Transcription of Controls, Start-Up, Operation, Service and Troubleshooting
1 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring No. 04-53300112-01 Printed in 30XA-5 TPg 1316 10-13 Replaces: 30XA-4 TControls, Start-Up, Operation, Service and TroubleshootingCONTENTSPageSAFETY CONSIDERATIONS.. 2,3 GENERAL.. 3-9 Conventions Used in This Manual.. 3 Display Module Usage .. 3 TOUCH PILOT DISPLAY NAVIGATOR DISPLAY MODULECONTROLS .. 9-22 General .. 9 Main Base Board (MBB).. 9 Compressor Protection Module (CPM) .. 9 Electronic Expansion Valve (EXV) Board.. 10 Fan Boards .. 16 Enable-Off-Remote Contact Switch (SW1).. 18 Emergency On/Off Switch (SW2).. 18 Hand-Off-Auto Switch.. 18 Energy Management Module (EMM).. 18 Hot Gas Bypass/Pump Board.
2 18 Local Equipment Network.. 20 Board Addresses .. 20 Touch Pilot Display .. 20 Control Module Communication .. 21 RED LED GREEN LED YELLOW LEDC arrier Comfort Network (CCN) Interface .. 21 Remote Alarm and Alert Relays .. 22 CONFIGURATION .. 22-63 Touch Pilot Operation Configuration Tables .. 22 Machine Control Methods.. 24 Machine On/Off Control .. 24 TOUCH PILOT MACHINE CONTROL NAVIGATOR DISPLAY MACHINE CONTROLF luid Set Point Control Location .. 29 Cooling Set Point Selection .. 29 SET POINT OCCUPANCYC hilled Water Fluid Type Selection.. 30 FRESH WATER BRINE OR GLYCOL OPERATIONC ooler Pump Control.. 31 NO PUMP CONTROL SINGLE PUMP CONTROL DUAL PUMP AND MANUAL CONTROLM achine Start Delay.. 33 Circuit/Compressor Staging and Loading.
3 33 CIRCUIT/COMPRESSOR STAGING CIRCUIT/COMPRESSOR LOADINGM inimum Load Control.. 35 Dual Chiller Control.. 35 DUAL CHILLER CONTROL FOR PARALLEL APPLICATIONS DUAL CHILLER PUMP CONTROL FOR PARALLEL CHILLER APPLICATIONSPage DUAL CHILLER CONTROL FOR SERIES APPLICATIONS DUAL CHILLER PUMP CONTROL FOR SERIES CHILLER APPLICATIONSN ight Time/Low Noise Operation.. 39 Ramp Loading .. 40 Temperature Reset.. 40 RETURN WATER RESET OUTSIDE AIR TEMPERATURE RESET SPACE TEMPERATURE RESET 4-20 mA TEMPERATURE RESETD emand Limit.. 44 SWITCH CONTROLLED DEMAND LIMIT EXTERNALLY POWERED CAPACITY BASED DEMAND LIMIT EXTERNALLY POWERED CURRENT BASED DEMAND LIMIT CCN LOADSHED CONTROLLED DEMAND LIMITIce Storage Operation.. 48 Broadcast Configuration.
4 48 ACTIVATE OAT BROADCAST BROADCAST ACKNOWLEDGERA larm Control.. 48 ALARM ROUTING CONTROL ALARM EQUIPMENT PRIORITY COMMUNICATION FAILURE RETRY TIME RE-ALARM TIME ALARM SYSTEM NAMED aylight Saving Time Configuration.. 49 Capacity Control Overrides .. 49 Head Pressure Control.. 52 LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPTION LOW AMBIENT TEMPERATURE HEAD PRESSURE CONTROL OPERATING INSTRUCTIONSPRE-START-UP .. 62 System Check.. 62 START-UP .. 62-72 Actual Start-Up.. 62 Operating Limitations.. 63 TEMPERATURES VOLTAGE MINIMUM FLUID LOOP VOLUME FLOW RATE REQUIREMENTSOPERATION .. 73-80 Sequence of Operation.. 73 ACTUATED BALL VALVE (ABV), FLOODED COOLER ONLYDual Chiller Sequence of Operation.. 74 PUMP OPERATIONO perating Modes.
5 74 Sensors.. 76 THERMISTORS TRANSDUCERSAQUAFORCE 30XA080-501 Air-Cooled Liquid Chillers2 CONTENTS (cont)PageSERVICE .. 80-95 Economizer Assembly .. 80 Electronic Expansion Valve (EXV).. 80 FLOODED COOLER MAIN EXV CONTROL DX COOLER MAIN EXV CONTROL ECONOMIZER EXV CONTROL EXV Troubleshooting PROCEDUREC ompressor Assembly.. 84 COMPRESSOR OIL SYSTEMC ooler Service .. 85 Flooded Cooler Units.. 85 FLOODED COOLER SUCTION Service VALVE FLOODED COOLER FREEZE PROTECTION FLOODED COOLER LOW FLUID TEMPERATURE FLOODED COOLER LOSS OF FLUID FLOWPROTECTION FLOODED COOLER TUBE PLUGGING FLOODED COOLER RETUBING FLOODED COOLER TIGHTENING COOLER HEAD BOLTS FLOODED COOLER INSPECTING/CLEANING HEAT EXHANGERS FLOODED COOLER WATER TREATMENTDX Cooler Units.
6 89 DX COOLER SUCTION Service VALVE DX COOLER FREEZE PROTECTION DX COOLER LIQUID FLUID TEMPERATURE DX COOLER LOSS OF FLUID FLOW PROTECTION DX COOLER TUBE PLUGGING DX COOLER RETUBING DX COOLER TIGHTENING COOLER HEAD BOLTS DX COOLER CHILLED WATER FLOW SWITCHDX Cooler and Flooded Cooler Units .. 92 PREPARATION FOR WINTER SHUTDOWNM icrochannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning Recommendations.. 93 RTPF Condenser Coil Maintenance and Cleaning Recommendations .. 93 REMOVE SURFACE LOADED FIBERS PERIODIC CLEAN WATER RINSE ROUTINE CLEANING OF RTPF COIL SURFACESC ondenser Fans.. 94 Refrigerant Circuit.. 94 LEAK TESTING REFRIGERANT CHARGES afety Devices .. 94 COMPRESSOR PROTECTION OIL SEPARATOR HEATERS COOLER PROTECTIONR elief Devices.
7 95 PRESSURE RELIEF VALVESMAINTENANCE.. 95 Recommended Maintenance Schedule .. 95 Troubleshooting .. 95-119 Alarms and Alerts .. 95 DIAGNOSTIC ALARM CODES AND POSSIBLE CAUSESS ervice Test.. 111 APPENDIX A TOUCH PILOT DISPLAY TABLES.. 120-139 APPENDIX B NAVIGATOR DISPLAY TABLES .. 140-154 APPENDIX C CCN TABLES.. 155-169 APPENDIX D 30XA080-500 CPMDIP SWITCH ADDRESSES.. 170-175 APPENDIX E PIPING AND INSTRUMENTATION .. 176-181 PageAPPENDIX F MAINTENANCE SUMMARYAND LOG SHEETS .. 182-184 APPENDIX G BACNET COMMUNICATON OPTION.. 185-195 APPENDIX H COOLER HEATER SENSOR SET POINT.. 196 INDEX.. 197 START-UP CHECKLIST FOR 30XA LIQUID CHILLERS .. CL-1 to CL-8 SAFETY CONSIDERATIONSI nstalling, starting up, and servicing this equipment can behazardous due to system pressures, electrical components, andequipment location (roof, elevated structures, etc.)
8 Onlytrained, qualified installers and Service technicians shouldinstall, start up, and Service this equipment. When working onthis equipment, observe precautions in the literature, on tags,stickers, and labels attached to the equipment, and any othersafety precautions that apply. Follow all safety codes. Wearsafety glasses and work gloves. Use care in handling, rigging,and setting this equipment, and in handling all electricalcomponents. WARNINGE lectrical shock can cause personal injury and death. Shutoff all power to this equipment during installation and ser-vice. There may be more than one disconnect switch. Tagall disconnect locations to alert others not to restore poweruntil work is NOT VENT refrigerant relief valves within a from relief valves must be vented in accordancewith the latest edition of ANSI/ASHRAE (AmericanNational Standards Institute/American Society of Heating,Refrigerating and Air Conditioning Engineers) 15 (SafetyCode for Mechanical Refrigeration).
9 The accumulation ofrefrigerant in an enclosed space can displace oxygen andcause asphyxiation. Provide adequate ventilation inenclosed or low overhead areas. Inhalation of high concen-trations of vapor is harmful and may cause heart irregulari-ties, unconsciousness or death. Misuse can be fatal. Vaporis heavier than air and reduces the amount of oxygen avail-able for breathing. Product causes eye and skin products are publication contains Controls, Operation, Start-Up, Service and Troubleshooting information for the 30XA080-501 air-cooled liquid chillers with electronic controls. The30XA chillers are equipped with ComfortLink controls andelectronic expansion valves. The AquaForce 30XA chillersoffer two different user interface devices, the Touch Pilot display and the Navigator Used in This Manual The follow-ing conventions for discussing configuration points for theNavigator module and Touch Pilot display will be used in names for the Touch Pilot display will be shown inbold.
10 See Appendix A for a complete list of point names. Itemnames for the Navigator module will be shown in bold Appendix B for the complete path name preceeding theitem name. The point and item names in Appendices A and Bwill be listed in alphabetical order and the path name for eachwill be written with the mode name first, then any sub-modes,each separated by an arrow symbol ( .This path name will show the user how to navigate through theNavigator module or the Touch Pilot display to reach the desiredconfiguration. The user would scroll through the modes andsub-modes using the and keys on the Navigator the Touch Pilot display, the user would simply touch the menuitem on the screen. The arrow symbol in the path name representspressing to move into the next level of the menu struc-ture for the Navigator module, or touching the menu item on thescreen for the Touch Pilot a value is included as part of the point name, it will beshown after the point name after an equals sign.)
