-
Manufacturer reserves the right to discontinue, or change at any
time, specifications or designs without notice and without
incurring obligations.Catalog No. 533-00069 Printed in U.S.A. Form
30XA-1T Pg 1 12-05 Replaces: NewBook 2
Tab 5c
Controls, Start-Up, Operation, Serviceand Troubleshooting
CONTENTSPage
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .
. 2GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 2-4Conventions Used in This Manual . . . . . .
. . . . . . . . . . 2Display Module Usage . . . . . . . . . . . . .
. . . . . . . . . . . . . . 3 NAVIGATOR DISPLAY MODULECONTROLS . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-41General . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 4Main Base Board (MBB) . . . . . . . .
. . . . . . . . . . . . . . . . . . 4Compressor Protection Module
(CPM) . . . . . . . . . . . 6Electronic Expansion Valve (EXV) Board
. . . . . . . . . 9Fan Boards. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 11Enable-Off-Remote Contact
Switch (SW1) . . . . . . . 13Emergency On/Off Switch (SW2) . . . .
. . . . . . . . . . . . 13Energy Management Module (EMM) . . . . .
. . . . . . . . 13Local Equipment Network . . . . . . . . . . . . .
. . . . . . . . . . 14Board Addresses. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 14Control Module Communication. .
. . . . . . . . . . . . . . . 14 RED LED GREEN LED YELLOW
LEDCarrier Comfort Network (CCN) Interface . . . . . .
15Configuration Options . . . . . . . . . . . . . . . . . . . . . .
. . . . 15 RAMP LOADING MINUTES OFF TIMEDual Chiller Control . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 15 DUAL CHILLER
PUMP CONTROL FOR PARALLEL
APPLICATIONS DUAL CHILLER PUMP CONTROL FOR SERIES
CHILLER APPLICATIONSCapacity Control . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 16 EQUAL LOADING STAGE LOADING
CAPACITY CONTROL OVERRIDESHead Pressure Control . . . . . . . . . .
. . . . . . . . . . . . . . . . 22 LOW AMBIENT TEMPERATURE HEAD
PRESSURE
CONTROL OPTION LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPERATING INSTRUCTIONSMachine Control Methods . . . . .
. . . . . . . . . . . . . . . . . . 29 SWITCH CONTROL TIME SCHEDULE
CCN CONTROL UNIT RUN STATUSCooling Set Point Selection . . . . . .
. . . . . . . . . . . . . . . 30 SET POINT 1 SET POINT 2 4 TO 20 mA
INPUT DUAL SWITCH ICE MODE SET POINT OCCUPANCYTemperature Reset . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Demand
Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 32 1-STEP SWITCH CONTROLLED 2-STEP SWITCH CONTROLLED
Page EXTERNALLY POWERED (4 to 20 mA Controlled) CCN LOADSHED
CONTROLLEDRemote Alarm and Alert Relays . . . . . . . . . . . . . .
. . . 40PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 41System Check. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 41START-UP . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 42-48Actual
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 42Operating Limitations . . . . . . . . . . . . . . . . . .
. . . . . . . . . 42 TEMPERATURES VOLTAGE MINIMUM FLUID LOOP VOLUME
FLOW RATE REQUIREMENTSOPERATION . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 48-55Sequence of Operation. . . . .
. . . . . . . . . . . . . . . . . . . . . 48 ACTUATED BALL VALVE
(ABV)Dual Chiller Sequence of Operation . . . . . . . . . . . . .
49 PARALLEL PUMP OPERATIONOperating Modes. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 49Sensors . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
THERMISTORS TRANSDUCERSSERVICE . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 56-66Economizer Assembly . .
. . . . . . . . . . . . . . . . . . . . . . . . 56Electronic
Expansion Valve (EXV) . . . . . . . . . . . . . . . 56 MAIN EXV
CONTROL ECONOMIZER EXV CONTROL EXV TROUBLESHOOTING
PROCEDURECompressor Assembly . . . . . . . . . . . . . . . . . . .
. . . . . . . 59 COMPRESSOR OIL SYSTEMCooler. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SUCTION SERVICE VALVE FREEZE PROTECTION LOW FLUID TEMPERATURE LOSS
OF FLUID FLOW PROTECTION TUBE PLUGGING RETUBING TIGHTENING COOLER
HEAD BOLTS INSPECTING/CLEANING HEAT EXHANGERS WATER TREATMENT
CHILLED WATER FLOW SWITCHCondenser Coil Maintenance and
Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 64 REMOVE SURFACE LOADED FIBERS PERIODIC CLEAN WATER RINSE
ROUTINE CLEANING OF COIL SURFACESCondenser Fans . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 65Refrigerant Circuit .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 LEAK
TESTING REFRIGERANT CHARGESafety Devices . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 66 COMPRESSOR PROTECTION
OIL SEPARATOR HEATERS COOLER PROTECTIONRelief Devices . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 PRESSURE
RELIEF VALVES
30XA080-500Air-Cooled Liquid Chillers
60 Hz
-
2CONTENTS (cont)MAINTENANCE. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 66Recommended Maintenance Schedule .
. . . . . . . . . 66TROUBLESHOOTING . . . . . . . . . . . . . . . .
. . . . . . . . . 66-86Alarms and Alerts . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 67 DIAGNOSTIC ALARM CODES AND
POSSIBLE
CAUSESService Test . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 82APPENDIX A LOCAL DISPLAY TABLES. . .
87-100APPENDIX B CCN TABLES . . . . . . . . . . . . . .
101-112APPENDIX C 30XA080-500 CPM
DIP SWITCH ADDRESSES. . . . . . . . . . . . . . . .
113-116APPENDIX D PIPING AND
INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . .
. . 117INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 118START-UP CHECKLIST
FOR 30XA LIQUID CHILLERS . . . . . . . .CL-1 to CL-8
SAFETY CONSIDERATIONSInstalling, starting up, and servicing this
equipment can be
hazardous due to system pressures, electrical components,
andequipment location (roof, elevated structures, etc.).
Onlytrained, qualified installers and service technicians
shouldinstall, start up, and service this equipment. When working
onthis equipment, observe precautions in the literature, and
ontags, stickers, and labels attached to the equipment, and
anyother 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
electri-cal components.
GENERALThis publication contains Controls, Operation,
Start-Up,
Service and Troubleshooting information for the 30XA080-500
air-cooled liquid chillers with electronic controls. The30XA
chillers are equipped with ComfortLink controls andelectronic
expansion valves.Conventions Used in This Manual The follow-ing
conventions for discussing configuration points for theNavigator
module will be used in this manual.
Point names will be written with the mode name first, thenany
sub-modes, then the point name, each separated by anarrow symbol
(). Names will also be shown in boldand italics. As an example, the
Lead/Lag Circuit Select Point,which is located in the Configuration
mode, Option sub-mode,would be written as Configuration
OPTNLLCS.
This path name will show the user how to navigate through
thelocal display to reach the desired configuration. The user
wouldscroll through the modes and sub-modes using the andkeys. 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
thevalue represents a configuration setting, an explanation willbe
shown in parenthesis after the value. As an
example,ConfigurationOPTNLLCS = 1 (Circuit A leads).
Pressing the and keys simultaneouslywill scroll an expanded text
description of the point name or valueacross the display. The
expanded description is shown in the localdisplay tables but will
not be shown with the path names in text.
The CCN (Carrier Comfort Network) point names arealso referenced
in the local display tables for users configuringthe unit with CCN
software instead of the local display. TheCCN tables are located in
Appendix B of the manual.
Electrical shock can cause personal injury and death. Shutoff
all power to this equipment during installation and ser-vice. There
may be more than one disconnect switch. Tagall disconnect locations
to alert others not to restore poweruntil work is completed.
DO NOT VENT refrigerant relief valves within a building.Outlet
from relief valves must be vented in accordancewith the latest
edition of ANSI/ASHRAE (AmericanNational Standards
Institute/American Society of Heating,Refrigerating and Air
Conditioning Engineers) 15 (SafetyCode for Mechanical
Refrigeration). The accumulation ofrefrigerant in an enclosed space
can displace oxygen andcause asphyxiation. Provide adequate
ventilation inenclosed or low overhead areas. Inhalation of high
concen-trations of vapor is harmful and may cause heart
irregulari-ties, unconsciousness or death. Misuse can be fatal.
Vaporis heavier than air and reduces the amount of oxygen
avail-able for breathing. Product causes eye and skin
irritation.Decomposition products are hazardous.
DO NOT attempt to unbraze factory joints when servicingthis
equipment. Compressor oil is flammable and there isno way to detect
how much oil may be in any of the refrig-erant lines. Cut lines
with a tubing cutter as required whenperforming service. Use a pan
to catch any oil that maycome out of the lines and as a gage for
how much oil to addto system. DO NOT re-use compressor oil.
This unit uses a microprocessor-based electronic controlsystem.
Do not use jumpers or other tools to short out com-ponents, or to
bypass or otherwise depart from recom-mended procedures. Any
short-to-ground of the controlboard or accompanying wiring may
destroy the electronicmodules or electrical components.
To prevent potential damage to heat exchanger tubes,always run
fluid through heat exchanger when adding orremoving refrigerant
charge. Use appropriate antifreezesolutions in cooler fluid loop to
prevent the freezing of heatexchanger or interconnecting piping
when the equipment isexposed to temperatures below 32 F (0 C).
Proof of flowswitch is factory installed on all models. Do NOT
removepower from this chiller during winter shut down
periodswithout taking precaution to remove all water from
heatexchanger. Failure to properly protect the system fromfreezing
may constitute abuse and may void warranty.
Compressors require specific rotation. Test condenserfan(s)
first to ensure proper phasing. Swap any two incom-ing power leads
to correct condenser fan rotation beforestarting compressors.
Operating the unit without testing thecondenser fan(s) for proper
phasing could result in equip-ment damage.
ENTER
ESCAPE ENTER
-
3Display Module UsageNAVIGATOR DISPLAY MODULE The Navigator
mod-ule provides a mobile user interface to the ComfortLinkcontrol
system. The display has up and down arrow keys, an
key, and an key. These keys are used tonavigate through the
different levels of the display structure.Press the key until
Select a Menu Item is dis-played to move through the top 11 mode
levels indicated byLEDs on the left side of the display. See Fig.
1. See Table 1and Appendix A for more details about the display
menustructure.
Once within a Mode or sub-mode, a > indicates the cur-rently
selected item on the display screen. Pressing the
and keys simultaneously will put the Nav-igator module into
expanded text mode where the full meaningof all sub-modes, items
and their values can be displayed. Press-ing the and keys when the
display saysSelect Menu Item (Mode LED level) will return the
Navigatormodule to its default menu of rotating display items
(those itemsin Run StatusVIEW). In addition, the password will be
dis-abled, requiring that it be entered again before changes can
bemade to password protected items. Press the key toexit out of the
expanded text mode.NOTE: When the Language Selection
(ConfigurationDISPLANG), variable is changed, all appropriate
displayexpansions will immediately change to the new language.
Nopower-off or control reset is required when
reconfiguringlanguages.
When a specific item is located, the item name appears on
theleft of the display, the value will appear near the middle of
thedisplay and the units (if any) will appear on the far right of
thedisplay. Press the key at a changeable item and the val-ue will
begin to flash. Use the up and down arrow keys to changethe value,
and confirm the value by pressing the key.
Changing item values or testing outputs is accomplished inthe
same manner. Locate and display the desired item. Press
so that the item value flashes. Use the arrow keys tochange the
value or state and press the key to acceptit. Press the key to
return to the next higher level ofstructure. Repeat the process as
required for other items.
Items in the Configuration and Service Test modes are pass-word
protected. The words Enter Password will be displayedwhen required,
with 1111 also being displayed. The defaultpassword is 0111. Use
the arrow keys to change each numberand press to enter the digit.
Continue with theremaining digits of the password. The password can
only bechanged through CCN operator interface software such
asComfortWORKS, ComfortVIEW and Service Tool.Adjusting the Contrast
The contrast of the display can beadjusted to suit ambient
conditions. To adjust the contrast ofthe Navigator module, press
the key until the dis-play reads, Select a menu item. Using the
arrow keys moveto the Configuration mode. Press to obtain access
tothis mode. The display will read:
> TEST OFFMETR OFFLANG ENGLISH
Pressing will cause the OFF to flash. Use the upor down arrow to
change OFF to ON. Pressingwill illuminate all LEDs and display all
pixels in the viewscreen. Pressing and simultaneouslyallows the
user to adjust the display contrast. The display willread:
Adjust Contrast- - - -+ - - - - - - - - - - - - - - -
Use the up or down arrows to adjust the contrast. Thescreens
contrast will change with the adjustment. Press
to accept the change. The Navigator module willkeep this setting
as long as it is plugged in to the LEN bus.Adjusting the Backlight
Brightness The backlight of thedisplay can be adjusted to suit
ambient conditions. The factorydefault is set to the highest level.
To adjust the backlight of theNavigator module, press the key until
the displayreads, Select a menu item. Using the arrow keys move to
theConfiguration mode. Press to obtain access to thismode. The
display will read:
> TEST OFFMETR OFFLANG ENGLISH
Pressing will cause the OFF to flash. Use the upor down arrow
keys to change OFF to ON. Pressing
will illuminate all LEDs and display all pixels in theview
screen. Pressing the up and down arrow keys simulta-neously allows
the user to adjust the display brightness. Thedisplay will
read:
Adjust Brightness- - - - - - - - - - - - - - - - - +
Use the up or down arrow keys to adjust screen brightness.Press
to accept the change. The Navigator modulewill keep this setting as
long as it is plugged in to the LEN bus.
ENTER ESCAPE
ESCAPE
ENTER ESCAPE
ENTER ESCAPE
ESCAPE
ENTER
ENTER
ENTERENTER
ESCAPE
ENTER
ESCAPE
ENTER
ENTERENTER
ENTER ESCAPE
ENTER
ESCAPE
ENTER
ENTER
ENTER
ENTER
Run StatusService TestTemperaturesPressuresSetpoints
InputsOutputs
ConfigurationTime ClockOperating ModesAlarms
ENTER
ESC
MODEAlarm Status
ComfortLink
Fig. 1 Accessory Navigator Display Module
-
4Table 1 ComfortLink Display Menu Structure
CONTROLSGeneral The 30XA air-cooled liquid chillers contain
theComfortLink electronic control system that controls andmonitors
all operations of the chiller. The control system iscomposed of
several components as listed in the following sec-tions. All
machines have at the very least a Main Base Board(MBB), Navigator
module, electronic expansion valve board(EXV), fan board,
Compressor Protection board, EmergencyOn/Off switch, an Enable-Off-
Remote Contact switch.Main Base Board (MBB) The MBB is the heart
ofthe ComfortLink control system, which contains the majorportion
of operating software and controls the operation of the
machine. See Fig. 2. The MBB continuously monitors input/output
channel information received from its inputs and fromall other
modules. The MBB receives inputs from status andfeedback switches,
pressure transducers and thermistors. TheMBB also controls several
outputs. Some inputs and outputs tocontrol the machine are located
on other boards, but are trans-mitted to or from the MBB via the
internal communicationsbus. Information is transmitted between
modules via a 3-wirecommunication bus or LEN (Local Equipment
Network). TheCCN (Carrier Comfort Network) bus is also supported.
Con-nections to both LEN and CCN buses are made at TB3. For
acomplete description of Main Base Board inputs and outputsand
their channel identifications, see Table 2.
MODERUN
STATUSSERVICE
TEST TEMPERATURES PRESSURESSET
POINTS INPUTS OUTPUTS CONFIGURATIONTIME
CLOCKOPERATING
MODES ALARMSAuto Display
(VIEW)Manual
Test Mode(TEST)
UnitTemperatures
(UNIT)Circuit A
Pressures(PRC.A)
CoolingSetpoints(COOL)
GeneralInputs
(GEN.I)Circuit AOutputs(CIR.A)
DisplayConfiguration
(DISP)Time of Day
(TIME)Operating
Control Type(SLCT)
Reset CurrentAlarms
(R.ALM)Remote
User Interface(R.CCN)
QuickTest Mode
(QUIC)Circuit A
Temperatures(CIR.A)
Circuit BPressures(PRC.B)
HeatingSetpoints(HEAT)
Circuit BOutputs(CIR.B)
UnitConfiguration
(UNIT)Day, Date
(DATE)Operating
Modes(MODE)
CurrentAlarms(ALRM)
MachineStarts/Hours
(RUN)Circuit B
Temperatures(CIR.B)
Circuit CPressures(PRC.C)
Misc.Setpoints(MISC)
Circuit COutputs(CIR.C)
ServiceConfigurations
(SERV)Schedule 1
(SCH1)AlarmHistory
(H.ALM)CompressorRun Hours
(HOUR)Circuit C
Temperatures(CIR.C)
GeneralOutputs(GEN.O)
OptionsConfiguration
(OPTN)Schedule 2
(SCH2)Compressor
Starts(STRT)
Reset,Demand Limit,Master/Slave
(RSET)
Holidays(HOLI)
Fan RunHours(FAN)
ServiceMaintenanceConfiguration
(MCFG)Compressor
Disable(CP.UN)
PredictiveMaintenance
(MAIN)Software Versions
(VERS)
221
221
221
221
195
195
195
195
195
195
195
CH1
CH2
CH3
CH4
CH11 CH12
LOCATION OFSERIAL NUMBER
CH13 CH14 CH15A
J4ANALOGINPUTSJ3
J2CJ2B
24 VAC
J1A
+ G
DISCRETEINPUTS
J5A
CH15a
11 C16J2A
TR1 TR2 TR3 TR4 TR5
CH19 CH20 CH21 CH22 CH23 CH24 CH25 CH26
J8
CH17 CH18
J5B J5C
THER
MIS
ERS
P
RESS
URES
CH5
CH6
CH7
CH8
CH9
J7A
J7B
J7C
J7D
RELAYOUTPUTS
MOV1
C41 C42 C43
C32 C33 C34 C35
12/1112/11
J10
LEN
+ G -
STATUS
J9A
K1 K2D15
J6
CCN
CH10
+ G SIO(LEN)
J9C J9B
+ G LEN LEN
CCN J13 J9D
+C
+C
CH16a
+C
CH16b
Fig. 2 Main Base Board
-
5Table 2 Main Base Board Inputs and Outputs
LEGEND
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINTPin Notation
Power (24 vac supply) MBB-J1, MBB-J1A,
MBB-J1B11 24 vac12 Ground
Local Equipment Network
MBB-J9A, MBB-J9B,MBB-J9C
+
G-
Carrier CommunicationNetwork
MBB-J12+
G-
Chilled Water Flow Switch CWFS Switch INPUTSGEN.ILOCK
MBB-J5B-CH1717
Demand Limit Switch No. 1 Demand Limit SW1 Switch
INPUTSGEN.IDLS1 MBB-J4-CH13
Circuit A DischargePressure Transducer DPTA Pressure Transducer
PRESSURESPRC.ADP.A
MBB-J7A-CH65V 5 vdc Ref.S SignalR Return
Circuit B DischargePressure Transducer DPTB Pressure Transducer
PRESSURESPRC.BDP.B
MBB-J7C-CH85V 5 vdc Ref.S SignalR Return
Dual ChillerLWT Thermistor DUAL 5k Thermistor
TEMPERATURESUNITCHWS MBB-J6-CH3
Dual Set Point Input Dual Set Point Switch INPUTSGEN.IDUAL
MBB-J4-CH12Entering Water Thermistor EWT 5k Thermistor
TEMPERATURESUNITEWT MBB-J6-CH2Leaving Water Thermistor LWT 5k
Thermistor TEMPERATURESUNITLWT MBB-J6-CH1
Outdoor Air Thermistor OAT 5k Thermistor TEMPERATURESUNITOAT
MBB-J6-CH4External Chilled
Water Pump Interlock PMPI Switch INPUTSGEN.ILOCK
MBB-J4-CH15A
Circuit A SuctionPressure Transducer SPTA Pressure Transducer
PRESSURESPRC.ASP.A
MBB-J7B-CH75V 5 vdc Ref.S SignalR Return
Circuit B SuctionPressure Transducer SPTB Pressure Transducer
PRESSURESPRC.BSP.B
MBB-J7D-CH95V 5 vdc Ref.S SignalR Return
Unit Status Remote Contact-Off-Enable Switch INPUTSGEN.IONOF
MBB-J4-CH11Alarm Relay ALM R Relay OUTPUTSGEN.OALRM
MBB-J3-CH24Alert Relay ALT R Relay OUTPUTSGEN.OALRT MBB-J3-CH25
Cooler Heater CL-HT Contactor OUTPUTSGEN.OCO.HT
MBB-J3-CH26Isolation Valve A ISVA Contactor OUTPUTSGEN.OBVL.A
MBB-J2A-CH19Isolation Valve B ISVB Contactor OUTPUTSGEN.OBVL.B
MBB-J2A-CH20
Isolation Valve C (Size 400-500) ISVC Contactor
OUTPUTSGEN.OBVL.C MBB-J2C-CH22Oil Heater A (Size 080 only) OIL HT_A
Contactor OUTPUTSCIR.AHT.A MBB-J2C-CH22Oil Heater B (Size 080 only)
OIL HT_A Contactor OUTPUTSCIR.BHT.B MBB-J2C-CH23
I/O Input or OutputLWT Leaving Water Temperature
-
6Compressor Protection Module (CPM) Thereis one CPM per
compressor. See Fig. 3. The device controls thecompressor
contactors, oil solenoid, loading/unloading thesolenoid, motor
cooling solenoid (30XA080 only) and the oilseparator heater
(30XA090-500). The CPM also monitorsthe compressor motor
temperature, high pressure switch, oil lev-el switch, discharge gas
temperature, oil pressure transducer,motor current, MTA setting and
economizer pressure transducer.The CPM responds to commands from
the MBB (Main Base
Board) and sends the MBB the results of the channels it
moni-tors via the LEN (Local Equipment Network). The CPM hasthree
DIP switch input banks, Switch 1 (S1), Switch 2 (S2), andSwitch 3
(S3). The CPM board S1 DIP switch configures theboard for the type
of starter, the location and type of the currenttransformers and
contactor failure instructions. See Table 3 fordescription of DIP
switch 1 (S1) inputs. See Appendix C for DIPswitch settings.
1 2 3 4 5 6 7 8
0N 40K
1 2 3 4 5 6 7 8
0N 40K
1 2 3 4
0N
102
151
102
102
101
101
101
101
100 K
620
561
2x151 151 151 151 151 151
151
151
151
561
561
2
2x
2
CH
05
CH
06
C
C
CH
10
CH
11
CH
12
CH
13
CH
14
J2
J11
11
12
J9
J10A
J10B
24 VDC/OLL
HPS1LOADERSOLS MOTOR COOLING
OIL
PRESS
CH01
CH02
CH03
CH04
SMT
MOT
TMP
DG
TMP
R R
R
R
S
5
S5
AUX
102
102
100 K
CH08
CH07
01 02 J3J5J12 J1
151
151
R20
102
G +3 2 1
G +3 2 1
100K
101
PRESS
ECO
SI0 STATUS
CT1CT12
CT13J8
151 151 151 151 151
561
151
151
151
151
151
151
J4CH 09
(LEN)
MTA
DIPSWITCH 3
(S3)
S1
S2
S3
DIPSWITCH 2
(S2)
DIPSWITCH 1
(S1)
LOCATION OFSERIAL NUMBER
STATUSSIO(LEN)
Fig. 3 Compressor Protection Module
-
7Table 3 DIP Switch 1 (S1) Inputs
The CPM board dip switch S2 setting determines the musttrip amps
(MTA) setting. See Appendix C for DIP switch set-tings. The MTA
setting which is calculated using the settingsS2 must match the MTA
setting in the software or an MTAalarm will be generated.
See below for CPM board S3 address information. SeeTable 4 for
CPM inputs and outputs.
NOTE: The CPM-A and CPM-B DIP switches are for allunits. The
CPM-C DIP switches are for 30XA400-500 units.
DIP SWITCH POSITION FUNCTION SETTING MEANING
1 Starter Configuration OFF Across-the-line StartON Y-Delta
Start
2, 3
Current Transformer (CT) Position OFF, OFF CT is located in the
main lineOFF, ON CT is located in the Delta of the motorON, OFF
Reserved for future useON, ON Invalid; will cause MTA configuration
alarm
4, 5, 6
Current Transformer (CT) Selection OFF, OFF, OFF 100A/1V CT1OFF,
OFF, ON 100A/0.503V CT2OFF, ON, OFF 100A/0.16V CT3OFF, ON, ON
Invalid; will cause MTA configuration alarmON, OFF, OFF Invalid;
will cause MTA configuration alarmON, OFF, ON Invalid; will cause
MTA configuration alarmON, ON, OFF Invalid; will cause MTA
configuration alarmON, ON, ON Invalid; will cause MTA configuration
alarm
7 Contactor Failure Action OFF All units should be offON Used
when Shunt Trip is available in the unit8 Not Used
CPM-A DIPSwitch 1 2 3 4
Address: OFF OFF OFF OFF
CPM-B DIPSwitch 1 2 3 4
Address: OFF OFF ON OFF
CPM-C DIPSwitch 1 2 3 4
Address: OFF OFF OFF ON
-
8Table 4 Compressor Protection Module Inputs and Outputs*
*X denotes the circuit, A, B or C.See Appendix C for MTA
settings.**Average current .x depending on circuit A, B, or C.
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINTPin Notation
Power (24 vac supply) CPM-X-J1
11 24 vac12 Ground
Local Equipment Network
CPM-X-JP121 +2 G3 -
CPM-X-J121 +2 G3 -
Circuit X High Pressure Switch HPS-X Switch Not
availableCPM-X-J7-CH05
1
2
Oil Level Switch Oil LS X Switch
OUTPUTSCIR.XOLS.XCPM-X-J6-CH06
1
2
Must Trip Amps MTA 8-Pin DIP Switch CONFIGURATIONUNIT MTA.X
Configuration Switch SW1 4-Pin DIP Switch Not available
Compressor X Motor Temperature MTR-X NTC Thermistor
TEMPERATURESCIR.X DGT.XCPM-X-J9-CH01
1
2
Compressor X Discharge Gas Temperature DGT X NTC Thermistor
TEMPERATURESCIR.X DGT.XCPM-X-J9-CH02
1
2
Oil Pressure Transducer OPT X Pressure Transducer
PRESSURESPRC.XOP.X
CPM-X-J10B-CH045V +, 5 vdc refS SignalR Return
Economizer Pressure Transducer EPT X Pressure Transducer
PRESSURESPRC.XECP.X
CPM-X-J10A5V +, 5 vdc refS SignalR Return
Compressor Current X Phase A** Current Sensor Not
availableCPM-X-J8-CH01
1
2
Compressor Current X Phase B Current Sensor
INPUTSCUR.XCPM-X-J8-CH02
1
2
Compressor Current X Phase C** Current Sensor Not
availableCPM-X-J8-CH3
1
2
Compressor X 1M Contactor C X 1M Contactor
OUTPUTSCIR.XCP.XCPM-X-J1-CH07
12
Compressor X 2M Contactor C X 2M Contactor Not
availableCPM-X-J2-CH8
12
Compressor X S Contactor C X S Contactor Not
availableCPM-X-J2-CH9
12
Oil Heater Relay X (090-500) Oil HTR X Contactor
OUTPUTSCIR.X_HT.XCPM-X-J2-CH10
12
Oil Solenoid X Oil solenoid-X Solenoid
OUTPUTSCIR.XOLS.XCPM-X-J2-CH12
12
Load Solenoid X Loading Solenoid-X Solenoid OUTPUTSCIR.ASL1.X
CPM-X-J2-CH131
Unload Solenoid X Unloading Solenoid-X Solenoid
OUTPUTSCIR.ASL2.XCPM-X-J2-CH14
12
Motor Cooling Solenoid X (080) Gas Cooling Solenoid-X Solenoid
OUTPUTSCIR.XDGT.XCPM-X-J2-CH10
12
-
9Electronic Expansion Valve (EXV) Board The 30XA080 unit has one
EXV board. The 30XA090-500units have one EXV board per circuit. See
Fig. 4. The board isresponsible for monitoring the suction gas
temperature andeconomizer gas temperature thermistors. The board
alsosignals the main EXV and economizer EXV (ECEXV) motorsto open
or close. The electronic expansion valve boardresponds to commands
from the MBB and sends the MBB theresults of the channels it
monitors via the LEN (Local Equip-ment Network). See below for DIP
switch information. SeeTables 5 and 6 for EXV inputs and
outputs.
EXV BOARD A(080-450)
DIP SWITCH1 2 3 4 5 6 7 8
Address: ON ON ON ON ON ON OFF ON
EXV BOARD B(090-500)
DIP SWITCH1 2 3 4 5 6 7 8
Address: OFF ON ON ON ON ON OFF ON
EXV BOARDC (400-500)
DIP SWITCH1 2 3 4 5 6 7 8
Address: ON OFF ON ON ON ON OFF ON
12
34
56
78
ON
100 100
257-01
712
100K
100K
100
12
34
5
3 2 1- G +
J3
12
34
5J2
A EX
VAJ2
B
EXV
B
24VAC
STATUS
MOV1
LOCATION OFSERIAL NUMBER
43
21
THA
THB
D4D6
J1
C15C16D5
U5
Q2 Q1
L4
U4
12/11
C17+
Q45
Q42Q37G2
Q35
Q25Q27Q30
Q20 Q22
Q17 Q15
Q12Q10
C10
Q7S1C1
1
U2D2
L1U1C37C39
SB
D15
U6
C25
C49
Q4Q5
L2 R2
R3 L3 D1
R9 TE
MP
D29 D9 D8
SI0(LEN)
COMM J4
DIP SWITCH
Fig. 4 EXV Board
-
10
Table 5 EXVA Board Inputs and Outputs (30XA080)
Table 6 EXV A,B,C Board Inputs and Outputs* (30XA090-500)
*X denotes the circuit, A, B or C.
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINTPin Notation
Power (24 vac supply) EXVA-J1
11 24 vac12 Ground
Local Equipment Network
EXVA-J41 +2 G3
Circuit A Suction Gas Thermistor SGTA 5k Thermistor
TEMPERATURESCIR.ASGT.AEXVA-J3
THA
Circuit B Suction Gas Thermistor SGTB 5k Thermistor
TEMPERATURESCIR.BSGT.BEXVA-J3
THB
Circuit A EXV EXV-A Stepper Motor OUTPUTSCIR.AEXV.A
EXVA-J2A1234
Circuit B EXV EXV-B Stepper Motor OUTPUTSCIR.BEXV.B
EXVA-J2B1234
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINTPin Notation
Power (24 vac supply) EXVX-J1
11 24 vac12 Ground
Local Equipment Network EXVX-J4
1 +2 G3
Circuit X Suction Gas Thermistor SGT X 5k Thermistor
TEMPERATURESCIR.XSGT.XEXVX-J3
THA
Circuit X Economizer GasThermistor ECT X 5k Thermistor
TEMPERATURESCIR.XECT.X
EXVX-J3THB
Circuit X EXV EXV-X Stepper Motor OUTPUTSCIR.XEXV.X
EXVX-J2A1234
Circuit X Economizer EXV ECEXV-X Stepper Motor
OUTPUTSCIR.XECO.X
EXVX-J2A1234
-
11
Fan Boards At least one fan board is installed in eachunit. See
Fig. 5A and 5B. There are two types of fan boards,with and without
an analog output signal for the low ambienttemperature head
pressure control fan speed controllers. If aunit does not have low
ambient temperature head pressure con-trol installed, it will not
have the analog connection terminals.The fan board responds to
commands from the MBB and sendsthe MBB the results of the channels
it monitors via the LocalEquipment Network (LEN). See below for fan
board A, B andC DIP switch addresses. See Tables 7-9 for inputs and
outputs.
FAN BOARD(080)
DIP SWITCH1 2 3 4 5 6 7 8
Address: OFF ON OFF OFF ON OFF ON OFF
FAN BOARD A(090-500)
DIP SWITCH1 2 3 4 5 6 7 8
Address: OFF ON OFF OFF ON OFF ON OFF
FAN BOARD B(140-500)
DIP SWITCH1 2 3 4 5 6 7 8
Address: ON ON OFF OFF ON OFF ON OFF
FAN BOARD C(400-500)
DIP SWITCH1 2 3 4 5 6 7 8
Address: OFF OFF ON OFF ON OFF ON OFF
1 2 3 4 5 6 7 8
ON
100K
100K
100K
CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8
TB1 TB2 TB3 TB4 TB5 TB6 TB7 TB8
STATUS SIO (LEN)
LOCATION OFSERIAL NUMBER
24 VAC
CH13
CH14
J9
J1
CH9 CH10 CH11 CH12
JP2
C61 CH13D12 JP1
L3
L5
U21
L2D6
D5Q5
Y1
D7
D8
S1
D3U1Q1
U5 U6 U7
U8
U9 Q10
Q11
U10
J4
J3J2
U4U2
Q12
Q60
3
2
1 G
+
3
2
1 G
+
DIP SWITCH
1 2 3 4 5 6 7 8
ON
100K
100K
100K
LOCATION OFSERIAL NUMBER
TB1 TB2 TB3 TB4 TB5 TB6 TB7 TB8
CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8
STATUS SIO (LEN)24 VAC
J1 J9
D4
U2
U5
Q2
Q7
Q3
U8
U9
Q9
Q10
Q11Q12
Q13
J4
J3J2
S1
D7
Q5
Y1
D5
D6
L2
U6
U1Q1
D3
C3
3
2
1
G
+
3
2
1
G
+
DIP SWITCH
Fig. 5A Fan Board (AUX 1) with Low Ambient Temperature Head
Pressure Control
Fig. 5B Fan Board (AUX 2) without Low Ambient Temperature Head
Pressure Control
-
12
Table 7 Fan Board A Outputs (30XA080-120)
*Output only on low ambient temperature head pressure control
(AUX1).
Table 8 Fan Board X Outputs (30XA140-350)
*Output only on units with low ambient temperature head pressure
control installed (AUX1).NOTES:
1. Fan Board B used on 30XA140-350.2. X indicates circuit A or
circuit B.3. See Fig. 9 for which contactor is used with circuit A
or B.
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINT
Pin Notation
Power (24 vac supply) FBA-J1
11 24 vac12 Ground
Local Equipment Network
FBA-J9+
G-
+
G-
Circuit A Low Ambient TemperatureHead Pressure Control Speed
Signal MM-A* 0-10 VDC OUTPUTSCIR.ASPD.A
FBA-CH9+
-
Circuit B Low Ambient TemperatureHead Pressure Control Speed
Signal MM-B* 0-10 VDC OUTPUTSCIR.BSPD.B
FBA-CH10+
-
Fan Contactor A1 FCA1 Contactor FBA-J2-CH1Fan Contactor A2 FCA2
Contactor FBA-J2-CH2Fan Contactor A3 FCA3 Contactor FBA-J2-CH3
Fan Contactor A4 FCA4 Contactor FBA-J2-CH4(090-120)Fan Contactor
B1 FCB1 Contactor FBA-J3-CH5Fan Contactor B2 FCB2 Contactor
FBA-J3-CH6Fan Contactor B3 FCB3 Contactor FBA-J3-CH7
Fan Contactor B4 FCB4 Contactor FBA-J3-CH8(090-120)
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINT
Pin Notation
Power (24 vac supply) FBX-J1
11 24 vac12 Ground
Local Equipment Network
FBX-J9+
G-
+
G-
Circuit X Low Ambient TemperatureHead Pressure Control
Speed SignalMM-n* 0-10 VDC OUTPUTSCIR.XSPD.X
FBX-CH9+
-
Fan Contactor X1 FCX1 Contactor FBX-J2-CH01Fan Contactor X2 FCX2
Contactor FBX-J2-CH02Fan Contactor X3 FCX3 Contactor FBX-J2-CH03Fan
Contactor X4 FCX4 Contactor FBX-J2-CH04Fan Contactor X5 FCX5
Contactor FBX-J3-CH05Fan Contactor X6 FCX6 Contactor FBX-J3-CH06Fan
Contactor X7 FCX7 Contactor FBX-J3-CH07Fan Contactor X8 FCX8
Contactor FBX-J3-CH08
-
13
Table 9 Fan Board C Inputs and Outputs (30XA400-500)
Enable-Off-Remote Contact Switch (SW1) This switch is installed
in all units and provides the owner andservice person with a local
means of enabling or disabling themachine. It is a 3-position
switch used to control the chiller.When switched to the Enable
position the chiller is under itsown control. Move the switch to
the Off position to shut thechiller down. Move the switch to the
Remote Contact positionand a field-installed dry contact can be
used to start the chiller.The contacts must be capable of handling
a 24-vac, 50-mAload. In the Enable and Remote Contact (dry contacts
closed)positions, the chiller is allowed to operate and respond to
thescheduling configuration, CCN configuration and set
pointdata.Emergency On/Off Switch (SW2) This switch isinstalled in
all units. The Emergency On/Off switch shouldonly be used when it
is required to shut the chiller off immedi-ately. Power to all
modules is interrupted when this switch isoff and all outputs from
these modules will be turned off.Energy Management Module (EMM) The
EMMis available as a factory-installed option or as a
field-installed
accessory. See Fig. 6. The EMM receives 4 to 20 mA inputs forthe
temperature reset, cooling set point and demand limitfunctions. The
EMM also receives the switch inputs for thefield-installed second
stage 2-step demand limit and ice donefunctions. The EMM
communicates the status of all inputswith the MBB, and the MBB
adjusts the control point, capacitylimit, and other functions
according to the inputs received. SeeTable 10.
DESCRIPTION INPUT/OUTPUT I/O TYPE NAVIGATOR MODULEPOINT
NAMECONNECTION POINT
(Unit Size)Pin Notation
Power (24 vac supply) FBC-J1
11 24 vac12 Ground
Local Equipment Network
FBC-J9+
G-
+
G-
Circuit C DischargePressure Transducer DPTC Pressure Transducer
PRESSURESPRC.CDP.C FBC-J7-CH13
Circuit C SuctionPressure Transducer SPTC Pressure Transducer
PRESSURESPRC.CSP.C FBC-J8-CH14
Circuit C Low AmbientTemperature Head Pressure
Control Speed SignalMM-C 0-10 VDC OUTPUTSCIR.CSPD.C
FBC-CH9+
-
Fan Contactor C1 FCC1 Contactor FBC-J2-CH1Fan Contactor C2 FCC2
Contactor FBC-J2-CH2Fan Contactor C3 FCC3 Contactor FBC-J2-CH3Fan
Contactor C4 FCC4 Contactor FBC-J2-CH4Fan Contactor C5 FCC5
Contactor FBC-J3-CH5Fan Contactor C6 FCC6 Contactor FBC-J3-CH6Fan
Contactor C7 FCC7 Contactor FBC-J3-CH7Fan Contactor C8 FCC8
Contactor FBC-J3-CH8
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,which could lead to
equipment damage. The two differentpower supplies cannot be mixed.
ComfortLink controlsuse half wave rectification. A signal isolation
device shouldbe utilized if incorporating a full wave bridge
rectifier sig-nal generating device is used.
-
14
Table 10 Energy Management Module (EMM) Inputs and Outputs
NOTE: Used on 30XA080-500.
Local Equipment Network Information is trans-mitted between
modules via a 3-wire communication bus orLEN (Local Equipment
Network). External connection to theLEN bus is made at TB3.Board
Addresses All boards (except the Main BaseBoard, Energy Management
Module Board, and CompressorProtection Module Board) have
8-position DIP switches.Addresses for all boards are listed with
the Input/Output Tablesfor each board.Control Module
CommunicationRED LED Proper operation of the control boards can
bevisually checked by looking at the red status LEDs
(light-emitting diodes). When operating correctly, the red
statusLEDs will blink in unison at a rate of once every 2 seconds.
Ifthe red LEDs are not blink in unison, verify that correct poweris
being supplied to all modules. Be sure that the Main Base
Board (MBB) is supplied with the current software. If
neces-sary, reload current software. If the problem still
persists,replace the MBB. A red LED that is lit continuously or
blink-ing at a rate of once per second or faster indicates that the
boardshould be replaced.GREEN LED All boards have a green LEN (SIO)
LEDwhich should be blinking whenever power is on. If the LEDsare
not blinking as described check LEN connections forpotential
communication errors at the board connectors. SeeInput/Output Table
2, and 4-10 for LEN Connector designa-tions. A 3-wire bus
accomplishes communication betweenmodules. These 3 wires run in
parallel from module to module.The J9A connector on the MBB
provides communication di-rectly to the Navigator display
module.YELLOW LED The MBB has one yellow LED. TheCarrier Comfort
Network (CCN) LED will blink duringtimes of network
communication.
INPUT DESCRIPTION I/O TYPE I/O POINT NAME CONNECTION POINT4-20
mA Demand Limit 4-20 mA Demand Limit 4-20 mA INPUTSGEN.IDMND
EMM-J7B-CH64-20 mA TemperatureReset/Cooling Setpoint
4-20 mA Temperature Reset/Cooling Set point
4-20 mA INPUTSGEN.IRSET EMM-J7A-CH5
Demand Limit SW2 Demand Limit Step 2 Switch Input
INPUTSGEN.IDLS2 EMM-J4-CH9Ice Done Ice Done Switch Switch Input
INPUTSGEN.IICE.D EMM-J4-CH11AOccupancy Override Occupied Schedule
Override Switch Input INPUTSGEN.IOCCS EMM-J4-CH8Remote Lockout
Switch Chiller Lockout Switch Input INPUTSGEN.IRLOC EMM-J4-CH10SPT
Space Temperature Thermistor 10k Thermistor TEMPERATUREUNITSPT
EMM-J6-CH2
OUTPUT DESCRIPTION I/O TYPE I/O POINT NAME CONNECTION POINT%
Total Capacity 0-10 vdc OUTPUTSGEN.OCATO EMM-J8-CH7RUN R Run Relay
Relay OUTPUTSGEN.ORUN EMM-J3-CH25SHD R Shutdown Relay Relay
OUTPUTSGEN.OSHUT EMM-J3-CH24
221221
221
221
100K
100K
100K
100K
100K
CH17
CH17
CH16
CH CH18
CH19
CH20
CH22
CH21
CH23
24 VAC12 11 C
H11
bCH 12
CH 13CH 14
CH 15CH
1CH
2CH
3CH
4CH
5CH
6CH
7
SIO LEN
+ G -
+ G -
SIO LEN
Fig. 6 Energy Management Module
-
15
Carrier Comfort Network (CCN) Interface All 30XA units can be
connected to the CCN, if desired. Thecommunication bus wiring is a
shielded, 3-conductor cablewith drain wire and is field supplied
and installed. The systemelements are connected to the
communication bus in a daisychain arrangement. The positive pin of
each system elementcommunication connector must be wired to the
positive pins ofthe system elements on either side of it, that is
also required forthe negative and signal ground pins of each system
element.Wiring connections for CCN should be made at TB3.
Consultthe CCN Contractors Manual for further information. SeeFig.
7.NOTE: Conductors and drain wire must be 20 AWG (Ameri-can Wire
Gage) minimum stranded, tinned copper. Individualconductors must be
insulated with PVC, PVC/nylon, vinyl,Teflon, or polyethylene. An
aluminum/polyester 100% foilshield and an outer jacket of PVC,
PVC/nylon, chrome vinyl,or Teflon with a minimum operating
temperature range of20 C to 60 C is required. See Table 11 for
recommended wiremanufacturers and part numbers.
Table 11 CCN Communication Bus Wiring
It is important when connecting to a CCN communicationbus that a
color-coding scheme be used for the entire networkto simplify the
installation. It is recommended that red be usedfor the signal
positive, black for the signal negative, and whitefor the signal
ground. Use a similar scheme for cables contain-ing different
colored wires.
At each system element, the shields of its communicationbus
cables must be tied together. If the communication bus isentirely
within one building, the resulting continuous shieldmust be
connected to a ground at one point only. If the commu-nication bus
cable exits from one building and enters another,the shields must
be connected to grounds at the lightningsuppressor in each building
where the cable enters or exits thebuilding (one point per building
only). To connect the unit tothe 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 appropri-ate
colors for different colored cables.)
3. Connect the red wire to (+) terminal on TB3 of the plug,the
white wire to COM terminal, and the black wire to the()
terminal.
4. The RJ14 CCN connector on TB3 can also be used, but isonly
intended for temporary connection (for example, alaptop computer
running Service Tool).
Configuration OptionsRAMP LOADING (ConfigurationOPTNRL.S),
limitsthe rate of change of leaving fluid temperature. If the unit
is ina Cooling mode and configured for Ramp Loading, the
controlmakes 2 comparisons before deciding to change stages
ofcapacity. The control calculates a temperature differencebetween
the control point and leaving fluid temperature. If thedifference
is greater than 4 F (2.2 C) and the rate of change(F or C per
minute) is more than the configured Cool RampLoading
(SetpointsCOOLCRMP), the control does notallow any changes to the
current stage of capacity.MINUTES OFF TIME (ConfigurationOPTN DELY)
isa time delay added to the start when the machine is com-manded
ON. This is a field configurable item from 1 to15 minutes. The
factory default is 1 minute. This feature isuseful when multiple
units are installed. Staggering the startwill reduce the inrush
potential.Dual Chiller Control The dual chiller routine isavailable
for the control of two units installed in series orparallel
supplying chilled fluid on a common loop. One chillermust be
configured as the master chiller, the other as the slavechiller.
For parallel chiller application, an additional leavingfluid
temperature thermistor (Dual Chiller LWT) must beinstalled in the
common chilled water piping as described inthe Installation
Instructions for both the master and slavechillers. See the Field
Wiring section in the 30XA InstallationInstructions for Dual
Chiller LWT sensor control wiring. Achilled water flow switch is
factory-installed for each chiller.DUAL CHILLER PUMP CONTROL FOR
PARALLELAPPLICATIONS It is recommended that a dedicatedpump be used
for each unit. Chiller must start and stop its ownwater pump
located on its own piping. If pumps are not dedi-cated for each
chiller, chiller isolation valves are required: eachchiller must
open and close its own isolation valve.
MANUFACTURER PART NUMBERRegular Wiring Plenum WiringAlpha 1895
American A21451 A48301Belden 8205 884421Columbia D6451 Manhattan
M13402 M64430Quabik 6130
IMPORTANT: A shorted CCN bus cable will preventsome routines
from running and may prevent the unitfrom starting. If abnormal
conditions occur, discon-nect the CCN bus. If conditions return to
normal,check the CCN connector and cable. Run new cable
ifnecessary. A short in one section of the bus can causeproblems
with all system elements on the bus.
Fig. 7 ComfortLink CCN Communication Wiring
-
16
DUAL PUMP CONTROL FOR SERIES CHILLERAPPLICATIONS If pump control
is required, the chillerpump needs to be controlled by the master
chiller only. Thecontrol of the slave chiller is directed through
commandsemitted by the master chiller. The slave chiller has no
action inmaster/slave operations; it shall only verify that CCN
commu-nication with its master is present. See the Dual
ChillerSequence of Operation section on page 49.
Use dual chiller control to designate a lead chiller betweenthe
master and slave chiller. Configure the Lead/Lag BalanceSelect
(ConfigurationRSETLLBL) to ENBL to base theselection on the
Lead/Lag Balance Delta (ConfigurationRSETLLBD) between the master
and slave run hours. Ifthe run hour difference between the master
and the slaveremains less than LLBD, the chiller designated as the
lead willremain the lead chiller. The Lead/Lag changeover between
themaster and the slave chiller due to hour balance will occur
dur-ing chiller operating odd days, such as day 1, day 3, and day
5of the month, at 12:00 a.m. If a lead chiller is not
designated,the master chiller will always be designated the lead
chiller.
The dual chiller control algorithm has the ability to be
con-figured for series or parallel operation. To configure chillers
inseries, set ConfigurationRSETSERI to YES for seriesoperation, or
NO for parallel operation. Both the master andslave chiller must be
configured the same.
The dual chiller control algorithm has the ability to delaythe
start of the lag chiller in two ways. The Lead PulldownTime
(ConfigurationRSETLPUL) provides a field con-figurable time delay
of 0 to 60 minutes. This time delay givesthe lead chiller a chance
to remove the heat that the chilled wa-ter loop picked up while
being inactive during an unoccupiedperiod. The Lead Pulldown Time
parameter is a one-time timedelay initiated after starting the lead
chiller, manually or by aschedule, before checking whether to start
an additional chiller.This routine provides the lead chiller an
opportunity to pulldown the loop temperature before starting
another chiller. Thesecond time delay, Lead/Lag Delay
(ConfigurationRSET LLDY) is a time delay imposed between the last
stage of thelead chiller and the start of the lag chiller. This
preventsenabling the lag chiller until the lead/lag delay timer
hasexpired. See Tables 12 and 13.Capacity Control The control
system cycles com-pressors and positions the slide valve of each
compressor tomaintain the user-configured leaving chilled fluid
temperatureset point. Entering fluid temperature is used by the
Main BaseBoard (MBB) to determine the temperature drop across
thecooler and is used in determining the optimum time to add
orsubtract capacity. Return fluid temperature, space
temperature(requires additional sensor), or outdoor-air temperature
resetfeatures can automatically reset the leaving chilled
fluidtemperature set point. It can also be reset from an external 4
to20-mA signal (requires Energy Management Module). Tem-perature
reset requires a temperature sensor and the EnergyManagement
Module.
The control has an automatic lead-lag feature built in
forcircuit and compressor starts. If enabled, the control will
deter-mine which circuit (ConfigurationOPTNLLCS=0) andcompressor to
start to even the wear. The compressor wearfactor (combination of
starts and run hours) is used to deter-mine which compressor
starts.
Compressor Wear Factor = (Compressor Starts) + 0.1(Compressor
Run Hours)
In this case, the circuit with the lowest compressor wearfactor
is the circuit that starts first. The following settings
willdetermine what circuit starts first:ConfigurationOPTNLLCS=1,
Circuit A startsConfigurationOPTNLLCS=2, Circuit B
startsConfigurationOPTNLLCS=3, Circuit C starts
If Minimum Load Control is enabled (ConfigurationUNITHGBP=1),
the valve will be operational only duringthe first stage of
cooling.EQUAL LOADING (ConfigurationOPTNLOAD=0) The circuit which
has started will maintain minimum stage ofcapacity and slide valve
fully unloaded; when additional capac-ity is required the next
circuit with the lowest compressor wearfactor is started with the
slide valve at minimum position. Asadditional capacity is required
the slide valve for a circuit willbe adjusted in approximately 5%
increments to match capacityrequirements. The control will
alternate between circuits tomaintain the same percentage of
capacity on each circuit. SeeFig. 8.STAGE LOADING If stage-loading
is selected (Configu-rationOPTNLOAD=1), the circuit which has
started willgradually load the slide valve to match capacity
requirementsuntil the circuit is fully loaded. Once the circuit is
fully loadedand additional capacity is required, the control will
start an ad-ditional circuit fully unloaded and gradually unload
the circuitwhich was fully loaded to match capacity
requirements.
The capacity control algorithm runs every 30 seconds.
Thealgorithm attempts to maintain the Control Point at the
desiredset point. Each time the capacity control algorithm runs,
thecontrol reads the entering and leaving fluid temperatures.
Thecontrol determines the rate at which conditions are changingand
calculates 2 variables based on these conditions. Next, acapacity
ratio is calculated using the 2 variables to determinewhether or
not to make any changes to the current stages of ca-pacity. This
ratio value ranges from 100 to +100%. If the nextchange of capacity
is a compressor, the control starts (stops) acompressor when the
ratio reaches +100% (100%). If the nextchange of capacity is to
reposition the slide valve, the controlenergizes both slide valve
solenoids when ratio is +60% anddeenergizes both slide valve
solenoids when ratio is 60%. Ifinstalled, the minimum load valve
solenoid will be energizedwith the first stage of capacity. Minimum
load valve value isfixed at 10 tons in the total capacity
calculation. The controlwill also use the minimum load valve
solenoid as the last stageof capacity before turning off the last
compressor. A delay of90 seconds occurs after each capacity step
change. A delay of3 minutes occurs after each compressor capacity
step change.
-
17
Table 12 Configuring the Master Chiller
NOTE: Bold values indicate sub-mode level.
MODE KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTCONFIGURATION
DISP
UNIT
SERV
OPTN
CCNA CCN Address Confirm address of chiller. The master and
slave chiller musthave different addresses.
1 Factory default address is 1.
CCNA
CCNB CCN Bus Number Confirm the bus number of the chiller. The
master and slavechiller must be on the same bus.0 Factory default
is 0.
CCNB
OPTN
RSET Reset Cool and Heat Tmp
CRST Cooling Reset Type
x 5 MSSL Master/Slave Select
0 Disable
0 Disable Flashing to indicate Edit mode. May require
Password.
1 Master Use up arrows to change value to 1.
1 Accepts the change.
MSSL
SLVA Slave Address
1
1 Flashing to indicate Edit mode.
2 Use up arrows to change value to 2. This address mustmatch the
address of the slave chiller.2 Accepts the change.
SLVA
LLBL Lead/Lag Balance Select
DSBL Factory Default is DSBL.
LLBL
LLBD Lead/Lag Balance Delta
168 Factory Default is 168.
LLBD
LLDY Lead/Lag Delay
10 Factory Default is 10.
LLDY
LAGP Lag Unit Pump Select
0 Off if U Stp Factory Default is 0, Off if unit is stopped.
LAGP
LPUL Lead Pulldown Time
0 Factory Default is 0.
At mode level.
SER1 Chillers in Series
OPERATINGMODES OPER Operating Control Type
0 Switch Control Master chiller should be configured for job
requirements,Switch Control, Time Schedule, or CCN.At mode
level.
ENTER
ENTER
ENTER
ESCAPE
ENTER
ESCAPE
ESCAPE
ENTER
ENTER
ENTER
ENTER
ESCAPE
ENTER
ENTER
ENTER
ESCAPE
ENTER
ESCAPE
ENTER
ESCAPE
ENTER
ESCAPE
ENTER
ESCAPE
ENTER
ESCAPE
ESCAPE
ENTER
ENTER
ENTER
ESCAPE
-
18
Table 13 Configuring the Slave Chiller
NOTE: Bold values indicate sub-mode level.
MODE KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTCONFIGURATION
DISP
UNIT
SERV
OPTN
CCNA CCN Address Confirm address of chiller. The master and
slave chillermust have different addresses.
1 Factory default address is 1. The slave chiller addressmust
match what was programmed in the Master ChillerSLVA item.
1 Flashing to indicate Edit Mode.
2 This item must match Master Chiller SLVA item.
2 Accepts the change.
CCNA
CCNB CCN Bus Number Confirm the bus number of the chiller. The
master andslave chiller must be on the same bus.
0 Factory default bus number is 0.
CCNB
OPTN
RSET Reset Cool and Heat Tmp
CRST Cooling Reset Type
x 5 MSSL Master/Slave Select
0 Disable
0 Disable Flashing to indicate Edit mode. May require
Password
2 Slave Use up arrows to change value to 2.
2 Accepts the change.
MSSL
SLVA Slave Address Not required.
LLBL Lead/Lag Balance Select Not required.
LLBD Lead/Lag Balance Delta Not required.
LLDY Lead/Lag Delay Not required.
LAGP Lag Unit Pump Select Not required.
LPUL Lead Pulldown Time Not required.
At mode level
SER1 Chillers in Series
OPERATING MODES OPER Operating Control Type
0 Switch Control
0 Flashing to indicate Edit Mode.
2 CCN Control Use up arrows to change value to 2.NOTE: Must be
configured for CCN.
2 Accepts the value.
OPER
At mode level
ENTER
ENTER
ENTER
ENTER
ENTER
ESCAPE
ENTER
ESCAPE
ESCAPE
ENTER
ENTER
ENTER
ENTER
ESCAPE
ESCAPE
ESCAPE
ENTER
ENTER
ENTER
ENTER
ENTER
ESCAPE
ESCAPE
-
19
0
20
40
60
80
100
Load (%)
Lead Compressor LoadingLag Compressor LoadingLead Compressor
UnloadingLag Compressor Unloading
1000 0
Lag compressor can fall anywhere in this areawhen load between
40%~65%
Lead compressor can fall anywhere in this areawhen load between
40%~65%
LOADING UNLOADINGCo
mpr
esso
r Cap
acity
(%)
Unit Loading Unloading (Staged circuit loading)
0
20
40
60
80
100
Load (%)
LoadingUnloading
1000 0
Unit
Tota
l Cap
acity
(%)
Equal Circuit Loading
Staged Circuit LoadingFig. 8 Compressor Loading and
Unloading
-
20
CAPACITY CONTROL OVERRIDES (Run StatusVIEWCAP.S) The following
overrides will modify thenormal operation routine. If any of the
following override con-ditions listed below is satisfied, it shall
determine the capacitychange instead of the normal control.
Overrides are listed bypriority order and are often linked to unit
operating modes. SeeTable 14 for a list of operating modes and
correspondingoverrides.Override #1: Cooler Freeze Protection This
override at-tempts to avoid the freeze protection alarm. If the
LeavingWater Temperature is less than Brine Freeze Set Point
(Config-urationSERVLOSP) + 2.0 F (1.1 C) then a stage of ca-pacity
is removed.NOTE: The freeze set point is 34 F (1.1 C) for fresh
watersystems (ConfigurationSERVFLUD=1). The freeze setpoint is
Brine Freeze Set Point (ConfigurationSERVLOSP), for Medium
Temperature Brine systems (Configu-rationSERVFLUD=2).Override #2:
Circuit A Low Saturated Suction Temperaturein CoolingOverride #3:
Circuit B Low Saturated Suction Temperaturein CoolingOverride #4:
Circuit C Low Saturated Suction Temperaturein Cooling These
overrides attempt to avoid the low suctiontemperature alarms. and
is active only when more than onecompressor in a circuit is ON. The
slide valve in the affectedcircuit will be decreased in position if
the Saturated SuctionTemperature is less than Brine Freeze Set
Point (Configura-tionSERVLOSP) 18.0 F (10 C) for 90 seconds, or
theSaturated Suction Temperature is less than 4 F (20 C).Override
#5: Low Temperature Cooling and High Tempera-ture Heating This
override removes one stage of capacitywhen the difference between
the Control Point (Run StatusVIEWCTPT) and the Leaving Water
Temperature (RunStatusVIEWLWT) reaches a predetermined limit and
therate of change of the water is 0 or still decreasing.Override
#6: Low Temperature Cooling and High TemperatureHeating This
override removes two stages of capacity whenthe Entering Water
Temperature (Run StatusVIEWEWT)is less than the Control Point (Run
StatusVIEWCTPT.)Override #7: Ramp Loading No capacity stage
increasewill be made if the unit is configured for ramp loading
(Config-urationOPTNRL.S=ENBL) and if the difference be-tween the
Leaving Water Temperature and the Control Point isgreater than 4 F
(2.2 C) and the rate of change of the leavingwater is greater than
Cool Ramp Loading Rate (SetpointsCOOLCRMP). Operating mode 5 (MD05)
will be in effect.Override #8: Service Manual Test Override The
manualtest consists in adding a stage of capacity every 30 seconds,
un-til the control enables all of the requested compressors
andMinimum Load Control selected in the ComfortLink displayService
Test menu. All safeties and higher priority overridesare monitored
and acted upon.Override # 9: Demand Limit This override mode is
activewhen a command to limit the capacity is received. If
thecurrent unit capacity is greater than the active capacity
limitvalue, a stage is removed. If the current capacity is lower
thanthe capacity limit value, the control will not add a stage
thatwill result in the new capacity being greater then the
capacitylimit value. Operating mode 4 (MD04) will be in
effect.Override #10: Cooler Interlock Override This
overrideprohibits compressor operation until the Cooler
Interlock(InputsGEN.ILOCK) is closed.Override #11: High Temperature
Cooling and Low Temper-ature Heating This override algorithm runs
once when theunit is switched to ON. If the difference between the
LeavingWater Temperature (Run StatusVIEWLWT) and the Con-trol Point
(Run StatusVIEWCTPT) exceeds a calculated
value and the rate of change of the water temperature is
greaterthan 0.1 F/min, a stage will be added.
Table 14 Operating Modes andCorresponding Overrides
Override #12: High Temperature Cooling and Low Temper-ature
Heating This override runs only when MinimumLoad Control is
Enabled, (ConfigurationSERVHGBP) is1, 2 or 3. This override will
add a stage of capacity if the nextstage is Minimum Load Control,
when the difference betweenthe Leaving Water Temperature (Run
StatusVIEWLWT)and the Control Point (Run StatusVIEWCTPT) exceeds
acalculated value and the rate of change of the water tempera-ture
is greater than a fixed value.
OPERATING MODES OVERRIDES1 Startup Delay in Effect 2 Second
Setpoint in Use 3 Reset in Effect 4 Demand Limit Active 9 Demand
Limit5 Ramp Loading Active 7 Ramp Loading6 Cooler Heater Active 7
Cooler Pumps Rotation 8 Pump Periodic Start 9 Night Low Noise
Active
10 System Manager Active 13 Minimum On/Off andOff/On Time
Delay
22 Minimum On Time Delay11 Mast Slave Ctrl Active 12 Auto
Changeover Active 13 Free Cooling Active 14 Reclaim Active 15
Electric Heat Active 16 Heating Low EWT Lockout 17 Condenser Pumps
Rotation 18 Ice Mode in Effect 19 Defrost Active on Cir A 20
Defrost Active on Cir B 21 Low Suction Circuit A 23 Circuit A
Low
Saturated SuctionCircuit A LowRefrigerant
22 Low Suction Circuit B 24 Circuit B LowSaturated
SuctionCircuit B LowRefrigerant
23 Low Suction Circuit C 25 Circuit C LowSaturated
SuctionCircuit C LowRefrigerant
24 High DGT Circuit A 26 High Discharge GasOverride Circuit
A
25 High DGT Circuit B 27 High Discharge GasOverride Circuit
B
26 High DGT Circuit C 28 High Discharge GasOverride Circuit
C
27 High Pres Override Cir A 16 Circuit A HighPressure
Override
28 High Pres Override Cir B 17 Circuit B HighPressure
Override
29 High Pres Override Cir C 18 Circuit C HighPressure
Override
30 Low Superheat Circuit A 31 Low Superheat Circuit B 32 Low
Superheat Circuit C 33 High Compressor Current
Circuit A41 Circuit A High
Current Override34 High Compressor Current
Circuit B42 Circuit B High
Current Override35 High Compressor Current
Circuit C43 Circuit C High
Current Override
-
21
Override #13: Minimum On/Off and Off/On Time Delay Whenever a
capacity change has been made, the control willremain at this
capacity stage for the next 90 seconds. Duringthis time, no
capacity control algorithm calculations will bemade. If the
capacity step is a compressor, an additional90-second delay is
added to the previous hold time (see Over-ride #22). This override
allows the system to stabilize beforeanother capacity stage is
added or removed. If a condition of ahigher priority override
occurs, the higher priority override willtake precedence. Operating
Mode 10 (MD10) will be in effect.Override #14: Slow Change Override
This override pre-vents compressor stage changes when the leaving
temperatureis close to the control point and slowly moving towards
thecontrol point.Override #15: System Manager Capacity Control If
aChillervisor module is controlling the unit and the
Chillervisormodule is controlling multiple chillers, the unit will
increasecapacity to attempt to load to the demand limited
value.Override #16: Circuit A High Pressure OverrideOverride #17:
Circuit B High Pressure OverrideOverride #18: Circuit C High
Pressure Override This over-ride attempts to avoid a high pressure
failure. The algorithm isrun every 4 seconds. If the Saturated
Condensing Temperaturefor the circuit is above the High Pressure
Threshold (Configu-ration SERVHP.TH) then the position of slide
valve willbe unloaded.Override #19: Standby Mode This override
algorithm willnot allow a compressor to run if the unit is in
Standby mode,(Run StatusVIEWHC.ST=2).Override #22: Minimum On Time
Delay In addition toOverride #13 Minimum On/Off and Off/On Time
Delay, forcompressor capacity changes, an additional 90-second
delaywill be added to Override #13 delay. No compressor will
bedeenergized until 3 minutes have elapsed since the last
com-pressor has been turned ON. When this override is active,
thecapacity control algorithm calculations will be performed, butno
capacity reduction will be made until the timer has expired.A
control with higher precedence will override the MinimumOn Time
Delay.Override #23: Circuit A Low Saturated SuctionTemperature in
CoolingOverride #24: Circuit B Low Saturated SuctionTemperature in
CoolingOverride #25: Circuit C Low Saturated Suction Tempera-ture
in Cooling If the circuit is operating in an area close tothe
operational limit of the compressor, the circuit capacity
willremain at the same point or unload to raise the saturated
suctiontemperature. This algorithm will be active if at least 1
compres-sor in the circuit is on and one of the following
conditions is true:
1. Saturated Suction Temperature is less than the BrineFreeze
Setpoint (ConfigurationSERVLOSP) 6 F(3.3 C).
2. Saturated Suction Temperature is less than the BrineFreeze
Setpoint (ConfigurationSERVLOSP) andthe circuit approach (Leaving
Water Temperature Satu-rated Suction Temperature) is greater than
15 F (8.3 C)and the Circuit Superheat (Discharge Gas Temperature
Saturated Discharge Temperature) is greater than 25 F(13.9 C).NOTE:
The freeze set point is 34 F (1.1 C) for freshwater systems
(ConfigurationSERVFLUD=1). Thefreeze set point is Brine Freeze Set
Point (ConfigurationSERVLOSP), for Medium Temperature Brinesystems
(ConfigurationSERVFLUD=2).
If any of these conditions are met, the appropriate
operatingmode, 21 (Circuit A), 22 (Circuit B) or 23 (Circuit C)
will be ineffect.
Override #26: Circuit A High Discharge Gas OverrideOverride #27:
Circuit B High Discharge Gas OverrideOverride #28: Circuit C High
Discharge Gas Override When the temperature is above the limit
curve minus 2 F(1.1 C) increase in capacity will not be allowed.
This overridewill remain active until the DGT goes below the limit
curve by3 F (1.7 C).Override #34: Circuit A Low Refrigerant
ChargeOverride #35: Circuit B Low Refrigerant ChargeOverride #36:
Circuit C Low Refrigerant Charge The ca-pacity override attempts to
protect the compressor from start-ing with no refrigerant in the
circuit. This algorithm runs onlywhen the circuit is not
operational (no compressors are ON).There are several criteria that
will enable this override:
1. The saturated suction temperature or saturated
dischargetemperature is less than 13 F (10.6 C).
2. All of these conditions must be true:a. The saturated suction
temperature or saturated
discharge temperature is less than leaving watertemperature by
more than 5.4 F (3.0 C).
b. Saturated suction temperature or saturated dis-charge
temperature is less than 41 F (5 C).
c. Outdoor air temperature is less than 32 F (0 C).d. Saturated
suction temperature or saturated discharge
temperature is less than the outdoor air temperatureby more than
5.4 F (3.0 C).
3. All of these conditions must be true:a. The saturated suction
temperature or saturated
discharge temperature is less than leaving watertemperature by
more than 5.4 F (3.0 C).
b. Saturated suction temperature or saturated dis-charge
temperature is less than 41 F (5 C).
c. Saturated suction temperature or saturated dis-charge
temperature is less than the brine freezepoint
(ConfigurationSERVLOSP) by morethan 6 F (3.3 C).NOTE: The freeze
set point is 34 F (1.1 C)for fresh water systems (Configuration
SERVFLUD=1). The freeze set point is brine freezeset point
(ConfigurationSERVLOSP), formedium temperature brine systems
(Configura-tionSERVFLUD=2).
4. All of these conditions must be true:a. The saturated suction
temperature or saturated
discharge temperature is less than leaving watertemperature by
more than 5.4 F (3.0 C).
b. Saturated suction temperature or saturated
dischargetemperature is less than 41 F (5 C).
c. Saturated suction temperature or saturated
dischargetemperature is less than the outdoor air temperatureby
more than 9 F (5 C).
If any of these conditions 1, 2, 3 or 4 are met, the
appropri-ate operating mode, 21 (Circuit A), 22 (Circuit B) or
23(Circuit C) will be in effect.Override #41: Circuit A High
Current OverrideOverride #42: Circuit B High Current
OverrideOverride #43: Circuit C High Current Override
This override attempts to avoid an overcurrent failure.
Thealgorithm is run every 4 seconds. If the compressor current
isgreater than 79% of must trip amps (MTA) but less than 85%MTA
then the capacity will be held at current capacity. If
thecompressor current is greater than 85% MTA then capacitywill be
reduced by repositioning the slide valve until thecurrent is less
than 85% MTA (ConfigurationUNITMTA.X).
-
22
Override #44: Circuit A High Suction Superheat at Part
LoadOverride #45: Circuit B High Suction Superheat at Part
LoadOverride #46: Circuit C High Suction Superheat at Part Load If
the compressor of the circuit is on, the compressor currentis no
more than 30% of the MTA, main EXV is more than 90%open and the
suction superheat is higher than the superheatcontrol point for
more than 5 minutes, the circuit will be shutdown.Override #50:
Circuit A MCHX MOP ControlOverride #51: Circuit B MCHX MOP
ControlOverride #52: Circuit C MCHX MOP Control This over-ride is
not currently used or supported.Override #53: Circuit A Delay for
Unloading the Slide ValveOverride #54: Circuit B Delay for
Unloading the Slide ValveOverride #55: Circuit C Delay for
Unloading the SlideValve If the compressor is stopped normally, no
slidevalve delay is applied. If the circuit is shut down by
lockedrotor alarm, full delay is applied before the compressor
isallowed to start (20 minutes for a compressor with 165 to185 tons
of nominal capacity, 8 minutes for a compressor with90 to 120 tons
of nominal capacity, and 5 minutes for acompressor with 45 to 60
tons of nominal capacity). If acompressor is shut off on an alarm,
this delay is adjusted basedon the last nominal capacity of the
last compressor.NOTE: Refer to Tables 1A and 1B in the 30XA
InstallationInstructions for unit compressor nominal
capacity.Override #56: Circuit A Delay for Refrigeration
IsolationValve to OpenOverride #57: Circuit B Delay for
Refrigeration IsolationValve to OpenOverride #58: Circuit C Delay
for Refrigeration IsolationValve to Open This override allows the
discharge motor-ized ball valve to open before the compressor
starts. The delayis 2 minutes and 30 seconds.Override #59: Circuit
A Low Oil LevelOverride #60: Circuit B Low Oil LevelOverride #61:
Circuit C Low Oil Level This override isonly effective when the
circuit is not running. It shall preventthe circuit from starting
up with a low oil level. If this overrideoccurs three times, the
low oil level alarm will be tripped.Head Pressure Control The Main
Base Board(MBB) controls the condenser fans to maintain the
lowestcondensing temperature possible, and thus the highest unit
effi-ciency. The MBB uses the saturated condensing temperatureinput
from the discharge pressure transducer to control thefans. Head
pressure control is maintained through a calculatedset point which
is automatically adjusted based on actualsaturated condensing and
saturated suction temperatures so thatthe compressor(s) is (are)
always operating within the manu-facturers specified envelope (see
Fig. 9). Each time a fan isadded the calculated head pressure set
point will be raised
25 F (13.9 C) for 35 seconds to allow the system to
stabilize.The control will automatically reduce the unit capacity
as thesaturated condensing temperature approaches an upper
limit.See capacity overrides 16-18. The control will indicate
throughan operating mode that high ambient unloading is in effect.
Ifthe saturated condensing temperature in a circuit exceeds
thecalculated maximum, the circuit will be stopped. For
thesereasons, there are no head pressure control methods or
setpoints to enter. The control will turn off a fan stage when
thecondensing temperature is below the minimum head
pressurerequirement for the compressor. Fan sequences are shown
inFig. 9.LOW AMBIENT TEMPERATURE HEAD PRESSURECONTROL OPTION Units
will start and operate down to32 F (0 C) as standard. Operation to
20 F (29 C) requiresoptional low ambient head pressure control as
well as windbaffles (field fabricated and installed to all units
for operationbelow 32 F [0 C]) if wind velocity is anticipated to
be greaterthan 5 mph (8 kp/h). Inhibited propylene glycol or other
suit-able corrosion-resistant anti-freeze solution must be field
sup-plied and installed in all units for unit operation below 34
F(1.1 C). Solution must be added to fluid loop to protect loopdown
to 15 F (8.3 C) below minimum operating ambienttemperature.
Concentration should be based on expected mini-mum temperature and
either Burst or Freeze protectionlevels. At least 6 gal per ton
(6.5 l/kW) of water volume is therecommended minimum for a moderate
system load.
For low-ambient temperature operation, the lead fan on acircuit
can be equipped with low ambient temperature headpressure control
option or accessory. The controller adjusts fanspeed to maintain
the calculated head pressure set point.LOW AMBIENT TEMPERATURE HEAD
PRESSURECONTROL OPERATING INSTRUCTIONS The 30XAlow ambient control
is a variable speed drive (VFD) that variesthe speed of the lead
condenser fan in each circuit to maintainthe calculated head
pressure control set point. The fan speedvaries in proportion to
the 0 to 10 vdc analog signal producedby the AUX1 fan board. The
display indicates motor speed inHz by default.Operation The low
ambient temperature head pressure con-troller is pre-configured to
operate from a 0 to 10 vdc analoginput signal present on terminals
3(AIN+) and 4(AIN). Jump-ers between terminals 2 and 4 and
terminals 5 and 8 (5 and 9for 575-v drives) are required for proper
operation. The drive isenabled based on an increase in the analog
input signal above0 vdc. Output is varied from 0 Hz to 60 Hz as the
analog signalincreases from 0 vdc to 10 vdc. When the signal is at
0 vdc thedrive holds the fan at 0 rpm. The head pressure control
set pointis not adjustable. The MBB determines the control set
point asrequired.
-
23
LEGEND
Fig. 9 Fan Staging
30XA080
Fan Output Ckt A 1 2 3 4 5 6 7
Contactor Number FC A1 FC A2 FC A3 FC B1 FC B2 FC B3
Fan Position FM5 FM3 FM6 FM1 FM4 FM2
Fan Output Ckt B 1 2 3 4 5 6 7
Contactor Number FC A1 FC A2 FC A3 FC B1 FC B2 FC B3
Fan Position FM5 FM3 FM6 FM1 FM4 FM2
30XA090-120
Fan Output Ckt A 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC B1 FC B2 FC B3 FC
B4
Fan Position FM7 FM5 FM8 FM6 FM1 FM3 FM2 FM4
Fan Output Ckt B 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC B1 FC B2 FC B3 FC
B4
Fan Position FM7 FM5 FM8 FM6 FM1 FM3 FM2 FM4
30XA140, 160
Fan Output Ckt A 1 2 3 4 5 6
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6
Fan Position FM9 FM7 FM5 FM10 FM8 FM6
Fan Output Ckt B 1 2 3 4
Contactor Number FC B1 FC B2 FC B3 FC B4
Fan Position FM1 FM2 FM3 FM4
30XA180,200
Fan Output Ckt A 1 2 3 4 5 6
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6
Fan Position FM11 FM9 FM7 FM12 FM10 FM8
Fan Output Ckt B 1 2 3 4 5 6
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6
Fan Position FM1 FM3 FM5 FM2 FM4 FM6
30XA220, 240
Fan Output Ckt A 1 2 3 4 5 6 7
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7
Fan Position FM13 FM11 FM9 FM7 FM14 FM12 FM10
Fan Output Ckt B 1 2 3 4 5 6
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6
Fan Position FM1 FM3 FM5 FM2 FM4 FM6
30XA260
Fan Output Ckt A 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8
FC A9
Fan Position FM15 FM13 FM11 FM9 FM7 FM16 FM14 FM12 FM10
Fan Output Ckt B 1 2 3 4 5 6
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6
Fan Position FM1 FM3 FM5 FM2 FM4 FM6
30XA280
Fan Output Ckt A 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8
FC A9
Fan Position FM15 FM13 FM11 FM9 FM7 FM16 FM14 FM12 FM10
Fan Output Ckt B 1 2 3 4 5 6 7
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6 FC B7
Fan Position FM1 FM3 FM5 FM8 FM2 FM4 FM6
30XA300
Fan Output Ckt A 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8
FC A9 FC A10
Fan Position FM15 FM13 FM11 FM9 FM7 FM16 FM14 FM12 FM10 FM8
Fan Output Ckt B 1 2 3 4 5 6
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6
Fan Position FM1 FM3 FM5 FM2 FM4 FM6
30XA325, 350
Fan Output Ckt A 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8
FC A9
Fan Position FM17 FM15 FM13 FM11 FM9 FM18 FM16 FM14 FM12
Fan Output Ckt B 1 2 3 4 5 6 7 8
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6 FC B7 FC B8
FC B9
Fan Position FM1 FM3 FM5 FM7 FM10 FM2 FM4 FM6 FM8
FM1
FM2
FM3
FM4
COMP B COMP A
FM5
FM6
FM1
FM2
FM3
FM4
COMP B COMP A
FM5
FM6
FM7
FM8
FM1
FM2
FM3
FM4
FM5
FM6
FM7
FM8
FM9
FM10
COMP APEBCOMP B
FM1
FM2
FM3
FM4
FM5
FM6
FM7
FM8
FM9
FM10
FM11
FM12
COMP APEBCOMP B
FM1
FM2
FM3
FM4
COMP A
FM5
FM6
FM7 FM9
FM10
FM11
FM12
FM13
FM14
PEBCOMP B
FM1
FM2
FM3
FM4
COMP A
FM5
FM6
FM7 FM9
FM10
FM11
FM12
FM13
FM14
FM15
FM16
PEBCOMP B
FM1
FM2
FM3
FM4
COMP A
FM5
FM6
FM7
FM8
FM9
FM10
FM11
FM12
FM13
FM14
FM15
FM16
PEBCOMP B
FM1
FM2
FM3
FM4
COMP A
FM5
FM6
FM7
FM8
FM9
FM10
FM11
FM12
FM13
FM14
FM15
FM16
PEBCOMP B
FM1
FM2
FM3
FM4
COMP A
FM5
FM6
FM7
FM8
FM9
FM10
FM11
FM12
FM13
FM14
FM15
FM16
FM17
FM18
PEBCOMP B
Ckt Circuit FM Fan MotorCOMP Compressor PEB Power Electrical
BoxFC Fan Contactor
-
24
LEGEND
Fig. 9 Fan Staging (cont)Replacement If the controller is
replaced the parameters inTable 15 must be configured. See Fig. 10
and 11.
Table 15 Head Pressure Control Parameters
*6-pole motors.8-pole motors.**Remove jumper from terminals 5
and 8 before configuring parameter.Reinstall jumper after
configuration is complete.
DIP switch settings:DIP switch 1 is not used.DIP switch 2 is the
motor frequency. (OFF = 50 Hz,ON = 60 Hz)Drive Programming
Parameter values can be altered viathe operator panel. The operator
panel features a five-digit,seven-segment display for displaying
parameter numbers andvalues, alarm and fault messages, set points,
and actual values.See Fig. 12 and 13. See Table 16 for additional
information onthe operator panel.NOTE: The operator panel motor
control functions are dis-abled by default. To control the motor
via the operator panel,parameter P0700 should be set to 1 and P1000
set to 1. Theoperator panel can be fitted to and removed from the
drivewhile power is applied. If the operator panel has been set as
theI/O control (P0700 = 1), the drive will stop if the
operatorpanel is removed.Changing Parameters with the Operator
Panel See Fig. 13for the procedure for changing the value of
parameter P0004.Modifying the value of an indexed parameter is
illustrated inFig. 13 using the example of P0719. Follow the same
proce-dure to alter other parameters using the operator panel.NOTE:
In some cases when changing parameter values thedisplay on the
operator panel displays . This means thedrive is busy with tasks of
higher priority.
30XA400
Fan Output Ckt A 1 2 3 4 5 6
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6
Fan Position FM11 FM9 FM7 FM12 FM10 FM8
Fan Output Ckt B 1 2 3 4 5 6
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6
Fan Position FM1 FM3 FM5 FM2 FM4 FM6
Fan Output Ckt C 1 2 3 4 5 6 7 8
Contactor Number FC C1 FC C2 FC C3 FC C4 FC C5 FC C6 FC C7 FC
C8
Fan Position FM19 FM17 FM15 FM13 FM20 FM18 FM16 FM14
30XA450, 500
Fan Output Ckt A 1 2 3 4 5 6 7 8
Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC
A8
Fan Position FM13 FM11 FM9 FM7 FM14 FM12 FM10 FM8
Fan Output Ckt B 1 2 3 4 5 6
Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6
Fan Position FM1 FM3 FM5 FM2 FM4 FM6
Fan Output Ckt C 1 2 3 4 5 6 7 8
Contactor Number FC C1 FC C2 FC C3 FC C4 FC C5 FC C6 FC C7 FC
C8
Fan Position FM21 FM19 FM17 FM15 FM22 FM20 FM18 FM16
FM1
FM2
FM3
FM4
COMP C
FM5
FM6
FM7
FM8
FM9
FM10
FM11
FM12
FM13
FM14
FM15
FM16
FM17
FM18
FM19
FM20
PEBCOMP B PEB A/B COMP A
FM1
FM2
FM3
FM4
COMP C
FM5
FM6
FM7
FM8
FM9
FM10
FM11
FM12
FM13
FM14
FM15
FM16
FM17
FM18
FM19
FM20
FM21
FM22
PEB CCOMP B PEB A/B COMP A
Ckt Circuit FM Fan MotorCOMP Compressor PEB Power Electrical
BoxFC Fan Contactor
PARAMETER VALUE DESCRIPTIONP0010 1 Enter Quick Commissioning
P03111140*
Rated Motor Speed850P3900 1 End of Quick Commissioning
P0003** 3 User Access LevelP1210 ** 6 Automatic RestartP1310 10%
Continuous Boost
P - - - -
T2
L3
L2
L1
T3
WV
DC
DC
LL1
NL2
L3
+ -
U
T1TO CONDENSER
FAN MOTOR
Fig. 10 Low Ambient TemperatureControl Power Wiring
ON
1 2 3 4
98765
DIN1 DIN2 DIN3 24V+ 0V
AOUT+ AOUT- P+ N-
12 13 14 15
DIP Switch 250 / 60 HzkW / hpON = 60 Hz
RLB RLC
10 11
10V+ 0V AIN+ AIN-
+0-10 VDC SIGNAL FROM FAN BOARD
ENABLEJUMPER
Fig. 11 Low Ambient TemperatureControl Signal Wiring
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25
Changing Single Digits in Parameter Values For chang-ing the
parameters value rapidly, the single digits of the displaycan be
changed by performing the following actions:
Ensure the operator panel is in the parameter value chang-ing
level as described in the Changing Parameters with theOperator
Panel section.
1. Press (function button), which causes the farthestright digit
to blink.
2. Change the value of this digit by pressing or .3. Pressing
(function button) again to cause the next
digit to blink.4. Perform steps 2 to 4 until the required value
is displayed.5. Press (parameter button) to exit the parameter
value
changing level.
NOTE: The function button may also be used to acknowledgea fault
condition.Quick Commissioning (P0010=1) It is important
thatparameter P0010 is used for commissioning and P0003 is usedto
select the number of parameters to be accessed. The P0010parameter
allows a group of parameters to be selected that willenable quick
commissioning. Parameters such as motor set-tings and ramp settings
are included. At the end of the quickcommissioning sequences, P3900
should be selected, which,when set to 1, will carry out the
necessary motor calculationsand clear all other parameters (not
included in P0010=1 to thedefault settings. This will only occur in
Quick Commissioningmode. See Fig. 14.Reset to Factory Default To
reset all parameters to the fac-tory default settings, the
following parameters should be set asfollows:
1. Jumpers must be in place from terminals 2 and 4 and 5and 8 (5
and 9 for 575v drives only).
2. Remove the keypad (pull out from top) and verify thatDIP
switch 1 is OFF and 2 is ON. Replace keypad.
3. Power up the drive. Press Parameter key. Pressto Parameter
P0010.
4. Press , then to change the 0 to a 1. Pressagain to accept the
change.
5. Press to Parameter P0311. Press and pressto change this value
to 1140 for 6-pole motors
or 850 for units with 8-pole motors. Press to accept.
Fn
Fn
P
P
P P
P
P
Fig. 12 Low Ambient Temperature Controller
CHANGING P0004 PARAMETER FILTER FUNCTION
CHANGING P0719 AN INDEXED PARAMETERSELECTION OF COMMAND/SETPOINT
SOURCE
Fig. 13 Changing Parameterswith the Operator Panel
STEP RESULT ONDISPLAY1 Press to access parameters
2 Press until P0004 is displayed
3 Press to access the parameter
value level
4 Press or to the requiredvalue
5 Press to confirm and store thevalue
6 Only the command parameters arevisible to the user.
STEP RESULT ONDISPLAY
1 Press to access parameters
2 Press until P0719 is displayed
3 Press to access the parametervalue level
4 Press to display current set value
5 Press or to the requiredvalue
6 Press to conform and store thevalue
7 Press until r0000 is displayed
8 Press to return the display to thestandard drive display (as
defined bythe customer)
P
P
P
P
P
P
P
P
-
26
6. Press to Parameter P3900. Press and useto change this value
to 1. Press to accept.
7. The drive will finish standard programming. Remove oneend of
the jumper wire from terminal 8.
8. Press again and go to Parameter P0003. Pressand use to change
this value to 3. Press toaccept.
9. Press to Parameter P1210. Press and useto change this value
to 6. Press to accept.
10. Press to Parameter P1310. Press and useto change this value
to 10%. Press to accept.
11. Press the Function key and then . The displaywill read 0.00
Hz.
12. Replace the wire jumper in terminal 8.13. The drive is now
active. Check fan rotation prior to testing.
If the fan is spinning forward, further adjustment is needed.Fan
should sit still when commanded speed is 0%. If thefan is spinning
forward slightly, press and toParameter P0761. Press and use to
change thisvalue to 0.1. Press to accept. Check the fan. If
rotationhas stopped no further adjustment is required. If the fanis
still rotating forward, press and use to changethis value to 0.2.
Press to accept. Repeat as neededuntil the fan is holding still or
is just barely moving ineither direction. Do NOT enter a value
greater than 0.5for this parameter without first contacting your
Carrierrepresentative.
Table 16 Low Ambient Temperature Controller Operator Panel
P
P
P P
P
P
P
P
P
Fn P
P
P
P
P
P
PANEL/BUTTON FUNCTION DESCRIPTIONIndicates Status The LCD
displays the settings currently used by the converter.
Start Converter The Start Converter button is disabled by
default. To enable this button set P0700 = 1.
Stop Converter Press the Stop Converter button to cause the
motor to come to a standstill at the selectedramp down rate.
Disabled by default, to enable set P0700 = 1.Press the Stop
Converter button twice (or hold) to cause the motor to coast to a
standstill.This function is always enabled.
Change Direction Press the Change Direction button to change the
direction of rotation of the motor.Reverse is indicat