30 Series Screw Liquid Chiller Maintenance Data Log

Book 2
Tab 5c
PLANT _____________________ CHILLER MODEL NO. __________________________ CHILLER SERIAL NO. __________________________

Operator COOLER CONDENSER COMPRESSOR

Initials % Refrigerant Water Refrigerant Water Cooled Oil Motor
Capacity Air
Circuit Cooled Discharge
Per Sat. Pressure Temp. Sat. Pressure Temp. Oil
Date/ Suction Econ. EXV Discharge No. Gas Oil
Circuit Suct. Cond. Temp. Temp.

PC 903
Time Pressure Press. Pos Pressure Outside Pressure Pressure
Temp In Out In Out Temp In Out In Out Air Temp Diff.

A1

Copyright 2004 Carrier Corporation

A A2
B1
B B2
A1
A A2
B1

Catalog No. 533-00052

B B2
A1
A A2
B1
B B2
A1
A A2

Printed in U.S.A.
B1
B B2
APPENDIX J

A1
A A2
B1
B B2
A1

Form 30G,H-9T
A A2
B1
B B2
A1

Pg 130
A A2
B1
B B2

REMARKS: Indicate start counts, operating hours, shutdowns on safety controls, repairs made, oil or refrigerant added or removed (include amounts).

612 1-04
________________________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________________________________________________________

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
________________________________________________________________________________________________________________________________________________________________________

Replaces: New
----------------------------------------------------------------------------------------------------------------------------------------------------------------- START-UP CHECKLIST FOR 30GX,HX LIQUID CHILLER

I. Project Information

Job Name _______________________________________________________________________

Address ________________________________________________________________________

City ______________________________________________State __________ Zip __________

Installing Contractor _______________________________________________________________

Sales Office _____________________________________________________________________

CUT ALONG DOTTED LINE

Start-up Performed By _____________________________________________________________

Design Information

Capacity EWT LWT Fluid Type Flow Rate P.D. Ambient

Cooler
Condenser

Equipment

Model ____________________________________ Serial ________________________________

Compressors

A1) Model _________________________________ Serial ________________________________

A2) Model _________________________________ Serial ________________________________

B1) Model _________________________________ Serial ________________________________

CUT ALONG DOTTED LINE

B2) Model _________________________________ Serial ________________________________

Condenser (30HXA only)

Circuit A Circuit B

Model ____________________________________ Model _______________________________

Serial ____________________________________ Serial ________________________________

Model ____________________________________ Model _______________________________

Serial ____________________________________ Serial ________________________________

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 PC 903 Catalog No. 533-00052 Printed in U.S.A. Form 30G,H-9T Pg CL-1 612 1-04 Replaces: New
Tab 5c
II. Preliminary Equipment Check (to be completed by installing contractor)

Is there any physical damage?  Yes  No

Description _________________________________________________________________________

__________________________________________________________________________________

1. Unit is installed level as per the installation instructions.  Yes  No

2. Power supply agrees with the unit nameplate.  Yes  No
3. Correct control voltage ________vac.  Yes  No
4. Electrical power wiring is installed properly. (Branch circuit fused
or HACR breaker)  Yes  No
5. Unit is properly grounded.  Yes  No
6. Electrical circuit protection has been sized and installed properly.  Yes  No
7. All terminals are tight.  Yes  No
8. All plug assemblies are tight.  Yes  No
9. All cables and thermistors have been inspected for crossed wires.  Yes  No
10. All thermistors are fully inserted into wells.  Yes  No
11. Mechanical room maintained above 50 F (10 C) (30HX only).  Yes  No
12. Relief valve vent piping installed per local codes.  Yes  No
13. Wind baffles installed (30GX, 09DX).  Yes  No
NOTE: Required for unit operation where winds of 5 mph (2.2 m/s) or
greater are anticipated at outdoor ambient temperatures below 32 F (0° C).

Chilled Water System Check

1. All chilled water valves are open.  Yes  No
2. All piping is connected properly.  Yes  No
3. All air has been purged from the system.  Yes  No
4. Chilled water pump is operating with the correct rotation.  Yes  No
5. Chilled water pump starter interlocked with chiller.  Yes  No
6. Inlet piping to cooler includes a 20 mesh strainer.  Yes  No
7. Water loop volume greater than 3 gal/ton for air conditioning
or 6 gal/ton for process cooling and low ambient operation.  Yes  No
8. Proper loop freeze protection provided to ____ F (C).  Yes  No
Antifreeze type__________________ Concentration _________%.
(If antifreeze solution is not utilized on 30GX machines and the minimum
outdoor ambient is below 32 F (0° C) then items 9-12 have to be
completed to provide cooler freeze protection to 0° F. Refer to Installation
Instructions for proper cooler winterization procedure.)
9. Outdoor piping wrapped with electric heater tape.  Yes  No
10. Cooler heaters installed and operational (30GX Only).  Yes  No
11. Cooler heads and tube sheets are insulated.  Yes  No
12. Chilled water pump controlled by chiller.  Yes  No
(Chilled water pump will start automatically to circulate water through
cooler during potential freezing conditions.)

CL-2
----------------------------------------------------------------------------------------------------------------------------------------------------------------- Condenser Water System Check (30HXC Only)
1. All condenser water valves are open.  Yes  No
2. All piping is connected properly.  Yes  No
3. All air has been purged from the system.  Yes  No
4. Condenser water pump is operating with the correct rotation.  Yes  No
5. Condenser water pump controlled by chiller.  Yes  No
6. Inlet piping to condenser includes a 20 mesh strainer.  Yes  No
7. Condenser water flow switch installed. (Required for 30HXC Brine.)  Yes  No
8. Condenser water flow switch configured and operational.  Yes  No
9. Condenser water control valve installed.  Yes  No
CUT ALONG DOTTED LINE

(Separate control power required.)

Remote Condenser System Check (30HXA Only)

1. All refrigerant piping is connected properly.  Yes  No
2. Equalizer line is installed from motor cooling line to back-pressure valve.  Yes  No
3. Liquid line filter driers installed.  Yes  No
4. Liquid line solenoid valves installed.  Yes  No
5. R-134a fan cycling pressure switches installed (09DK).  Yes  No
6. Refrigerant piping and condenser have been leak checked and evacuated.  Yes  No

III. Unit Start-Up

1. All liquid line valves are open.  Yes  No
2. All discharge valves are open.  Yes  No
3. All suction service valves are open (if equipped).  Yes  No
4. All oil line valves are open.  Yes  No
CUT ALONG DOTTED LINE

5. Chilled water flow switch is operational.  Yes  No

6. Leak check unit. Locate, repair and report any refrigerant leaks.  Yes  No
7. Voltage is within unit nameplate range.  Yes  No
8. Check voltage imbalance: A-B________ A-C________B-C________
Average voltage = ____________ (A-B + A-C + B-C)/3
Maximum deviation from average voltage = _________
Voltage imbalance = ________% (max. deviation/average voltage) x 100
Voltage imbalance less than 2%.  Yes  No
(DO NOT start chiller if voltage imbalance is greater than 2%.
Contact local Utility for assistance.)
9. Verify cooler flow rate (maximum and minimum)  Yes  No
Pressure entering cooler _______ psig (kpa)
Pressure leaving cooler _______ psig (kpa)
Cooler pressure drop _______ psig (kpa)
Psig x 2.31 ft/psi = _______ ft of water
Kpa x 0.334 m/psi = _______ m of water
Maximum cooler flow rate _____ gpm (l/s) (See Cooler Pressure Drop Curve)
Minimum cooler flow rate _____ gpm (l/s) (See Cooler Pressure Drop Curve)

CL-3
III. Unit Start-Up (cont)
9. Verify condenser flow rate.  Yes  No
Pressure entering condenser _______ psig (kpa)
Pressure leaving condenser _______ psig (kpa)
Condenser pressure drop _______ psig (kpa)
Psig x 2.31 ft/psi = _______ ft of water
Kpa x 0.334 m/psi = _______ m of water
Condenser flow rate _______ gpm (l/s) (See Condenser Pressure Drop Curve)

Start and operate machine. Complete the following:

1. Complete component test.  Yes  No
2. Check refrigerant and oil charge. Record charge information.  Yes  No
3. Record compressor motor current.  Yes  No
4. Record two sets of operational log readings.  Yes  No
5. Provide operating instructions to owner’s personnel. Instruction time _______ hrs.

Refrigerant Charge Circuit A__________ Circuit B___________

Additional charge required __________ ___________

Oil Charge
Additional charge required __________ ___________

Comments:
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________

Signatures:

Start-up Technician__________________________ Customer Representative __________________________

Date____________ Date____________

CL-4
----------------------------------------------------------------------------------------------------------------------------------------------------------------- Record Software Versions
MODE — RUN STATUS
ITEM
SUB-MODE ITEM DISPLAY
EXPANSION
VERS MBB CESR131344-__ __-__ __
EXV CESR131172-__ __-__ __
EMM CESR131174-__ __-__ __
CP1 100233-1R3-__ __-__ __
CP2 100233-1R3-__ __-__ __
SCB CESR131226-__ __-__ __
NAVI CESR131227-__ __-__ __
(Press ENTER
and ESCAPE simultaneously to obtain software versions)
CUT ALONG DOTTED LINE

Record Configuration Information

MODE — CONFIGURATION
SUB-MODE ITEM DISPLAY ITEM EXPANSION ENTRY
DISP TEST ON/OFF TEST DISPLAY LED’S
METR ON/OFF METRIC DISPLAY
LANG x LANGUAGE SELECTION
PAS.E ENBL/DSBL PASSWORD ENABLE
PASS xxxx SERVICE PASSWORD
UNIT TYPE x UNIT TYPE
TONS xxx UNIT SIZE
CAP.A xxx% CIRCUIT A% CAPACITY
CMP.A x NUMBER CIRC A COMPRESSOR
CMP.B x NUMBER CIRC B COMPRESSOR
DIS.S xx.x DISCHARGE SUPER SETPOINT
FAN.S x FAN STAGING SELECT
CM.A1 xxx AMPS COMPR. A1 MUST TRIP AMPS
CM.A2 xxx AMPS COMPR. A2 MUST TRIP AMPS
CM.B1 xxx AMPS COMPR. B1 MUST TRIP AMPS
CM.B2 xxx AMPS COMPR. B2 MUST TRIP AMPS
CUT ALONG DOTTED LINE

OPT1 FLUD x COOLER FLUID

MLVS YES/NO MIN LOAD VALVE SELECT
HPCT x HEAD PRESSURE CONTROL TYPE
VHPT x VAR HEAD PRESSURE SELECT
PRTS YES/NO PRESSURE TRANSDUCERS
CPC ON/OFF COOLER PUMP CONTROL
CNP.I ON/OFF CONDENSER PUMP INTERLOCK
CNPC x CONDENSER PUMP CONTROL
CWT.S YES/NO CONDENSER FLUID SENSORS
EMM YES/NO EMM MODULE INSTALLED

CL-5
 Record Configuration Information (cont)
MODE — CONFIGURATION (cont)
SUB-MODE ITEM DISPLAY ITEM EXPANSION ENTRY
OPT2 CTRL x CONTROL METHOD
CCNA xxx CCN ADDRESS
CCNB xxx CCN BUS NUMBER
BAUD x CCN BAUD RATE
LOAD x LOADING SEQUENCE SELECT
LLCS x LEAD/LAG SEQUENCE SELECT
CP.SQ x COMPRESSOR SEQUENCE
LCWT xx.x HIGH LCW ALERT LIMIT
DELY xx MINUTES OFF TIME
CLS.C ENBL/DSBL CLOSE CONTROL SELECT
ICE.M ENBL/DSBL ICE MODE ENABLE
C.UNB xx% CURRENT UNBALANCE SETPOINT
NO.FL ENBL/DSBL NO REFRIGERANT FLOW ALRM ENABLE
W.MSG ENBL/DSBL WINTERIZE ALERT CONFIG
ALR.C x ALARM RELAY USAGE
RSET CRST x COOLING RESET TYPE
CRT1 xxx.x NO COOL RESET TEMP
CRT2 xxx.x FULL COOL RESET TEMP
DGRC xx.x DEGREES COOL RESET
HRST x HEATING RESET TYPE
HRT1 xxx.x NO HEAT RESET TEMP
HRT2 xxx.x FULL HEAT RESET TEMP
DGRH xx.x DEGREES HEAT RESET
DMDC x DEMAND LIMIT SELECT
DM20 xxx% DEMAND LIMIT AT 20 MA
SHNM xxx LOADSHED GROUP NUMBER
SHDL xxx% LOADSHED DEMAND DELTA
SHTM xxx MAXIMUM LOADSHED TIME
DLS1 xxx% DEMAND LIMIT SWITCH 1
DLS2 xxx% DEMAND LIMIT SWITCH 2
LLEN ENBL/DSBL LEAD/LAG CHILLER ENABLE
MSSL SLVE/MAST MASTER/SLAVE SELECT
SLVA xxx SLAVE ADDRESS
LLBL x LEAD/LAG BALANCE SELECT
LLBD xxx LEAD/LAG BALANCE DELTA
LLDY xxx LAG START DELAY
PARA YES/NO PARALLEL CONFIGURATION
SLCT CLSP x COOLING SETPOINT SELECT
HTSP x HEATING SETPOINT SELECT
RL.S ENBL/DSBL RAMP LOAD SELECT
CRMP x.x COOLING RAMP LOADING
HRMP x.x HEATING RAMP LOADING
HCSW COOL/HEAT HEAT COOL SELECT
Z.GN x.x DEADBAND MULTIPLIER
BRN.L YES/NO HXC BRINE CONFIG LOCK

CL-6
----------------------------------------------------------------------------------------------------------------------------------------------------------------- Record Configuration Information
MODE — CONFIGURATION (cont)
SUB-MODE ITEM DISPLAY ITEM EXPANSION ENTRY
SERV H.PGN xx.x HEAD PRESSURE P GAIN
H.IGN xx.x HEAD PRESSURE I GAIN
H.DGN xx.x HEAD PRESSURE D GAIN
H.MIN xxx.x WATER VALVE MINIMUM POS
MT.SP xxx.x MOTOR TEMP SETPOINT
BR.FZ xxx.x BRINE FREEZE POINT
MC.SP xxx.x MAX. COND. TEMP SETPOINT
EX.S.A xx.x EXVA START POSITION
EX.S.B xx.x EXVB START POSITION
EN.A1 ENBL/DSBL ENABLE COMPRESSOR A1
EN.A2 ENBL/DSBL ENABLE COMPRESSOR A2
CUT ALONG DOTTED LINE

EN.B1 ENBL/DSBL ENABLE COMPRESSOR B1

EN.B2 ENBL/DSBL ENABLE COMPRESSOR B2
W.DNE YES/NO WINTERIZATION PERFORMED
ECON YES/NO ECONOMIZED
EVPS x NUMBER OF EVAP. PASSES
LWTC A/B CIRCUIT WITH LWT SENSOR
AP.SP xxx.x APPROACH SETPOINT
BCST TD.B.C ON/OFF CCN TIME/DATE BROADCAST
OAT.B ON/OFF CCN OAT BROADCAST
GS.B.C ON/OFF GLOBAL SCHEDULE BROADCAST
BC.AK ON/OFF BROADCAST ACKNOWLEDGER

MODE — SETPOINT
SUB-MODE ITEM DISPLAY ITEM EXPANSION ENTRY
COOL CSP.1 xxx.x COOLING SETPOINT 1
CSP.2 xxx.x COOLING SETPOINT 2
CSP.3 xxx.x ICE SETPOINT
HEAT HSP.1 xxx.x HEATING SETPOINT 1
HSP.2 xxx.x HEATING SETPOINT 2
CUT ALONG DOTTED LINE

HEAD HD.P.A xxx.x HEAD PRESSURE SETPOINT A

HD.P.B xxx.x HEAD PRESSURE SETPOINT B

CL-7
 Component Test — Complete the following tests to make sure all peripheral components
are operational before the compressors are started.
MODE – SERVICE TEST
To Enable Service Test Mode, move Enable/Off/Remote Contact
Switch to OFF. Configure TEST to ON. Move Switch to ENABLE.
SUB-MODE ITEM DISPLAY ITEM EXPANSION ENTRY
TEST ON/OFF SERVICE TEST MODE COMPLETE
OUTS EXV.A xxx % EXV % OPEN
VH.PA xxx % VAR HEAD PRESS %
OL.P.A ON/OFF OIL PUMP
MC.A1 ON/OFF MOTOR COOLING SOLENOID A1
MC.A2 ON/OFF MOTOR COOLING SOLENOID A2
OS.A1 ON/OFF OIL SOLENOID A1
OS.A2 ON/OFF OIL SOLENOID A2
EXV.B xxx % EXV % OPEN
VH.PB xxx % VAR HEAD PRESS %
OL.P.B ON/OFF OIL PUMP
MC.B1 ON/OFF MOTOR COOLING SOLENOID B1
MC.B2 ON/OFF MOTOR COOLING SOLENOID B2
OS.B1 ON/OFF OIL SOLENOID B1
OS.B2 ON/OFF OIL SOLENOID B2
FAN1 ON/OFF FAN 1 RELAY
FAN2 ON/OFF FAN 2 RELAY
FAN3 ON/OFF FAN 3 RELAY
FAN4 ON/OFF FAN 4 RELAY
CLR.P ON/OFF COOLER PUMP RELAY
CLR.H ON/OFF COOLER HEATER
CND.P ON/OFF CONDENSER PUMP RELAY
RMT.A ON/OFF REMOTE ALARM RELAY
COMP CC.A1 ON/OFF COMPRESSOR A1 RELAY
CC.A2 ON/OFF COMPRESSOR A2 RELAY
LD.A1 ON/OFF LOADER A1 RELAY
LD.A2 ON/OFF LOADER A2 RELAY
MLV ON/OFF MINIMUM LOAD VALVE
OL.H.A ON/OFF OIL HEATER
CC.B1 ON/OFF COMPRESSOR B1 RELAY
CC.B2 ON/OFF COMPRESSOR B2 RELAY
LD.B1 ON/OFF LOADER B1 RELAY
LD.B2 ON/OFF LOADER B2 RELAY
OL.H.B ON/OFF OIL HEATER

CL-8
----------------------------------------------------------------------------------------------------------------------------------------------------------------- ALL UNITS:
Record the following information from the Pressures and Temperatures Modes when machine is in a stable operation
condition.

COOLER ENTERING FLUID ____________________

COOLER LEAVING FLUID ____________________
OUTSIDE AIR TEMPERATURE ____________________
SPACE TEMPERATURE ____________________
CONDENSER ENTERING FLUID ____________________
CONDENSER LEAVING FLUID ____________________
LEAD/LAG LEAVING FLUID ____________________

CIRCUIT A CIRCUIT B
SATURATED CONDENSING TEMP _____________________ ____________________
CUT ALONG DOTTED LINE

SATURATED SUCTION TEMP _____________________ ____________________

DISCHARGE SUPERHEAT TEMP (Comp 1/Comp 2) _____________________ ____________________
MOTOR TEMPERATURE (Comp 1/Comp 2) _____________________ ____________________
DISCHARGE PRESSURE _____________________ ____________________
SUCTION PRESSURE _____________________ ____________________
ECONOMIZER PRESSURE _____________________ ____________________
OIL PRESSURE (Comp 1/Comp 2) _____________________ ____________________
OIL PRESSURE DIFF. (Comp 1/Comp 2) _____________________ ____________________
OIL FILTER DIFF. (Comp 1/Comp 2) _____________________ ____________________
CALCULATED OIL PRESS (Comp 1/Comp 2) _____________________ ____________________

Compressor Running Current — All readings taken at full load.

L1 L2 L3
Compressor A1 _____ _____ _____
Compressor A2 _____ _____ _____
Compressor B1 _____ _____ _____
Compressor B2 _____ _____ _____
CUT ALONG DOTTED LINE

Condenser Fan Motor Current

L1 L2 L3
Fan Motor 1 _____ _____ _____
Fan Motor 2 _____ _____ _____
Fan Motor 3 _____ _____ _____
Fan Motor 4 _____ _____ _____
Fan Motor 5 _____ _____ _____
Fan Motor 6 _____ _____ _____
Fan Motor 7 _____ _____ _____
Fan Motor 8 _____ _____ _____
Fan Motor 9 _____ _____ _____
Fan Motor 10 _____ _____ _____
Fan Motor 11 _____ _____ _____
Fan Motor 12 _____ _____ _____
Fan Motor 13 _____ _____ _____
Fan Motor 14 _____ _____ _____
Fan Motor 15 _____ _____ _____
Fan Motor 16 _____ _____ _____

CL-9