30GXN,R080-528 E> 30HXA,HXCO76-271 Air-Cooled and Water-Cooled Chillers with ComfortLink™ Controls 50/60 Hz Series 6 Controls Start-Up, Operation, Service, and Troubleshooting SAFETY CONSIDERATIONS Installing stating up, and servicing this equipment can be hacardous die to system pressures, elecal components, and DO NOT attempt ro unbraze factory joints when servicing equipment location (roof, elevated. stctures, ete). Only this equipment. Compressor ol is flammable and there 8 truined, qualified installers and service mechanics) should no way to dteet how moch oll may bein any of the rei install, startup, and service this equipment erant ins. Cot lines with tubing cuter as required when ‘When working on tis equipment, observe precautions in performing service. Use a pan € eatch any ol that may the litrature, and on tg, stckes, ad labels attached to the come out ofthe lines and asa gage for how much elt add equipment, and any other safety precautions that apply. Follow to system, DO NOT re-use compressor oil. Do NOT leave all satety codes, Wear safety glasses and work gloves. Use care refrigerant system open to air any logger than necessary. ‘Seal circuits being serviced and charge With dry nitrogen 10 jn handling, sigging, and setting this equipment, and in i ig thls equipment, and prevent oil contamination when timely repairs cannot be handling al lectcal components completed, CONTENTS. Electrical shock can eause personal injury and death, Shut Page oft all power to this equipment during installation and ser ‘SAFETY CONSIDERATIONS. 1 Yiee, There may be more than one disconnect switch. Tag GENERAL. 3 I icone loan fo ale tes not ese power MAJOR SYSTEM COMPONENTS. Ba intl work is compl Main Base Board (MBB)... 3 Screw Compressor Board (SCB) 3 Electronic Expansion Valve (EXV) Board. 3 Xs) ComfortLink Compressor Protection (CCP) Bi . 3 "This unit uses a microprocessor-based electronic contol Energy Management Module (ENN) 3 sysem a moteur or aes og eu con- EnabielOttiMemote Connect Switch 3 fonents, of 10 bypass or olhervise depar. fom recom- Emergency On/Off Switch. 3 mended procedures. Any shor-io-ground of the contol Board addresses. 3 board or accompanying wiring may destroy the electronic Control Module Communication, 3 _madules or electrical components Carrier Comfort Network (CCN) interface. --......3 ‘OPERATION DATA. . +40 Electronic Expansion Vaive (EXV) 4 EXV OPERATION "To prevent potential damage to heat exchanger tubes + ECONOMIZER OPERATION always run Aid through heat exchangers when adding or ll Pumps. 3 removing refrigerant charge. Use appropriate brine solu- Motor Cooling, 5 tions in cooler and condenser fluid loops to prevent the Back Pressure Vaive (30GXN,R frecing of heat exchangers when the equipment is exposed ‘and 30HXA only) 5 to temperatures below 32 F (0°C). Sensors 5 DO NOT VENT refrigerant relief valves within a building, ‘amfortLink Compressor Protection ‘Outlet from slit valves must be vented outdoors in accor (CCP) Board 7 lance with the latest edition of ANSVASHRAE (American + OUTPUTS National Standards Instute/American Society of Heating, « INBUTS: Retiigeraton and Ait Conditioning Engineers) 15 (Safety ‘Wye-Delta vs Across-the-Line (XL) Code for Mechanical Refrigeration). The accumulation of starting Option 8 refrigerant in an enclosed space ean displace oxygen and Capacity Control 8 cause asphysiaton, Provide adequate vention in enclosed MINUTES LEFT FOR START fr low overhead areas, Inhalation of high concentrations of + MINUTES OFF TIME Yepor is harmful and. may. cause heart iegularies, + LOADING SEQUENCE “unconsciousness or death. Misuse can be fatal. Vapor is + CLOSE CONTROL heavier than air and reduces the amount of oxygen available + LEAD/LAG DETERMINATION for breathing, Product causes eye and skin imitation + CAPACITY SEQUENCE DETERMINATION ‘Decomposition product are hazardous + MINIMUM LOAD VAL + CAPACITY CONTROL OVERRIDES Tansnoue revere a orci er any ie seconenso a winatPoe sgn Fa PODTRTONCONTENTS (cont) Page Head Pressure Control i GENERAL + AIR-COOLED UNITS (20GXN.R) + WATER-COOLED UNITS (@0HXC) CONDENSERLESS UNITS (GOHXA) + 09DK AIR-COOLED CONDENSERS + 09AZ AIR-COOLED CONDENSERS + OPERATION SEQUENCE + VARIABLE SPEED FAN CONTROL, + ADJUSTING PID ROUTINES Control Methods ” + SWITCH + 7-DAY SCHEDULE + OCCUPANCY + CCN Cooling Setpoint Select 7 Ice Mode fed Cooler and Condenser (30HXC) Pump Control 7 + COOLER PUMP CONTROL + CONDENSER PUMP CONTROL Flow Sensor. ... 8 Cooler Heater Coniroi 18 Oil Heater Control 18 Navigator Display Niodule Usage is Service Test. 9 Configuring and Operating Duai Chiller Control 9 Alarms/Alerts, 36 Run Hours and Starts 36 Temperature Reset 36 Demand Limit 38 + DEMAND LIMIT (2:Stage Switch Controlled) + EXTERNALLY POWERED DEMAND LIMIT + DEMAND LIMIT (CCN Loadshed Controlled) Cooling Set Point (4 to 20 mA). fee 39) ‘TROUBLESHOOTING. 41st Checking Display Codes 41 Unit Shutott : 41 Complete Unit Sioppage . . val Single Circuit Stoppage 2000000000000. 0a Restart Procedure 4 + POWER FAILURE EXTERNAL TO THE UNIT Alarms and Alerts wl Compressor AlarmiAlert Circuit... nia EXV Troubleshooting Procedure. 50 + INSPECTING/OPENING ELECTRONIC EXPANSION VALVES + BRAZED-PLATE ECONOMIZERS SERVICE Servicing Coolers and Condensers + TUBE PLUGGING + RETUBING «_ TIGHTENING COOLERICONDENSER HEAD BOLTS Inspecting/Cleaning Heat Exchanger + COOLERS, © CONDENSERS (30HX Only) Water Treatment 33 Condenser Coils (30GXN.R Only). sens + COIL CLEANING +. CLEANING E-COATED COILS Condenser Fans (30GXN,R Only) 4 Refrigerant Charging/Adding Charge 35 ll Charging/L ow Oil Recharging, 56 Oli Filter Maintenance 3 + REPLACING THE EXTERNAL OI FILTER +. REPLACING THE INTERNAL OIL FILTER Compressor Changeout Sequence... 3” Pag a + BURNOUT CLEAN-UP PROCEDURE Moisture-Liquid Indicator. Filter Drier. Liquid Line Service Vaive Thermistors: + LOCATION + THERMISTOR REPLACEMENT Pressure Transducers... + TROUBLESHOOTING + FLOW SENSOR Safety Devices ..... + COMPRESSOR PROTECTION + OIL SEPARATOR HEATERS (30GX) + COOLER PROTECTION Relief Devices 66 + PRESSURE RELIEF VALVES Control Modules. 68 MAIN BASE BOARD (MBB), SCREW COMPRESSOR ‘BOARD (SCB), EXPANSION VALVE BOARD (EXV), ENERGY MANAGEMENT MODULE (EMM), COMFORTLINK™ COMPRESSOR PROTECTION BOARD (CCP), AND THE NAVIGATOR bese RED LED + GREEN LED YELLOW LED. Cartier Comfort Network (CCN) Interface ° Replacing Defective Processor Module. oe Winter Shutdown Preparation 210 Maintenance. : 270) PRE-START-UP PROCEDURE........ 7 System Check....... INIEIINI a START-UP AND OPERATION. . Tg Actual Start-up Sa Operating Sequence. 7 FIELD WIRING. 14 APPENDIX A (Compressor Must Trip Amps) 75-84 APPENDIX B (Capacity Loading Sequence)... = 85-89 APPENDIX C (Available Accessories). 9091 APPENDIX D (Building Interface) 92.94 APPENDIX E (Cooler and ‘Condenser Pressure Drop). 95-100 APPENDIX F (Typical System Components) woL-u2 APPENDIX G (CCN Cor 113125 APPENDIX H (30GXN,R Duplex Combinations). 126 APPENDIX | (Motormaster® V Operation Instructions) 127-129 APPENDIX J (Maintenance Log) 130 START-UP CHECKLIST (For 30GX,HX Liquid Chiller) CL @CL-10 GENERAL IMPORTANT, These unis use religernt RISE smpressor ofl used with R-I34s is Castol Ieematic 20, Carrer Specification #PP 47-32 This publication contains Contos Start ation and "rovbleshooting data forthe 30GXN,R080-528 and BOHXA,CO76-271 screw chillers Circuits are identified as circuits A and B, and compressors axe identified as Al or A2 in circuit A, and BI or B2 in circuit B. Refer to Appendix H for Duplex unit combinations. The J0GXN,GARHX Series chillers feature microproces sorbased electronic controls and electronic expansion valves (EXV) in each reffigeraton circuit“The control system eycles compressor loaders andr com- pressors to maintain the selected leaving Quid temperature set point. The system automatically positions the EXV to maintain the specified discharge gas supecheat temperature inthe circuit ‘The system also has capabilites to contol a condenser water valvé to maintain suitable discharge pressure for the 30HXC Unit. Safeties are continuously monitored to prevent the unit from operating ander unsafe conditions. A vheduling function can be programmed by the user to contro the unit's occupies fnd unoeeupied schedules. The control also operates a test function snd a manual control fonction tha allows the operator to check output signals and ensure components are operable. MAJOR SYSTEM COMPONENTS Main Base Board (MBB) — This board consis the trajnty ofthe conto system opeaing software and controls the operation ofthe machine. It has 1) input channels and ouput channels ‘The MBB continuously monitors inpuvoutt chanel in- formation receive from all he modules and controls ll ouput ‘Sinals for all output channels. ‘The processor module also conols the EXV driver module, commanding it open or elose each EXV in order 1 mainain the proper cooler lve {nformation is transite between the MBB: Confort ink™ Compressor Prtetion (CCP) boards, the EXY driver module, the Serew Compressor Board (SCB), the Energy Management Module (EMM) and the Navigator todules through & Sire Communications bus called the Local Equipment Network {LEN). The emote enhanced display is comecte to the MBB through a wire communications bus, but uses «diferent {communication bes called the Carer Comfort Network (CEN). The CCN bus #8 also used to communicate 10 ther CCN devices when the nit is installed in & network ‘pplication, ‘Screw Compressor Board (SCB) — The SCB bas 3 inp alongwith 2 analog and 5 discrete outputs, The SCB nodule communicates the stats ofthe inpts with the MBB fnd-operates tho oll eater (30GXN,R only), cooler heater GHW only) ad pump opus Electronic Expansion Valve (EXV) Board — The EXV board has 4 inputs and 2 outputs It receives signals from the MBB and operates the electronic expansion devices. ‘The electronic expansion valve board also sends the MBB the status oF 4 inpet channels ComfortLink Compressor Protection (CCP) Board — The CCP toart monitors the high-pressure Sitch slau, runing eument and motor temperature Tor each ompressor. Each CCP board contol up 10 2 compressors ‘The CCP boart aso controls the motor cooling solenoid, oi solenoid and contactor outputs. A pre-punched configuration header for each compressor determines the must tap amps setting. Each CCP board sends the MBB each compressors fnotoe temperature, relay satus and running cUTeM as. a percentage of the mus ip amps value. The CCP board also Communicates any alam condition as the feedback value. Energy Management Module (EMM) — The EMM is availble a a factory-installed option ot as afield installed accessory. The EMM receives 4 10 20 mA inputs for the tempertire reset, cooling set point reset and demand init functions. The EMM. also receives the sivich inputs forthe fiekinsalled 2stage demand limit and ice done fonctions. ‘The EMM communicates the status ofall inputs with the MBB, andthe MBB aus te convo pi, Expy ii, and other fuanetions acording tthe inp received Enable/Off/Remote Contact Switch — The Enable! OlRemote Contact switch is a position switch used to ont the chile (ee Table 1). When switched tothe Enable position the chiller is under its own control, Move the switch {he Off position to shut the chiller down. Move the switch to the Remote Contact postion and a fiek-intalled dry contact ‘canbe used to star the chiller. The contacts must be capable of handling a 24-vac, 20-mA. load. In the Enable and Remote ‘Contact (dry contacts closed) position, the chillers allowed to fperate and respond tothe scheduling configuration, CCN con- figuration and setpoint data Emergency On/Off Switch —The Emergency On! (Off swith should only be used when itis required to shut the chiller off immediately. Power tothe MBB, EMM, EXY, SCB and Nevigetor display is incerupted when this switch is off and tl outputs from these modules willbe tumed off. Board Addresses — Tie Main Base Board (MBB) has ‘an Instance jumper that must be seo *I'. The EXY, SCB and EMM boards have 4-postion DIP switches that must be set to ‘On’ for all hoards. The CCP address has a 4-position DIP switch, Switches 3 and 4 st the address. Control Module Communication RED LED — Proper operation ofthe contol boards canbe vi- sually checked by looking at the red status LEDs (light- ‘emitting diodes). When operating. comectly, 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, verity the ‘bom adress and that comect power is being supplied to all ‘modules, Be sure thatthe Main Base Board (MBB) is supplied With the curtent software, f necessary, reload current software. I the problem stil persists, eplace the MBB. A board LED that isi continuously or blinking at arate of once per second ‘or faster indicates that the board shouldbe replaced. GREEN LED — The MBB has one green LED. The Local Exuipment Network (LEN) LED should always be blinking ‘whenever power ison. All other bourds have a LEN LED that Should be Blinking whenever power is on, Check LEN connec tions for potential communication eros at the board 13 and/or 42" comieetors. Communication between modules is accom plished by a S-wire bus. These 3 wires run in parallel from fniodile 1 module. The 25 connector on the MBB provides, ‘both power and communication direct to the Navigator, YELLOW LED —The MBB has one yellow LED. The Canicr Comfort Neowork (CCN) LED will blink during times of network communication Cartier Comfort Network (CCN) Interface — The JOGXN.R and 30HX chiller unis canbe connected 10 the CON i desired. The communication bus wiring is a shielded ‘Scondctor cable with dan vie ands supplied and installed i th field, The system elements are connected 0 the comm nication bos ine daisy chain arangement. The positive pin of ‘ich sem element communication connector must be wired tothe postive ps ofthe system elements on ether side of {Tiss als required forthe uegave and signal groond pins of cach system element, Wiring éonnectons for CCN should be made TB, Com he CCN Contactors Maral or therinformabon NOTE: Conductors and dain wie must be 20 AWG (Amer: fan Wire Gage) minimum stranded, tinned copper. Individual conductors mst be insulated with PYG, PVCHnyon, vinyl, Teflon, or polyethylene. An aluminumipolyeste 106% fo shield ‘and an outer jacket of PVC, PYCInyion, chrome vin or Teflon with a minimum operating temperate renge of “SoC to 60. is required. Wire manuactued by Alpha 2413 or $463}, American (A22503), Belden (8772), of Columbia {2525 meets the above mentioned requierents. tis impor {an when connecting to CCN. communication bus, that olor coding scheme be use forthe entre network vo simplify the insallagon Its recommended that red be used for the Signal postive lack for he signal negative and white forthe Signal ground, Use a similar scheme for cables containingdifferent colored wires, At each system element, the shields of| its communication bus cables must be ted togeter. Ifthe com- ‘munication bus is entirely within one building, the resulting continuous shield must be connected toa ground at one point cly. If the communication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building where the eable enters or exits the building (one point pr buikng onl). ‘To.connect the unit tothe network: 1. Tum off power tothe contol box. 2, Cut the CCN wire and strip the ends ofthe red (4, white (_roend), and black (~) conductors. (Substitute appropti- ate colors for different colored cables.) 3. Connect the red wite to (+) terminal on TB3, the white wire to COM terminal, and the black wire to the (terminal, 4, The RJ-I4 CCN connector on TB3 can also be used, but {s only intended for temporary connection (for example: a laptop computer running Service Too). Table 1 — Unit Mode trom Control/Enable/Ott/ Remote Contact and CCN State Serer] ReoTe. car co] par Posmrion | contacts | conrigunarion | stare | WOBe. enaoe | nn FUN] GEN oN ENABLE TOF | CONDFF on i TNR | LOCAL OFF FEN Hi RR LOGAC OFF REMOTE pisasLe [ha toca ow contact | c.osco FUN CcNON ensee [sige | conor NAY — Input Read by Processor NOTE: in nti cored era cock enh rt under cock conti OPERATION DATA Electronic Expansion Valve (EXV) — ‘The MBB ‘controls the EXV through the EXV board. The EXV (electron- je expansion valve) isa device that contains a linear actuator Stepper motor See Fig. 1 EXV OPERATION — High-pressure liquid refrigerant enters the valve through the side. A series of calibrated slot are lat ‘ed inside the orifice assembly. As refrigerant passes through the orifice, dhe pressure drops and the refigeramt changes to a 2-phase condition (liquid and vapor). To contol reffigerant fow for different operating, conditions, the sleeve moves up and down over the orifice, thereby changing onifice size. The Sleeve is moved by a linear stepper motor. The stepper motor ‘moves in increments and is controlled directly by the processor module. As the stepper motor roates, motion is transferred into Tinear movement by the lead screw. Through the sepper motor and lead serew, 15,000 discrete steps of motion are obtained. ‘The large number of steps and long stoke result in very accu- sate control of refrigerant flow. Each compressor has a discharge gas temperature sensor mounted Vertically in the top of the muffler assembly. The discharge gas temperature sensor monitors the discharge gas smperature leaving each compressor aad sends this informax tion to the MBB through LEN communication with the EXV board. At initial statsup, the EXV positon is at zero, After that, the microprocessor keeps accurate tack of the valve ‘postion in order 10 use this information as input forthe other ‘contro functions. The processor does this by initializing the EXVs at star-up. The processor sends out enough closing pulses tothe valve co move it from flly open to fully closed, ‘then resets the position counter to zero, From this point, unt Fig. 1 — Electronic Expansion Valve (EXV) the next initialization, the processor counts the total number of| ‘open and closed steps ithas sen to each valve. ECONOMIZER OPERATION — Beonomizers are factory installed. on. 30GXN,RI08,118-350 and associeted modular lnits and 30HXA,C161-271 units. All other sizes use standard EXVs. The economizer is a brazed plate heat exchanger Gesigned to improve chiller capacity and efficiency as well as providing compressor motor cooling. See Fig. 2. On 30GX chillers the economizer is active when any compressor fully loaded. On 30HXA,C chillers the economizer is active all the time i regen is supplied fom the condenser tothe twp of the economizer” Ae the rfgeran poses though the ecenoniver its press redwed to an stemnediate level Net the eigen lows ote EXV which regula Now io the cooler to mn the charge pera spine The increase in pefmane: is achieved by diveing a small amount of il hugh thematic expansion valve to second cet nthe raed pls exchanger Tis wil farther sabccoling the igi in te fst cet ate regan ashes to wapee This iereasensuheooing provides ion: ATeapacy Alo sne th aiinal power ogi waccon- Bl hse mininal; the efcency ofthe machin improves. "The vapor tat fates leaves the top ofthe economizer hers it pass to the compressor d's led to provide motor col. ing Alter passing ver the motor wings, the rengeran seer they aan nip i he ompreson Sete ‘ay Soleo (BhenRONY eazen puare ECONOIZER Fig, 2— Brazed Plate EconomizerOil Pumps — The 30GXN,GXREX serew chillers se fone externally mounted prelubrcating oil pump per cient. ‘This pump is operated as part of the startup sequence. On. 30GXNER units, the pumps are mounted above the base ails ‘on the ol separator sie ofthe unit (se Fig. 3. The pumps are nouated toa bracket on the condensers of SOHXC units and t0 the ol sepiatcr on 30HXA unit ‘When a circuit is roquired ro star, the controls energize the oil pur first and read the ol pressure transducer reading. The pup is operated fora period of 20 seconds, after which the off Enlenoid is energized to open the ol inet valve atthe compres Soe The contol again reads the pressure from the oil pressure transducer. Ifthe pump has built up sufficient oil pressure, the ‘compressor is allowed to start after 15 secon ‘Once the compressor has started, the oil pump will continue to run for 120 seconds, If the pum is not able to build wp enough ol pressure, the pam is tured off, Within 3 seconds, the pump is re-energized End makes two additional attempts, if necessary, 10 build oil presi The comol gents an slams he hd tempt ‘Theol pump is ls use to sopplement system presi unr carts operating conaton. ie of ow requremens Un comrenr ary bed on presse diferent across the Sime Teun s deed poe fetal ob reser dung lo’ pesure diferentalconitns Ics mot signed wo overcome high pressure dop oss irs Suing high presse diferent onan, ifthe ferent oi pressive (oll pressure ~ economizer ross) fora compres sto ow the ol pump vil be Ee. Just efron pp sa th comol esse ihe presse fret botwesn te dacharge pressure ano prea (ei sys prssre do). The of stem pressure Epic andi ermine vie el pnp Su weet ‘When he ol ump s operating, ti capable of increasing ait pose rn? Os to 30 pu depencing onthe ol ow ‘eatroments fhe compressor For example he compres Serincods gpm (high presse ciferenial condition) and ‘Re oalpurp eupablsof 12 gpm, there sno pressures and ‘teal Row wl yas te cck valve an apply the 2 gpm 1B be compress If te compreser requires 75 gpm, the SSipump ei inceisepremure to sts the ol ese ‘eadrenent “The pump wil contin o operate unl he dichae pres sore mips Gomer peste peatr then 17 pi ps the oil system pressure drop. Example: Discharge pressure 80 psi Oil pressure 65 psi Gilsystem pressure drop 80-65=15 psi ‘Economizer pressure 35 psi Differential ol pressure (@5~$5)= 10 pst Suetion pressure 40 psi Based on the above conditions the oil pump willbe started because differential il pressure equals 10 psi. See Table 2 on. supeey’ Shee Pa Z| Sj tate | rarer Fig. 3— Ol Pump ‘Table 2— Oil Pump Suction Pressure eer SRE TREO — cucrongpessne | _ QunTaPeTEN sar: PRESSURE IS LESS THAN: — ee Se ee ‘The oil pump will continue to operate until the discharge pressure minus economizer pressure (which equals 25) is Sreater than IT plus 15 (il system Toss, before pump was Sarted), The only way this can be satisfied is ifthe discharge pressure increases or the compressor unloads at which point the 63 pump will be shut of. Motor Cooling — Compressor motor winding tempera- tures are controled (oa st point of 200 F (93.3 C), The control tecoomplishes ths by cycling the motor cooling solenoid valve to allow guid refrigerant to flow across the motor windings as needed. On 30GXN,R nits equipped with economizers, fash igs leaves the top of the economizer (when the cieuit 6 fully foaded for 30GXN,R models only) and continually flows tothe ‘moter windings. Al refrigerant used fr motor cooling reenters the rotors through a port located midway along the eompres- sion eyele and is compressed 1 dischare presse. Back Pressure Valve (30GXN,R and 30HXA only) — This valve is located on the oil separator outlet on SOGXNGR units and mounted on the oil separator shell of 30HXA’ units, The valve's function is to ensire that there is Sufficient system differential pressure to allow for oil © be ‘iven back to the compressor sinall copper line (eeonomiz~ pressure) is connected tothe op ofthe valve, which contains fn internal spring that closes a piston ifthe pressure in the oil Separator is not at least 15 psig greater than the economizer pressure. Sensors — The 30GXN,GXR.HX ComforiLink™ contr System gathers information from sensors to contol the operation Ofte filer The ns se wp 0 stan rsa tans fers and up to 10 sndard thermistor (including, 4_motor temperature thermistor). The sensors ar listed in Table 3‘Table 3 — Thermistor and Transducer Locations THERRISTORS Sensor ‘Beseripion Tesaton ‘Connection Terminal wi [Gooter Leaving Fus Temp [Gasier Head Leaving Fiad Sido MBB, J6-73,14 a [Cooler Entering Fd Temp [Goole Head Entering Fuld Si MBG, 8TH 2 Motor Temp AT Motor Temperature Ai [Gempressor At Junction Box (CCPH, oka Motor Tomp A Mota Torporatre Az [Compressor A2 junction Boe (cra, lug JS Motor Temp Bt Nota Terperatuee 8 (Gompressor Bt suncton Bax (GCP, og Ja Motor Temp 825 Motor Temperature [Gompressor B Junction Box (COP2, lug JB 75 [Diccharge Gas Temp Camp AT Top of Comp AT Discharge Line EX, J5-17,72 76 Discharge Gas Temp Comp Bt Top of Comp BY Discharge Line EXV, 5-90 cc Dicchargo Ga Temp Comp AZ, Top of Comp Aa Discharge Line ENV IS7.8 Tap Disenayge Gas Temp Comp 62 op of Comp Be Discharge Line EXUJ556 779 (optional [Outdoor Ale TherristovDual LWT | Ousige Ar Steam/Comeron Leaving Fu | T35, terminals 76 “F0 (optionay= Spa00 Temperatue ‘Conditioned Spas a5, erminals 5 ‘COND EWT (optionaly= [Condenser Enierin Water Thermieor Condenser Entering ud Line Te2. orm 12 ‘COND LWT (optional) [Condenser Leaving Water Thormitor ‘Condenser Leaving Fut Lino Te2, minal 3.4 PRESSURE TRANSDUCERS ‘Sensor ‘Bescripton Toeation ‘Connection Terminals DPA [Discharge Pressure Creu Top of Condenser Separator OrSun A MB, 8-71 2028 ‘PTA [Suction Pressure Grout A Tap of Goole Greut A MB, 16-24-2526 EPTA [Economizer Preseure Cicut A ‘Economizer Line Entering Comp A 508,157.89 ‘OPrAT [ou Pressure Compressor At ‘Compressor At Ol Conmecton 308.5456 ‘OPFAR [ou Pressure Compressor AZ [Gamgressar AZ Gl Connector 508,154.23 Pre: Discharge Prossue Crcut & Top of Ox Separator Crcut 8 MB 165,167 ‘SPrB [Suction Preseure Cul Top of Gooler Grout M8, J8-18,1020 PTE, Economizer Pressure Creu 6 Economizer Une Enerng Carne 505,16 7,89 ‘opreT [O1 Pressure Compressor 51 [Gomoressor 81 Oi Connection 308.6456 ‘oprah [O1 Pressure Compressor 82 (Gampressor BY Gl Connection S08. 61.23 301208-271 and 206XN, 204-960, 970-528 ony. {00xH 81-360 ont ‘Sonor are salable as accessories for fold instalation (90HXC only),ComfortLink™ Compressor Protection (CCP) INPUTS: Board — One CCP board conttols up to 2 compressors + motor temperature “The CCP provides the Following Funktion three-phase current highepressure switch 7 gale matty So « Sipbsiaconortenetion 2 diagram of te CCP boris shown in Fig 4. On CP + ee pon ot eteton aro oe ean OM Band STRAT 86 > Se emer ceten aa ep burs we sald on SOCRNR20.350 + Mpa protection a sean unt The es for exch OC? boa + reverse rotation protection is set using DIP (dual in-line package) switches, For CCP] 1 Sin ane prteton ee ae ei Bib wick | sould fe sto core al sleet cots) compra LEN communeaien, Syncs 2} and 4 «emer ing sleet sen eae CORE petiny or Ces conpresor + TaN Smeaton sere ate ace aed 3rb%a e206) an come coe een overureat precio pg SORT eh i Fee ee Sane tenia besa CON pst) ‘The CCP asthe lowing ouput ly an ps Fares a eo Pertion) Soro 4 Bt ourrurs See the CCP hs trot ton ltd o pemenennnce Seem uh an e110 comet 1 Sareea scion ch conpresrs MTA (nt pang) tings Orme * compressor motor cooling solenoid nicated to the MBB during the initialization period. See Table 5 + Wye-Delta transition relay for DIP switch settings. ‘ low 1 “"\] ° Teees fe} A & i N s Tel Senn, fs! . aie 5 a lz i Siro | © us = asa Lao soen ee, EB LED yht-Emitting Diode BUTTON | AB x parent FEB. smell NTA — Must re LI" = TEN (cea Eauipment Nerwork) § = S10 (Sensor inpuvoutput Notes: 2 The fed LED blinks continvously when the moc: so—,)2 Uo oporating propery. 4 ‘ike continuously when com- * ‘he teen Lek ; a =e Le Oo creenteo murda repr with BS. Spal comoctor pit nid bya Sone pre Coe tears mit ng aioe {raking ry ehangos te DIP such se Bip sdeeBles cemoressc gourd curert prtstion, ON SAB 0 ESE oe Bae e Fig. 4 — Comforf.ink™ Compressor Protection (CCP) BoardTable 4 — ComfortLink™ Compressor Protection (CCP) Board Plug Connections. PPE] DESCRIPTION | Bavae Pomeragut———— [case Connery nace) Tigh Pressure Switch, and Water Coal Solenes me [ Curent Sencar aga ‘Compressor Noor Tarpartare pat ‘Gormunicain Connections NOTE: Plugs J2,J8 are for compraseors At (CCP) or A2 (CCP2}. Plugs J6-8 ae far compressors (CoP) or Bo (CCP 2}, Table 5 — CCP Address DIP Switch Settings ‘CEPT COPE unt Tepes WRN ANOTE | LO) OPO] —]—]—}— SoHRAg76“ Souxcare-t BOGHN,Aa04-360 | T[OFF] OO] for Ta aoHkAzoe 271 Sonxc206-271 ‘To verify proper must trip amps header configuration, use the Navigutor and the Configuration mode porion of Appendix ‘Avo locate the items CM.AL, CM.A2, CM.BI and CM.B2 in the UNIT sub-mode, See Appendix A for correct settings. f the values do not match those in Appendix A, verify that the configuration headers have been properly punched out ‘The CCP communicates on the LEN (Local Equipment Network) bus to the MBB. Proper operation ofthe CCP board can be verified by observing the 2 LEDs located on the board The red LED blinks at arate of once every | to 2 seconds. Tis indicates that the module is powered und operating correctly ‘The green LED blinks when the module i satisfactorily com: ‘unicaung with the MBB. The CCP communicates status of its inputs and outputs and reports 13 different alarm conditions to the MBB. iy "The CCP module has many features that are specifically designed to protect the compressor, including reverse rota tion protection. Do not attempt to bypass or alter any of te ‘actory Wiring. Any compressor operation in the reverse ‘oucoor-aic temperature reset features. It ea also be ese fort fan external 4 % 20 mA signal (requtes optional EMM), or from a network signal ‘The capacity control algorithm runs every 30 seconds. The algorithm attempts to maintain the Control Pont atthe desired set point, Bach time it runs, the control reads the entering snd leaving fluid temperatures. The control determines the rate at Which conditions are changing and calculates 2 variables based fon these conditions. Next, a capacity ratio (SMZ, Outputs ‘under Sub-mode GEN.O) is caleulated using the 2 variables to determine whether of not to make any changes to the current Stages. of capacity. This ratio value ranges from —100 to + 100%. Ifthe next stage of capacity isa compressor, the con- trol stars (stops) a compressor when the ratio reaches + 100% (100%). If the next stage of capacity is a loader, che contol enerpizes (deenerpizes) a loader when the raio reaches + 0% (60%), Loaders are allowed to cycle faster than compressors, ‘ominimize the numberof starts and stops on each compressor ‘A delay of 90 seconds occurs after exch capacity step change MINUTES LEFT FOR START — This value is displayed in the Status subfunetion and represents the amount of time 10 clapse before the unit is started. This valve can be zero without the machine running in many situations. Tis can include being unoccupied, Remote ContacvOR/Enable switch in the (OFF porition, CCN not allowing unit to stat, Demand Limitin eifect, no call for cooling dve to no load, and alsem or alee Conklitions present. Ifthe machine should be running and none Of the shove are true, minimom off time may be in effect The machine should start normally once the time limit has expired‘TERIANAL BLOCK ‘COMPRESSOR coNTACTOR, ‘COMPRESSOR JUNCTION BOX YH He fH H fl fal | lds} pf Fig. 5 — Across-the-Line (XL) Compressor Wiring (COMPRESSOR STARTER ASSEMBLY cow Al a_|s LL om JuuPen eaRs! ra bs & 1M &h 5) | f] 2) [am Fig. 6 — Wye-Delta Compressor Wiring MINUTES OFF TIME (DELY, Configuration mode under sub-mode OPT2) —This user-configurable time period is ted by the contol 0 determine how long unit operation is telayed after power is appied/estoed to the unit. Typicely, this time petied is configured when multiple machines are located on a single site. For example, this gives the user the ability to prevent all dhe units from restarting at once after a power failure, A value of zero for this variable does not mean thatthe unit shouldbe running. LOADING SEQUENCE — The 30GXN,GXR.HX compres sor efficiency is greatest at full load, Therefor, the following Sequence ist applies to capacity contol. Th The next compressor is not started und ll others are running at 100%. 2, The second unloading stage is only used during initial capacity staging of the unit at start-up. 3. Whenever a compressor is stated ina circuit the loaders in the citeuit ae doenergized for 15 seconds before the is started, The loaders are energized 90 se- fonds after the compressor is started CLOSE CONTROL (CLS.C, Configuration mode under sub-mode OPT2) — When configured for Close Cont, the Control is allowed to use any loading/eapacity control devices required to meintain better leaving uid temperatre fegulation. All” stages of unloading” are availble. See ‘Appendis for an example. LEAD/LAG DETERMINATION (LLCS, Configuration ‘mode under sub-mode OPT2)— This is,'a configurable choice and is factory set to be automatic. The value can be hanged to Cireuit A of Circuit B leading, as desired. Set at fuiomatic, the eircuit with the lowest bours is started first. ‘Changes to wich cireit isthe lead circuit and which is the lag ae made when shutting off compressors, (On 30HX206-271 and 30GXN,R204-350 units, set_ for staged loading, the contol fully loads the lead circuit before Starting the lag cirouit and unloads the lag cireuit first. Wren these units are set for equal loading, the control maintains heer equal eapaciis in each circuit when the chiller is loa: ing and unloading. CAPACITY SEQUENCE DETERMINATION (LOAD, Configuration mode, under sub-mode OPT2) — This is con- figurable es equal circuit loading or staged circuit londing with the default set at staged. The conteol determines the order in whieh the steps of capacity for each circuit are changed. This Control choice does NOT have any impact on machines with ‘only 2 compressors.MINIMUM LOAD VALVE (MLVS, Configuration mode under sub-mode OPT1)— When ths option is instlled and configured, the fist stage of capacity is altered by energizing the Minimum Load valve relay. Once the coniol requizes more capacity, the minimum load valve is Geenergized and normal capacity staging resumes with loaders and compres- sors. Similarly, the Minimum Load valve relay wil be ener ized forthe last stage of capacity tobe used before the circuit ‘s shut down, Configure Upit for Minimum Load Control — The chiller ‘must be configured for minimom load control operation. This may be done using the Navigator. Set the Enable/Oti/Remote Contact siitch in the Of postion, 1, Press i) unt ‘Selot a Meno Temi splayed 2. Press fy] illuminate the Configuration mode LED. 3, Press [a] and fg] to selet OFTT’. Press} and then fm to select MLV". 4, Press es] and_ enter the Password (we arow Aeysand press f= foreach di) if required 5. Use [al] to chang the ashing ‘Noto "Yes. Press f=) andthe display says ‘MLV Yes ‘The chillers now configured fo minimum lad valve contr ‘Test Minimum Load Relay Outputs — After the unit is con- ‘gure, test the operation of the relay and solenoid valve using the Serviee Test mode. 1. Switch the EnableOntRemote Contact switch 10 the “Om positon 2, Press 9 on the Navigator to display ‘Select a Ment tem’ and press fg] olluminl the Service Test LED, Press [0] and “TEST OFF will be displayed. 4, Press [re (enter Password if required, [a] and then fred display TEST ON". 5. Switch the BOR (Enable/OfiiRemote Contact) switch to the “Enable” postion 6, Press [to select “COMP” and press Press Yo select ‘MLV OF, Press $3] folloned ty fax} and Fr} again, The minimum oad valve output willbe tumed on, Both circuits solenoids are ramed on at the same ime. 8, Press fe, followed by [] and Fa] again to tum the vale op oft ‘Adjust Setting of Minimum Loud Ball Vale — The mini ‘mum Toad ball valve must be adjusted fo suit the application, Calibrate one circuit ata time a follows: 1. Adjust the ball valve so that it is approximately half ope. 2. Operate the chiller in Manual Contzol mode, with one cieuit operating, and all compressor loaders deenergized. 3. Record the cooler AT (the difference between cooler centering. fluid. temperatuze and cooler leaving fluid temperature) at this fully unloaded condition. 4, Use the Manual Control feature to enable the minimum Toad valve for the circuit that i operating, 5. Observe and record the cooler AT with the minimom load valve energized, 6. Adjost the minimum oad ball valve until the cooler temperature difference reading from Step 5 is equal to half ofthe temperatare difference reading from Step 3. 7. Open the ball valve 10 decrease the temperature difer- ence or close the ball valve to increase the temperature Uifference (AT). When the valve is adjusted comet, the difference between cooler entering an¢ leaving uid tem peratures when the miimam load contol is energized ust be atleast half ofthe temperature difference when the minimum load contol is deenergized, For example if the difference between the cooler entering and leaving ‘water temperature is 3° F with the valve deenergize, then the difference between cooler entering and leaving ‘Water temperature must be atleast 15° F withthe valve energized Once the ourputs have been tested and the ball valve adjusted, the installation is complete. Disable manual contol and reum chiller to desired operatonel stats. CAPACITY CONTROL OVERRIDES — The following over- rides will modify the normel operation ofthe routine. Deadband Maliplier — ‘The user configurable Desdband “Multiplier (Z.GN, Configuration mode under su-mode SLCT) has a default vale of 20. The range i from 1.0 to 4.0. When set to other than 1.0, tis factor is applied othe eapacity Load’ Unload Factor. The larger this value is set, te longer the eon- trol will delay between adding or removing sages of capacity. Figure 7 shows how compressor stats can be reduced over time if the leeving water temperature i allowed to drifta larger amount above and helow the et point. This value shoud be st in the range of 30 t0 40 for systems with smal loop volumes ‘The Main Base Board (MBB) closely follows the rte of com: pressor eyling foreach circuit. Fits Stage Override — Ifthe curent capacity stage is zero, the contol will modify the roti with a 1.2 factor on adding the fist stage to rede eyeling. 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 ‘tags from being changed when the leaving Mud temperate is cose fo the se poi (within an adjustable deadband) and ‘moving towards the set pont. ‘Ramp Loading — (RLS, Configuration mode under sub- mode SLCT) — Limits the rate of change of leaving fluid temperature Ifthe unit is in a Cooling mode and configured for Ramp Loading, the contol makes 2 comparisons before deciding to change siages of capacity, The contol caleultes a temperature difference between the contol point and leaving fluid temperatre. I the difference is greater than 4° F (22" C) and the rate of change (TF or °C per minute) is more than the Configured Cooling Ramp Loading value (CRMP, Confira tion mode under stb-mode SLCT), the contol doesnot allow any changes tothe curent stage of capacity. ow Entering Fluid Temperature Unloading — When the entering uid temperature i Below the convo} point, the oni wil atempr to remove 254% of the curentstges being used, If exactly 25% cannot be removed, the contol removes an amount greater than 25%, but no more than necessary. The lowest stage will not be remaved Low Discharge Superneat — Ifa circuit’ discharge superheat 38 less than 15°F (83° C), the contol does not increase the current capacity sage. IF the discharge superteat is less than SF (28 ©) and decreasing, the ereuit is unloaded every 30 seconds unt the superheat is greater than 5°F (28°C), The Final eapacity sage is not unioaded unless an alam condition nin. hs oveme i ignored Tor he fist 3 minutes er 4 ‘compressors sated.estar DEADBAND EXAMPLE saa LEGEND BEADED LWT — Leaving Water Teroerature “Tne (8ECONOS) STARTS Fig. 7 — Deadband Multiplier Low Ssturste Suction — Toei ectng the ove, the conol wil compre the cc Sud Suton temperate witha predetermined ecze pon Por vats bie] cul the Satire Suction per tue tl below 34F (L1G) the Brine Freeze Pin th unit city wil not increase he Satine Suton temperature fale below 28." 22 Othe Brine Freee Pont mms 6” F G.3* for 90 second sl onder fa the ce ae med Of Mls condon cones for allo 3 ints, the et Sai will aa and shot down For Brine applications, the Brine Frosze Point (Configure sion Mode, SERV stbvmode BRIZ) must be cong fr the deere point ofthe bane soliton. The convo wil se the Bane rece Pont vale minut 6° E G3" C) 8 he pat to Compare with ue Sarted Sucon Tempra. The default for he Bane Feze Point is 34 F (11.0), whch means the fonel wise 98 F C22 C) a9 the fee point The Baie fees Poin aljustabe rom —20 Fw MF €29Cw LIC) Faire to set the Dine Freee Poin comsay will case Inprope unit operation. High Condensing Temperate Unloading — Every 10 se: Enis consol checks for the coniions flow. Loaders wl Be ejeed as needed to como! the saraed omens tempat below the configued maximum condense temperature. Configured maximums are 154 F (678) for SUCRNR, 152 F (651 ) for 3OHXA, and 122 ¥ (50 ©) fr SOHC ui, a cui saested condensing tegen more than 13° F(6.7" ©) below the maximum eondens temperature, the cuit capacity snot allowed to incase. tetas Sonning temper is moe han 2 {151°C above: the maximum condensing temperature for {second oars ted It sted condensing tempt ns fo more than 3° F (28°C) above the tum condensing temperature dng the 0 secon onde ‘ormed off meditate loaders were aleady ofthe Compressors st dow and an lar peered ‘MOP (Meximum Operat Jp — The on. tol onto sttaedcondemsing and suction err fc Ecrareut a: well difeeathl of per. Basel 00 8 oniguable maximum operating se point (arated suction tempat, staat Condssing temperate, and frum fread ll presre, the conol my reduce the mumer of capacky sigs being used arr may Tower the EXD positon sen system pressures apa the st parame Head Pressure Control GENERAL — The eropocesso consol the condenses fans (GOGXN.R) fo maintain he strated condensing temperate tot comigusble set poin. The SOHKA condensers unl Sih 5 O9DK condor ate a combination of factory supplied fan cycling pressure switches (Shipped in the 30HXA contol bor), temperature switches, andl an accessory Motormastes® conto to maintain head pressure independent of 3OHXA unit contol. The fans are staged or speed varied GOGXNR) oF ‘water valve contolled GOHXC) bused on each circuit’ sat rated condensing temperature and compressor status. Water ‘cooled units (SOHXC) operating at less than 70 F (21.1 C) for fetering condenser water require the use of head presure ‘one “The ehiller must be field configured for the options shown, in Table 6, Fan stage settings are shown in Table 7 AIR-COOLED UNITS GOGXN.R) — See Fig. 8 for con- denser fan locations. ‘Without Motormaster V Control — The first stage of fans are tumed on based on compressor ams ora Head Pressure Set Point based on Saturated Condensing Temperature (SCT). ‘Additional fan stages are added when the SCT exceeds the Head Pressure Set Point. The Head Pressure Set Point is configurable in the Set Point subsmode. The default is 113 F G5.C), Once fan stage has been added, the software tempo~ rarily modifies the head pressure set point by ang 13° F (83°C) for 35 seconds, 4 fan stage wil be removed when the ‘Sniuraed Condensing Temperature has been Jess than the Head Pressure Set Point minus 35° F(19.4° C) for minutes ‘The control uses the higher of the 2 Saturated Condensing ‘Temperature. values_ for 30GXN,RO80-160 units. For the SOGXNVRIS3, 163-380 units, each circus fan stages are independent’ convoled baled on, te ere Seared Condensing Temperature. Refer to Table 8 for condenser fan contol informition, See Fig. 98 for operational information. With Motormaster V Control — For low-ambient operation, ihe lead fan in each cizeuit can be equipped with the optional or aceessory Motormaster head pressure contol, If factory installed, the eontoller will be configord for 4 10 2) mA con- tol, With the Variable Head Pressure Select option set to 1 (4 {0-20 mA), the MBB module calculates the required output ‘based on Saturated Condensing temperature, Head Pressure se Point, nd « PID (proportional integral derivative) loop calculae tion. ‘This 4 to 20 mA output is driven through the SCB. Proportional, Ioegral, and Derivative gain parameters for tircooled contols are adjustable and can be found in the SERV sub-mode under the Configuration mode. Only cerfied Carrer Comfort Network technicians should perform checkout ‘and adjustment of the PID loop. To obtain this accessory for field installation, onder by part mumber 30GX-900~-071, 072, Oi fora sna sone ache GUGXN ROO 16, Order pant number 300X-900-074, 075, 076 for a dual controller package GOGXN.RIS3, 163-350). These packages contain all the hardware rege ins hs acsestay See Fg 9B for ‘operational information‘The contol will we the higher of the 2 Saturated Condens- ing Temperature values for 30GXN,ROSO-160 units. For the BOGXN,RI53, 163-350 units, each circuit's fan stages are independently’ controled based on the circuit's Saturated Condensing Temperature. Refer to Table 9 for condenser fan Staging information, WATER-COOLED UNITS (30HXC) —- The 30HXC ciller ‘can be configured to control direct acting water valves that are Controlled by a t0 20 mA (2 to 10 vde) signal. A 0 to 20 mA (0 © 10 vde) oF 20 0.0 mA (10 to 0 vde) can also be config ‘ured, Installing a 500-ohmn tp watt resistor across the 2 output terminals of the mA signal enables the use of the vée signal Set this configuration (VHPT, configuration mode under sub-mode OPT1) to 1 (4 to 20'mA or 2 to 10 vee), 2 (0 19 20 mA or 0 to 10 vée), or 3 20 to 0 mA or 10 100 vee) as Gesired depending on valve type. Signal connections are made at terminal block TB2, terminals 14 and 15. The control Scheme reads the saturated condensing temperature and uses a PID (proportional integral derivative) loop to control the head pressure. Proportional, Integral and Derivative gain parameters forthe water-cooled controls are adjustable and can be found in the SERV sub-mode under the Configuration mode. Only eeri- fied Carier Comfor Network technicians. should perform checkout and adjustment of the PID loop. CONDENSERLESS UNITS (30HXA)— The 0HXA unit is often applied with an 09DK air-cooled condenser. The remote condenser fans are contolled by 2 relay outputs. ‘These connections are in the 30HXA contol box. See Field Wiring Section on page 72 for wiring details. The 30HXA control must be configured to tum the O9DK fans on andor off. To set the 30HXA control for this configuration, Unit Type (TYPE, Configuration mode under sub-mode UNIT) must be config ured to 3 (Split System). The Head Pressure Control Type (HPCT under sub-mode OPT!) must be configured t0 1 (sir. cooled), and Condenser Pump contro! must beset vo 0 (CNPC must be sett No contol, Configuration made under sub-mode ort). Low ambient head pressure control ean be accomplished with fan eycling pressure switches (QODKOSA-004), tempers ture switches (9DKO44, 074-094), and Motormaster® control. The Motormaster eonral requires a temperature sensor input to contol condenser fan cycling. The Motormaster V control also requires a temperate sensor input or the 4 to 20 mA output signal from the Comyforlink™ contol system, See accessory installation instructions for further informatio, ‘The Head Pressure Control Type (HPCT under sub-mode OPTI) may be set to control various types of head pressure control devices. HPCT may be set to 0 (No Control), 1 {Air Cooled), 3 (Common Condenser), or 4 (ndependent Condenser. ‘The 30HXA chillers alo support the use of a4 to 20 mA, (210 10 vde), 01020 mA (Oto 10 vée), o 20 10 mA (10 to 0 ve) for fan speed contol. Installing & $00-obm > watt resistor across the 2 output terminals of the mA signal enables the use ofthe vde signal. Set tis configuration (VHT, con tration mode under sub-mode OPT!) to 1 (4 10 20 mA or 210 10 vée), 2 (0 t9 20 mA or 0 to 10 va), or 3 (20 100 mA or 10 to 0 vas) as desired depending on contol type. For common ‘output applications (single output for both circuits), the signal ‘omnections are made at terminal block TB2, terminals 1 and 15, For independent (one output for each cicut) applications the signal connections are made at terminal block TB2, ter nals 14 and 15 for circuit A, and terminals 12 and’ 13 for circuit. Table 6 — Field Configured Head Pressure Control Options TDRIT | CONFIGURATION OPTION T DESCRIPTION PORT RANE! FACTORY CONFIGURATION ead Prossure Gontol Type | Method ot contoling head TPCT [Av Gosles 20GX Dau, Do not modiyy Fan Staging Saeeh Mothos of convoiing an sagng —| FAVS [See Table 06x |Yarable Heed Pressure [Method ct convoting variate head | —VHPT 10 = None (Delay Select persue = 1080 m8 (Ont Motormaster IOP is esac) Settee 20 mai Motoastracoseory = Toad Pressure Conalype | Method of conraling head pres” | —FPGT | Wat Cooled GOAN Do, Do nat modi) [Yarable Head Pressure | Metned of controting arabe head | —VHPT | O=Hone. OHS | Bshack pressure 1020 mA("2 to 10 vee }2=0%0 20mat-ot0 +0 wae bt OMA TO%e vse) oad Pressure Conval Type | Mathod of convoting heed FECT [No Goniat pressure Air Cooled (S0HKA Detout) Earn Canara SOKA [arabia Head Pacee | Vatnea a conraig vaab wT None. Select ead pressure fo 20 mA("2 to 10 vee) to 20 mAL9 1010 vas) Nod mafs0%00 ve inal can be gener 1 by aling & SODonm Vj walt eestor across the @ output taminals othe mA signalTable 7 — Fan Staging Select Configuration Settings for Air Cooled (30GXN,R) Units ‘SONPUTER UNTTS0GXNR | gorRUARe DISbLay | NAVIGATOR DISPLAY DESCRIPTION o2a.080" e (1 STAGE Com) Bruce orien contol booeuee hapa Oo 053,085,708 108, z eemct cow Tl lage compressor staus and SCT cctpolnt 2rd ana Se sage common contol based on highest SCT 119,128,198, a Tal siage corsrossor status and SCT setpomn "160" £ (STAGE COM 2nd tough ai sage common convo bases on highest SCT 7a lage eaoh croul, compressor sats 15,174, ? 4 (A261 IND) 2nd stage Creu 8 independant onze ‘ ‘and and ard sage Creu Andopendont $63,178" 2 (@ STAGE IND) nd an rd lage euch cPeut ndopen dnt some Yi stage each orcu, compressor eats 249.264" 5 (as62 IND) 2na sage Creu inependent = nd. sd and scape Cre Aindspendont Tal sage each ofcur, compressor sats 2c Sr an th stage each eet noe endant 3 (@ STAGE IND) 28228, 59 288,261-350" LEGEND ‘SCT — Saturated Condensing Temperatire And wssooiates moduler ees. 06xN,RO80, 080° S06 N08, 902 16,108,114 28, oO O|g™ 00 Ol 902 JOO 2, 90GXN,AYSD, 174, 204, 225° ‘OOO|]OC]a= = gr LP O1O S0Gx0yR2SS, 268, 281-350 woe 5565]]0000 lem s99elloQae 80GKN,8163, 178° Soo|O00|z™ POOTOOQ “And associated modula sizes Fig. 8 — 30GX Conden: 1B30GXN,A UNITS — MOTORMASTER V CONTROL NOT INSTALLED ae oe Ronee Raa igzasgero LEGEND SCT — Saturated Condensing Temperature Fig. 9A — 30GXN,R Units Head Pressure Control Without Motormaster® V Control 0GXN,R UNITS —MOTORMASTER V CONTROL INSTALLED ean cinounr anHeas, wo | Rovaltetooes, No. RSA GT | ww Baie ieee ener ieee ieee her es = jes y Sikae By ONE STAGE BY OME Siase BY OME 4 Fig. 9B — 30GXN,A Units Head Pressure Control With Motormaster V Control Table 8 — Control Methods and Cooling Set Points ‘coNTROL TYPE | OCgUPANGY COOLNG SET PONT SELECT (CLEP) (en) stare ‘Stage [Baal Switch Dual, conOce [He maT Denied GNESPI on ‘onGSPY oN ot ‘Unoaaupied ‘ON.CSPT ONT ‘ON.CSP2 ‘ON Deewsied ORCSPI OF Tegal Tegal OF Tay Ove ‘Vroouled OFF OFF egal Tegal OFF Scone Seamed CRGSFT On Tees Teg OW. yin d Unocoupled ‘OFF OFF Wegel ‘Wegal OFF oR Decusied ORCS OFF ‘onesri —[—oncsrr on Trost CNGSPL ON ‘oNesr2 —[—oncsP2 OF “Dual ce pent sich input used. CSP used whon cvtch input ic open. CSP2 used when suitch input is closed + ootng set pont determined om 410 20 A input o Energy Managertent Module (EM) to ermal TBO. 4‘Table 9 — 30GXN,R080-350 Condenser Fan Staging (Main Base Board Controlled) {OGRA UNIT SE PANE 8,080 ah Sate 083, 089, 108194 125,135 Hon ate 116,128,198 150,160 Han state 4,264 Hon site sinter 00,228 emp. — Congreso BE = rie Tae FAN CONTAGTOR FANS CONTROLLED z 3 TET Ser TA oS oa a0 “Frapz tan of hese fe be chested when compsaea) ib nog TSoPEI°E' candeter in issasone non enn om he er Sak OTe: For 30530159, 19:99 unt, an ene Fon ae Fan 9 ener EELS LRN SS near Pan nrg GaTable 9 — 30GXN,RO80-350 Condenser Fan Staging (Main Base Board Controlled) (cont) RANGATOR OUTPUT Pay MAME FAN CONTAGTOR Fang CONTROLLED 7 ea Ta S0GKNA UNIT Size FaNTVPE 253,268 Hon stat . suncars anise sn sate TEEN Come. — Compressor FE" = BarBeile 09DK AIR-COOLED CONDENSERS 09DKO44 Units — The O9DKO44 units have accessory provi- sion for fully automatic intermediate-eason head pressure control through condenser fan cycling, Fan number 2 and 3 ‘yeling is controlled by ouldoor-air temperature Uiough aie temperature switcbes (ATS) | and 2 The air temperature switches are loctted in the lower divider panel undemeath the coil header. The sensing element is exposed to ar entering the no, | fan compartment through & hole in the panel. Fan no. 1 is non-cycling. ‘he air temperature switch controls the fans as shown in ‘Table 10, Table 10 — Air Temperature Switch Control (090K044 Units) Fa | eanowreH TeUpERATORE ome STS VBS) Benson Soar oo (8nd TSC) fanstomoeste tng sow S523 (282170 Beiveon Soars OF (28 acd TSC] and tomperte rg [abo 8035 G57 #170) BenweonYOard UF @1 1 and7RTC) Boon 70237 112170 Bewoen ued OF Pht and RTC) [andtemperse ring on ran rana Bob Fgr'’ ev condone fan ecatons hon Rewng ier eco) 6k NOTE: Fy 200x815, 165.850 n,n oly Fan} anand oer 09DKO54.094 — The capacity of an air-cooled condenser Increases with increased temperature difference (defined as saturated condensing temperature minus entering outdoor-ir temperature) and deereases with decreased temperature differ- fence. A drop in entering outdoor-ir temperate results in Tower saturated condensing temperature. When outdoor temperature drops below the minimum temperature for stan 100 F {G78 ©) and compressors are of. The heaters deeersized it thei evel swith is open Navigator Di play Module Usage (See Fig. 10 and Tables 11-24B) — The Navigator module provides 4 mobile user interface tothe ComforLink™ control sytem. “Te display hos up and down ow keys, an Fer key and en Ena] key. These keys are used to navigate through the different levels ofthe display stture. See Tale 11, Press the for] key unt ‘Select a Meno tem’ is spayed to move through the top 11 mode level insted by LEDs on he let sie ofthe display Pressing the =) and Fe keys simultaneously wil pt the Navigator nb expanded ext mode where fll meaning of al sub-modes, tems and her values canbe displayed, Press ing the fe) and fo hays when te display says ‘Selecta ene item (Mode LED level) wil ream the Navigator is default menu of rotating dspay items (tose items in the ‘VIEW sub-mode under the Ran Status mode). In aon, heFig. 10 — Navigator Module password will be disbled requiring that it be ener agsin before changes can be made to password protected items The Service Test function should be wsed to verify proper protected items Press the fuse) ey to exit out fhe expand text mode NOTE: When the LANG variable is change, all sppropriate Uisplay expansions wll immediately change 10 the new ftopuage, No powers or contol rset i regied When ‘econfigurng languages ‘When a specfc item is loci the tem nae appears on the eft ofthe display, the valve wil pear ea he idle of the display and the units GF any wil appea on the Far right of the dil, Press the Key ata changeable tem andthe ‘ave wil begin lah Hes in the Configuration and Se vice Test moses are password protected. The password can be “hanged ulizng the Navigator a though CEN devices sch as Comfon WORKS, ComfonVIEW™ and Service Tool ‘The words ‘Enter Password” wil be displayed when required wot the deft password also being played. Use the fr Ind arow Keys 10 ener the 4 digis ofthe password. The default password is TIT1. Use the folowing procedure f0 change te password 1 Enter the caret password under PASS, Senice Passwort (Conigraion Mose, Si-node DIP) 2. Change PAS. Password Enable (Configuration Mode, Stbsmode DISP) to DSBL. 3. Retum tothe PASS, Service Password, and change the password te desied alse, Por example, 2222 Once Efanged tne srcen wl sow the new vale, 2222 4 Retum tothe PASE Password Enable, and change the value to ENBL “The pasword has been changed. I the password js requted! tie machine wil show the defasit It ay the [wor Use the up dw aos” key 0 chang the value {othe come passed Changing tem vas or testing ouput is accomplishe i the same manner. Locate and Gsply the desired tem. Dress fe so that the ite value lathes. Use the aw eys 1 ange the valve or state ofa item and press the Pr Ke 10 seeept it res the fed key to return to the net higher vel of wrvtre Repeat fe proves as requied for ther tems. Se Tables 1225 fr fuer deta ‘wo items, OAT Ouside Air Tenperaure Cenperatne Mode, Subsmode UNIT) and. SPT" Space Tenperanre {Tenpecatre Moe, Sub>mode UNIT) canbe force to vate he Navigator I one ofthese wo pos has ben forced, ashing wl appeac ex fo the ae nating ced Tate. To rove tie fore eet he em and res the oe Key so that he vale Is ashing. Pres he up an down aiow keys simulans andthe orc wl beemoved Service Test (See Table 13) — Both main power ond onto cit power must be on The Service Tes function Shaul be wed to esi proper operation a the emer, Tenders, pumps, solenoids any beaters, te. To acts the Senice Test note, te EnabisOfRemt Contact switch tnt be inthe OF poston. Use the pay key © enter the Senvice Test mode snd spay “TEST OFF, Press he fey and ‘Of will ash Enter the password if equiel), Cie citer row key to change te “OAT to "On! and res Sich the EmbelOfRemote Contact switch wo the Enable poston, Use the anow keys to sls eer submode OUTS SECOMP. Test the expansion valves, ol pumps fs, cooker feates, covlerondenser pump relay, remote alam rely fead pressure contol, and compressor i nd motor cous Solenss under the OUTS sod, Noe that condenser mora NOT sed dung VE.PA or VELPB test on SOGHN unis with Motormaser® contol. Mesure 10 Doma de ute wsing mee in sees with wt rink wie to convolee Referto te Feld Wing secon, Tete dscres nips ae then tuned off there ino Keypad sii for TO mimes Tes te compressors, loaders, minimum Toad ‘alves and ei esters under the COMP stb-mode, Compressor Tenders minimum fad valve and il esters ca be eed with Compressors on or of Al compressor uu cn be tured oo. butte conte lithe tb staging one compressor permite The elas unde the COMP aub-node wilson for 10 mines if tere isn Keypad sti. Compressors wil sy on unt they are tuned off By the operator. The Service Text mode wl remain enabled as Tonga Gee is mare than che compressor tne on. Al safeties ae moniter ring this tet and wl tum acompestor, ito mor off ee txsry. Another mae ors abe views changed Caring fe TEST mode. The STAT tem (Ran Sts mode um der subsmode VIEW) will display “SERVICE TEST” long ts the Sovice mode s enabled, The TEST subsmode vale tres be chonged tack to OFF before the chile can be Shite to Enable or Remote coat for oral operation Configuring and Operating Dual Chiller Con- trol (See Table 24A and 248) — Thc dual chile routine is available for the contol of two units supplying chilled fd ona common loop. This contol is designe fore ther series of parallel uid flow (PARA, Configuration mode Under sub-mode RSET) arrangements, One chiller must be configured as the master chiller, the other as the slave chiller. For series fluid flow, the mestr chiller is nsalled so that tre- eives entering fui from the slave chiller and it leaving fod ‘Supplies ths load. See Fig 1. For paral! flow applications an ‘tditional leaving wate re thermistor (Dual Chit LWT) most be installed as shown in Fig. 12 and 13 and con- nected to the maser chil. Refer to Thermistors section for senvor wiring.—» SEE |g — Eee Fig. 11 — Dual Chiller Piping Arrangement oP GBeries Fluid Flow) aware rum CHILLER uD ae (ae | CEamING Ft FeMPeRaTORE ‘wermieTon (79) MERE * Depending on pioing sizes, use othr: < RH7ONZ014 sensor OH50'0880" well (Sin. sensevel) OTOMBBDTOGEOC well tin. sersodvel) Fig. 12 — Dual Chiller Thermistor Location Parallel Fluid Flow To congue the so chiles for operon, flow the example sho in Tables 244 and 24B- The master eis wil Beconfigured wit astave chile at adress 2. Also in his ex fp, the maser ler wl be conned fo use Lead ag Batts ocven cus the clr rntmes wk The La Sat Del fangs oil be set to 10 minus” The hus il be point of the slave chiles. The master chiller will also split demand limiting. function appropriately between the two chiles, if demand limiting is enabled. ‘The master chiller is now configured for dual chiller opera- tion, To configute the slave chiller, only the LLEN, PARA and MSSL variables need to be set. Enable the Lead/Lag chiller variable (LEN) as shown in Tables 244 and 24B. Similly, set the Master/Slave Select variable (MSL) to SLVE. The par allel variable (PARA) must be configured the same ss the ‘aster chiller. The slave ciller does not use the variables LLBL, LLBD ond LLDY. kis recommended to set the cooling set points to the same setting on both Master and Slave chilles for series flow @upiex) applications. If outdoor air rset is required the ‘outdoor air thermistor must be connected to the Slave chiller (TBS term, 7 and 8). Outdoor Air Broadcast (BCST, OAT) rust be configured “ON”. Remote contacts should be connect ed to both Master and Slave to control unit operation. Optional control inputs and Energy Management Module (EMM) ‘shouldbe connected to the Master chiller. ‘PART | —OMENSTONSTa. ra) — NUMBER 3 Torssoroseor [S10 re TSS oa ~yons0106a02 | 10 108.1) | 7.28 G25) configured for parallel Hid flow. The master and slave chillers 4 cannot have the same CCN aldest (CCNA, Contguration ; rode under OPT2). In addition, the chillers must be connected cS | together on the same CCN bus. Connections can be made 9 i sue, | the CCN serew terminals on TB3 in both chillers. The master ner b-cugaRancs 599- chile will determine which chiller willbe Lead a whch eo will be Lag. The master cher congos te slave chiller by 1 Torcing the slave chiller ON and OFF, and foreing te contol Fig, 13 — Dual Leaving Water Thermistor Well ‘Table 11 — Navigator Display Menu Structure wills | "SEE" [reurenorones [onescunes]| Sui | weure | ourpurs [eowneunanon] GMS, [ ER [auanne chpay | ‘aie! | Temeeteres | petites | 508 | cutee | otcee | Rd [AWE | cos | ean Si | as | Maka | pci eis | BS Taare —|-Sa8 | oa oe] ae | eae | GER | es ar ousistane| Outpuss | Tomperaures | Preseues | (Heat) | foncr) | (Cina) (ann are sins, ang | foutss_| Gia enc - t En | ee (aan) car [Conamene| a8 ae saa i ene ee] eee cas | Gey | Sa fee a i (0st) Tae mae 7 ‘Sone pene | ectey mn, vere “Hace es fn ping aah, omg Bier confgion eet ext ores 20‘Table 12 — Contigurat In Mode and Sub-Mode Directory Se | SR | ew oiseuav witlon COMMENT S| EST ONO TESTOSPLAY LEDs] So Baa a Conan agHRTTONTH w METR ‘ONOFF ‘METRIC DISPLAY [Ow = English enatiee me TNGIRGE SELECTION —|DsatErioh Espa Franca Ponies _ i PAS.E | ENBLDSBL PASSWORD ENABLE iM PASS: OOK ‘SERVICE PASSWORD Detaut: 1111 wi] pe | PE TRITTVFE rar coven OND fWawr seamen ste Peat Kachine nes Bess Foxe | ox our see : TER WKH] ORCUTT CARTY —— SON Ee Oso, 1o2= se eG 10192131, 1 fear Ebel =a oa R978 zetas0 20 Soa es fesse te: fi. 7e8, 161 = 50 oe; aue ez Bee] RE ORG A COMPRESSOR RR CHTETE= | Pea Seog ar <2 iSanroee 78 23 Seo 0 22 TIP SE] OCT COMPRESSOR fin rar = } Te [ess | mace | BSONARGE SUPER SETPONT [Det 2 F ISCHARGE SUPERAEAT NS] x FARTSTHGING SELECT Ng OAR, SORRCI Pee Re 3 STAGE IND (ax 6a, 27) 5 Sra nD B0GRN FE S520, 28 35a a FES FA oor iss, 174 208.225) fs ib Soest, 2) SSiage cae (aE He. 0 ESR co oso 08 10,14 5 SS1A82 com concxne, 129, 198,150,160) GAT | RRR NAPS | _ COMPA. ATMUSTTRIP AMPS |Voty wh Appenei A f=] | cae [yoo airs | COUP A2MUSTTRP AMPS [Very wih Appandi A ==] [cer [oo ars | _ COMPA 61 MUSTTAP AMPS [Very wih ApandicA Tex [case | vooraue | COMPA 82 MUSTTRIP AMPS | voy wit Append A aTable 12 — Configuration Mode and Sub-Mode Directory (cont) ‘SUB: wove KEYPAD ENTRY TEM DISPLAY Trew EXPANSION, ‘COMMENT ‘OPT FLD x COOLER FLUD Daiaak Water Water Medium Temperature Brine Lew Tarporature Brio [304% en uve YESINO TANLOAD VALVE SELGT nina Load Vaio PCT HEAD PRESS CONTROL TYPE No Control Air Cooled s0SxNF, 90HXA deta ater Cooled SOHC defau). Geran Cand BORA Connon Condens ind Gond (OFA Indopendet Gendenser, vePT ‘VaR HEAD PRESSURE SELECT Thane (Hk, SOGX No Motormacior 8°20 ma (2-10 vas) (30GX wih Mtmastr) 0.20 ma (0-10 ve 200 ma (10-0 se PATS YESING PRESSURE TRANSDUCERS Detar: Yes PC ‘COOLER PUMP CONTROL, Defauk OF ‘CHP ‘CONDENSER PUMP INTERLOGK [Satu OF (Soest require condoncer pump conte! CPC ‘CONDENSER PUMP CONTAGT etait No Cone Neconra ‘On wen couples Sn wim compressors) ‘ewrs: YESING ‘CONDENSEA FLUID SENSORS Detaut No ea YESINO ‘EMM MODULE INSTALLED CTRL ‘CONTROL METHOD atau Seen Baten = EnablesOttRemote Contact Say Soe 7 Day Sonedule Qecupaney = CCN Occupancy een Cen Contor Gena 3 CEN ADORESS Defaut: | Range: 110239 Cone we CONUS NOWEER Dera Range: 010299 mab CEN BAUD RATE Defaui $800 200 00 900 19,200 38.400 TORDING SEQUENCE SELEGT Defauk Equar Equal Sages TEADILAG SEQUENCE SELECT ‘Dau Aarate Aomate eu Loses Gieut 8 Coeds Psa ‘COMPRESSOR SEQUENCE Defaule Avoratc automate {Compressor 1 Loads Compressor 2 Leads Tow WORF GHW ALERT ORT Deu 60 ange 21060 F DEY 7 TaNUTES OFF TIME Dela 0 Mutas Range: 01015 Minos ase ENBUDSEL ‘CLOSE CONTROL SELECT Default sate 1M ENBUOSBL IGE MODE ENABLE Defaute Dieabe CN WR ‘CURRENT UNBALANCE SETPONT Deak 15% ange: 1016 25% ROFL ENBUOSEL ENABLE NO FLOW DETECTION Detauk Enable wee ENBUOSL ‘WINTERIZE ALERT GONFIG Detaat Enable isla) akakalel i oO ARC ¥ “ALARM RELAY USAGE Delguk Aone + Aare [Alerts Arms me Oniy 2‘Table 12 — Configuration Mode and Sub-Mode Directory (cont) S08: mode KEYPAD ENTRY TEM DISPLAY TEN EXPANSION ‘COMMENT RSET CAST ¥ ‘COOLING RESET TYPE Daa Ne Feset No es i020 mA tnt JGutdeer Ae Temperature Beta Fu |Seaeo Temperature ww oR WRF NO COOL RESET TEMP Deaul 125 Range: 0°10 125 Foctotun hs reset use coolr aT CRE WOKE FULL COOL RESET TEM Deiat °F ange: 0°10 125 F Fortetum Suisse use cooler aT GRC TKaF ‘DEGREES COOL RESET Dela OFF Pange~20 1030 F gq W FAST % HEATING RESET TYPE [Defauic No Reset [No Reset /$t0207A Input [Gutdoor ai Temperature eter aT WKF TO REAT RESET TEMP Defauk oF Range: 0°10 125 F FATE WF FOUL HEAT RESET TEMP Dotaut 125 F Renae 01025 F GAH TRXEF DEGREES HEAT RESET Detaut OF Range! ~30 to 30 F ‘oMBE x DEMAND CRT SELECT Dotaui None Rene Stan 1920 mA Int (GEN tomesnos ‘DN WR DEMAND CIT ATAD IR Defaut: 100% Range: 010 100% Sea co TOADSHED GROUP NUMBER Dotaut0 Range: 0 to 99 oo RH TOADSRED DEMAND DELTA Detauts 0% Range: Ot 60% oan WH THARIMUM CORDSHED TE Dafa 60 Minuto Pango: 0% 120 Winstos Dist roe ‘DEMAND LIMIT SWITCH T Dea: So Range: 00 100% dal dalla afta a Dse WR DENAND LIT SWITCRE Dea ange: Ot 100% LEN’ ENBUDSEL TLEADILAG CHILLER ENABLE Detour: sable wes SIVERAST MASTERISLAVE SELECT eau: Master soe WH ‘SLAVE ADDRESS Dara Range: 010239 Ta x TEADIAG BALANCE SELECT Defau: Masior pads Master vaace Save Leads, somatic a5 7 TERDILAG BALANCE DELTA Detauk: 168 hours Range: 40 to £00 hours To wo TAG STRAT DELAY Dorautes minutos nga! 01030 minutes () (a} (| adlakala PARA YESNO PARALLEL CONFIGURATION Dota: No (Series Flow)Table 12 — Configuration Mode and Sub-Mode Directory (cont) Sus] Eva Tem Se | SHR [ew | _oisrcar ello comment SLT few] | OP x COOLING SETPOINT SELECT — [Daa Sagi Sea But Saaen Buel Posy Psat CSN costes a ma rt es EN) ey x FERTNESETFONT SELECT — Deiat ae ae Ba Sen Boal aay Bsal CON cocpies 2 20 mA nt (recurs EMM) fel ms _| enwvose RANPLOADSELEGT _[Oetaut Erabie fe] oP |e ‘COOUNG RAMP LOADING Dott 15 range 030 20 fe | ee TERTING RAVPTORONG [Deft 19 ange 021020 Fel_|_rosw_| coounem HEAT COOL SELECT [Detaut Coot fe Er DEROBAND MUCTPLER [Defeat 2 Panga: 1040 fey at] en TRE BANE CONFIGLOGK [Beta no See fhe nae Ht no SERV | fay] FERD PRESSURE GAN [Dela 19 ange’ 9 19 20 | Ree] FEADPRESSURETGAN [Detar amt 20 fe] | Bon] x HERD PRESSURED GAN [Detaut 09 Range’ 19 20 Fe) | HRN] ac | Wnt VALVE TION POS — [Osu 70% Range 1 100% i MOTOR TENP SETPONT |Defaut 200 (170 F tr Binoy fe) | BRFE | a RINE FREEZE PONT [Deu a2 F Range 2010 94 & Fey | eS) — ni TEN SFO — oem eH 12 F pany ig) Range: 100 Ff Geb By ae ERA START POSTION Beau 20% ¥ Range: 5 730% fe) se | exe Wve START POSTION Default 20% Pan 090 40% Fel |_evar_| cnouoser | ENAn.e COMPRESSOR AT [Detar Enable a) Te] | ERA? ENBUOSEL| ENABLE COVPRESSOR A — [Dine Hore 196 GEN papa Erbe faoeart Gunn os) fel [ever | cnouose. | ENABLE COMPRESSORG) _[Detaue Enable (A) [fe] | ENB2]ENBUDSGL | ENABLE COMPRESSOR BE [Diao EHOTE.a71 GHW OBO [Brae (Sheer 550 fel_|_wone | vesnio | _wiTERIZATiON PERFORMED fw) | scow | vesmo TECONOWIZED No gorna7etas soGney eee 08,19 fee BONOToT a7 Sees ATGE E50) was % NUMBER OF EVAR PASSES _[Range: 1 Toa | we aa CIRCUIT TH LWT SENSOR [According mmber of coder pastes 5 Dour sor fel | sr | mee APPROACH SETPONT soar sest | fa] | roac | oworr | conTmepaTeanonncast — [Detaut or fel | ome | _onorr CGN OATaROKDGAST | Deteuk OF [feL_| esse | oworr | ciosar screoULe aACADGAST [Deut OF fel | scax | oworF | BAOADCASTACKNOWEDGER |Dciu OF 24Table 18 — Serie Test Mode and Sub-Mede Director eee = r= wobe_|"Evray | eM | oispLay EXPANSION. ‘COMMENT ) Tr Ee Sa | ane SS TEST : Eta aoa eae Srmscmen hee ours fos} [ ewe | oom EVs OPEN fel | oLPA | ONO ‘OL PUNP fence [nor — | Woron SoouNn BOURNODA LL nse | ovorr [oven cooune sounovone besa | enor] on sou lw eXv.s OK % EXV % OPEN fe] | ware [0c VAR HEAD PRESS % [wl | onre | ONO OIL PUMP ey Trncar | oworr | waroR cooune sorzneo [sae] oworr | waren cooune eoueNon 2 ess anor] on souenon er Tose | onort | on sounoo ce HE ep ocr a aE Sueea— ae RF ENTER — per Ca Son TASRER —— leet Fane 7, 8 (18, 128, 128, 160, 160) Ce es Fe Ah aes ae | nr rr eee jesecernan as eS aS Parr [owore | coocer emer ee Spar [Covor | Rance nareraecar COMP” CC.At ON/OFF ‘COMPRESSOR 47 RELAY 1 [ocx [ovorr | conressonaa i Speman [tonne ar rear tae [over [ connec Fee [over OLEATE [eee [vor conrrastona naar ) fe] | ona | _onore OIL HEATERTable 14 — Temperature Mode and Sub-Mode Directory susmooe | "VPA? | rem | _oisPLar palition comment unr Fre) | cewr | r00ex ‘COOLER ENTERING FLUID Ee oe ‘COOLER LEAVING FLU ce OUTSIDE AR TEMPERATURE fel | st | moxr ‘SPACE TEMPERATURE fe] | ence 0c CONDENSER ENTERING FLUD fel | ox | xexxr ‘CONDENSER LEAVING FLUIO GRA i oe SATURATED CONDENSING TH Tw | sta, [xx ‘SATURATED SUCTION TEMP fe | sa | mmx DISCHARGE SUPERHEAT TEM | octa | wor DISCHARGE GAS TEMP este Aten rete er fe] | ocar | vax DISCHARGE GAS TENP-At fe) | cae | wxxer DISCHARGE GAS TewP-a2 | GXILRADE 80 no wwe | war "Ai MOTOR TEMPERATURE fe | wee | woxr ‘Ae MOTOR TEMPERATURE ex san4 69 are one fe] | sore | xx ‘SATURATED CONDENSING TMP fe] | ste | vox ‘SATURATED SUCTION TEMP fw) | see | wxxer DISCHARGE SUPERHEAT TEMP fe) | octe | wx DISCHARGE GAS TEMP average of BYB2 values for fe] | 2oar | vax DISCHARGE GAS TENP-B fe] | ocee | maxr DISCHARGE GAS TEMP-2 —_[@RIURART-860 ony fe | me: | mcr 1 MOTOR TEMPERATURE fe) | tee | moor 82 MOTOR TEMPERATURE [enn Rae+-250 ony 26Table 15 — Pressure Mode and Sub-Mode Directory sue-wooe | SAP | vem | _osPar wiiton couMENT PACA fr] | mea | oxxrac DISCHARGE PRESSURE fel | sea_| vaxxrais ‘SUCTION PRESSURE fe] | cova | vnxxrse ECONOMIZER PRESSURE fw) | oa | mxxrae 1A Ol PRESSURE fel [ona | rxxxrsia 'A2 O1L PRESSURE fw | c081 | oxxxes ’A7 OL PRESSURE DIF Equa of prosaure minus fw] | om | unre 7201 PRESSURE DFE [eMac reese mins Tw | roar | 0cxrs: ATOILFIETERDIFR PRESS [quale decharge pressure fo | roa | omnes AOOLFETERDIFF PRESS [pinawalganae fol rear | xxrsr CALCULATED OL PRESSAT_|RTAGI osu HSOMTT fw] | Psa | murs CALCULATED ON PRESS AZ _|CRTASI Sous spoil Pace faq| ore | xaxrse DISCHARGE PRESSURE fe] | | oxxra SUCTION PRESSURE fe | cone | maxes ECONOWIZER PRESSURE iwi | om | oxxrse 7 Ol PRESSURE fe) | one | oxxraie 32 01 PRESSURE fe] [post | woxrsi 1 OIL PRESSURE DIFF Equals a pressire Tims fe] | cose | axes GeO PRESSURE DFR, | ERUAE opessire mires fw) | For | exxrst 1 OIL FILTER DIFF Equals cschorge pressure fw | roe | _oxxes 22 01 FILTER OFF quai charge petire fw | eso: | «xs! cavcutareoonenesser [OKT Salreseue siint fe) | esee | xxxrsi CALCULATED ONL PRESs62 [ATS alpreseue sepont2 Table 16 — Set Point Mode and Sub-Mode Directory suswooe | GYPAP | rem | _isruay witlon ‘comment ‘coor eq | csr: | Kx (COOLING SETPOINT 1 Pama fw osP2 HX F COOLING SETPOINT 2 ‘cil fel | ose | oxxer Ice seTPowt Pea se WeAT fe HSP1 XXX. SF HEATING SETPOINT + ar wi HSP2 XXX SF HEATING SETPOINT 2 [Dotan 100 F HERO fe]_| mora | oaxe EAD PRESSURE SETROWTA __[eSDSIREE ORFHAT | ore | omxe HEAD PRESSURE SETPOWTB _[RRUEYEEE GOOKFOAT aTable 17 — Inputs Mode and Sub-Mode Directory suesooe | AP | ew | osruay alition COMMENT GENT =| _svst_ | strvistor STARTISTOP SWITCH fw | row | oor (COGLER FLOW SviTCH fel | csr | oworr ‘CONDENSER FLOW SWITCH fw [os ONOFF DEMAND LNT SWITOR A fw | se | oNorr DEMAND LMiT SWITCH fw | | oworr IGEDONE fw} | ow | onor DUAL SETPOWNT SWITCH act es ‘COMPRESSOR Ai FEEDBACK Mm | rk | oor ‘COMPRESSOR A2 FEEDBACK fel | ova | oPewause OL LEVEL SwiTCH fel | vcr | somans ‘COMP At RUNNING CURRENT fe | mecn | vox anes ‘COMP A2 RUNNING CURRENT | er ONOFF (COMPRESSOR Bt FEEDBAOK fel | reee | onorr ‘COWPRESSOR 62 FEEDBAGK fo | ove | orencise (OL LEVEL SWITCH fe|_| sicr | oxaues ‘COMP Bt RUNNING CURRENT fe _| s2cn | soxanes ‘COMP 82 RUNNING CURRENT 20 fy | oo | vcxma “4-20 MA DEMAND SIGNAL fw | mer | xmxma #20 WA RESET SIGNAL wo 1K MA “20 MA COOLING SETPOINT fw | tse RMA 420 MA HEATING SETPOINT 28Table 18 — Outputs Mode and Sub-Mode Directory KEYPAD TEM suBso0e | RAP | Tem | IsPLay eatitlon comment aeno | fen] | ran | ONOFF FAN 1 RELAY Fa_| ae | oworr FAN? RELAY fe] rns_[_onorr AN RELAY fw | Neoware FAN RELAY fw) [my _ | onore THINMUMLOAD VALVE fe _| cone [_onorr GOOLER PUMP RELAY fel_| cat | onorr COOLER HEATER fei _| oxo | oworr ‘CONDENSER PUMP RELAY fw [sw |x LOADIUNLOAD FAGTOR RA | _pe]_| coat | ONOFF COMPRESSOR AT RELAY fe]_| come | oNorr COMPRESSOR M2 RELAY fw) [at onorr LOADER AY RELAY fei [ om | onorr LOADER A2 RELAY fel_[ oven | onorr 1 PuMe fe) _|_Ncar | oNoFF | MOTOR COOLING At SOLENOD fe] | ucae | oworr | MOTOR COGUNG Ae SOLENOD fe _[ ona [ onorr Ou HEATER fe on oNorr OIL SOLENOID AT fi [cum | onore ‘OIL SOLENOID AZ Fe_[ own | v0 XV OPEN fw | HPA [Kw ‘VARIABLE HEAD PRESS ome | fey | coer | onore COMPRESSOR 67 RELAY fe_| cose | onorr COMPRESSOR Ba RELAY fw) [woe [ower OADER 81 RELAY fe toe | ono LOADER B2 RELAY fw | cre | oworr OPN fw) wes: | oworr | woTon cooune at SOLENOID feL_| wees | oworr | moron coouns Be SOLENOD fe] ons [_onorr OL HEATER fe_[ ove: | onorr OL SOLENOID fw) _[ ose | onore ‘OL SOLENOID 62 | ews | xe AV HOPEN fw | wire [xx VARIABLE HEAD PRESS Ey‘Table 19 — Operating Mode and Sub-Mode Directory KEYPAD suewooe | "REP | rreW | osPLar extn Commun wooE | fas _woor_| _ONOFF GS CONTROLLING GHILER fel _| woo oworr WSN CONTAOLUNG CHILLER fv ‘MDo3 ONIOFF MASTERISLAVE CONTROL fw _|_wooe | oworr LOW SOURCE PROTECTION fw [wos | oworr AD LOAD LATED fel | woe _|_oworr TIMED OVERRIDE EFFECT fy) | wor | oworr | _LowCOoLER SUCTION Tewex Tw] | woe | oworr | Low coo.ea suction ewe fe) _| wooo | oworr SLOW CHANGE OVERRIDE fw | wow | oNorr TWNIMOM OFF TIME ATE i A a fel_| wow | oworr | LOW OISGHRGE SUPERHEATS fi | wow | wor GUALSETPONT Sa TEUPERATURE RESET fe] | wos | oworr DEMAND LMITINEFFEGT fw | wore | onorr (COOLER FREEZE PROTECTION | ww | oworr LOW Ta GOOUHITP HEAT | _woie_|_oworr HTM COOLAO TH HEAT fel _| wow | oorr ARNG ICE fst] were | “onorF TORN wv p21 ‘ON/OFF HIGH SCT CIRCUIT A fei | woz | oworF HIGH SCT CIRCUIT 8 oe HIGH WOTOR GURRENT GIR A fe | wom | oworr HIGH MOTOR CURRENT OR 8 vv M025 ‘ON/OFF (CKT A OFF REF FLOW DELAY" fe | wom _|_oworr XT OFF REF FLOW DELAP ea CIRCUTA—PUMPNGOUT | SHUTOOWN N PROGRESS fe | vow | oworr GRGUTa—PUNPOUTOUT | SHUTDOWNIN PROGRESS fei] wee | oworr UNT OFF NO WATER FLOW “Recycle resiart pencing 1S minute delay due oss of rrgeran ow deleted at ear-up. 30‘Table 20 — Run Status Mode and Sub-Mode Directory suewooe | EAP] mew | PLAY wilion coMMENT view fl ew WO ENTERING FLUIO TEMP a a WORF TEAMING FLUID TEMP ic] see | our ACTIVE SEYPORT vl corer 20K E ‘CONTROL PONT Siar x ‘CONTROL ODE SENTCETEST Ber een SFr Etiocy exe Sai wi 066 VEEN OeCuPED fl Tan TN TaNUTES LEFT FOR START a Toor | Yesno | OVERRIDE MODES EFFECT wi oP TOR PERCENT TOTAL GAPAGITY fi DEM 70 -ASTIVE DEMAND LT fw AR "Om CURRENT ALARVS 8 ALERTS wa Tie ORK TIME OF OAV oo coas0 wi wr me WONTH OF YEAR Lemur, Febuary ee wi one ~ DAY OF MONTH orn a YEAR mx von aun a FASO | WOKCHAS | _WAGHINE OPERATING ROURS a oRU 30504 WACHINE STARTS HOUR bel TSA | OKHAS CIRCUIT A RUN HOURS wi vase | OOKHAS COIROUITS RaN HOURS fal Tam | 000s | COMPRESSOR At RUN HOURS a] wane | 000cHRS | COMPRESSOR A RIN HOURS wi Tas1 | s000cnRS [COMPRESSOR 61 AUN HOURS iwi ps2) 20G0¢HRS | _COWFRESSOR 2 RUN HOURS over = SRA 7008 GROUT A STARTS a ai 70K ‘COMPRESSOR AT STARTS fw Sia "00 COMPRESSOR Aa STARTS fw oR 7000 ‘RGU E STARTS wi So 790m CouPRESSOR OY STARTS al sree 790K COMPRESSOR 2 STARTS 31Table 20 — Run Status Mode and Sub-Mode Directory (cont) suswooe | GP] ew DISPLAY extn OMEN vers | fe} v8 GEsRABI2ee faa isVrsin nab fl ow GESR-anTER paras Veron ruber SI ev CESRABTT TERM lacie Version ruber Tvl or 700288 fevers Veron rrr il ore 100239-1At ocx Version number fl sce ESR ASTRO acer Verio number fw Na ESRB RO fcc versonnbor Table 21 — How to Adjust Navigator Backlight from Configuration Mode TEVEAD Tre ‘susuooe | “GRrAP Tew DISPLAY tow COMMENT Oise =I TEST ONOFF | _TESTOISPLAY LEDS Tre Faso Fito pana ae quad ang ENTER tin key ate each number ° Test OFF OFF wibe fashng. ial TEST oN [Crange valve to°ON FONT Tasos. Dipti Tass Enabled. The arm ard Test on a rade edsight un tte Nawigsor i ls lay a sock Sarnia w Press arom keys a he Sane ino, Tre ali) Nevigator wi api ac Breningce: 1 Te te aon oy To Baghan Te Ba tally os a the um ow iy oa he Packigrt. Pres the ESCAPE key wen sneo en he mode, Table 22 — How to Adjust Navigator Contrast from Configuration Mode KEYPAD Te susuooe | EyrAP Tem DISPLAY EXPANSION COMMENT Dis EI TEST ONOFF | _TEST DISPLAY LEDS = Ti Fase Fir pared ae roqured wang ENTER S fe fay afer each nanset 9 Test rr [OFF wi be tasting fal Test on [Cnange value ON’ FON Rashes. TEST on DispayTeetie Enables. he alarm are at i] Frode 2D igh up. The Novigat wl iy al Sock segment. =] Frese Ee ond Eecape Kas ose [CONTRAST wit a percentage incieaton, ae se te up arow key fo erease contrast sn he Sou stron hay to ecrones a coast Pres re ESCAPE Koy when Sedo ew he mode. 2Table 23 — Time Clock Mode and Sub-Mode Directory suewooe | SPP | rem | ospuay Daron COMMENT Tae | paw | 000 HOUR AND MINT iiny(on60 — 250) one wm [oem fe MONTH OF YEAR henuany, Febrero fw [oom wm DAY OF WONTH Farge 31 fw oY x ON OF WEE acndag Tow 2 iw | yeas 000 YEAR Det fe | saw | ONT pala wm | saw [x WEEK Beat, fw | sno x bay BT, fw pone [x TNUTES TO ADD ee : mlm | WONTH peut 0, fw | sew | WEEK paaut 5 fw) | smo | ony Beau 7 wis |x TWNUTES TO SUBTRACT ree sono fm] | mono | ox TWONDAY OGOUPIED TIE [BBE SOE 29 fw | wore | ox WwoNDAYUNOSOUPED TINE [BUM BERD, an cp [mee | ox “TUESDAY OGSUPIED TIME BOL 0 55 fw | eu | ox TUESDAY UNOGUPIED TINE [BU SO oo fe) | weno | oom TWEDNESOAY GOSUMEDTINE [DEBE SO, fe [_weov | ron | WeDnesoarunocourico we [RUE SS 259 fe | mo | mx THURSDAY OSGUPIED TIME [BEB SO 95. ee a ce ww | emo | mmr FRIDAY OGCUPED THE Be cas fl] rn |x FRIDAY UNOGOUPIED TM —_[REMUE QO. 25.59 fw) | smo [ox SATURONY OCCUPIED TIE [BEBE caso fw [sw | mom SATURDAY UNOGSUPIEDTIME [REID on co fw) | so [xxx Ee ee fe | see [mmx sunoarnoccureD TIME [BHM 22059 3Table 24A — Example of Configuring Dual Chiller Control (Master Chiller) SIS WOOE [AER] RR TA [BRL TETEPNOT ome erm fet ‘waren VALUE FLAGHES orm Fl wuron conten ween _|SEENOTET ona Fs 1 a ona Fs + en ADORESS [ence REQUIRED cena ke @ berate ona [=| @ ‘con ausmomen __[owiNGE FREGURED cena ei oma wi RESET PROGEDE To BUBNGDE REET reer [ser eq const NORESET TOOING RESET PE uN ee EADIAG CHILER ENABLE | SOROULNG STOPS = ALLE RASHES ene seer exer tes om TERENAS CHALE ENDL [ORANGE ACCEPTED fw wsst os et wast MSTERRUNE REST —_[DEAIATWAST sa =I ° alu RASHES ‘swvA =I 2 ‘SLAVE ADDRESS [cvANGe ACCEPTED ua ix WASTER LEADS | LEADLAGEALAKEE SeLEGT _[TAIUE FLASHES (al ‘avrountie eicor Arrouare ua et ‘uroumme | \EABLAGSALANGE SELECT _[onaNGe AGOEPTED ivi a0 =] ‘8 LeaDuaa Balance paca [DEFAULT 103 bel =e =e a 2 faiue riasnes 7 el © ee a) om z x0 Taras conniauration —|oeraucrno tal 68 [sevect ves ama = ves Tanne Conieunation |seenore? fed ‘RSET fuxsTER COMPLETE fhe sestad conse metos erosion corr ft te Mareen, Tne sae ie ays congue etn ea 2: Yee SB ping congo No See pt Coiuion Mas snd Sam Chas ht DS conte ore same ping ceniguaon, 34Table 248 — Example of Configuring Dual Chiller Control (Slave Chiller) Sue Too | Te | RETRO ENTRY [FLA TE EANSTON Same om |_oFre Fe crm =I oo cowrna.uenion —_|SEENOTET fed uo fel oi om wl cou ona = 4 Cow ADDRESS [SeRouNG TORS I 1: aie LASHES tal 2 SELECT a SEENOTED cone =I 2 ‘oN ADBRESS [vance ACCEPTED El cou w one cn Es ° Tovasmneen _|SEPALLTOGEENOTED fed cow fel one wl ae PROGECD TO SUBMOOE RSET reer | ase =I ont COUN RESET TPE i en Taos cmuaneuae [fy] 1mTeH5 usw Ee} aa sonouin OFS f=] oa VALUE RASHES laa) Bi eeigoT EN uae Et eo CEAORAGCHALER ENABLE [CHANGE ACCEPTED ed ua fl wast WASTERGUNE SELECT la Fe wasT RoROULNG STORE i MAST ALU FASHES lal Swe, [SeLecT SLAVE uss =I ove WASTERSLAVESELEGT __[OUNGE AOOEPTED tel Ms wl wae PARA el nO ‘PARALLEL CONFIGURATION fl ves SELECT VES Pana el ve aRALLEL cowRGURATON [SEENOTES el reer Suave COMPLETE Nore SE waren cotvata gan SSoe eee ti SER cum ee en ior ana Save cers mst bo be corgured esas png ceaouaon, 35and alerts are messages that fone ar more faults have been detected. The alarms and alerts indicate failures that eause the unit to shut down, terminate an ‘option (such as eset) or result in the use ofa default value such as a set point, Refer to the Troubleshooting section for more information Up to 25 alarmsalers can be displayed in curently active alarms. Up to 50 alarmsfalerts can be stored inthe alan histo- 1, See Tables 25 and 26 to view and cler alarms, IMPORTANT Do not clear the alarns withow fist reviewing the fill list and investigating and correcting the cause of the alarms. ‘When an alarm or alew is stored in the display and the ‘machine automaticaly resets, te alannlalert is deleted. Codes for safeties which do not automatically reset are not deleted ntl the problem is corrected and the machine is reset, To clear ‘manual reset alarms ffom the CCP modules, press the reset button located on the CCP board generating the alarm, for 5 seconds, (CCPI for compressors Al or BI, CCP2 for compressors A2 or B2). Next, follow the example in Table 26 to clear the alarm from the Maia Base Board (MBB) history ‘Alarm relay usage alerts and alarms are configurable in (CONFIGURATION MODE, SUB-MODE OPT2) t0 be both one orthe her or ff paragraph, Run Hours and Starts — The HOUR and STRT sub- modes under the Run Status mode contai items for number of hours for each circuit and each compressor and the total number of starts foreach compressor. All tems are password protected, but can be changed if a replacement MBB. is Installed, Press fo] to make the curent value flash, Use the atrow keys (0 configure the conect value and press the f= key again. Record the current values from the MBB before remov- ‘ng the modole or downloading new sofware ‘Temperature Reset — The contol system is capable of handing leaving-uid temperature rest based on retum cooler fluid temperature. Because the change in temperature through the cooler isa measure ofthe building load, the return tempers ture reset i in effect an average building load reset method "The contol system is also capable of temperature reset based ‘on outdoor-sir temperature (OAT), space temperature (SPT), or from an extemaliy powered 4 (9 20 mA signal. Accessory ‘sensors must be used for OAT and SPT reset HH79NZ023 for ‘OAT and HHS1BX006 for SPT), The Energy Management ‘Module (EMM) must be used for temperature reset sing a 40 20:mA signal, ‘Tose the return reset, four variables must be configured. In the Configuration mode under the sub-mode RSET, items RST, CRI, CRT2, and DGRC must be set properly. See “Tubes 27 and/28 on page 37 for correct configurstion. ‘To reset the retum fluid temperature, the unit set point i reset fiom full load based on the chilled fluid return tempera ture. The example use a reset value of 10 degrees at fll reset, Full reset is at a 2-degree temperature difference aeross the cooler and no reset would be at 10 F difference across the cnoler See Fig. 14-17 and Table 29, ‘Under normal operation, the chiller will maintain a constant, leaving fluid temperature approximately equal to the chilled fluid setpoint. As the cooler load varies, the entering cooler fluid wail change in proportion co the load as shown in Fig 14 Usually the chiller sie and leaving.fluid temperature st point ae selected based on a full-load condition. At part load, the fluid temperature setpoint may be colder than required. If he Teaving fluid temperature was allowed to increase st part load, the efficiency ofthe machine would increase Retum temperature reset allows for the leaving temperature set point to be reset upward as a function of the ret fuid temperature or, inefect, the building load. Figure 14 isan example of no eset. Figures 15, 16, and 17 are examples of outdoor air, space and retumm water tempera- Table 25 — Alarms Mode and Sub-Mode Directory SUEMODE | KEYEAD ENTRY Tew EW EXPANSION commen RN el TANK oO | CURRENTLY ACTIVE aLaRwS [RETTS ara shown a8 AEE RcRN & YESNO | _RESETAIL GURRENT ALARMS Hist Es} AXXK 0F THK ALARM HISTORY alerts ate shown ns TOC Table 26 — Example of Reading and Clearing Alarms suesove | "EYPAP eu ITEM EXPANSION ‘COMMENT cat | Es) | novcornon | _cunReNTIVAcTWE ARS RIERA GRE DS, ‘cnn = nO Useie der acve alamaterts NO NO Flashes Roan ved [Seect YES xo [Warriors cea, VES charges © NO -Prese FS] and FE] simutanecutt clay expanded arm deacon 36‘Table 27 — Configuring Temperature Reset nose | SYPAP| suemooe [EYP] ew [ossruar] —exiitlon oUNENT CONFIGURATION fej | me | fo} | vest [oworr | vest o1spuay tebe Lie | oe | fe [vee | x ONT TE fw opt fee] | Luo x COOLER FLUID fel [_orre | fet | orm |__| _conrnocmerion wl 3 COOLS RESET TESTOR SEF ot fl =o 20 A input (EMM require icomcaie Eanes [= Saiesear rans eect Sees) = Sere RS gears So a eT fet | on [ooxe| nocoot neserrew (2rat9 S25 Rees Meester Gnereo baer rea) fe | corre [ocx |Futt coo. Reser TEMP eae ot asT=t Seat Recent a crores beac FC) Ta_| wane [oxar [DEGREES coor RESET POE SFE wre7 ‘Table 28 — Return Water Reset cwuot [SRP [re [owe | oalon come a == coonnese cI st NPE is Bot Fuld la = Senco Tempers wm ben | 2F TO COOL RESET aL TEE ETTO mt | oe Seu Ranga nee 208 FLL COO coaracaaeaa Ri | ome | Gfo ESET TEMP Range: Oto son S008 DEGREE COOL [Beau OF 6) fe [cone | S885 Aeser Renae: 20 0 30 F (167 to 167 6) 2. 1 wf of LTT TTT a by ole) || Etats Fe. borg | e.g ss LI fel Got] a ae Zool ; \ oo] Eee! er | ele | ccs ae ool B i" 4 1 pees “| 5b UI Bor Bape Ti Retssshuelsertowr| scr ere Sao cansce eveenrne LEcEND rote reno WT — Enoing Wier (4s Tempore LeceNo Give = Exner i enforce LWT —Loavng tr (ued) Tempers Fig. 14 — Cooling Return Water — No Reset Fig. 15 — Outdoor-Air Temperature Reset 37ot. [| oti fer EOL ESD [Peel TEN be bh thy ee et LWT — Leaving Water (Fuld) Temperature Fig. 16 — Space Temperature Reset +} essen rise ——__— este ache ote ee a io ‘TewPenaTURE DIFFERENCE (EWTN DEGREES F cilia a dla Oe TT Ba 2a ag a9 aa 3088 ‘TEUPERATURE DIFFERENCE (EWTL.T) DEGREES C LEGEND EWT — Entering Water (ua) Temperature wt = Coaving Pater (i) Tomporaturo Fig. 17 — Return Water Reset Demand Limit — Demand Limit is feature hat allows ‘he unic capacity toe limited during periods of peak energy us- age. See Fig. 18. There are 3 types of demand limiting that can bbe configured, The frst type is through 2-sage switch conto, ‘hich will rice the maximum capacity 2 use-configurable (7 CAPACITY AT Ama MAX. ALLOWABLE LOAD 9) 24 © 2 percentages. The second type is by 4 t0 20 mA signal input which wal reduce the maximum capacity linearly between 100% st a 4 mA inpot signal (no reduction) down 0 the userconfguable level at 20 mA np igh. The tind ype Uses the CCN Loadshed module and asthe ability lit the fume opeaing expat t maximum and futher reduce the ‘xpaciysreuied. NOTE: The 2-stage switch control and 4- to 20-mA input signal types of demand limiting rai the Energy Manage- ment Mode (EMM). ‘To use Demand Limit, selet the typeof demand liming to use Then configure the Demand Limi set points based onthe type selected, DEMAND LIMIT @-Suge Switch Conwolled) —To conig- ure Demand Limit for 2-stage switch contol set the Demand Limit Seleet (OMDC) to 1. Then configure the 2 Demand nut Switeh pons (DLS1 and DLS2) 0 the desired capacity limit, See Table 29. Capacity steps are controlled by 2 relay switch inputs field wired to TBS. For Demand Limit by 2stage switch contol, closing the fist stage demand limit contact will put the unit on the Bist ‘demand limit level, The unit wil not exceed the percentage of ‘capacity entered as Demand Limit Switch 1 set pint. Closing onticts on the second demand limit switch prevents the unit ffom exceeding the capacity entered as Demand Linst Switch 2st point. The demand Vit stage that set (othe lowest ‘demand takes prioiy i both demand limit inputs ae closed. 1f the demand limit percentage does not match unit staging, tbe nit wil mit eapacity tthe closest expacty stage. “To disable demand lit configue the DMDC to 0. See ‘Table 2. EXTERNALLY POWERED DEMAND LIMIT (4.0 20 ma Controlled) — To configure Demand Limit for 4 ‘0 20 mA contol set the Demand Limit Seeet MDC) 10 2 ‘Then configure the Demand Limit at 20 mA (DM20) to the rpaximum loadshed value dested, The contol wil sodoce $Mlowable capacity to his evel forthe 20 mA sina DEMAND LIMIT (CCN Loadsied Controlled) —To_c figore Demand Limit for CCN Loadshed contol set the Demand Limit Select (DMDC) (0 3. Then configure the Loadshed Group Number (SHNM), Loudshed Demand Deta (HDL), and Masimam Loagshed Time (SHIM), See Table 2. “The Loadshed Group number is established by the CCN system designer The Comfort ink™ Control wil spond toa Redline command from tbe Loaished contol. When the Red- Tine command is received, to current stage of capacity is et 0 the maximum stages available, Should the leashed control send’ Loadshed commang, the ConyorLink Control wll TR PAST ATE mk TOCCATA 1B ‘DEMAND LMT S;GMAL= 4-20 mAINPUT Fig. 18 — 4 to 20 mA Demand Limiting 38reduce the current stages by the value entered for Loadshed Demand delta. The Maximom Loadshed Time is the defines te maximum length of tine that a loadshed condition is allowed to exist. The contol will dissble the Redline/Lcadshed ‘command if no Cancel command has been received within the ‘configured maximum loadshed time limit Cooling Set Point (4 to 20 mA) — Unit operation is based on an external 4 to 20 mA signal input to the Energy ‘Management Module (EMM). The signal is connected 10 ‘TB6-3.5 (+). Figure 19 shows how the 4 t0 20 mA signal is linear calculated on an overall 10 F to 80 F for both Water ‘and Medium Temperature Brine COOLER FLUID eonfigurs- tions. See Table 30 for configuration instructions. % & —t @, [ & ” Seon 9 roraiia | | & | é | Tags sm | * RSS) & 1 a = 2, SER te U9.) ep T ~ en “ “3 ae ne 7 0 ‘70 oma SaNALTOEIM LeSEND EMM — Energy Management Module Fig. 19 — Cooling Set Point (4 to 20 mA) 39Table 29 — Configuring Demand Limit KEYPAD WOoE | SEVPAP [sueanooe | SYP | ew | OmPLAY | _TEWEXPANGION OMEN CONFIGURATION | Gon! | vise | fn) | test | ONOFF “Test Daplay LEDS Rw [own | el [we | x Unite i cc Gooer Fiza fw [om [| [om [x Gant anos i RSET f=] | cast x Cooling Reset Type Fel_|_ cart _[.000cr | No 000i Reset Temperature fe | cnte | s00cx-F | Fa Coot reset Temperate f¥1_| cone | xcxar | _esrove con Aesot mH | owe | x Demand uit Slot Fe | 20 | 00% | Demendtimnar20ma [BER gOP%, ‘Loadshed Grour Default: 0 fe | raw | xxx cqnesroup |S! Sto 90 emu ox fe] | suo | soon | ‘eedsigdpemand TRS TS on oma earn fe) | sem | sooceam | Meverumonsnen ROR So min > Bora fe] | cist | v0 Depa Ut Range: ot 100% omar se Bw | ose | 00m Depandtimit ——_|RSage to 100% ‘NOTE: Heating eset values stioned ints exami Table 30 — Menu Configuration of 4 to 20 mA Cooling Set Point Control eo) | SEEPAP | sue-nooe | “EYPAP Trew | osseuay lion ‘COMMENT conriunanion | fx] | oP fe | or fel _|_orrs fel | ore fel | reer fel_| ster | Pel [os] 0 | coouNeserrowr seiecr Fl ° scing Sepa =) ° ashing o fal 4 ser b=] 4 [change Accepied 40‘TROUBLESHOOTING ‘The 30GXNRR and 30HX serew chiller contol as many features to aid in troubleshooting. By using the Navigator Control, operating conditions of the chiller canbe viewed while the chiller is running. The Service Test function allows for {esting ofall outputs and compressors. Verity thatthe chiller is properly configured, including options andor accessories, fsing the Configuration mode. For checking specific items, refer tothe Mode/Sub-Mode directory (Table 11). Checking Display Codes —‘To determine how the machine hes been programmed to ope, check the diagnostic {information displayed inthe Status function and the configurs- tion information displayed inthe Serie function Unit Shutoff — To shot the unit off, move the Enable! OfffRemote Contact switch to the OFT postion. Both circuits ‘will complete a pumpdown cycle and all compressors and sole roids wil shutoff, For extreme cases, move the Emergency OnVOf switch to the Off postion, AIl compressor, solenoids and ether outputs will sop immediately Complete Unit Stoppage — Complete unit stoppage can be caused by aay of te following conditions; + cooling load satisfied emote on/off contacts open programmed schedule femergency stop command from CCN igeneral power failure blown fuse in control power feed disconnect ‘open control circuit fuse(s) Enable/OMRemote Contact switch moved to Off position eze protection tip low flow protection trip ‘open contacts in chilled water flow switch ‘Open contacts in any auxiliary interlock. Terminals that are jumpered from factory are in series with control ‘wih Opening the Grit beeen tes, eminaly places unit in Stop mode, similar to moving the control Switeh to Of position. Unit cannot start if these contacts are open. If they open while unit is running, the unit stops ‘+ cooler entering or leaving fuid thermistor failure + lowihigh transducer supply voltage 1 joss of communications Between the Main Base Boars (MBB) and either the EXV board, SCB board or either CCP module + Tow refrigerant pressure + off-to-on delay Is in effect TF a stoppage occurs more than once as a result of any of shut down immediately and EXV closes, Refer to Table 31 for typical stoppage faults and reset types, PX Ifa stoppage occurs more than once as a result of any of the preceding safety devices, determine and correct t ‘cause before tempting another restart Restart Procedure — After the cause for stoppage has been corte, restarts either automatic or manta, depending conte ful. Manal reset requires hatte alarn() be est vi the Navigator Select the RCRN item under the Alarms moe. ress ee}, fa] and foo] again worse ll eument las and alerts. A password eof may be required. Some typical faut conditions are deseribed in Table 31, Fora complete list of fault conditions, codes and reset ype, see Table 32. POWER FAILURE EXTERNAL TO THE UNIT — Unit restr automaticlly when power is restored Alarms and Alerts — These are warnings of abnormal or fault conditions and may cause either one circuit or the ‘whole unit o shut down. They are assigned code numbers and ‘2 detailed description of each slamvalert code ertor including possible causes #8 shown in Table 32. The alarm descriptions fe displayed on the Navigator under the *CRNT" or “HIST: sub-modes of the Alarms mode. The Main Base Board also recognizes and reports illegal configurations as shown in Table 32, ‘When an alarm or alert i activated configurable, the alata relay output (MBB relay K7, temminals TS-11,12) is ener tized, The alarms and aleas indicate failures that cause te unit to shut down, terminate sn option (Such as reset) or result inthe tse ofa default value suchas ase point. Refer to Table 32 for ‘more information Up to 50 alarnsalens can be stored at once. Use Alarm and Alert tables to view apd clear alarms. Comfort.ink™ Cor pressor Protection (CCP) module alarms require an additional ep to reset alarms. To clear these alarms, frst find and comect the cause ofthe alarm, Then press and hold the reset button 00 the CCP board for $ seconds. This action will reset only the alarmed cieuit or compressor, and clear the CCP. Next, reset the alarms) using the Navigator as shown in Table 26, For configuration header fault alarms from the CCP module, move the Enable/Of/Remote Contact switch (0 the Off position ‘Wait for all compressors to stop. Tum off toe unit contol pow- ex Conect the configuration header problem and restore unit control power, Table 31 — Typical Stoppage Faults ‘and Reset Types the above sefety devices, determine and corect the —aor at nse cause before atempting anther restart anc En ER RG) [Wanralesst ‘Cooler Froeze Protein (Chilled [Auto resol rt ihe, FART Single Circuit Stoppage — single circuit stoppage Flu Low Temperature) __{repeated in sare _ ‘ean be eaused by the following: Tow oil pressure ‘open contacts in high pressure switch low refrigerant pressure thermistor failure ‘wansducer failure alarm condition from CCP module Stoppage of one circuit by a safety device action does not affect ether circuit, When a safety device tips, the ciruit is a Cooler irik anual Uniross anately ‘Conta Creu Fuse Blown “High-Pressure Sich Open | anal reset Tow Sat, Sulion Temperature | anual reset Wer 1 Low 0 Pressure Loss of Commanicavane Wik ‘Wait or Con Contre. LEGENo (68! — chleriear™ Syetm Manager WSU ator Syston Manager AatcmaticrosetCompressor Alarm/Alert Circuit — Each compres- sors directly controlled by & CCP module. Compressor fats (TOSI, 7052, TOSS, TOS6) are reported as alerts. The specific fault condition fora compressor alert is included as part ofthe lent description displayed on the Navigator, Press es] and simultaneously to display description. Table 32 — Alarm and Alert Codes AARUALERT ‘cove ACARILOR ALERT DESCRIPTION WHY WAS THIS ALARA GENERATED? “RETION TAKEN BY CONTROL ESET merWoo PROBABLE CAUSE Tae rt en ert [Gopresso At Cow [Srresaue + compressor At Low \orProssvr 2 symone feces compressor 2 Low [Si lessure 2 compressor 81 Low (or Pressure = compressor 31 Low [Si Pressure 2 ISonpresa 2 Low compressor 82 Low [Secs =2 [ea Fg oi Se pont [eSerico't ane Pig BU on Jose leo-Pe- 26 Psi |Comp. AZo tlnes | Manual |Fauty of okra valve sctotoa ldvioaperod sterci pup [aan {urs and betas of sce fait opens oto ‘nam — |conp. 81 Faled 0: pit, OF Presaute > 2.581. |Conp. Bt not alowed | Memisl [Fauty of eolnols vale Ssieola [au percd ater cigar fcc Sara before os ak opens host ‘vm —|comp. 52 FaiedO1 [OH Ot Pressure > 26°! |comp.82 not atoned | Marval |Fauty ot solenad vale Ssiona arkgpeadaecpuno [os 43‘Table 32 — Alarm and Alert Codes (cont) Ser aE [EER ETSI RENT ae ode | ALERT | _CESCRIPTION GENERATED? ‘conmon. | neTwoo | PROBABLE CAUSE Eee PEE : tes saris paaet ie creo a Fal Span tne aaron . Ee eee oe ae es Eeaats Siete [a Wt fort second farareaer cera cma arian — | a RTT Sarr — pera mT —| Ta wae be ess as esas ne iecennenaas aos, a se os case as eaves ds sai param — paren gers ome —| Taare ay an eimai board. * rrasha aaa aR SE | poner eis ame ine pagncciim (amen sit ar snes en leaner, TT cnTable 32 —Alarm and Alert Codes (cont) EER EE | oacarnon | ER | RN ALERT CODE |" ALERT ——_ GENERATED? CONTROL METHOD | PROBABLE CAUSE Suan Reese [Scnerannes Ree cee Discharge Gos. 40 to 240" F (-40 10 136" C) " cablelwre, wiring exror rae ee Pie Base eae mos | non [Emcraotree |utngate meme feorpatsncann |ssonte ums prcn Paras damageteror ° Ree se stmt rut [oeetatnmr [tsrpm [oes encinn | inal Serene epee asian [Esra eens nor | son |Bratasenme [weaermerreten,, fortesnasom |Asat |mte pon saeieemmee WEST romiseennas rae oe BE ene ue |Get ceaugas [estar premiman [omaosnacon | wows ser Eocene gener ene ects scenes an Pe PREY eae 45‘Table 32 — Alarm and Alert Codes (cont) RR] RRRION| pesca Ta WaR Tas | ASTER |_RRRET ALERT CODE |" ALERT DESCRIPTION ALARM GENERATED? CONTROL METHOD. —— Ta | Ae?” ESRR [Sees err clar [Ranashatcom | hal paaTanae Pape femoris [ores se eters le gear ear iats Sater rir | ase fescaaton — festiensecriasreyar lesomasnrdan | mama [onrtgean age, Sette an PEER Cer, Lee A pa isseuaso" panentens lspeseraray eae Tht a TT | a TT fSaen (erasoamee [eee fee” cea twa | awe [oreasrign — [atereateopenin sar foram ont cown | Mans! [ay mpain ve Sites in (tise rants? sss fmemisn b Rraoa a tus | am forousioncr finwtacrinnccnen —fetutBatarconn | ara [ovo et ne ens cea asc cer am tan ase at —] eos ET OTP TF Set Room | [ea RST Souham Era ents eeatch Sacto rar | smn fomugignos |gcrencr.sr+s'r —[eroupsnacown | atonte~ [rans erasers casquetaahme |asra) rasan seen sects a a a I [vose cmcton” [PScPe'sarG ie)” fRonseonaeresr aun [eteneae lara ion ge emreniesee eri rar ares eo rae | Aum [eranncenaoes lrowarcodescnm ony ontrenacemn, | auoate (raring sacs poe ease cacao liga cet om ent Se ang sence es, farmer ervemartee Pert sera cee FE] aa Fase TR NO Taras tee ET re aa Whence? Se eee SS Ee es rear ciaS rem | amt fesemproneio iinet sine 857 nt fone ana |ratyvrscie ox eeeteeme'e fuses een te Pearce? BES Leases rhea Se oa Geatimen |B eae Re eae ru | am forsieronse laymen ca = Sch’ Gorprossor soard b. 1K(Pq— Pe) > 125 and < 165, then Oil Set Point 2 = 2.0 x TERRE ean septs i eae = ‘Systom Manager = DOA2 (Pressures ea ge ‘sub-mode PRC.A) for ‘harmisors Very fret thatthe protler is not & wing eror botoe ving backup tharmstr {anda eae! ser eset om PRESSURE SETPOINT? PSIG "ur rem seerrenee ume, manval#repested onthe care date, 4 iNote tnt the tighoressre sun shel p Deore hs slr fs ‘generated. Chack HPS operation ths alot generated ~fanimum power loesoe at CGP fn one hour 23, At erteve i bused on operating time. 2. Gn ome less than § seconde ob presout is ignored noe: Tone of he folowing conions ue (Po = Pa) < Ol Sot Bon or 15 seconds. {B5=B3 £0 Set Pain 2 for 18 soconds \ 100. CODE HUMBER TI | To) 20 ao Go GO 70 GOB 100 HO 120125 160 WO 150 T8D 165170 180 190 200 210.220 200 240 (O\SCHARGE SUCTION) PRESSURE PS! Fig. 20 — Oil Pressure Set Point 2 Calculation Table 33 — Illegal Configurations (Alarm A151) TELEGAL CONFIGURATION DESCRIPTION THT ype BUS range oS ‘umber ol eampreseorsn Great A curse rango ot -2 ‘Nuriber of eompressrsin Creu 6 ouside rango ot F2 Tivald FAN'S of HPCT Solecton ‘Ai-cooed hie with Low Temperature ine Rud (FLUD = Low Brine) ier cosied ener configured for ai-cooled Head pressure con ype (HPCT) ‘Alncosied cher with condenser pum earre onabiod “Airsooted ler wih condenser fd sensors enable, 49 On ime Setveen § and 120 seconde, tho alert wil be gener. Seg he folowing eonditon bue fr conescuve ad (P85 by «(18 pxig29 see «Compressor un Tie nso c. 5nd sae Qn 28 sass Ne am ne genoEXV Troubleshooting Procedure — Follow steps below to diagnose and cores EX Economizer problems ‘Check EXV motor operation fit. Switch the Enable/Of Remote (EOR) Contact switch tothe OFF positon. Pres fs] onthe Navignor uni ‘Selecta menu item’ appears onthe ds- play. Use the arow keys to selet the Servie Test mode. Press fb} The display wi be: > TEST ours comP. Press Fa] (pasword entry may be required) and use {fa} 10 change “OFF wo “ON". Switch the EOR switch to Ehable, The Service Test made is now erabed. Move the olnter down othe OUTS sub-mode and pres ro]. Move te Pointer t item EXWA or EXVB as needed, Press fs} and the valve position will flash. Use [a] to select 1009 valve peston (hod fa or quick movement) and press}. You should be able to feel the actuator moving by placing ‘your hand on the EXV. A sight glass i located on the val thdy o verify thatthe sleeve fs moving to exposecover its in the orice. A har knocking shoul be fet fom the actuator when it reaches the top ofits stroke (canbe heard if szound- sae relatively quiet), Press fo] ays twice i necessary to confi this. To lose the valve, press Fe, select O% with fw] and press fon. The actuator shold Knock went reaches the botiom off stoke. IF iis belived tat the valve is not working. properly, continue with the checkout procedure below: Check the EXV output signals at appropriate terminals on the EXV module (cee Fig 21) Connect postive est lead to red wire (EX*V/6 terminal 3 for Caeut A, EXVCIT terminal 3 for ‘Circuit B). Set meter to approximately 20 vde. Using the Serie Test proce above, mone te valve utp oer sk to 100%. DO NOT short meter leads together or pin 3 0 ty ‘other pin a board damage wil occur. During the next sever Seconds, careolly connect the negative tes Tea to pins 12. and 5 in succession (plug J6 for Circuit A, plug J? for Circuit 1B), Digital voluneters wl average this signal snd dopey ap- proximately 6 vde.Iitremins constant ata vollage ole han EVDC or shows 0 vols, emove he connector tothe valve and recheck ‘The EXV motor moves at 300 steps per second. Command- ing the valve to ether O% or 100% will add 7500 sep o he move, For example if the EXY is uly closed, selecting 100% ‘would allow 73 seconds fr the de voltage to be checked {15,000/300 + 75007500, Press fre] and select 6 to close the valve. Check the 4 po- sition DIP switch on the board (all switches should beset (On). Ifa problem stil exists replace the EXY module f the reading i corec, the expansion valve and EXY wiring should be checked, Check the EXV termina sip and interconnecting Wiring. 1, Check color coding and wire connections. Make sure they ave connected tothe comect terminals atthe EXV ‘river and EX plug and ha the cables are not rosed 2, Check for continuity and ight conection at all pin terminals Check the resistance of the EXV motor windings. Remove the EXV module plug 6 fr Circuit A, J7 for Cucut ) and check the reitane ofthe to win for one winding and pins 4 and 5 forthe oter winding (2 Fig, 21). The resistance should be 75 ohms 75 ms OFF 50 INSPECTING/OPENING ELECTRONIC EXPANSION VALVES IMPORTANT: Obtain replacement O-ring before open ing EXV. Do not euse O-rings “To check the physical operation ofan EXV, the following steps must be pecfomed. 1. Chose the liquid line service vale of the cuit 1 be checked. Put the Enable/OF/Remote Contact switch in the Of position. Using the Navigator, enter the Service ‘Test mode and change the sub-mode TEST from ‘OFF to ‘ON. Switch the EOR switch tothe Enable poston Under te COMP sub-mode, enable the desired compes- 0 (CC) forthe cre. Let compressor un unl page cn suction pressure port read 10 psig. Press foe}, [FV] and fe] to turn the compressor of. The compressor Will complete its parnpostrotine and tum of. Immediately after the compressor shuts of, clove the discharge valve 2. Remove any remaining refrigerant from the system low side sing proper reclaiming techniques. Drain of from cooler using Schrader pon cooler inlet line, Tur oft the line volage power supply to the compressor and conto iret power 3. The expansion valve motors hexmsiely sealed inside the top portion ofthe valve, Caeflly unscrew he lange ‘Plann nu seczing the motor porion othe bod ofthe ‘lve making sute the EXYV plugs sl connected. The EXY lead sctew and sieve wil cme off withthe motor porn ofthe devie. 4, Enter the appropriate EXV test step under te OUTS sub- ‘mode inthe Service Test mode, Locate the desired item “EXV.A' of “EXV.B" Press fo] to make the valve pos sion of O% fash, Press and old [a] until 100% is displayed and press fe]. Observe the operation ofthe lead srew and sleeve. The motor shouldbe uming the Jead serew and sleeve counterclockwise, raising the sleeve cote tothe moet Lead sere movement should be smooth and uniform from fll closed to filly postion Pres fe, use [to select 86 and press {gui to check open t closed operation. Ifthe valve & Properly connected tothe processor and receiving comet. Signals, yet does not operte as described above, the sealed motor portion ofthe valve shouldbe replaced pews Q>—w 2 DP IS) ae J7 |os: ae OP a1 @— a5 eg 2 — "2a DS om , JE jos} ev (" @>— any ow Fig. 21 — EXV Cable Connections to EXV ModuleBRAZED-PLATE ECONOMIZERS — Brazed-plate econo- amizers are fatory-installed in each circuit on S0GXN,R108, 18-350 and 30HXA,C161-271 models. A TXY is included to meter the flow of refigerant to the economizer port of the compressor. Flow through the TXV is enabled only when the circnit is fully loaded for 30GXN,R nosels. The TXV bulb is secured to the side ofthe economizer outlet tube. See Fig. 22 for typical piping arrangement. Brazed-plate heat exchangers cannot be repaired if they de~ ‘velop leak, If refrigerant leak is detected, the heat exchanger _musL.be replaced. To replace a brazed-plate heat exchanger the following steps must be performed: 1, Using proper techniques, move the refrigerant remaining in the circuit to the high side and close the discharge and liquid line ball valves. Reclaim any refrigerant remsining inthe low side. 2. Unsolder the refgerant-in and efigerant-out connections. 3, Remove the four 8mm (N20 on 30HX. units) nuts holding the hest exchanger tothe brackets. Save the muts and hardware 4, Check thatthe replacement heat exchangers the same 2s ‘the original heat exchanger 5, Insulate the new heat exchanger to match the original and attach tothe mounting brackes with the handvare removed in Step 3. 6. Carefully braze the refrigerant lines tothe connections oa the heat exchanger. Lines shouldbe soldered using silver as the soldering material witha minimum of 45% silver, Keep the temperature below 1472 F (800 C) under oral soldering conditions (no vacum) to prevent the Copper solder of the brazed plate heat exchanger from ‘hanging its structure, Failure to do so ean result in inter ‘al of extemal leakage atthe connections which cannot be repaired, 7. Braze equalize line in place if removed. Atach econo: ‘mizer and motor cooling solenoid coils to their bodies i removed. 8, Dehydrate and recharge the citcuit. Check for leaks. NOTE: The brazed-plate heat economizers are not serviceable. If operating problems persist fer ceonomizer replacement, they may be due to a bat liquid level senso, suction pressure ‘cunsdicer, discharge gas thermistor or intemmitent connections ‘between the processor board terminals and EXY plug, Recheck all wiring cotnections and voltage signals, Other possible causes of improper refrigerant flow contol ‘could be restrictions in the lguid line. Check for plugged Strainer(s) or resrited metering slots inthe EXY (see Fig. 23). Formation af ice or fost on lower bod of electronic expansion valve is one symptom of resticted metering slots. However, frost or iee formation is normally expected when leaving fluid temperature from the cooler is below 40 F (4.4 C), Clean or re- place valve ifnecessry. NOTE (noneconomized units only): Frosting of valve is normal during compressor test steps and at initial start-up. Frost should dissipate after 5 t0 10 minutes operation in a system that is operating propery. IF valve is to be replaced, ‘wrap valve with a wet cloth to prevent excessive heat from damaging internal components Fig. 22 — Brazed-Plate Economizer seavcar Moron Assewaty SIOHTGLASS oniice \. Torque Specifications eit Te = Sieh Gass 1525 203 Seal Cap ee BaD Fig. 23 — Typical 30GXN,GXR,HX EXV 31SERVICE Servicing Coolers and Condensers — Wren cool- ex heads and panition plotes are removed, tube sheets are exposed showing the ends of tubes. The 30GXN,GXR HX Units use a flooded cooler design. Water flows inside the mbes. ‘TUBE PLUGGING — A leaky tube in one circuit can be plugged until retubing can be done. ‘The number of tubes ‘lugged determines how soon the cooler mast be retubed, All tubes in the 30GXNJR and 30HX coolers and 30HX condens- ers can be removed. Loss of unit capacity and efficieney as well as increased pump power will result from plugging tubes Failed tubes should be replaced as soon as possible, Up to 10% of the total namber of tubes can be plugged before retubing is necessary Figure 24 shows an Elliot tube plug and a cross sectional view of a plug in place, The same components for plugging and rolling tubes can be used for all cooless and BOHXC condensers. See Table 34, If rube failure is in both Circuits, using tube plugs will not correct problem. Contact {Your Carrer representative for assistance. Pi Use extreme care when instal Jugs to prevent damage to the tube sheet section beteen the holes, RETUBING (See Table 35) — When retubing is tobe done, bvain service of qualified personnel experienced in boiler maintenance and repair. Mos standard procedures can be followed when retubing the 30GXN,R and 30HX heat exchangers, Care must be faken as the tubes are rolled in the centertube sheet and require special pulling tools, A 74 crush is recommended when rolling replacement tubes into the tubesheet. A'7% crush can be achieved by seting the corque on the gun at 48 t0 $0 ine-lb (Sa to 56N-m), The following Elliot Co. rubewolling tools are vequired 113123 Bxpander Assembly 213123 Mandel 2134123 Cage 2115122 Rolls Place one drop of Loctite No, 675 or equivalent on top of tube prior to rolling. This material is intended to “wick” ito the area ofthe tube that is not rolled into the tube sheet, and prevent fluid from accumulating between the tube and the tube Sheet, New tubes must also be roed into the center tube sheet to prevent circuit-o-ircue refrigerant leakage. Table 34 — Plugging Components TeONPORENTS FOR PLUGGING —| PART ROMER — For Tubes assi034 1953002640" 0-657 asat0aat Brase Rng esuoue 736° ‘Sera “Can be obtsine loeay. ‘Table 35 — Tube Diameters Treit TRGHES | WICUMETERS— Tue aieat hale Teme oTee , Tube OD 0750 1905 ‘Tbe ID after rin 080 test “includes expansion . "e, Se to elearance) 0.567 16.04 NOTE: Tubes replaces slong heat exchanger head partons must Bets wth be sheet ger nese 32 (> @) PN RING srube SHEET PIN ANO RING INSTALLED Fig. 24 — Tube Plugging ‘TIGHTENING COOLER/CONDENSER HEAD BOLTS O-Ring Preparation — When reassembling cooler and con- denser beads always check the condition of the O-ting() first. ‘The O-ring should be eplaced if there are any visible signs of deterioration, cus or damage. Apply a thin film of grease to the Oxring before installation, This will aid in holding the O-ring into the groove while the head is installed. Torgue all bolts to the following specification and in the sequence shown in Fig. 25, ein. Diameter Perimeter and Plate Bolts. 200 to 225 fulb (271 305N-m) 1. Instal all bots Singer 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, Load all bolts to each one-third step before proceeding to the next one-third step. 4. No less than one hour later, retighten all bolts to required torque values. 5. Restore watefbrine flow aad check for leaks. Fix leaks as necessary. Replace insulation (on cooler heads only) Inspecting/Cleaning Heat Exchangers COOLERS — Inspect and clezn the cooler tubes atthe end of the first operating season, Because these tubes have intemal ridges, a ouary-tpe tube cleaning system is necessary to filly clean the rubes. Tube condition in the cooler will determine the Scheduled frequency for cleaning, and will indicate whether ‘waier meatment is adequate inthe chilled waterorine circuit Tnspet the entering and leaving thermistrs fr signs of coro sion or scale. Replace the sensor if corroded or emove any scale if foundFig. 25 — Cooler and Condenser Head Recommended Bolt Torque Sequence CONDENSERS (30HX Only) — Since this water circuit is ‘usually an open-iype system, the tubes may be subject (0 ‘contamination and scale. Clean the condenser tubes with & rotary tube cleaning system a regular intervals, and more often Hf the water is contaminated. Inspect the entering and leaving Condenser water thermistrs (if installed) for signs of corrosion for scale, Replace the sensor if coroded or remove any scale i found. Higher than normal condenser pressures, together within ability to reach full refrigeration load, usually indicate dirty tubes or arin the machine. If the refrigeration fog indicates & rise above normel condenser pressure, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design Uiference is supposed to be, then the condenser tubes may be ‘ints, or water flow may be incomeet. Due the pressure inthe eI3da system, ac usually will not enter the machine; the figerant wil leak out Daring the tube cleaning process, use brushes specially designed to avoid scraping and seratching the tube wall ‘Contact yon Carer representative ro obtain these brushes. Do rt use wire brushes. Ps Hard seale may regu chemical tion of removal. Consult @ water tretment specialist for roper treatment procedures, Water Treatment — Untreated or improperly weated wa- ter may result in corosion, sealing, erosion, oF alpae. The se ‘ices ofa qualified water treatment specialist should be ob- tained to develop and monitor a treeument program. Pe Water must be within design flow limits clean and teated to ensure proper machine performance and reduce the Potential of tubing damage due to cortosion, sealing, Erosion, and algue. Cartier assumes no responsibility tor chiller or condenser damage resulting from unteated or improperly weated water Condenser Coils (30GXN,R only) COIL CLEANING — For standard aluminum, copper and ‘pre-coated aluminum fin cols, clean the coils with a vacuum leanet, fresh water, compressed ait, or a bristle brush (not Wire). Units installed in corrosive environments should have Coil cleaning as pat ofa planned maintenance schedule. In this type of application, all accumulations of dit should be cleaned off the col PX Do not use high-pressure water or at (0 cle wage may result. CLEANING E-COATED COILS — Follow the eatlned pro- cedure below for proper care, cleaning and maintenance of coated aluminum or eapper fin coils Coil Maintenance and Cleaning Recommendations — Rot tine cleaning of coil surfaces i essential to maintain proper ‘operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life ofthe coil and extend the life of the uniRemove Surface Loaded Fibers — Surface loaded fibers or dit should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft brush may be used. In ether ‘case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) ifthe fool is applied across the fins, NOTE: Use of a water steam, such asa garden hose, against a surface loaded coil will drive the fibers and dit into the col, ‘This will make cleaning effors more difficult, Surface loaded fibers must be completely removed prior fo using low velocity clean water rinse, Periodic Clean Water Rinse — A pesiodic clean water rinse is very beneficial for coils that are appliod in coastal or industrial environments. However, itis very important thatthe water rinse ig made with very low velocity water stream to avoid

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