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 be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment.
Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 • PRESSURE RELIEF VALVES Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 • PROCESSOR MODULE (PSIO-1), HIGH VOLTAGE RELAY MODULE (DSIO-HV), AND EXV DRIVER MODULE (DSIO-EXV), 12/6 MODULE (PSIO-2) • RED LED • GREEN LED Carrier Comfort Network (CCN) Interface . . . . . 64 • PROCESSOR MODULE (PSIO-1) • HIGH VOLTAGE RELAY MODULE (DSIO-HV) Replacing Defective Processor Module . . . . . . .
Table 1 — Unit Mode from LOR Switch and CCN State MAJOR SYSTEM COMPONENTS Processor Module (PSIO-1) — This module is an upgrade to the original PSIO (8088) module, with superior electrical noise immunity capability. It contains the operating software and controls the operation of the machine. It has 12 input channels and 6 output channels. The PSIO-1 continuously monitors input/output channel information received from all the modules and controls all output signals for all output channels.
ECONOMIZER OPERATION — Economizers are factory installed on 30GX105-265 units and 30HXA,C161-271 units. All other sizes use standard EXVs. The economizer improves both the chiller capacity and efficiency as well as providing compressor motor cooling. Inside the economizer are both a linear stepper motor (same as standard EXV motor) and a float valve. The stepper motor is controlled by the processor to maintain the desired liquid level in the cooler (as is done for chillers without economizers).
Table 2 — Thermistor and Transducer Locations THERMISTORS Sensor T1 T2 Motor Temp A1 Motor Temp A2* Motor Temp B1 T5 T6 LL-A (T3) LL-B (T4) T7 (optional)† STP (optional)† T8 (optional)† T9 (optional)† Sensor DPT-A SPT-A EPT-A OPT-A1 OPT-A2* DPT-B Description Cooler Leaving Fluid Temp Cooler Entering Fluid Temp Motor Temperature A1 Motor Temperature A2 Motor Temperature B1 Discharge Gas Temp A Location Cooler Head Leaving Fluid Side Cooler Head Entering Fluid Side Compressor A1 Junction Box Compressor A2 J
COMPRESSOR PROTECTION MODULE (CPM) PUSH THIS SIDE OF SWITCH DOWN TO SET ADDRESS L1 24/115/230 VAC INPUTS/OUTPUTS L2 1 ROCKER DOWN L3 CURRENT TOROID INPUT PLUG 1 0 2 COMM3 3 1 2 MOTOR INPUT TEMPERATURE ADDRESS DIP SWITCH RED LED YELLOW LED T T COMPRESSOR MUST TRIP AMPS HEADER GREEN LED 4 3 2 1 2 3 4 5 LED — Light-Emitting Diode NOTES: 1. The red LED blinks continuously when the module is operating properly. 2.
COMPRESSOR JUNCTION BOX COMPRESSOR CONTACTOR TERMINAL BLOCK 1 1 21 L1 T1 L2 T1 2 2 22 2 4 3 3 5 3 T3 L3 23 6 1 JUMPER BARS Fig. 2 — Across-the-Line (XL) Compressor Wiring 1 1 21 T1 L1 2 L2 22 3 23 COMPRESSOR JUNCTION BOX COMPRESSOR STARTER ASSEMBLY TERMINAL BLOCK 6 4 2 1M T2 3 L3 T3 L1 T1 1 6 2 4 3 5 21 L2 T2 2M T3 L3 23 T1 L1 L2 22 S T2 5 T3 L3 Fig.
2 STARTS DEADBAND EXAMPLE 47 7 6 46 45 LWT (F) LWT (C) 8 44 43 42 5 41 0 200 400 600 800 LEGEND LWT — Leaving Water Temperature 1000 3 STARTS TIME (SECONDS) STANDARD DEADBAND MODIFIED DEADBAND Fig. 4 — Deadband Multiplier water (brine) circuits, if the Saturated Suction temperature falls below 34 F (1.1 C) (the Brine Freeze Point), the unit capacity will not increase. If the Saturated Suction temperature falls below 28 F (−2.2 C), the Brine Freeze Point minus 6° F (3.
20 mA output is driven through the PSIO-2 module. To obtain this accessory for field installation, order by part number 30GX-900---012 for a single controller package (30GX080150 and 160). Order part number 30GX-900---014 for a dual controller package (30GX151 and 161-265). These packages contain all the hardware required to install the accessory. See Fig. 6B. The control will use the higher of the 2 Saturated Condensing Temperature values for 30GX080-150 and 160 units.
30GX080-105 30GX106-125 2 4 30GX136, 150, 160 6 4 2 4 6 8 2 1 3 1 CONTROL BOX END CONTROL BOX END CONTROL BOX END 3 5 1 30GX151, 161, 175, 205, 225 10 8 6 4 3 5 30GX176 2 12 10 8 6 4 2 CONTROL BOX END 9 7 5 3 CONTROL BOX END 1 11 9 7 30GX206, 226, 250 1 3 5 7 5 3 1 30GX251, 265 7 9 11 14 12 10 8 4 6 2 CONTROL BOX END CONTROL BOX END 2 4 6 8 10 12 13 11 9 7 5 3 1 Fig.
Table 6 — 30GX080-265 Condenser Fan Staging (PSIO-1 Controlled) 30GX UNIT SIZE FAN TYPE Standard 080-105 High Static Standard 106-125 High Static Standard 136, 150, 160 High Static Standard 151, 161, 175 205, 225 High Static Standard 176 High Static Standard 206, 226, 250 High Static Standard 251, 265 High Static LEGEND Comp.
30GX UNITS — MOTORMASTER III CONTROL NOT INSTALLED IS SCT GREATER THAN HEAD PRESSURE SET POINT? READ CIRCUIT SATURATED CONDENSING TEMPERATURE AND CURRENT FAN STAGE NO HAS SCT BEEN 35° F LESS THAN HEAD PRESSURE SET POINT 2 MINUTES? NO YES YES DECREASE CURRENT FAN STAGE BY ONE INCREASE CURRENT FAN STAGE BY ONE ADD 15° F TO HEAD PRESSURE SET POINT FOR NEXT 35 SECONDS LEGEND SCT — Saturated Condensing Temperature Fig.
Leaving Fluid Temp xx.x° F Percent Total Capacity xxx.x% Total Number of Alarms xx MODES : MODE_TBL Current active modes Cooler Heater Control — Accessory cooler heaters can be ordered for the 30GX chillers. If installed and enabled, these heaters are turned on only when the machine is in the off state and the chiller is in a saturated suction temperature freeze condition. Keypad and Display Module (Also Called HSIO-II) — This module allows the operator to communicate with the processor.
Table 8A — HSIO Functions and Subfunctions SUBFUNCTION NO.
Table 8B — Functions and Subfunctions Cross-Reference for the Optional LID-2B Controller The optional LID-2B controller cross reference table bereference 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. In another example, outlined in the HSIO functions and subfunctions table (see from Table 8A, pressing 3 and the Status button on the HSIO Table 8A).
Table 9 — Accessing Functions and Subfunctions OPERATION KEYPAD ENTRY To access a function, press subfunction no. and function name key. Display shows subfunction group. To move to other elements, scroll up or down using arrow keys. DISPLAY RESPONSE Circuit A Discrete Outputs Loader A1 Relay is OFF Loader A2 Relay is OFF Minimum Load Valve A Relay is OFF Circuit A Oil Heater Relay is OFF A1 Mtr. Cooling Solenoid Relay is OFF A2 Mtr.
Unit Analog Parameters and Temperature Reset — Press and scroll down to display the unit entering and leaving fluid temperatures as well as the temperature reset signal and calculated values. Miscellaneous Inputs and Outputs — Pressing and scrolling down will reveal the On/Off status of the condenser fans (30GX only). Also found here are the Demand Limit settings, pump relay and switch status, and miscellaneous items such as Heat/Cool and Dual Set Point switch positions. See Table 10 for a complete list.
Table 10 — Status Function and Subfunction Directory SUBFUNCTION 1 Alarms 2 General Parameters KEYPAD ENTRY DISPLAY Alarm : xx Reset Alarms: 1 All current alarms are displayed Use as needed GENERAL PARAMETERS Control Mode 3 Circuit A Analog Values COMMENT Run Status Off/On Occupied ? Yes/No CCN Enable Off/On CCN Chiller Start/Stop Start/Stop Alarm State Normal/Alarm Current Alarm 1 x.xx Current Alarm 2 x.xx Current Alarm 3 x.xx Current Alarm 4 x.xx Current Alarm 5 x.
Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION 3 Circuit A Analog Valves (cont) 4 Circuit A Discrete Inputs/Outputs KEYPAD ENTRY DISPLAY 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 CPM A1 Feedback x.x Volts CPM A2 Feedback x.x Volts Circuit A Econ Pressure xxx.x PSI CIR. A DISCRETE OUTPUTS COMMENT See Table 3. See Table 3.
Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION 5 Circut B Analog Valves (cont) KEYPAD ENTRY 6 Circuit B Discrete Inputs/Outputs DISPLAY 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 xxx.x% Water Valve Position xxx.x% Cooler Level Indicator x.xx CPM B1 Feedback x.x Volts CPM B2 Feedback x.x Volts Circuit B Econ Pressure xxx.x PSI CIR.
Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION 7 Unit Analog Parameters (cont) 8 Misc. Inputs/Outputs KEYPAD ENTRY DISPLAY TEMPERATURE RESET COMMENT 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 MISC INPUTS/OUTPUTS FAN_1 Off/On FAN_2 Off/On FAN_3 Off/On FAN_4 Off/On FAN_5 Off/On FAN_6 Off/On DEMAND LIMIT 4-20 mA Demand Signal xx.
Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION 9 Operating Modes (cont) KEYPAD ENTRY DISPLAY 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 TIMED OVERRIDE ACTIVE LOW COOLER SUCTION TEMP WSM CONTROLLING SLOW CHANGE OVERRIDE OFF TO ON DELAY ACTIVE FSM CONTROLLING 2 CHILLR LEAD LAG ACTIVE 2 CHILLR LL COMM FAILURE CIR A LOW DISCHG SUPERHT CIR B
Table 10 — Status Function and Subfunction Directory (cont) SUBFUNCTION 11 Dual Chiller KEYPAD ENTRY DISPLAY DUAL CHILLER Unit Master / Slave 0/1/2 Master / Slave Ctrl Active Yes / No Lead Chiller 1/2 Slave Chiller State 0/1/3/5/6 Slave Chiller Total Cap xxx.
Table 12 — Operational and Mode Display Codes CODE LOCAL OFF DESCRIPTION Unit is off. LOCAL/OFF/REMOTE switch is in OFF position or LOCAL/OFF/REMOTE switch is in REMOTE position and remote contacts are open. CCN OFF Unit is off. LOCAL/OFF/REMOTE switch is in LOCAL position and CCN control is enabled (Stop state) or CCN is enabled (Stop state) with LOR switch in REMOTE position and remote contacts closed. CLOCK OFF Unit is off due to internal clock schedule. LOR switch is in LOCAL position.
SET POINT FUNCTION — Set points are entered through the keypad. Set points can be changed within the upper and lower limits, which are fixed. The ranges are listed below. Refer to Table 17 for a complete description of the function. Cooling Set Point 1,2 Medium Low Water: Temperature Brine: Temperature Brine: 38 to 70 F 14 to 70 F −13 to 70 F (3.3 to 21.1 C) (−10 to 21.1 C) (−25 to 21.
Table 14 —Test Function and Subfunction Directory SUBFUNCTION 1 Circuit A Discrete Output KEYPAD ENTRY DISPLAY Circuit A Discrete Output Loader A1 Relay is OFF Loader A1 Relay is ON Loader A2 Minimum Load Valve A COMMENT Similarly, use to test remaining outputs. Press the down arrow key or to turn an output off. Circuit A Oil Heater A1 Mtr. Cooling Solenoid A2 Mtr.
Table 14 —Test Function and Subfunction Directory (cont) SUBFUNCTION KEYPAD ENTRY DISPLAY 3 Unit Discrete Output (cont) Remote Alarm 2 COMMENT 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. Remote Alarm 7 Currently not supported. Remote Alarm 8 Currently not supported. Remote Alarm 9 Currently not supported. Remote Alarm 10 Currently not supported.
Table 16 — History Function and Subfunction Directory SUBFUNCTION KEYPAD ENTRY DISPLAY 1 Operating Hours Machine Operating Hours xxx.x hours Machine Starts xxx Circuit A COMMENT Number of hours unit has at least 1 compressor running Number of unit starts from zero capacity These values may be changed once, when new software is downloaded or when the PSIO-1 module is replaced (Version 4.0 and later). Operating Hours xxx.x hours Compressor A1 Hours xxx.x hours Compressor A2 Hours xxx.
Table 17 — Set Point Function and Subfunction Directory SUBFUNCTION 1 Set Point Table KEYPAD ENTRY DISPLAY COOLING 2 Units 3 Address 4 Time 5 CCN Disable Cool Setpoint 1 xx.x dF Cool Setpoint 2 xx.x dF Cooling Ramp Loading xx.x dF HEATING Default: 44.0 Heat Setpoint 1 xx.x dF Heat Setpoint 2 xx.x dF Heating Ramp Loading xx.x dF HEAD PRESSURE NOT SUPPORTED Default: 98.0 NOT SUPPORTED Default: 98.0 NOT SUPPORTED Default: 0.5 Head Pressure Setpoint A xxx.x dF Head Pressure Setpoint B xxx.
Table 18 — Reading and Changing Chilled Fluid Set Point Transducer Calibration — Press and scroll down to view the transducer calibration information. See Table 19 for a complete list, and the Pressure Transducers section on page 59 for a description of this subfunction. Manual Control Mode — This control allows the user to have full control over the compressors, loaders, and the minimum load valve (if installed) of the machine.
Table 19 — Service Function and Subfunction Directory SUBFUNCTION 1 Service Configuration 2 Options Configuration 1 3 Options Configuration 2 KEYPAD ENTRY DISPLAY Software CESR_500100 Ver xxx Unit Type x Number of Cir A Comp x Compressor A1 Tonnage xx Compressor A2 Tonnage xx Oil Switch Configuration x Number of Cir B Comp x Compressor B1 Tonnage xx Compressor B2 Tonnage xx Max. Cond. Temp Setpoint xxx.x dF MOP Set point xx.x dF Fan Staging Select x CPM Board Used? Yes Compr. A1 Must Trip Amps xxx.
Table 19 — Service Function and Subfunction Directory (cont) SUBFUNCTION 3 Options Configuration 2 (cont) KEYPAD ENTRY DISPLAY Ramp Load Select x Clock Control Select x Ice Configuration Select x OAT Sensor Select x Remote Alarm Select x Alarm Reset Select x 4 Reset Configuration Table Close Control Select x Deadband Multiplier x.x Current Unbalance Alarm x Voltage Unbalance Alarm x COOLING RESET TYPE 1 Degrees Reset at 20 mA xx.x dF COOLING RESET TYPE 2 Remote temp=No Reset xx.
Table 19 — Service Function and Subfunction Directory (cont) SUBFUNCTION 4 Reset Configuration Table (cont) 5 Factory Configuration Codes 6 NOT USED 7 Transducer Calibration KEYPAD ENTRY DISPLAY Demand Limit Select x Loadshed Group Number x Loadshed Demand Delta xxx% Maximum Loadshed Time xx min WATER VALVE PID COMMENT 0 = None (Default), 1 = Two step switch, 2 = 4-20 mA, 3 = CCN Loadshed 0-99, Default: 0 Proportional PID Gain x.x Integral PID Gain x.x Derivative PID Gain x.
Table 19 — Service Function and Subfunction Directory (cont) SUBFUNCTION 8 Manual Control Table KEYPAD ENTRY DISPLAY Manual Control Enable Dsable Password Protected Enter: COMMENT LOR switch should be in OFF position Will be displayed if not entered earlier in current HSIO use Manual Control Enable Dsable Manual Control Enable Enable Switch LOR switch to Local before proceeding Circuit A Compressor 1 Off Circuit A Compressor 1 On Provided no alarms exist, control will attempt circuit start within 2 m
Table 20 — Displaying Current Software Version FUNCTION KEYPAD ENTRY Software Version DISPLAY COMMENT Software CESR_500100 Ver XXX Carrier Software Part Number, where XXX is the revision number. Table 21 — Compressor Lead/Lag Configuration SUB-FUNCTION KEYPAD ENTRY DISPLAY Options Configuration 1 Cooler Fluid Select 1 Min.
Table 22 — Factory and Service Configuration Code Values UNIT MODEL NUMBER 30GX080 30GX090,105 30GX106 30GX115 30GX125 30GX136 30GX150 30GX151 30GX160 30GX161 30GX175 30GX176 30GX205 30GX206 30GX225 30GX226 30GX250 30GX251 30GX265 30HXA076 30HXA086 30HXA096 30HXA106 30HXA116 30HXA126 30HXA136 30HXA146 30HXA161 30HXA171 30HXA186 30HXA206 30HXA246 30HXA261 30HXA271 30HXC076 30HXC086 30HXC096 30HXC106 30HXC116 30HXC126 30HXC136 30HXC146 30HXC161 30HXC171 30HXC186 30HXC206 30HXC246 30HXC261 30HXC271 CONF.
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 Configuration Code 5 00000000 Configuration Code 5 00000058 SCHEDULE FUNCTION — This function provides a means to automatically switch the chiller from an occupied mode to
Table 24 — Schedule Function and Subfunction Directory SUBFUNCTION 1 Ice Build Schedule* KEYPAD ENTRY 2 Local Schedule† 3 Remote Schedule (Currently Not Used) 4 Holiday Configuration** 5-33 Holiday Configuration through DISPLAY SCHEDULES: OCCPC01S Timed Override: 00 SCHEDULES: OCCPC01S Timed Override: 02 COMMENT Extended Occupied Time MTWTFSSH OCC UNOCC 01- 00000000 00:00 00:00 MTWTFSSH OCC UNOCC 01- 11111000 00:00 00:00 MTWTFSSH OCC UNOCC 01- 11111000 21:00 00:00 MTWTFSSH OCC UNOCC 01- 11111000 21
RETURN FLUID TEMPERATURE RESET — In this example, the unit set point is reset from full load based on the chilled fluid return temperature. The example uses a reset value of 10 degrees at full reset. Full reset is at a 2-degree temperature difference across the cooler and no reset would be at a 10° F difference across the cooler. See Fig. 10 and Table 28. Temperature Reset — The control system is capable of providing leaving fluid temperature reset based on return fluid temperature.
6.7 (12) RESET AMOUNT 100 4.4 (8) 80 3.3 (6) 60 2.2 (4) 40 20 1.1 (2) BUILDING LOAD 0.0 (0) -18 (0) PERCENT BUILDING LOAD RESET AMOUNT C (F) 5.5 (10) 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. 8 — Cooling External Temperature Reset 6.7 (12) RESET AMOUNT C (F) 5.5 (10) 4.4 (8) 3.3 (6) 2.2 (4) 1.
Table 26 — Setting External Temperature Reset KEYPAD ENTRY Table 27 — Setting Externally Powered Reset KEYPAD ENTRY DISPLAY COMMENTS RESPONSE Cooler Fluid Select 1 Min. Load Valve Select Disable Loading Sequence Select 1 Lead/Lag Sequence Select 1 Head Press. Control Type 0 Motormaster Select 0 Water Valve Type 0 Ext. Reset Sensor Select 0 Ext.
Table 30 — Setting Demand Limit (4 to 20 mA Controlled; 2 to 10 vdc With 500-Ohm Resistor) EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled) — In this example, the 4 to 20 mA Demand Limit will be configured and the 20 mA demand limit percentage will be set to 50%. See Table 30 and Fig. 11. DEMAND LIMIT (CCN Loadshed Controlled) — In this example, the CCN Loadshed Demand Limit will be configured.
TROUBLESHOOTING The 30GX,HX screw chiller control has many features to aid in troubleshooting. By using the keypad and display module and the Status function, operating conditions of the chiller are displayed while the unit is running. The Test function allows for operational checkout of compressor loaders, fans, EXVs, solenoids, and other components while the chiller is stopped.
Table 33 — Alarm and Alert Codes ALARM/ALERT CODE 0 1.xx 2.xx 5.xx 6.
Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT CODE CPM SUBCODES (xx) x.85 ALARM OR ALERT DESCRIPTION WHY WAS THIS ALARM GENERATED? Alarm Motor Over Temperature CPM detects high motor temperature x.9 Alarm Open Thermistor x.95 Alarm Config. Header Fault x.10 Alarm ALARM/ALERT CODE 7 RESET METHOD PROBABLE CAUSE Comp. shut down Manual/Button CPM detects open circuit in motor temp thermistor CPM finds error with MTA value punched out in header Comp.
Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT CODE 28 ALARM OR ALERT Alert WHY WAS THIS ALARM GENERATED? Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%. Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%. Calibration offset more than 6 PSIG or Voltage ratio (volts read/ref. voltage) more than 99.9% or less than 0.5%.
Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT CODE 45 ALARM OR ALERT Alarm 46 Alarm Cooler Freeze Protection 47 Alert Circuit A High Saturated Suction Temperature 48 Alert Circuit B High Saturated Suction Temperature 49 Alarm Loss of Condenser Flow 50 Alarm Illegal Configuration x 51 Alarm 52 Alarm 53 Alarm Initial Configuration Required Unit is in Emergency Stop Cooler Pump Interlock Failed at Start-Up 54 Alarm Cooler Pump Interlock Opened Unexpectedly 55 Alarm 56 Alert
Table 33 — Alarm and Alert Codes (cont) ALARM/ALERT CODE 68 ALARM OR ALERT Alert WHY WAS THIS ALARM GENERATED? SCT > MCT_SP + 5 F (2.8 C) ACTION TAKEN BY CONTROL Circuit shut down RESET METHOD Automatic** High Leaving Chilled Water Temperature LCW read > LCW Delta Alarm limit and total capacity is 100% and current LCW > LCW reading 1 minute ago Alert only.
Table 34 — Hardware Point Communications Loss/Action Taken HARDWARE POINT ALARM CFLOW_SW COND_ENT COND_LWT COND_PMP COOL_EWT COOL_LWT COOL_HTR COOL_PMP DFLOW_SW DISTMP_A DISTMP_B DISTMP_B DMD_SW1 DMD_SW2 DPA DPB DUAL ECN_PR_A ECN_PR_B EXVA EXVB FAN_1 FAN_2 FAN_3 FAN_4 FAN_5 FAN_6 HC_SW HR_EWT HR_LWT ICE_DONE ICE_VALV K_A1_FBK K_A1_RLY K_A2_FBK K_A2_RLY K_B1_FBK K_B1_RLY K_B2_FBK K_B2_RLY LOADR_A1 LOADR_A2 LOADR_B1 LOADR_B2 LMT_MA LOR_SW MLV_A MLV_B MOTOR_A MOTOR_B MTRCL_A1 MTRCL_A2 MTRCL_B1 MTRCL_B2 OAT OIL
Table 35 — Illegal Configurations Recognized by PSIO-1 it reaches the top of its stroke (can be heard if surroundings are relatively quiet). Press again if CODE NUMBER necessary to confirm this. Press four times to step the actuator closed in 25% increments, waiting again in between each move. The actuator should knock when it reaches the bottom of its stroke.
2. Remove any remaining refrigerant from the system low side and discharge piping using proper reclaiming techniques. For 30GX units, there is no shutoff valve in the bubbler tube line. Drain oil from cooler using Schrader port in cooler inlet line. Turn off the line voltage power supply to the compressors and control circuit power. 3. Remove the shell retaining bolts on the bottom of the economizer and the bolts that secure the shell to the unit frame or mounting bracket.
OUTLET FOR MOTOR COOLING LINE CONNECTION STEPPER MOTOR STEPPER MOTOR HARNESS PIN RING TUBE SHEET MOUNTING BRACKET BOLTS FLOAT ASSEMBLY DISCHARGE GAS BUBBLER TUBE SHELL BOLTS PIN LIQUID INLET TUBE FROM CONDENSER OUTLET TO BOTTOM OF COOLER Fig. 13 — 30GX,HX Cutaway View of Economizer Assembly TUBE RING SERVICE PIN AND RING INSTALLED Servicing Coolers and Condensers — When cooler Fig. 14 — Tube Plugging heads and partition plates are removed, tube sheets are exposed showing the ends of tubes.
10 11 9 6 5 6 5 BLANK PLATE 3 2 3 1 4 1 10 4 7 12 11 14 13 10 9 11 9 6 3 2 3 5 6 5 2 12 8 7 8 9 10 12 16 14 2 BLANK PLATES 1 12 1 4 14 13 7 8 7 8 13 11 4 15 Fig. 15 — Cooler and Condenser Head Recommended Bolt Torque Sequence 1. Install all bolts finger tight. 2. Follow numbered sequence shown for head type being installed. This will apply even pressure to the O-ring. 3. Apply torque in one-third steps until required torque is reached.
PLASTIC FAN PROPELLER Do not use high-pressure water or air to clean coils as fin damage may result. Condenser Fans (30GX Only) — Each fan is supported by a formed wire mount bolted to a fan deck and covered with a wire guard. The exposed end of the fan motor shaft is protected from weather by grease. If the fan motor must be removed for service or replacement, be sure to regrease fan shaft and reinstall fan cover, retaining clips, and fan guard.
3. After running the unit for 11⁄2 hours, allow the unit to restart and run normally. If the Low Oil Level alarms persist, continue following this procedure. 4. Close the liquid line service valve, and place a pressure gage on top of the cooler. Enable the manual control feature using the HSIO keypad, and turn the LOR switch to local. Start the desired compressor by pressing on the keypad, at the appropriate line on the display. 5.
2. Close the discharge and liquid valve(s), suction valve, and cooler inlet line service valve (if equipped), oil line shutoff valve, economizer bubble tube valve (30HXA,C161-271 only) and minimum load shutoff valve (if equipped) for circuit to be changed. Disconnect the oil inlet line from the compressor. Disconnect oil filter with fitting at shutoff valve side and set filter and compressor inlet line assembly aside. 3.
9. Remove the four M14 bolts securing the discharge line flange to the compressor. Two of the bolts also secure the mounting bracket for the external oil filter. Support the oil line to prevent damage to the line while the compressor is being changed. For 30GX units, place temporary protection over coils to prevent fin and tube damage. 10. Move lifting apparatus into place and attach to the 2 lifting rings on the compressor. Apply minimal tension to hold the compressor while the remaining bolts are removed.
Use the Carrier Standard Service Techniques Manual as a source of reference. 22. Restore main and control power to the machine. Using the HSIO, enter the quick test function by pressing (for compressor A1 or A2 replacement) or (for compressor B1 replacement). Test the operation of the solenoids. Press to test each loader solenoid, then use the key to find the motor cooling and oil solenoids and test them in the same manner. Pressing the key after each output turns the solenoid off (or press ).
ambient temperature when calibrating. Calibrating a transducer when the system is under nitrogen charge will result in an incorrect offset being applied to the reading (due to temperature correction). Although these transducers are calibrated at the factory, replacement transducers require calibration for accurate readings. Calibration is also required when replacing a PSIO.
Table 39A — Thermistor Temperatures (°F) vs Resistance/Voltage Drop (NOTE: These values do NOT Apply to the Motor Temperature Thermistors ) TEMP (F) −25 −24 −23 −22 −21 −20 −19 −18 −17 −16 −15 −14 −13 −12 −11 −10 −9 −8 −7 −6 −5 −4 −3 −2 −1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 VOLTAGE DROP (V) 4.821 4.818 4.814 4.806 4.800 4.793 4.786 4.779 4.772 4.764 4.757 4.749 4.740 4.734 4.
Table 39B — Thermistor Temperatures (°C) vs Resistance/Voltage Drop (NOTE: These Values do NOT Apply to the Motor Temperature Thermistors) TEMP (C) −40 −39 −38 −37 −36 −35 −34 −33 −32 −31 −30 −29 −28 −27 −26 −25 −24 −23 −22 −21 −20 −19 −18 −17 −16 −15 −14 −13 −12 −11 −10 −9 −8 −7 −6 −5 −4 −3 −2 −1 0 1 2 3 4 5 6 7 8 9 VOLTAGE DROP (V) 4.896 4.889 4.882 4.874 4.866 4.857 4.848 4.838 4.828 4.817 4.806 4.794 4.782 4.769 4.755 4.740 4.725 4.710 4.693 4.676 4.657 4.639 4.619 4.598 4.577 4.554 4.531 4.507 4.
Table 40 — Thermistor Temperatures vs Resistance, Motor Temperature Thermistors TEMP (F) −22 −13 −4 5 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 212 221 230 239 248 TEMP (C) −30 −25 −20 −15 −10 −5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 Safety Devices — The 30GX/HX chillers contain many safety devices and protection logic built into the electronic control. Following is a description of the major safeties. RESISTANCE (Ohms) 88,480.
COMPRESSOR A2 (206-271 ONLY) COMPRESSOR B1 COMPRESSOR A1 4 4 3 3 3 COOLER 2 2 CONDENSER (30HXC MODEL) OIL SEPARATOR (30HXA MODEL) 1 1 1 DISCHARGE PRESSURE 3 OIL PRESSURE 2 4 ECONOMIZER PRESSURE (LOCATED IN MOTOR COOLING LINE) SUCTION PRESSURE Fig.
On sensor bus terminal strips, terminal 1 of PSIO module is connected to terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner. See Fig. 24. If a terminal 2 wire is connected to terminal 1, system does not work.
1 1 1 1 1 1 1 2 2 2 2 2 2 2 3 3 3 3 3 3 3 PSIO-1-J8 DSIO-HV-J2 DSIO-EXV-J2 HSIO-II CPM-A1 CPM-B1 PSIO-2-J8 Fig.
2. Remove the defective PSIO-1 module by removing its mounting screws with a Phillips screwdriver, and removing the module from the control box. Save the screws for later use. 3. Use a small screwdriver to set the address switches S1 and S2 on the new PSIO module to exactly match the settings on the defective module. 4. Package the defective module in the carton of the new module for return to Carrier. 5.
second terminal block, a current phase reversal alarm will be generated when an attempt is made to start this compressor. The compressor will be shut down within 15 milliseconds. To correct this, interchange 2 power leads at this terminal block only. PRE-START-UP PROCEDURE IMPORTANT: Before beginning Pre-Start-Up or StartUp, complete the Start-Up Checklist for the 30GX,HX Liquid Chillers on pages CL-1 to CL-8.
LEGEND FOR FIG. 25-37 FIELD WIRING ALM C CFC CPR CWP DSIO EQUIP EXV FU GFI-CO GND NEC PL PSIO RB TB Field wiring is shown in Fig. 25-37.
EQUIP GND RELAY BOARD 1 SEPARATE 115 OR 230 V FIELD POWER SUPPLY TB2 T4 BLK 4 T3 BLK 5 K3 C1 CWP C2 TB2 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 115 OR 230 V FIELD POWER SUPPLY T4 K3 T3 C1 CWP C2 MAX. LOAD ALLOWED FOR THE CWP RELAY IS 125 VA SEALED, 1250 VA INRUSH AT 115 OR 230 VOLT. ACCESSORY ONLY Fig.
GFI-CO ACCESSORY GRN/YEL TEST RESET 15 AMPS TB4 1 BLK FU1 BLU TB4 WHT BRASS SCREWS 2 SILVER SCREWS Fig. 30 — Ground Fault Interrupter-Convenience Outlet Accessory Wiring 230V CONTROL CIRCUIT WIRING BRN VIO PNK ORN BLU 115V CONTROL CIRCUIT WIRING RED BLU BLK BRN VIO PNK ORN BLU BLU BLK RED BLK BLK Fig.
RELAY BOARD 2 TB4 TB2 T6 BLK K4 1 C1 CFCA C2 C1 CPR/ CFCB C2 2 RB2PL2-5 TB2 6 BLK K5 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 TB2 TB2 11 12 RED 3 CHILLED WATER PUMP INTERLOCK CONTACTS Fig.
PSIO-2, J7 PLUGS CONDENSER ENTERING WATER THERMISTOR FIELD SUPPLIED 14 15 TOP CONDENSER LEAVING WATER THERMISTOR FIELD SUPPLIED 17 18 + FIELD SUPPLIED AND POWERED 4-20 mA SIGNAL 4-20 mA SIGNAL GENERATOR TEMPERATURE RESET 19 500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR - 20 BOTTOM FIELD SUPPLIED AND POWERED 4-20 mA SIGNAL 4-20 mA SIGNAL GENERATOR DEMAND LIMIT + 22 500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR - 23 CONDENSER FLOW SWITCH 25 28 REMOTE DUAL SETPOINT FIELD SUPPLIED 24 VAC 31 ICE DONE 3
PSIO-2, J7 PLUGS TOP + FIELD SUPPLIED AND POWERED 4-20 mA SIGNAL 13 4-20 mA SIGNAL GENERATOR DEMAND LIMIT 500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR - 14 OUTDOOR AIR THERMISTOR FIELD SUPPLIED 20 21 BOTTOM FIELD SUPPLIED AND POWERED 4-20 mA SIGNAL + 4-20 mA SIGNAL GENERATOR TEMPERATURE RESET 22 - 23 SPACE TEMPERATURE SENSOR FIELD SUPPLIED 500 OHM, 1/2 WATT FIELD SUPPLIED RESISTOR 24 STAGE 2 25 DEMAND LIMIT EXTERNAL SWITCH STAGE 1 28 REMOTE DUAL SETPOINT 31 ICE DONE FIELD SUPPLIED 24 VAC 3
APPENDIX A Compressor Must Trip Amps (Determined by CPM Modules) COMPRESSOR MUST TRIP AMPS 2-COMPRESSOR UNITS Compressor A1, B1 Unit Size Unit Voltage Must Trip Amps 575-3-60 98, 82 380-3-60 148,124 208/230-3-60 270,226 30GX080 460-3-60 122,102 230-3-50 256,212 380/415-3-50 156,128 575-3-60 120, 82 380-3-60 180,124 208/230-3-60 328,226 30GX090 460-3-60 148,102 230-3-50 310,212 380/415-3-50 188,128 230-3-50 344,238 30GX105 380/415-3-50 208,144 575-3-60 134, 92 380-3-60 202,140 208/230-3-60 368,254 30GX106 46
APPENDIX A (cont) Compressor Must Trip Amps (Determined by CPM Modules) (cont) Unit Size 30HXC076 30HXC086 30HXC096 30HXC106 30HXC116 30HXC126 COMPRESSOR MUST TRIP AMPS 2-COMPRESSOR UNITS Compressor A1, B1 Unit Voltage Must Trip Amps 575-3-60 56, 56 380-3-60 84, 84 346-3-50 96, 96 208/230-3-60 154,154 460-3-60 70, 70 230-3-50 144,144 380/415-3-50 88, 88 575-3-60 68, 56 380-3-60 102, 84 346-3-50 116, 96 208/230-3-60 186,154 460-3-60 84, 70 230-3-50 176,144 380/415-3-50 106, 88 575-3-60 82, 56 380-3-6
APPENDIX A (cont) Compressor Must Trip Amps (Determined by CPM Modules) (cont) COMPRESSOR MUST TRIP AMPS 3-COMPRESSOR UNITS Compressor A1, A2, B1 Unit Size Unit Voltage Must Trip Amps 230-3-50 418,238,520 30GX205 380/415-3-50 254,144,314 575-3-60 198, 92,162 380-3-60 300,140,246 30GX206 208/230-3-60 546,254,448 460-3-60 248,114,204 230-3-50 520,288,520 30GX225 380/415-3-50 314,174,314 575-3-60 198,110,198 380-3-60 300,168,300 208/230-3-60 546,306,546 30GX226 460-3-60 248,138,248 230-3-50 520,288,520 380/415
APPENDIX B compressor has 2 loaders. There is no difference in operation between ‘‘Staged’’ and ‘‘Equal’’ circuit loading on 2 comlowing tables show the loading sequence for a 30HX186 pressor chillers. (50/50 split) and a 30HX161 (59/41 split) chiller.
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 LOADER LOADER COMP COMP LOADER LOADER CAPACITY A1 A2 A2 B1 B1 B2 (57/43 Split) 0 0 0 0 0 0 0.0 0 0 0 0 0 0 14.3 1 0 0 0 0 0 25.0 1 1 0 0 0 0 35.7 1 0 0 1 1 0 55.2 1 0 0 1 1 1 68.2 1 1 0 1 1 1 78.
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 comA2 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. See Note 3.
APPENDIX C The following are the available accessories for 30GX/HXA/HXC units.
APPENDIX D Compressor Protection Module Configuration Header Punch-Outs and Overload Settings 2-Compressor Units UNIT MODEL NUMBER 30GX-080---1 30GX-080---2 30GX-080---5 30GX-080---6 30GX-080---8 30GX-080---9 30GX-090---1 30GX-090---2 30GX-090---5 30GX-090---6 30GX-090---8 30GX-090---9 30GX-105---8 30GX-105---9 30GX-106---1 30GX-106---2 30GX-106---5 30GX-106---6 30GX-106---8 30GX-106---9 30GX-115---1 30GX-115---2 30GX-115---5 30GX-115---6 30GX-115---8 30GX-115---9 30GX-125---1 30GX-125---2 30GX-125---5 30GX
APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 2-Compressor Units UNIT MODEL NUMBER 30HXA096---1 30HXA096---2 30HXA096---3 30HXA096---5 30HXA096---6 30HXA096---8 30HXA096---9 30HXA106---1 30HXA106---2 30HXA106---3 30HXA106---5 30HXA106---6 30HXA106---8 30HXA106---9 30HXA116---1 30HXA116---2 30HXA116---3 30HXA116---5 30HXA116---6 30HXA116---8 30HXA116---9 30HXA126---1 30HXA126---2 30HXA126---3 30HXA126---5 30HXA126---6 30HXA126---8 30HXA126---9 30H
APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 2-Compressor Units UNIT MODEL NUMBER 30HXC096---1 30HXC096---2 30HXC096---3 30HXC096---5 30HXC096---6 30HXC096---8 30HXC096---9 30HXC106---1 30HXC106---2 30HXC106---3 30HXC106---5 30HXC106---6 30HXC106---8 30HXC106---9 30HXC116---1 30HXC116---2 30HXC116---3 30HXC116---5 30HXC116---6 30HXC116---8 30HXC116---9 30HXC126---1 30HXC126---2 30HXC126---3 30HXC126---5 30HXC126---6 30HXC126---8 30HXC126---9 30H
APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 3-Compressor Units UNIT MODEL NUMBER 30GX205---8 30GX205---9 30GX206---1 30GX206---2 30GX206---5 30GX206---6 30GX225---8 30GX225---9 30GX226---1 30GX226---2 30GX226---5 30GX226---6 30GX226---8 30GX226---9 30GX250---8 30GX250---9 30GX251---1 30GX251---2 30GX251---5 30GX251---6 30GX265---1 30GX265---2 30GX265---5 30GX265---6 30GX265---8 30GX265---9 30HXA206---1 30HXA206---2 30HXA206---3 30HXA206---5 30H
APPENDIX D (cont) Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont) 3-Compressor Units UNIT MODEL NUMBER 30HXA261---1 30HXA261---2 30HXA261---3 30HXA261---5 30HXA261---6 30HXA261---8 30HXA261---9 30HXA271---1 30HXA271---2 30HXA271---3 30HXA271---5 30HXA271---6 30HXA271---8 30HXA271---9 30HXC206---1 30HXC206---2 30HXC206---3 30HXC206---5 30HXC206---6 30HXC206---8 30HXC206---9 30HXC246---1 30HXC246---2 30HXC246---3 30HXC246---5 30HXC246---6 30HXC246---8 30HXC246---9 30H
APPENDIX E The following charts list pressure drops for coolers and condensers. 100 116, 126 136, 146 076, 086 186 096 PRESSURE DROP (FT WG) 161, 171 106 206 246-271 10 1 100 1000 COOLER FLOW RATE (GPM) Unit Size Range NOTE: Ft of water = 2.31 x change in psig.
APPENDIX E (cont) Unit Size Range NOTE: Ft of water = 2.31 x change in psig.
APPENDIX E (cont) NOTE: Ft of water = 2.31 x change in psig.
Typical System Components, 30GX, With Economizer LEGEND EXV — Electronic Expansion Valve HPS — High Pressure Switch APPENDIX F 89
Typical System Components, 30HX, Without Economizer LEGEND EXV — Electronic Expansion Valve HPS — High Pressure Switch APPENDIX F (cont) 90
INDEX Accessing Functions and Subfunctions, 13 Actual Start-Up, 67 Adjusting PID Routines, 10 Alarms and Alerts, 43 Automatic Default Display, 13 Back Pressure Valve, 4 Burnout Clean-Up Procedure, 58 Capacity Control Overrides, 7 Capacity Control, 6 Capacity Sequence Determination, 7 Carrier Comfort Network (CCN) Interface, 64 Checking Display Codes, 43 Close Control, 7 Coil Cleaning, 53 Complete Unit Stoppage, 43 Compressor Alarm/Alert Circuit, 43 Compressor Changeout Sequence, 56 Compressor Protection Mod
SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Installation Overview • Maintenance • Operating Sequence A large selection of product, theory, and skills programs are available, using popular video-based formats and materials. All include video and/or slides, plus companion book.
START-UP CHECKLIST FOR 30GX,HX LIQUID CHILLERS (Remove and use for job file.) A.
B.
C.
CHECK PRESSURE DROP ACROSS THE COOLER: PSIG (kPa) ENTERING COOLER: LEAVING COOLER: PSIG (kPa) (LEAVING − ENTERING) × 2.31 FT OF H2O/PSIG = FT OF H2O (LEAVING − ENTERING) × 0.334 M OF H2O/kPa = M OF H2O 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.
PERFORM TEST FUNCTION (INDICATE POSITIVE RESULT): ONCE POWER IS SUPPLIED TO THE UNIT, CHECK THE DISPLAY FOR ANY ALARMS, SUCH AS PHASE REVERSAL. FOLLOW THE TEST FUNCTION INSTRUCTIONS IN THE CONTROLS AND TROUBLESHOOTING LITERATURE. BE SURE TO CHECK FOR PROPER FAN ROTATION WITH THE FAN TEST SECTIONS. BE SURE ALL SERVICE VALVES ARE OPEN BEFORE BEGINNING THE COMPRESSOR TEST SECTION. ITEMS MARKED WITH ‘‘†’’ CAN BE TESTED ONLY IF THE UNIT IS CONFIGURED FOR THIS OPTION.
M REVIEW AND RECORD FACTORY CONFIGURATION CODES, CONFIGURATION CODE 1: CONFIGURATION CODE 2: CONFIGURATION CODE 3: CONFIGURATION CODE 4: CONFIGURATION CODE 5: M REVIEW AND RECORD SOFTWARE VERSION, SOFTWARE CESR500100 VERSION M REVIEW AND RECORD FIELD CONFIGURATION, COOLER FLUID SELECT COOLER PUMP CONTROL MIN LOAD VALVE SELECT CONDENSER PUMP CONTROL LOADING SEQ. SELECT CONDENSER FLOW SWITCH LEAD/LAG SEQ.
NOTES: CL-7
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.
