R % AV:12 capa_a_1 Percent Available Cap. CAPB_A R % AV:22 capb_a_1 Percent Total Capacity CAP_T R % AV:3 cap_t_1 Percent Total Capacity CAPA_T R % AV:11 capa_t_1 Percent Total Capacity CAPB_T R % AV:21 capb_t_1 Pump 1 Maintenance Done P1_MAINT R/W No Yes/No BV:52 p1_maint_1 Pump 1 Run Hours HR_PUMP1 R hr AV:75 hr_pump1_1 Pump 1 Service Countdown P1_CDOWN R hr AV:46 p1_cdown_1 Pump 2 Maintenance Done P2_MAINT R/W No Yes/No BV:53 p2_maint_1 Pump 2 Run Hours HR_PUMP2 R hr AV:76 hr_pump2_1 Pump 2 Service Countdown P2_CDOWN R hr AV:47 p2_cdown_1 Pump Changeover Hours PMP_DLTA R/W hr 500 10 - 2000 AV:39 pmp_dlta_1 Pump Off Delay Time MODE_24 R BV:50 mode_24_1 Pump Service Interval SI_PUMPS R/W hr 8760 0 - 65535 AV:48 si_pumps_1 Ramp Load Limited MODE_5 R BV:33 mode_5_1 Requested Stage STAGE R AV:9 stage_1

R Read W Write

135

APPENDIX D BACNET COMMUNICATION OPTION (cont) Table G Network Points List (cont)

LEGEND

POINT DESCRIPTION POINT NAME READ/ WRITE UNITS DEFAULT

VALUE RANGE BACNET OBJECT ID

BACNET OBJECT NAME

Rotate Cooler Pumps Now ROT_PUMP R/W No No/Yes BV:12 rot_pump_1 Saturated Condensing Tmp TMP_SCTA R F AV:16 tmp_scta_1 Saturated Condensing Tmp TMP_SCTB R F AV:25 tmp_sctb_1 Saturated Suction Temp TMP_SSTA R F AV:17 tmp_ssta_1 Saturated Suction Temp TMP_SSTB R F AV:26 tmp_sstb_1 Slow Change Override MODE_9 R BV:37 mode_9_1 Storing ICE MODE_20 R BV:46 mode_20_1 Strainer Maint. Done ST_MAINT R/W No Yes/No BV:55 st_maint_1 Strainer Srvc Countdown ST_CDOWN R hr AV:52 st_cdown_1 Strainer Srvc Interval SI_STRNR R/W hr 8760 0 - 65535 AV:51 si_strnr_1 Suction Pressure SP_A R psig AV:14 sp_a_1 Suction Pressure SP_B R psig AV:24 sp_b_1 Suction Superheat Temp SH_A R ^F AV:44 sh_a_1 Suction Superheat Temp SH_B R ^F AV:45 sh_b_1 System Cooling Demand Level R AV:9006 cool_demand_level_1 System Demand Limiting R BV:83 dem_lmt_act_1 Temperature Reset MODE_14 R BV:40 mode_14_1 Timed Override In Effect MODE_6 R BV:34 mode_6_1 User Defined Analog 1 R/W sq m AV:2901 user_analog_1_1 User Defined Analog 2 R/W sq m AV:2902 user_analog_2_1 User Defined Analog 3 R/W sq m AV:2903 user_analog_3_1 User Defined Analog 4 R/W sq m AV:2904 user_analog_4_1 User Defined Analog 5 R/W sq m AV:2905 user_analog_5_1 User Defined Binary 1 R/W sq m BV:2911 user_binary_1_1 User Defined Binary 2 R/W sq m BV:2912 user_binary_2_1 User Defined Binary 3 R/W sq m BV:2913 user_binary_3_1 User Defined Binary 4 R/W sq m BV:2914 user_binary_4_1 User Defined Binary 5 R/W sq m BV:2915 user_binary_5_1 Var Head Press Output VHP_ACT R mA AV:19 vhp_act_1 WSM Controlling Chiller MODE_2 R BV:31 mode_2_1

R Read W Write

136

APPENDIX E MAINTENANCE SUMMARY AND LOG SHEETS

30RAP WEEKLY MAINTENANCE LOG

Plant ___________________________

Machine Model No. ________________

NOTE: Equipment failures caused by lack of adherence to the Mainte- nance Interval Requirements are not covered under warranty.

NOTE: To avoid injury to personnel and damage to equipment or property when performing maintenance listed in this maintenance log, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sec- tions of this Controls, Start-Up, Operation, Service, and Trouble- shooting document.

DATE OIL LEVEL CHECK

ALARMS / FAULTS

OPERATOR INITIALS REMARKS

137

APPENDIX E MAINTENANCE SUMMARY AND LOG SHEETS (cont) 30RAP Monthly Maintenance Log

NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.

NOTE: To avoid injury to personnel and damage to equipment or property when performing maintenance listed in this maintenance log, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Controls, Start-Up, Operation, Service, and Troubleshooting document.

MONTH 1 2 3 4 5 6 7 8 9 10 11 12 DATE / / / / / / / / / / / / / / / / / / / / / / / /

OPERATOR

UNIT SECTION ACTION UNIT ENTRY

COMPRESSOR Check Oil Level yes/no Leak Test yes/no Check Crankcase Heater If Equipped yes/no

COOLER

Inspect and Clean Cooler yes/no Every 3 - 5 Years Inspect Cooler Heater amps Leak Test yes/no Record Water Pressure Differential (PSI) PSI Inspect Water Pumps yes/no

CONDENSER Leak Test yes/no

Inspect and Clean Condenser Coil yes/no

CONTROLS

General Cleaning and Tightening Connections yes/no Annually Check Pressure Transducers yes/no Confirm Accuracy of Thermistors yes/no Check Chilled Water Flow Switch Operation yes/no

STARTER General Tightening and Cleaning Connections yes/no Annually Inspect All Contactors yes/no

SYSTEM Check Refrigerant Charge yes/no Verify Operation of EXVs and Record Position 0-100% Record System Superheat deg. F

138

APPENDIX E MAINTENANCE SUMMARY AND LOG SHEETS (cont) 30RAP Seasonal Shutdown Log

NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.

MONTH 1 2 3 4 5 6 7 8 9 10 11 12 DATE / / / / / / / / / / / / / / / / / / / / / / / /

OPERATOR

UNIT SECTION ACTION ENTRY

COOLER Isolate and Drain Cooler Add Glycol for Freeze Protection

CONTROLS Do Not Disconnect Control Power

139

INDEX 4 to 20 mA demand limiting 50

Input 39 Reset 47

Accessory Navigator display module 7 Adjusting the backlight brightness 7 Adjusting the contrast 7

Actual start-up 51 Advanced scroll temperature protection 85 Alarm and alert codes table 77-82 Alarm control 29

Alarm routing control 30 Alarm equipment priority 29 Alarm routing control 29 Alarms and alerts 92 Alarm system name 29 AUX. See Auxiliary (AUX) board. Auxiliary (AUX) board 27

Inputs 28 Outputs 28

BACnet communication option 128-136 Basic controls usage 4 Board addresses 27 Brazed-plate cooler heat exchanger

Cleaning 60 Replacement 60

Capacity control 31 Capacity control overrides 32 Carrier comfort network

Carrier Comfort Network (CCN) inter- face 29

CCN communications bus wiring to op- tional space sensor RJ11 connector 30

CCN control 38 CCN tables 114-126 CCN wiring diagram 27

CCN. See Carrier Comfort Network (CCN) Interface.

Charge adjustment for brine operation 52 Check refrigerant charge 52 Check refrigerant feed components 61 Check unit safeties 62 Chilled fluid proof-of-flow switch open 76 Chilled water flow switch 67 Communication failure retry time 29 Complete unit stoppage and restart 76 Component drawings 8 Component location figures 58, 59 Compressor expansion board (CXB) 27

Output relays 28 Status inputs 28

Compressor failure alerts 92-96 Compressor motor sensor harness installa-

tion figure 87 Compressor replacement 57 Compressor return gas temperature sensor 30 Compressor safeties 85 Condenser coil maintenance and cleaning

recommendations 75 Condenser fan layout 35 Condenser fans 68 Configuring and operating dual chiller con-

trol 43 Configuring outdoor air and space tempera-

ture reset table 47

Configuring return temperature reset 48 Control box 9-11 Control box maintenance 75 Control components 54 Control methods and cooling set points 39 Control module communication 27 Controls 7-50 Conventions used in this manual 3 Cooler 60 Cooler entering fluid sensor 30 Cooler flow rates and loop volumes 52 Cooler freeze protection 34 Cooler freeze-up protection 62 Cooler leaving fluid sensor 30 Cooler pump

Control 41 Operation 41 Sequence of operation 41

Cooling load satisfied 76 Cooling set point select 39 Copeland compressor troubleshooting 86 CoreSense communication module

DIP switch settings 88 DIP switch settings for Kriwan retrofit 87 LED flash codes 89 Motor protection wiring 88 Motor thermistor plug 88 Mounting 88

Crankcase heater 51, 59, 60 Detail under compressor 60

CSB. See Current Sensor Board. Current sensor board (CSB) 27 CXB. See Compressor Expansion Board. Deadband multiplier 32, 34 Demand limit 49

Configuring 50 Digital compressor configuration 50 Digital scroll

Operation 50 Option 49

Disassembly and assembly of EXV motor 57 Discharge temperature thermistor 30 Display tables 97-113 Dual chiller configuration tables 44-46 Dual leaving water temperature sensor 30 Dual leaving water thermistor well 43 Electronic components 54 Electronic expansion valve 31, 54

Cable connections to EXV module 55 Cutaway figure 54 Externally powered demand limit 49 EXV board 27 Replacement 55 Steps 54 Troubleshooting Procedure 54 Valve motor replacement 56

Emergency on/off switch 27 EMM. See Energy Management Module

(EMM). Enable/off/remote contact switch 27 Energy management module (EMM) 27, 31 EXV. See Electronic Expansion Valve. Fan drive operation 37 Fan stages 36

Fault codes 71 Field servicing instructions 55 Filter drier 61 General power failure 76 Head pressure control 34 Heater cable 62 Heating operation 40 HEVCF. See High-efficiency variable con-

denser fans. High-efficiency fan drive parameters 37 High-efficiency variable condenser fans

(HEVCF) Alarm/alert details 84 Common alarms 83 Fans 37 Parameters reset at chiller power cycle 38

High-pressure switch 62 Factory settings 62

Hydronic package 41, 74 Ice mode 39 Kriwan motor protection wiring 86 Lead/lag determination 32 Loading sequence select 32 Loss-of-cooler flow protection 31 Low-ambient operation 53 Low saturated suction 85 Low saturated suction protection 34 Low sound fan 69 Low sound mode operation 40 Main base board (MBB) 26

Output relays 28 Thermistor designations 28

Maintenance 75 Recommended schedule 75 Summary and log sheets 137-139

MBB. See Main Base Board (MBB). Microchannel heat exchanger (MCHX) con-

denser coil maintenance and cleaning recommendations 61

Minimum cooler flow rates 52 Minimum load control 34 Minimum load valve 61 Minutes left for start 32 Minutes off time 32 Moisture-liquid indicator 61 Motormaster V controller 37, 70

Buttons and mode display 73 Configuration 71 Drive programming 73 EPM chip 73 General operation 71 Loss of CCN communications 73 Program parameters for operating modes

72 Replacing defective modules 74 Wiring 70

Motor overload protection 86 Motor protection module 90 No integral pump dual external pump

control 41 Occupancy schedule 38 Oil charge 60 Open 24-V control circuit breaker(s) 76 Operating envelope 35

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300221-01 Printed in U.S.A. Form 30RAP-7T Rev. A Pg 140 5-21 Replaces: 30RAP-6T

2021 Carrier

Operating limitations 52 Operating modes 6 Operation of machine based on control meth-

od and cooling set point selection settings 38

Operation sequence 53 Outdoor-air temperature reset 48 Outdoor-air temperature sensor 30 Part load data percent displacement, standard

units with minimum load valve 33 Pressure relief devices 61 Pressure transducers 62, 67

Troubleshooting 67 Pre-start-up 51 Pump and manual starters, factory settings

127 Pump performance check 75 Re-alarm time 29 Recommended minimum cool down time af-

ter compressor is stopped 85 Remote space temperature sensor 30

Replacement modules 74 Replacing thermistors 62 Round tube plate fin condenser coil mainte-

nance and cleaning recommendations 61 Safety considerations 2 Scrolling marquee display 4

Menu structure 5 Sensors 29

Cooler leaving fluid sensor 30 Service 54-75 Service Test 40 Sight glass location 51 Space temperature reset 48 Space temperature sensor wiring 30 Standard chilled fluid temperature control

no reset 49 Start-up and operation 51-53 Start-up checklist CL-1 Strainer 68 System check 51 Temperature limits 53

Temperature reset 43 Thermistor/temperature sensor check 62 Thermistor connections to main base board

67 Thermistor failure 76 Thermistors 62 Thermistor temperatures vs. resistance/volt-

age drop 63-66 Thermistor well 67 Troubleshooting 76-96 Unit enable-off-remote contact switch is off

76 Unit sizes 4 Unit torque specification 59 Voltage 53 Winter shutdown 62 Wiring

Control 13, 15, 17, 19, 21, 23, 25 Power 12, 14, 16, 18, 20, 22, 24

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300221-01 Printed in U.S.A. Form 30RAP-7T Rev. A Pg CL-1 5-21 Replaces: 30RAP-6T

START-UP CHECKLIST FOR 30RAP LIQUID CHILLER

(Remove and use for Job File)

I. Project Information Job name ______________________________________ Installing contractor________________________________ Address ______________________________________ Sales office ______________________________________ City ____________________State_____ Zip ___________ Start-up performed by______________________________

Unit Model _______________________________________ Serial _________________________________________

II. Preliminary Equipment Check (To Be Performed By Installing Contractor)

IS THERE ANY PHYSICAL DAMAGE? YES NO

IF YES, WAS IT NOTED ON THE FREIGHT BILL, AND HAS A CLAIM BEEN FILED WITH THE SUPPLIER? YES NO

DESCRIPTION ____________________________________________________________________________

_________________________________________________________________________________________

1. UNIT IS INSTALLED LEVEL AS PER THE INSTALLATION INSTRUCTIONS. YES NO

2. POWER SUPPLY AGREES WITH THE UNIT NAMEPLATE. YES NO

3. ELECTRICAL POWER WIRING IS INSTALLED PROPERLY. YES NO

4. UNIT IS PROPERLY GROUNDED. YES NO

5. ELECTRICAL CIRCUIT PROTECTION HAS BEEN SIZED AND INSTALLED PROPERLY. YES NO

6. ALL TERMINALS ARE TIGHT. YES NO

7. ALL PLUG ASSEMBLIES ARE TIGHT. YES NO

8. REMOVE SHIPPING BRACKETS FROM COMPRESSORS. YES NO

Chilled Water System Check (to be performed by installing contractor)

1. SYSTEM HAS BEEN PROPERLY CLEANED AND FILLED. YES NO

2. ALL CHILLED WATER VALVES ARE OPEN. YES NO

II. Preliminary Equipment Check (Cont)

3. ALL PIPING IS CONNECTED PROPERLY. YES NO

4. ALL AIR HAS BEEN PURGED FROM THE SYSTEM. YES NO

5. CHILLED WATER PUMP IS OPERATING WITH THE CORRECT ROTATION. YES NO

6. CHILLED WATER PUMP CONTROLLED BY CHILLER. YES NO

NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preced- ing sections of this Controls, Start-Up, Operation, Service, and Troubleshooting document.

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7. CHILLED WATER PUMP STARTER INTERLOCKED WITH CHILLER. YES NO

8. INTEGRATED 40 MESH Y STRAINER CLEAN. YES NO

9. WATER LOOP VOLUME GREATER THAN MINIMUM REQUIREMENTS. (See Table 30). YES NO

10. PROPER LOOP FREEZE PROTECTION PROVIDED TO _____ F (C). YES NO ANTIFREEZE TYPE _____________________ CONCENTRATION __________%. IF OUTDOOR AMBIENT IS BELOW 32 F (0 C) THEN ITEMS 11-13 HAVE TO BE COMPLETED TO PROVIDE COOLER FREEZE PROTECTION TO 20 F (29 C). (REFER TO WINTER SHUTDOWN FOR PROPER COOLER WINTERIZATION PROCEDURE.)

NOTE: GLYCOL CONCENTRATIONS ABOVE 30% MAY REQUIRE A FLOW SWITCH RE-CALIBRATION.

11. OUTDOOR PIPING WRAPPED WITH ELECTRIC HEATER TAPE, YES NO INSULATED AND OPERATIONAL.

12. COOLER HEATERS INSTALLED AND OPERATIONAL. YES NO

13. CRANKCASE HEATERS (IF EQUIPPED) ARE SECURELY ATTACHED, OPERATIONAL, AND ENERGIZED TO REMOVE ANY LIQUID FROM THE COMPRESSOR. YES NO

SIGNATURE REQUIRED

PRELIMINARY START-UP COMPLETE.

INSTALLING/MECHANICAL CONTRACTOR ____________________________________ DATE_________________

III. Unit Start-Up (Qualified individuals only. Factory start-up recommended.)

Design Information

1. ALL CABLES AND THERMISTORS HAVE BEEN INSPECTED FOR CROSSED WIRES. YES NO

2. ALL THERMISTORS ARE FULLY INSERTED INTO WELLS. YES NO

3. COMPRESSOR OIL LEVEL IS CORRECT. YES NO

4. VERIFY CRANKCASE HEATERS (IF EQUIPPED) HAVE BEEN ENERGIZED FOR 24 HOURS. YES NO

5. VERIFY COMPRESSOR MOUNTING BOLT TORQUE IS 7-10 FT-LB (9.5-13.5 N-M). YES NO

6. LEAK CHECK UNIT. LOCATE, REPAIR AND REPORT ANY REFRIGERANT LEAKS. YES NO

7. VOLTAGE IS WITHIN UNIT NAMEPLATE RANGE. YES NO

8. CONTROL TRANSFORMER PRIMARY CONNECTION SET FOR PROPER VOLTAGE. YES NO

9. CONTROL TRANSFORMER SECONDARY VOLTAGE =

CAPACITY CEAT EWT LWT FLUID TYPE FLOW RATE P.D.

CL-3

III. Unit Start-Up (cont)

10. CHECK VOLTAGE IMBALANCE: A-B A-C B-C AVERAGE VOLTAGE = (A-B + A-C + B-C)/3 MAXIMUM DEVIATION FROM AVERAGE VOLTAGE = VOLTAGE IMBALANCE = ____________% (MAX. DEVIATION/AVERAGE VOLTAGE) X 100 VOLTAGE IMBALANCE LESS THAN 2%. YES NO (DO NOT START CHILLER IF VOLTAGE IMBALANCE IS GREATER THAN 2%. CONTACT LOCAL UTILITY FOR ASSISTANCE.)

11. VERIFY COOLER FLOW RATE. YES NO 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 (l/s) (See Cooler Pressure

Drop Curves from Installation Instructions)

12. FLOW SWITCH OPERATION CHECKED. YES NO

Start and Operate Machine. Complete the Following:

1. COMPLETE COMPONENT TEST. YES NO

2. CHECK REFRIGERANT AND OIL CHARGE. YES NO

3. RECORD COMPRESSOR MOTOR CURRENT. YES NO

4. RECORD CONFIGURATION SETTINGS. YES NO

5. RECORD OPERATING TEMPERATURES AND PRESSURES. YES NO

6. PROVIDE OPERATING INSTRUCTIONS TO OWNERS PERSONNEL. Instruction Time ________ hours.

OPERATING DATA:

RECORD THE FOLLOWING INFORMATION FROM THE PRESSURES AND TEMPERATURES MODES WHEN MACHINE IS IN A STABLE OPERATING CONDITION:

PRESSURE/TEMPERATURE

*Readings taken with a digital thermometer.

III. Unit Start-Up (cont)

CIRCUIT A CIRCUIT B DISCHARGE PRESSURE DP.A DP.B SUCTION PRESSURE SP.A SP.B SATURATED CONDENSING TEMP SCT.A SCT.B SATURATED SUCTION TEMP SST.A SST.B RETURN GAS TEMPERATURE RGT.A RGT.B LIQUID LINE TEMPERATURE* DISCHARGE LINE TEMPERATURE*

COOLER EWT EWT COOLER LWT LWT OUTDOOR-AIR TEMPERATURE OAT CONTROL POINT CTPT PERCENT TOTAL CAPACITY CAP LEAD/LAG LEAVING FLUID DLWT (DUAL CHILLER CONTROL ONLY)

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Compressor Running Current All readings taken at full load.

Record Software Versions MODE RUN STATUS

PRESS ENTER AND ESCAPE KEYS SIMULTANEOUSLY TO OBTAIN SOFTWARE VERSIONS.

COMPRESSOR MOTOR CURRENT L1 L2 L3 COMPRESSOR A1 COMPRESSOR A2 COMPRESSOR A3 COMPRESSOR B1 COMPRESSOR B2 COMPRESSOR B3

CONDENSER FAN MOTOR CURRENT L1 L2 L3 FAN MOTOR 1 FAN MOTOR 2 FAN MOTOR 3 FAN MOTOR 4 FAN MOTOR 5 FAN MOTOR 6 FAN MOTOR 7 FAN MOTOR 8 FAN MOTOR 9 FAN MOTOR 10

COOLER PUMP MOTOR CURRENT L1 L2 L3 COOLER PUMP 1 COOLER PUMP 2

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

VERS

MBB CESR-131460- _ _-_ _ EXV CESR-131172- _ _-_ _

AUX1 CESR-131333- _ _-_ _ EMM CESR-131174- _ _-_ _

MARQ CESR-131171- _ _-_ _ NAVI CESR-131227- _ _-_ _ CXB CESR-131173- _ _-_ _

CL-5

III. Unit Start-Up (cont)

PRESS ESCAPE KEY TO DISPLAY UNIT. RECORD CONFIGURATION SETTINGS BELOW.

UNIT (Configuration Settings)

PRESS ESCAPE KEY TO DISPLAY UNIT. PRESS DOWN ARROW KEY TO DISPLAY OPT1. PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW.

OPTIONS1 (Options Configuration)

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

UNIT

UNIT CONFIGURATION

SIZE UNIT SIZE XXX

SZA.1 COMPRESSOR A1 SIZE XX TONS

SZA.2 COMPRESSOR A2 SIZE XX TONS

SZA.3 COMPRESSOR A3 SIZE XX TONS

SZB.1 COMPRESSOR B1 SIZE XX TONS

SZB.2 COMPRESSOR B2 SIZE XX TONS

SZB.3 COMPRESSOR B3 SIZE XX TONS

SH.SP SUPERHEAT SETPOINT XX.X F

FAN.S FAN STAGING SELECT XX

EXV EXV MODULE INSTALLED YES/NO

A1.TY COMPRESSOR A1 DIGITAL? YES/NO

MAX.T MAXIMUM A1 UNLOAD TIME XX SEC

FN.SQ CONDFAN SEQ FOR SSN 2214 YES/NO

VLTS UNIT VOLTAGE XXX

F.POL NUM POLES IN FAN X

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

OPT1

UNIT OPTIONS 1 HARDWARE

FLUD COOLER FLUID X

MLV.S MINIMUM LOAD VALVE SELECT YES/NO

CSB.E CSB BOARDS ENABLE ENBL/DSBL

CPC COOLER PUMP CONTROL ON/OFF

PM1E COOLER PUMP 1 ENABLE YES/NO

PM2E COOLER PUMP 2 ENABLE YES/NO

PM.P.S COOLER PMP PERIODIC STRT YES/NO

PM.SL COOLER PUMP SELECT X

PM.DY COOLER PUMP SHUTDOWN DLY XX MIN

PM.DT PUMP CHANGEOVER HOURS XXXX HRS

ROT.P ROTATE COOLER PUMPS NOW YES/NO

PMP.O COOLER PUMP OPERATION X

PM.HT PUMP HIGH TEMP CUT OFF XX.XF

EMM EMM MODULE INSTALLED YES/NO

CND.T CND HX TYP 0=RTPF 1=MCHX 0/1

MOPS EXV MOP SET POINT XX

APPR CONFIG APPROACH SETPOINT XX

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III. Unit Start-Up (cont)

PRESS ESCAPE KEY TO DISPLAY OPT1. PRESS DOWN ARROW KEY TO DISPLAY OPT2. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW.

OPTIONS2 (Options Configuration)

PRESS ESCAPE KEY TO DISPLAY OPT2. PRESS DOWN ARROW KEY TO DISPLAY CCN. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW.

CCN (CCN Network Configuration)

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

OPT2

UNIT OPTIONS 2 CONTROLS

CTRL CONTROL METHOD X

LOAD LOADING SEQUENCE SELECT X

LLCS LEAD/LAG CIRCUIT SELECT X

LCWT HIGH LCW ALERT LIMIT XX.X F

DELY MINUTES OFF TIME XX

ICE.M ICE MODE ENABLE ENBL/DSBL

LS.MD LOW SOUND MODE SELECT X

LS.ST LOW SOUND START TIME 00:00

LS.ND LOW SOUND END TIME 00:00

LS.LT LOW SOUND CAPACITY LIMIT XXX %

ALR.C ALARM RELAY USAGE X

SER.T SERVICE TRIO ENABLE ENBL/DSBL

SUB-MODE ITEM ITEM EXPANSION DISPLAY ENTRY

CCN

CCNA CCN ADDRESS XXX

CCNB CCN BUS NUMBER XXX

BAUD CCN BAUD RATE X

CL-7

III. Unit Start-Up (cont)

PRESS ESCAPE KEY TO DISPLAY CCN. PRESS DOWN ARROW KEY TO DISPLAY EXV.A. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW.

EXV.A (Circuit A EXV Configuration)

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 ITEM ITEM EXPANSION DISPLAY ENTRY

EXV.A

EXV.L EXV OPENING AT LOW LWT XX%

LWT.L LWT FOR EXV MIN OPENING XX F

EXV.H EXV OPENING AT HIGH LWT XX%

LWT.H LWT FOR EXV MAX OPENING XX F

MIN.A EXV CIRC.A MIN POSITION XXX.X%

RNG.A EXVA STEPS IN RANGE XXXXX

SPD.A EXVA STEPS PER SECOND XXXXX

POF.A EXVA FAIL POSITION IN% X.XX%

MIN.A EXVA MINIMUM STEPS XXXXX

MAX.A EXVA MAXIMUM STEPS XXXXX

OVR.A EXVA OVERRUN STEPS XXX.X%

A.ST.P EXV CIRC A START POS XXX.X%

TYP.A EXVA STEPPER TYPE 0,1

H.SCT HIGH SCT THRESHOLD XXX.X F

X.PCT OPEN EXV X% ON 2ND COMP XX.X%

X.PER MOVE EXV X% ON DISCRSOL XX.X%

A.PCT PRE-OPEN EXV - FAN ADDING XXX.X%

M.PCT PRE-CLOSE EXV - FAN SUB XXX.X%

S.PCT PRE-CLOSE EXV - LAG SHUT XXX SEC

DELY LAG START DELAY XXX SEC

L.DL.T LOW SH DELTA T - EXV MOVE XXX SEC

SHR.T EXV RATE THRESHOLD XX.X F

L.EX.M LOW SH OVERRIDE EXV MOVE X.X%

SUB-MODE ITEM ITEM EXPANSION DISPLAY ENTRY

EXV.B

MIN.B EXV CIRC.B MIN POSITION XXX.X%

RNG.B EXVB STEPS IN RANGE XXXXX STEP

SPD.B EXVB STEPS PER SECOND XXXXX

POF.B EXVB FAIL POSITION IN % XXX.X%

MIN.B EXVB MINIMUM STEPS XXXXX STEP

MAX.B EXVB MAXIMUM STEPS XXXXX STEP

OVR.B EXVB OVERRUN STEPS XXX STEP

TYP.B EXVB STEPPER TYPE 0,1

CL-8

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III. Unit Start-Up (cont)

PRESS ESCAPE KEY TO DISPLAY EXV.B. PRESS DOWN ARROW KEY TO DISPLAY MM. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW.

MM (Motormaster Configuration Settings)

PRESS ESCAPE KEY TO DISPLAY MM. PRESS DOWN ARROW KEY TO DISPLAY RSET. PRESS ENTER KEY.

RECORD CONFIGURATION INFORMATION BELOW.

RSET (Reset Configuration Settings)

SUB-MODE ITEM ITEM EXPANSION DISPLAY ENTRY

MM

MMR.S MOTORMASTER SELECT X

P.GAN HEAD PRESSURE P GAIN XX.X

I.GAN HEAD PRESSURE I GAIN XX.X

D.GAN HEAD PRESSURE D GAIN XX.X

MIN.S MINIMUM FAN SPEED XXX.X%

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

RSET

RESET COOL TEMP

CRST COOLING RESET TYPE X

MA.DG 4-20 - DEGREES RESET XX.X F

RM.NO REMOTE - NO RESET TEMP XXX.X F

RM.F REMOTE - FULL RESET TEMP XXX.X F

RM.DG REMOTE - DEGREES RESET XX.X F

RT.NO RETURN - NO RESET TEMP XXX.X F

RT.F RETURN - FULL RESET TEMP XXX.X F

RT.DG RETURN - DEGREES RESET XX.X F

DMDC DEMAND LIMIT SELECT X

DM20 DEMAND LIMIT AT 20 MA XXX %

SHNM LOADSHED GROUP NUMBER XXX

SHDL LOADSHED DEMAND DELTA XXX %

SHTM MAXIMUM LOADSHED TIME XXX MIN

DLS1 DEMAND LIMIT SWITCH 1 XXX.X %

DLS2 DEMAND LIMIT SWITCH 2 XXX.X %

LLEN LEAD/LAG CHILLER ENABLE ENBL/DSBL

MSSL MASTER/SLAVE SELECT SLVE/MAST

SLVA SLAVE ADDRESS XXX

LLBL LEAD/LAG BALANCE SELECT X

LLBD LEAD/LAG BALANCE DELTA XXX HRS

LLDY LAG START DELAY XXX MIN

PARA PARALLEL CONFIGURATION YES/NO

CL-9

III. Unit Start-Up (cont)

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)

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 ITEM ITEM EXPANSION DISPLAY ENTRY

SLCT

SETPOINT AND RAMP LOAD

CLSP COOLING SETPOINT SELECT X

RL.S RAMP LOAD SELECT ENBL/DSBL

CRMP COOLING RAMP LOADING X.X F

SCHD SCHEDULE NUMBER XX

Z.GN DEADBAND MULTIPLIER X.X

SUBMODE ITEM ITEM EXPANSION DISPLAY ENTRY

COOL

COOLING SETPOINTS

CSP.1 COOLING SETPOINT 1 XXX.X F

CSP.2 COOLING SETPOINT 2 XXX.X F

CSP.3 ICE SETPOINT XXX.X F

HEAD

HEAD PRESSURE SETPOINTS

H.DP HEAD SET POINT XXX.X F

F.ON FAN ON SET POINT XXX.X F

F.OFF FAN OFF SET POINT XXX.X F

B.OFF BASE FAN OFF DELTA TEMP XX.X F

F.DLT FAN STAGE DELTA XX.X F

FRZ BRINE FREEZE SETPOINT

BR.FZ BRINE FREEZE POINT XXX.X F

CL-10

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III. Unit Start-Up (cont)

COMPONENT TEST

USE ESCAPE/ARROW KEYS 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 ILLUMINATE THE SERVICE TEST LED. PRESS ENTER TO DISPLAY TEST. PRESS ENTER TO STOP DIS- PLAY 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

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM

EXPANSION COMMENT COMPLETED (YES/NO)

TEST

ON/OFF SERVICE TEST MODE To Enable Service Test Mode, move Enable/Off/Remote Control switch to OFF. Change TEST to ON. Move switch to ENABLE.

OUTS OUTPUTS AND PUMPS

EXV.A xxx% EXV% OPEN

EXV.B xxx% EXV% OPEN

FAN1 ON/OFF FAN 1 RELAY Condenser fan contactor 1

FAN2 ON/OFF FAN 2 RELAY Condenser fan contactor 2

FAN3 ON/OFF FAN 3 RELAY Condenser fan contactor 3

FAN4 ON/OFF FAN 4 RELAY Condenser fan contactor 4

FAN5 ON/OFF FAN 5 RELAY Condenser fan contactor 5

FAN6 ON/OFF FAN 6 RELAY Condenser fan contactor 6

FAN7 ON/OFF FAN 7 RELAY Condenser fan contactor 7

FAN8 ON/OFF FAN 8 RELAY Condenser fan contactor 8

V.HPA xx VAR HEAD PRESS% CIRCUIT A

V.HPB xx VAR HEAD PRESS% CIRCUIT B

CLP.1 ON/OFF COOLER PUMP RELAY 1

CLP.2 ON/OFF COOLER PUMP RELAY 2

DIG.P xxx COMPRESSOR A1 LOAD PERCENT

Digital Scroll option only

CL.HT ON/OFF COOLER/PUMP HEATER

CCH.A ON/OFF CRANKCASE HEATER CIRCUIT A

CCH.B ON/OFF CRANKCASE HEATER CIRCUIT B

RMT.A ON/OFF REMOTE ALARM RELAY

ENTER

ENTER

CL-11

III. Unit Start-Up (cont)

Service Test Mode and Sub-Mode Directory (cont)

NOTE: If the unit has a single circuit, the Circuit B items will not appear in the display.

SUB-MODE KEYPAD ENTRY ITEM DISPLAY ITEM

EXPANSION COMMENT COMPLETED (YES/NO)

CMPA

CIRCUIT A COMPRESSOR TEST

CC.A1 ON/OFF COMPRESSOR A1 RELAY

DIG.P XXX% COMP A1 UNLOAD PERCENT Digital Scroll option only

CC.A2 ON/OFF COMPRESSOR A2 RELAY

CC.A3 ON/OFF COMPRESSOR A3 RELAY

MLV ON/OFF MINIMUM LOAD VALVE RELAY

CMPB

CIRCUIT B COMPRESSOR TEST

CC.B1 ON/OFF COMPRESSOR B1 RELAY See Note

CC.B2 ON/OFF COMPRESSOR B2 RELAY See Note

CC.B3 ON/OFF COMPRESSOR B3 RELAY See Note

ENTER

ENTER

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300221-01 Printed in U.S.A. Form 30RAP-7T Rev. A Pg CL-2 5-21 Replaces: 30RAP-6T

2021 Carrier

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Manualsnet FAQs

If you want to find out how the 30RAP011-060 Carrier works, you can view and download the Carrier 30RAP011-060 v3 Installation Instructions on the Manualsnet website.

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