30XA080-500
Air-Cooled Liquid Chillers
60 Hz
Controls, Start-Up, Operation, Service
and Troubleshooting
CONTENTS
Page
SAFETY CONSIDERATIONS ...................... 2
GENERAL ...................................... 2-4
Conventions Used in This Manual ................ 2
Display Module Usage ........................... 3
• NAVIGATOR TM DISPLAY MODULE
CONTROLS ................................... 4-41
General .......................................... 4
Main Base Board (MBB) .......................... 4
Compressor Protection Module (CPM) ........... 6
Electronic Expansion Valve (EXV) Board ......... 9
Fan Boards ...................................... 11
Enable-Off-Remote Contact Switch (SWl) ....... 13
Emergency On/Off Switch (SW2) ................ 13
Energy Management Module (EMM) ............. 13
Local Equipment Network ....................... 14
Board Addresses ................................ 14
Control Module Communication ................. 14
• RED LED
• GREEN LED
• YELLOW LED
Carrier Comfort Network® (CCN) Interface ...... 15
Configuration Options .......................... 15
• RAMP LOADING
• MINUTES OFF TIME
Dual Chiller Control ............................. 15
• DUAL CHILLER PUMP CONTROL FOR PARALLEL
APPLICATIONS
• DUAL CHILLER PUMP CONTROL FOR SERIES
CHILLER APPLICATIONS
Capacity Control ................................ 16
• EQUAL LOADING
• STAGE LOADING
• CAPACITY CONTROL OVERRIDES
Head Pressure Control .......................... 22
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OFf'ION
• LOW AMBIENT TEMPERATURE HEAD PRESSURE
CONTROL OPERATING INSTRUCTIONS
Machine Control Methods ....................... 29
• SWITCH CONTROL
• TIME SCHEDULE
• CCN CONTROL
• UNITRUN STATUS
Cooling Set Point Selection ..................... 3O
• SET POINT 1
• SET POINT 2
• 4 TO 20 mA INPUT
• DUAL SWITCH
• ICE MODE
• SET POINT OCCUPANCY
Temperature Reset .............................. 31
Demand Limit ................................... 32
• I-STEP SWITCH CONTROLLED
• 2-STEP SWITCH CONTROLLED
Page
• EXTERNALLY POWERED (4 to 20 mA Controlled)
• CCN LOADSHED CONTROLLED
Remote Alarm and Alert Relays ................. 4O
PRE-START-UP .................................. 41
System Check ................................... 41
START-UP .................................... 42-48
Actual Start-Up .................................. 42
Operating Limitations ........................... 42
• TEMPERATURES
• VOLTAGE
• MINIMUM FLUID LOOP VOLUME
• FLOW RATE REQUIREMENTS
OPERATION .................................. 48-55
Sequence of Operation .......................... 48
• ACTUATED BALL VALVE (ABV)
Dual Chiller Sequence of Operation ............. 49
• PARALLEL PUMP OPERATION
Operating Modes ................................ 49
Sensors ......................................... 52
• THERMISTORS
• TRANSDUCERS
SERVICE ..................................... 56-66
Economizer Assembly .......................... 56
Electronic Expansion Valve (EXV) ............... 56
• MAIN EXV CONTROL
• ECONOMIZER EXV CONTROL
• EXV TROUBLESHOOTING PROCEDURE
Compressor Assembly .......................... 59
• COMPRESSOR OIL SYSTEM
Cooler ........................................... 61
• SUCTION SERVICE VALVE
• FREEZE PROTECTION
• LOW FLUID TEMPERATURE
• LOSS OF FLUID FLOW PROTECTION
• TUBE PLUGGING
• RETUBING
• TIGHTENING COOLER HEAD BOLTS
• INSPECTING/CLEANING HEAT EXHANGERS
• WATER TREATMENT
• CHILLED WATER FLOW SWITCH
Condenser Coil Maintenance and Cleaning
Recommendations ............................ 64
• REMOVE SURFACE LOADED FIBERS
• PERIODIC CLEAN WATER RINSE
• ROUTINE CLEANING OF COIL SURFACES
Condenser Fans ................................ 65
Refrigerant Circuit .............................. 65
• LEAK TESTING
• REFRIGERANT CHARGE
Safety Devices .................................. 66
• COMPRESSOR PROTECTION
• OIL SEPARATOR HEATERS
• COOLER PROTECTION
Relief Devices ................................... 66
• PRESSURE RELIEF VALVES
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 533-00069 Printed in U,S.A, Form 30XA-1T Pg 1 12-05 Replaces: New
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