EMan-Carrier Air-Cooled Liquid Chillers - Controls, Start-Up, Operation, Service and Troubleshooting

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)


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.


Power (24 vac supply) CPM-X-J1

11 24 vac12 Ground


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


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.


Power (24 vac supply) EXVA-J1

11 24 vac12 Ground


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


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


TB1 TB2 TB3 TB4 TB5 TB6 TB7 TB8

STATUS SIO (LEN)


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


TB1 TB2 TB3 TB4 TB5 TB6 TB7 TB8


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


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)


Pin Notation

Power (24 vac supply) FBX-J1

11 24 vac12 Ground


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.


(Unit Size)Pin Notation

Power (24 vac supply) FBC-J1

11 24 vac12 Ground


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


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


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.


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.


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).



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).



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


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


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 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 B 1 2 3 4 5 6

Contactor Number FC B1 FC B2 FC B3 FC B4 FC B5 FC B6


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




30XA260


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




30XA280




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


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




30XA325, 350




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


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 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


30XA450, 500


Contactor Number FC A1 FC A2 FC A3 FC A4 FC A5 FC A6 FC A7 FC A8





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


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

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

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EMan-Carrier Air-Cooled Liquid Chillers - Controls, Start-Up, Operation, Service and Troubleshooting

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