Carrier start-up and Specifications

Controls, Start-Up, Operation,Service, and TroubleshootingSAFETY CONSIDERATIONSInstalling, starting up, and servicing this equipment canbe hazardous d

ADJUSTING PID ROUTINES — The 30GX and 30HXChead pressure control routines use PID (proportional inte-gral derivative) loops to maintain a user-configur

Copyright 1998 Carrier CorporationManufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and w

Table 6 — 30GX080-265 Condenser Fan Staging (PSIO-1 Controlled)30GX UNIT SIZE FAN TYPE FAN CONTACTOR FANS CONTROLLED FAN RELAY NO.*080-105StandardFC-1

CONDENSER PUMP CONTROL ( ) — Factory de-faults for both condenser pump control and condenser flowswitch are set to ‘‘Not Controlled’’ and ‘‘Disabled,’’

Cooler Heater Control — Accessory cooler heaterscan be ordered for the 30GX chillers. If installed and en-abled, these heaters are turned on only when

Table 8A — HSIO Functions and SubfunctionsSUBFUNCTIONNO.FUNCTIONSStatusTest Schedule Service History Set Point1AlarmDisplayCircuit ADiscrete OutputsIc

Table 8B — Functions and Subfunctions Cross-Reference for the Optional LID-2B ControllerThe optional LID-2B controller cross reference table be-low ca

Table 9 — Accessing Functions and SubfunctionsOPERATION KEYPAD ENTRY DISPLAY RESPONSETo access a function, presssubfunction no. and functionname key.

Unit Analog Parameters and Temperature Reset — Pressand scroll down to display the unit entering and leav-ing fluid temperatures as well as the tempera

Table 10 — Status Function and Subfunction DirectorySUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT1 AlarmsAlarm : xxReset Alarms: 1 <ENTER>All current

Table 10 — Status Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT3 Circuit A Analog Valves (cont)SAT Condensing Temp

CONTENTS (cont)Page• COOLER PUMP CONTROL• CONDENSER PUMP CONTROLCooler Heater Control ...13Keypad and Display Module(Also Called H

Table 10 — Status Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT5 Circut B Analog Valves (cont)B1 Motor Temperature

Table 10 — Status Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT7 Unit Analog Parameters (cont)TEMPERATURE RESET4-2

Table 10 — Status Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT9 Operating Modes (cont)CLOCK OFFLOCAL ONCCN ONCLOC

Table 10 — Status Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT11 Dual ChillerDUAL CHILLERUnit Master / Slave0/1/2

Table 12 — Operational and Mode Display CodesCODE DESCRIPTIONLOCAL OFF Unit is off. LOCAL/OFF/REMOTE switch isin OFF position or LOCAL/OFF/REMOTEswitc

TEST FUNCTION — The test function operates the diag-nostic program. To initiate the test function, the LOCAL/OFF/REMOTE switch must be in the OFF posi

Table 14 —Test Function and Subfunction DirectorySUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT1 Circuit A Discrete OutputCircuit A Discrete OutputLoader A1

Table 14 —Test Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT3 Unit Discrete Output (cont)Remote Alarm 2 Currently

Table 16 — History Function and Subfunction DirectorySUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT1 Operating HoursMachine Operating Hoursxxx.x hoursNumber

Table 17 — Set Point Function and Subfunction DirectorySUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT1 Set Point TableCOOLINGCool Setpoint 1xx.x dFDefault:

MAJOR SYSTEM COMPONENTSProcessor Module (PSIO-1) —This module is anupgrade to the original PSIO (8088) module, with superiorelectrical noise immunity

Table 18 — Reading and ChangingChilled Fluid Set PointKEYPAD ENTRY DISPLAY RESPONSE COMMENTSCOOLING Change set point fromdefault to 48 F.Cool Set poin

Table 19 — Service Function and Subfunction DirectorySUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT1 Service ConfigurationSoftware CESR_500100 VerxxxUnit Typ

Table 19 — Service Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT3 Options Configuration 2 (cont)Ramp Load Selectx0

Table 19 — Service Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT4 Reset Configuration Table (cont)Demand Limit Sele

Table 19 — Service Function and Subfunction Directory (cont)SUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT8 Manual Control TableManual Control EnableDsableL

Table 20 — Displaying Current Software VersionFUNCTIONKEYPADENTRYDISPLAY COMMENTSoftwareVersionSoftware CESR_500100 VerXXXCarrier Software PartNumber,

Table 22 — Factory and Service Configuration Code ValuesUNIT MODEL NUMBER CONF. CODE 1* CONF. CODE 2 CONF. CODE 3 CONF. CODE 4 CONF. CODE 530GX080 1146

Table 23 — Entering Configuration CodesKEYPAD ENTRY DISPLAY RESPONSEFACTORY CODESConfiguration Code 100000000Configuration Code 121660010Configuration Cod

Table 24 — Schedule Function and Subfunction DirectorySUBFUNCTION KEYPAD ENTRY DISPLAY COMMENT1 Ice Build Schedule*SCHEDULES: OCCPC01STimed Override:

Temperature Reset — The control system is capableof providing leaving fluid temperature reset based on returnfluid temperature. Because the temperature

ECONOMIZER OPERATION — Economizers are factoryinstalled on 30GX105-265 units and 30HXA,C161-271 units.All other sizes use standard EXVs. The economize

-18 (0) -12 (10) -7 (20) -1 (30) 4 (40) 10 (50) 16 (60)21 (70) 27 (80)32 (90)38(100)RESET REFERENCE TEMPERATURE-OUTDOOR AIR OR SPACE TEMPERATURE THERM

Table 26 — Setting External Temperature ResetKEYPADENTRYDISPLAYRESPONSECOMMENTSCooler Fluid Select1Min. Load Valve SelectDisableLoading Sequence Selec

EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mAControlled) — In this example, the 4 to 20 mA Demand Limitwill be configured and the 20 mA demand limit perc

TROUBLESHOOTINGThe 30GX,HX screw chiller control has many features toaid in troubleshooting. By using the keypad and display mod-ule and the Status fu

Table 33 — Alarm and Alert CodesALARM/ALERTCODEALARM ORALERTDESCRIPTIONWHY WAS THISALARM GENERATED?ACTION TAKENBY CONTROLRESETMETHODPROBABLECAUSE0 — N

Table 33 — Alarm and Alert Codes (cont)ALARM/ALERTCODEALARM ORALERTDESCRIPTIONWHY WAS THISALARM GENERATED?ACTION TAKENBY CONTROLRESETMETHODPROBABLECAU

Table 33 — Alarm and Alert Codes (cont)ALARM/ALERTCODEALARM ORALERTDESCRIPTIONWHY WAS THISALARM GENERATED?ACTION TAKENBY CONTROLRESETMETHODPROBABLECAU

Table 33 — Alarm and Alert Codes (cont)ALARM/ALERTCODEALARM ORALERTDESCRIPTIONWHY WAS THISALARM GENERATED?ACTION TAKENBY CONTROLRESETMETHODPROBABLECAU

Table 33 — Alarm and Alert Codes (cont)ALARM/ALERTCODEALARM ORALERTDESCRIPTIONWHY WAS THISALARM GENERATED?ACTION TAKENBY CONTROLRESETMETHODPROBABLECAU

Table 34 — Hardware Point Communications Loss/Action TakenHARDWARE POINT CONTROL POINT NAMEACTION TAKEN UNTILCOMMUNICATION RESTOREDALARM Alarm Relay N

Table 2 — Thermistor and Transducer LocationsTHERMISTORSSensor Description Location Connection TerminalsT1 Cooler Leaving Fluid Temp Cooler Head Leavi

Table 35 — Illegal Configurations Recognizedby PSIO-1CODENUMBERILLEGAL CONFIGURATIONDESCRIPTION1Incorrect Check Sum in configuration code(factory or ser

INSPECTING/OPENING ELECTRONIC EXPANSIONVALVESIMPORTANT: Obtain replacement O-ring before open-ing EXV. Do not reuse O-rings.To check the physical oper

SERVICEServicing Coolers and Condensers —When coolerheads and partition plates are removed, tube sheets are ex-posed showing the ends of tubes. The 30

1. Install all bolts finger tight.2. Follow numbered sequence shown for head type beinginstalled. This will apply even pressure to the O-ring.3. Apply

Do not use high-pressure water or air to clean coils asfin damage may result.Condenser Fans (30GX Only) — Each fan is sup-ported by a formed wire mount

6. When the EXV Percent Open is in the range of 40 to 60%,check the liquid line sight glass. Slowly add enough ad-ditional liquid charge to ensure a c

Oil Filter Maintenance — Each compressor has its owninternal oil filter and each circuit also has an in-line externalfilter. The internal oil filter pres

9. Remove the four M14 bolts securing the discharge lineflange to the compressor. Two of the bolts also securethe mounting bracket for the external oil

22. Restore main and control power to the machine. Usingthe HSIO, enter the quick test function by pressing(for compressor A1 or A2 replacement) or(fo

to the high side. Transfer refrigerant and reclaim any refrig-erant remaining in the low side.NOTE: A new packing nut and ferrule will be required ast

Where current limitations exist, the Wye-Delta option maybe used. See Fig. 3. This option uses a factory-installed starterassembly for each compressor

Table 39A — Thermistor Temperatures (°F) vs Resistance/Voltage Drop(NOTE: These values do NOT Apply to the Motor Temperature Thermistors )TEMP(F)VOLTA

Table 39B — Thermistor Temperatures (°C) vs Resistance/Voltage Drop(NOTE: These Values do NOT Apply to the Motor Temperature Thermistors)TEMP(C)VOLTAG

Table 40 — Thermistor Temperatures vsResistance, Motor Temperature ThermistorsTEMP(F)TEMP(C)RESISTANCE(Ohms)−22 −30 88,480.0−13 −25 65,205.0−4 −20 48,

COMPRESSOR A1COMPRESSOR B13321COOLERCONDENSER (30HXC MODEL)OIL SEPARATOR (30HXA MODEL)214412334DISCHARGE PRESSURESUCTION PRESSUREOIL PRESSUREECONOMIZE

Pressure relief valves located on cooler and condenser shellsand 30HXA oil separator shells have3⁄4-in. NPT connec-tions for relief. The 30GX oil sepa

Table 43 — Compressor Control TroubleshootingSYMPTOMS CAUSE REMEDYCOMPRESSOR DOES NOTRUNPower line open Check main disconnect.Control fuse open Check

3. Remove the 4-pin female plug from the PSIO-1 COMM1plug and connect the red wire to terminal 1 of the plug,the white wire to terminal 2, and the bla

PRE-START-UP PROCEDUREIMPORTANT: Before beginning Pre-Start-Up or Start-Up, complete the Start-Up Checklist for the 30GX,HXLiquid Chillers on pages CL

FIELD WIRINGField wiring is shown in Fig. 25-37.LEGEND FOR FIG. 25-37ALM — AlarmC—ContactorCFC — Condenser Fan ContactorCPR — Condenser Pump RelayCWP

RELAY BOARD 1K3T4T3BLKBLKTB2TB245C1C2EQUIP GNDSEPARATE115 OR 230 VFIELD POWERSUPPLYCWPMAX. LOAD ALLOWED FOR THE CWP RELAY IS125 VA SEALED, 1250 VA INR

CLOSE CONTROL ( ) — When configured for CloseControl, the control is allowed to use any loading/capacitycontrol devices required to maintain better lea

GFI-COGRN/YELSILVER SCREWSBRASS SCREWSBLKBLU115 AMPSFU1TESTRESETACCESSORYTB4WHTTB42Fig. 30 — Ground Fault Interrupter-Convenience Outlet Accessory Wir

T6BLKK5RB2PL2-3RELAY BOARD 2K4RB2PL2-5C1C22TB26C1C2TB2CPR/CFCBBLK1CFCATB4FIELD SUPPLIEDFig. 33 — Condenser Pump Relay Wiring, 30HXC and Remote Condens

FIELD SUPPLIEDAND POWERED4-20 mA SIGNALFIELD SUPPLIEDAND POWERED4-20 mA SIGNALOUTDOOR AIR THERMISTORFIELD SUPPLIED4-20 mAWATERVALVE+-+-4-20 mA SIGNALG

FIELD SUPPLIEDAND POWERED4-20 mA SIGNALFIELD SUPPLIEDAND POWERED4-20 mA SIGNALTOPPSIO-2, J7 PLUGSBOTTOM4-20 mA SIGNALGENERATORTEMPERATURERESET+-500 OH

APPENDIX ACompressor Must Trip Amps (Determined by CPM Modules)COMPRESSOR MUST TRIP AMPS2-COMPRESSOR UNITSUnit Size Unit VoltageCompressor A1, B1Must

APPENDIX A (cont)Compressor Must Trip Amps (Determined by CPM Modules) (cont)COMPRESSOR MUST TRIP AMPS2-COMPRESSOR UNITSUnit Size Unit VoltageCompress

APPENDIX A (cont)Compressor Must Trip Amps (Determined by CPM Modules) (cont)COMPRESSOR MUST TRIP AMPS3-COMPRESSOR UNITSUnit Size Unit VoltageCompress

APPENDIX BCapacity Loading Sequence Example — The fol-lowing tables show the loading sequence for a 30HX186(50/50 split) and a 30HX161 (59/41 split) c

APPENDIX B (cont)The following tables show the loading sequence for 30HX206(57/43 split) and 30HX271 (67/33 split) chillers. Allcompressors have two l

APPENDIX B (cont)The following tables show the loading sequence for 30HX206(57/43 split) and 30HX271 (67/33 split) chillers. All com-pressors have two

Slow Change Override — The control prevents the capacitystages from being changed when the leaving fluid tempera-ture is close to the set point (within

APPENDIX CThe following are the available accessories for 30GX/HXA/HXC units.ACCESSORYPART NUMBERUSED ON DESCRIPTION OF ACCESSORY COMMENTS30GX-900-001

APPENDIX DCompressor Protection Module Configuration Header Punch-Outs and Overload Settings2-Compressor UnitsUNITMODEL NUMBERPUNCH OUTSFOR CPM-APUNCH

APPENDIX D (cont)Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont)2-Compressor UnitsUNITMODEL NUMBERPUNCH OUTSF

APPENDIX D (cont)Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont)2-Compressor UnitsUNITMODEL NUMBERPUNCH OUTSF

APPENDIX D (cont)Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont)3-Compressor UnitsUNITMODEL NUMBERPUNCH OUTSF

APPENDIX D (cont)Compressor Protection Module Configuration Header Punch-Outs and Overload Settings (cont)3-Compressor UnitsUNITMODEL NUMBERPUNCH OUTSF

APPENDIX EThe following charts list pressure drops for coolers and condensers.076, 086116, 126136, 146161, 171246-2710961061862061001011001000COOLER F

APPENDIX E (cont)30HX CONDENSER PRESSURE DROP — ENGLISHUnit Size RangeNOTE: Ft of water = 2.31 x change in psig.30HX CONDENSER PRESSURE DROP — SIUnit

APPENDIX E (cont)30GX080-176 COOLER PRESSURE DROP —ENGLISHNOTE: Ft of water = 2.31 x change in psig.30GX080-176 COOLER PRESSURE DROP —SI1001011001000C

Typical System Components, 30GX, With EconomizerLEGENDEXV — Electronic Expansion ValveHPS — High Pressure SwitchAPPENDIX F89

No Motormastert Control — The fans are controlled basedon Saturated Condensing Temperature. The first fan stagefor each circuit is turned on whenever t

Typical System Components, 30HX, Without EconomizerLEGENDEXV — Electronic Expansion ValveHPS — High Pressure SwitchAPPENDIX F (cont)90

INDEXAccessing Functions and Subfunctions, 13Actual Start-Up, 67Adjusting PID Routines, 10Alarms and Alerts, 43Automatic Default Display, 13Back Press

SERVICE TRAININGPackaged Service Training programs are an excellent way to increase your knowledge of the equip-ment discussed in this manual, includi

START-UP CHECKLIST FOR 30GX,HX LIQUID CHILLERS(Remove and use for job file.)A. Preliminary InformationJOB NAMELOCATIONINSTALLING CONTRACTORDISTRIBUTORS

B. Preliminary Equipment CheckIS THERE ANY SHIPPING DAMAGE? IF SO, WHEREWILL THIS DAMAGE PREVENT UNIT START-UP?M UNIT IS LEVEL IN ITS INSTALLATIONM UN

C. Unit Start-UpM CWP STARTER HAS BEEN PROPERLY INTERLOCKED WITH THE CHILLERM ALL LIQUID VALVES ARE BACKSEATEDM ALL DISCHARGE VALVES ARE OPENM ALL SUC

CHECK PRESSURE DROP ACROSS THE COOLER:ENTERING COOLER:PSIG (kPa)LEAVING COOLER:PSIG (kPa)(LEAVING − ENTERING) × 2.31 FT OF H2O/PSIG = FT OF H2O(LEAVIN

PERFORM TEST FUNCTION (INDICATE POSITIVE RESULT):ONCE POWER IS SUPPLIED TO THE UNIT, CHECK THE DISPLAY FOR ANY ALARMS, SUCH AS PHASE REVER-SAL. FOLLOW

M REVIEW AND RECORD FACTORY CONFIGURATION CODES,CONFIGURATION CODE 1:CONFIGURATION CODE 2:CONFIGURATION CODE 3:CONFIGURATION CODE 4:CONFIGURATION CODE

NOTES:CL-7