Carrier PRO-DIALOG Plus 30GK Series, Installation, Operation & Maintenance Instructions Manual

Page 1: ...1 30GK Series PRO DIALOG Control Air Cooled Liquid Chillers 50 Hz Installation operation and maintenance instructions ...

Page 2: ... 2 1 Description 11 4 2 2 Stopping the unit in local mode 11 4 2 3 Starting unit and selecting an operating type 11 4 3 Menus 12 4 3 1 Selecting a menu 12 4 3 2 Selecting a menu item 12 4 3 3 Modifying the value of a parameter access to a sub menu 12 4 3 4 Expand display 12 4 4 General menu structure 13 4 5 Menu tree structure 14 4 5 1 Description of the Information menu 15 4 5 2 Description of th...

Page 3: ...ead circuit 29 5 11 Circuit loading sequence 29 5 12 Slave compressor start up sequence 30 5 13 Controlling the EXV 30 5 14 Head pressure control on air cooled units 30 5 15 Head pressure control on water cooled units 30 5 16 Active setpoint selection 30 5 17 High pressure load shedding function 31 5 18 Pumping down 31 5 19 Master slave assembly 31 5 20 Controlling Pro Dialog Plus units with a Sys...

Page 4: ...mission may be permitted access to electrical components It is parti cularly recommended that all sources of electricity to the unit be shut off before any work is begun Shut off the main power supply at the main circuit breaker or isolator IMPORTANT Risk of electrocution Even when the main power isolator or circuit breaker is off it is still possible for certain compo nents such as crankcase heat...

Page 5: ... is controlled by commands from the Carrier Comfort Network CCN In this case a data communication cable is used to connect the unit to the CCN communication bus The operating mode must be chosen with the Operating Type selection button described in section 4 2 1 When the PRO DIALOG Plus system operates autonomously Local or Remote mode it retains all of its own control capa bilities but does not o...

Page 6: ...d This board can be used to control fan stages PD4 EXV board This board can control two EXV valves and two suction temperature sensors 4xAI 2xAO board This optional board can be used to read sensors oil pressure or to control variable speed fans air cooled units or the condenser valve water cooled units NRCP BASE board This optional board is used to control the inputs and outputs of the heat recla...

Page 7: ...2xAO board which can deliver a 0 10 V d c or 4 20 mA signal depending on the configuration 3 2 3 The user interface The user interface is in two parts The main interface This gives access to all of the control parameters for the unit It consists of a 2 digit primary display block and a secondary 4 digit display block with 10 LEDs and 5 buttons The summary interface This gives quick access to just ...

Page 8: ...h 3 3 6 Thermistors These all have similar characteristics Evaporator entering water temperature sensor The evaporator entering water temperature sensor is installed in the evaporator wall in the free space at the side of the tube bundle Evaporator leaving water temperature sensor The evaporator leaving water temperature sensor is installed in evaporator leaving water piping The sensor bulb is dir...

Page 9: ...e supplied by a user command or a 0 10 V temperature sensor A RS 485 bus is used for connection to the CCN The CCN connector is located on the CCN clock board inserted on the PD4 Basic Board Pin 1 signal Pin 2 ground Pin 3 signal REMARKS Volt free contacts 24 V a c 48 V d c max 20 V a c or V d c 3 A max 80 mA min external power supply Connector 6 pin WAGO 231 306 026000 pitch 5 08 24 V a c 20 mA C...

Page 10: ...ed INPUTS menu Displays the status of the unit digital and analogue inputs OUTPUTS TESTS menu Displays the status of the unit outputs and enables them to be tested CONFIGURATIONS menu Displays the unit configuration and enables it to be modified ALARMS menu Displays active alarms ALARMS HISTORY menu Displays the history of the alarms OPERATING LOG menu Displays the operating times and number of st...

Page 11: ...LAY DESCRIPTION LOFF Local Off The unit is halted in local mode L On Local On The unit is in local control mode and is authorised to start L Sc Local On timer control The unit is in local control mode It is authorised to start if the period is occupied If the timer program for unit operation is unoccupied the unit remains shut down until the period next becomes occupied CCN CCN The unit is control...

Page 12: ... Once the required value is obtained press the Enter button again to validate the change or to access the sub menu The LED for the menu to which the item belongs then stops flashing indicating that modification mode no longer applies In modification mode the value to be modified increases or decreases in steps of 0 1 every time you press the Arrow buttons Holding one of these buttons down increase...

Page 13: ...ERVICE 1 SErviCE 1 SERVICE 2 SErviCE 2 SERVICE 3 SErviCE 3 MASTER SLAVE MAStEr SLAvE 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 HOLIDAYS 3 HoLidAy 3 HOLIDAYS 4 HoLidAy 4 HOLIDAYS 5 HoLidAy 5 HOLIDAYS 6 HoLidAy 7 HOLIDAYS 7 HoLidAy 7 HOLIDAYS 8 HoLidAy 8 HOLIDAYS 15 HoLidAy15 HOLIDAYS 16 HoLidAy16 H...

Page 14: ...Cooling setpoint 2 Heating setpoint Condensing setpoint Heat reclaim setpoint Demand limit setpoint in Cooling mode ramp Heating mode ramp Cooling threshold for zero reset Cooling threshold for max reset Cooling max reset value Heating threshold for zero reset Heating threshold for max reset Heating max reset value INPUTS Contact 1 remote on off Contact 2 remote setpoint Contact 3 remote heating c...

Page 15: ...e if forced through CCN Start up delay This item indicates the minutes left before the unit can be started This delay at start up is always active after the unit has been switched on The delay can be configured in the User Configuration 1 menu Heating cooling on selection This item is accessible in read write if the unit is in local control mode It is only displayed if the unit is in LOFF L On or ...

Page 16: ...Circuit A or circuit B operates in heat reclaim mode and not in standard cooling mode pumpdown phase is activated Mode active if risk of frost exists Two evaporator water pumps installed on the unit and pump reversal is active See section 5 3 The unit is shut down and is started every day at 14 00 hours for 2 seconds This function must be configured in the User1 menu See sections 5 3 and 4 5 7 3 U...

Page 17: ...ts you display and modify the heat reclaim setpoint As item 3 this is used for condensing setpoint control Capacity limit setpoint Limitation by volt free contact This item is used to define the maximum capacity that the unit is authorised to use if the capacity limit contact activate the limit See section 5 8 Cooling ramp loading rate This parameter is only accessible if the ramp function is vali...

Page 18: ...9 1 nn n Legend 1 This item is displayed in certain unit configurations only 2 Access to this menu is read only Active in all operating types See section 3 4 COMMENTS Remote contact 1 status This contact is used to start contact closed and stop contact open the chiller It is only valid if the unit is in the remote operating control rEM mode Remote contact 2 status This contact is used to select a ...

Page 19: ...the following display appears Fail displayed if the test has failed because the pump is not started Good displayed if the test succeeds Evaporator water pump No 2 command status Not displayed if unit does not control a pump On the pump operates Stop the pump has stopped Forc This item is only displayed if the unit is in local off mode LOFF Selecting this item permits energising the pump without de...

Page 20: ...ctivity i e no buttons pressed or after powering up SUB MENU USER CONFIGURATION SCHEDULE 1 ScHEduLE 1MEnu Return to previous menu SUB MENU Period 1 PErIod 1 SUB MENU Period 2 PErIod 2 SUB MENU Period 3 PErIod 3 SUB MENU Period 4 PErIod 4 SUB MENU Period 5 PErIod 5 SUB MENU Period 6 PErIod 6 SUB MENU Period 7 PErIod 7 SUB MENU Period 8 PErIod 8 DATE dAtE Return to previous menu Hour Day of the week...

Page 21: ...pied period 2 End of occupied period 3 Selection Monday 4 Selection Tuesday 5 Selection Wednesday 6 Selection Thursday 7 Selection Friday 8 Selection Saturday 9 Selection Sunday 10 Selection holidays USER USEr CONFIGURATION PERIOD 1 PERIOD 2 PERIOD 3 PERIOD 4 PERIOD 5 PERIOD 6 PERIOD 7 PERIOD 8 USER2 USEr 2 SCHEDULE 1 SCHEduLE 1 SCHEDULE 2 SCHEduLE 2 HOLIDAYS HOLIDAYS HOUR DATE dAtE BROADCAST broA...

Page 22: ...rs when the rotation delay is elapsed If the manual sequence is selected then the selected pump is used in priority Change over occurs if one pump fails 6 1 24 to 3000 hours 48 Pump changeover delay Displayed if auto pump sequence is selected This parameter is used for pump auto rotation the control tries to limit the pump run time difference to the pump changeover delay value Change over between ...

Page 23: ...ides two timer programs time schedule 1 and time schedule 2 The first timer program schedule 1 provides a means to automatically switch the unit from an occupied mode to an unoccupied mode the unit is started during occupied periods The second timer program schedule 2 provides a means to automatically switch when auto mode is selected the active setpoint from an occupied setpoint to an unoccupied ...

Page 24: ...1h00 Public holidays P7 period 7 Not used in this example P8 period 8 Not used in this example Occupied Unoccupied MON Monday TUE Tuesday WED Wednesday THU Thursday FRI Friday SAT Saturday SUN Sunday HOL Public holidays 4 5 7 7 Description of the Holidays sub menus This function is used to define 16 public holiday periods Each period is defined with the aid of three parameters the month starting d...

Page 25: ...adcaster will adjust its time for the start of daylight 1 to 1440 minutes saving time 9 nn Daylight saving stop month In this mode you enter the month in which the broadcaster will adjust its time for the end of 1 to 12 daylight saving time 10 nn Daylight saving stop day In this mode you enter the day on which the broadcaster will adjust its time for the end of daylight 1 to 31 saving time 11 n1 n...

Page 26: ...ressor B4 starts NOTES 1 This item is masked when not used Certain values are divided by 10 or by 100 so that number of hours or start ups of less then 10 are displayed as 0 When the value is divided by 10 or by 100 it is displayed in turn with M 10 or M100 4 5 10 2 Description of the Runtimes 2 menu RUNTIMES MENU 2 iTEM FORMAT UNIT COMMENTS 0 When selected this item authorises return to the previ...

Page 27: ...formation menu and by the heat cool LEDs on the summary interface ON OFF STATUS Off On On On On On On CONTROL TYPE Local Local Remote Remote CCN CCN HEATING COOLING SELECTION IN LOCAL MODE Cooling Heating REMOTE HEATING COOLING CONTACTS Cooling mode Heating mode HC_SEL Cooling Heating OPERATING MODE Cooling Cooling Heating Cooling Heating Cooling Heating PARAMETER STATUS ACTIVE OPERATING TYPE STAT...

Page 28: ...sor is activated 5 5 Control interlock contact This contact can control the status of the water loop Its function is to prevent unit start up if it is open and if the start up delay has passed Furthermore this contact must remain closed when the unit is not in local off remote or CCN control mode Opening this contact for more than 8 seconds while the unit is operating will cause immediate shut dow...

Page 29: ...and the difference between entering and leaving water temperatures in order to determine the optimum moment at which to add or withdraw a capacity stage NOTE If the same compressor undergoes too many starts per hour this automatically brings about reduction of compressor starts which makes leaving water temperature control less precise 5 10 Determining the lead circuit This function commands the s...

Page 30: ...eat with the fans When the second condensing setpoint is selected reclaim setting the control system will automatically revert to controlling by reference to a setpoint even if control by reference to the EXV has been selected The original configuration is reinitialised when the first condensing setpoint is re selected NOTE Certain units can have up to 8 fan stages of which one per circuit is a va...

Page 31: ...TING MODE PARAMETER STATUS All control commands to the master slave assembly start stop setpoint heating cooling operation load shedding etc are handled by the unit which is configured as the master and must therefore only be applied to the master unit They will be trans mitted automatically to the slave unit The master unit can be controlled locally remotely or by CCN commands Therefore to start ...

Page 32: ...m mand However any faults active when the supply is inter rupted are saved and may in certain cases prevent a circuit or a unit from restarting A manual reset must be run from the main interface using the following procedure RESET OF ACTIVE ALARMS OPERATION ITEM NUMBER ITEM VALUE PRESS MENU 2 DIGIT DISPLAY 4 DIGIT DISPLAY BUTTON LED Hold down the MENU button until the LED 0 for alarms lights The 4...

Page 33: ...communication with compressor board A1 Communication with the compressor Circuit A shut down No Auto Wiring fault faulty module board is lost incorrect module address 27 Loss of communication with compressor board A2 Ditto Compressor A2 shut down No Auto Ditto 28 Loss of communication with compressor board A3 Ditto Compressor A3 shut down No Auto Ditto 29 Loss of communication with compressor boar...

Page 34: ...e two units for more than 2 mins 68 Master slave configuration error Poor master slave configuration Master slave control not allowed Auto manual in Master slave configuration case of heating fault cooling fault 69 Initial factory configuration necessary All factory parameters are at zero Unit prevented from starting Auto No factory configuration 70 Poor factory configuration Poor factory configur...

Page 35: ...mpressor B2 shut down Ditto Hot gas thermostat contact open 602 Starter Guard fault compressor B 2 Compressor B2 shut down Ditto Crankcase heater fault and open motor current fault detection board contact 701 DGT fault compressor B3 Compressor B3 shut down Ditto Hot gas thermostat contact open 702 Starter Guard fault compressor B3 Compressor B3 shut down Ditto Crankcase heater fault and open motor...

Page 36: ...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 chlorine free paper ...