Carrier 30RAP010-060 User Manual

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

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

30RAP010-060

AQUASNAP

Air-Cooled Chillers

with COMFORTLINK™ Controls