Appendix_8_-_XX_Carrier_30HK_Controls_Manual.pdf

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 903 Catalog No. 563-048 Printed in U.S.A. Form 30G,H-6T Pg 1 2-00 Replaces: NewBook 2

Tab 5c

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, mechanical rooms, etc.). Only trained, qualified installers and service me-chanics 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. Follow all safety codes. Wear safety glasses and work gloves. Use care in handling, rigging, and setting this equipment, and in han-dling all electrical components. CONTENTS

Page

SAFETY CONSIDERATIONS

GENERAL

MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . . . . .3,4

General Main Base Board (MBB) QuickSet Set Point Adjustment Alarm/Alert Indicator Light Scrolling Marquee Display Energy Management Module (EMM) Enable/Off/Remote Contact Switch Emergency On/Off Switch Board Addresses Control Module Communication Carrier Comfort Network Interface

OPERATING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Sensors

• T1 — COOLER LEAVING FLUID SENSOR

• T2 — COOLER ENTERING FLUID SENSOR

• T3 — SATURATED CONDENSING TEMPERATURE

SENSOR

• T9 — OUTDOOR-AIR TEMPERATURE SENSOR

• T10 — REMOTE SPACE TEMPERATURE SENSOR

Energy Management Module Loss-of-Cooler Flow Protection Compressor Ground Fault Sensor Thermostatic Expansion Valves (TXV) Compressor Control Relay (CR) Capacity Control

• MINUTES LEFT FOR START

• MINUTES OFF TIME

• LOADING SEQUENCE

• LEAD/LAG DETERMINATION

• CAPACITY SEQUENCE DETERMINATION

• CAPACITY CONTROL OVERRIDES

• HOT GAS BYPASS

Head Pressure Control

• COMFORTLINK UNITS (30GTN Only) Operation of Machine Based on Control Method and Cooling Set Point Selection Settings

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and ser-vice. 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 control system. Do not use jumpers or other tools to short out com-ponents, or to bypass or otherwise depart from recom-mended 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 always run fluid through heat exchangers when adding or removing refrigerant charge. Use appropriate brine solu-tions in cooler and condenser fluid loops to prevent the freezing of heat exchangers when the equipment is exposed to temperatures below 32 F (0° C). Proof of flow switch is required to protect coolers from freezing.

DO NOT VENT refrigerant relief valves within a building.

Outlet from relief valves must be vented outdoors in accor-dance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of Heating, Refrigeration and Air Conditioning Engineers) 15 (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. Provide adequate ventilation in enclosed or low overhead areas. Inhalation of high concen-trations of vapor is harmful and may cause heart irregulari-ties, unconsciousness or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen avail-able for breathing. Product causes eye and skin irritation.

Decomposition products are hazardous.

DO NOT attempt to unbraze factory joints when servicing this equipment. Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrig-erant 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 compressor oil.

30HK,HL040-060,

30HWA,B,C,S018-040,

30GTN015-035

Reciprocating Liquid Chillers with ComfortLink™ Controls

50/60 Hz

CONTENTS (cont) Page

Pumpout (30HL, 30GTN Units) Marquee Display Usage Service Test QuickSet Set Point Adjustment Usage

• QUICKSET CALIBRATION

Configuring and Operating

Dual Chiller Control Temperature Reset Demand Limit

• DEMAND LIMIT (2-Stage Switch Controlled)

• EXTERNALLY POWERED DEMAND LIMIT

(4 to 20 mA Controlled)

• DEMAND LIMIT (CCN Loadshed Controlled)

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 40-50

Complete Unit Stoppage and Restart

• GENERAL POWER FAILURE

• UNIT ENABLE-OFF-REMOTE CONTACT SWITCH

IS OFF

• CHILLED FLUID PROOF-OF-FLOW SWITCH(ES)

OPEN

• OPEN LOW-PRESSURE SWITCH

• OPEN HIGH-PRESSURE SWITCH(ES)

• OPEN COMPRESSOR INTERNAL THERMAL

PROTECTION (30HW and 30GTN Units)

• OPEN OIL PRESSURE SWITCH

• OPEN CONTACTS ON COMPRESSOR GROUND-

CURRENT SENSOR(S) (Accessory)

• OPEN 24-V CONTROL CIRCUIT BREAKERS

• COOLING LOAD SATISFIED

• THERMISTOR FAILURE

Alarms and Alerts SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-62 Electronic Components

• CONTROL COMPONENTS

Compressor Replacement (30HK,HL,HW) Compressor Replacement (30GTN) 30HK,HL,HW Condenser and 30HW Cooler

• BRAZED-PLATE COOLER AND CONDENSER

HEAT EXCHANGER REPLACEMENT

• BRAZED-PLATE COOLER AND CONDENSER

HEAT EXCHANGER CLEANING

• SHELL-AND-TUBE CONDENSER CLEANING

30HK,HL Cooler

• TUBE PLUGGING

• RETUBING

• TIGHTENING COOLER HEAD BOLTS

30GTN Cooler

• TUBE PLUGGING

• RETUBING

• TIGHTENING COOLER HEAD BOLTS

Check Oil Charge

• 30GTN

• 30HK,HL,HW

Condenser Section and Coils (30GTN Only)

• COIL CLEANING

• CLEANING E-COATED COILS

• CONDENSER SECTION

Check Refrigerant Feed Components

• THERMOSTATIC EXPANSION VALVE (TXV)

• FILTER DRIER

• MOISTURE-LIQUID INDICATOR

• LIQUID LINE SERVICE VALVE

• DISCHARGE LINE CHECK VALVE

• HOT GAS BYPASS VALVE

• LIQUID LINE SOLENOID VALVE

(30HL and 30GTN Only)

• PRESSURE RELIEF DEVICES

Page Compressor and Unit Protective Devices

• CIRCUIT BREAKER

• COMPRESSOR INTERNAL THERMAL

PROTECTION

• CRANKCASE HEATER

• OIL PRESSURE SAFETY SWITCH (OPS)

Check Unit Safeties

• HIGH-PRESSURE SWITCH

• LOW-PRESSURE SWITCH

• COOLER FREEZE-UP PROTECTION

• HEATER CABLE (30GTN Only)

• WINTER SHUTDOWN (30GTN Only) Thermistors

• REPLACING THERMISTORS T1 and T2

• THERMISTOR T3 (30GTN Only)

• THERMISTOR/TEMPERATURE SENSOR CHECK

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63,64

System Check

START-UP AND OPERATION. . . . . . . . . . . . . . . . . . 64-66

Actual Start-Up Check Refrigerant Charge — 30HK,HL,HW

• LIQUID CHARGING METHOD

Check Refrigerant Charge — 30GTN Operating Limitations

• TEMPERATURES — 30HK,HL,HW

• TEMPERATURES — 30GTN

• VOLTAGE — ALL UNITS

OPERATION SEQUENCE

APPENDIX A — CCN TABLES . . . . . . . . . . . . . . . . 67-79

START-UP CHECKLIST FOR COMFORTLINK™

CHILLER SYSTEMS . . . . . . . . . . . . . . . . . . .CL-1-CL-12

GENERAL

This publication contains Start-Up, Service, Controls, Oper-ation, and Troubleshooting information for the 30HK,HWB, and HWC,S water-cooled chillers and the 30HL,HWA and 30GTN air-cooled chillers. See Table 1. These liquid chillers are equipped with ComfortLink controls and conventional ther-mostatic expansion valves (TXVs). The 30GTN and 30HL are also equipped with liquid line solenoid valves (LLSVs).

Table 1 — Unit Sizes (30G,H)

*60 Hz only.

This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out or bypass components or otherwise depart from recom-mended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the board or electrical component.

UNIT MODEL NOMINAL TONS

30HK040 40

30HK050 50

30HK060 60

30HL050 50

30HL060 60

30HW018 15

30HW025 20

30HW028 25

30HW035 30

30HW040 35

30GTN015 15

30GTN020 20

30GTN025 25

30GTN030 30

30GTN035* 35

MAJOR SYSTEM COMPONENTS

General — The 30HK,HL,HW, 30GTN air-cooled recipro-cating chillers contain the ComfortLink™ electronic control system that controls and monitors all operations of the chiller.

The control system is composed of several components as listed in the sections below. See Fig. 1 for typical control box drawing. See Fig. 2-4 for control schematics.

Main Base Board (MBB) — See Fig. 5. The MBB is the heart of the ComfortLink control system. It contains the ma-jor portion of operating software and controls the operation of the machine. The MBB continuously monitors input/output channel information received from its inputs and from all other modules. The MBB receives inputs from thermistors T1, T2, T9, and T10. The 30GTN models also include thermistor T3.

See Table 2. The MBB also receives the feedback inputs from compressors A1 (all) and B1 (30HK,HL only) and other status switches. See Table 3. The MBB also controls several outputs.

Relay outputs controlled by the MBB are shown in Table 4.

Information is transmitted between modules via a 3-wire com-munication bus or LEN (Local Equipment Network). The CCN (Carrier Comfort Network) bus is also supported. Con-nections to both LEN and CCN buses are made at TB3. See Fig. 5.

QuickSet Set Point Adjustment — This standard device is used for setting the desired leaving fluid temperature set point. This device is the factory-installed standard.

Alarm/Alert Indicator Light — This light comes fac-tory installed with the QuickSet Set Point Adjustment. It is illu-minated when any alarm or alert conditions are present.

Scrolling Marquee Display — This optional device is the keypad interface used for accessing chiller information, reading sensor values, and testing the chiller. The marquee dis-play is a 4-key, 4-character, 16-segment LED (light-emitting diode) display. Eleven mode LEDs are located on the display as well as an Alarm Status LED. See Marquee Display Usage section on page 15 for further details.

Energy Management Module (EMM) — The EMM module is available as a factory-installed option or as a field-installed accessory. The EMM module receives 4 to 20 mA inputs for the temperature reset, cooling set point reset and demand limit functions. The EMM module also receives the switch inputs for the field-installed 2-stage demand limit and ice done functions. The EMM module communicates the status of all inputs with the MBB, and the MBB adjusts the control point, capacity limit, and other functions according to the inputs received.

Enable/Off/Remote Contact Switch — The Enable/Off/Remote Contact switch is a 3-position switch used to control the chiller. When switched to the Enable position the chiller is under its own control. Move the switch to the Off po-sition to shut the chiller down. Move the switch to the Remote Contact position and a field-installed dry contact can be used to start the chiller. The contacts must be rated for dry circuit appli-cation capable of handling a 5-vdc, 1- to 20-mA load. In the Enable and Remote Contact (dry contacts closed) positions, the chiller is allowed to operate and respond to the scheduling con-figuration, CCN configuration and set point data. See Fig. 6.

Emergency On/Off Switch — The Emergency On/ Off switch should only be used when it is required to shut the chiller off immediately. Power to the MBB, EMM, and mar-quee display is interrupted when this switch is off and all out-puts from these modules will be turned off.

Board Addresses — The Main Base Board (MBB) has a 3-position Instance jumper that must be set to ‘1.’ All other boards have 4-position DIP switches. All switches are set to ‘On’ for all boards.

Control Module Communication RED LED — Proper operation of the control boards can be visually checked by looking at the red status LEDs (light-emitting diodes). When operating correctly, the red status LEDs should be blinking in unison at a rate of once every 2 seconds. If the red LEDs are not blinking in unison, verify that correct power is being supplied to all modules. Be sure that the Main Base Board (MBB) is supplied with the current soft-ware. If necessary, reload current software. If the problem still persists, replace the MBB. A board LED that is lit continuously or blinking at a rate of once per second or faster indicates that the board should be replaced.

GREEN LED — The MBB has one green LED. The Local Equipment Network (LEN) LED should always be blinking whenever power is on. All other boards have a LEN LED which should be blinking whenever power is on. Check LEN connections for potential communication errors at the board J3 and/or J4 connectors. Communication between modules is ac-complished by a 3-wire sensor bus. These 3 wires run in paral-lel from module to module. The J4 connector on the MBB pro-vides both power and communication directly to the marquee display only.

YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication.

Carrier Comfort Network (CCN) Interface — The 30HK,HL,HW and 30GTN chiller units can be connected to the CCN if desired. The communication bus wiring is a shielded, 3-conductor cable with drain wire and is supplied and installed in the field. See Table 5. The system elements are connected to the communication bus in a daisy chain arrange-ment. The positive pin of each system element communication connector must be wired to the positive pins of the system ele-ments on either side of it. This is also required for the negative and signal ground pins of each system element. Wiring con-nections for CCN should be made at TB3. Consult the CCN Contractor’s Manual for further information.

NOTE: Conductors and drain wire must be 20 AWG (Amer-ican Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 C to 60 C is required. Wire manufactured by Alpha (2413 or 5463), American (A22503), Belden (8772), or Columbia (02525) meets the above mentioned requirements.

It is important when connecting to a CCN communication bus that a color coding scheme be used for the entire network to simplify the installation. It is recommended that red be used for the signal positive, black for the signal negative, and white for the signal ground. Use a similar scheme for cables contain-ing different colored wires.

At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to a ground at one point only. If the commu-nication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning sup-pressor in each building where the cable enters or exits the building (one point per building only). To connect the unit to the network:

1. Turn off power to the control box.

2. Cut the CCN wire and strip the ends of the red (+), white (ground), and black (–) conductors. (Substitute appropriate colors for different colored cables.)

3. Connect the red wire to (+) terminal on TB3 of the plug, the white wire to COM terminal, and the black wire to the (–) terminal.

4. The RJ14 CCN connector on TB3 can also be used, but is only intended for temporary connection (for example, a laptop computer running Service Tool).

Table 2 — Thermistor Designations

LEGEND

Table 3 — Status Switches

*Standard on 30HL, 30HWA, and brine 30GTN units.

LEGEND FOR FIG. 2-4

Table 4 — Output Relays

*Hot Gas Bypass is energized for 30GTN models 015 (50 Hz), 020 (60 Hz) and 30HW025.

Table 5 — CCN Communication Bus Wiring

OPERATING DATA

Sensors — The electronic control uses 2 to 6 thermistors to sense temperatures for controlling chiller operation. See Table 2. These sensors are outlined below. Thermistors T1, T2, T3, T9 and condenser entering and leaving thermistors (30HWB,C,S HL) are 5 kΩ at 77 F (25 C) and are identical in temperature versus resistance and voltage drop performance.

Thermistor T10 is 10 kΩ at 77 F (25 C) and has a different tem-perature vs resistance and voltage drop performance. See Thermistors section on page 58 for temperature-resistance-voltage drop characteristics.

T1 — COOLER LEAVING FLUID SENSOR — This ther-mistor is located in the leaving-fluid nozzle for 30HK,HL and 30GTN models. The sensor is installed in a friction-fit well which is located directly in the fluid path. For 30HW models, the sensor itself is installed directly in the fluid path using a compression fitting. Pressure must be relieved from the cooler and fluid drained before the sensor is removed.

T2 — COOLER ENTERING FLUID SENSOR — This ther-mistor is located in the entering fluid nozzle. The thermistor probe is inserted into a friction-fit well. The sensor is located directly in the fluid path. This sensor is factory-supplied and field-installed on 30HW units only. Sensor and probe are secured to the back of the 30HW control box. Sensor is factory-installed for all other models.

T3 — SATURATED CONDENSING TEMPERATURE

SENSOR — This thermistor is factory installed on 30GTN models only. The sensor is clamped to the outside of a return bend on the condenser coil. Sensor location is shown in Fig. 7.

IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent the unit from starting. If abnormal conditions occur, unplug the connector. If conditions return to normal, check the CCN connector and cable. Run new cable if necessary.

A short in one section of the bus can cause problems with all system elements on the bus.

THERMISTOR

NO.

PIN

CONNECTION

POINT

THERMISTOR INPUT

T1 J8-13,14 (MBB) Cooler Leaving Fluid T2 J8-11,12 (MBB) Cooler Entering Fluid T3 J8-21,22 (MBB) Saturated Condensing

Temperature, Circuit A (30GTN Only)

T9 J8-7,8 (MBB) Outdoor-Air Temperature Sensor or Dual LWT Sensors (Accessory)

T10 J8-5,6 (MBB) Remote Space Temperature Sensor (Accessory)

LWT — Leaving Water Temperature MBB — Main Base Board

STATUS

SWITCH

PIN

CONNECTION

POINT

30HK,HL

040-060

30HW

018-040

30GTN

015-035

OIl Pressure, Ckt B* J7-1,2 OPSB Not Used Not Used

Oil Pressure, Ckt A* J7-3,4 OPSA OPSA OPSA

Remote On/Off TB5-9,10 Field-Installed Relay Closure Compressor

Fault Signal, B1 J9-8,12 CR-B1 Not Used Not Used

Compressor Fault Signal, A1 J9-11,12 CR-A1 CR-A1 CR-A1

ALM — Alarm C — Compressor Contactor CB — Circuit Breaker COTP — Compressor Overtemperature Protection CWFS — Chilled Water Flow Switch CWPI — Chilled Water Pump Interlock CR — Control Relay EMM — Energy Management Module FB — Fuse Block FIOP — Factory-Installed Option Package FM — Fan Motor GCS — Ground Current Sensing HGBP — Hot Gas Bypass HPS — High-Pressure Switch LPS — Low-Pressure Switch OAT — Outdoor-Air Temperature OPS — Oil Pressure Switch PL — Plug POT — Potentiometer R — Relay SPT — Space Temperature SW — Switch TB — Terminal Block TRAN — Transformer UL — Unloader

RELAY

NO. DESCRIPTION

K1 Energize Compressor A1 (30HK,HL,HW) Energize Compressor A1 and Condenser Fan Motor

OFM1 (30GTN)

K2 Energize Compressor B1 (30HK,HL) K3 Energize Unloader A1

K4 Energize Unloader B1 (30HK,HL) Energize Unloader A2 (30HW, 30GTN)*

K5 Energize Liquid Line Solenoid Valve for Circuit A

(30HL, 30GTN)

K6 Energize Liquid Line Solenoid Valve for Circuit B

(30HL)

K7 Alarm K8 Cooler Pump

K9

Energize Condenser Fan Relay for Circuit A

(30HL, 30HWA)

Energize Condenser Pump Relay (30HK, 30HWB,C,S) Energize Condenser Fan Motor OFM2

(30GTN015-035)

K10 Energize Condenser Fan Relay for Circuit B (30HL) Energize Condenser Fan Motor OFM3 (30GTN035)

K11 Hot Gas Bypass

MANUFACTURER

PART NO.

Regular Wiring Plenum Wiring Alpha 1895 — American A21451 A48301 Belden 8205 884421 Columbia D6451 — Manhattan M13402 M64430 Quabik 6130 —

F ig

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R

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Fa ct or y

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Fig. 2 — Low-Voltage (24-V) Control Schematic; 30HK,HL Units

Fig. 3 — Low-Voltage (24-V) Control Schematic; 30HW Units

Fig. 4 — Low-Voltage (24-V) Control Schematic; 30GTN Units

CEPL130346-01

STATUS

LEN

J1 J2

J4 J3

J5

J6

J7 J8 J9

J10

CCN

RED LED - STATUS GREEN LED -

LEN (LOCAL EQUIPMENT NETWORK)

YELLOW LED -

CCN (CARRIER COMFORT NETWORK)

INSTANCE JUMPER

Fig. 5 — Main Base Board

Fig. 6 — LEN/CCN Interface, Enable/Off/Remote Contact Switch, and Emergency On/Off Switch Locations

SET POINT POTENTIOMETER MARQUEE DISPLAY LOCATION

LEN/CCN INTERFACE

ENABLE/OFF/REMOTE

CONTACT SWITCH

EMERGENCY ON/OFF

SWITCH

LEGEND

A — Alarm C — Contactor CB — Circuit Breaker CCN — Carrier Comfort Network CR — Control Relay EMM — Energy Management Module EQUIP — Equipment FU — Fuse GCS — Ground Current Sensing GND — Ground LEN — Local Equipment Network MBB — Main Base Board TB — Terminal Board TDR — Time-Delay Relay TRAN — Transformer

T9 — OUTDOOR-AIR TEMPERATURE SENSOR —

Sensor T9 is an accessory sensor that is remotely mounted and used for outdoor-air temperature reset.

T10 — REMOTE SPACE TEMPERATURE SENSOR —

Sensor T10 (part no. HH51BX006) is an accessory sensor that is remotely mounted in the controlled space and used for space temperature reset. The sensor should be installed as a wall-mounted thermostat would be (in the conditioned space where it will not be subjected to either a cooling or heating source or direct exposure to sunlight, and 4 to 5 ft above the floor). The push button override button is not supported by the ComfortLink™ Controls.

Space temperature sensor wires are to be connected to ter-minals in the unit main control box. The space temperature sensor includes a terminal block (SEN) and a RJ11 female connector. The RJ11 connector is used to tap into the Carrier Comfort Network (CCN) at the sensor.

To connect the space temperature sensor (Fig. 8):

1. Using a 20 AWG twisted pair conductor cable rated for the application, connect 1 wire of the twisted pair to one SEN terminal and connect the other wire to the other SEN terminal located under the cover of the space temperature sensor.

2. Connect the other ends of the wires to terminals 5 and 6 on TB5 located in the unit control box.

Units on the CCN can be monitored from the space at the sensor through the RJ11 connector, if desired. To wire the RJ11 connector into the CCN (Fig. 9):

1. Cut the CCN wire and strip ends of the red (+), white (ground), and black (–) conductors. (If another wire color scheme is used, strip ends of appropriate wires.)

2. Insert and secure the red (+) wire to terminal 5 of the space temperature sensor terminal block.

3. Insert and secure the white (ground) wire to terminal 4 of the space temperature sensor.

4. Insert and secure the black (–) wire to terminal 2 of the space temperature sensor.

5. Connect the other end of the communication bus cable to the remainder of the CCN communication bus.

IMPORTANT: The cable selected for the RJ11 connec-tor wiring MUST be identical to the CCN communica-tion bus wire used for the entire network. Refer to Table 5 for acceptable wiring.

T3

LOCATION T3 LOCATION FOR

30GTN 015, 025

T3 LOCATION FOR

30GTN 020, 030

T3 LOCATION FOR

30GTN 035

MOTORMASTER

SENSOR LOCATION

FOR 30GTN 015, 025

MOTORMASTER

SENSOR LOCATION

FOR 30GTN 020, 030

MOTORMASTER

SENSOR LOCATION

FOR 30GTN 035

R

COMPRESSOR END, LEFT FRONT ACCESS DOOR

(WHEN FACING COOLER)

Fig. 7 — Thermistor T3 Location, 30GTN Units

SPT (T10) PART NO. HH51BX006

SENSOR

SEN SEN

TB5

Fig. 8 — Typical Space Temperature Sensor Wiring

T-55 SPACE

SENSOR

CCN+

CCN GND

CCN-

TO CCN

COMM 1

BUS (PLUG)

AT UNIT

Fig. 9 — CCN Communications Bus Wiring to Optional Space Sensor RJ11 Connector

Energy Management Module (Fig. 10) — This factory-installed option or field-installed accessory is used for the following types of temperature reset, demand limit, and/or ice features:

• 4 to 20 mA leaving fluid temperature reset (requires field-supplied 4 to 20 mA generator)

• 4 to 20 mA cooling set point reset (requires field-supplied 4 to 20 mA generator)

• Discrete inputs for 2-step demand limit (requires field-supplied dry contacts capable of handling a 5 vdc, 1 to 20 mA load)

• 4 to 20 mA demand limit (requires field-supplied 4 to 20 mA generator)

• Discrete input for Ice Done switch (requires field-supplied dry contacts capable of handling a 5 vdc, 1 to 20 mA load) See Demand Limit and Temperature Reset sections on pages 39 and 37 for further details.

Loss-of-Cooler Flow Protection — A proof-of-cooler flow device (accessory flow switch) MUST be used with all chillers. The device should be set to shut the unit off if cooler gpm drops below the minimum flow rate for the ma-chine. Refer to Pre-Start-Up, System Check section on page 63. The flow switch contacts are connected to TB5-1,2.

Compressor Ground Fault Sensor — The ground fault sensor accessory (Part Number 30HW900004) monitors all phases of the 3-phase power supply to the compressor. If a short to ground is sensed by the sensor, the compressor auto-matically shuts down. This action prevents contamination of the refrigeration system from acid formation. The compressor shuts down when a 2.5 ± 2 amp ground current is sensed by a toroid installed around the compressor power leads. The MBB will lock the compressor off until the compressor failure alert is reset. For installation details, see the instructions included with the accessory package.

NOTE: Two accessory packages are required for 30HK,HL units.

Thermostatic Expansion Valves (TXV) — All units are equipped from the factory with conventional TXVs.

The 30HL and 30GTN models also have factory-installed liquid line solenoids. The liquid line solenoid valves are not intended to be a mechanical shut-off. When service is required, use the liquid line service valve to pump down the system.

The TXV is set at the factory to maintain approximately 8 to 12° F (4.4 to 6.7° C) suction superheat leaving the cooler by monitoring the proper amount of refrigerant into the cooler. All TXVs are adjustable, but should not be adjusted unless abso-lutely necessary.

The TXV is designed to limit the cooler saturated suction temperature to 55 F (12.8 C). This makes it possible for unit to start at high cooler fluid temperatures without overloading the compressor.

Compressor Control Relay (CR) — Each compres-sor has its own control relay. The CR is used to control and pro-tect the compressors and crankcase heaters. The CR provides the following functions:

• compressor contactor and crankcase heater control

• status communication to the processor board

A high-pressure switch is wired in series between the MBB and CR. If the high-pressure switch opens during operation of a compressor, the compressor will be stopped, the failure will be detected through the signal contacts and the compressor will be locked off.

Capacity Control — The control system cycles com-pressors, unloaders, and hot gas bypass solenoids to maintain the user-configured leaving chilled fluid temperature set point.

Entering fluid temperature is used by the Main Base Board (MBB) to determine the temperature drop across the cooler and is used in determining the optimum time to add or subtract ca-pacity stages. The chilled fluid temperature set point can be au-tomatically reset by the return temperature reset space, or outdoor-air temperature reset features. It can also be reset from an external 4- to 20-mA signal (requires Energy Management Module FIOP or accessory).

With the automatic lead-lag feature in the unit, the control determines by compressor wear factor (combination of starts and run hours) which circuit will start first (30HK,HL only). At the first call for cooling, the compressor crankcase heater will be deenergized, a condenser fan (30GTN) or condenser fan relay (30HL, 30HWA) will start and the compressor will start unloaded.

If the circuit has been off for 15 minutes, the liquid line solenoid (if installed) will remain closed for 10 seconds while the cooler and suction lines are purged of any liquid refrigerant.

After the purge period, the liquid line solenoid (if installed) will open allowing the TXV to meter the refrigerant to the cooler. If the off-time is less than 15 minutes, the liquid line solenoid will be opened as soon as the compressor starts.

The TXVs will open gradually to provide a controlled start-

up. During start-up, the low pressure and oil pressure (if in-stalled) switches will be bypassed for 2 minutes to allow for the transient changes during start-up. As additional stages of com-pression are required, the processor control will add them. See Table 5.

If a circuit is to be stopped, the following occurs:

For 30HK, 30HW units, the compressor will be shut off.

For 30HL, 30GTN units, the control will first close the liquid line solenoid valve. The compressor will operate until the low pressure switch opens and will then be shut off. If the low pres-sure switch does not open within 3 minutes, the alarm/alert indictor light will be illuminated and alert 135 (Circuit A) or 136 (Circuit B, 30HL only) will be generated (with Scrolling Marquee option only).

During shutdown all diagnostic conditions will be honored.

If a safety trips or alarm condition is detected before pumpout is complete, the circuit will be shut down.

The capacity control algorithm runs every 30 seconds. The algorithm attempts to maintain the Control Point at the desired set point. Each time it runs, the control reads the entering and leaving fluid temperatures. The control determines the rate at which conditions are changing and calculates 2 variables based on these conditions. Next, a capacity ratio is calculated using the 2 variables to determine whether or not to make any chang-es to the current stages of capacity. This ratio value ranges from –100 to +100%. If the next stage of capacity is a compressor, the control starts (stops) a compressor when the ratio reaches +100% (–100%). If the next stage of capacity is an unloader, the control deenergizes (energizes) an unloader when the ratio reaches +60% (–60%). Unloaders are allowed to cycle faster than compressors, to minimize the number of starts and stops on each compressor. A delay of 90 seconds occurs after each capacity step change. Refer to Table 6.

Table 6 — Part Load Data Percent Displacement, Standard Units

*Unloaded compressor, one unloader energized.

†Unloaded compressor, two unloaders energized.

**Hot gas bypass energized as first stage.

UNIT

TYPE

CONTROL

STEPS

LOADING SEQ A LOADING SEQ B

% Displacement Compressor % Displacement Compressor

30HK,HL

040 (60 Hz)

1 25 A1* 25 B1* 2 50 A1 50 B1 3 75 A1*,B1 75 A1,B1* 4 100 A1,B1 100 A1,B1

30HK,HL

040 (50 Hz) 050 (60 Hz)

1 40 A1* 16 B1* 2 60 A1 40 B1 3 — — 60 A1*,B1* 4 80 A1*,B1 80 A1,B1* 5 100 A1,B1 100 A1,B1

30HK,HL

050 (50 Hz)

060 (All)

1 33 A1* 33 B1* 2 50 A1 50 B1 3 67 A1*,B1* 67 A1*,B1* 4 83 A1*,B1 83 A1,B1* 5 100 A1,B1 100 A1,B1

30HW (All) 018,028-040

1 33 A1† — — 2 67 A1* — — 3 100 A1 — —

30HW (All)

1 50 A1** — — 2 100 A1 — —

30GTN

015 (60 Hz) 020 (50 Hz)

025-035 (All)

1 33 A1† — — 2 67 A1* — —

3 100 A1 — —

30GTN

015 (50 Hz) 020 (60 Hz)

1 50 A1** — —

2 100 A1 — —

CEBD430351-0396-01C

T E

S T

C E

P L1

1-

P W

R

TEST 2

J1 J2

J4 J3

J5

J6 J7

LEN

STATUS

RED LED - STATUS

GREEN LED -

LEN (LOCAL EQUIPMENT NETWORK)

ADDRESS

DIP SWITCH

Fig. 10 — Energy Management Module

MINUTES LEFT FOR START — This value is displayed only in the network display tables (using Service Tool or ComfortWORKS® software) and represents the amount of time to elapse before the unit will start its initialization routine.

This value can be zero without the machine running in many situations. This can include being unoccupied, ENABLE/OFF/ REMOTE CONTACT switch in the OFF position, CCN not allowing unit to start, Demand Limit in effect, no call for cool-ing due to no load, and alarm or alert conditions present. If the machine should be running and none of the above are true, a minimum off time (DELY, see below) may be in effect. The machine should start normally once the time limit has expired.

MINUTES OFF TIME (DELY, Configuration Mode under OPT2) — This user-configurable time period is used by the control to determine how long unit operation is delayed after power is applied/restored to the unit. It is also used to delay compressor restarts after the unit has shut off its lowest stage of capacity. Typically, this time period is configured when multi-ple machines are located on a single site. For example, this gives the user the ability to prevent all the units from restarting at once after a power failure. A value of zero for this variable does not mean that the unit should be running.

LOADING SEQUENCE (30HK,HL) — The compressor ef-ficiency is greatest at partial load. Therefore, the following se-quence list applies to capacity control.

The next compressor will be started with unloaders ener-gized on the lead compressor.

All valid capacity combinations using unloaders will be used as long as the total capacity is increasing.

LEAD/LAG DETERMINATION — This is a configurable choice and is factory set to be automatic for 30HK,HL units. It is set for Circuit A leading for 30HW and 30GTN units. The value can be changed (30HK,HL only) to Circuit A or Circuit B leading as desired. Set at automatic, the control will sum the current number of logged circuit starts and one-quarter of the current operating hours for each circuit. The circuit with the lowest sum is started first. Changes to which circuit is the lead circuit and which is the lag are also made when total ma-chine capacity is at 100% or when there is a change in the di-rection of capacity (increase or decrease) and each circuit’s ca-pacity is equal.

CAPACITY SEQUENCE DETERMINATION — This con-trol choice does NOT have any impact on these machines.

CAPACITY CONTROL OVERRIDES — The following overrides will modify the normal operation of the routine.

Deadband Multiplier — The user configurable Deadband Multiplier (Z.GN, Configuration Mode under SLCT) has a default value of 1.0. The range is from 1.0 to 4.0. When set to other than 1.0, this factor is applied to the capacity Load/ Unload Factor. The larger this value is set, the longer the con-trol will delay between adding or removing stages of capacity.

Figure 11 shows how compressor starts can be reduced over time if the leaving water temperature is allowed to drift a larger amount above and below the set point. This value should be set in the range of 3.0 to 4.0 for systems with small loop volumes.

First Stage Override — If the current capacity stage is zero, the control will modify the routine with a 1.2 factor on adding the first stage to reduce cycling. This factor is also applied when the control is attempting to remove the last stage of capacity.

Slow Change Override — The control prevents the capacity stages from being changed when the leaving fluid temperature is close to the set point (within an adjustable deadband) and moving towards the set point.

Ramp Loading (CRMP, Configuration Mode under SLCT) — Limits the rate of change of leaving fluid temperature. If the unit is in a Cooling mode and configured for Ramp Loading, the control makes 2 comparisons before deciding to change stages of capacity. The control calculates a temperature differ-ence between the control point and leaving fluid temperature. If the difference is greater than 4° F (2.2° C) and the rate of change (°F or °C per minute) is more than the configured Cool-ing Ramp Loading value (CRMP), the control does not allow any changes to the current stage of capacity.

Low Entering Fluid Temperature Unloading — When the entering fluid temperature is below the control point, the con-trol will attempt to remove 25% of the current stages being used. If exactly 25% cannot be removed, the control removes an amount greater than 25% but no more than necessary. The lowest stage will not be removed.

HOT GAS BYPASS — If equipped, the hot gas bypass valve is energized only when all unloaders are energized. The valve is closed when unloaders are deenergized to increase capacity.

The valve is energized on 30HK,HL units only when one cir-cuit is operating unloaded.

Cooler Freeze Protection — The control will try to prevent shutting the chiller down on a Cooler Freeze Protection alarm by removing stages of capacity. If the cooler fluid selected is Water, the freeze point is 34 F (1.1 C). If the cooler fluid select-ed is Brine, the freeze point is 8° F (4.4° C) below the cooling set point (or lower of two cooling set points in dual set point configurations). If the cooler leaving fluid temperature is less than the freeze point plus 2.0° F (1.1° C), the control will im-mediately remove one stage of capacity. This can be repeated once every 30 seconds.

0 200 400 600 800 1000

TIME (SECONDS)

2 STARTS

3 STARTS

DEADBAND EXAMPLE

LW

T

F

MODIFIED

DEADBAND

STANDARD

DEADBAND

LW

T

C

LEGEND

LWT — Leaving Water Temperature

Fig. 11 — Deadband Multiplier

Head Pressure Control COMFORTLINK™ UNITS (30GTN Only) — The Main Base Board (MBB) controls the condenser fans to maintain the lowest condensing temperature possible, and thus the highest unit efficiency. The fans are controlled by the saturated con-densing temperature set from the factory. Fan control is deter-mined by the Head Pressure Control Method (HPCM) setting in the Configuration Mode under the OPT1 sub-mode. This setting (HPCM=2) indicates set point control. During the first 10 minutes after circuit start-up, MBB-controlled fans are not turned on until T3 is greater than the head pressure set point plus 10° F (5.6° C). If T3 is greater than 95 F (35 C) just prior to circuit start-up, all MBB-controlled fan stages are turned on to prevent excessive discharge pressure during pull-down. At each change of the fan stage, the system will wait one minute to allow the head pressure to stabilize unless T3 is greater than 125 F (51.6 C), in which case all MBB-controlled fans will start immediately. This method allows the unit to run at very low condensing temperatures at part load. The control will turn off a fan stage when T3 is below the head pressure set point by 35 F (19.4 C). Fan sequences are shown in Fig. 12.

Motormaster® Option — For low-ambient operation, the lead fan on 30GTN units can be equipped with the Motormaster head pressure controller option or accessory. The fan con-trolled is that which is energized with compressor A1. Refer to Fig. 12 for condenser fan staging information.

Operation of Machine Based on Control Method and Cooling Set Point Selection Set-tings — Machine On/Off control is determined by the con-figuration of the control method (CTRL, Configuration mode under sub-mode OPT2) and cooling set point select (CLSP, Configuration mode under sub-mode SLCT) variables. For models using the Quickset Set Point Adjustment, these vari-ables are factory configured for control method of 0 (Enable/ Off/Remote Contact) and a cooling set point select of 5 (Exter-nal Quickset POT). Models with the optional Scrolling Mar-quee have the same control method, but have cooling set point select set to 1 (single set point, CSP1). With the control method set to 0, simply switching the Enable/Off/Remote Contact switch to the Enable or Remote Contact position (external con-tacts closed) will put the chiller in an occupied state. The control mode (MODE) will be 1 when the switch is Off and will be 5 when in the Enable position or Remote Contact posi-tion with external contacts closed.

Three other control methods are available for Machine On/ Off control:

7-DAY SCHEDULE (CTRL=1) — The Main Base Board will use the schedule defined under the Time Clock mode. This schedule is accessible ONLY from the Scrolling Marquee or accessory Navigator display. Refer to example tables in the Marquee Display Usage section, page 15. The Enable/Off/ Remote Contact must be in the Enable or Remote Contact posi-tion. Note that this is NOT the same schedule that is seen when using Building Supervisor, Service Tool, ComfortWORKS®, etc. The control mode (MODE) will be 1 when the switch is Off. The control mode will be 3 when the Enable/Off/Remote Contact switch input is On and the time of day is during an un-occupied period. Similarly, the control mode will be 7 when the time of day is during an occupied period OCCUPANCY SCHEDULE (CTRL=2) — The Main Base Board will use the operating schedules that can only be access-ed and configured using a CCN tool such as Building Supervi-sor, Service Tool or ComfortWORKS software. The Enable/ Off/Remote Contact must be in the Enable or Remote Contact position. The control mode (MODE) will be 1 when the switch is Off. The control mode will be 3 when the Enable/Off/ Remote Contact switch input is On and the time of day is dur-ing an unoccupied period. Similarly, the control mode will be 7 when the time of day is during an occupied period.

CCN SCHEDULE (CTRL=3) — An external CCN device such as Flotronic™ System Manager controls the On/Off state of the machine. This CCN device forces the variable ‘CHIL_S_S’ between Start/Stop to control the chiller. The con-trol mode (MODE) will be 1 when the switch is Off. The con-trol mode will be 2 when the Enable/Off/Remote Contact switch input is On and the CHIL_S_S variable is ‘Stop.’ Simi-larly, the control mode will be 6 when the CHIL_S_S variable is ‘Start.’

Table 7 illustrates how the control method and cooling set point select variables direct the operation of the chiller and the set point to which it controls. The illustration also shows the ON/OFF state of the machine for the given combinations.

Pumpout (30HL, 30GTN Units) — Pumpout is a time-based feature. On a command for start-up, the compressor starts with the liquid line solenoid closed (provided 15 minutes has elapsed since previous start). After 10 seconds, the liquid line solenoid opens. At shutdown, the liquid line solenoid is closed and the compressor is turned off 10 seconds later.

Fig. 12 — 30GTN Condenser Fan Sequence

FAN ARRANGEMENT FAN NO. FAN RELAY NORMAL CONTROL

30GTN015-030

1 — Compressor A1

2 1 First Stage Condenser Fan

30GTN035 1 — Compressor A1

2 1 First Stage Condenser Fan

3 2 Second Stage Condenser Fan

Table 7 — Control Methods and Cooling Set Points

*Dual set point switch input used. CSP1 used when switch input is closed. CSP2 used when switch input is open.

†Cooling set point determined from 4 to 20 mA input to Energy Management Module (EMM) to terminals TB6-3,5.

**Cooling set point determined from QuickSet Set Point Adjustment input to the Main Base Board (MBB), J8 pins 9,10.

Marquee Display Usage (See Fig. 13 and Tables 8-27) — The Optional Marquee display module provides the user interface to the ComfortLink™ control sys-tem. The display has up and down arrow keys, an key, and an key. These keys are used to navigate through the different levels of the display structure. See Table 8. Press the key until the display is blank to move through the top 11 mode levels indicated by LEDs on the left side of the display.

Pressing the and keys simultaneously will scroll a clear language text description across the display indicating the full meaning of each display acronym. Pressing the and keys when the display is blank (Mode LED level) will return the Marquee display to its default menu of rotating display items. In addition, the password will be disabled requiring that it be entered again before changes can be made to password protected items.

Clear language descriptions in English, Spanish, French, or Portuguese can be displayed when properly configuring the LANG variable in the Configuration Mode, under DISP sub-mode. See Tables 17A and 17B.

NOTE: When the LANG variable is changed to 1, 2, or 3, all appropriate display expansions will immediately change to the new language. No power-off or control reset is required when reconfiguring languages.

When a specific item is located, the display will flash show-ing the operator, the item, followed by the item value and then followed by the item units (if any). Press the key to stop the display at the item value. Items in the Configuration and Service Test modes are password protected. The display will flash PASS and WORD when required. Use the and arrow keys to enter the 4 digits of the password. The default password is 1111. The password can only be changed through CCN devices such as ComfortWORKS® and Service Tool.

Changing item values or testing outputs is accomplished in the same manner. Locate and display the desired item. Press to stop the display at the item value. Press the key again so that the item value flashes. Use the ar-row keys to change the value or state of an item and press the key to accept it. Press the key and the item, value, or units display will resume. Repeat the process as required for other items.

See Tables 8-27 for further details.

Service Test (See Tables 10A and 10B) — Both main power and control circuit power must be on.

The Service Test function should be used to verify proper operation of compressors, unloaders, liquid line solenoids, hot gas bypass (if installed), cooler pump and remote alarm relays, condenser pump, and condenser fans/relays. To use the Service Test mode, the Enable/Off/Remote Contact switch must be in the OFF position. Use the display keys and Tables 10A and 10B to enter the mode and display TEST. Press twice so that OFF flashes. Enter the password if required. Use either arrow key to change the TEST value to the On position and press . Press and the button to enter the OUTS or COMP sub-mode.

Test the condenser fans, liquid line solenoids, cooler pump, condenser pump, and alarm relays by changing the item values from OFF to ON. These discrete outputs are then turned off if there is no keypad activity for 10 minutes. All compressor out-puts can be turned on, but the control will limit the rate by stag-ing one compressor per minute. Compressor unloaders and hot gas bypass relays/solenoids (if installed) can be tested with compressors on or off. The relays under the COMP sub-mode will stay on for 10 minutes if there is no keypad activity. Com-pressors will stay on until they are turned off by the operator.

The Service Test mode will remain enabled for as long as there is one or more compressors running. All safeties are monitored during this test and will turn a compressor, circuit or the machine off if required. Any other mode or sub-mode can be accessed, viewed, or changed during the TEST mode. The STAT item (Run/status mode under sub-mode VIEW) will dis-play “0” as long as the Service mode is enabled. The TEST sub-mode value must be changed back to OFF before the chiller can be switched to Enable or Remote contact for normal operation.

CONTROL

TYPE

(CTRL)

OCCUPANCY

STATE

COOLING SET POINT SELECT (CLSP)

(single)

(dual, switch)

(dual, 7 day)

(dual, occ)

(4 to 20 mA)

(QuickSet)

0 (switch) Occupied ON,CSP1 ON* ON,CSP1 ON,CSP1 ON† ON** Unoccupied ON,CSP1 ON* ON,CSP2 ON,CSP2 ON ON**

1 (7 day) Occupied ON,CSP1 ON* Illegal Illegal ON† ON** Unoccupied OFF OFF Illegal Illegal OFF OFF

2 (Occupancy) Occupied ON,CSP1 ON* Illegal Illegal ON† ON** Unoccupied OFF OFF Illegal Illegal OFF OFF

3 (CCN)

Occupied ON,CSP1 ON* ON,CSP1 ON,CSP1 ON† ON** Unoccupied ON,CSP1 ON* ON,CSP2 ON,CSP2 ON† ON**

ESCAPE

ENTER

ESCAPE

ESCAPE ENTER

ESCAPE ENTER

ENTER

ENTER

ENTER

ENTER

ENTER ESCAPE

ENTER

ENTER ESCAPE

Run Status

Service Test

Temperature

Pressures

Setpoints

Inputs

Outputs

Configuration

Time Clock

Operating Modes

Alarms

Alarm Status

ENTER

MODE

ESCAPE

Fig. 13 — Scrolling Marquee Display

QuickSet Set Point Adjustment Usage — Stand-ard units are shipped with the QuickSet Potentiometer. This de-vice is used to set the desired leaving fluid temperature set point. The potentiometer is factory calibrated and the pointer on the dial should be aligned to the desired leaving fluid tem-perature. The chiller is factory configured for fluid type of water (FLUD=1) and the set point can be adjusted from 38 F to 70 F (3.3 C to 21.1 C). Settings between the –20 F to 38 F (–28.9 C to 3.3 C) temperature range are for brine applications only and require that the unit be equipped with the Scrolling Marquee display.

NOTE: Medium temperature brine units are factory-shipped with set point adjustable from 15 F to 70 F (–9.4 C to 21.1 C).

Ensure that cooler fluid is adequately protected from freezing before setting desired temperatures below 38 F (3.3 C).

QUICKSET CALIBRATION — The potentiometer MUST be calibrated if it or the Main Base Board (MBB) is replaced.

To calibrate the potentiometer, follow the steps shown below:

1. Turn the knob fully counterclockwise (CCW) so that the pointer is pointing to the asterisk on the label. The alarm/ alert indicator light will illuminate.

2. Turn the knob clockwise (CW) so that the pointer is…