Carrier AQUASNAP 30RAP010-150 Manuals

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300132-01 Printed in U.S.A. Form 30RAP-5T Pg 1 515 4-14 Replaces: 30RAP-4T 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Energy Management Module (EMM) . . . . . . . . . . . . . . . .24 Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . . . .24 AUX Board (AUX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Expansion Valve Board (EXV) . . . . . . . . . . . . . . . . . . . . . .24 Compressor Expansion Board (CXB) . . . . . . . . . . . . . .24 Enable/Off/Remote Contact Switch . . . . . . . . . . . . . . . . .24 Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . .24 Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Control Module Communication . . . . . . . . . . . . . . . . . . . .24 Carrier Comfort Network® (CCN) Interface . . . . . . . . . .25 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 • 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 . . . . . . . . . . . . . . . . . . . . . . .27 Loss-of-Cooler Flow Protection. . . . . . . . . . . . . . . . . . . . .27 Electronic Expansion Valves (EXV) . . . . . . . . . . . . . . . . .27 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 • MINUTES LEFT FOR START • MINUTES OFF TIME • LEAD/LAG DETERMINATION • LOADING SEQUENCE SELECT • CAPACITY CONTROL OVERRIDES Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 • MOTORMASTER V OPTION Operation of Machine Based on Control Method and Cooling Set Point Selection Settings. . . . . . . . .33 Cooling Set Point Select. . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Cooling Set Point (4 to 20 mA). . . . . . . . . . . . . . . . . . . . . .34 Low Sound Mode Operation . . . . . . . . . . . . . . . . . . . . . . . .34 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Optional Factory-Installed Hydronic Package. . . . . . .34 Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Cooler Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Cooler Pump Sequence of Operation . . . . . . . . . . . . . . .35 Configuring and Operating Dual Chiller Control . . . .36 Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Page Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 • DEMAND LIMIT (2-Stage Switch Controlled) • EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled) • DEMAND LIMIT (CCN Loadshed Controlled) Digital Scroll Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 • DIGITAL SCROLL OPERATION • DIGITAL COMPRESSOR CONFIGURATION PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 START-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . 45-48 Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Check Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 46 Charge Adjustment for Brine Operation . . . . . . . . . . . 46 Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 • COOLER FLOW RATES AND LOOP VOLUMES • TEMPERATURES • LOW AMBIENT OPERATION • VOLTAGE — ALL UNITS OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 48 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-68 Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 • CONTROL COMPONENTS Electronic Expansion Valve (EXV). . . . . . . . . . . . . . . 48 EXV Troubleshooting Procedure . . . . . . . . . . . . . . . . . . .49 • FIELD SERVICING INSTRUCTIONS • EXV VALVE REPLACEMENT • VALVE MOTOR REPLACEMENT Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . 52 Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 • BRAZED-PLATE COOLER HEAT EXCHANGER REPLACEMENT • BRAZED-PLATE COOLER HEAT EXCHANGER CLEANING Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Microchannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Round Tube, Plate Fin (RTPF) Condenser Coil Maintenance and Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 • REMOVE SURFACE LOADED FIBERS • PERIODIC CLEAN WATER RINSE • ROUTINE CLEANING OF COIL SURFACES Check Refrigerant Feed Components . . . . . . . . . . . .56 • FILTER DRIER • MOISTURE-LIQUID INDICATOR • MINIMUM LOAD VALVE • PRESSURE RELIEF DEVICES AquaSnap® 30RAP010-150 Air-Cooled Chillers with Puron® Refrigerant (R-410A)

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300131-01 Printed in U.S.A. Form 30RAP-12SI Pg 1 3-14 Replaces: 30RAP-11SI Installation Instructions CONTENTS Page SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . .1,2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Step 1 — Place and Rig the Unit. . . . . . . . . . . . . . . . . . 2 • PLACING UNIT • RIGGING • MOUNTING UNIT Step 2 — Check Compressor Mounting . . . . . . . . . 11 Step 3 — Cooler Fluid and Drain Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 • ALL UNITS • UNITS WITH FACTORY-INSTALLED HYDRONIC PACKAGES • AIR SEPARATION Step 4 — Fill the Chilled Water Loop . . . . . . . . . . . . 25 • WATER SYSTEM CLEANING • FILLING THE SYSTEM • PREPARATION FOR YEAR-ROUND OPERATION • FREEZE PROTECTION • PREPARATION FOR WINTER SHUTDOWN Step 5 — Make Electrical Connections . . . . . . . . . . 35 • POWER SUPPLY • POWER WIRING • FIELD CONNECTIONS Step 6 — Install Accessories . . . . . . . . . . . . . . . . . . . . 53 • ELECTRICAL Step 7 — Check Refrigerant Circuit . . . . . . . . . . . . . 53 • LEAK TESTING • DEHYDRATION • REFRIGERANT CHARGE BACnet Communication Option Wiring. . . . . . . . . . 55 APPENDIX A (Pressure Drop Curves) . . . . . . . . 58-70 SAFETY CONSIDERATIONS Installing, starting up, and servicing air-conditioning equip- ment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated struc- tures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment (Fig. 1). Untrained personnel can perform basic maintenance func- tions such as cleaning coils. All other operations should be performed by trained service personnel. When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment. • Follow all safety codes. • Wear safety glasses and work gloves. • Keep quenching cloth and fire extinguisher nearby when brazing. • Use care in handling, rigging, and setting bulky equipment. . 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 discon- nect locations to alert others not to restore power until work is completed. 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 sys- tem 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 nec- essary. Oil can ignite when exposed to torch flame. Failure to follow these procedures may result in personal injury or death. Fig. 1 — Typical 30RAP Unit (018-030 Shown) AquaSnap® 30RAP010-150 Liquid Chillers with Puron® Refrigerant (R-410A)

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300221-01 Printed in U.S.A. Form 30RAP-7T Rev. A Pg 1 5-21 Replaces: 30RAP-6T Controls, Start-Up, Operation, Service, and Troubleshooting CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Conventions Used in This Manual . . . . . . . . . . . . . . . 3 Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . 4 • SCROLLING MARQUEE DISPLAY • ACCESSORY NAVIGATOR™ DISPLAY MODULE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . 26 Energy Management Module (EMM) . . . . . . . . . . . . 27 Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . 27 Auxiliary (AUX) Board . . . . . . . . . . . . . . . . . . . . . . . . 27 Electronic Expansion Valve (EXV) Board . . . . . . . . 27 Compressor Expansion Board (CXB) . . . . . . . . . . . 27 Enable/Off/Remote Control Switch . . . . . . . . . . . . . 27 Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . 27 Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Control Module Communication . . . . . . . . . . . . . . . 27 • RED LED • GREEN LED • YELLOW LED Carrier Comfort Network® (CCN) Interface . . . . . . . 28 Alarm Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 • ALARM ROUTING CONTROL • ALARM EQUIPMENT PRIORITY • COMMUNICATION FAILURE RETRY TIME • RE-ALARM TIME • ALARM SYSTEM NAME Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 • 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 . . . . . . . . . . . . . . . . . . 30 Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . 31 Electronic Expansion Valves (EXVs) . . . . . . . . . . . . 31 Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 • MINUTES LEFT FOR START • MINUTES OFF TIME • LEAD/LAG DETERMINATION • LOADING SEQUENCE SELECT • LOW AMBIENT LOCKOUT • CAPACITY CONTROL OVERRIDES • SLOW CHANGE OVERRIDE Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . .34 • MOTORMASTER® V OPTION High-Efficiency Variable Condenser Fans . . . . . . . .37 • 30RAP011-060 WITH GREENSPEED® INTELLIGENCE • FAN DRIVE OPERATION Operation of Machine Based on Control Method and Cooling Set Point Selection Settings . . . . . . . . .38 • OCCUPANCY SCHEDULE • CCN CONTROL Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . .39 • SINGLE • DUAL SWITCH • DUAL CCN OCCUPIED • 4 TO 20 MA INPUT • CONFIGURATION SET POINT LIMITS Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . .39 Low Sound Mode Operation . . . . . . . . . . . . . . . . . . .40 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Optional Factory-Installed Hydronic Package . . . .41 Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . .41 Cooler Pump Operation . . . . . . . . . . . . . . . . . . . . . . .41 Cooler Pump Sequence of Operation . . . . . . . . . . .41 • NO INTEGRAL PUMP — SINGLE EXTERNAL PUMP CONTROL • NO INTEGRAL PUMP — DUAL EXTERNAL PUMP CONTROL • SINGLE INTEGRAL PUMP CONTROL • DUAL INTEGRAL PUMP CONTROL Configuring and Operating Dual Chiller Control . .43 Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . .43 Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 • DEMAND LIMIT (2-STAGE SWITCH CONTROLLED) • EXTERNALLY POWERED DEMAND LIMIT (4 TO 20 MA CONTROLLED) • DEMAND LIMIT (CCN LOADSHED CONTROLLED) Digital Scroll Option . . . . . . . . . . . . . . . . . . . . . . . . .49 • DIGITAL SCROLL OPERATION • DIGITAL COMPRESSOR CONFIGURATION PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 START-UP AND OPERATION . . . . . . . . . . . . . . . . . .51 Crankcase Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Check Refrigerant Charge . . . . . . . . . . . . . . . . . . . . .52 Charge Adjustment for Brine Operation . . . . . . . . .52 Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . .52 AquaSnap® 30RAP010-150 Air-Cooled Chillers and 30RAP011-060 Air-Cooled Chillers with Greenspeed® Intelligence with Puron® Refrigerant (R-410A) 50/60 Hz