Controls, Start-Up, Operation, Service and Troubleshooting

1 AQUAFORCE . 30XA080-500. Air-Cooled Liquid Chillers Controls, start -Up, Operation, Service and Troubleshooting CONTENTS Page Page DUAL CHILLER CONTROL FOR SERIES. SAFETY CONSIDERATIONS ..2,3 APPLICATIONS. GENERAL .. 3-8 DUAL CHILLER PUMP CONTROL FOR SERIES. Conventions Used in This Manual .. 3 CHILLER APPLICATIONS. Display Module Usage .. 3 Night Time/Low Noise Applications .. 37. TOUCH PILOT DISPLAY Ramp Loading .. 38. NAVIGATOR DISPLAY MODULE Temperature Reset .. 38. CONTROLS .. 8-21 RETURN WATER RESET. General .. 8 OUTSIDE AIR TEMPERATURE RESET. Main Base Board (MBB) .. 8 SPACE TEMPERATURE RESET. Compressor Protection Module (CPM) .. 9 4-20 mA TEMPERATURE RESET. Electronic Expansion Valve (EXV) Board.

2 9 Demand Limit .. 42. Fan Boards.. 15 SWITCH CONTROLLED DEMAND LIMIT. Enable-Off-Remote Contact Switch (SW1) .. 17 EXTERNALLY POWERED CAPACITY BASED. Emergency On/Off Switch (SW2) .. 17 DEMAND LIMIT. Energy Management Module (EMM) .. 17 EXTERNALLY POWERED CURRENT BASED. Hot Gas Bypass/Pump Board .. 17 DEMAND LIMIT. Local Equipment Network .. 19 CCN LOADSHED CONTROLLED DEMAND LIMIT. Board Addresses.. 19 Ice Storage Operation .. 46. Touch Pilot Display.. 19 Broadcast Configuration .. 46. Control Module Communication.. 19 ACTIVATE. RED LED OAT BROADCAST. GREEN LED BROADCAST ACKNOWLEDGER. YELLOW LED Alarm Control .. 46. Carrier Comfort Network (CCN) Interface.. 20 ALARM ROUTING CONTROL. Remote Alarm and Alert Relays.

3 20 ALARM EQUIPMENT PRIORITY. COMMUNICATION FAILURE RETRY TIME. CONFIGURATION .. 21-59. RE-ALARM TIME. Touch Pilot Operation Configuration Tables .. 21 ALARM SYSTEM NAME. Machine Control Methods .. 22 Daylight Saving Time Configuration.. 47. Machine On/Off Control .. 22. Capacity Control Overrides .. 47. TOUCH PILOT MACHINE CONTROL. Head Pressure Control .. 50. NAVIGATOR DISPLAY MACHINE CONTROL LOW AMBIENT TEMPERATURE HEAD PRESSURE. Fluid Set Point Control Location .. 27 CONTROL OPTION. Cooling Set Point Selection .. 27. LOW AMBIENT TEMPERATURE HEAD PRESSURE. SET POINT OCCUPANCY CONTROL OPERATING INSTRUCTIONS. Chilled Water Fluid Type Selection .. 28. FRESH WATER PRE- start -UP .. 59. BRINE OR GLYCOL OPERATION System Check.

4 59. Cooler Pump Control.. 30 start -UP .. 59-67. NO PUMP CONTROL Actual start -Up.. 59. SINGLE PUMP CONTROL Operating Limitations .. 60. DUAL PUMP AND MANUAL CONTROL TEMPERATURES. Machine start Delay .. 31 VOLTAGE. Circuit/Compressor Staging and Loading .. 31 MINIMUM FLUID LOOP VOLUME. CIRCUIT/COMPRESSOR STAGING FLOW RATE REQUIREMENTS. CIRCUIT/COMPRESSOR LOADING OPERATION.. 67-74. Minimum Load Control .. 32 Sequence of Operation.. 67. Dual Chiller Control .. 32 ACTUATED BALL VALVE (ABV), FLOODED. DUAL CHILLER CONTROL FOR PARALLEL COOLER ONLY. APPLICATIONS Dual Chiller Sequence of Operation .. 68. DUAL CHILLER PUMP CONTROL FOR PARALLEL PUMP OPERATION. CHILLER APPLICATIONS Operating Modes.. 68. Sensors.

5 71. THERMISTORS. TRANSDUCERS. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300091-01 Printed in Form 30XA-4T Pg 1 612 10-11 Replaces: 30XA-3T. CONTENTS (cont) Page APPENDIX F MAINTENANCE SUMMARY. Page AND LOG SHEETS.. 165-167. Service .. 74-87 APPENDIX G BACNET COMMUNICATONS. Economizer Assembly.. 74 OPTION .. 168-178. Electronic Expansion Valve (EXV) .. 74 INDEX .. 179. FLOODED COOLER MAIN EXV CONTROL start -UP CHECKLIST. DX COOLER MAIN EXV CONTROL FOR 30XA LIQUID CHILLERS .. CL-1 to CL-8. ECONOMIZER EXV CONTROL. EXV Troubleshooting PROCEDURE SAFETY CONSIDERATIONS. Compressor Assembly.

6 77. COMPRESSOR OIL SYSTEM Installing, starting up, and servicing this equipment can be Flooded Cooler Units.. 79 hazardous due to system pressures, electrical components, and FLOODED COOLER SUCTION Service VALVE equipment location (roof, elevated structures, etc.). Only FLOODED COOLER FREEZE PROTECTION trained, qualified installers and Service technicians should FLOODED COOLER LOW FLUID TEMPERATURE install, start up, and Service this equipment. When working on FLOODED COOLER LOSS OF FLUID FLOW this equipment, observe precautions in the literature, on tags, PROTECTION stickers, and labels attached to the equipment, and any other FLOODED COOLER TUBE PLUGGING safety precautions that apply. Follow all safety codes.

7 Wear FLOODED COOLER RETUBING safety glasses and work gloves. Use care in handling, rigging, FLOODED COOLER TIGHTENING COOLER HEAD and setting this equipment, and in handling all electrical BOLTS components. FLOODED COOLER INSPECTING/CLEANING. HEAT EXHANGERS WARNING. FLOODED COOLER WATER TREATMENT. DX Cooler Units .. 82 Electrical shock can cause personal injury and death. Shut DX COOLER SUCTION Service VALVE off all power to this equipment during installation and ser- DX COOLER FREEZE PROTECTION vice. There may be more than one disconnect switch. Tag DX COOLER LIQUID FLUID TEMPERATURE all disconnect locations to alert others not to restore power DX COOLER LOSS OF FLUID FLOW PROTECTION until work is completed.

8 DX COOLER TUBE PLUGGING. DX COOLER RETUBING. DX COOLER TIGHTENING COOLER HEAD BOLTS WARNING. DX COOLER CHILLED WATER FLOW SWITCH. DX Cooler and Flooded Cooler Units .. 84 DO NOT VENT refrigerant relief valves within a building. PREPARATION FOR WINTER SHUTDOWN Outlet from relief valves must be vented in accordance Microchannel Heat Exchanger (MCHX) Condenser with the latest edition of ANSI/ASHRAE (American Coil Maintenance and Cleaning National Standards Institute/American Society of Heating, Recommendations .. 85 Refrigerating and Air Conditioning Engineers) 15 (Safety RTPF Condenser Coil Maintenance and Cleaning Code for Mechanical Refrigeration). The accumulation of Recommendations .. 85 refrigerant in an enclosed space can displace oxygen and REMOVE SURFACE LOADED FIBERS cause asphyxiation.

9 Provide adequate ventilation in PERIODIC CLEAN WATER RINSE enclosed or low overhead areas. Inhalation of high concen- ROUTINE CLEANING OF RTPF COIL SURFACES trations of vapor is harmful and may cause heart irregulari- Condenser Fans.. 86 ties, unconsciousness or death. Misuse can be fatal. Vapor Refrigerant Circuit.. 86 is heavier than air and reduces the amount of oxygen avail- LEAK TESTING able for breathing. Product causes eye and skin irritation. REFRIGERANT CHARGE Decomposition products are hazardous. Safety Devices .. 87. COMPRESSOR PROTECTION . OIL SEPARATOR HEATERS WARNING. COOLER PROTECTION. Relief Devices .. 87 DO NOT USE TORCH to remove any component. System PRESSURE RELIEF VALVES contains oil and refrigerant under pressure.

10 MAINTENANCE.. 87,88 To remove a component, wear protective gloves and gog- Recommended Maintenance Schedule .. 87 gles and proceed as follows: Troubleshooting .. 88-109 a. Shut off electrical power to unit. Alarms and Alerts .. 88 b. Recover refrigerant to relieve all pressure from sys- DIAGNOSTIC ALARM CODES AND POSSIBLE tem using both high-pressure and low pressure ports. CAUSES. Service Test .. 104 c. Traces of vapor should be displaced with nitrogen APPENDIX A TOUCH PILOT and the work area should be well ventilated. Refrig- DISPLAY TABLES .. 110-127 erant in contact with an open flame produces toxic gases. APPENDIX B NAVIGATOR . DISPLAY TABLES.. 128-141 d. Cut component connection tubing with tubing cutter APPENDIX C CCN TABLES.