carrier aquasnap chiller service manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300170-01 Printed in U.S.A. Form 30MP-4T Pg 1 8-17 Replaces: 30MP-3T Controls, Start-Up, Operation, Service, and Troubleshooting CONTENTS Page SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . 2,3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Conventions Used in this Manual . . . . . . . . . . . . . . . . 3 Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 7 AUX Board (AUX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Energy Management Module (EMM) . . . . . . . . . . . . . . 7 Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . . 7 Expansion Valve (EXV) Board . . . . . . . . . . . . . . . . . . . . 7 Enable/Off/Remote Control Switch . . . . . . . . . . . . . . . 7 Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . 7 Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Control Module Communication . . . . . . . . . . . . . . . . . 7 Carrier Comfort Network ® Interface . . . . . . . . . . . . . 13 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 • COOLER LEAVING FLUID SENSOR • COOLER ENTERING FLUID SENSOR • CONDENSER LEAVING FLUID SENSOR • CONDENSER ENTERING FLUID SENSOR • COMPRESSOR RETURN GAS TEMPERATURE SENSOR • OUTDOOR-AIR TEMPERATURE SENSOR • DUAL LEAVING WATER TEMPERATURE SENSOR • DISCHARGE TEMPERATURE THERMISTOR • SPACE TEMPERATURE SENSOR Energy Management Module . . . . . . . . . . . . . . . . . . . . 16 Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . . 16 Condenser Flow Protection . . . . . . . . . . . . . . . . . . . . . 16 Thermostatic Expansion Valves (TXV) . . . . . . . . . . 16 Electronic Expansion Valves (EXV) . . . . . . . . . . . . . 17 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 • MINUTES LEFT FOR START • MINUTES OFF TIME • CAPACITY CONTROL OVERRIDES Time, Day, and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Operation of Machine Based on Control Method. . 21 Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . . . . 25 Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Alarm Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Cooler Pump Sequence of Operation . . . . . . . . . . . 27 Condenser Pump/Condenser Fan Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Configuring and Operating Dual Chiller Control . . 27 Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 • 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) . . . . . . . . . . . . . . . . . . 34 Page Digital Scroll Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,37 System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 START-UP AND OPERATION. . . . . . . . . . . . . . . . . 37-40 Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Check Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . 38 Check Compressor Oil Level . . . . . . . . . . . . . . . . . . . . 39 Adjust Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 • TEMPERATURES • VOLTAGE — ALL UNITS OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 40 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52 Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . 41 • CONTROL COMPONENTS Electronic Expansion Valve (EXV) . . . . . . . . . . . . . . . 41 EXV Troubleshooting Procedure . . . . . . . . . . . . . . . . 42 Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . 44 30MP Cooler and 30MPW Condenser . . . . . . . . . . . 44 • BRAZED-PLATE COOLER AND CONDENSER HEAT EXCHANGER REPLACEMENT • BRAZED-PLATE COOLER AND CONDENSER HEAT EXCHANGER CLEANING Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Check Refrigerant Feed Components . . . . . . . . . . . 45 • FILTER DRIER • MOISTURE-LIQUID INDICATOR • THERMOSTATIC EXPANSION VALVE (TXV) • MINIMUM LOAD VALVE • PRESSURE RELIEF DEVICES Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Chilled Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . 47 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Replacing Defective Modules . . . . . . . . . . . . . . . . . . . 52 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Recommended Maintenance Schedule . . . . . . . . . . 52 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 52-71 Complete Unit Stoppage and Restart . . . . . . . . . . . . 52 • GENERAL POWER FAILURE • UNIT ENABLE-OFF-REMOTE CONTROL SWITCH IS OFF • CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN • OPEN 24-V CONTROL CIRCUIT BREAKER(S) • COOLING LOAD SATISFIED • THERMISTOR FAILURE • ENABLING AND DISABLING COMPRESSORS • COMPRESSOR DISCHARGE CHECK VALVE • LOW SATURATED SUCTION • COMPRESSOR SAFETIES AquaSnap ® 30MPA,MPW015-071 Liquid Chillers with Scroll Compressors and ComfortLink Controls

2 CONTENTS (cont) Page Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . 54 • COPELAND COMPRESSOR MODELS WITH ELECTRICAL CODE TF • COPELAND COMPRESSOR MODELS WITH ELECTRICAL CODE TW OR TE • BITZER PROTECTION MODULE • FIELD TROUBLESHOOTING SOLID-STATE MOTOR PROTECTION MODULE Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 APPENDIX A — LOCAL DISPLAY TABLES . . . 72-81 APPENDIX B — CCN TABLES . . . . . . . . . . . . . . . . 82-87 APPENDIX C — BACNET COMMUNICATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-94 APPENDIX D — MAINTENANCE SUMMARY AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95,96 INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 START-UP CHECKLIST FOR 30MP LIQUID CHILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-8 SAFETY CONSIDERATIONS Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (elevated structures, mechanical rooms, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment. When working on this equipment, observe precautions in the literature, and on tags, stickers, and labels attached to the 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. WARNING Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed. WARNING DO NOT VENT refrigerant relief valves within a building. Outlet from relief valves must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of Heating, Refrigerating and Air-Conditioning Engineers) 15 (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. Provide adequate ventilation in enclosed or low overhead areas. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous. WARNING DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective gloves and gog- gles and proceed as follows: a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from system using both high-pressure and low pressure ports. c. Traces of vapor should be displaced with nitrogen and the work area should be well ventilated. Refrig- erant in contact with an open flame produces toxic gases. d. Cut component connection tubing with tubing cutter and remove component from unit. 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 the system. e. Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame. Failure to follow these procedures may result in personal injury or death. CAUTION DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations. DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed. Failure to follow these procedures may result in damage to equipment. CAUTION This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out components, or to bypass or otherwise depart from recommended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the electronic modules or electrical components. CAUTION 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 fluid loop to prevent the freezing of brazed plate heat exchanger when the equipment is exposed to temperatures below 32 F (0° C). Proof of flow switch is 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 the system from freezing may constitute abuse and may result in loss of warranty coverage. CAUTION Compressors require specific rotation. Monitor control alarms during first compressor start-up for reverse rotation protection. Damage to unit may result.

3 GENERAL This publication contains Start-Up, Service, Controls, Oper- ation, and Troubleshooting information for the 30MPW water- cooled chillers and the 30MPA air-cooled chillers. For unit sizes, see Table 1. These liquid chillers are equipped with Com- fortLink controls and conventional thermostatic expansion valves (TXVs, units 30MP015-045) or electronic expansion valves (EXVs, units 30MP050-071). The 30MPA units and the 30MPW units with optional medium temperature brine are also equipped with liquid line solenoid valves (LLSVs). Table 1 — Unit Sizes Conventions Used in This Manual — The following conventions for discussing configuration points for the local display (scrolling marquee or Navigator™ accessory) will be used in this manual. Point names will be written with the mode name first, then any sub-modes, then the point name, each separated by an arrow symbol (. Names will also be shown in bold and italics. As an example, the Minimum Load Valve Select Point, which is located in the Configuration mode, Option 1 sub-mode, would be written as ConfigurationOPT1 MLV.S. This path name will show the user how to navigate through the local display to reach the desired configuration. The user would scroll through the modes and sub-modes using the and keys. The arrow symbol in the path name represents pressing to move into the next level of the menu structure. When a value is included as part of the path name, it will be shown at the end of the path name after an equals sign. If the value represents a configuration setting, an explanation will be shown in parenthesis after the value. As an example, ConfigurationOPT1MLV.S = YES (Minimum Load Valve Select). Pressing the and keys simultaneously will scroll an expanded text description of the point name or value across the display. The expanded description is shown in the local display tables but will not be shown with the path names in text. The CCN (Carrier Comfort Network ® ) point names are also referenced in the local display tables for users configuring the unit with CCN software instead of the local display. The CCN tables are located in Appendix B of the manual. Basic Control Usage SCROLLING MARQUEE DISPLAY — This device is the keypad interface used for accessing unit information, reading sensor values, and testing the unit. The scrolling marquee display is a 4-key, 4-character, 16-segment LED (light-emitting diode) display. Eleven mode LEDs are located on the display as well as an Alarm Status LED. See Table 2. For further details, see Appendix A—Local Display Tables on page 72. The scrolling marquee display module provides the user interface to the ComfortLink control system. The display has up and down arrow keys, an key, and an key. These keys are used to navigate through the different levels of the display structure. See Appendix A—Local Display Tables on page 72. Press the key until the display is blank to move through the top 11 mode levels indicated by LEDs on the left side of the display. Pressing the and keys simultaneously will scroll a clear language text description across the display indicating the full meaning of each display acronym. Clear language descriptions will be displayed in the language of choice. Pressing the and keys when the display is blank (Mode LED level) will return the scrolling marquee display to its default menu of rotating display items, found under Run StatusVIEW. In addition, the password will be disabled, requiring that it be entered again before changes can be made to password protected items. After a period of time with no key activity, the scrolling marquee will display its default menu of rotating display items found under Run StatusVIEW. When a specific item is located, the display will flash show- ing the operator, the item, the item value and then the item units (if any). Press the key to stop the display at the item value. Press the key again so that the item value flashes. Use the arrow keys to change the value or state of an item and press the key to accept it. Press the key and the item, value, or units display will re- sume. Repeat the process as required for other items. NOTE: If a value has been forced, the lower right “.” will be flashing. See Table 3 and Appendix A for further details. CAUTION Refrigerant charge must be removed slowly to prevent loss of compressor oil that could result in compressor failure. CAUTION Puron ® refrigerant (R-410A) systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment. If service equipment is not rated for Puron refrigerant, equipment damage or personal injury may result. CAUTION This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out or bypass components or otherwise depart from recommended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the board or electrical component. UNIT MODEL NOMINAL TONS 30MPA,MPW015 15 30MPA,MPW020 20 30MPA,MPW030 30 30MPA,MPW040 40 30MPA,MPW045 45 30MPA,MPW050 50 30MPA,MPW055 55 30MPA,MPW060 60 30MPA,MPW065 65 30MPA,MPW071 71 ENTER ESCAPE ENTER ENTER ESCAPE ESCAPE ENTER ESCAPE ENTER ESCAPE ENTER ENTER ENTER ESCAPE

4 Table 2 — Scrolling Marquee Display Menu Structure* *Throughout this text, the location of items in the menu structure will be described in the following format: Item Expansion (Mode NameSub-mode NameITEM) For example, using the language selection item: Language Selection (ConfigurationDISPLANG) MODE RUN STATUS SERVICE TEST TEMPERATURES PRESSURES SET POINTS INPUTS OUTPUTS CONFIGURATION TIME CLOCK OPERATING MODES ALARMS SUB-MODE Auto View of Run Status (VIEW) Service Test Mode (TEST) Unit Temperatures (UNIT) Pressures Circuit A (PRC.A) Cooling Setpoints (COOL) General Inputs (GEN.I) General Outputs (GEN.O) Display Configuration (DISP) Time of Day (TIME) Modes (MODE) Current (CRNT) Unit Run Hour and Start (RUN) Outputs and Pumps (OUTS) Temperatures Circuit A (CIR.A) Head Pressure Setpoint (HEAD) Circuit Inputs (CRCT) Outputs Circuit A (CIR.A) Unit Configuration (UNIT) Month, Date, Day, and Year (DATE) Reset Alarms (RCRN) Circuit and Compressor Run Hours (HOUR) Circuit A Comp Test (CMPA) Brine Freeze Setpoint (FRZ) 4-20mA Inputs (4-20) Outputs Circuit A EXV (A.EXV) Unit Options 1 Hardware (OPT1) Daylight Savings Time (DST) Alarm History (HIST) Local Holiday Schedules (HOL.L) Compressor Starts (STRT) Unit Options 2 Controls (OPT2) Preventive Maintenance (PM) Circuit A EXV Configuration (EXV.A) Schedule Number (SCH.N) Software Version (VERS) CCN Network Configuration (CCN) Local Occu- pancy Schedule (SCH.L) Reset Cool Temp (RSET) Schedule Override (OVR) Set Point and Ramp Load (SLCT) Service Configuration (SERV) Broadcast Configuration (BCST)

5 Table 3 — Operating Modes LEGEND MODE NO. ITEM EXPANSION DESCRIPTION 01 CSM CONTROLLING CHILLER Chillervisor System Manager (CSM) is controlling the chiller. 02 WSM CONTROLLING CHILLER Water System Manager (WSM) is controlling the chiller. 03 MASTER/SLAVE CONTROL Dual Chiller control is enabled. 05 RAMP LOAD LIMITED Ramp load (pull-down) limiting in effect. In this mode, the rate at which leaving fluid temperature is dropped is limited to a predetermined value to prevent compressor overloading. See Cooling Ramp Loading (ConfigurationSLCTCRMP). The pull-down limit can be modified, if desired, to any rate from 0.2° F to 2° F (0.1° to 1° C)/minute. 06 TIMED OVERRIDE IN EFFECT Timed override is in effect. This is a 1 to 4 hour temporary override of the programmed schedule, forcing unit to Occupied mode. Override can be implemented with unit under Local (Enable) or CCN (Carrier Comfort Network ® ) control. Override expires after each use. 07 LOW COOLER SUCTION TEMPA Circuit A cooler Freeze Protection mode. At least one compressor must be on, and the Sat- urated Suction Temperature is not increasing greater than 1.1° F (0.6° C) in 10 seconds. If the saturated suction temperature is less than the Brine Freeze Point (Set PointsFRZ BR.FZ) minus 6° F (3.4° C) and less than the leaving fluid temperature minus 14° F (7.8° C) for 2 minutes, a stage of capacity will be removed from the circuit. Or, If the saturated suction temperature is less than the Brine Freeze Point minus 14° F (7.8° C), for 90 seconds, a stage of capacity will be removed from the circuit. The control will continue to decrease capacity as long as either condition exists. 09 SLOW CHANGE OVERRIDE Slow change override is in effect. The leaving fluid temperature is close to and moving towards the control point. 10 MINIMUM OFF TIME ACTIVE Chiller is being held off by Minutes Off Time (ConfigurationOPT2DELY). 13 DUAL SETPOINT Dual Set Point mode is in effect. Chiller controls to Cooling Set Point 1 (Set PointsCOOL CSP.1) during occupied periods and Cooling Set Point 2 (Set PointsCOOLCSP.2) during unoccupied periods. 14 TEMPERATURE RESET Temperature reset is in effect. In this mode, chiller is using temperature reset to adjust leaving fluid set point upward and is currently controlling to the modified set point. The set point can be modified based on return fluid, outdoor-air-temperature, space temperature, or 4 to 20 mA signal. 15 DEMAND LIMITED Demand limit is in effect. This indicates that the capacity of the chiller is being limited by demand limit control option. Because of this limitation, the chiller may not be able to pro- duce the desired leaving fluid temperature. Demand limit can be controlled by switch inputs or a 4 to 20 mA signal. 16 COOLER FREEZE PROTECTION Cooler fluid temperatures are approaching the Freeze point (see Alarms and Alerts section for definition). The chiller will be shut down when either fluid temperature falls below the Freeze point. 17 LOW TEMPERATURE COOLING Chiller is in Cooling mode and the rate of change of the leaving fluid is negative and decreasing faster than -0.5° F (-0.3° C) per minute. Error between leaving fluid and control point exceeds fixed amount. Control will automatically unload the chiller if necessary. 18 HIGH TEMPERATURE COOLING Chiller is in Cooling mode and the rate of change of the leaving fluid is positive and increasing. Error between leaving fluid and control point exceeds fixed amount. Control will automatically load the chiller if necessary to better match the increasing load. 19 MAKING ICE Chiller is in an unoccupied mode and is using Cooling Set Point 3 (Set PointsCOOL CSP.3) to make ice. The ice done input to the Energy Management Module (EMM) is open. 20 STORING ICE Chiller is in an unoccupied mode and is controlling to Cooling Set Point 2 (Set PointsCOOL CSP.2). The ice done input to the Energy Management Module (EMM) is closed. 21 HIGH SCT CIRCUIT A Chiller is in a Cooling mode and the Saturated Condensing Temperature (SCT) is greater than the calculated maximum limit. No additional stages of capacity will be added. Chiller capacity may be reduced if SCT continues to rise to avoid high-pressure switch trips by reducing condensing temperature. 23 MINIMUM COMP ON TIME Cooling load may be satisfied, however control continues to operate compressor to ensure proper oil return. May be an indication of oversized application, low fluid flow rate or low loop volume. 24 PUMP OFF DELAY TIME Cooling load is satisfied, however cooler pump continues to run for the number of minutes set by the configuration variable Cooler Pump Shutdown Delay (ConfigurationOPT1 PM.DY). CSM — Chillervisor System Manager SCT — Saturated Condensing Temperature WSM — Water System Manager

6 ACCESSORY NAVIGATOR™ DISPLAY MODULE — The Navigator module provides a mobile user interface to the ComfortLink control system. The display has up and down arrow keys, an key, and an key. These keys are used to navigate through the different levels of the display structure. Press the key until ‘Select a Menu Item’ is displayed to move through the top 11 mode levels indicated by LEDs on the left side of the display. See Fig. 1. Once within a Mode or sub-mode, a “>” indicates the currently selected item on the display screen. Pressing the and keys simultaneously will put the Nav- igator module into expanded text mode where the full meaning of all sub-modes, items and their values can be displayed. Press- ing the and keys when the display says ‘Select Menu Item’ (Mode LED level) will return the Navigator module to its default menu of rotating display items (those items in Run StatusVIEW). In addition, the password will be disabled, requiring that it be entered again before changes can be made to password protected items. Press the key to exit out of the expanded text mode. NOTE: When the Language Selection (Configuration DISPLANG), variable is changed, all appropriate display expansions will immediately change to the new language. No power-off or control reset is required when reconfiguring languages. When a specific item is located, the item name appears on the left of the display, the value will appear near the middle of the display and the units (if any) will appear on the far right of the display. Press the key at a changeable item and the value will begin to flash. Use the up and down arrow keys to change the value, and confirm the value by pressing the key. Changing item values or testing outputs is accomplished in the same manner. Locate and display the desired item. Press so that the item value flashes. Use the arrow keys to change the value or state and press the key to accept it. Press the key to return to the next higher level of structure. Repeat the process as required for other items. Items in the Configuration and Service Test modes are password protected. The words Enter Password will be displayed when required, with 1111 also being displayed. The default password is 1111. Use the arrow keys to change the number and press to enter the digit. Continue with the remaining digits of the password. The password can only be changed through CCN operator interface software such as ComfortWORKS, ComfortVIEW and Service Tool. Adjusting the Contrast — The contrast of the display can be adjusted to suit ambient conditions. To adjust the contrast of the Navigator module, press the key until the display reads, “Select a menu item.” Using the arrow keys move to the Configuration mode. Press to obtain access to this mode. The display will read: > TEST OFF METR OFF LANG ENGLISH PAS.E ENBL Pressing will cause the “OFF” to flash. Use the up or down arrow to change “OFF” to “ON”. Pressing will illuminate all LEDs and display all pixels in the view screen. Pressing and simultaneously allows the user to adjust the display contrast. Use the up or down arrows to adjust the contrast. The screen’s contrast will change with the adjustment. Press to accept the change. The Navigator module will keep this setting as long as it is plugged in to the LEN bus. Adjusting the Backlight Brightness — The backlight of the display can be adjusted to suit ambient conditions. The factory default is set to the highest level. To adjust the backlight of the Navigator module, press the key until the display reads, “Select a menu item.” Using the arrow keys move to the Configuration mode. Press to obtain access to this mode. The display will read: > TEST OFF METR OFF LANG ENGLISH PAS.E ENBL Pressing will cause the “OFF” to flash. Use the up or down arrow keys to change “OFF” to “ON.” Pressing will illuminate all LEDs and display all pixels in the view screen. Pressing the up and down arrow keys simultaneously allows the user to adjust the display brightness. Use the up or down arrow keys to adjust screen brightness. Press to accept the change. The Navigator module will keep this setting as long as it is plugged in to the LEN bus. CHANGING THE DISPLAY LANGUAGE — The factory default language is English. Several other languages are available, including Spanish, French, and Portugese. Required Configurations — Table 4 shows the required configurations for Language Selection. Table 4 — LANG (Language Selection) Required Configurations NOTE: When the Language Selection (Configura- tionDISPLANG) variable is changed, all appropriate display expansions will immediately change to the new language. No power-off or control reset is required when reconfiguring Language Selection. CHANGING THE UNITS OF MEASURE — The factory default unit of measure is English (for example, °F, ^F, psi). The display can be changed to metric units (for example, °C, ^C, kPa). ENTER ESCAPE ESCAPE ENTER ESCAPE ENTER ESCAPE ESCAPE ENTER ENTER ENTER ENTER ESCAPE ENTER ESCAPE ENTER ENTER ENTER ENTER ESCAPE SUB- MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT DISP LANG X Language Selection Default: 0 Range: 0 to 3 0=English 1=Espanol 2=Francais 3=Portugese ENTER ESCAPE ENTER ENTER ENTER ENTER Run Status Service Test Temperatures Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms ENTER ESC MODE Alarm Status ComfortLink Fig. 1 — Accessory Navigator™ Display Module

7 Required Configurations — Table 5 shows the required configurations for Metric Display. Table 5 — METR (Metric Display) Required Configurations NOTE: When the Metric Display (Configura- tionDISPMETR) variable is changed, all appropriate display expansions will immediately change to the new units of measure. No power-off or control reset is required when reconfiguring Metric Display. CONFIGURATION AND SERVICE PASSWORD — Items in the Configuration and Service Test modes are password protected. The words PASS and WORD will flash on the scrolling marquee. Press for the digits 1111 to be displayed. On the Navigator, press Enter Password and 1111 will be displayed. The default password is 1111. Use the arrow keys to change each number if required and press to accept the digit. Continue with the remaining digits of the password. Changing Service Password — The password can only be changed through CCN operator interface software such as ComfortWORKS™, ComfortVIEW™, and Service Tool. Caution should be exercised when changing the password. Once changed, the only way to determine the password is through one of these devices. To view or change the password, use the CCN Variable PASSWORD found in Service Configu- ration/Display. CONTROLS General — The 30MP liquid scroll chillers contain the ComfortLink electronic control system that controls and monitors all operations of the chiller. The control system is composed of several components as listed in the sections below. See Fig. 2 for a typical control box drawing. See Fig. 3 and 4 for power and control schematics. See Table 6 for drawing designation. Main Base Board (MBB) — See Fig. 5. The MBB is the heart of the ComfortLink control system. It contains the major portion of operating software and controls the operation of the machine. The MBB continuously monitors input/output channel information received from its inputs and from all other modules. The MBB receives inputs from the discharge and suction pressure transducers and thermistors. See Table 7. The MBB also receives the feedback inputs from each compressor current sensor board and other status switches. See Table 8. The MBB also controls several outputs. Relay outputs controlled by the MBB are shown in Table 9. Information is trans- mitted between modules via a 3-wire communication bus or LEN (Local Equipment Network). The CCN (Carrier Comfort Network) bus is also supported. Connections to both LEN and CCN buses are made at the LVT (low voltage terminal). The Instance Jumper must be on “1.” AUX Board (AUX) — The AUX board is used with the digital scroll option (020-045 only). It provides additional inputs and outputs for digital scroll control. See Fig. 6. Energy Management Module (EMM) — The EMM module is available as a factory-installed option or as a field- installed accessory. The EMM module receives 4 to 20 mA inputs for the leaving fluid temperature reset, cooling set point and demand limit functions. The EMM module also receives the switch inputs for the field-installed 2-stage demand limit and ice done functions. The EMM module communicates the status of all inputs with the MBB, and the MBB adjusts the control point, capacity limit, and other functions according to the inputs received. Current Sensor Board (CSB) — The CSB is used to monitor the status of the compressors by measuring current and providing an analog input to the main base board (MBB). Expansion Valve (EXV) Board (050-071 only) — The EXV board communicates with the MBB and directly controls the expansion valves to maintain the correct compressor superheat. Enable/Off/Remote Control Switch — The Enable/ Off/Remote Control switch is a 3-position switch used to control the chiller. When switched to the Enable position the chiller is under its own control. Move the switch to the Off position to shut the chiller down. Move the switch to the Remote Control position and a field-installed dry contact can be used to start the chiller. The contacts must be capable of handling a 24 vac, 50-mA load. In the Enable and Remote Control (dry contacts closed) positions, the chiller is allowed to operate and respond to the scheduling configuration, CCN configuration and set point data. See Fig. 7. Emergency On/Off Switch — The Emergency On/Off switch should only be used when it is required to shut the chiller off immediately. Power to the MBB, EMM, EXV, AUX, and marquee display is interrupted when this switch is off and all outputs from these modules will be turned off. See Fig. 7. Board Addresses — The main base board (MBB) has a 3-position instance jumper that must be set to 1. The EMM and EXV board has 4-position DIP switches. All switches are set to ON for all boards except the AUX board. The AUX board DIP switch settings are shown on the wiring schematic. Control Module Communication RED LED — Proper operation of the control boards can be visually checked by looking at the red status LEDs. During ini- tial power-up the LED will signal a 1 / 2 -second blink 3 times, followed by a pause. This indicates that the processor is boot- ing. If this pattern repeats, it is an indication that the control board is in a continuous reboot loop and the board should be replaced. When operating correctly, the red status LEDs should be blinking in unison at a rate of once every 2 seconds. If the red LEDs are not blinking in unison, verify that correct power is being supplied to all modules. Be sure that the main control is supplied with the current software. If necessary, reload current software. If the problem still persists, replace the control board. A red LED that is lit continuously or blinking at a rate of once per second or faster indicates that the control board should be replaced. GREEN LED — The MBB has one green LED. The Local Equipment Network (LEN) LED should always be blinking whenever power is on. All other boards have a LEN LED which should be blinking whenever power is on. Check LEN connections for potential communication errors at the board J3 and/or J4 connectors. Communication between modules is accomplished by a 3-wire sensor bus. These 3 wires run in parallel from module to module. The J4 connector on the MBB provides both power and communication directly to the marquee display only. YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication. SUB- MODE ITEM DISPLAY ITEM DESCRIPTION COMMENT DISP METR OFF/ON Metric Display Default: OFF OFF=English ON=Metric ENTER ENTER

8 Table 6 — Component, Power, and Control Drawings LEGEND FOR FIG. 3-5 30MPA,MPW UNIT DESCRIPTION LOCATION 015 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 020 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 030 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 040 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 045 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 050 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 055 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 060 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 065 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 071 Component Arrangement Fig. 2, page 9 Power Wiring Schematic Fig. 3, page 10 Control Wiring Schematic Fig. 4, page 11 ALMR — Alarm Relay AUX — Auxilliary C — Contactor, Compressor CB — Circuit Breaker CCB — Compressor Circuit Breaker CCH — Crankcase Heater Relay CNFS — Condenser Water Flow Switch CNPI — Condenser Pump Interlock COMP — Compressor CR — Control Relay CSB — Current Sensing Board CWFS — Chilled Water Flow Switch DGS — Digital Scroll Compressor DPT — Discharge Pressure Transducer DTT — Discharge Temperature Thermistor DUS — Digital Unloader Solenoid EMM — Energy Management EXV — Expansion Valve Board/Electronic Expansion Valve FB — Fuse Block FIOP — Factory-Installed Option FU — Fuse GND — Ground HPS — High-Pressure Switch LLSV — Liquid Line Solenoid Valve LON — Local Operating Network LVT — Low Voltage Terminal LWT — Leaving Water Temperature MBB — Main Base Board MLV — Minimum Load Valve MP — Modular Motor Protection MTT — Motor Temperature Thermistor NEC — National Electrical Code OAT — Outdoor-Air Thermistor OPT — Option PL — Plug RGT — Return Gas Temperature SPT — Suction Pressure Transducer SW — Switch TB — Terminal Block TRAN — Transformer UPC — Unitary Protocol Converter Terminal Block Terminal (Unmarked) Terminal (Marked) Splice Factory Wiring Field Wiring Accessory or Option Wiring To indicate common potential only; not to represent wiring.

9 a30-5984 Fig. 2 — Typical Control Box — 30MP015-071 Units

10 Fig. 3 — Typical Power Wiring Schematic — 30MP015-071 Units

carrier aquasnap chiller service manual

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