30skb iom
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Chiller catalogTRANSCRIPT
Installation, Start-Up 30SKBand Service Instructions 180-600
50Hz
30SKB180-600 Water Cooled Screw Chillers
30SKB 180
30SKB 200
30SKB 250
30SKB 300
30SKB 355
30SKB 400
30SKB 500
30SKB 600
- 1 -
INTRODUCTION
Prior to initial start-up of the 30SKB unit, those involved in the
start up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data. This
manual provides an overview for the familiarization with the
control system before performing start-up procedures.
Procedures in this manual are arranged in the sequence required
for proper machine start-up and operation.
SAFETY CONSIDERATIONS
30SKA liquid chillers are designed to provide safe and reliable
service when operated within design specifications. When
operating this equipment, use good judgment and safety
precautions to avoid damage to equipment and property or injury
to personnel.
Follow the procedures and safety precautions contained in the
machine instructions as well as those listed in this guide.
DANGER
DO NOT VENT refrigerant relief valves within a building. Outlet
from relief valve must be vented outdoors. The accumulation of
refrigerant in an enclosed space can displace oxygen and cause
asphyxiation.
PROVIDE adequate ventilation, especially for enclosed and low
overhead spaces. Inhalation of high concentrations of vapor is
harmful and may cause heart irregularities, unconsciousness, or
death. Misuse can be fatal. Vapor is heavier than air and reduces
the amount of oxygen available for breathing. Product causes eye
and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
machine for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
NEVER EXCEED specified test pressures, VERIFY the allowable
test pressure by checking the instruction literature and the design
pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed
before operating any machine.
WARNING
DO NOT WELD OR FLAMECUT any refrigerant line or vessel
until all refrigerant (liquid and vapor) has been removed from
chiller. Traces of vapor should be displaced with dry air nitrogen
and the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
DO NOT work on high-voltage equipment. Only qualified
electricians can do so.
DO NOT WORK ON electrical components, including control
panels, switches, relays etc., unless ALL POWER IS OFF and
there is no residual voltage in capacitors or solid state
components.
LOCK OPEN AND TAG electrical circuits during servicing. USE
SAFETY GOGGLES. Wash off any spills from the skin with soap
and water. If liquid refrigerant enters eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to refrigerant
cylinder. Dangerous over pressure can result. If it is necessary to
heat refrigerant, use only warm water.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the unit. The introduction of the wrong refrigerant can cause
damage or malfunction to this machine.
DO NOT ATTEMPT TO REMOVE fittings, components, etc.,
while machine is under pressure or while machine is running.
Be sure pressure is at 0 kPa before breaking refrigerant
connection.
CAREFULLY INSPECT all relief devices, AT LEAST ONCE A
YEAR. If machine operates in a corrosive atmosphere, inspect
the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. Replace
the device.
DO NOT install relief devices in series or backwards.
CAUTION
DO NOT STEP on refrigerant lines. Broken lines can whip about
and release refrigerant, causing personal injury.
DO NOT climb over the unit. Use platform, or staging.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
move heavy components. Even if components are light, use
mechanical equipment when there is a risk of slipping or losing
your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE TOWER FAN, OR PUMPS. Open the disconnect
ahead of the tower fans, or pumps.
USE only repair or replacement parts that meet the code
requirements of the original equipment.
DO NOT VENT OR DRAIN water boxes containing industrial
brines without the permission of your process control group.
DO NOT LOOSEN water box bolts until the water box has been
completely drained.
DO NOT LOOSEN a packing gland nut before checking that the
nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for
corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate water.
- 2 -
DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION
30SKB180,200
30SKB250,300
- 3 -
30SKB355
30SKB400
- 4 -
30SKB500,600
Fig.1-Dimensions
UNITTotal operating
weight Center of gravity Weight distribution at the six mounting holes(kg) X Y Z A B C D E F
30SKB180 1,900 833 450 902 257 257 218 218 476 47630SKB200 1,950 833 452 905 263 263 223 223 486 48630SKB250 2,220 1,018 453 879 338 338 216 216 554 55430SKB300 2,260 1,017 453 879 345 345 220 220 565 56530SKB355 2,900 1,468 459 916 386 386 338 338 724 72430SKB400 2,980 1,468 461 919 397 397 348 348 746 74630SKB500 3,420 2,014 462 886 449 449 407 407 856 85630SKB600 3,530 2,014 462 885 463 463 420 420 883 883
Fig.2Weight Distribution
- 5 -
●CLEARANCES
Fig.3-Clearances
Legend:
Service clearances required
It is recommended to secure a minimum 700mm clearance above the chiller
top to allow service mechanics to access to compressors.
UNIT 30SKB180 30SKB200 30SKB250 30SKB300
"A" 1,740 1,740 2,286 2,286
UNIT 30SKB355 30SKB400 30SKB500 30SKB600
"A" 3,035 3,035 4,128 4,128
- 6 -
RIGGING INSTRUCTIONS
RiggingLifting holes are provided on base or the cooler tube
sheet. Do not uncrate the unit until it is in final
location to protect unit from damage. Never tilt the
unit more than 15 ゚ during transportation (see
Fig.4).
Vibration IsolationPlace vibration isolator pads of 10-20mm thickness
under the unit and hold it secure with anchor bolts.
See Fig.5 for positions of vibration isolators and
anchor bolts.
30SKB180-300
30SKB355-600
Fig.4-Rigging
UNIT "A" "B" "C" "D"30SKB180 1,840 820 850 1,04030SKB200 1,840 820 850 1,04030SKB250 2,386 1,093 850 1,04030SKB300 2,386 1,093 850 1,04030SKB355 3,135 1,468 846 1,01430SKB400 3,135 1,468 846 1,01430SKB500 4,228 2,014 846 1,01430SKB600 4,228 2,014 846 1,014
Fig.5- Vibration Isolation
- 7 -
Table 1 - Physical data
WATER PIPING
The cooler and condenser are of the multi-tube shell
and tube type with removable water boxes to
facilitate cleaning of the tubes.
Determine water piping size in the piping system
design. To install water piping systems, pay
attention to the following.
1) Never use a water inlet for a water outlet or vice
versa.
2) Install thermometers on the water piping inlet and
outlet.
3) Install manual or automatic air vent valve at high
location in the water piping.
4) Connect circulation pump at the inlet (return
water line).
5) Be sure to install strainer in the piping to the inlet
to prevent foreign matter from entering cooler.
6) Install expansion tank at a higher location than
the unit level.
7) Connect air vent and drain lines with valve for the
cooler.(The size for these connections are
1/4F.P.T.)
8) Use flexible connections to reduce vibration
transmission.
9) Cover all piping with proper thickness of
insulation. Where the ambient temperature falls
down to freezing point, wrap field piping with pipe
heater cables.
Condenser Water Piping - Run water supply lines as
short as possible. Size lines according to head
pressure available(not necessarily connection size),
especially on cooling tower applications. For once
thru system using natural water or city water, a
water regulating valve is required for each circuit.
Water bypass valves must be installed on cooling
tower applications where low outdoor ambient affect
head pressure. Water regulating valve is also useful
to maintain proper head pressure.
Use flexible connections to reduce vibration
transmission.
Provide means for draining the system in winter and
for servicing the unit.
MODEL 30SKB 180 200 250 300 355 400 500 600REFRIGERANT
No. of Circuits 1 1 1 1 2 2 2 2R-134a Charge (kg) 45 39 64 57 45x2 39x2 64x2 57+65
COMPRESSORS50Hz 06NW (Qty) *174(1) *209(1) *250(1) *300(1) *174(2) *209(2) *250(2) *300(2)Type of StartOil Charge/Compr. (L) 21 21 21 21 21x2 21x2 21x2 21x2Capacity Control Steps 6 6 6 6 6 6 6 6% Capacity
COOLER No. of Refrigerant Circuit 1 1 1 1 2 2 2 2Water Volume (L) 60 70 80 90 110 130 150 170Max Working Press
Water Conn.(Inlet & Outlet)Drain (M.P.T.)
CONDENSERMax Working Press
Water Conn.(Inlet & Outlet)DI DIMENSIONS (mm)
Width 1,740 1,740 2,286 2,286 3,035 3,035 4,128 4,128Depth 900 900 900 900 900 900 900 900Height 1,900 1,900 1,900 1,900 1,822 1,822 1,822 1,822
R-134a
Screw, Semi-hermetic
100-83-70-54-45-23-0 100-85-73-50-35-23-0
Star Delta
Flooded shell and tube
Refrigerant Side......0.87MpaWater Side......1.0Mpa
4"Flange 5"Flange
Water Side......1.0Mpa4"Flange 5"Flange
1/2" 1/2"×2Shell and tube
Refrigerant Side......2.02Mpa
- 8 -
Table 2 - Electrical data
ELECTRICAL CHARACTERISTICS
●The 30SKB180-600 have only one power terminal
block.
Power Supply - The power supply must conform to
the specification on the chiller nameplate. The
supply voltage must be within the range specified in
the electrical data table.
Control Supply - Amperage required for control
circuit is as follows:
CONTROL VOLTAGE AMPS
230V-1Ph-50Hz 10A
Warning: Operation of the chiller with an improper
supply voltage or excessive phase imbalance
constitutes abuse which will invalidate the Carrier
warranty .If the phase imbalance exceeds 2% for
voltage, or 10% for current, contact your local
electricity supply at once and ensure that the chiller
is not switched on until corrective measures have
been taken.
Power Wiring - All power wiring must comply with
applicable local codes.
1) Install field supplied branch circuit disconnects
within sight from unit.
2) To determine power wire size, refer to electrical
data table.
3) When connecting power supply wire to unit ,open
control box cover and connect wire to power supply
terminals R, S, T in box.
Pass wires thru the opening on the top of control
box on unit.
Control Circuit Interlocks - A flow switch should
be installed in the water line in the event that water
flow should stop. Also, auxiliary contacts for the
water pump starter should be installed in the control
circuit as additional protection against unit operation
when the pump is not running.
Field Control Wiring
MODEL NO.POWERSUPPLY
VOLTAGES RANGE
MCA[A]
MFA[A]
RFA[A]
ICF[A]
MODEL × NO.RLA(ea)
[A]LRA(ea)
[A]MTA(ea)
[A]30SKB180 80 125 80 128 06NW*174×1 64 128 10530SKB200 95 150 90 155 06NW*209×1 76 155 12630SKB250 115 200 110 186 06NW*250×1 92 186 15130SKB300 400V-3Ph-50Hz 342-440 140 250 125 219 06NW*300×1 112 219 18430SKB355 144 200 125 192 06NW*174×2 64 128 10530SKB400 171 225 150 231 06NW*209×2 76 155 12630SKB500 207 275 200 278 06NW*250×2 92 186 15130SKB600 251 350 250 331 06NW*300×2 112 219 184
ICF - Maximum Instantaneous Current Flow during starting (the point in the stating sequence where the sum of the LRA for the starting compressor plus the total RLA for all running compressors is maximum).
LRA - Locked Rotor AmpsMCA - Minimum Circuit Amp (for wire sizing)MFA - Maximum Fuse AmpsMTA - Must Trip Amps (Circuit Breaker)RFA - Recommended Fuse AmpsRLA - Rated Load Amps (Compressors) * - Compressor revision number
- 9 -
OPERATION OF MICRO PROCESSOR
CONTROLLER
The Microprocessor controls water temperature,
chilled water safety thermostat, EXV, and other
functions. See Fig.6 for microprocessor controller
board - PIO (processing I/O) Board.
Fig.6 - PIO (Processing I/O) BOARD
Function of Switch
Start Button (Green Button)To start unit, push start button.
Stop/Reset Button (Red Button)To stop or reset unit when unit alarm detected,
push stop button.
CAUTION :Unit shall not restart in 30 seconds after stop
button is pushed to reset microprocessor.
To restart unit, push start button after 30 seconds
and confirm the Running Lamp lights on.
REMOTE-UNIT Transfer SwitchFor remote control operation, select “REMOTE”.
In remote control operation, unit can stop with
stop button on the unit while unit can not start
with start button on the unit.
Function of Lamp
Power Lamp (White Lamp)Power Lamp lights on as long as unit is
energized even if unit is in fault conditions or
not in operation.
Running Lamp (Green Lamp)Running Lamp lights on when unit is operating.
It lights on when all compressors stop by
capacity control or unit is not in operation due
to any failure.
Warning Lamp (Orange Lamp)Warning Lamp lights on when unit is in fault or
abnormal conditions. The Warning Lamp
where failure detected lights on. There is a
case that a circuit operates continuously when
Warning Lamp is lighting if a failure is not
serious to stop the circuit. Warning Lamp goes
off when reset button is pushed. Failures are
assigned to alarm code numbers shown on
LED of microprocessor.
Water Temperature Control
Constant Leaving Water TemperatureBy computing the leaving water temperature
differential between a set point and cut-in or cut
out temperature based on unit operating
condition, the microprocessor determines
optimum capacity control.
Capacity control steps is 6 steps (30SKB180 -
600). In the following cases, the capacity is
automatically stepped up without computing
the leaving water temperature differential.
1) In cooling operation, leaving water
temperature is above 2℃ higher than
setting point.
Factory pre-set leaving water temperature is
7℃ for cooling.
For field adjustment, refer to “Adjustment of
Setting Point for Operating Condition”.
NOTE :Set point can be changed within the upper and
lower limits. The range of the Leaving ChilledWater Temperature (LCWT) is 5 to 20℃
Safety Stop ControlUnit stops temporary when leaving water
temperature reaches below 3℃.
(Low water temp cutout 2℃ + 1℃)
Unit restart operation automatically without
manual reset and restart when leaving water
temperature is above setting point.
- 10 -
Compressor Start delay timer and Time GuardThe starting of each compressor is controlled by
Microprocessor. The compressors do not start
immediately after start button is pushed.
Microprocessor incorporates Time Guard function.
The Time Guard provides 3-minute delay in restart
of each compressor to prevent short cycling.
Compressor minimum operating timeOnce each compressor has started, it shall continue
to run for at least two minutes regardless thermostat
setting of water temperature unless a safety trips. It
helps return oil back to compressor.
Display Function1) LED display on the PIO board of the controller
shows following operating conditions. Numbers of capacity control step Fault conditions detected
2) The following status of unit can be shown by
LED display. Leaving water temperature set point
(SP-C) water temperature Discharge gas temperature(dGt), and
compressor motor temperature(Cct) of
each circuits. Alarm Resume. Unit running condition before activation of
any safety device. Discharge gas pressure (dGP), Suction
gas pressure (SGP), Oil pressure(OIP),
and Economizer pressure(SIP) of each
circuits. Saturated temperature of Discharge (Sdt)
and suction (SSt) of each circuit. Discharge superheat(SHD) of each
circuits compressor. Electronic Expansion Valve (EXV) and
valve lift (EPC,EPE) of each circuit.
3) Function of display selector switch (SW7), see
Table 3.
Table 3 - Function of display selector switch
(SW7)
SW7 Title Description
0 StAt Unit running mode
1 SEtSetting of leaving chilled water
temperature
2 tH-1
Display entering and leaving
water temperature and leaving
condenser water temperature
3 tH-2
Display discharge gas and
compressor motor temperature
of each circuits compressor
4 HISt Display Unit Alarm history
5 Cunt Compressor running counter
6 runt Compressor running hours
9 PrES
Display discharge pressure,
suction gas pressure, oil
pressure and economizer
pressure of each circuits
compressor
A CALCDisplay temperature calculated
by microprocessor
B StEPDisplay valve lift of electronic
expansion valve (EXV)
C CodE Low Pressure cutoff
D EStSDisplay latest unit running
condition before alarm detected
Safety and Control DevicesTable 4 shows setting value of safety and control
devices.
Table 4 - Safety and Control Devices
Cut-out Cut-in REMARKS
High-pressure
switch
1.42
MPa
1.13
MPa
Low-pressure
Cut-out0 MPa -
Discharge Gas
Thermostat104℃ -
Compressor Motor
temperature118℃ -
Low Water Temp,
Cut-out2℃ 5℃
Micro-
processor
Controller
manually
reset
Fusible Plug Melts at 72℃
- 11 -
START-UP AND ADJUSTMENT
Initial CheckDo not attempt to start the chiller until the following
checks have been completed.
1) Check that all components of water system and
electric wiring system are properly installed.
Auxiliary contacts for water pump starter must
be properly interlocked in the control circuit.
2) Open the discharge and liquid valves in each
circuit.
3) Open the oil shut off valves located by the oil
pre-filter.
4) Check clean water is in water piping system
and air vent is provided.
5) Check tightness of all electrical connections.
6) Check the incoming power supply for proper
phasing. This can be done by turning on both
the line voltage and control voltage power
supplies. If incoming power is not phased
correctly, shut down power supplies and switch
any two incoming power leads at the control
box terminal block.
ATTENTIONDO NOT make any changes to the factory installed
compressor power wiring in the control box or at the
compressor junction box. Doing so will cause
permanent damage to the compressor and will
require compressor replacement.
7) Check all field configuration data and setpoints.
8) Check incoming power supply for proper
nameplate voltage and for any voltage
imbalance as defined below.
9) Open condenser water valves. Check
condenser water pump for proper operation.
CHECKS AND ADJUSTMENT OF MICRO-
PROCESSOR CONTROLLER BEFORE
STARTING
Before initial start-up, check the input switch of the
controller for normal operation, and adjust the
setting point for operating condition by the following
directions. See Fig.7 for detail switch arrangement
of PIO board.
Fig.7 - Switch Arrangement of PIOA. Check the Input Switch1) Set the display selector switch (SW7) of the
PIO board inside the switch box at “0”. LED
display shows “StAt” and unit operating mode a
few seconds later. When a start button is not
pushed, LED display shows operating mode in
step 1 as shown in Table 5. When a start
button is pushed, LED display shows Step 2
Table 5 - Unit running mode
LED DisplayDescription
COOL Unit Running Mode (COOL)
StOP Unit is stopped by alarms.
C-□□ Unit Capacity Step (COOL)
ALt Oil filter alert
E□□□Any Safety Device is Opened.
Alarm code is displayed in □□□
POFF Pump Inter Lock Open
2) Set the display selector switch (SW7) of the
PIO board at “4”. LED display shows “HISt” and
the latest unit alarm code (1□□□) a few
seconds later. “1” means the latest alarm No.
and “□□□” shows alarm code. Alarm history
is recorded in microprocessor board. Push
setting change switch ▲(SW3) or ▼(SW4) of
PIO board inside the switch box. LED display
shows alarm history one by one. Up to 8
current alarm codes are stored. The oldest
alarm code is shown as “8□□□”. To clear
alarm history, push enter switch (SW5) until
LED display shows “- - - - “. Note that alarm
history can not be cleared during operation. For
checking specific items, see Table 6.
- 12 -
Table 6 - Alarm Code(30SKB180-600)
Code(LED1-3) Description
A000 No alarms
A002 Pump Interlock error
AC04 Internal Interface error
A005 Entering Water
A006 Leaving Water
Thermistor
Error
A010 Low Water Temp. Cutout
A011 Low Flow Rate Protector
A013 Water Piping or Sensor Error
AB14 High pressure switch
AB15 Low suction pressure
AB16 High discharge temperature
AB19 Compressor over load
AB20 Discharge gas
AB22 Comp. MotorThermistor error
AB25High Comp. Motor
winding temperature
AB30 Low oil level
AB31 High Oil filter pressure drop
AB32 Low oil pressure 1
AB33 Low oil pressure 2
AB40 Discharge
AB41 Suction
AB42 Oil
AB43 Economizer
Pressure
Transducer
Error
A = Alarm Resume No. (1-8):SW7="4" Only
A = E :SW7="0" Only
B = 0 : 30SKB180-300
B = Circuit No.(1,2) :30SKB355-600
C = EEV Adress(0) :30SKB180-300
B = EEV,EIO Adress(0-3) : 30SKB355-600
3) Set the display selector switch (SW7) of the
PIO board at “D”. LED display shows “EStS”
and the latest unit running conditions before
activation of any safety device. Running
conditions are recorded in micro-processor
board. Push setting change switch ▲(SW3) or
▼(SW4) of PIO board inside the switch box.
LED display shows running conditions before
activation of any safety device one by one. 9 or
15 latest running condition codes are stored.
Details of recorded running conditions, see
Table 7. To clear running conditions, push
enter switch (SW5) until LED display shows “- -
- -“. Note that running conditions can not be
cleared during operation.
Table 7 - Unit Running Conditions30SKB180-300
Code Description
Et Entering Water Temperature
Lt Leaving Water Temperature
StEP Capacity Steps
dGP□ Discharge Gas Pressure
SGP□ Suction Gas Pressure
OIP□ OIL Pressure
ECP□ Economizer Pressure
EPC□ EXV valve lift (main)
EPE□
No.1
Circuit
EXV valve lift
(for motor cooling)
30SKB355-600
Code Description
Et Entering Water Temperature
Lt Leaving Water Temperature
StEP Capacity Steps
dGP1 Discharge Gas Pressure
SGP1 Suction Gas Pressure
OIP1 OIL Pressure
ECP1 Economizer Pressure
EPC1 EXV valve lift (main)
EPE1
No.1
Circuit
EXV valve lift
(for motor cooling)
dGP2 Discharge Gas Pressure
SGP2 Suction Gas Pressure
OIP2 OIL Pressure
ECP2 Economizer Pressure
EPC2 EXV valve lift (main)
EPE2
No.2
Circuit
EXV valve lift
(for motor cooling)
B. Adjustment of Setting Point for Operating
Condition1) Setting of Leaving Chilled Water Temperature
(SP-C)
Set the display selector switch (SW7) of the
PIO board inside the switch box at “1”. LED
display shows “SEt”. A few seconds later, LED
display shows set-point of Leaving Chilled
Water Temperature code “SP-C” and the set
temperature (default is 7.0℃).
- 13 -
To change the setting point of leaving chilled
water temperature, push enter switch ●(SW5)
when LED display shows setting point. LED
display shows the setting point blinking. Push
the setting change switch ▲ (SW3) or ▼
(SW4) to select setting point. Push the enter
switch ●(SW5) to set the temperature and the
display shows setting point lighting.
(Setting range of “SP-C” is 5 to 20℃)
After checking the input switch and adjusting
the setting point of operating condition, set the
display selector switch (SW7) at “0”
Actual Start-upActual start-up should be done only under
supervision of a qualified refrigeration mechanic.
1) Set leaving fluid temperature. No cooling range
adjustment is necessary.
2) Start chilled fluid pump.
3) Switch LOCAL/REMOTE switch to LOCAL or
REMOTE.
4) Provided there is load on the chiller, allow the
machine to operate and conform that
everything is functioning properly. Verify that
the leaving fluid temperature agrees with the
cooling setpoint(1or2), or if reset is being used,
the modified setpoint.
Operating Sequence
The chiller is started by switching the
LOCAL/REMOTE switch to either LOCAL or
REMOTE. The oil pump will be turned on to start the
pre-lubrication process. After a short period of time,
the oil solenoid will be opened and the compressor
will start. For star delta start chillers, contactors C
and CS will be closed and the compressor will be
started in a Wye configuration. This method reduces
the rocked rotor current requirements by
approximately 60%, while maintaining enough
torque to bring the compressor up to full speed.
After 3 seconds, the PIO module will switch out
contactor CS and bring In contactor CD which will
run the motor in a Delta configuration.
Once the compressor is successfully running, the
control will load the compressor and add additional
stages of capacity as needed to satisfy the leaving
fluid setpoint. Head pressure can be controlled with
a field installed condenser water valve.
LED DISPLAY DURING OPERATION
AND REMEDY
During normal operation (the display selector
switch of PIO board is set at “0”), the capacity
steps are shown on LED display of PIO board.
When any failure occurs during operation, the
failure is indicated with code numbers on LED
display. When a trouble indicator lamp (OL) is
on, check the failure with alarm code numbers
on LED display and correct cause before
restarting.1) Refer to Table 6 for alarm code shown on LED
display.
2) For resetting alarms, push a unit stop button
when cause is corrected.
Temperature indication of ThermistorWhile unit is in operation or not in operation the
detected temperature by Thermistor can be
checked by LED display.
Entering and leaving and Leaving
condenser water Temperature. (See Table
8)1) Set the display selector switch (SW7) of the
PIO board inside the switch box at “2”. LED
display shows “tH-1”. A few seconds later, LED
display shows entering water temperature code
“Et“ and detected temperature.
2) Push the setting change switch ▲ (SW3)
under this state. LED shows leaving water
temperature code “Lt“ and detected
temperature.
3) Push the setting change switch ▲ (SW3)
under this state. LED shows leaving condenser
water temperature code “LHt“ and detected
temperature.
4) As explained, the detected temperature by
each Thermistor can be found by pushing the
setting change switch ▲(SW3) and ▼(SW4)
respectively.
5) After checking the temperature indication of
Thermistor, return the display selector switch
(SW7) to “0”.
- 14 -
Discharge gas and compressor motor
temperature of each circuit.1) Set the display selector switch (SW7) of the
PIO board inside the switch box at “3”. LED
display shows “tH-2”. A few seconds later,
LED display shows discharge gas temperature
code of No.1 circuit “dGt□ ” and detected
temperature.
2) Push the setting change switch ▲(SW3) under
this state. LED shows Compressor Motor
temperature code of No.1 circuit “Cct□ “ and
detected temperature.
3) As explained, the detected temperature of
other circuit (□□□2: No.2 circuit) can be
found by pushing the setting change switch ▲
(SW3) and ▼(SW4) repeatedly.
4) After checking the temperature indication of
Thermistor, return the display selector switch
(SW7) to “0”.
Table 8 - Thermistor Code
30SKB180-300
Code Description
Et Entering Water Temperature
Lt Leaving Water Temperature
LHtLeaving Condenser Water
Temperature
dGt□ No.1 CKT.Discharge Gas
Temperature
Cct□ No.1 CKT.Compressor Motor
Temperature
30SKB355-600
Code Description
Et Entering water Temperature
Lt Leaving water Temperature
LHtLeaving Condenser Water
Temperature
dGt1 No.1 CKT.
dGt2 No.2 CKT.
Discharge Gas
Temperature
Cct1 No.1 CKT.
Cct2 No.2 CKT
Compressor Motor
Temperature
Pressure indication of pressure transducerWhile unit is in operation or not in operation, the
detected pressure by pressure transducer can be
checked with LED display. (See Table 9)
Discharge gas pressure, Oil pressure
Economizer pressure of each Compressor,
and Suction gas pressure of each circuit.1) Set the display selector switch (SW7) of the
PIO board inside the switch box at “9”. LED
display shows “PrES”. A few seconds later,
LED display shows discharge gas pressure
code of No.1 circuit “dGP□ “ and detected
pressure.
2) Pushing the setting change switch ▲(SW3)
under this state, LED shows suction gas
pressure code of No.1 circuit “SGP□ ” and
detected pressure.
3) Pushing the setting change switch ▲(SW3)
under this state, LED shows oil pressure code
of No.1 circuit “OIP□” and detected pressure.
4) Pushing the setting change switch ▲(SW3)
under this state, LED shows economizer
pressure code of No.1 circuit “ECP□ ” and
detected pressure.
5) As explained, the detected pressure of other
circuit (□□□2: No.2 circuit) can be found by
pushing the setting change switch ▲ (SW3)
and ▼(SW4) repeatedly.
6) After checking the pressure indication of
pressure transducer, return the display selector
switch (SW7) to “0”.
Table 9 - Pressure Code
30SKB180-300
Code Description
dGP□ No.1 CKT. Discharge Gas Pressure
SGP□ No.1 CKT. Suction Gas Pressure
OIP□ No.1 CKT. Oil Pressure
ECP□ No.1 CKT. Economizer Pressure
30SKB355-600
Code Description
dGP1 No.1 CKT.
dGP2 No.2 CKT.Discharge Gas Pressure
SGP1 No.1 CKT.
SGP2 No.2 CKT.Suction Gas Pressure
OIP1 No.1 CKT.
OIP2 No.2 CKT.Oil Pressure
ECP1 No.1 CKT.
ECP2 No.2 CKTEconomizer Pressure
Temperature calculated by microprocessorWhile unit is in operation or not in operation, the
temperature calculated by microprocessor can be
checked with LED display. (See Table 10)
- 15 -
Discharge and suction saturated
temperature and discharge superheat of
each circuit.1) Set the display selector switch (SW7) of the
PIO board inside the switch box at “A”. LED
display shows “CALC”. A few seconds later,
LED display shows discharge saturated
temperature code of No.1 circuit “Sdt□“ and
calculated temperature.
2) Push the setting change switch ▲(SW3) under
this state. LED shows suction saturated
temperature code of No.1 circuit “SSt□” and
detected temperature.
3) Push the setting change switch ▲(SW3) under
this state. LED shows discharge superheat
code of No.1 circuit “SHd□ ” and detected
temperature.
4) As explained, the calculated temperature of
other circuit (□□□2: No.2 circuit) can be
found by pushing the setting change switch ▲
(SW3) and ▼(SW4) repeatedly.
5) After checking the calculated temperature from
microprocessor, return the display selector
switch (SW7) to “0”.
Table 10 - Calculated Temp. Code
30SKB180-300
Code Description
Sdt□ No.1 CKT.Saturated Discharge
Temperature
Sst□ No.1 CKT.Saturated Suction
Temperature
SHd□ No.1 CKT.Discharge
Super Heat
30SKB355-600
Code Description
Sdt1 No.1 CKT.
Sdt2 No.2 CKT.
Saturated Discharge
Temperature
Sst1 No.1 CKT.
Sst2 No.2 CKT.
Saturated Suction
Temperature
SHd1 No.1 CKT.
SHd2 No.2 CKT.
Discharge
Super Heat
Valve lift of electronic expansion valve(EXV)While unit is in operation or not in operation, the
valve lift of electric expansion valve (EXV) can be
checked with LED display. (See Table 11)
1) Set the display selector switch (SW7) of the
PIO board inside the switch box at “B”. LED
shows “StEP”. A few seconds later, LED
display shows valve lift of EXV code of No.1
circuit “EPC□“ and valve lift.
2) Push the setting change switch ▲(SW3) under
this state. LED shows valve lift of EXV code of
No.1 circuit “EPE□“ and valve lift.
3) As explained, the valve lift of EXV of other
circuit (□□□2: No.2 circuit)can be found by
pushing the setting change switch ▲ (SW3)
and ▼(SW4) repeatedly.
4) After checking the valve lift of EXV, return the
display selector switch (SW7) to “0”.
Table 11 - Valve Lift of EXV Code
30SKB180-300
Code Description
EPC□ No.1 CKT.
EXV Valve lift
(main)
1500Step 100% Open
EPE□ No.1 CKT.
EXV Valve lift
(For Motor Cooling)
240Step 100% Open
30SKB355-600
Code Description
EPC1 No.1 CKT.
EPC2 No.2 CKT.
EXV Valve lift
(main)
1500Step 100% Open
EPE1 No.1 CKT.
EPE2 No.2 CKT.
EXV Valve lift
(For Motor Cooling)
240Step 100% Open
To Shut Off Unit For Long PeriodComplete the following steps.
1) Push the unit stop button.
2) To prevent corrosion, drain heat exchanger,
and charge it with nitrogen gas to slightly
higher pressure than atmospheric pressure.
3) Turn unit power supply switch OFF.(main and
control)
To Start Unit After Prolonged ShutdownFollow the same steps as START-UP procedures.
- 16 -
To Stop Unit For Short PeriodFor shutting down unit daily or less than 7 days,
push the unit stop button. Do not turn unit control
power supply switch off.
To Start Unit After Short-period ShutdownPush a start button to start operation.
MAINTENANCE
Refrigerant Charging - Adding Charge
IMPORTANT30SKB is designed for use with R134a only. DO
NOT USE ANY OTHER refrigerant in these units.
CAUTIONWhen adding or removing charge, circulate water
through the condenser and cooler at all times to
prevent freezing. Freezing damage is considered
abuse and may void Carrier warranty.
CAUTIONDO NOT OVERCHARGE system. Overcharging
results in higher discharge pressure with higher
cooling fluid consumption, possible compressor
damage and higher power consumption.
Indication of low charge on a 30SKB system
NOTETo check for low refrigerant charge on a 30SKB,
several factors must be considered. A flushing
liquid-line sightglass is not necessarily an indication
of inadequate charge. There are many system
conditions where a flashing sightglass occurs under
normal operation. The 30SKB metering device is
designed to work properly under these conditions.
1. Make sure that the circuit is running at a full-
load condition. To check whether circuit No.1 is
fully loaded. If the circuit capacity step is 100%,
the circuit is full-load.
2. With the circuit running at full-load, verify that
the cooler leaving fluid temperature is in the
range of 5.0-7.0 ℃.
3. At this condition, observe the refrigerant in the
liquid line sightglass. If there is a clear
sightglass, and no signs of flashing, then the
circuit is adequately charged. Skip the
remaining steps.
4. If the refrigerant appears to be flashing, the
circuit is probably low on charge. Verify this by
checking the EXV Percent Open(See table 11).
5. If the EXV Percent Open is greater than 60%,
and the liquid line sightglass is flashing, then
the circuit is low on charge. Follow the
procedure for adding charge.
To add charge to the 30SKB systems
1. Make sure that the unit is running at full-load,
and that the cooler leaving fluid temperature is
in the range of 5.0-7.0℃.
2. At these operating conditions, check the liquid-
line sightglass. If there is a clear sightglass,
then the unit has sufficient charge. If the
sightglass is flashing, then check the EXV
Percent Open. If this is greater than 60%, then
begin adding charge.
NOTE
A flashing liquid-line sightglass at operating
conditions other than those mentioned above is
not necessarily an indication of low refrigerant
charge.
3. Add 2.5 kg of liquid charge into the cooler using
the charging port on the liquid line.
4. Observe the EXV Percent Open value. The
EXV should begin closing as charge is being
added. Allow the unit to stabilize. If the EXV
Percent Open remains above 60%, and the
sightglass continues flashing, add an additional
2.5 kg of liquid charge.
5. Allow the unit to stabilize, and again check the
EXV Percent Open. Continue adding 2.5 kg of
liquid refrigerant charge at a time, and allow the
unit to stabilize before checking the EXV
position.
6. When the EXV Percent Open is in the range of
40-60%, check the liquid line sightglass. Slowly
add enough additional liquid charge to ensure
a clear sightglass. This should be done slowly
to avoid overcharging the unit.
- 17 -
7. Verify adequate charge by continuing to run at
full-load with 5.0-7.0℃ cooler laving fluid
temperature. Check that the refrigerant is not
flashing in the liquid-line sightglass. The EXV
Percent Open should be between 40 and 60%.
Proper amount Shortage
Fig.8 - Moisture Indicator
Oil ChargingCAUTION
DO NOT add oil at any other location as
improper unit operation may result.
1. Make sure that the unit is not running when
adding oil, as this will make the oil charging
process easier. Because the system is under
pressure even when the unit is not running, it
will be necessary to use a suitable pump (hand
or electric pump) to add oil to the system.
2. Using a suitable pump, add 2 litters of
Polyolester oil to the system (CARRIER
SPEC:PP47-32). Make sure that the oil level
safety switch is NOT jumpered, and allow the
unit to restart and run normally after charging
oil.
3. If low oil level problems persist, add another 2
litters of oil. Continue adding oil in 2 litters
increments until the problem is resolved. If it is
necessary to add more than 6 litters of oil to the
system, then contact your local Carrier.
Maintenance of Water PipingMajor points of maintenance of water piping are to
provide water treatment for preventing scale or
corrosion and to protect piping and devices from
damage caused by freezing during cold weather.
1) Confirm that cooler and condenser are
provided with proper quantity of water.
Occasionally check on strainer in water piping.
Vent air occasionally.
2) When shutting down unit for long period, to
maintain cooler and condenser, refer to
Shutdown instructions.
Electronic Expansion Valve(EXV)High-pressure liquid refrigerant enters valve through
bottom. A series of calibrated slots have been
maintained inside of orifice assembly. As refrigerant
passes through orifice, pressure drops and
refrigerant changes to a 2-phase condition (liquid
and vapor). To control refrigerant flow for different
operating conditions, sleeves moves up and down
over orifice and modulates orifice size. Sleeve is
moved by a linear stepper motor. Stepper motor
moves in increments and is controlled directly by
EEV board. As stepper motor rotates, motion is
transferred into linear movement by lead screw.
Through stepper motor and lead screw, 1500
discrete steps of motion are obtained. The large
number of steps and long stroke results in very
accurate control of refrigerant flow.
Integral oil filter changeAn integral oil filter in the 06N screw compressor is
specified to provide a high level of filtration(3μ)
required for long bearing life. As system cleanliness
is critical to reliable system operation, there is also a
pre-filter (12μ) in the oil line just before entering the
integral compressor filter.
Filter Change-Out ScheduleThe filter should be checked after the first 1000
hours of operation, and every subsequent 4000
hours. The filter should be replaced at any time
when the PIO BOARD LED shows “Alt”(filter alert).
For replacement items use Carrier Specified Parts
Manufacturing reserves the right to discontinue, or charge at any time, specifications or designs without notice and without incurring obligations
TOYO CARRIER ENGINEERING COMPANY LIMITED
Tokyo, Japan
From 30SKB180-01ISE New Printed in Japan EIS0206