Carrier Ecologic 30GX080-265 Controls, Start-Up, Operation, Service, And Troubleshooting
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Carrier Ecologic 30GX080-265 Controls, Start-Up, Operation, Service, And Troubleshooting

Carrier Ecologic 30GX080-265 Controls, Start-Up, Operation, Service, And Troubleshooting

Ecologic air-cooled and fluid cooled chillers
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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.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Tab
5c
ECOLOGIC™ Air-Cooled and Fluid Cooled Chillers
Catalog No. 533-062
Printed in U.S.A.
30HXA,HXC076-271
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
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . . . 3
Processor Module (PSIO-1) . . . . . . . . . . . . . . . . . . . 3
DSIO-HV Relay Module . . . . . . . . . . . . . . . . . . . . . . . 3
PSIO-2 (8052) Module . . . . . . . . . . . . . . . . . . . . . . . . 3
(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
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• MINUTES LEFT FOR START
• LOADING SEQUENCE
• CAPACITY CONTROL OVERRIDES
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . 8
• GENERAL
• AIR COOLED UNITS (30GX)
• WATER COOLED UNITS (30HX)
Cooler and Condenser (30HXC)
Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Form 30G,H-3T
Pg 1
30GX080-265
50/60 Hz
Series 0,1,2
Page
1-98
Replaces: 30G,H-2T

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Summary of Contents for Carrier Ecologic 30GX080-265

  • Page 1: Table Of Contents

    30GX080-265 30HXA,HXC076-271 ECOLOGIC™ Air-Cooled and Fluid Cooled Chillers 50/60 Hz Series 0,1,2 Controls, Start-Up, Operation, Service, and Troubleshooting SAFETY CONSIDERATIONS Installing, starting up, and servicing this equipment can DO NOT attempt to unbraze factory joints when ser- be hazardous due to system pressures, electrical compo- vicing this equipment.

  • Page 2: General

    • GREEN LED • ACCESSING FUNCTIONS Carrier Comfort Network (CCN) Interface ..64 AND SUBFUNCTIONS..... . . 13 •...

  • Page 3: Major System Components

    3-wire communications bus, but uses a different commu- control if it is in an ON mode. nication bus called COMM1. The COMM1 bus is also used to communicate to other CCN (Carrier Comfort Network) devices when the unit is installed in a network application. OPERATION DATA DSIO-HV Relay Module —...

  • Page 4: Oil Pumps

    ECONOMIZER OPERATION — Economizers are factory Back Pressure Valve (30GX and 30HXA only) installed on 30GX105-265 units and 30HXA,C161-271 units. — This valve is located on the oil separator outlet on 30GX All other sizes use standard EXVs. The economizer im- units and mounted on the oil separator shell of 30HXA units.

  • Page 5: Wye-Delta Vs Across-The-Line (Xl) Starting Option

    Table 2 — Thermistor and Transducer Locations THERMISTORS Sensor Description Location Connection Terminals Cooler Leaving Fluid Temp Cooler Head Leaving Fluid Side PSIO-2, J7 pins 2,3 Cooler Entering Fluid Temp Cooler Head Entering Fluid Side PSIO-2, J7 pins 5,6 Motor Temp A1 Motor Temperature A1 Compressor A1 Junction Box CPM-A1, T terminals...

  • Page 6: Capacity Control

    COMPRESSOR PROTECTION MODULE (CPM) PUSH THIS SIDE OF SWITCH DOWN TO SET ADDRESS 24/115/230 VAC INPUTS/OUTPUTS ROCKER DOWN CURRENT TOROID INPUT PLUG COMM3 LED — Light-Emitting Diode ADDRESS DIP NOTES: SWITCH RED LED 1. The red LED blinks continuously when the module is operating properly.

  • Page 7: Close Control

    COMPRESSOR JUNCTION BOX TERMINAL BLOCK COMPRESSOR CONTACTOR JUMPER BARS Fig. 2 — Across-the-Line (XL) Compressor Wiring COMPRESSOR JUNCTION BOX COMPRESSOR STARTER ASSEMBLY TERMINAL BLOCK Fig. 3 — Wye-Delta Compressor Wiring CLOSE CONTROL ( ) — When configured for Close MINIMUM LOAD VALVE ( ) —...

  • Page 8: Head Pressure Control

    2 STARTS DEADBAND EXAMPLE 1000 3 STARTS TIME (SECONDS) STANDARD DEADBAND LEGEND MODIFIED LWT — Leaving Water DEADBAND Temperature Fig. 4 — Deadband Multiplier Slow Change Override — The control prevents the capacity water (brine) circuits, if the Saturated Suction temperature falls below 34 F (1.1 C) (the Brine Freeze Point), the unit stages from being changed when the leaving fluid tempera- capacity will not increase.
  • Page 9 Motormaster III option enabled, the PSIO-1 module cal- tion. Checkout and adjustment of the PID loop should culates the required output based on Saturated Condensing only be performed by certified Carrier Comfort Network temperature, Head Pressure set point, and a PID (propor- technicians.

  • Page 10: Adjusting Pid Routines

    30GX080-105 30GX106-125 30GX136, 150, 160 CONTROL CONTROL CONTROL 30GX151, 161, 175, 205, 225 30GX176 CONTROL CONTROL 30GX206, 226, 250 30GX251, 265 CONTROL CONTROL Fig. 5 — 30GX Condenser Fan Locations ADJUSTING PID ROUTINES — The 30GX and 30HXC COOLER PUMP CONTROL ( ) —...
  • Page 11 Table 6 — 30GX080-265 Condenser Fan Staging (PSIO-1 Controlled) 30GX UNIT SIZE FAN TYPE FAN CONTACTOR FANS CONTROLLED FAN RELAY NO.* FC-1 1, 2 Standard FC-2 3, 4 080-105 FC-1, 1A 1, 2 High Static FC-2, 2A 3, 4 FC-1 1, 2 Standard FC-2...

  • Page 12: Condenser Pump Control

    30GX UNITS — MOTORMASTER III CONTROL NOT INSTALLED HAS SCT BEEN 35° F IS SCT GREATER READ CIRCUIT LESS THAN HEAD THAN HEAD SATURATED PRESSURE SET POINT PRESSURE CONDENSING 2 MINUTES? SET POINT? TEMPERATURE AND CURRENT FAN STAGE INCREASE DECREASE CURRENT FAN CURRENT FAN STAGE BY ONE...

  • Page 13: Cooler Heater Control

    Leaving Fluid Temp Cooler Heater Control — Accessory cooler heaters xx.x° F can be ordered for the 30GX chillers. If installed and en- abled, these heaters are turned on only when the machine is Percent Total Capacity in the off state and the chiller is in a saturated suction tem- xxx.x% perature freeze condition.
  • Page 14 Table 8A — HSIO Functions and Subfunctions FUNCTIONS SUBFUNCTION Status Test Schedule Service History Set Point Alarm Circuit A Ice Build Factory Operating Hours Set Points Display Discrete Outputs Occupancy Configuration Schedule General Parameters Circuit B Local/Normal Options Alarm History English/Metric Display Discrete Outputs...
  • Page 15 Table 8B — Functions and Subfunctions Cross-Reference for the Optional LID-2B Controller The optional LID-2B controller cross reference table be- reference table lists the menu item from the LID-2B which low can be used as a guide to access the same information contains the alarm history information.

  • Page 16: Status Function

    Table 9 — Accessing Functions and Subfunctions OPERATION KEYPAD ENTRY DISPLAY RESPONSE To access a function, press Circuit A Discrete Outputs subfunction no. and function name key. Display shows sub- Loader A1 function group. Relay is OFF To move to other elements, Loader A2 scroll up or down using arrow keys.
  • Page 17 Unit Analog Parameters and Temperature Reset — Press To enter the MODES subfunction, press and use and scroll down to display the unit entering and leav- key to view all current modes of operation. See ing fluid temperatures as well as the temperature reset signal Table 13.
  • Page 18 Table 10 — Status Function and Subfunction Directory SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 Alarms Alarm : xx Reset Alarms: 1 <ENTER> All current alarms are displayed as needed 2 General Parameters GENERAL PARAMETERS Displays LOCAL ON/OFF or CCN ON/OFF Control Mode Run Status Off/On...
  • Page 19 Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 3 Circuit A Analog Valves (cont) SAT Condensing Temp xxx.x dF Saturated Suction Temp xxx.x dF EXV Percent Open xxx.x% Motormaster Speed xxx.x% Water Valve Position xxx.x% Cooler Level Indicator x.xx...
  • Page 20 Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 5 Circut B Analog Valves (cont) B1 Motor Temperature xxx.x dF B2 Motor Temperature xxx.x dF SAT Condensing Temp xxx.x dF Saturated Suction Temp xxx.x dF EXV Percent Open xxx.x% Motormaster Speed...
  • Page 21 Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 7 Unit Analog Parameters (cont) TEMPERATURE RESET 4-20 mA Reset Signal xx.x mA Return Reset Signal xx.x dF External Reset Signal xx.x dF Outdoor Air Temp xx.x dF Calculated Reset xx.x dF...
  • Page 22 Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 9 Operating Modes (cont) CLOCK OFF LOCAL ON CCN ON CLOCK ON DUAL SP ACTIVE (1st SP) DUAL SP ACTIVE (2nd SP) TEMPERATURE RESET ACTIVE DEMAND LIMIT ACTIVE LOAD LIMIT ACTIVE LOW SOURCE TEMP PROTECT RAMP LOADING ACTIVE...
  • Page 23 3 = Chiller in Local Mode 4 = Slave Shutdown on Alarm(s) 5 = Master Configured for Heating 6 = No Slave Configured LEGEND CCN — Carrier Comfort Network CPM — Compressor Protection Module — Degrees Fahrenheit — Electronic Expansion Valve — Flotronic™ System Manager —...
  • Page 24 Override can be implemented with HIGH SCT unit under LOCAL/REMOTE or CCN control. LEGEND Override expires after each use. — Carrier Comfort Network Water System Manager is controlling the — Cooling Set Point CONTROLLING chiller. CRAMP — Cooling Ramp Loading SLOW CHANGE Slow change override is in effect.

  • Page 25: Test Function

    TEST FUNCTION — The test function operates the diag- SET POINT FUNCTION — Set points are entered through nostic program. To initiate the test function, the LOCAL/ the keypad. Set points can be changed within the upper and OFF/REMOTE switch must be in the OFF position. lower limits, which are fixed.
  • Page 26 Table 14 —Test Function and Subfunction Directory SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 Circuit A Discrete Output Circuit A Discrete Output Loader A1 Relay is OFF Loader A1 Relay is ON Loader A2 Similarly, use to test remaining outputs. Press the down arrow key or to turn an output off.
  • Page 27 Table 14 —Test Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 3 Unit Discrete Output (cont) Remote Alarm 2 Currently not supported. Remote Alarm 3 Currently not supported. Remote Alarm 4 Currently not supported. Remote Alarm 5 Currently not supported. Remote Alarm 6 Currently not supported.
  • Page 28 Table 16 — History Function and Subfunction Directory SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 Operating Hours Machine Operating Hours Number of hours unit has at least xxx.x hours 1 compressor running Machine Starts Number of unit starts from zero capacity Circuit A Operating Hours These values may be changed once, when new software is down-...
  • Page 29 5 CCN Disable Disable CCN Control 0=no, 1=yes Default: 0 LEGEND CCN — Carrier Comfort Network LCW — Leaving Chilled Water NOTE: If metric option is selected under , temperatures are expressed in degrees Celsius and pressures are expressed in kPa.

  • Page 30: Service Function

    Table 18 — Reading and Changing Chilled Fluid Set Point Transducer Calibration — Press and scroll down to view the transducer calibration information. See Table 19 KEYPAD ENTRY DISPLAY RESPONSE COMMENTS for a complete list, and the Pressure Transducers section on COOLING Change set point from page 59 for a description of this subfunction.
  • Page 31 Table 19 — Service Function and Subfunction Directory SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 Service Configuration Software CESR_500100 Ver Unit Type 1 = Air-cooled, 2 = Water-cooled 3 = Split system Number of Cir A Comp Compressor A1 Tonnage Compressor A2 Tonnage Oil Switch Configuration Number of Cir B Comp Compressor B1 Tonnage...
  • Page 32 Table 19 — Service Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 3 Options Configuration 2 (cont) Ramp Load Select 0 = Disabled, 1 = Enabled (Default) See page 8 Clock Control Select 0 = No clock control (Default) 1 = Local clock control 65 = CCN Clock Control Ice Configuration Select...
  • Page 33 Table 19 — Service Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 4 Reset Configuration Table (cont) Demand Limit Select 0 = None (Default), 1 = Two step switch, 2 = 4-20 mA, 3 = CCN Loadshed Loadshed Group Number 0-99, Default: 0 Loadshed Demand Delta 0-60%,Default: 0...
  • Page 34 1 = Enabled Lead/Lag Balance Delta Default = 168 xxx hours Adjustable from 40-400 LEGEND CCN — Carrier Comfort Network CHW — Chilled Water CPM — Compressor Protection Module HSIO — Standard Keypad HTW — Hot Water — Local/Off/Remote MOP — Maximum Operating Pressure —...
  • Page 35 Table 20 — Displaying Current Software Version KEYPAD FUNCTION DISPLAY COMMENT ENTRY Carrier Software Part Software Software CESR_500100 Ver Number, where XXX is Version the revision number. Table 21 — Compressor Lead/Lag Configuration SUB-FUNCTION KEYPAD DISPLAY ENTRY Options Cooler Fluid Select Configuration 1...
  • Page 36 Table 22 — Factory and Service Configuration Code Values UNIT MODEL NUMBER CONF. CODE 1* CONF. CODE 2 CONF. CODE 3 CONF. CODE 4 CONF. CODE 5 30GX080 11460010 13900000 00000170 15400521 12000093 30GX090,105 11560010 13900000 00000180 15400521 12000093 30GX106 11560010 13900000 00000180...

  • Page 37: Schedule Function

    Table 23 — Entering Configuration Codes KEYPAD ENTRY DISPLAY RESPONSE FACTORY CODES Configuration Code 1 00000000 Configuration Code 1 21660010 Configuration Code 2 00000000 Configuration Code 2 13900000 Configuration Code 3 00000000 Configuration Code 3 00000200 SERVICE CODES Configuration Code 4 00000000 Configuration Code 4 12200521...
  • Page 38 Table 24 — Schedule Function and Subfunction Directory SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT 1 Ice Build Schedule* SCHEDULES: OCCPC01S Extended Occupied Time Timed Override: 00 SCHEDULES: OCCPC01S Two hour override entered Timed Override: 02 MTWTFSSH OCC UNOCC Displays current stored schedule 01- 00000000 00:00 00:00 (First 2 numbers are schedule, 01-08) MTWTFSSH OCC UNOCC...

  • Page 39: Temperature Reset

    RETURN FLUID TEMPERATURE RESET — In this ex- Temperature Reset — The control system is capable ample, the unit set point is reset from full load based on the of providing leaving fluid temperature reset based on return chilled fluid return temperature. The example uses a reset fluid temperature.
  • Page 40 6.7 (12) RESET AMOUNT 5.5 (10) 4.4 (8) 3.3 (6) 2.2 (4) 1.1 (2) BUILDING LOAD 0.0 (0) -18 (0) -12 (10) -7 (20) -1 (30) 4 (40) 10 (50) 16 (60) 21 (70) 27 (80) 32 (90) 38(100) RESET REFERENCE TEMPERATURE-OUTDOOR AIR OR SPACE TEMPERATURE THERMISTOR C (F) Fig.
  • Page 41 Table 26 — Setting External Temperature Reset Table 27 — Setting Externally Powered Reset KEYPAD DISPLAY KEYPAD DISPLAY COMMENTS COMMENTS ENTRY RESPONSE ENTRY RESPONSE COOLING RESET TYPE Cooler Fluid Select Min. Load Valve Select Degrees Reset at 20 mA Disable 0.0 dF Loading Sequence Select Degrees Reset at 20 mA...

  • Page 42: Externally Powered Demand Limit

    Table 30 — Setting Demand Limit EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled) — In this example, the 4 to 20 mA Demand Limit (4 to 20 mA Controlled; 2 to 10 vdc With 500-Ohm Resistor) will be configured and the 20 mA demand limit percentage will be set to 50%.

  • Page 43: Troubleshooting

    TROUBLESHOOTING The 30GX,HX screw chiller control has many features to If a stoppage occurs more than once as a result of any aid in troubleshooting. By using the keypad and display mod- of the preceding safety devices, determine and correct ule and the Status function, operating conditions of the chiller the cause before attempting another restart.
  • Page 44 Table 33 — Alarm and Alert Codes ALARM/ALERT ALARM OR WHY WAS THIS ACTION TAKEN RESET PROBABLE DESCRIPTION CODE ALERT ALARM GENERATED? BY CONTROL METHOD CAUSE — No Alarms or Alerts — — — — Exist 1.xx See CPM subcodes Compressor A1 Failure See CPM subcodes See CPM subcodes...
  • Page 45 Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT ALARM OR WHY WAS THIS ACTION TAKEN RESET PROBABLE DESCRIPTION CODE ALERT ALARM GENERATED? BY CONTROL METHOD CAUSE CPM SUBCODES (xx) x.85 Alarm Motor Over Temperature CPM detects high motor Comp. shut down Manual/Button Motor cooling (all) or temperature...
  • Page 46 Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT ALARM OR WHY WAS THIS ACTION TAKEN RESET PROBABLE DESCRIPTION CODE ALERT ALARM GENERATED? BY CONTROL METHOD CAUSE Alert Comp B1 Oil Pressure Calibration offset more Comp B1 shut down Automatic Transducer failure, Transducer Failure than 6 PSIG or Voltage...
  • Page 47 Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT ALARM OR WHY WAS THIS ACTION TAKEN RESET PROBABLE DESCRIPTION CODE ALERT ALARM GENERATED? BY CONTROL METHOD CAUSE Alarm Circuit B Condenser For W/C chillers only , if Chiller shut down. Turn Automatic Failed/bad discharge Freeze Protection...
  • Page 48 LEGEND NOTES: 1. Low Oil Pressure Alert Criteria and Set Points — Carrier Comfort Network Where: P d = Discharge pressure, P s = Suction pressure, — Compressor Protection Module — Discharge Gas Temperature P o = Oil pressure and P e = Economizer pressure —...
  • Page 49 Table 34 — Hardware Point Communications Loss/Action Taken ACTION TAKEN UNTIL HARDWARE POINT CONTROL POINT NAME COMMUNICATION RESTORED ALARM Alarm Relay No Action CFLOW _ SW Cooler Flow Switch Chiller shut down COND _ ENT Condenser Entering Water Thermistor Same as Alert 12 COND _ LWT Condenser Leaving Water Thermistor Same as Alert 11...

  • Page 50: Exd Troubleshooting Procedure

    Table 35 — Illegal Configurations Recognized it reaches the top of its stroke (can be heard if by PSIO-1 surroundings are relatively quiet). Press again if necessary to confirm this. Press four times to step CODE ILLEGAL CONFIGURATION NUMBER DESCRIPTION the actuator closed in 25% increments, waiting again in be- Incorrect Check Sum in configuration code tween each move.

  • Page 51: Inspecting/Opening Electronic Expansion Valves

    INSPECTING/OPENING ELECTRONIC EXPANSION 2. Remove any remaining refrigerant from the system low VALVES side and discharge piping using proper reclaiming tech- niques. For 30GX units, there is no shutoff valve in the IMPORTANT: Obtain replacement O-ring before open- bubbler tube line. Drain oil from cooler using Schrader ing EXV.

  • Page 52: Service

    OUTLET FOR STEPPER MOTOR MOTOR COOLING LINE CONNECTION STEPPER MOTOR HARNESS RING TUBE SHEET MOUNTING BRACKET FLOAT BOLTS ASSEMBLY DISCHARGE GAS BUBBLER TUBE SHELL BOLTS LIQUID INLET OUTLET TO BOTTOM TUBE FROM OF COOLER CONDENSER Fig. 13 — 30GX,HX Cutaway View of Economizer Assembly TUBE RING...

  • Page 53: Inspecting/Cleaning Heat Exchangers

    3. Apply torque in one-third steps until required torque is designed to avoid scraping and scratching the tube wall. Con- reached. Load all bolts to each one-third step before pro- tact your Carrier representative to obtain these brushes. Do ceeding to the next one-third step. not use wire brushes.

  • Page 54: Condenser Fans (30Gx Only)

    5. If the refrigerant appears to be flashing, the circuit is prob- vent freezing. Freezing damage is considered abuse and ably low on charge. Verify this by checking the EXV may void the Carrier warranty. Percent Open. This information can be accessed by entering on the HSIO keypad for Circuit A, or for Circuit B.

  • Page 55: Oil Charging/Low Oil Recharging

    10. Using a suitable pump, add ⁄ gal. (1.89 L) of Castrol glass is flashing, the circuit is undercharged. Icematic SW-220 Polyolester oil (Carrier Specifica- 5. Add 5 lb of liquid charge into the cooler using the ⁄ -in. tion number is PP47-32; absolutely no substitutes are Schrader-type fitting located on the tube entering the bot-...

  • Page 56: Oil Filter Maintenance

    2. Close the discharge and liquid valve(s), suction valve, Oil Filter Maintenance — Each compressor has its own and cooler inlet line service valve (if equipped), oil line internal oil filter and each circuit also has an in-line external shutoff valve, economizer bubble tube valve filter.
  • Page 57 9. Remove the four M14 bolts securing the discharge line OIL PRESSURE JUNCTION BOX TRANSDUCER flange to the compressor. Two of the bolts also secure OIL BLEED PORT the mounting bracket for the external oil filter. Support INTERNAL OIL the oil line to prevent damage to the line while the com- FILTER ACCESS SOLENOID (3/4 in.)

  • Page 58: Burnout Clean-Up Procedure

    Let the Whenever moisture-liquid indicator shows presence of moisture, replace filter drier. Refer to Carrier circuit stabilize with both loaders energized. Refer to the Standards Service Technique Manual, Chapter 1, Refrig- Refrigerant and Oil Charging sections of this document erants, for details on servicing filter driers.

  • Page 59: Pressure Transducers

    to the high side. Transfer refrigerant and reclaim any refrig- ambient temperature when calibrating. Calibrating a trans- erant remaining in the low side. ducer when the system is under nitrogen charge will result in an incorrect offset being applied to the reading (due to NOTE: A new packing nut and ferrule will be required as temperature correction).
  • Page 60 Table 39A — Thermistor Temperatures (°F) vs Resistance/Voltage Drop (NOTE: These values do NOT Apply to the Motor Temperature Thermistors ) VOLTAGE VOLTAGE VOLTAGE TEMP RESISTANCE TEMP RESISTANCE TEMP RESISTANCE DROP DROP DROP (Ohms) (Ohms) (Ohms) −25 4.821 98,010 3.437 7,868 1.250 1,190...
  • Page 61 Table 39B — Thermistor Temperatures (°C) vs Resistance/Voltage Drop (NOTE: These Values do NOT Apply to the Motor Temperature Thermistors) VOLTAGE VOLTAGE VOLTAGE TEMP RESISTANCE TEMP RESISTANCE TEMP RESISTANCE DROP DROP DROP (Ohms) (Ohms) (Ohms) −40 4.896 168 230 3.680 9 949 1.291 1 244...

  • Page 62: Safety Devices

    Table 40 — Thermistor Temperatures vs Safety Devices — The 30GX/HX chillers contain many Resistance, Motor Temperature Thermistors safety devices and protection logic built into the electronic control. Following is a description of the major safeties. TEMP TEMP RESISTANCE (Ohms) COMPRESSOR PROTECTION Motor Overload —...
  • Page 63 COMPRESSOR A2 COMPRESSOR B1 COMPRESSOR A1 (206-271 ONLY) COOLER CONDENSER (30HXC MODEL) OIL SEPARATOR (30HXA MODEL) DISCHARGE PRESSURE OIL PRESSURE SUCTION PRESSURE ECONOMIZER PRESSURE (LOCATED IN MOTOR COOLING LINE) Fig. 23A — 30HX Pressure Transducer Locations COMPRESSOR A2 COMPRESSOR A1 COMPRESSOR B1 (205-265 ONLY) COOLER...

  • Page 64: Control Modules

    PSIO and DSIO modules all perform continuous diagnostic information. evaluations of the condition of the hardware. Proper opera- Carrier Comfort Network (CCN) Interface — tion of these modules is indicated by LEDs on the front sur- 30GX,HX chiller units can be connected to the CCN if de- face of the DSIOs, and on the top horizontal surface of the sired.
  • Page 65 DSIO-EXV-J2 PSIO-2-J8 HSIO-II CPM-A1 CPM-B1 PSIO-1-J8 DSIO-HV-J2 Fig. 24 — Sensor Bus Wiring (Communications) Table 43 — Compressor Control Troubleshooting SYMPTOMS CAUSE REMEDY COMPRESSOR DOES NOT Power line open Check main disconnect. Control fuse open Check control circuit for ground or short. Replace fuse. High-Pressure Switch (HPS) tripped Move LOCAL/OFF/REMOTE switch to OFF position then back to LOCAL or REMOTE position.

  • Page 66: Processor Module (Psio-1)

    (30HX). The proper software and cooling season the fluid should be drained from the system. unit configuration data is factory installed by Carrier in the However, due to the cooler circuiting, some fluid will re- replacement module.

  • Page 67: Pre-Start-Up Procedure

    Actual start-up should be done only under supervision of a qualified refrigeration mechanic and System Check qualified Carrier Comfort Network personnel. 1. Check all auxiliary components such as the chilled fluid 1. Set leaving fluid temperature. No cooling range adjust- circulating pump, air-handling equipment, or other equip- ment is necessary.

  • Page 68: Field Wiring

    LEGEND FOR FIG. 25-37 FIELD WIRING — Alarm Field wiring is shown in Fig. 25-37. — Contactor — Condenser Fan Contactor NEC FUSED DISCONNECT — Condenser Pump Relay — Chilled Water Pump DSIO — High Voltage Relay Module EQUIP — Equipment 115 V CONTROL CIRCUITS —...
  • Page 69 EQUIP GND RELAY BOARD 1 SEPARATE 115 OR 230 V FIELD POWER SUPPLY MAX. LOAD ALLOWED FOR THE CWP RELAY IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT. ACCESSORY ONLY Fig. 28 — Chilled Water Pump Relay Wiring; 30HXA,C EQUIP GND RELAY BOARD 1 SEPARATE...
  • Page 70 GFI-CO ACCESSORY GRN/YEL TEST 15 AMPS RESET BRASS SCREWS SILVER SCREWS Fig. 30 — Ground Fault Interrupter-Convenience Outlet Accessory Wiring 230V CONTROL CIRCUIT WIRING 115V CONTROL CIRCUIT WIRING ORN BLU Fig. 31 — Oil Pump Motor Junction Box Wiring RELAY BOARD 2 MINIMUM LOAD CONTROL CIRCUIT B MINIMUM LOAD CONTROL CIRCUIT A NOTE: Gray, Pink, and White wires are included in the control box as part of the factory wire harness.
  • Page 71 RELAY BOARD 2 CFCA RB2PL2-5 CPR/ CFCB RB2PL2-3 MAX. LOAD ALLOWED AT TB2-1 AND TB2-6 IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLTS. FIELD SUPPLIED Fig. 33 — Condenser Pump Relay Wiring, 30HXC and Remote Condenser Fan On/Off Wiring, 30HXA DSIO (EXV)-J3 COOLER FLOW SWITCH CHILLED WATER...
  • Page 72 PSIO-2, J7 PLUGS CONDENSER ENTERING WATER THERMISTOR FIELD SUPPLIED CONDENSER LEAVING WATER THERMISTOR FIELD SUPPLIED FIELD SUPPLIED 4-20 mA SIGNAL 500 OHM, 1/2 WATT AND POWERED GENERATOR FIELD SUPPLIED 4-20 mA SIGNAL TEMPERATURE RESISTOR RESET BOTTOM FIELD SUPPLIED 4-20 mA SIGNAL 500 OHM, 1/2 WATT AND POWERED GENERATOR...
  • Page 73 PSIO-2, J7 PLUGS FIELD SUPPLIED 4-20 mA SIGNAL 500 OHM, 1/2 WATT AND POWERED GENERATOR FIELD SUPPLIED 4-20 mA SIGNAL DEMAND LIMIT RESISTOR OUTDOOR AIR THERMISTOR FIELD SUPPLIED BOTTOM FIELD SUPPLIED 4-20 mA SIGNAL 500 OHM, 1/2 WATT GENERATOR AND POWERED FIELD SUPPLIED TEMPERATURE 4-20 mA SIGNAL...

  • Page 74: (Compressor Must Trip Amps)

    APPENDIX A Compressor Must Trip Amps (Determined by CPM Modules) COMPRESSOR MUST TRIP AMPS COMPRESSOR MUST TRIP AMPS 2-COMPRESSOR UNITS 2-COMPRESSOR UNITS Compressor A1, B1 Compressor A1, B1 Unit Size Unit Voltage Unit Size Unit Voltage Must Trip Amps Must Trip Amps 575-3-60 98, 82 575-3-60...
  • Page 75 APPENDIX A (cont) Compressor Must Trip Amps (Determined by CPM Modules) (cont) COMPRESSOR MUST TRIP AMPS COMPRESSOR MUST TRIP AMPS 2-COMPRESSOR UNITS 2-COMPRESSOR UNITS Compressor A1, B1 Compressor A1, B1 Unit Size Unit Voltage Unit Size Unit Voltage Must Trip Amps Must Trip Amps 575-3-60 56, 56...
  • Page 76 APPENDIX A (cont) Compressor Must Trip Amps (Determined by CPM Modules) (cont) COMPRESSOR MUST TRIP AMPS COMPRESSOR MUST TRIP AMPS 3-COMPRESSOR UNITS 3-COMPRESSOR UNITS Compressor A1, A2, B1 Compressor A1, A2, B1 Unit Size Unit Voltage Unit Size Unit Voltage Must Trip Amps Must Trip Amps 230-3-50...

  • Page 77: (Capacity Loading Sequence)

    APPENDIX B compressor has 2 loaders. There is no difference in opera- Capacity Loading Sequence Example — The fol- tion between ‘‘Staged’’ and ‘‘Equal’’ circuit loading on 2 com- lowing tables show the loading sequence for a 30HX186 pressor chillers. (50/50 split) and a 30HX161 (59/41 split) chiller.
  • Page 78 APPENDIX B (cont) The following tables show the loading sequence for 30HX206 compressors have two loaders and the chillers are config- (57/43 split) and 30HX271 (67/33 split) chillers. All ured for equal circuit loading. See Note 2. STANDARD LOADING SEQUENCE (CIRCUIT A LEAD CIRCUIT, 3-COMPRESSOR UNIT) % TOTAL % TOTAL COMP...
  • Page 79 APPENDIX B (cont) The following tables show the loading sequence for 30HX206 staged circuit loading. Loaders A1 on compressors A1 and (57/43 split) and 30HX271 (67/33 split) chillers. All com- A2 are energized in parallel. The same is true for Loaders pressors have two loaders and the chiller is configured for A2 on both compressors A1 and A2.

  • Page 80: Appendix C (Available Accessories)

    APPENDIX C The following are the available accessories for 30GX/HXA/HXC units. ACCESSORY USED ON DESCRIPTION OF ACCESSORY COMMENTS PART NUMBER 30GX-900-001 30GX080-105 Condenser Grille Package 30GX-900-002 30GX106-125 Condenser Grille Package 30GX-900-003 30GX136, 150, 160 Condenser Grille Package 30GX-900-013 30GX151, 161, 175, 205, 225 Condenser Grille Package 30GX-900-024 30GX176...

  • Page 81: Appendix D (Cpm Configurations)

    APPENDIX D Compressor Protection Module Configuration Header Punch-Outs and Overload Settings 2-Compressor Units UNIT PUNCH OUTS PUNCH OUTS COMP A1 COMP B1 MODEL NUMBER FOR CPM-A FOR CPM-B OVERLOAD SETTING OVERLOAD SETTING 30GX-080---1 1,2,3,6,7,8 1,2,3,5,6,7,8 30GX-080---2 1,2,5,6,7 1,2,4,5,7 30GX-080---5 1,4,8 1,3,6,7,8 30GX-080---6 1,2,4,5,7,8...
  • Page 82 APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 2-Compressor Units UNIT PUNCH OUTS PUNCH OUTS COMP A1 COMP B1 MODEL NUMBER FOR CPM-A FOR CPM-B OVERLOAD SETTING OVERLOAD SETTING 30HXA096---1 1,2,4,5,6 1,2,3,5,6,7,8 30HXA096---2 1,3,4,5,6,7 1,2,4,5,7 30HXA096---3 1,3,4,8 1,2,4,7...
  • Page 83 APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 2-Compressor Units UNIT PUNCH OUTS PUNCH OUTS COMP A1 COMP B1 MODEL NUMBER FOR CPM-A FOR CPM-B OVERLOAD SETTING OVERLOAD SETTING 30HXC096---1 1,2,3,5,6,7,8 1,2,3,4,5,6 30HXC096---2 1,2,4,5,7 1,2,3,5,6,7 30HXC096---3 1,2,4,7 1,2,3,5...
  • Page 84 APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 3-Compressor Units COMP A1 COMP A2 COMP B1 UNIT PUNCH OUTS PUNCH OUTS PUNCH OUTS OVERLOAD OVERLOAD OVERLOAD MODEL NUMBER FOR CPM-A1 FOR CPM-A2 FOR CPM-B1 SETTING SETTING SETTING 30GX205---8...
  • Page 85 APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 3-Compressor Units COMP A1 COMP A2 COMP B1 UNIT PUNCH OUTS PUNCH OUTS PUNCH OUTS OVERLOAD OVERLOAD OVERLOAD MODEL NUMBER FOR CPM-A1 FOR CPM-A2 FOR CPM-B1 SETTING SETTING SETTING 30HXA261---1...

  • Page 86: Appendix E (Cooler And Condenser Pressure Drop)

    APPENDIX E The following charts list pressure drops for coolers and condensers. 136, 146 116, 126 161, 171 076, 086 246-271 1000 COOLER FLOW RATE (GPM) Unit Size Range NOTE: Ft of water = 2.31 x change in psig. 30HX COOLER PRESSURE DROP — ENGLISH 1000 136, 146 116, 126...
  • Page 87 APPENDIX E (cont) Unit Size Range NOTE: Ft of water = 2.31 x change in psig. 30HX CONDENSER PRESSURE DROP — ENGLISH Unit Size Range 30HX CONDENSER PRESSURE DROP — SI...
  • Page 88 APPENDIX E (cont) NOTE: Ft of water = 2.31 x change in psig. 30GX080-176 COOLER PRESSURE DROP — 30GX080-176 COOLER PRESSURE DROP — ENGLISH 1000 30GX205, 206 30GX250, 251, 265 30GX225, 226 COOLER FLOW RATE (L/s) 30GX205-265 COOLER PRESSURE DROP — 1000 COOLER FLOW RATE (GPM) 30GX205-265 COOLER PRESSURE DROP —...

  • Page 89: (Typical System Components)

    APPENDIX F...
  • Page 90 APPENDIX F (cont)

  • Page 91: Index

    Oil Charging/Low Oil Recharging, 55 Capacity Control, 6 Oil Filter Maintenance, 56 Capacity Sequence Determination, 7 Oil Pumps, 4 Carrier Comfort Network (CCN) Interface, 64 Oil Separator Heaters (30GX), 62 Checking Display Codes, 43 Operating Sequence, 67 Close Control, 7...
  • Page 92 CALL FOR FREE CATALOG 1-800-962-9212 [ ] Packaged Service Training [ ] Classroom Service Training Copyright 1998 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No.
  • Page 93 START-UP CHECKLIST FOR 30GX,HX LIQUID CHILLERS (Remove and use for job file.) A. Preliminary Information JOB NAME LOCATION INSTALLING CONTRACTOR DISTRIBUTOR START-UP PERFORMED BY EQUIPMENT: MODEL COMPRESSORS: CIRCUIT A CIRCUIT B 1) MODEL # 1) MODEL # 2) MODEL # 2) MODEL # COOLER: MODEL #...
  • Page 94 B. Preliminary Equipment Check IS THERE ANY SHIPPING DAMAGE? IF SO, WHERE WILL THIS DAMAGE PREVENT UNIT START-UP? UNIT IS LEVEL IN ITS INSTALLATION UNIT IS SUPPLIED WITH THE PROPER CONTROL VOLTAGE ELECTRICAL CIRCUIT WIRING HAS BEEN SIZED AND INSTALLED PROPERLY UNIT GROUND WIRE HAS BEEN CONNECTED ELECTRICAL CIRCUIT PROTECTION HAS BEEN SIZED AND INSTALLED PROPERLY ALL TERMINALS ARE TIGHT...
  • Page 95 C. Unit Start-Up CWP STARTER HAS BEEN PROPERLY INTERLOCKED WITH THE CHILLER ALL LIQUID VALVES ARE BACKSEATED ALL DISCHARGE VALVES ARE OPEN ALL SUCTION VALVES ARE OPEN, IF EQUIPPED ALL OIL LINE VALVES ARE OPEN UNIT HAS BEEN LEAK CHECKED LOCATE, REPAIR, AND REPORT ANY REFRIGERANT LEAKS CHECK VOLTAGE IMBALANCE: AVERAGE VOLTAGE...
  • Page 96 CHECK PRESSURE DROP ACROSS THE COOLER: ENTERING COOLER: PSIG (kPa) LEAVING COOLER: PSIG (kPa) (LEAVING − ENTERING) × 2.31 FT OF H O/PSIG = FT OF H (LEAVING − ENTERING) × 0.334 M OF H O/kPa = M OF H PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (IN PRODUCT DATA LITERATURE) TO DETERMINE TOTAL GALLONS/MINUTE (GPM) OR LITERS PER SECOND (L/S) AND FIND UNIT’S MINIMUM FLOW RATE.
  • Page 97 PERFORM TEST FUNCTION (INDICATE POSITIVE RESULT): ONCE POWER IS SUPPLIED TO THE UNIT, CHECK THE DISPLAY FOR ANY ALARMS, SUCH AS PHASE REVER- SAL. FOLLOW THE TEST FUNCTION INSTRUCTIONS IN THE CONTROLS AND TROUBLESHOOTING LITERA- TURE. BE SURE TO CHECK FOR PROPER FAN ROTATION WITH THE FAN TEST SECTIONS. BE SURE ALL SERV- ICE VALVES ARE OPEN BEFORE BEGINNING THE COMPRESSOR TEST SECTION.
  • Page 98 REVIEW AND RECORD FACTORY CONFIGURATION CODES, CONFIGURATION CODE 1: CONFIGURATION CODE 2: CONFIGURATION CODE 3: CONFIGURATION CODE 4: CONFIGURATION CODE 5: REVIEW AND RECORD SOFTWARE VERSION, SOFTWARE CESR500100 VERSION REVIEW AND RECORD FIELD CONFIGURATION, COOLER FLUID SELECT COOLER PUMP CONTROL MIN LOAD VALVE SELECT CONDENSER PUMP CONTROL LOADING SEQ.
  • Page 99 NOTES: CL-7...
  • Page 100 Copyright 1998 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No. 533-062 Printed in U.S.A. Form 30G,H-3T Pg CL-8 1099 1-98...

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