Carrier AquaForce 30XV275 - User Manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300197-01 Printed in U.S.A. Form 30XV-3T Pg 1 6-19 Replaces: New
Controls, Start-Up, Operation, Service
and Troubleshooting
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions Used in This Manual . . . . . . . . . . . . . . . 3
Abbreviations Used in This Manual . . . . . . . . . . . . . 3
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Carrier Controller Display . . . . . . . . . . . . . . . . . . . . . 5
Carrier Controller Display User Interface . . . . . . . . . 5
Input/Output (SIOB) Boards . . . . . . . . . . . . . . . . . . . 15
Auxiliary Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Enable-Off-Remote Switch (SW1) . . . . . . . . . . . . . . 18
Emergency On/Off Switch (SW2) . . . . . . . . . . . . . . . 18
Energy Management Module (EMM) . . . . . . . . . . . . 18
Local Equipment Network . . . . . . . . . . . . . . . . . . . . 19
Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Module Communication . . . . . . . . . . . . . . . 19
Carrier Comfort Network® Interface . . . . . . . . . . . 19
External Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Alarm and Alert Relays . . . . . . . . . . . . . . . . 20
CONFIGURATION (SOFTWARE) . . . . . . . . . . . . . . . . . 20
Carrier Controller Operation Configuration Tables . . 20
Carrier Controller Menu Tables . . . . . . . . . . . . . . . . 20
Machine Control Methods . . . . . . . . . . . . . . . . . . . . 25
Chilled Water Set Point Configuration . . . . . . . . . . 27
Evaporator Pump Control . . . . . . . . . . . . . . . . . . . . 31
Circuit/Compressor Staging and Loading . . . . . . . 32
Dual Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Machine Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fast Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ice Storage Operation . . . . . . . . . . . . . . . . . . . . . . . . 46
Broadcast Configuration . . . . . . . . . . . . . . . . . . . . . 46
Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Daylight Savings Time Configuration . . . . . . . . . . . 47
Capacity Control Overrides . . . . . . . . . . . . . . . . . . . 47
Head Pressure Control (Variable Speed Fans) . . . . 48
Head Pressure Control (Fixed Speed Fans) . . . . . . 49
Sound Optimization . . . . . . . . . . . . . . . . . . . . . . . . . 49
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . .50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . .55
Dual Chiller Sequence of Operation . . . . . . . . . . . . .55
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Economizer Assembly . . . . . . . . . . . . . . . . . . . . . . . .64
Electronic Expansion Valve . . . . . . . . . . . . . . . . . . .64
Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . .67
Evaporator Service . . . . . . . . . . . . . . . . . . . . . . . . . .68
All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
MCHX Condenser Coil:
Maintenance and Cleaning . . . . . . . . . . . . . . . . .74
RTPF Condenser Coil:
Maintenance and Cleaning . . . . . . . . . . . . . . . . .74
Condenser Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
High Static Fan Option . . . . . . . . . . . . . . . . . . . . . . .75
Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Variable Frequency Drives . . . . . . . . . . . . . . . . . . . .76
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
Recommended Maintenance Schedule . . . . . . . . .208
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .208
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . .208
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . .226
Quick Test (Service Test) . . . . . . . . . . . . . . . . . . . .226
APPENDIX A — CARRIER CONTROLLER
DISPLAY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . .249
APPENDIX B — CCN POINT TABLE . . . . . . . . . . . . . .281
APPENDIX C — LON POINT TABLE . . . . . . . . . . . . . .308
APPENDIX D — BACNET/MODBUS
TRANSLATOR POINTS . . . . . . . . . . . . . . . . . . . . .309
APPENDIX E — BACNET IP POINTS . . . . . . . . . . . . . .310
APPENDIX F — PIPING AND INSTRUMENTATION . .328
APPENDIX G — MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . .330
APPENDIX H — EVAPORATOR HEATER SENSOR
SET POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332
APPENDIX I — CARRIER CONTROLLER WEB AND
NETWORK INTERFACE PARAMETERS. . . . . . .333
APPENDIX J — FACTORY SUPPLIED PUMPS . . . . .336
AquaForce
®
30XV140-500, Series B
Variable Speed Air-Cooled Liquid Chillers
with Greenspeed
®
Intelligence
and Carrier Controller

Summary

Controls, Start-Up, Operation, Service and Troubleshooting

Safety Considerations

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

Carrier Controller Display and User Interface

Details on the Carrier Controller HMI, Welcome Screen, and Home Screen.

Carrier Controller Login and Display Setup

User access levels, password protection, display language, and measurement units.

Energy Management Module (EMM)

Carrier Controller Operation Configuration Tables

Parameters for configuring operating conditions and equipment arrangements.

Machine Control Methods

Available methods for starting and stopping the machine.

Alarm Control

Configuration for routing alarms through the CCN.

Capacity Control Overrides

Demand Limit

Three types of demand limiting configurations available.

Head Pressure Control (Variable Speed Fans)

Head Pressure Control (Fixed Speed Fans)

PRE-START-UP

Checks to be completed before initial start-up.

START-UP

Procedure for actual start-up of the chiller.

Operating Limitations

Unit operating temperature limits and voltage requirements.

OPERATION

Sequence of operation for chiller start-up and shutdown.

Dual Chiller Sequence of Operation

Sequence for master/slave control of two chillers in parallel or series.

Operating Modes

EVAPORATOR FREEZE PROTECTION

Logic and configuration for energizing evaporator heaters.

LOW FLUID TEMPERATURE

MCHX Condenser Coil: Maintenance and Cleaning

RTPF Condenser Coil: Maintenance and Cleaning

Refrigerant Circuit

Details on leak testing and refrigerant charge.

Safety Devices

Variable Frequency Drives

VFD DISPLAY NAVIGATION

VFD STATUS

VFD CONFIGURATION TABLES

VFD REPLACEMENT PROCEDURE

Procedure for replacing Variable Frequency Drives.

Troubleshooting Guide

Guide for identifying unit issues and their possible solutions.

Electrical Schematics

Quick Test (Service Test)

Function to verify proper operation of various chiller devices.

APPENDIX A - CARRIER CONTROLLER DISPLAY TABLES

Detailed tables of Carrier Controller display menus and parameters.

APPENDIX B - CCN POINT TABLE

Table of CCN points for system communication and control.

APPENDIX D - BACNET;MODBUS TRANSLATOR POINTS

APPENDIX E - BACNET IP POINTS

APPENDIX G - MAINTENANCE SUMMARY AND LOG SHEETS

APPENDIX I - CARRIER CONTROLLER WEB AND NETWORK INTERFACE PARAMETERS

APPENDIX J - FACTORY-SUPPLIED PUMPS

Start-Up Checklist for 30 XV Liquid Chillers

Checklist for installing contractor to complete during unit start-up.

Carrier AquaForce 30XV275 Specifications