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Controls, Start-Up, Operation, Service, and Troubleshooting

30RA010-055. AquaSnap Air-Cooled Chillers with ComfortLink Controls 50/60 Hz Controls, start -Up, Operation, Service, and Troubleshooting SAFETY CONSIDERATIONS. Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and This unit uses a microprocessor-based electronic control equipment location (roof, elevated structures, mechanical system. Do not use jumpers or other tools to short out rooms, etc.). Only trained, qualified installers and service components, or to bypass or otherwise depart from recom- mechanics should install, start up, and service this equipment. mended procedures. Any short-to-ground of the control When working on this equipment, observe precautions in board or accompanying wiring may destroy the electronic the literature, and on tags, stickers, and labels attached to the modules or electrical components.

3 Table 1 — Unit Sizes *60 Hz only. †50 Hz only. MAJOR SYSTEM COMPONENTS General — The 30RA air-cooled reciprocating chillers contain the ComfortLink™ electronic control system that controls and monitors all operations of the chiller.

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Transcription of Controls, Start-Up, Operation, Service, and Troubleshooting

1 30RA010-055. AquaSnap Air-Cooled Chillers with ComfortLink Controls 50/60 Hz Controls, start -Up, Operation, Service, and Troubleshooting SAFETY CONSIDERATIONS. Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and This unit uses a microprocessor-based electronic control equipment location (roof, elevated structures, mechanical system. Do not use jumpers or other tools to short out rooms, etc.). Only trained, qualified installers and service components, or to bypass or otherwise depart from recom- mechanics should install, start up, and service this equipment. mended procedures. Any short-to-ground of the control When working on this equipment, observe precautions in board or accompanying wiring may destroy the electronic the literature, and on tags, stickers, and labels attached to the modules or electrical components.

2 Equipment, and any other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves. Use care in handling, rigging, and setting this equipment, and in handling all electrical components. To prevent potential damage to heat exchanger, always run fluid through heat exchanger when adding or removing refrigerant charge. Use appropriate brine solutions in cooler Electrical shock can cause personal injury and death. Shut fluid loop to prevent the freezing of brazed plate heat off all power to this equipment during installation and exchanger, optional hydronic section and/or interconnecting service. There may be more than one disconnect switch. piping when the equipment is exposed to temperatures Tag all disconnect locations to alert others not to restore below 32 F (0 C).

3 Proof of flow switch and strainer are power until work is completed. factory installed on all models. Do NOT remove power from this chiller during winter shutdown periods without taking precaution to remove all water from heat exchanger and optional hydronic system. Failure to properly protect DO NOT VENT refrigerant relief valves within a building. the system from freezing may constitute abuse and may Outlet from relief valves must be vented outdoors in void warranty. accordance with the latest edition of ANSI/ASHRAE. (American National Standards Institute/American Society of Heating, Refrigeration and Air Conditioning Engineers). 15 (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

4 Provide adequate Compressors and optional hydronic system pumps require ventilation in enclosed or low overhead areas. Inhalation of specific rotation. Test condenser fan(s) first to ensure high concentrations of vapor is harmful and may cause proper phasing. Swap any two incoming power leads to heart irregularities, unconsciousness or death. Misuse can correct condenser fan rotation before starting any other be fatal. Vapor is heavier than air and reduces the amount motors. of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous. Refrigerant charge must be removed slowly to prevent loss DO NOT attempt to unbraze factory joints when servicing of compressor oil that could result in compressor failure. this equipment.

5 Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrigerant lines. Cut lines with a tubing cutter as required when performing service. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to system. DO NOT re-use compressor oil. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 PC 903 Catalog No. 533-00047 Printed in Form 30RA-2T Pg 1 1-03 Replaces: 30RA-1T. Tab 5c CONTENTS. Page Page Condenser Section and Coils .. 60. SAFETY CONSIDERATIONS.. 1 COIL CLEANING. GENERAL..2,3 CLEANING E-COATED COILS. MAJOR SYSTEM COMPONENTS..3,4 CONDENSER SECTION. General .. 3 Check Refrigerant Feed Components.

6 61. Main Base Board (MBB).. 3 THERMOSTATIC EXPANSION VALVE (TXV). Scrolling Marquee Display .. 3 FILTER DRIER. Energy Management Module (EMM) .. 3 MOISTURE-LIQUID INDICATOR. Enable/Off/Remote Contact Switch.. 3 MINIMUM LOAD VALVE. Emergency On/Off Switch.. 3 PRESSURE RELIEF DEVICES. Board Addresses .. 3 Compressor and Unit Protective Devices .. 62. control Module Communication .. 3 MANUAL STARTER. Carrier Comfort Network Interface .. 3 COMPRESSOR INTERNAL THERMAL PROTECTION. OPERATING DATA .. 4-46 Check Unit Safeties .. 62. Sensors .. 4 HIGH-PRESSURE SWITCH. T1 COOLER LEAVING FLUID SENSOR PRESSURE TRANSDUCERS. T2 COOLER ENTERING FLUID SENSOR COOLER FREEZE-UP PROTECTION. T7,T8 COMPRESSOR RETURN GAS HEATER CABLE. TEMPERATURE SENSOR (ACCESSORY) WINTER SHUTDOWN. T9 OUTDOOR-AIR TEMPERATURE SENSOR Thermistors.

7 63. T10 REMOTE SPACE TEMPERATURE SENSOR OR Pressure Transducers .. 63. DUAL LEAVING WATER TEMPERATURE SENSOR Flow Sensor .. 63. Energy Management Module .. 17 Strainer .. 68. Loss-of-Cooler Flow Protection .. 17 Motormaster V Controller .. 68. Thermostatic Expansion Valves (TXV) .. 17 GENERAL OPERATION. Capacity control .. 17 SET POINTS. MINUTES LEFT FOR start INSTALLATION. MINUTES OFF TIME PROGRAMMING. LEAD/LAG DETERMINATION EPM CHIP. CAPACITY control OVERRIDES LIQUID LINE PRESSURE SET POINT ADJUSTMENT. Head Pressure control .. 21 LOSS OF CCN COMMUNICATIONS. Operation of Machine Based on control Method REPLACING DEFECTIVE MODULES. and Cooling Set Point Selection Settings .. 22 Hydronic Package .. 73. Cooling Set Point Select .. 22 MAINTENANCE .. 74. Marquee Display Usage.

8 23 Recommended Maintenance Schedule .. 74. Service Test.. 23 PRE- start -UP .. 74. Optional Factory-Installed Hydronic Package .. 24 System Check .. 74. Cooler Pump control .. 24 start -UP AND OPERATION ..74-76. Cooler Pump Sequence of Operation .. 24 Actual start -Up .. 74. Configuring and Operating Dual Chiller control .. 26 Check Refrigerant Charge .. 75. Temperature Reset .. 43 Operating Limitations.. 75. Demand Limit .. 44 TEMPERATURES. DEMAND LIMIT (2-Stage Switch Controlled) LOW AMBIENT OPERATION. EXTERNALLY POWERED DEMAND LIMIT VOLTAGE ALL UNITS. (4 to 20 mA Controlled) OPERATION SEQUENCE.. 76. DEMAND LIMIT (CCN Loadshed Controlled) APPENDIX A CCN TABLES..77-88. Cooling Set Point (4 to 20 mA) .. 45. APPENDIX B FACTORY SETTINGS FOR. Troubleshooting .. 46-57 COMPRESSOR, FAN, PUMP AND MANUAL.

9 Complete Unit Stoppage and Restart .. 46 STARTERS ..89,90. GENERAL POWER FAILURE. UNIT ENABLE-OFF-REMOTE CONTACT SWITCH IS APPENDIX C BUILDING INTERFACE ..91,92. OFF start -UP CHECKLIST FOR 30RA LIQUID. CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN CHILLER ..CL-1-CL-8. OPEN HIGH-PRESSURE SWITCH(ES). OPEN COMPRESSOR INTERNAL THERMAL GENERAL. PROTECTION. OPEN 24-V control CIRCUIT BREAKERS This publication contains Controls start -Up, Service, Oper- COOLING LOAD SATISFIED ation, and Troubleshooting information for the 30RA. THERMISTOR FAILURE AquaSnap air-cooled chillers. See Table 1. These chillers are LOW SATURATED SUCTION equipped with ComfortLink controls and conventional Alarms and Alerts.. 53 thermostatic expansion valves (TXVs). SERVICE .. 58-73. Electronic Components.

10 58. control COMPONENTS. Compressor Replacement .. 58 This unit uses a microprocessor-based electronic control Cooler .. 58 system. Do not use jumpers or other tools to short out or BRAZED-PLATE COOLER HEAT EXCHANGER bypass components or otherwise depart from recom- REPLACEMENT mended procedures. Any short-to-ground of the control BRAZED-PLATE COOLER HEAT EXCHANGER board or accompanying wiring may destroy the board or CLEANING electrical component. Check Oil Charge .. 60. 2. Table 1 Unit Sizes Contact (dry contacts closed) positions, the chiller is allowed to NOMINAL CAPACITY. operate and respond to the scheduling configuration, CCN. UNIT configuration and set point data. See Fig. 8. (TONS) 50/60 Hz 30RA010 10/10 Emergency On/Off Switch The Emergency On/Off 30RA015 14/13 switch should only be used when it is required to shut the 30RA018 16/16 chiller off immediately.


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