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Carrier AQUAFORCE 30XA080-500 User Manual

Carrier AQUAFORCE 30XA080-500
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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300091-01 Printed in U.S.A. Form 30XA-4T Pg 1 612 10-11 Replaces: 30XA-3T
Controls, Start-Up, Operation, Service
and Troubleshooting
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .2,3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Conventions Used in This Manual. . . . . . . . . . . . . . . . 3
Display Module Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOUCH PILOT™ DISPLAY
NAVIGATOR™ DISPLAY MODULE
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor Protection Module (CPM) . . . . . . . . . . . 9
Electronic Expansion Valve (EXV) Board . . . . . . . . . 9
Fan Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Enable-Off-Remote Contact Switch (SW1). . . . . . . 17
Emergency On/Off Switch (SW2) . . . . . . . . . . . . . . . . 17
Energy Management Module (EMM) . . . . . . . . . . . . . 17
Hot Gas Bypass/Pump Board . . . . . . . . . . . . . . . . . . . 17
Local Equipment Network. . . . . . . . . . . . . . . . . . . . . . . 19
Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Touch Pilot Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Module Communication. . . . . . . . . . . . . . . . . 19
•RED LED
GREEN LED
YELLOW LED
Carrier Comfort Network
®
(CCN) Interface. . . . . . . 20
Remote Alarm and Alert Relays . . . . . . . . . . . . . . . . . 20
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-59
Touch Pilot Operation Configuration Tables. . . . . 21
Machine Control Methods . . . . . . . . . . . . . . . . . . . . . . . 22
Machine On/Off Control . . . . . . . . . . . . . . . . . . . . . . . . . 22
TOUCH PILOT MACHINE CONTROL
NAVIGATOR DISPLAY MACHINE CONTROL
Fluid Set Point Control Location . . . . . . . . . . . . . . . . 27
Cooling Set Point Selection . . . . . . . . . . . . . . . . . . . . . 27
SET POINT OCCUPANCY
Chilled Water Fluid Type Selection . . . . . . . . . . . . . . 28
FRESH WATER
BRINE OR GLYCOL OPERATION
Cooler Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
NO PUMP CONTROL
SINGLE PUMP CONTROL
DUAL PUMP AND MANUAL CONTROL
Machine Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit/Compressor Staging and Loading . . . . . . . 31
CIRCUIT/COMPRESSOR STAGING
CIRCUIT/COMPRESSOR LOADING
Minimum Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DUAL CHILLER CONTROL FOR PARALLEL
APPLICATIONS
DUAL CHILLER PUMP CONTROL FOR PARALLEL
CHILLER APPLICATIONS
Page
DUAL CHILLER CONTROL FOR SERIES
APPLICATIONS
DUAL CHILLER PUMP CONTROL FOR SERIES
CHILLER APPLICATIONS
Night Time/Low Noise Applications . . . . . . . . . . . . . 37
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RETURN WATER RESET
OUTSIDE AIR TEMPERATURE RESET
SPACE TEMPERATURE RESET
4-20 mA TEMPERATURE RESET
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SWITCH CONTROLLED DEMAND LIMIT
EXTERNALLY POWERED CAPACITY BASED
DEMAND LIMIT
EXTERNALLY POWERED CURRENT BASED
DEMAND LIMIT
CCN LOADSHED CONTROLLED DEMAND LIMIT
Ice Storage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Broadcast Configuration . . . . . . . . . . . . . . . . . . . . . . . . 46
•ACTIVATE
OAT BROADCAST
BROADCAST ACKNOWLEDGER
Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ALARM ROUTING CONTROL
ALARM EQUIPMENT PRIORITY
COMMUNICATION FAILURE RETRY TIME
RE-ALARM TIME
ALARM SYSTEM NAME
Daylight Saving Time Configuration. . . . . . . . . . . . . 47
Capacity Control Overrides . . . . . . . . . . . . . . . . . . . . . 47
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 50
LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPTION
LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPERATING INSTRUCTIONS
PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59-67
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TEMPERATURES
•VOLTAGE
MINIMUM FLUID LOOP VOLUME
FLOW RATE REQUIREMENTS
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-74
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 67
ACTUATED BALL VALVE (ABV), FLOODED
COOLER ONLY
Dual Chiller Sequence of Operation . . . . . . . . . . . . . 68
•PUMP OPERATION
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
THERMISTORS
TRANSDUCERS
AQUAFORCE
®
30XA080-500
Air-Cooled Liquid Chillers

Table of Contents

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Carrier AQUAFORCE 30XA080-500 Specifications

General IconGeneral
BrandCarrier
ModelAQUAFORCE 30XA080-500
CategoryChiller
LanguageEnglish

Summary

Controls, Start-Up, Operation, Service and Troubleshooting

SAFETY CONSIDERATIONS

Essential safety precautions for installing, starting up, and servicing the equipment.

GENERAL

General information about the chiller, including manual conventions and display module usage.

CONTROLS

Overview of the electronic control system components and their functions.

CONFIGURATION

Detailed tables for Touch Pilot™ display operation and user configuration settings.

START-UP

Procedures and checks required for the actual start-up of the chiller unit.

OPERATION

Description of the chiller's sequence of operation and various operating modes.

Display Module Usage

TOUCH PILOT™ DISPLAY

Description of the standard user interface, its buttons, and navigation.

NAVIGATOR™ DISPLAY MODULE

Description of the mobile user interface, keys, and navigation structure.

Setup Menu

REGIONAL

Configuration for time/date format and units of measure (US/Metric).

LANGUAGE

Selection of display language and font.

CONTRAST

Adjusting the LCD contrast for optimal visibility.

BACKLIGHT

Setting backlight to remain on or turn off during inactivity.

CALIBRATE

Adjusting the LCD touch screen calibration.

PASSWORDS

Configuration of limited and full logged-in access system passwords.

DISPLAY

Viewing device information and specifying operating mode.

CCN

Configuration of bus and element numbers, and baud rate for network control.

Compressor Protection Module (CPM)

CPM DIP switch 1 (S1) inputs

Description of DIP switch 1 (S1) inputs for starter, CT position, and contactor failure.

Fan Boards

DIP SWITCH addresses

Addresses for Fan Board A, B, and C DIP switches for unit configuration.

Key Operational Controls

Enable-Off-Remote Contact Switch (SW1)

Provides local means for enabling or disabling the machine's operation.

Emergency On/Off Switch (SW2)

Used for immediate shutdown, interrupting power to all modules.

Energy Management Module (EMM)

Receives inputs for temperature reset, set point, and demand limit functions.

Hot Gas Bypass/Pump Board

Controls hot gas bypass solenoids and pump contactors.

Machine Control Methods

TOUCH PILOT MACHINE CONTROL

Local control determined by the Start/Stop button on the Touch Pilot display.

NAVIGATOR™ DISPLAY MACHINE CONTROL

Control determined by OPER variable: Switch Control, Time Schedule, or CCN.

Fluid Set Point Control

Cooling Set Point Selection

Options for controlling the Leaving Chilled Water Set Point.

BRINE OR GLYCOL OPERATION

Configuration for brine or glycol chilled water loops for freeze protection.

Advanced Chiller Operations

Circuit/Compressor Staging and Loading

Configuration for staging circuits/compressors and their loading sequence.

Minimum Load Control

Enabling and configuring the minimum load control accessory.

Dual Chiller Control

Configuration for master/slave operation of two chillers in series or parallel.

Night Time/Low Noise Operation

Configuration for reducing sound level by limiting fan operation.

Temperature Reset

RETURN WATER RESET

Fluid temperature reset based on cooler fluid temperature difference.

OUTSIDE AIR TEMPERATURE RESET

Temperature reset based on outdoor-air temperature (OAT).

SPACE TEMPERATURE RESET

Temperature reset based on space temperature (SPT).

4-20 mA TEMPERATURE RESET

Temperature reset based on an externally powered 4 to 20 mA signal.

Demand Limit

SWITCH CONTROLLED DEMAND LIMIT

Demand limiting via field-supplied switch for 1-step or 2-step control.

Switch Controlled (Capacity Based)

2-step demand limit based on capacity, reducing capacity to set points.

Switch Controlled (Current Based)

2-step demand limit based on current, limiting capacity to set points.

EXTERNALLY POWERED (4 to 20 mA) CAPACITY BASED DEMAND LIMIT

Demand limit based on unit capacity via 4-20mA signal.

EXTERNALLY POWERED (4 to 20 mA) CURRENT BASED DEMAND LIMIT

Demand limit based on compressor current via 4-20mA signal.

System Management and Alarms

CCN LOADSHED CONTROLLED DEMAND LIMIT

Demand limit for CCN loadshed control when unit is in CCN control.

Ice Storage Operation

Chiller operation configured for making and storing ice.

Broadcast Configuration

Configuration for broadcasting OAT, time, date, and holiday status.

Alarm Control

Configuration for routing alarms through the CCN.

Capacity Control Overrides

Head Pressure Control

Main Base Board controls condenser fans to maintain lowest condensing temperature.

LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPTION

Option for low ambient operation using accessory head pressure control.

Operation

ACTUATED BALL VALVE (ABV), FLOODED COOLER ONLY

Description and manual operation of the motorized ball valve in the discharge line.

Dual Chiller Sequence of Operation

Determines lead chiller, manages lag chiller operation based on configuration.

Operating Modes

Override modes that affect normal equipment operation.

Sensors

THERMISTORS

Description and identification of thermistors monitoring chiller operation.

TRANSDUCERS

Description of pressure transducers for monitoring chiller operation.

SERVICE

Economizer Assembly

Description of the economizer assembly and its function.

Electronic Expansion Valve (EXV)

Overview of the EXV, its operation, and control logic.

EXV TROUBLESHOOTING PROCEDURE

Steps for diagnosing and correcting EXV problems.

Compressor Oil System

Oil Charge

Specifications and procedure for adding oil or a complete charge.

Cooler Protection and Maintenance

FLOODED COOLER FREEZE PROTECTION

Logic for energizing cooler heaters to prevent freeze-up.

FLOODED COOLER LOW FLUID TEMPERATURE

Shuts down chiller if leaving fluid temperature drops below specified limits.

FLOODED COOLER LOSS OF FLUID FLOW PROTECTION

Integral flow switch protects cooler against loss of cooler flow.

FLOODED COOLER TUBE PLUGGING

Procedure for plugging leaky tubes until retubing.

DX COOLER CHILLED WATER FLOW SWITCH

Function of the factory-installed flow switch in the entering water nozzle.

DX Cooler and Flooded Cooler Units PREPARATION FOR WINTER SHUTDOWN

Steps to complete at the end of the cooling season for winter shutdown.

Coil Maintenance and Refrigerant Circuit

Microchannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning Recommendations

Procedures for cleaning MCHX condenser coils using high pressure water.

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

Procedures for routine maintenance and cleaning of RTPF coil surfaces.

Refrigerant Circuit

Description of the refrigerant circuit and procedures for leak testing and charging.

Safety Devices and Maintenance

COMPRESSOR PROTECTION

Description of safety devices protecting the compressor from overcurrent.

COOLER PROTECTION

Shuts down chiller if leaving fluid temperature drops below specified limits.

Relief Devices

Fusible plugs and pressure relief valves designed to relieve abnormal pressure.

Recommended Maintenance Schedule

Guidelines for routine, monthly, quarterly, and annually maintenance tasks.

TROUBLESHOOTING

Alarms and Alerts

Monitoring of unit for abnormal or fault conditions, generating warnings or shutdowns.

Table 59 — Alarm Codes

Detailed list of alarm codes, reasons, actions, and probable causes.

Low Suction Temperature Protection

Circuit A Low Suction Temperature

Alarm triggered if circuit Saturated Suction Temperature is below specified limits.

Circuit A High Suction Superheat

Alarm triggered if circuit superheat exceeds set point or MOP.

Circuit A Low Suction Superheat

Alarm triggered if circuit superheat is below set point or MOP.

Service Test and Schematics

Service Test

Function to verify proper operation of various chiller devices.

Figure 63 — 30XA080,082 Low Voltage Control Schematic

Wiring schematic for low voltage control of 30XA080,082 units.

Figure 64 — 30XA090-352 Low Voltage Control Schematic

Wiring schematic for low voltage control of 30XA090-352 units.

Figure 65 — 30XA400-500 Low Voltage Control Schematic

Wiring schematic for low voltage control of 30XA400-500 units.

APPENDIX A — TOUCH PILOT™ DISPLAY TABLES

APPENDIX B — NAVIGATOR™ DISPLAY TABLES

MODE — RUN STATUS

Navigator display table for run status of various parameters.

MODE — SERVICE TEST

Navigator display table for service test functions.

MODE — TEMPERATURE

Navigator display table for temperature readings.

MODE — PRESSURE

Navigator display table for pressure readings.

MODE — INPUTS

Navigator display table for input status.

MODE — SET POINTS

Navigator display table for set point configurations.

MODE — OUTPUTS

Navigator display table for output status.

MODE — CONFIGURATION

Navigator display table for system configuration settings.

MODE — TIMECLOCK

Navigator display table for timeclock schedule configurations.

MODE — OPERATING MODE

Navigator display table listing active operating modes.

MODE — ALARMS

Navigator display table for active alarms.

APPENDIX C — CCN TABLES

STATUS DISPLAY TABLES

CCN table mapping for status display points.

CONFIGURATION TABLES

CCN table mapping for configuration settings.

APPENDIX D — 30XA080-500 CPM DIP SWITCH ADDRESSES

APPENDIX E — PIPING AND INSTRUMENTATION

30XA080 Flooded Cooler Units

Piping and instrumentation diagram for 30XA080 Flooded Cooler Units.

30XA090, 100, 110, 120, 140, 160, 180, 200, 220, 240, 260, 280, 300, 325, 350 Flooded Cooler Units

Piping and instrumentation diagram for multiple 30XA flooded cooler units.

30XA082 DX Cooler Units

Piping and instrumentation diagram for 30XA082 DX Cooler Units.

30XA092, 102, 112, 122, 142, 162, 182, 202, 222, 242, 262, 282, 302, 327, 352 DX Cooler Units

Piping and instrumentation diagram for multiple 30XA DX Cooler Units.

APPENDIX F — MAINTENANCE SUMMARY AND LOG SHEETS

30XA Maintenance Interval Requirements

Summary of required maintenance intervals for 30XA units.

30XA Monthly Maintenance Log

Log sheet for recording monthly maintenance actions.

30XA Seasonal Shutdown Log

Log sheet for recording seasonal shutdown procedures.

APPENDIX G — BACNET COMMUNICATIONS OPTION

TO ADDRESS THE UPC OPEN CONTROLLER

Procedure for assigning a unique address to the UPC Open controller.

CONFIGURING THE BAS PORT FOR BACNET MS/TP

Settings for the BAS Port DIP switches for MS/TP communication.

WIRING THE UPC OPEN CONTROLLER TO THE MS/TP NETWORK

Recommendations for wiring the UPC Open controller to the MS/TP network.

Table C — MS/TP Wiring Recommendations

Specifications for MS/TP wiring, including cable and vendor recommendations.

CONFIGURING THE UPC OPEN CONTROLLER'S PROPERTIES

Setting CCN Address and Bus Number for ComfortLink and UPC Open.

COMMUNICATION LEDS

Indicators for controller communication status.

TROUBLESHOOTING

Troubleshooting common issues with UPC Open controller wiring or addressing.

Table G — Network Points List

BACNET OBJECT ID

List of BACnet object identifiers for network points.

POINT NAME

List of point names for network communication.

READ/WRITE

Indicates if network points are readable or writable.

UNITS

Units of measurement for network points.

DEFAULT VALUE

Default values for network points.

RANGE

Allowed range of values for network points.

START-UP CHECKLIST FOR 30XA LIQUID CHILLERS

A. PROJECT INFORMATION

Project details for the chiller installation.

B. PRELIMINARY EQUIPMENT CHECK

Contractor checklist for verifying equipment condition before start-up.

Chilled Water System Check

Checks for proper installation and operation of the chilled water system.

C. UNIT START-UP

Start and Operate Machine

Steps for testing components and operating the machine.

Record Configuration Information

Component Test

Operating Data:

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