Carrier ComfortLink 30GXN User Manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 903 Catalog No. 533-00052 Printed in U.S.A. Form 30G,H-9T Pg 1 1-04 Replaces: New
Book 2
Tab 5 c
Controls Start-Up, Operation,
Service, and Troubleshooting
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, etc.). Only
trained, qualified installers and service mechanics should
install, start up, and service this equipment.
When working on this equipment, observe precautions in
the literature, and on tags, stickers, and labels attached to the
equipment, and any other 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 electrical components.
CONTENTS
Page
SAFETY CONSIDERATIONS ...................... 1
GENERAL .......................................2,3
MAJOR SYSTEM COMPONENTS ................3,4
Main Base Board (MBB) .......................... 3
Screw Compressor Board (SCB) ................. 3
Electronic Expansion Valve (EXV) Board ......... 3
Comfort Link Compressor Protection
(CCP) Board ................................... 3
Energy Management Module (EMM) .............. 3
Enable/Off/Remote Connect Switch .............. 3
Emergency On/Off Switch ........................ 3
Board Addresses................................. 3
Control Module Communication.................. 3
Carrier Comfort Network (CCN) Interface......... 3
OPERATION DATA............................. 4-40
Electronic Expansion Valve (EXV) ................ 4
• EXV OPERATION
•ECONOMIZEROPERATION
Oil Pumps........................................ 5
Motor Cooling....................................5
Back Pressure Valve (30GXN,R
and 30HXA only) ............................... 5
Sensors ..........................................5
Comfort Link Compressor Protection
(CCP) Board 7
• OUTPUTS
• INPUTS
Wye-Delta vs Across-the-Line (XL)
Starting Option ................................8
Capacity Control ................................. 8
• MINUTES LEFT FOR START
• MINUTES OFF TIME
• LOADING SEQUENCE
• CLOSE CONTROL
• LEAD/LAG DETERMINATION
• CAPACITY SEQUENCE DETERMINATION
• MINIMUM LOAD VALVE
• CAPACITY CONTROL OVERRIDES
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
This unit uses a microprocessor-based electronic control
system. 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 control
board or accompanying wiring may destroy the electronic
modules or electrical components.
To prevent potential damage to heat exchanger tubes
always run fluid through heat exchangers when adding or
removing refrigerant charge. Use appropriate brine solu-
tions in cooler and condenser fluid loops to prevent the
freezing of heat exchangers when the equipment is exposed
to temperatures below 32 F (0° C).
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented outdoors in accor-
dance with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigeration and Air Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerantinanenclosedspacecandisplaceoxygenand
cause asphyxiation. Provide adequate ventilation in enclosed
or low overhead areas. Inhalation of high concentrations of
vapor is harmful and may cause heart irregularities,
unconsciousness or death. Misuse can be fatal. Vapor is
heavier than air and reduces the amount of oxygen available
for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.
DO NOT attempt to unbraze factory joints when servicing
this equipment. Compressor oil is flammable and there is
no way to detect how much oil may be in any of the refrig-
erant lines. Cut lines with a tubing cutter as required when
performing service. Use a pan to catch any oil that may
come out of the lines and as a gage for how much oil to add
to system. DO NOT re-use compressor oil. Do NOT leave
refrigerant system open to air any longer than necessary.
Seal circuits being serviced and charge with dry nitrogen to
prevent oil contamination when timely repairs cannot be
completed.
30GXN,R080-528
30HXA,HXC076-271
Air-Cooled and Water-Cooled Chillers with
Comfort Link™ Controls
50/60 Hz
Series 6

Carrier ComfortLink 30GXN Specifications

General

Refrigerant	R-134a
Compressor Type	Screw
Control System	ComfortLink
Efficiency	High
Sound Power Level	80-85 dBA (typical, varies by model)
Operating Voltage Range	380-480V, 3-phase, 50/60 Hz
Dimensions (L x W x H)	Varies significantly by model (Consult specific model data)

Summary

Safety Considerations

Electrical Shock Hazard

Electrical shock can cause personal injury and death. Shut off all power.

Microprocessor Control System Precautions

Do not use jumpers or short components; may destroy modules.

Heat Exchanger Protection

Run fluid through heat exchangers when adding/removing refrigerant charge.

Refrigerant Relief Valve Venting

Vent relief valves outdoors per ANSI/ASHRAE 15.

Major System Components

Operation Data

Electronic Expansion Valve (EXV) Operation

Controls refrigerant flow via stepper motor for precise cooler level control.

Oil Pumps

Prelubricates compressor and maintains oil pressure during operation.

Head Pressure Control

Air-Cooled Units (30GXN,R)

Fan staging controlled by SCT or Head Pressure Set Point.

With Motormaster V Control

Optional controller for low-ambient operation using temperature sensor.

Troubleshooting

Complete Unit Stoppage

Lists conditions causing total unit stoppage, including safety trips and power failures.

Single Circuit Stoppage

Lists conditions causing stoppage of only one circuit, like low oil pressure.

Restart Procedure

Steps for restarting after stoppage, noting manual reset requirements.

Alarms and Alerts

Warnings of abnormal conditions causing unit shutdown or default value usage.

EXV Troubleshooting Procedure

Inspecting/Opening Electronic Expansion Valves

Steps for physical inspection and opening of EXV valves, including O-ring replacement.

Service

Servicing Coolers and Condensers

Procedures for tube plugging, retubing, and tightening head bolts.

Inspecting/Cleaning Heat Exchangers

Guidelines for cleaning cooler tubes and inspecting sensors for corrosion.

Refrigerant Charging/Adding Charge

Indication of Low Charge on a System

How to check for low refrigerant charge using sight glass and EXV percent open.

Procedure to Add Charge to 30HXC Systems

Procedure for adding refrigerant charge to 30HXC units.

Procedure to Add Charge to 30GX and 30HXA Systems

Procedure for adding refrigerant charge to 30GX and 30HXA systems.

Oil Filter Maintenance

Compressor Changeout Sequence

Compressor Changeout Procedure

Step-by-step procedure for changing a compressor, including tool requirements.

Thermistors

Thermistor Replacement

Procedures for replacing thermistors T1-T6 and motor thermistors.

Control Modules

Main Base Board (MBB), SCB, EXV, EMM, CCP, and Navigator

Details on module operation, LEDs, communication, and troubleshooting.

Winter Shutdown Preparation

Recommended Maintenance Schedule

Guidelines for routine, monthly, and yearly maintenance tasks.

Pre-Start-Up Procedure

System Check

Ensures all auxiliary components and accessories are installed and wired correctly.

Start-Up and Operation

Procedure for actual chiller start-up and verifying proper operation.

Appendix A: Compressor Protection Module Configuration

30GXN,R (High Ambient Data)

Configuration header punch-outs and must trip amps for 30GXN,R high ambient models.

30GXN,R (Reduced Ambient Data)

Configuration header punch-outs and must trip amps for 30GXN,R reduced ambient models.

30HXC Models

Configuration header punch-outs and must trip amps for 30HXC models.

30HXA Models

Configuration header punch-outs and must trip amps for 30HXA models.

Appendix G: Configuration Options

RESETCON: Options Configuration

SETPOINT: Configuration

UNIT: Base Unit Configuration

SERVICE: Configuration

Configuration settings for PID gains, motor temperature, and compressor enable.

CURRMODS: Maintenance Display

Component Test

Mode: Service Test

Enables testing of peripheral components before compressor start-up.