Carrier Ecologic 30GX080-265 User Manual

Controls, Start-Up, Operation,
Service, and Troubleshooting
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can
be hazardous due to system pressures, electrical compo-
nents, 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. Fol-
low all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting this equipment,
and in handling all electrical components.
Electrical shock can cause personal injury and death.
Shut off all power to this equipment during installation
and service. 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 con-
trol system. Do not use jumpers or other tools to short
out components, or to bypass or otherwise depart from
recommended 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 al-
ways run fluid through heat exchangers when adding or
removing refrigerant charge.
DO NOT VENT refrigerant relief valves within a build-
ing. Outlet from relief valves must be vented outdoors
in accordance with the latest edition of ANSI/ASHRAE
(American National Standards Institute/American Soci-
ety of Heating, Refrigeration and Air Conditioning En-
gineers) 15 (Safety Code for Mechanical Refrigeration).
The accumulation of refrigerant in an enclosed space
can displace oxygen and cause asphyxiation. Provide ad-
equate 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 ser-
vicing this equipment. Compressor oil is flammable and
there is no way to detect how much oil may be in any
of the refrigerant 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 com-
pressor oil.
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
GENERAL ...................................2
MAJOR SYSTEM COMPONENTS ..............3
Processor Module (PSIO-1) ...................3
DSIO-HV Relay Module .......................3
Electronic Expansion Device Module .........3
Compressor Protection Module (CPM) .........3
PSIO-2 (8052) Module ........................3
Keypad and Display Module
(Also Called HSIO-II) .......................3
Control (LOR) Switch .........................3
OPERATION DATA ..........................3-42
Electronic Expansion Device (EXD) ...........3
• EXV OPERATION
• ECONOMIZER OPERATION
Oil Pumps ...................................4
Motor Cooling ...............................4
Back Pressure Valve (30GX and 30HXA only) ..4
Sensors .....................................4
Compressor Protection Module (CPM) .........4
• OUTPUTS
• INPUTS
Wye-Delta vs Across-the-Line (XL)
Starting Option ............................5
Capacity Control .............................6
• MINUTES LEFT FOR START
• MINUTES OFF TIME
• LOADING SEQUENCE
• CLOSE CONTROL
• LEAD/LAG DETERMINATION
• CAPACITY SEQUENCE DETERMINATION
• MINIMUM LOAD VALVE
• CAPACITY CONTROL OVERRIDES
Head Pressure Control .......................8
• GENERAL
• AIR COOLED UNITS (30GX)
• WATER COOLED UNITS (30HX)
• ADJUSTING PID ROUTINES
Cooler and Condenser (30HXC)
Pump Control .............................10
30GX080-265
30HXA,HXC076-271
ECOLOGIC™ Air-Cooled and Fluid Cooled Chillers
50/60Hz
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg 1 1-98 Replaces: 30G,H-2T
Series 0,1,2

Carrier Ecologic 30GX080-265 Specifications

General

Brand	Carrier
Model	Ecologic 30GX080-265
Category	Chiller
Language	English

Summary

SAFETY CONSIDERATIONS

Electrical Hazards

Warning about electrical shock and the need to shut off all power.

Control System Precautions

Caution against bypassing electronic control components to prevent damage.

Refrigerant Handling Safety

Safety instructions for venting refrigerant relief valves and general handling.

Safety Devices

Compressor Safety Features

Lists safety devices for compressor protection and their functions.

Cooler Safety Features

Lists safety devices related to cooler protection.

GENERAL UNIT INFORMATION

Refrigerant and Oil Specifications

Specifies refrigerant type (R-134a) and compressor oil used.

Control System Overview

Describes the microprocessor-based control system and its components.

MAJOR SYSTEM COMPONENTS

Core Control Modules

Details PSIO-1, DSIO-HV, EXD Module, CPM, PSIO-2, and HSIO-II modules.

Unit Control Interface

Explains the LOCAL/OFF/REMOTE switch for controlling unit operation modes.

OPERATION DATA

Electronic Expansion Device (EXD) Operation

Explains how the EXD controls refrigerant flow and cooler level.

Component Operations

Economizer Operation

How the economizer improves capacity and efficiency, and provides motor cooling.

Oil Pump and Motor Cooling

Details oil pump operation and motor cooling control logic.

Back Pressure Valve and Sensors

Function of the back pressure valve and the role of system sensors.

Compressor Protection Module (CPM)

Explains CPM functions, inputs, and outputs for compressor protection.

Compressor Protection Module (CPM)

CPM Status Indicators and Alarms

Explains CPM LEDs and lists alarm conditions with feedback codes.

Compressor Starting Options

Details the Wye-Delta vs. Across-the-Line starting options for compressors.

Capacity Control Logic

Capacity Control Routine

How the control system manages capacity stages to meet the set point.

Start-Up and Operation Delays

Explains "Minutes Left for Start" and "Minutes Off Time" parameters.

Loading Sequence

Describes the sequence for compressor and loader engagement for efficiency.

Capacity Control Sequences

Close Control Logic

How close control uses loading devices for precise temperature regulation.

Lead/Lag and Capacity Sequence Determination

Logic for determining lead/lag circuits and capacity stage order.

Minimum Load Valve and Overrides

Operation of the minimum load valve and capacity control overrides.

Control Logic Overrides

Temperature and Superheat Control

How overrides like slow change, ramp loading, and low superheat affect operation.

Freeze Protection and High Condensing Temp

MOP Override and Head Pressure Control

Head Pressure Control Logic

Fan Control Without Motormaster

Fan Control With Motormaster

Water-Cooled Unit Control

Control Adjustments and Pump Control

Adjusting PID Routines

Cooler and Condenser Pump Control

Unit Interface and Control

Cooler Heater Operation

Keypad and Display Module (HSIO-II)

Description of the HSIO-II module for unit interaction and configuration.

Accessing Functions and Subfunctions

Automatic Default Display

Status Function Operations

Status Function Overview

Alarms and Alerts Information

General Operating Parameters

Circuit A Analog Values

System Monitoring Displays

Unit Analog Parameters and Reset

Miscellaneous Inputs/Outputs Display

Operating Modes and Capacity Control

Dual Chiller Status

Unit Testing and Configuration

Test Function Procedures

History Function Access

Set Point Configuration

How to enter and adjust various unit set points.

SERVICE FUNCTION

Configuration Management

Calibration and Manual Control

Dual Chiller and System Configuration

Scheduling and Set Point Control

Schedule Function Operation

Dual Set Point Control

Temperature Reset and Demand Limit

Temperature Reset Logic

Demand Limit Functionality

How demand limit reduces unit capacity during peak energy usage.

TROUBLESHOOTING GUIDANCE

Troubleshooting Overview and Unit Shutdown

Unit Stoppage and Restart Procedures

Lists causes of unit stoppages and procedures for restarting.

Alarms, Alerts, and Compressor Circuits

EXD Troubleshooting

EXV Operation and Wiring Checks

Component Inspection Procedures

Electronic Expansion Valve (EXV) Inspection

Economizer Inspection

Service Procedures

Cooler and Condenser Servicing

Tube Plugging and Retubing

Head Bolt Torque Specifications

Heat Exchanger Maintenance

Cooler Tube Inspection and Cleaning

Condenser Tube Inspection and Cleaning

Water Treatment Recommendations

Refrigerant Management

Condenser Fan Checks

Low Refrigerant Charge Detection

Methods for identifying low refrigerant charge in 30HXC and 30HXA/GX systems.

Adding Refrigerant Charge

Refrigerant and Oil Management

Low Charge Identification (30HXA/GX)

Oil Charging and Low Oil Alarms

Procedure for adding oil and addressing low oil level alarms.

Oil Filter Maintenance and Compressor Replacement

Oil Filter Maintenance Procedures

Compressor Changeout Sequence

Detailed steps for replacing a compressor, including wiring and handling.

System Monitoring and Troubleshooting

Moisture-Liquid Indicator and Filter Drier

Thermistor Checks and Replacement

How to check thermistor performance and replace faulty units.

Pressure Transducer Calibration

How to calibrate pressure transducers using the HSIO software.

Pressure Transducer Calibration and Troubleshooting

Pressure Transducer Calibration Procedure

Transducer Troubleshooting

Safety Devices and Protection

Compressor Protection Mechanisms

Oil Separator Heaters and Cooler Protection

Pressure Relief Valves

Control Module Operations

Processor Module (PSIO-1) and Related Modules

Replacing the Processor Module

Winter Shutdown Preparation

Carrier Comfort Network (CCN) Interface

Compressor Control Troubleshooting

Compressor Not Running Troubleshooting

Compressor Cycling and Shutdown Troubleshooting

Unit Operation and System Noise Issues

Compressor Oil Loss and Loader Issues

Pre-Start-Up and Start-Up Procedures

Pre-Start-Up Checklist and System Checks

Start-Up and Operating Sequence

How to perform the actual start-up and understand the operating sequence.

FIELD WIRING DIAGRAMS

Power Supply and Alarm Relay Wiring

APPENDIX A - Compressor Must Trip Amps

Compressor Must Trip Amps Data

APPENDIX B - Capacity Loading Sequence

Loading Sequence Examples

APPENDIX C - Available Accessories

Accessory Part Numbers and Descriptions

APPENDIX D - Compressor Protection Module Configuration

CPM Configuration Header Punch-Outs

APPENDIX E - Pressure Drop Charts

30HX Cooler Pressure Drop Data

APPENDIX E - Pressure Drop Charts (cont)

30HX Condenser Pressure Drop Data

30GX Cooler Pressure Drop Data

APPENDIX F - System Component Diagrams

30GX System Components with Economizer

APPENDIX F - System Component Diagrams (cont)

30HX System Components Without Economizer

START-UP CHECKLIST

Preliminary Information Gathering

Preliminary Equipment Checks

Shipping Damage and Installation Verification

System Component Verification

Unit Start-Up Procedures

Valve, Pump, and Leak Checks

Voltage and Current Checks

Cooler Water Loop Verification

System Loop Pressure Drop Checks

Cooler Pressure Drop Verification

Condenser Water Loop and Pressure Drop

PERFORM TEST FUNCTION

Test Function Overview and Alarms

Component Test Execution

Set Point and Schedule Verification

Configuration and Start-Up Data Recording

Reviewing Configuration and Software Versions

Field Configuration Review

Final Start-Up Steps

Performing final valve/pump checks, starting the unit, and recording temperatures/pressures.