Carrier 30RAP010-060 specifications Contents, Operation of Machine Based on Control Method

30RAP010-060 AQUASNAP® Air-Cooled Chillers with COMFORTLINK™ Controls

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

CONTENTS

Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . .2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Conventions Used in this Manual. . . . . . . . . . . . . . . . . . . .3 Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-44 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Energy Management Module (EMM) . . . . . . . . . . . . . . . .19 Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . . . .19 AUX Board (AUX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Expansion Valve Board (EXV) . . . . . . . . . . . . . . . . . . . . . .19 Enable/Off/Remote Contact Switch . . . . . . . . . . . . . . . . .19 Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . .19 Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Control Module Communication . . . . . . . . . . . . . . . . . . . .19 Carrier Comfort Network® (CCN) Interface . . . . . . . . . .19 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

•COOLER LEAVING FLUID SENSOR

•COOLER ENTERING FLUID SENSOR

•COMPRESSOR RETURN GAS TEMPERATURE SENSOR

•OUTDOOR-AIR TEMPERATURE SENSOR (OAT)

•DISCHARGE TEMPERATURE THERMISTOR (DTT)

•REMOTE SPACE TEMPERATURE SENSOR OR DUAL

LEAVING WATER TEMPERATURE SENSOR

Energy Management Module . . . . . . . . . . . . . . . . . . . . . . .29

Loss-of-Cooler Flow Protection. . . . . . . . . . . . . . . . . . . . .29

Electronic Expansion Valves (EXV) . . . . . . . . . . . . . . . . .29

Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

•MINUTES LEFT FOR START

•MINUTES OFF TIME

•LEAD/LAG DETERMINATION

•CAPACITY CONTROL OVERRIDES

Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Operation of Machine Based on Control Method

and Cooling Set Point Selection Settings. . . . . . . . .32

Cooling Set Point Select. . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Low Sound Mode Operation . . . . . . . . . . . . . . . . . . . . . . . .34

Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Optional Factory-Installed Hydronic Package. . . . . . .34

Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Cooler Pump Sequence of Operation . . . . . . . . . . . . . . .35

Configuring and Operating Dual Chiller Control . . . .36

Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

•DEMAND LIMIT (2-Stage Switch Controlled)

•EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled)

•DEMAND LIMIT (CCN Loadshed Controlled)

Cooling Set Point (4 to 20 mA). . . . . . . . . . . . . . . . . . . . . .43 Digital Scroll Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

•DIGITAL SCROLL OPERATION

•DIGITAL COMPRESSOR CONFIGURATION

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,45

Page

System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

START-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . 45,46

Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Check Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 45

Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

•TEMPERATURES

•LOW AMBIENT OPERATION

•VOLTAGE — ALL UNITS

OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . .46,47 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-63

Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

• CONTROL COMPONENTS

Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 47

EXV Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . 47

•FIELD SERVICING INSTRUCTIONS

•VALVE REPLACEMENT

•VALVE REASSEMBLY

Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 49 Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

•BRAZED-PLATE COOLER HEAT EXCHANGER REPLACEMENT

•BRAZED-PLATE COOLER HEAT EXCHANGER

CLEANING

Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Microchannel Heat Exchanger (MCHX)

Condenser Coil Maintenance and Cleaning

Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Check Refrigerant Feed Components . . . . . . . . . . . . . . 50

•FILTER DRIER

•MOISTURE-LIQUID INDICATOR

•MINIMUM LOAD VALVE

•PRESSURE RELIEF DEVICES

Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

•HIGH-PRESSURE SWITCH

•PRESSURE TRANSDUCERS

•COOLER FREEZE-UP PROTECTION

•HEATER CABLE

•WINTER SHUTDOWN

Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chilled Water Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 53

Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Condenser Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Motormaster® V Controller . . . . . . . . . . . . . . . . . . . . . . . . . 58

•GENERAL OPERATION

•CONFIGURATION

•DRIVE PROGRAMMING

•EPM CHIP

•LOSS OF CCN COMMUNICATIONS

•REPLACING DEFECTIVE MODULES

Hydronic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63,64

Recommended Maintenance Schedule . . . . . . . . . . . . . 63

Microchannel Heat Exchanger (MCHX)

Condenser Coil Maintenance and Cleaning

Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-73

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53300067-01 Printed in U.S.A. Form 30RAP-2T Pg 1 12-10 Replaces: 30RAP-1T