Carrier PRO-DIALOG Plus 30GK Series Installation, Operation & Maintenance Instructions Manual

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30GK Series
Air-Cooled Liquid Chillers
50 Hz
Installation, operation and maintenance instructions


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   Summary of Contents for Carrier PRO-DIALOG Plus 30GK Series

  • Page 1

    30GK Series PRO-DIALOG Control Air-Cooled Liquid Chillers 50 Hz Installation, operation and maintenance instructions...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1 - SAFETY CONSIDERATIONS ..............................4 1.1 - General ....................................4 1.2 - Avoiding electrocution ................................. 4 2 - GENERAL DESCRIPTION ..............................5 2.1 - General ....................................5 2.2 - Abbreviations used ................................5 3 - HARDWARE DESCRIPTION ..............................6 3.1 - General ....................................

  • Page 3: Table Of Contents

    5 - PRO-DIALOG PLUS CONTROL OPERATION ......................... 27 5.1 - Start/stop control ................................27 5.2 - Heating/cooling selection ..............................27 5.3 - Evaporator water pump control ............................28 5.4 - Condenser water pump control ............................28 5.5 - Control interlock contact ..............................28 5.6 - Evaporator heater control ..............................

  • Page 4: Safety Considerations, General, Avoiding Electrocution

    1 - SAFETY CONSIDERATIONS IMPORTANT: Risk of electrocution: Even when the main power isolator or 1.1 - General circuit breaker is off, it is still possible for certain compo- nents such as crankcase heaters and trace heaters to be Installation, start-up and servicing of equipment can be hazard- energised, since they are connected to a separate power source.

  • Page 5: General Description, General, Abbreviations Used

    (volt-free contacts, analogue signals). • CCN mode: the machine is controlled by commands from the Carrier Comfort Network (CCN). In this case a data communication cable is used to connect the unit to the CCN communication bus. The operating mode must be chosen with the Operating Type selection button described in section 4.2.1.

  • Page 6: Hardware Description, General, Electronic Boards, The Basic Board, Slave Boards

    SIO bus. It can also communicate with elements of the Carrier Comfort Network via the CCN bus. Legend CCN connector...

  • Page 7: The User Interface, Connections Between Boards, Slave Board Addresses, Power Supply To The Boards

    3.2.7 - Light emitting diodes on boards 3.2.3 - The user interface All boards continuously check and indicate the proper The user interface is in two parts: operation of their electronic circuits. A light emitting diode • The main interface: This gives access to all of the (LED) lights on each board when it is operating properly.

  • Page 8: The Evaporator Pumps, The Condenser Pump, Pressure Sensors, Thermistors

    The sensor is not They are located in the low-pressure side of the unit on the lead supplied by Carrier, and must be configured by the User Menu. compressor of each circuit. The suction pressure sensor reading is used to control the electronic expansion devices EXV.

  • Page 9: User Connections

    3.4 - User connections The connections below are available at the customer’s terminal block. Some of them can only be used in special operating modes. For further details see the sections that describe the functions (section 5) and the configurations (section 4.2.1). NOTE: The bridge between terminals 32, 63 and 65 on the customer’s terminal block must not be removed.

  • Page 10: Setting Up Pro-dialog Plus Control, Local Interface General Features


  • Page 11: Unit Start/stop Control, Description, Stopping The Unit In Local Mode

    The summary interface (right hand section) includes a mimic The following operating types can be selected using the diagram of the unit, together with push-buttons and LEDs. It Start/Stop button: gives quick access to the main operating parameters of the unit. OPERATING TYPES SUMMARY INTERFACE LEDS 4-DIGIT DISPLAY DESCRIPTION...

  • Page 12: Menus, Selecting A Menu, Selecting A Menu Item

    4.3 - Menus NOTE: The access to a sub-menu may require entering a password. This is automatically requested. See section 4.3.1 - Selecting a menu The MENU button authorises you to select a menu from the 10 The example below shows how to modify the value of item 1 main menus that are available.

  • Page 13: General Menu Structure

    4.4 - General menu structure...

  • Page 14: Menu Tree Structure

    4.5 - Menu tree structure MENU...

  • Page 15: Description Of The Information Menu

    4.5.1 - Description of the Information menu INFORMATION MENU [3] ITEM FORMAT UNITS DESCRIPTION Automatic display mode. It cycles through the following displays: ±nn.n °C Controlled water temperature: temperature of the water that the unit tries to maintain at the control point. Unit operating type LOFF Local Off...

  • Page 16: Description Of The Temperatures Menu, Description Of The Pressures Menu

    DESCRIPTION OF OPERATING MODES (ITEM 1 OF THE INFORMATION MENU) MODE # MODE NAME DESCRIPTION Delay at start-up active The delay at start-up operates after the unit has been switched on. If the delay has not expired, the mode is active. The delay is configured in the User1 configuration menu.

  • Page 17: Description Of The Setpoints Menu

    4.5.4 - Description of the Setpoints menu SETPOINTS MENU [2] ITEM FORMAT UNITS RANGE COMMENTS ±nn.n °C See table below This item lets you display and modify Cooling setpoint 1* ±nn.n °C See table below This item lets you display and modify Cooling setpoint 2* °C See table below This item lets you display and modify Heating setpoint*, only displayed for heat pumps.

  • Page 18: Description Of The Inputs Menu, Description Of The Outputs/tests Menu

    4.5.5 - Description of the Inputs menu INPUTS MENU [2] ITEM FORMAT UNITS COMMENTS OPEn/CLoS Remote contact 1 status This contact is used to start (contact closed) and stop (contact open) the chiller. It is only valid, if the unit is in the remote operating control (rEM) mode.

  • Page 19

    OUTPUTS STATUS 2 AND TESTS MENU [2] [3] - cont. ITEM FORMAT UNITS DESCRIPTION 4 [1] tESt Fan contactor status/test, circuit B b1 = fan contactor assembly 1 b2 = fan contactor assembly 2 b3 = fan contactor assembly 3 b4 = fan contactor assembly 4 This item permits display of the fan stages.

  • Page 20: Description Of The Configuration Menu - Manual tests The menus User 1 [USEr 1] and User 2 [USEr 2] are pass- This function allows the user to test the outputs individually, if word-protected. The other menus are directly accessible, except the machine is completely shut down (LOFF). To carry out a if item 12 of the User 1 menu (password for all configurations) manual test use the arrow keys to access the output to be tested has been validated.

  • Page 21: User Interface


  • Page 22 - Description of the User 1 Configuration sub-menu USER 1 CONFIGURATION SUB-MENU [2] ITEM FORMAT UNITS DEFAULT COMMENTS USEr MEnu When selected this item authorises return to the previous menu. 1 [1] 0/1/2 Lead circuit selection 0 = automatic based on the number of start-ups and the operating hours of each circuit 1 = lead circuit A 2 = lead circuit B 2 [1]...

  • Page 23 - Description of the User 2 Configuration sub-menu USER 1 CONFIGURATION SUB-MENU ITEM FORMAT UNITS DEFAULT COMMENTS USEr 2 Menu When selected this item authorises return to the previous menu. 1[1] YES/no Periodic pump quick-start of the water pump(s) Yes = the pump is started periodically when the unit is manually stopped.

  • Page 24

    PERIOD X CONFIGURATION SUB-MENUS (X = 1 to 8) - Description of the Holidays sub-menus ITEM # FORMAT COMMENTS This function is used to define 16 public holiday periods. Each Period X Menu Indicates the period (X) you are going to period is defined with the aid of three parameters: the month, configure.

  • Page 25: Description Of The Alarms Menu, Description Of The Alarms History Menu

    BROADCAST CONFIGURATION SUB-MENU ITEM # FORMAT COMMENTS broAdCASt MEnu When selected this item authorises a return to the main menu. YES/no Determines whether or not the unit is a broadcast acknowledger when the unit is connected on a CCN network. There must be only one broadcast acknowledger in a CCN.

  • Page 26: Runtime Menu Description

    4.5.10 - Runtime menu description - Description of the Runtimes 2 menu RUNTIMES MENU [2] RUNTIMES iTEM # FORMAT UNIT COMMENTS When selected this item authorises return to the previous menu RUNTIMES 1 RUNTIMES 2 MAINTENANCE [runtiMES 1] [runtiMES 2] [MAintEnAnCE] nnnn | M 10 | M100 hrs/10 or 100...

  • Page 27: Pro-dialog Plus Control Operation, Start/stop Control, Heating/cooling Selection

    5 - PRO-DIALOG PLUS CONTROL OPERATION Start/Stop schedule: occupied or unoccupied status of the unit as determined by the chiller start/stop program 5.1 - Start/stop control (Schedule #1). Used when the unit is equipped with an optional CCN/clock board, otherwise the chiller occupied The table below summarises the unit control type and stop or mode is forced to occupied all the time.

  • Page 28: Evaporator Water Pump Control, Condenser Water Pump Control, Control Interlock Contact, Evaporator Heater Control

    The condenser pump can be controlled by two modes, depend- Plus control system, the source of the reset can be configured ing on the configuration (only accessible by Carrier Service). in the User 1 configuration: it can be based on an external 0-10 V 1 - Control based on unit start/stop control.

  • Page 29: Demand Limit, Capacity Control, Determining The Lead Circuit, Circuit Loading Sequence

    5.8 - Demand limit NOTE: If the same compressor undergoes too many starts (per hour) this automatically brings about reduction of Generally, demand limit is used by an energy management compressor starts, which makes leaving water temperature system in order to restrict the unit electricity consumption. control less precise.

  • Page 30: Slave Compressor Start-up Sequence, Controlling The Exv, Head Pressure Control On Air-cooled Units

    5.14 - Head pressure control on air-cooled units as a function of the control typpes (local, remote or network), and the parameters below: There are two methods, configurable only by Carrier Service, • Local setpoint selection: item No. 11 of the Information...

  • Page 31: High Pressure Load Shedding Function, Pumping Down, Master/slave Assembly

    LOCAL OPERATING MODE PARAMETER STATUS All control commands to the master/slave assembly (start/stop, HEATING/ LOCAL SCHEDULE 2 ACTIVE SETPOINT setpoint, heating/cooling operation, load shedding, etc.) are COOLING SETPOINT PROGRAM STATUS handled by the unit which is configured as the master, and must OPERATING SELECTION MODE...

  • Page 32: Optional Heat Reclaim Module, Diagnostics - Troubleshooting, General, Displaying Alarms, Resetting Alarms

    5.21 - Optional heat reclaim module 6 - DIAGNOSTICS - TROUBLESHOOTING Change-over procedure from cooling mode to heat reclaim 6.1 - General mode: • Start-up of the condenser pump The PRO-DIALOG Plus control system has many fault tracing • Verification of the condenser flow switch control contact. aid functions.

  • Page 33: Alarm Codes

    6.4 - Alarm codes The following list gives a complete description of each alarm code and its possible cause. ALARM CODE DESCRIPTIONS Code Alarm name Description Action Pumpdown Reset type Probable cause Evaporator leaving water thermistor fault Thermistor outside range Unit shut down Auto Thermistor or wiring fault or...

  • Page 34

    ALARM CODE DESCRIPTIONS Code Alarm name Description Action Pumpdown Reset type Probable cause Low suction overheat, circuit B Circuit B shut down Manual Ditto Low oil pressure, compressor A1 Oil pressure < min. threshold Circuit A shut down Manual Compressor, crankcase heater, pressure sensor or EXV faulty, refrigerant charge too high, low oil...

  • Page 35: Compressor Faults

    This board patented by Carrier (also called AM board) monitors both the compressor regime and the status of its crankcase heaters which ensure correct lubrication when the - Compressor protection devices...

  • Page 36

    Order No. 13040-76, 05.2000. Supersedes order No.: New Manufactured by: Carrier S.A., Montluel, France. Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands on totally chlorine-free paper.

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  • Haris Dec 08, 2015 08:31:
    Net weight of carrier 30gk-100-0​304-NÉE.. Chiller
  • Anand May 24, 2014 03:30:
    Carrier aircooled chiller 300tr loss of communicat​ion compressor board b .solve the problem