Carrier 30GK manual

1 30GK Series PR O-DIALOG Contr ol Air-Cooled Liquid Chillers 50 Hz Installation, operation and maintenance instructions[...]

2 TABLE OF CONTENTS 1 - SAFETY CONSIDERATIONS ...................................................................................................... ............................................ 4 1.1 - General .................................................................................................................. .........................[...]

3 5 - PRO-DIALOG PLUS CONTROL OPERATION .......................................................................................... ....................... 27 5.1 - Start/stop control ....................................................................................................... ......................................................... 27 5.[...]

4 1 - SAFETY CONSIDERATIONS 1.1 - General Installation, start-up and servicing of equipment can be hazard- ous if factors particular to the installation are not considered: operating pressures, electrical components, voltages and the installation site itself (elevated plinths, rooftops and built-up structures). Only highly trained and qualified ins[...]

5 2 - GENERAL DESCRIPTION 2.1 - General PRO-DIALOG Plus is a system for controlling units which use reciprocating compressors*: • Single or dual circuit • Air or water-cooled condensers • Non-reversible heat pumps • Split systems * At present only air-cooled models are available. PRO-DIALOG Plus controls compressor start-up and demand limit[...]

6 3 - HARDWARE DESCRIPTION 3.1 - General Control board The various control components are arranged in modules within the control cabinet: • Control module: This comprises the basic board, the user interface, the EXV control board and option boards, as well as the customer’s terminal block. • Start-up module: This consists of the start-up boar[...]

7 3.2.7 - Light emitting diodes on boards All boards continuously check and indicate the proper operation of their electronic circuits. A light emitting diode (LED) lights on each board when it is operating properly. Red LED • The MAIN red LED flashes at about 2 second intervals to show that the module is working properly. • Irregular flashing [...]

8 3.3.3 - The evaporator pumps The controller can regulate one or two evaporator pumps, with automatic changeover between the two pumps. 3.3.4 - The condenser pump In appropriate cases the controller can regulate a condenser pump (for water -cooled units or air -cooled units with heat reclaim option). This control does not require an additional boa[...]

9 A V AILABLE TERMINALS DESCRIPTION Alarm relay output, circuit A Alarm relay output, circuit B User safety loop and chilled w ater pump interlock Remote star t/stop Remote cooling setpoint selection Remote heating/cooling control or remote heat reclaim control Demand limit command 0-10 V d.c. setpoint reset or demand limit entry Connection to CCN [...]

10 kP a MAIN INTERF ACE BUTTON NAME DESCRIPTION Menu P er mits the selection of a main menu. Each main menu is represented b y an icon. The icon is lit if activ e. Up arrow Permits scrolling through the menu items (in the two-digit display). If the modification mode is active this button aut horises increase of the value of any par ameter . Down ar[...]

11 kPa kPa The summary interface (right hand section) includes a mimic diagram of the unit, together with push-buttons and LEDs. It gives quick access to the main operating parameters of the unit. SUMMARY INTERF A CE LEDS LED INDICA TION WHEN LIT Green LED : The unit is authorised to start or is already running Red LED: - Lit: circuit A or unit shu[...]

12 kP a kP a 4.3 - Menus 4.3.1 - Selecting a menu The MENU button authorises y ou to select a menu from the 10 main menus that are a vailable. Each time you press this b utton one of the 10 LEDs lights up in turn alongside each of the icons representing a main menu. The acti ve menu is the one against which the LED is lit. If a menu is empty then i[...]

13 STATUS TEMPERATURES PRESSURES SETPOINTS INPUTS OUTPUTS CONFIGURATION ALARMS USER [USEr] SERVICE [SErviCE] FACTORY [FACtorY] RUNTIME 1 [RuntiME 1] MAINTENANCE [MAintEnAnCE] PERIOD 3 [PEriod 3] PERIOD 4 [PEriod 4] PERIOD 5 [PEriod 5] PERIOD 6 [PEriod 6] PERIOD 7 [PEriod 7] PERIOD 8 [PEriod 8] PERIOD 1 [PEriod 1] PERIOD 2 [PEriod 2] USER 1 [USEr 1][...]

14 MENU Legend ** Displayed if the alarm exists - Not in use ITEM 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ST A TUS Def ault display Active modes Chiller occupied/ unoccupied Minutes left before starting Cooling/heating selection Heat reclaim selection Unit capacity in % Capacity circuit A in % Capacity circuit B in % Present demand limit in [...]

15 INFORMA TION MENU [3] ITEM FORMA T UNITS 0 ±nn.n ° C LOFF - L-On - L-Sc - CCn - rEM - MASt - OFF - rEADY - dELA Y - StOPPing - running - triPout - OvErridE - OCCUPIEd - UNOCCUPIEd - COOL - HEA T - rECLAIM - ALArM - ALErt - MAStEr - SLAvE - 1 [1] nn - 2 [2] - occu unoc Forc 3 nn.n minutes 4 [2] - HEAt - COOL - 5 [2] YES - NO - 6 Nnn % 7 nnn % 8[...]

16 DESCRIPTION OF OPERA TING MODES (ITEM 1 OF THE INFORMA TION MENU) MODE # MODE NAME 7 Delay at start-up active 8 2nd cooling setpoint active 9 Setpoint reset active 10 Demand limit active 1 1 Ramp loading active 12 Low entering water temperature protection in heating mode 13,14 Low suction temperature protection 15,16 Low discharge superheat prot[...]

17 SETPOINTS MENU [2] ITEM FORMA T UNITS RANGE 0 ±nn.n ° C See table below 1 ±nn.n ° C See table below 2 nnn ° C See table below 3 [1] nnn ° C See table below 4 [1] nnn ° C See table below 5 nnn % 0 to 100 6 [1] ±nn.n ° C/min 0.1 to 1.1 7 [1] ±nn.n ° C/min 0.1 to 1.1 8 [1] ±nn.n [3] See table below 9 [1] ±nn.n [3] See table below 10 [ [...]

18 OUTPUTS ST A TUS AND TESTS MENU [2] [3] ITEM FORMA T UNITS 0 - - - - 1 [1] - - - - 2 [1] tEST - - 3 [1] tESt - - - - 4.5.6 - Description of the Outputs/Tests menu 4.5.6.1 - General This menu displays the status of the controller outputs. More- ov er , when the machine is fully stopped (LOFF) the outputs can be activated for manual or automatic t[...]

19 OUTPUTS ST A TUS 2 AND TESTS MENU [2] [3] - cont. ITEM FORMA T UNITS 4 [1] tESt - - - 5 tESt - - 6 tESt % 7 tESt % 8 [1] tESt % 9 [1] tESt % 10 On - Stop - tESt - F AIL - Good - Forc - 11 O n - OFF - tESt - F AIL - Good - Forc - 12 On - OFF - tESt F AIL Good Forc - 13[1] nn - - 14[1] tESt % 15[1] - - - - 16 YES no tESt Legend 1 This item is disp[...]

20 4.5.6.3 - Manual tests This function allo ws the user to test the outputs indi vidually , if the machine is completely shut down (LOFF). T o carry out a manual test use the arrow keys to access the output to be tested and press the Enter key (longer than 2 seconds) to activate the modifica tion mode. The passw ord is automatically r equested, if[...]

21 SUB-MENU HOLID A Y CONFIGURA TION* Item HOLID A YS 1 to 16 [HoLidAy X MEn u]* 0 Return to previous menu 1 Start month holidays 3 Start day holidays 4 Number of days, holidays Legend *: only displayed if configuration requires. NOTE: The items in brackets show what is displayed on the user interface. SUB-MENU PERIOD CONFIGURA TION* Item PERIOD 1 [...]

22 4.5.7.3 - Description of the User 1 Configuration sub-menu USER 1 CONFIGURA TION SUB-MENU [2] ITEM FORMA T UNITS DEF AUL T COMMENTS 0 USEr MEnu - - When selected this item authorises return to the previous menu. 1 [1] 0/1/2 0 Lead circuit selection 0 = automatic based on the number of start-ups and the operating hours of each circuit 1 = lead ci[...]

23 4.5.7.4 - Description of the User 2 Configuration sub-menu USER 1 CONFIGURA TION SUB-MENU ITEM FORMA T UNITS DEF AUL T COMMENTS 0 USEr 2 Menu When selected this item authorises return to the previous menu. 1[1] YES/no - no Periodic pump quick-start of the water pump(s) Y es = the pump is started per iodically when the unit is manually stopped. N[...]

24 PERIOD X CONFIGURA TION SUB-MENUS (X = 1 to 8) ITEM # FORMA T COMMENTS 0 Period X Menu Indicates the period (X) you are going to configure. When selected this item authorises a return to the main menu. 1n 1 n 2 n 3 n 4 Occupied period - Start time* . 00:00 to 24:00 Authorises entering the time of day at which the occupied period starts. 2n 1 n 2[...]

25 BRO ADCAST CONFIGURA TION SUB-MENU ITEM # FORMA T COMMENTS 0 broAdCASt MEnu When selected this item authorises a return to the main menu. 1 YES/no Determines whether or not the unit is a broadcast acknowledger when the unit is connected on a CCN network. There m ust be only one broadcast acknowledger in a CCN. W arning : if the unit operates in [...]

26 4.5.10 - Runtime menu description RUNTIMES RUNTIMES 1 [runtiMES 1] RUNTIMES 2 [runtiMES 2] MAINTENANCE [MAintEnAnCE] NOTE: The items in brackets show what is displayed on the user interface. 4.5.10.1 - Description of the Runtimes 1 menu RUNTIMES MENU [1] iTEM # FORMA T UNIT COMMENTS 0 - - When selected this item authorises return to the previous[...]

27 5 - PRO-DIALOG PLUS CONTROL OPERATION 5.1 - Start/stop control The table below summarises the unit control type and stop or go status with regard to the following parameters. - Operating type : this is selected using the start/stop button on the front of the user interface. - Remote start/stop contacts : these contacts are used when the unit is [...]

28 5.3 - Evaporator water pump control The unit can control one or two e v aporator water pumps. The evaporator water pump is turned on when this option is confi- gured (see User configuration) and when the unit is in one of the on modes described above or in delay mode. Since the minimum value for the delay at start-up is 1 minute (configurable be[...]

29 5.8 - Demand limit Generally, demand limit is used by an energy management system in order to restrict the unit electricity consumption. The PRO-DIALOG Plus control system for 30GX & 30HX provides two methods of demand limit: • By reference to a limiting signal from a user-controlled volt-free contact: the capacity of the unit cannot excee[...]

30 5.12 - Slave compressor start-up sequence Lag compressors are started and stopped in a sequence designed to equalise their number of start-ups (value weighted by their operating time). 5.13 - Controlling the EXV EXVs, if used, control the flow of r efrigerant in the ev aporator . They are controlled in order to maintain a constant level of super[...]

31 5.17 - High pressure load shedding function This function does not require an additional board. It prevents high pressure a break on a circuit by the following means: • Preventing any capacity increase on the circuit once the high pressure value has reached an initial threshold. • Shedding one or more capacity stages once a second protection[...]

32 6 - DIAGNOSTICS - TROUBLESHOOTING 6.1 - General The PRO-DIALOG Plus control system has many fault tracing aid functions. The local interf ace and its v arious menus give access to all unit operating conditions. The test function mak es it possible to run a quick test of all devices on the unit. If an operating fault is detected, an alarm is acti[...]

33 ALARM CODE DESCRIPTIONS Code Alarm name Description Action Pumpdown Reset type Probable cause 1 Evaporator leaving water thermistor fault Thermistor outside range Unit shut down Y e s Auto Thermistor or wiring fault or bad connection 2 Evaporator entering water thermistor fault Ditto Unit shut down Y es Auto Ditto 3 Condenser leaving water therm[...]

34 ALARM CODE DESCRIPTIONS Code Alarm name Description Action Pumpdown Reset type Probable cause 49 Low suction overheat, circuit B Circuit B shut down Y es Manual Ditto 50 Low oil pressure, compressor A1 Oil pressure < min. threshold Circuit A shut down No Manual Compressor , crankcase heater, pr essure sensor or EXV faulty , refrigerant charge[...]

35 ALARM CODE DESCRIPTIONS Code Alarm name Action Pumpdown Reset type Probable cause 101 DGT fault, compressor A1 Circuit A shut do wn No Manual Hot gas thermostat contact open 102 Star ter Guard fault compressor A1 Circuit A shut do wn No Ditto Crankcase heater fault and open motor current fault detection board contact 201 DGT fault, compressor A2[...]

36 Order No. 13040-76, 05.2000. Supersedes order No.: New Manufactured by: Carrier S.A., Montluel, France. Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands on totally chlor ine-free paper.[...]