Carrier AQUASNAP MPW015-045 Operation And Service Manual

Also see for AQUASNAP 30MPA: User manual Installation instructions Controls, start-up, operation, service, and troubleshooting

2CONTENTS PageSAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 1GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . 2Basic Controls Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Main Base Board (MBB). . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Energy Management Module (EMM). . . . . . . . . . . . . . . . 14Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . . . . 14Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . . . . 14Emergency On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 14Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Control Module Communication . . . . . . . . . . . . . . . . . . . 14Carrier Comfort Network ® Interface . . . . . . . . . . . . . . . . 14Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19• COOLER LEAVING FLUID SENSOR• COOLER ENTERING FLUID SENSOR• CONDENSER LEAVING FLUID SENSOR• CONDENSER ENTERING FLUID SENSOR• COMPRESSOR RETURN GASTEMPERATURE SENSOR• OUTDOOR-AIR TEMPERATURE SENSOR• DUAL LEAVING WATER TEMPERATURE SENSOR• REMOTE SPACE TEMPERATURE SENSOREnergy Management Module . . . . . . . . . . . . . . . . . . . . . . . 21Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . . . . . 21Condenser Flow Protection . . . . . . . . . . . . . . . . . . . . . . . . 21Thermostatic Expansion Valves (TXV) . . . . . . . . . . . . . 21Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21• MINUTES LEFT FOR START• MINUTES OFF TIME• LEAD/LAG DETERMINATION• CAPACITY CONTROL OVERRIDESOperation of Machine Based on Control Methodand Cooling Set Point Selection Settings . . . . . . . . 24Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Ice Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Service Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Cooler Pump Sequence of Operation . . . . . . . . . . . . . . 25Condenser Pump/Condenser Fan OutputControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Configuring and Operating Dual Chiller Control. . . . 25Temperature Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31• 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) . . . . . . . . . . . . . . . . . . . . . 32PRE-START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33,34System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33START-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . 34-36Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Check Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . 34Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35• TEMPERATURES• VOLTAGE — ALL UNITSOPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 36SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-44Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36• CONTROL COMPONENTSCompressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3630MPW Condenser and 30MP Cooler . . . . . . . . . . . . . . 36• BRAZED-PLATE COOLER AND CONDENSERHEAT EXCHANGER REPLACEMENT• BRAZED-PLATE COOLER AND CONDENSERHEAT EXCHANGER CLEANINGOil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Check Refrigerant Feed Components . . . . . . . . . . . . . . 37• FILTER DRIER• MOISTURE-LIQUID INDICATOR• THERMOSTATIC EXPANSION VALVE (TXV)• MINIMUM LOAD VALVE• PRESSURE RELIEF DEVICESCheck Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Chilled Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . 39Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Replacing Defective Modules. . . . . . . . . . . . . . . . . . . . 43MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,45Recommended Maintenance Schedule . . . . . . . . . . . . 44TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-52Complete Unit Stoppage and Restart . . . . . . . . . . . . . . 44• GENERAL POWER FAILURE• UNIT ENABLE-OFF-REMOTE CONTACT SWITCH ISOFF• CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN• OPEN 24-V CONTROL CIRCUIT BREAKERS• COOLING LOAD SATISFIED• THERMISTOR FAILURE• LOW SATURATED SUCTION• COMPRESSOR SAFETIESAlarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45APPENDIX A — LOCAL DISPLAY TABLES . . . . . . .53-64APPENDIX B — CCN TABLES. . . . . . . . . . . . . . . . . . . .65-72START-UP CHECKLIST FOR 30MP LIQUIDCHILLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1 to CL-8GENERALThis publication contains Start-Up, Service, Controls, Oper-ation, and Troubleshooting information for the 30MPW water-cooled chillers and the 30MPA air-cooled chillers. See Table 1.These liquid chillers are equipped with ComfortLink controlsand conventional thermostatic expansion valves (TXVs). The30MPA units and the 30MPW units with optional mediumtemperature brine are also equipped with liquid line solenoidvalves (LLSVs).Table 1 — Unit SizesConventions Used in This Manual — The follow-ing conventions for discussing configuration points for thelocal display (scrolling marquee or Navigator™ accessory)will be used in this manual.Point names will be written with the mode name first, thenany sub-modes, then the point name, each separated by anarrow symbol (. Names will also be shown in boldand italics. As an example, the Minimum Load Valve SelectPoint, which is located in the Configuration mode, Option 1sub-mode, would be written as ConfigurationOPT1MLV.S.This path name will show the user how to navigate throughthe local display to reach the desired configuration. The userwould scroll through the modes and sub-modes using theand keys. The arrow symbol in the path namerepresents pressing to move into the next level of themenu structure.CAUTIONThis unit uses a microprocessor-based electronic controlsystem. Do not use jumpers or other tools to short out orbypass components or otherwise depart from recom-mended procedures. Any short-to-ground of the controlboard or accompanying wiring may destroy the board orelectrical component.UNIT MODEL NOMINAL TONS30MPA,MPW015 1530MPA,MPW020 2030MPA,MPW030 3030MPA,MPW040 4030MPA,MPW045 45ENTER