30HZ/HZV/GK Series PRO-DIALOG Control Air- and …

1 30HZ/HZV/GK SeriesPRO-DIALOG ControlAir- and Water- cooled LiquidChillers50 HzInstallation, operation and maintenance instructions2 The cover illustrations are solely for illustration, and form no part of any offer for sale or any sale contract. Themanufacturer reserves the right to change the design at any time without - SAFETY CONSIDERATIONS .. - General .. - Avoiding electrocution .. 42 - GENERAL DESCRIPTION .. - General .. - Abbreviations used .. 53 - HARDWARE DESCRIPTION .. - General .. - Electronic boards .. - The controls .. - User connections .. 94 - SETTING UP PRO-DIALOG PLUS Control .. - Local interface general features .. - Unit start/stop Control .. - Menus .. - General menu structure .. - Menu tree structure .. 145 - PRO-DIALOG PLUS Control OPERATION .. - Start/stop Control .. - Heating/cooling selection .. - Evaporator water pump Control .. - Condenser water pump Control .

2 - Control interlock contact .. - Evaporator heater Control .. - Control point .. - Demand limit .. - Capacity Control .. - Determining the lead circuit .. - Circuit loading sequence .. - Slave compressor start-up sequence .. - Controlling the EXV .. - Head pressure Control on air- cooled units .. - Head pressure Control on water- cooled units .. - Active setpoint selection .. - High pressure load shedding function .. - Pumping down .. - Master/slave assembly .. - Controlling PRO-DIALOG Plus units with a System Manager .. - Optional heat reclaim module .. 326 - DIAGNOSTICS - TROUBLESHOOTING .. - General .. - Displaying alarms .. - Critical fault .. - Resetting alarms .. - Alarm codes .. 3341 - SAFETY - GeneralInstallation, start-up and servicing of equipment can be hazard-ous if factors particular to the installation are not considered:operating pressures, electrical components, voltages and theinstallation site itself (elevated plinths, rooftops and built-upstructures).

3 Only highly trained and qualified installation engineers andtechnicians, who are fully trained on the product, are authorisedto install and start up this all servicing operations, it is important to read, under-stand and follow all the recommendations and instructionsgiven in the installation and service instructions for the product,including the tags and labels affixed to the equipment, compo-nents and any parts supplied separately, and to comply with allother relevant safety regulations. Apply all safety codes and practices. Wear safety glasses and gloves. Use the proper tools to move heavy objects. Move unitscarefully and set them down - Avoiding electrocutionOnly personnel qualified in accordance with the recommenda-tions of the IEC (International Electrotechnical Commission)may be permitted access to electrical components. It is parti-cularly recommended that all sources of electricity to the unitbe shut off before any work is begun.

4 Shut off the main powersupply at the main circuit breaker or :Risk of electrocution: Even when the main power isolator orcircuit breaker is off, it is still possible for certain compo-nents such as crankcase heaters and trace heaters to beenergised, since they are connected to a separate power when the unit is switched off, the power circuit remainsenergised, as long as the unit or circuit disconnect is not to the wiring diagram for appropriate safety of burns: Electrical currents cause components to gethot either temporarily or permanently. Handle power cables,electrical cables and conduits, terminal box covers and motorframes with very great : This equipment uses and emits electromagneticsignals. The tests carried out on this product have shown thatit complies with all applicable codes regarding : If the boards need to be handled wear anti-static gloves to avoid exposing the electronic components to adestructive voltage.

5 Only unpack the boards from their anti-static bag when they need to be : If the head of the compressor Control contactoris kept pressed in manually the RCPM board treats this actionas a stuck contactor, and when the contactor is released, theRCPM board will keep the contactor closed, and the com-pressor turns compressor is shut down if disconnect switch QFupstream of the Control circuit of this compressor opens. Seequick test mode for manual compressor - GENERAL - GeneralPRO-DIALOG Plus is a system for controlling units which usereciprocating compressors*: Single or dual circuit Air or water- cooled condensers Non-reversible heat pumps Split systems** For the configuration of the head pressure Control contact Carrier Plus controls compressor start-up and demandlimits needed to maintain the desired entering or leaving tem-perature setpoint for water. It automatically sets the position ofthe electronic expansion valve (if used) to optimise the evapo-rator charge.

6 It controls operation of the fans (on air-cooledunits) or water valves (on water- cooled units) to maintain thecorrect head pressure in each circuits are constantly monitored by PRO-DIALOGPlus to ensure safe operation of the unit. PRO-DIALOG Plusalso gives access to a Quick Test program covering all inputsand PRO-DIALOG Plus controls can work in accordance withthree independent modes: Local mode: the machine is controlled by commands fromthe user interface. Remote mode: the machine is controlled by remotecontacts (volt-free contacts, analogue signals). CCN mode: the machine is controlled by commands fromthe Carrier Comfort Network (CCN). In this case a datacommunication cable is used to connect the unit to theCCN communication operating mode must be chosen with the Operating Typeselection button described in section the PRO-DIALOG Plus system operates autonomously(Local or Remote mode) it retains all of its own Control capa-bilities but does not offer any of the features of the - Abbreviations usedIn this manual the circuits are called circuit A and circuit compressors in circuit A are labelled A1, A2, A3 and in circuit B are labelled B1, B2, B3 and B4.

7 A1 and B1are the lead following abbreviations are frequently used:AI-Analogue InputAO-Analogue OutputCCn-Operating type: CCNCCN-Carrier Comfort is the Carrier communication networkDI-Discrete InputDO-Discrete OutputEXV-Electronic Expansion DeviceLED-Light Emitting DiodeLOFF-Operating type: Local offL-ON-Operating type: Local operationMASt-Master unit operating type (master/slaveassembly)RCPM-Reciprocating Compressor Protection ModulerEM-Operating type: by remote Control contactsSCT-Saturated disCharge TemperatureSIO-Standard Input/Output - internal communicationbus linking the basic board to the slave boardsSST-Saturated Suction TemperatureTXV-Thermostatic Expansion Device63 - HARDWARE - GeneralControl boardThe various Control components are arranged in moduleswithin the Control cabinet: Control module: This comprises the basic board, theuser interface, the EXV Control board and option boards,as well as the customer s terminal block.

8 Start-up module: This consists of the start-up boards,compressor protection boards, as well as the compressorcircuit breakers and contactors. Fan module (air- cooled unit): Consists of one or two8xDO boards together with the fan circuit breakers - Electronic - The basic boardIt can be used alone or in conjunction with slave boards. Itholds the program that controls the machine. It continuouslymanages the information coming in from the various pressureand temperature sensors, and communicates with the slaveboards via the SIO bus. It can also communicate with elementsof the Carrier Comfort Network via the CCN : After a power cut the unit restarts in the sameoperating mode as before the power - Slave boards Compressor board RCPM: This board is used to controla compressor. Up to eight RCPM boards can be connectedto the basic board. This board also controls the inputs andoutputs connected to the compressor, specifically the oilpressure, the capacity reduction, etc.

9 8xDO board (auxiliary type 2): This board can be usedto Control fan stages. PD4-EXV board: This board can Control two EXVvalves and two suction temperature sensors. 8xDO-4xAI-2xAO board (auxiliary type 1): Thisoptional board allows:- Control of the fan stages-reading the temperature in the heat reclaimcondensers- Control of the variable-speed fans (air- cooled units)or the condenser valve (water- cooled units).Legend1 CCN connector2 Red LED, status of the board3 Green LED, communication bus SIO4 Orange LED, communication bus CCN5 Remote master board customer Control connection contacts6 Remote master board customer Control connection signal7 Remote master board customer report connection contacts8 Master PD4 basic board9 CCN/clock boardThe Control system consists of at least a PD4 basic board, auser interface, a PD4-EXV slave board and, depending on theapplication, one or more RCPM compressor boards, 8xDOboards (auxiliary type 2) or 8xDO-4xAI-2xAO boards (auxiliarytype 1) and an NRCP-BASE slave boards are connected to the basic board via an internalcommunication bus (SIO).

10 The CCN/clock board is connectedand screwed to the master basic board. It permits communicationwith elements of the Carrier Comfort Network via the boxLegend1 Power supply disconnect switch2 Compressor start-up module3 Control system4 User - Light emitting diodes on boardsAll boards continuously check and indicate the properoperation of their electronic circuits. A light emitting diode(LED) lights on each board when it is operating LED The MAIN red LED flashes at about 2 second intervals toshow that the module is working properly. Irregular flashing or no flashing is a sign of a LED(item SIO on the board) This LED flashes continuously to show that the board iscommunicating correctly over its internal bus. If this LED is not flashing, check the wiring of the SIObus and the address of the board (slave board only). If thebasic board is not linked to any slave boards, this LEDshould not flash. If all slave boards indicate a communication fault, checkthe SIO bus connection on the basic board.