Carrier Pro-Dialog CONTROL 4 User manual

USER'S GUIDE
TITLE: PRO-DIALOG CONTROL 4 FOR AIR & WATER COOLED
CHILLERS SERIES 30 GX & HXC VERSION 2
REV: original
Property of CARRIER S.A. Montluel.
Not to be disclosed to persons outside the organization without Written authorization
SYNOPTIQUE CARRIER - AIR-COOLED BI CIRCUIT - ABC PARTNERS 08/06/98
DATE SPECIFICATION
N° COPY N°
ECG CARRIER S.A.
ECG-UG-00-001
06/12/00

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CarrierCarrier Service1COMPANYNAMECOPY #
Ba-Tung PHAM
ORIGINATOR
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: /98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

1 - INTRODUCTION ...................................4
1.1 - About This Manual .............................4
1.2 - Manual Structure and contents ..................4
2 - GENERAL DESCRIPTION ...........................4
2.1 - Generalities ...................................4
2.1 - Software Reference Number ....................7
2.3 - Abbreviations Used ............................7
3 - HARDWARE DESCRIPTION ........................8
3.1 - Produc Component ............................8
3.1.1 - Basic Board .............................10
3.1.2 - CCN/Clock Option Board .................10
3.1.3 - Screw Compressor Protection Module .....11
3.1.3.1 - Screw Compressor Module Layout 11
3.1.3.2 - Compressor Part Number/MTA Header
Configuration ....................12
3.1.4 - 4 xDO Board ............................12
3.1.4.1 - General ........................12
3.1.4..2 - Terminal J4 Description ........12
3.1.5 - AUX Boards .............................13
3.1.5.1 - General ........................13
3.1.6 - EXV Driver Board ........................14
3.1.7 - 4 x AI - 2 x AO Board ....................14
3.1.8 - Aquasnap Basic Board ..................16
3.2 - Pressure Sensors ..............................17
3.2.1 - High Pressure Side Sensors .............17
3.2.2 - Large Band Pressure Sensors ...........17
3.2.3 - Suction and economizer Pressure Sensors 18
3.3 - Thermistors ...................................18
3.3.1 - Discharge Gas temperature ..............18
3.3.2 - 5K Resistor : Resistance vs Temperature
Curve .................................19
4 - CONTROL DESCRIPTION ..........................20
4.1 - General ......................................20
4.2 - Configuration .................................20
4.2.1 - General ................................20
4.2.2 - Main Interface Configuration sub menu
structure ...............................20
4.2.3 - Factory Configuration ...................21
4.2.3.1 - Factory configuration from Service
Tool ............................21
4.2.3.2 - Factory configuration from Main
Interface ........................23
4.2.3.3 - Economizer TQ valve Feedback
Signal Wiring ....................24
4.2.4 - Service Configuration ...................25
4.2.4.1 - Service 1 configuration from Service
Tool ............................25
4.2.4.2 - Service 1 configuration from Main
Interface ........................27
4.2.4.3 - Service 2 configuration from Service
Tool ............................28
4.2.4.4 - Service 2 configuration from Main
Interface ........................29
4.2.4.5 - Service 3 configuration from Service
Tool ............................30
4.2.4.6 - Service 3 configuration from Main
Interface ........................31
4.2.4.7 - Service 4 configuration from Service
Tool ............................31
4.2.4.8 - Service 4 configuration from Main
Interface,runtimesubmenu ......31
4.2.5 - User Configuration ......................32
4.2.6 - Network Configuration ..................32
4.2.6.1 - General .......................32
4.2.6.2 - Configuring a Control as a
Broadcast Acknowledger ........32
4.2.6.3 - Setting Time and Date ..........32
4.2.6.4 - Alarm Configuration Table ......33
4.2.6.5 - Master/Slave Configuration .....35
4.3 - Cooler Interlock Contact ........................36
4.4 - Cooler heater control ...........................36
4.5 - Oil heater control ..........................36
4.6 - Motor cooling control without plate exchanger
economizer ....................................36
4.7 - Motor cooling control without sub cooling plate
exchanger economizer ..........................37
4.7.1 - Motor cooling with TQ feedback Signal Control 37
4.8 - Capacity Control ...............................38
4.8.1 - Logic Description .......................38
4.8.1.1 - Basic Logic ...................38
4.8.1.2 - Z Multiplier Calculation ........38
4.8.1.3 - Overrides ....................39
4.9 - Compressors & loaders loading sequence .......40
4.9.1 - General Description .....................40
4.9.2 - Compressor capacity determination ......41
4.9.3 - Staged Loading Increasing Capacity Logic 41
4.9.4 - Equal Loading Increasing Capacity Logic
with close control = NO .................41
4.9.5 - Equal Loading Increasing Capacity Logic
with close control = YES ................42
4.9.6 - Equal Loading Decreasing Capacity Logic
with close control = YES ................42
4.9.7 - Equal Loading Decreasing Capacity Logic
with close control = NO .................43
4.9.8 - Staged Loading Decreasing Capacity Logic
with close control = NO .................43
4.9.9 - Staged Loading Decreasing Capacity Logic
with close control = YES ................44
4.10 - EXV Control ..................................45
4.10.1 - General ...............................45
4.10.2 - Overrides .............................45
4.11 - Air Cooled Condensing Pressure Control .......46
4.12.1 - Air Cooled Condensing Pressure Control -
Fan staging with AUX board .................46
4.12.2 - Air Cooled Condensing Pressure Control -
Fan staging ................................46
4.13 - Water Cooled Condensing Pressure Control ....47
4.14 - High Pressure Override .......................48
4.15 - High Current Override .........................48
CONTENTS
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page:2 /98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

4.16 - Stopping Function ............................48
4.16.1 - Stopping a compressor by capacity
unloading .............................48
4.16.2 - Stopping the unit by manual command
(OFF) .................................48
4.16.3 - Stopping a circuit by failure .............48
4.17 - Oil pressure control ...........................49
4.17.1 - Oil pressure setpoint determination .....49
4.17.2 - Oil pump control .......................49
4.17.3 - Low oil pressure alarm determination ....49
4.17.4 - Differential Oil Pressure Setpoint 1
alarm condition summary ...............50
4.18 - Reclaim Operation ............................51
4.18.1 - General Description ...................51
4.18.2 - Reclaim to Air Cooled Changeover
Initiation ...............................51
4.18.3 - Air Cooled To Reclaim Changeover
Initiation ...............................52
4.18.4 - Reclaim Operation hr_status
Description ............................52
4.18.5 - Reclaim Operation Using Air Cooled
Exchanger ............................52
4.18.6 - Reclaim Condenser Water Valve Control 52
4.18.7 - Reclaim Condenser Heater Control .....52
4.19 - Two Units Master/Slave Control ................53
4.19.1 - General ...............................53
4.19.2 - Abnormal Conditions ..................55
5 - CCN ALARM MESSAGES ...........................57
6 - CCN COMPATIBILITY ..............................60
7 - PRO_DIALOG 4 DOWNLOADER ADDENDUM
INFORMATION ....................................60
Appendix A - CCN DIPSLAY, SETPOINT, MAINTENANCE,
CONFIGURATION TABLE SCREENS .......61
Appendix B - CCN Variables ............................76
Appendix C - Wiring Schemes ..........................83
Appendix D - JBUS memory with GX& HX
default configuration ........................96
Appendix E - SAM Screen ..............................97
Appendix F - CCN Network Example .....................98
CONTENTS
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page:3 /98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

1 - INTRODUCTION
1.1 - ABOUT THIS MANUAL
This manual is intended to be used as an additional guide for using and configuring the Pro-Dialog control for
the 30GX & HX chillers. The use of this document does not substitute the IOM.
This manual is intended for use by Service organizations inside the Carrier corporation. It is delivered on
the express condition that it is not to be disclosed, reproduced in whole or in part, or used for
manufacture by anyone other than Carrier Corporation.
1.2 - MANUAL STRUCTURE AND CONTENTS
This manual includes the following sections:
vIntroduction
vProduct general description
vHardware description
vControl description
vAppendixes
The introduction and product general description sections contain information about this manual as an overview
of the 30GX&HX Pro-Dialog Plus controls.
The hardware section provides complete information on boards, devices and connections used by the product.
The control description section is divided in several subsections. First provides a main description of hardware
configuration. This subsection provides sufficient information to runs the control in the most operating cases. For
more complete information, use the remaining sections and also IOM. Second subsection describes all the unit
configuration and the methods to modify it. The last subsections describe the unit control logic’s.
2 - GENERAL DESCRIPTION
2.1 - GENERALITIES
PRO-DIALOG is a system for controlling units which use screw compressors:
wDual circuits
wAir cooled and water cooled chillers
wNon reversible heat machines
PRO-DIALOG controls compressors and loaders needed to maintain the desired leaving or entering water
control point. It automatically sets the position of the electronic expansion valve to maintain a correct refrigerant
flow in the cooler. For air cooled units it controls the operation of the fans to maintain the correct condensing
pressure in each circuit.
Safety circuits in the unit are constantly monitored by PRO-DIALOG to ensure its safe operation. PRO-DIALOG
also gives access to a Quick Test program covering all inputs and outputs excepted compressors outputs.
The control features of the 30GX&HX Pro-Dialog Plus are divided into standard features and options
(additional board needed):
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 4/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

Standard features:
wLocal control
wRemote control (external contacts)
wCCN control
wCompressor & loader sequence control (up to 4 compressors - two loaders per compressor)
wCooler leaving or entering fluid temperature control
wRamp loading
wDelay at startup
wCircuit & Compressors loading sequence optimization
wHeat machine condenser entering or leaving fluid control
wHead pressure control
wCooling dual setpoints control
wTemperature reset
wOutdoor temperature monitoring
wDemand limit control
wHigh pressure and high current override
wCooler and Condenser pump control
wOil temperature control
wMotor temperature control
wSafety lock control
wQuick test function
wDiagnostics function
wLocal Interface Display with Metric units
wDigital pressure gauges through the main interface
wDisplay of all I/O and other data
wCCN Network compatibility
wOccupancy and dual setpoint schedules
wSAM (LID 1B) compatibility
wAlarm POC
wSystem Manager compatibility
wIntegrated two chillers master/slave control
Available options With optional board:
wVarifan control
wCondenser water valve control
wReclaim sensors
wCooler heater control
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 5/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

xxCondenser Varifan or Water Valve
0-10 Vdc
10-0 Vdc
4-20 mA
20-4 mA
No confi
g
uration re
q
uiredOil Transducers On all com
p
ressors
xxReclaim Condenser Water Valve
xxHeat Reclaim Sensors
xxCondenser Sensors
xDela
y
at startu
p
xCooling and heating Capacity Adjustment
(
z multi
p
lier
)
xRam
p
Loadin
g
(
Heat & Cool
)
No confi
g
uration re
q
uiredSet
p
oint Control
(
sin
g
le or dual
)
xReset T
yp
e Select
(
Heat & Cool
)
xDemand Limit T
yp
e Select
xLoading Sequence
Equal
Sta
g
ed
XCondenser Pum
p
Control Select
XEnterin
g
Fluid Control
xCooler
p
um
p
#1 and # 2 control se
q
uence
xx**Water
p
um
p
p
eriodical
q
uick start se
q
uence
xx**Time and OAT broadcast ca
p
abilit
y
xx**Ni
g
ht ca
p
acit
y
limitation mode
xx**Ni
g
ht head
p
ressure control mode
xx**Unit on/off schedule control
xCom
p
ressor Number
(
1 to 4
)
& Ca
p
acit
y
xEconomizer Motor cooling TQ valve feedback
si
g
nal
xxxCooler Heater Select
xxFans
2 Separate Circuits with 1 to 8 fans per circuit
x
EXV
1500 steps = Mueller, unipolar, 33 steps/s
No confi
g
uration re
q
uiredLoader
(
2
p
er com
p
ressor
)
xCom
p
ressor Number
(
1 to 4
)
& Ca
p
acit
y
xLar
g
e Band Oil Transducer Select
xEconomizer Select
xCooler Fluid Type
Water
Medium Brine
Low Tem
p
erature Brine
xx
xHeat Reclaim Option
No confi
g
uration re
q
uiredRefri
g
erant R134
xChiller Type
Air Cooled
Water Cooled
Heat Machine
USER
CONFIG
SERVICE
CONFIG
FACTORY
CONFIG
HARDWARE
OPTION
FUNCTIONS
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 6/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

xTwo units Master/Slave Control
xFSM & CSM II Control
xClose Control Select
xMaximum Current Override
xMaximum Condensin
g
Tem
p
erature Override
USER
CONFIG
SERVICE
CONFIG
FACTORY
CONFIG
HARDWARE
OPTION
FUNCTIONS
** : require a CCN/Clock board
All Pro-Dialog controls can work either autonomously or they can be interfaced with the Carrier Comfort Network
(CCN). In the later case a communication data cable is used to connect the unit to the CCN communication bus.
When Pro-Dialog system operates autonomously it retains all of its own control capabilities but does not offer
the functionality of the CCN network.
2.2 - SOFTWARE REFERENCE NUMBER
This software is referenced under the 15 digits software reference number:
CSA-SR-208410XX
The two last digits (XX) provides the software version (e.g. 2.0).
15 digits reference number can be displayed in the CCN configuration Ctrl_ID table through the Building
Supervisor, the Network Service Tool or the 30GX&HX Downloader.
Unit Main Interface Configuration Menu allows to display the software version: item #13, user 1 menu.
2.2 - Abbreviations Used
In this manual, the refrigeration circuits are called circuit A and circuit B. The compressors in circuit A are
labeled A1, and A2. Those in circuit B are B1 and B2.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 7/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

3 - HARDWARE DESCRIPTION
3.1 - PRODUCT COMPONENT
This control shall employ the following electronic modules:
Basic Board 32 GB 500 182 EE
NRCP Board 32 GB 500 052 EE
CCN and RTC Board 32 GB 500 062 EE
4 x DO Board (087) OP 12AS 004 EE
4xAI - 2xAO Board OP 12AS 005 EE
8 x DO Board (Auxiliary 2) 32 GB 500 312 EE
8xDO - 4xAI - 2xAO Board (Auxiliary 1) 32 GB 500 322 EE
EXV Board 32 GB 500 192 EE
Screw Compressor Protection Module 32 GB 500 232 EE
Local Interface Device 30GX dual circuits 32 GB 500 092 EE
Local Interface Device 30HX dual circuits 32 GB 500 112 EE
Local Interface Device 30GX single circuit 32 GB 500 082 EE
Local Interface Device 30HX single circuit 32 GB 500 102 EE
This control shall employ the following sensors modules:
Thermistors HH79NZ047C (small size)
HH79NZ059C (large size)
Low Pressure Transducer OP12DA040 EE
High Pressure Transducer OP12DA039 EE
Large Band Oil transducer OP12DA057 (for unit operating in low ambient)
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 8/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION

COMPONENT USAGE
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
AUX 1 BOARD
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
4 x AI-2xAO BOARD
2
[
2
]
2
[
2
]
2
[
2
]
1PD4 - EXV BOARD
4321PD4 - SCPM BOARD
1111PD4 - BASIC BOARD
4321
NUMBER OF COMPRESSORS
COMPONENTS
UNIT TYPE : WATER COOLED
2
[
1
]
2
[
1
]
2
[
1
]
1
[
1
]
AUX 1 BOARD
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
4 x AI-2xAO BOARD
1
[
4
]
1
[
4
]
1
[
4
]
1
[
4
]
NRCP BASIC BOARD
1
[
3
]
1
[
3
]
1
[
3
]
1
[
3
]
AUX 2 BOARD
(
8xDO
)
1
[
3
]
1
[
3
]
1
[
3
]
2
[
3
]
4x DO BOARD
2
[
2
]
2
[
2
]
2
[
2
]
1PD4 - EXV BOARD
4321PD4 - SCPM BOARD
1111PD4 - BASIC BOARD
4321
NUMBER OF COMPRESSORS
COMPONENTS
UNIT TYPE : AIR COOLED - 2 FAN STAGES PER CIRCUIT MAX
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
AUX 1 BOARD
1
[
1
]
1
[
1
]
1
[
1
]
1
[
1
]
4 x AI-2xAO BOARD
1
[
4
]
1
[
4
]
1
[
4
]
0NRCP BASIC BOARD
1
[
3
]
1
[
3
]
1
[
3
]
1
[
3
]
AUX 2 BOARD
(
8xDO
)
2
[
3
]
2
[
3
]
2
[
3
]
2
[
3
]
4x DO BOARD
2
[
2
]
2
[
2
]
2
[
2
]
1PD4 - EXV BOARD
4321PD4 - SCPM BOARD
1111PD4 - BASIC BOARD
4321
NUMBER OF COMPRESSORS
COMPONENTS
UNIT TYPE : AIR COOLED - MORE THAN 2 FAN STAGES (if no AUX board) or MORE
THAN 4 FAN STAGES
(
AUX BOARD
)
PER CIRCUIT
1 - additional 4 x AI - 2 x AO board or 8xD0-4xAI-2xAO board required for varifan or reclaim sensors or
water valve option
2 - Second EXV board is required for motor cooling using EXV valve on economizer units
3- 4xDO board or 8xDO board is required to control fans. 4xDO is also used to control hot gas bypass
valve on units with single compressor.
4-additional NRCP board is required for reclaim option or cooler heater option.
CARRIER SA
USER'S GUIDE FOR
30GX&HX PRO_DIALOG 4 V.2 ECG-UG-02-002
Rev: original Page: 9/98
© CARRIER S.A
NOT TO BE DISCLOSED TO PERSONS OUTSIDE CARRIER ORGANIZATION