Installation, Start-Up 30SKBand Service Instructions 180-600

50Hz

30SKB180-600 Water Cooled Screw Chillers

30SKB 180

30SKB 200

30SKB 250

30SKB 30０

30SKB 355

30SKB 400

30SKB 500

30SKB 600

- 1 -

INTRODUCTION

Prior to initial start-up of the 30SKB unit, those involved in the

start up, operation, and maintenance should be thoroughly

familiar with these instructions and other necessary job data. This

manual provides an overview for the familiarization with the

control system before performing start-up procedures.

Procedures in this manual are arranged in the sequence required

for proper machine start-up and operation.

SAFETY CONSIDERATIONS

30SKA liquid chillers are designed to provide safe and reliable

service when operated within design specifications. When

operating this equipment, use good judgment and safety

precautions to avoid damage to equipment and property or injury

to personnel.

Follow the procedures and safety precautions contained in the

machine instructions as well as those listed in this guide.

DANGER

DO NOT VENT refrigerant relief valves within a building. Outlet

from relief valve must be vented outdoors. The accumulation of

refrigerant in an enclosed space can displace oxygen and cause

asphyxiation.

PROVIDE adequate ventilation, especially for enclosed and low

overhead spaces. Inhalation of high concentrations of vapor is

harmful and may cause heart irregularities, unconsciousness, or

death. Misuse can be fatal. Vapor is heavier than air and reduces

the amount of oxygen available for breathing. Product causes eye

and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a

machine for any purpose. Oxygen gas reacts violently with oil,

grease, and other common substances.

NEVER EXCEED specified test pressures, VERIFY the allowable

test pressure by checking the instruction literature and the design

pressures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry

nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed

before operating any machine.

WARNING

DO NOT WELD OR FLAMECUT any refrigerant line or vessel

until all refrigerant (liquid and vapor) has been removed from

chiller. Traces of vapor should be displaced with dry air nitrogen

and the work area should be well ventilated. Refrigerant in

contact with an open flame produces toxic gases.

DO NOT work on high-voltage equipment. Only qualified

electricians can do so.

DO NOT WORK ON electrical components, including control

panels, switches, relays etc., unless ALL POWER IS OFF and

there is no residual voltage in capacitors or solid state

components.

LOCK OPEN AND TAG electrical circuits during servicing. USE

SAFETY GOGGLES. Wash off any spills from the skin with soap

and water. If liquid refrigerant enters eyes, IMMEDIATELY

FLUSH EYES with water and consult a physician.

NEVER APPLY an open flame or live steam to refrigerant

cylinder. Dangerous over pressure can result. If it is necessary to

heat refrigerant, use only warm water.

CHECK THE REFRIGERANT TYPE before adding refrigerant to

the unit. The introduction of the wrong refrigerant can cause

damage or malfunction to this machine.

DO NOT ATTEMPT TO REMOVE fittings, components, etc.,

while machine is under pressure or while machine is running.

Be sure pressure is at 0 kPa before breaking refrigerant

connection.

CAREFULLY INSPECT all relief devices, AT LEAST ONCE A

YEAR. If machine operates in a corrosive atmosphere, inspect

the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief

device when corrosion or build-up of foreign material (rust, dirt,

scale, etc.) is found within the valve body or mechanism. Replace

the device.

DO NOT install relief devices in series or backwards.

CAUTION

DO NOT STEP on refrigerant lines. Broken lines can whip about

and release refrigerant, causing personal injury.

DO NOT climb over the unit. Use platform, or staging.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or

move heavy components. Even if components are light, use

mechanical equipment when there is a risk of slipping or losing

your balance.

BE AWARE that certain automatic start arrangements CAN

ENGAGE TOWER FAN, OR PUMPS. Open the disconnect

ahead of the tower fans, or pumps.

USE only repair or replacement parts that meet the code

requirements of the original equipment.

DO NOT VENT OR DRAIN water boxes containing industrial

brines without the permission of your process control group.

DO NOT LOOSEN water box bolts until the water box has been

completely drained.

DO NOT LOOSEN a packing gland nut before checking that the

nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, fittings, and piping for

corrosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each

pressure relief device to prevent a build-up of condensate water.

- 2 -

DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION

30SKB180,200

30SKB250,300

- 3 -

30SKB355

30SKB400

- 4 -

30SKB500,600

Fig.1-Dimensions

UNITTotal operating

weight Center of gravity Weight distribution at the six mounting holes(kg) X Y Z Ａ Ｂ Ｃ Ｄ Ｅ Ｆ

30SKB180 1,900 833 450 902 257 257 218 218 476 47630SKB200 1,950 833 452 905 263 263 223 223 486 48630SKB250 2,220 1,018 453 879 338 338 216 216 554 55430SKB300 2,260 1,017 453 879 345 345 220 220 565 56530SKB355 2,900 1,468 459 916 386 386 338 338 724 72430SKB400 2,980 1,468 461 919 397 397 348 348 746 74630SKB500 3,420 2,014 462 886 449 449 407 407 856 85630SKB600 3,530 2,014 462 885 463 463 420 420 883 883

Fig.2Weight Distribution

- 5 -

●CLEARANCES

Fig.3-Clearances

Legend：

Service clearances required

It is recommended to secure a minimum 700mm clearance above the chiller

top to allow service mechanics to access to compressors.

UNIT 30SKB180 30SKB200 30SKB250 30SKB300

"A" 1,740 1,740 2,286 2,286

UNIT 30SKB355 30SKB400 30SKB500 30SKB600

"A" 3,035 3,035 4,128 4,128

- 6 -

RIGGING INSTRUCTIONS

RiggingLifting holes are provided on base or the cooler tube

sheet. Do not uncrate the unit until it is in final

location to protect unit from damage. Never tilt the

unit more than 15 ﾟ during transportation (see

Fig.4).

Vibration IsolationPlace vibration isolator pads of 10-20mm thickness

under the unit and hold it secure with anchor bolts.

See Fig.5 for positions of vibration isolators and

anchor bolts.

30SKB180-300

30SKB355-600

Fig.4-Rigging

UNIT "A" "B" "C" "D"30SKB180 1,840 820 850 1,04030SKB200 1,840 820 850 1,04030SKB250 2,386 1,093 850 1,04030SKB300 2,386 1,093 850 1,04030SKB355 3,135 1,468 846 1,01430SKB400 3,135 1,468 846 1,01430SKB500 4,228 2,014 846 1,01430SKB600 4,228 2,014 846 1,014

Fig.5- Vibration Isolation

- 7 -

Table 1 - Physical data

WATER PIPING

The cooler and condenser are of the multi-tube shell

and tube type with removable water boxes to

facilitate cleaning of the tubes.

Determine water piping size in the piping system

design. To install water piping systems, pay

attention to the following.

1) Never use a water inlet for a water outlet or vice

versa.

2) Install thermometers on the water piping inlet and

outlet.

3) Install manual or automatic air vent valve at high

location in the water piping.

4) Connect circulation pump at the inlet (return

water line).

5) Be sure to install strainer in the piping to the inlet

to prevent foreign matter from entering cooler.

6) Install expansion tank at a higher location than

the unit level.

7) Connect air vent and drain lines with valve for the

cooler.(The size for these connections are

1/4F.P.T.)

8) Use flexible connections to reduce vibration

transmission.

9) Cover all piping with proper thickness of

insulation. Where the ambient temperature falls

down to freezing point, wrap field piping with pipe

heater cables.

Condenser Water Piping - Run water supply lines as

short as possible. Size lines according to head

pressure available(not necessarily connection size),

especially on cooling tower applications. For once

thru system using natural water or city water, a

water regulating valve is required for each circuit.

Water bypass valves must be installed on cooling

tower applications where low outdoor ambient affect

head pressure. Water regulating valve is also useful

to maintain proper head pressure.

Use flexible connections to reduce vibration

transmission.

Provide means for draining the system in winter and

for servicing the unit.

MODEL 30SKB 180 200 250 300 355 400 500 600REFRIGERANT

No. of Circuits 1 1 1 1 2 2 2 2R-134a Charge (kg) 45 39 64 57 45x2 39x2 64x2 57+65

COMPRESSORS50Hz 06NW (Qty) *174(1) *209(1) *250(1) *300(1) *174(2) *209(2) *250(2) *300(2)Type of StartOil Charge/Compr. (L) 21 21 21 21 21x2 21x2 21x2 21x2Capacity Control Steps 6 6 6 6 6 6 6 6% Capacity

COOLER No. of Refrigerant Circuit 1 1 1 1 2 2 2 2Water Volume (L) 60 70 80 90 110 130 150 170Max Working Press

Water Conn.(Inlet & Outlet)Drain (M.P.T.)

CONDENSERMax Working Press

Water Conn.(Inlet & Outlet)DI DIMENSIONS (mm)

Width 1,740 1,740 2,286 2,286 3,035 3,035 4,128 4,128Depth 900 900 900 900 900 900 900 900Height 1,900 1,900 1,900 1,900 1,822 1,822 1,822 1,822

R-134a

Screw, Semi-hermetic

100-83-70-54-45-23-0 100-85-73-50-35-23-0

Star Delta

Flooded shell and tube

Refrigerant Side......0.87MpaWater Side......1.0Mpa

4"Flange 5"Flange

Water Side......1.0Mpa4"Flange 5"Flange

1/2" 1/2"×2Shell and tube

Refrigerant Side......2.02Mpa

- 8 -

Table 2 - Electrical data

ELECTRICAL CHARACTERISTICS

●The 30SKB180-600 have only one power terminal

block.

Power Supply - The power supply must conform to

the specification on the chiller nameplate. The

supply voltage must be within the range specified in

the electrical data table.

Control Supply - Amperage required for control

circuit is as follows:

CONTROL VOLTAGE AMPS

230V-1Ph-50Hz 10A

Warning: Operation of the chiller with an improper

supply voltage or excessive phase imbalance

constitutes abuse which will invalidate the Carrier

warranty .If the phase imbalance exceeds 2% for

voltage, or 10% for current, contact your local

electricity supply at once and ensure that the chiller

is not switched on until corrective measures have

been taken.

Power Wiring - All power wiring must comply with

applicable local codes.

1) Install field supplied branch circuit disconnects

within sight from unit.

2) To determine power wire size, refer to electrical

data table.

3) When connecting power supply wire to unit ,open

control box cover and connect wire to power supply

terminals R, S, T in box.

Pass wires thru the opening on the top of control

box on unit.

Control Circuit Interlocks - A flow switch should

be installed in the water line in the event that water

flow should stop. Also, auxiliary contacts for the

water pump starter should be installed in the control

circuit as additional protection against unit operation

when the pump is not running.

Field Control Wiring

　　　　　　　　　　　　　　

MODEL NO.POWERSUPPLY

VOLTAGES RANGE

MCA[A]

MFA[A]

RFA[A]

ICF[A]

MODEL × NO.RLA(ea)

[A]LRA(ea)

[A]MTA(ea)

[A]30SKB180 80 125 80 128 06NW*174×1 64 128 10530SKB200 95 150 90 155 06NW*209×1 76 155 12630SKB250 115 200 110 186 06NW*250×1 92 186 15130SKB300 400V-3Ph-50Hz 342-440 140 250 125 219 06NW*300×1 112 219 18430SKB355 144 200 125 192 06NW*174×2 64 128 10530SKB400 171 225 150 231 06NW*209×2 76 155 12630SKB500 207 275 200 278 06NW*250×2 92 186 15130SKB600 251 350 250 331 06NW*300×2 112 219 184

ICF - Maximum Instantaneous Current Flow during starting (the point in the stating sequence where the sum of the LRA for the starting compressor plus the total RLA for all running compressors is maximum).

LRA - Locked Rotor AmpsMCA - Minimum Circuit Amp (for wire sizing)MFA - Maximum Fuse AmpsMTA - Must Trip Amps (Circuit Breaker)RFA - Recommended Fuse AmpsRLA - Rated Load Amps (Compressors) * - Compressor revision number

- 9 -

OPERATION OF MICRO PROCESSOR

CONTROLLER

The Microprocessor controls water temperature,

chilled water safety thermostat, EXV, and other

functions. See Fig.6 for microprocessor controller

board - PIO (processing I/O) Board.

Fig.6 - PIO (Processing I/O) BOARD

Function of Switch

Start Button (Green Button)To start unit, push start button.

Stop/Reset Button (Red Button)To stop or reset unit when unit alarm detected,

push stop button.

CAUTION :Unit shall not restart in 30 seconds after stop

button is pushed to reset microprocessor.

To restart unit, push start button after 30 seconds

and confirm the Running Lamp lights on.

REMOTE-UNIT Transfer SwitchFor remote control operation, select “REMOTE”.

In remote control operation, unit can stop with

stop button on the unit while unit can not start

with start button on the unit.

Function of Lamp

Power Lamp (White Lamp)Power Lamp lights on as long as unit is

energized even if unit is in fault conditions or

not in operation.

Running Lamp (Green Lamp)Running Lamp lights on when unit is operating.

It lights on when all compressors stop by

capacity control or unit is not in operation due

to any failure.

Warning Lamp (Orange Lamp)Warning Lamp lights on when unit is in fault or

abnormal conditions. The Warning Lamp

where failure detected lights on. There is a

case that a circuit operates continuously when

Warning Lamp is lighting if a failure is not

serious to stop the circuit. Warning Lamp goes

off when reset button is pushed. Failures are

assigned to alarm code numbers shown on

LED of microprocessor.

Water Temperature Control

Constant Leaving Water TemperatureBy computing the leaving water temperature

differential between a set point and cut-in or cut

out temperature based on unit operating

condition, the microprocessor determines

optimum capacity control.

Capacity control steps is 6 steps (30SKB180 -

600). In the following cases, the capacity is

automatically stepped up without computing

the leaving water temperature differential.

1) In cooling operation, leaving water

temperature is above 2℃ higher than

setting point.

Factory pre-set leaving water temperature is

7℃ for cooling.

For field adjustment, refer to “Adjustment of

Setting Point for Operating Condition”.

NOTE :Set point can be changed within the upper and

lower limits. The range of the Leaving ChilledWater Temperature (LCWT) is 5 to 20℃

Safety Stop ControlUnit stops temporary when leaving water

temperature reaches below 3℃.

(Low water temp cutout 2℃ + 1℃)

Unit restart operation automatically without

manual reset and restart when leaving water

temperature is above setting point.

- 10 -

Compressor Start delay timer and Time GuardThe starting of each compressor is controlled by

Microprocessor. The compressors do not start

immediately after start button is pushed.

Microprocessor incorporates Time Guard function.

The Time Guard provides 3-minute delay in restart

of each compressor to prevent short cycling.

Compressor minimum operating timeOnce each compressor has started, it shall continue

to run for at least two minutes regardless thermostat

setting of water temperature unless a safety trips. It

helps return oil back to compressor.

Display Function1) LED display on the PIO board of the controller

shows following operating conditions. Numbers of capacity control step Fault conditions detected

2) The following status of unit can be shown by

LED display. Leaving water temperature set point

(SP-C) water temperature Discharge gas temperature(dGt), and

compressor motor temperature(Cct) of

each circuits. Alarm Resume. Unit running condition before activation of

any safety device. Discharge gas pressure (dGP), Suction

gas pressure (SGP), Oil pressure(OIP),

and Economizer pressure(SIP) of each

circuits. Saturated temperature of Discharge (Sdt)

and suction (SSt) of each circuit. Discharge superheat(SHD) of each

circuits compressor. Electronic Expansion Valve (EXV) and

valve lift (EPC,EPE) of each circuit.

3) Function of display selector switch (SW7), see

Table 3.

Table 3 - Function of display selector switch

(SW7)

SW7 Title Description

0 StAt Unit running mode

1 SEtSetting of leaving chilled water

temperature

2 tH-1

Display entering and leaving

water temperature and leaving

condenser water temperature

3 tH-2

Display discharge gas and

compressor motor temperature

of each circuits compressor

4 HISt Display Unit Alarm history

5 Cunt Compressor running counter

6 runt Compressor running hours

9 PrES

Display discharge pressure,

suction gas pressure, oil

pressure and economizer

pressure of each circuits

compressor

A CALCDisplay temperature calculated

by microprocessor

B StEPDisplay valve lift of electronic

expansion valve (EXV)

C CodE Low Pressure cutoff

D EStSDisplay latest unit running

condition before alarm detected

Safety and Control DevicesTable 4 shows setting value of safety and control

devices.

Table 4 - Safety and Control Devices

Cut-out Cut-in REMARKS

High-pressure

switch

1.42

MPa

1.13

MPa

Low-pressure

Cut-out0 MPa -

Discharge Gas

Thermostat104℃ -

Compressor Motor

temperature118℃ -

Low Water Temp,

Cut-out2℃ 5℃

Micro-

processor

Controller

manually

reset

Fusible Plug Melts at 72℃

- 11 -

START-UP AND ADJUSTMENT

Initial CheckDo not attempt to start the chiller until the following

checks have been completed.

1) Check that all components of water system and

electric wiring system are properly installed.

Auxiliary contacts for water pump starter must

be properly interlocked in the control circuit.

2) Open the discharge and liquid valves in each

circuit.

3) Open the oil shut off valves located by the oil

pre-filter.

4) Check clean water is in water piping system

and air vent is provided.

5) Check tightness of all electrical connections.

6) Check the incoming power supply for proper

phasing. This can be done by turning on both

the line voltage and control voltage power

supplies. If incoming power is not phased

correctly, shut down power supplies and switch

any two incoming power leads at the control

box terminal block.

ATTENTIONDO NOT make any changes to the factory installed

compressor power wiring in the control box or at the

compressor junction box. Doing so will cause

permanent damage to the compressor and will

require compressor replacement.

7) Check all field configuration data and setpoints.

8) Check incoming power supply for proper

nameplate voltage and for any voltage

imbalance as defined below.

9) Open condenser water valves. Check

condenser water pump for proper operation.

CHECKS AND ADJUSTMENT OF MICRO-

PROCESSOR CONTROLLER BEFORE

STARTING

Before initial start-up, check the input switch of the

controller for normal operation, and adjust the

setting point for operating condition by the following

directions. See Fig.7 for detail switch arrangement

of PIO board.

Fig.7 - Switch Arrangement of PIOA. Check the Input Switch1) Set the display selector switch (SW7) of the

PIO board inside the switch box at “0”. LED

display shows “StAt” and unit operating mode a

few seconds later. When a start button is not

pushed, LED display shows operating mode in

step 1 as shown in Table 5. When a start

button is pushed, LED display shows Step 2

Table 5 - Unit running mode

LED DisplayDescription

COOL Unit Running Mode (COOL)

StOP Unit is stopped by alarms.

C-□□ Unit Capacity Step (COOL)

ALt Oil filter alert

E□□□Any Safety Device is Opened.

Alarm code is displayed in □□□

POFF Pump Inter Lock Open

2) Set the display selector switch (SW7) of the

PIO board at “4”. LED display shows “HISt” and

the latest unit alarm code (1□□□) a few

seconds later. “1” means the latest alarm No.

and “□□□” shows alarm code. Alarm history

is recorded in microprocessor board. Push

setting change switch ▲(SW3) or ▼(SW4) of

PIO board inside the switch box. LED display

shows alarm history one by one. Up to 8

current alarm codes are stored. The oldest

alarm code is shown as “8□□□”. To clear

alarm history, push enter switch (SW5) until

LED display shows “- - - - “. Note that alarm

history can not be cleared during operation. For

checking specific items, see Table 6.

- 12 -

Table 6 - Alarm Code(30SKB180-600)

Code(LED1-3) Description

A000 No alarms

A002 Pump Interlock error

AC04 Internal Interface error

A005 Entering Water

A006 Leaving Water

Thermistor

Error

A010 Low Water Temp. Cutout

A011 Low Flow Rate Protector

A013 Water Piping or Sensor Error

AB14 High pressure switch

AB15 Low suction pressure

AB16 High discharge temperature

AB19 Compressor over load

AB20 Discharge gas

AB22 Comp. MotorThermistor error

AB25High Comp. Motor

winding temperature

AB30 Low oil level

AB31 High Oil filter pressure drop

AB32 Low oil pressure 1

AB33 Low oil pressure 2

AB40 Discharge

AB41 Suction

AB42 Oil

AB43 Economizer

Pressure

Transducer

Error

A = Alarm Resume No. (1-8):SW7="4" Only

A = E :SW7="0" Only

B = 0 : 30SKB180-300

B = Circuit No.(1,2) :30SKB355-600

C = EEV Adress(0) :30SKB180-300

B = EEV,EIO Adress(0-3) : 30SKB355-600

3) Set the display selector switch (SW7) of the

PIO board at “D”. LED display shows “EStS”

and the latest unit running conditions before

activation of any safety device. Running

conditions are recorded in micro-processor

board. Push setting change switch ▲(SW3) or

▼(SW4) of PIO board inside the switch box.

LED display shows running conditions before

activation of any safety device one by one. 9 or

15 latest running condition codes are stored.

Details of recorded running conditions, see

Table 7. To clear running conditions, push

enter switch (SW5) until LED display shows “- -

- -“. Note that running conditions can not be

cleared during operation.

Table 7 - Unit Running Conditions30SKB180-300

Code Description

Et Entering Water Temperature

Lt Leaving Water Temperature

StEP Capacity Steps

dGP□ Discharge Gas Pressure

SGP□ Suction Gas Pressure

OIP□ OIL Pressure

ECP□ Economizer Pressure

EPC□ EXV valve lift (main)

EPE□

No.1

Circuit

EXV valve lift

(for motor cooling)

30SKB355-600

Code Description

Et Entering Water Temperature

Lt Leaving Water Temperature

StEP Capacity Steps

dGP1 Discharge Gas Pressure

SGP1 Suction Gas Pressure

OIP1 OIL Pressure

ECP1 Economizer Pressure

EPC1 EXV valve lift (main)

EPE1

No.1

Circuit

EXV valve lift

(for motor cooling)

dGP2 Discharge Gas Pressure

SGP2 Suction Gas Pressure

OIP2 OIL Pressure

ECP2 Economizer Pressure

EPC2 EXV valve lift (main)

EPE2

No.2

Circuit

EXV valve lift

(for motor cooling)

B. Adjustment of Setting Point for Operating

Condition1) Setting of Leaving Chilled Water Temperature

(SP-C)

Set the display selector switch (SW7) of the

PIO board inside the switch box at “1”. LED

display shows “SEt”. A few seconds later, LED

display shows set-point of Leaving Chilled

Water Temperature code “SP-C” and the set

temperature (default is 7.0℃).

- 13 -

To change the setting point of leaving chilled

water temperature, push enter switch ●(SW5)

when LED display shows setting point. LED

display shows the setting point blinking. Push

the setting change switch ▲ (SW3) or ▼

(SW4) to select setting point. Push the enter

switch ●(SW5) to set the temperature and the

display shows setting point lighting.

(Setting range of “SP-C” is 5 to 20℃)

After checking the input switch and adjusting

the setting point of operating condition, set the

display selector switch (SW7) at “0”

Actual Start-upActual start-up should be done only under

supervision of a qualified refrigeration mechanic.

1) Set leaving fluid temperature. No cooling range

adjustment is necessary.

2) Start chilled fluid pump.

3) Switch LOCAL/REMOTE switch to LOCAL or

REMOTE.

4) Provided there is load on the chiller, allow the

machine to operate and conform that

everything is functioning properly. Verify that

the leaving fluid temperature agrees with the

cooling setpoint(1or2), or if reset is being used,

the modified setpoint.

Operating Sequence

The chiller is started by switching the

LOCAL/REMOTE switch to either LOCAL or

REMOTE. The oil pump will be turned on to start the

pre-lubrication process. After a short period of time,

the oil solenoid will be opened and the compressor

will start. For star delta start chillers, contactors C

and CS will be closed and the compressor will be

started in a Wye configuration. This method reduces

the rocked rotor current requirements by

approximately 60%, while maintaining enough

torque to bring the compressor up to full speed.

After 3 seconds, the PIO module will switch out

contactor CS and bring In contactor CD which will

run the motor in a Delta configuration.

Once the compressor is successfully running, the

control will load the compressor and add additional

stages of capacity as needed to satisfy the leaving

fluid setpoint. Head pressure can be controlled with

a field installed condenser water valve.

LED DISPLAY DURING OPERATION

AND REMEDY

During normal operation (the display selector

switch of PIO board is set at “0”), the capacity

steps are shown on LED display of PIO board.

When any failure occurs during operation, the

failure is indicated with code numbers on LED

display. When a trouble indicator lamp (OL) is

on, check the failure with alarm code numbers

on LED display and correct cause before

restarting.1) Refer to Table 6 for alarm code shown on LED

display.

2) For resetting alarms, push a unit stop button

when cause is corrected.

Temperature indication of ThermistorWhile unit is in operation or not in operation the

detected temperature by Thermistor can be

checked by LED display.

Entering and leaving and Leaving

condenser water Temperature. (See Table

8)1) Set the display selector switch (SW7) of the

PIO board inside the switch box at “2”. LED

display shows “tH-1”. A few seconds later, LED

display shows entering water temperature code

“Et“ and detected temperature.

2) Push the setting change switch ▲ (SW3)

under this state. LED shows leaving water

temperature code “Lt“ and detected

temperature.

3) Push the setting change switch ▲ (SW3)

under this state. LED shows leaving condenser

water temperature code “LHt“ and detected

temperature.

4) As explained, the detected temperature by

each Thermistor can be found by pushing the

setting change switch ▲(SW3) and ▼(SW4)

respectively.

5) After checking the temperature indication of

Thermistor, return the display selector switch

(SW7) to “0”.

- 14 -

Discharge gas and compressor motor

temperature of each circuit.1) Set the display selector switch (SW7) of the

PIO board inside the switch box at “3”. LED

display shows “tH-2”. A few seconds later,

LED display shows discharge gas temperature

code of No.1 circuit “dGt□ ” and detected

temperature.

2) Push the setting change switch ▲(SW3) under

this state. LED shows Compressor Motor

temperature code of No.1 circuit “Cct□ “ and

detected temperature.

3) As explained, the detected temperature of

other circuit (□□□2: No.2 circuit) can be

found by pushing the setting change switch ▲

(SW3) and ▼(SW4) repeatedly.

4) After checking the temperature indication of

Thermistor, return the display selector switch

(SW7) to “0”.

Table 8 - Thermistor Code

30SKB180-300

Code Description

Et Entering Water Temperature

Lt Leaving Water Temperature

LHtLeaving Condenser Water

Temperature

dGt□ No.1 CKT.Discharge Gas

Temperature

Cct□ No.1 CKT.Compressor Motor

Temperature

30SKB355-600

Code Description

Et Entering water Temperature

Lt Leaving water Temperature

LHtLeaving Condenser Water

Temperature

dGt1 No.1 CKT.

dGt2 No.2 CKT.

Discharge Gas

Temperature

Cct1 No.1 CKT.

Cct2 No.2 CKT

Compressor Motor

Temperature

Pressure indication of pressure transducerWhile unit is in operation or not in operation, the

detected pressure by pressure transducer can be

checked with LED display. (See Table 9)

Discharge gas pressure, Oil pressure

Economizer pressure of each Compressor,

and Suction gas pressure of each circuit.1) Set the display selector switch (SW7) of the

PIO board inside the switch box at “9”. LED

display shows “PrES”. A few seconds later,

LED display shows discharge gas pressure

code of No.1 circuit “dGP□ “ and detected

pressure.

2) Pushing the setting change switch ▲(SW3)

under this state, LED shows suction gas

pressure code of No.1 circuit “SGP□ ” and

detected pressure.

3) Pushing the setting change switch ▲(SW3)

under this state, LED shows oil pressure code

of No.1 circuit “OIP□” and detected pressure.

4) Pushing the setting change switch ▲(SW3)

under this state, LED shows economizer

pressure code of No.1 circuit “ECP□ ” and

detected pressure.

5) As explained, the detected pressure of other

circuit (□□□2: No.2 circuit) can be found by

pushing the setting change switch ▲ (SW3)

and ▼(SW4) repeatedly.

6) After checking the pressure indication of

pressure transducer, return the display selector

switch (SW7) to “0”.

Table 9 - Pressure Code

30SKB180-300

Code Description

dGP□ No.1 CKT. Discharge Gas Pressure

SGP□ No.1 CKT. Suction Gas Pressure

OIP□ No.1 CKT. Oil Pressure

ECP□ No.1 CKT. Economizer Pressure

30SKB355-600

Code Description

dGP1 No.1 CKT.

dGP2 No.2 CKT.Discharge Gas Pressure

SGP1 No.1 CKT.

SGP2 No.2 CKT.Suction Gas Pressure

OIP1 No.1 CKT.

OIP2 No.2 CKT.Oil Pressure

ECP1 No.1 CKT.

ECP2 No.2 CKTEconomizer Pressure

Temperature calculated by microprocessorWhile unit is in operation or not in operation, the

temperature calculated by microprocessor can be

checked with LED display. (See Table 10)

- 15 -

Discharge and suction saturated

temperature and discharge superheat of

each circuit.1) Set the display selector switch (SW7) of the

PIO board inside the switch box at “A”. LED

display shows “CALC”. A few seconds later,

LED display shows discharge saturated

temperature code of No.1 circuit “Sdt□“ and

calculated temperature.

2) Push the setting change switch ▲(SW3) under

this state. LED shows suction saturated

temperature code of No.1 circuit “SSt□” and

detected temperature.

3) Push the setting change switch ▲(SW3) under

this state. LED shows discharge superheat

code of No.1 circuit “SHd□ ” and detected

temperature.

4) As explained, the calculated temperature of

other circuit (□□□2: No.2 circuit) can be

found by pushing the setting change switch ▲

(SW3) and ▼(SW4) repeatedly.

5) After checking the calculated temperature from

microprocessor, return the display selector

switch (SW7) to “0”.

Table 10 - Calculated Temp. Code

30SKB180-300

Code Description

Sdt□ No.1 CKT.Saturated Discharge

Temperature

Sst□ No.1 CKT.Saturated Suction

Temperature

SHd□ No.1 CKT.Discharge

Super Heat

30SKB355-600

Code Description

Sdt1 No.1 CKT.

Sdt2 No.2 CKT.

Saturated Discharge

Temperature

Sst1 No.1 CKT.

Sst2 No.2 CKT.

Saturated Suction

Temperature

SHd1 No.1 CKT.

SHd2 No.2 CKT.

Discharge

Super Heat

Valve lift of electronic expansion valve(EXV)While unit is in operation or not in operation, the

valve lift of electric expansion valve (EXV) can be

checked with LED display. (See Table 11)

1) Set the display selector switch (SW7) of the

PIO board inside the switch box at “B”. LED

shows “StEP”. A few seconds later, LED

display shows valve lift of EXV code of No.1

circuit “EPC□“ and valve lift.

2) Push the setting change switch ▲(SW3) under

this state. LED shows valve lift of EXV code of

No.1 circuit “EPE□“ and valve lift.

3) As explained, the valve lift of EXV of other

circuit (□□□2: No.2 circuit)can be found by

pushing the setting change switch ▲ (SW3)

and ▼(SW4) repeatedly.

4) After checking the valve lift of EXV, return the

display selector switch (SW7) to “0”.

Table 11 - Valve Lift of EXV Code

30SKB180-300

Code Description

EPC□ No.1 CKT.

EXV Valve lift

(main)

1500Step 100% Open

EPE□ No.1 CKT.

EXV Valve lift

(For Motor Cooling)

240Step 100% Open

30SKB355-600

Code Description

EPC1 No.1 CKT.

EPC2 No.2 CKT.

EXV Valve lift

(main)

1500Step 100% Open

EPE1 No.1 CKT.

EPE2 No.2 CKT.

EXV Valve lift

(For Motor Cooling)

240Step 100% Open

To Shut Off Unit For Long PeriodComplete the following steps.

1) Push the unit stop button.

2) To prevent corrosion, drain heat exchanger,

and charge it with nitrogen gas to slightly

higher pressure than atmospheric pressure.

3) Turn unit power supply switch OFF.(main and

control)

To Start Unit After Prolonged ShutdownFollow the same steps as START-UP procedures.

- 16 -

To Stop Unit For Short PeriodFor shutting down unit daily or less than 7 days,

push the unit stop button. Do not turn unit control

power supply switch off.

To Start Unit After Short-period ShutdownPush a start button to start operation.

MAINTENANCE

Refrigerant Charging - Adding Charge

IMPORTANT30SKB is designed for use with R134a only. DO

NOT USE ANY OTHER refrigerant in these units.

CAUTIONWhen adding or removing charge, circulate water

through the condenser and cooler at all times to

prevent freezing. Freezing damage is considered

abuse and may void Carrier warranty.

CAUTIONDO NOT OVERCHARGE system. Overcharging

results in higher discharge pressure with higher

cooling fluid consumption, possible compressor

damage and higher power consumption.

Indication of low charge on a 30SKB system

NOTETo check for low refrigerant charge on a 30SKB,

several factors must be considered. A flushing

liquid-line sightglass is not necessarily an indication

of inadequate charge. There are many system

conditions where a flashing sightglass occurs under

normal operation. The 30SKB metering device is

designed to work properly under these conditions.

1. Make sure that the circuit is running at a full-

load condition. To check whether circuit No.1 is

fully loaded. If the circuit capacity step is 100%,

the circuit is full-load.

2. With the circuit running at full-load, verify that

the cooler leaving fluid temperature is in the

range of 5.0-7.0 ℃.

3. At this condition, observe the refrigerant in the

liquid line sightglass. If there is a clear

sightglass, and no signs of flashing, then the

circuit is adequately charged. Skip the

remaining steps.

4. If the refrigerant appears to be flashing, the

circuit is probably low on charge. Verify this by

checking the EXV Percent Open(See table 11).

5. If the EXV Percent Open is greater than 60%,

and the liquid line sightglass is flashing, then

the circuit is low on charge. Follow the

procedure for adding charge.

To add charge to the 30SKB systems

1. Make sure that the unit is running at full-load,

and that the cooler leaving fluid temperature is

in the range of 5.0-7.0℃.

2. At these operating conditions, check the liquid-

line sightglass. If there is a clear sightglass,

then the unit has sufficient charge. If the

sightglass is flashing, then check the EXV

Percent Open. If this is greater than 60%, then

begin adding charge.

NOTE

A flashing liquid-line sightglass at operating

conditions other than those mentioned above is

not necessarily an indication of low refrigerant

charge.

3. Add 2.5 kg of liquid charge into the cooler using

the charging port on the liquid line.

4. Observe the EXV Percent Open value. The

EXV should begin closing as charge is being

added. Allow the unit to stabilize. If the EXV

Percent Open remains above 60%, and the

sightglass continues flashing, add an additional

2.5 kg of liquid charge.

5. Allow the unit to stabilize, and again check the

EXV Percent Open. Continue adding 2.5 kg of

liquid refrigerant charge at a time, and allow the

unit to stabilize before checking the EXV

position.

6. When the EXV Percent Open is in the range of

40-60%, check the liquid line sightglass. Slowly

add enough additional liquid charge to ensure

a clear sightglass. This should be done slowly

to avoid overcharging the unit.

- 17 -

7. Verify adequate charge by continuing to run at

full-load with 5.0-7.0℃ cooler laving fluid

temperature. Check that the refrigerant is not

flashing in the liquid-line sightglass. The EXV

Percent Open should be between 40 and 60%.

Proper amount Shortage

Fig.8 - Moisture Indicator

Oil ChargingCAUTION

DO NOT add oil at any other location as

improper unit operation may result.

1. Make sure that the unit is not running when

adding oil, as this will make the oil charging

process easier. Because the system is under

pressure even when the unit is not running, it

will be necessary to use a suitable pump (hand

or electric pump) to add oil to the system.

2. Using a suitable pump, add 2 litters of

Polyolester oil to the system (CARRIER

SPEC：PP47-32). Make sure that the oil level

safety switch is NOT jumpered, and allow the

unit to restart and run normally after charging

oil.

3. If low oil level problems persist, add another 2

litters of oil. Continue adding oil in 2 litters

increments until the problem is resolved. If it is

necessary to add more than 6 litters of oil to the

system, then contact your local Carrier.

Maintenance of Water PipingMajor points of maintenance of water piping are to

provide water treatment for preventing scale or

corrosion and to protect piping and devices from

damage caused by freezing during cold weather.

1) Confirm that cooler and condenser are

provided with proper quantity of water.

Occasionally check on strainer in water piping.

Vent air occasionally.

2) When shutting down unit for long period, to

maintain cooler and condenser, refer to

Shutdown instructions.

Electronic Expansion Valve(EXV)High-pressure liquid refrigerant enters valve through

bottom. A series of calibrated slots have been

maintained inside of orifice assembly. As refrigerant

passes through orifice, pressure drops and

refrigerant changes to a 2-phase condition (liquid

and vapor). To control refrigerant flow for different

operating conditions, sleeves moves up and down

over orifice and modulates orifice size. Sleeve is

moved by a linear stepper motor. Stepper motor

moves in increments and is controlled directly by

EEV board. As stepper motor rotates, motion is

transferred into linear movement by lead screw.

Through stepper motor and lead screw, 1500

discrete steps of motion are obtained. The large

number of steps and long stroke results in very

accurate control of refrigerant flow.

Integral oil filter changeAn integral oil filter in the 06N screw compressor is

specified to provide a high level of filtration(3μ)

required for long bearing life. As system cleanliness

is critical to reliable system operation, there is also a

pre-filter (12μ) in the oil line just before entering the

integral compressor filter.

Filter Change-Out ScheduleThe filter should be checked after the first 1000

hours of operation, and every subsequent 4000

hours. The filter should be replaced at any time

when the PIO BOARD LED shows “Alt”（filter alert）.

For replacement items use Carrier Specified Parts

Manufacturing reserves the right to discontinue, or charge at any time, specifications or designs without notice and without incurring obligations

TOYO CARRIER ENGINEERING COMPANY LIMITED

Tokyo, Japan

From 30SKB180-01ISE New Printed in Japan EIS0206