General - Carrier ComfortLink 6 Series Controls, Start-Up, Operation, Service, And Troubleshooting

CONTENTS (cont)
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 11

• GENERAL

• AIR-COOLED UNITS (30GXN,R)
• WATER-COOLED UNITS (30HXC)
• CONDENSERLESS UNITS (30HXA)
• 09DK AIR-COOLED CONDENSERS
• 09AZ AIR-COOLED CONDENSERS
• OPERATION SEQUENCE
• VARIABLE SPEED FAN CONTROL
• ADJUSTING PID ROUTINES
Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• SWITCH
• 7-DAY SCHEDULE
• OCCUPANCY
• CCN
Cooling Setpoint Select . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cooler and Condenser (30HXC)
Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• COOLER PUMP CONTROL
• CONDENSER PUMP CONTROL
Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cooler Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Navigator Display Module Usage . . . . . . . . . . . . . . . . 18
Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Configuring and Operating Dual Chiller
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Alarms/Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Run Hours and Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• DEMAND LIMIT (2-Stage Switch Controlled)
• EXTERNALLY POWERED DEMAND LIMIT
• DEMAND LIMIT (CCN Loadshed Controlled)
Cooling Set Point (4 to 20 mA). . . . . . . . . . . . . . . . . . . 39
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 41-51
Checking Display Codes . . . . . . . . . . . . . . . . . . . . . . . . 41
Unit Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Complete Unit Stoppage . . . . . . . . . . . . . . . . . . . . . . . . 41
Single Circuit Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . 41
Restart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
• POWER FAILURE EXTERNAL TO THE UNIT
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Compressor Alarm/Alert Circuit . . . . . . . . . . . . . . . . . 42
EXV Troubleshooting Procedure. . . . . . . . . . . . . . . . . 50
• INSPECTING/OPENING ELECTRONIC
EXPANSION VALVES
• BRAZED-PLATE ECONOMIZERS
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-71
Servicing Coolers and Condensers. . . . . . . . . . . . . . 52
• TUBE PLUGGING
• RETUBING
• TIGHTENING COOLER/CONDENSER HEAD BOLTS
Inspecting/Cleaning Heat Exchangers . . . . . . . . . . . 52
• COOLERS
• CONDENSERS (30HX Only)
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Condenser Coils (30GXN,R Only). . . . . . . . . . . . . . . . 53
• COIL CLEANING
• CLEANING E-COATED COILS
Condenser Fans (30GXN,R Only) . . . . . . . . . . . . . . . . 54
Refrigerant Charging/Adding Charge . . . . . . . . . . . . 55
Oil Charging/Low Oil Recharging . . . . . . . . . . . . . . . . 56
Oil Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
• REPLACING THE EXTERNAL OIL FILTER
• REPLACING THE INTERNAL OIL FILTER
Compressor Changeout Sequence . . . . . . . . . . . . . . 57
• BURNOUT CLEAN-UP PROCEDURE
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Moisture-Liquid Indicator. . . . . . . . . . . . . . . . . . . . . . . . 59
Filter Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Liquid Line Service Valve. . . . . . . . . . . . . . . . . . . . . . . . 59
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
• LOCATION
• THERMISTOR REPLACEMENT
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• TROUBLESHOOTING
• FLOW SENSOR
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• COMPRESSOR PROTECTION
• OIL SEPARATOR HEATERS (30GX)
• COOLER PROTECTION
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• PRESSURE RELIEF VALVES
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• MAIN BASE BOARD (MBB), SCREW COMPRESSOR
BOARD (SCB), EXPANSION VALVE BOARD (EXV),
ENERGY MANAGEMENT MODULE (EMM),
COMFORTLINK™ COMPRESSOR PROTECTION
BOARD (CCP), AND THE NAVIGATOR
• RED LED
• GREEN LED
• YELLOW LED
Carrier Comfort Network (CCN) Interface . . . . . . . . 69
Replacing Defective Processor Module. . . . . . . . . . 69
Winter Shutdown Preparation . . . . . . . . . . . . . . . . . . . 70
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
PRE-START-UP PROCEDURE. . . . . . . . . . . . . . . . . . . . 71
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
START-UP AND OPERATION. . . . . . . . . . . . . . . . . . 71,72
Actual Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Operating Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
FIELD WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-74
APPENDIX A
(Compressor Must Trip Amps) . . . . . . . . . . . . . 75-84
APPENDIX B
(Capacity Loading Sequence) . . . . . . . . . . . . . . 85-89
APPENDIX C (Available Accessories). . . . . . . . . 90,91
APPENDIX D (Building Interface) . . . . . . . . . . . . . 92-94
APPENDIX E (Cooler and
Condenser Pressure Drop) . . . . . . . . . . . . . . . . 95-100
APPENDIX F
(Typical System Components) . . . . . . . . . . . 101-112
APPENDIX G (CCN Configuration). . . . . . . . . . 113-125
APPENDIX H (30GXN,R Duplex Combinations) . . 126
APPENDIX I (Motormaster® V
Operation Instructions) . . . . . . . . . . . . . . . . . . 127-129
APPENDIX J (Maintenance Log) . . . . . . . . . . . . . . . . 130
START-UP CHECKLIST (For 30GX,HX
Liquid Chiller) . . . . . . . . . . . . . . . . . . . . . . .CL-1 to CL-10
IMPORTANT: These units use refrigerant R-134a.
Compressor oil used with R-134a is Castrol Icematic
SW-220, Carrier Specification #PP47-32.
This publication contains Controls Start-Up, Service, Oper-
ation and Troubleshooting data for the 30GXN,R080-528 and
30HXA,C076-271 screw chillers.
Circuits are identified as circuits A and B, and compressors
are identified as A1 or A2 in circuit A, and B1 or B2 in
circuit B. Refer to Appendix H for Duplex unit combinations.
The 30GXN,GXR,HX Series chillers feature microproces-
sor-based electronic controls and electronic expansion valves
(EXV) in each refrigeration circuit.
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GENERAL
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