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Field Issues:
30 Series
Packaged Chillers
Woody Clark Syracuse, NY
NE Regional Service Managers Meeting 2008
General Topics
• 30RAN Aquasnap Field Issues
• 30RB Aquasnap Field Issues
• 30XA Aquaforce Field Issues
• 30GX/HX Field Issues
30RAN Aquasnap Field Issues
• Two-Speed Fan Motor w/MMV
• Low Ambient Operation
• Chilled Water Strainer
30RAN Two-Speed Fan Motor w/MMV
– High failure rate experienced when used with MMV.
– GE single speed 1140 rpm fan motor will replace Leroy-Somer dual speed 1140/570 rpm motor for use with MMV.
– SSN 4207Qnnnnn units ordered with the Motormaster FIOP will ship with the new motor.
– Will continue to use 5 hp MM-V with this motor.
New GE Fan Motor
Leroy-Somer
• 30RAN010,015,018,035 & 040 utilize two-speed condenser fan motor.
30RAN Two-Speed Fan Motor w/MMV
• Units can be converted in the field. – GE single speed 1140 rpm fan motor is available from RCD.
– New mounting brackets will be required. • Qty (4) - 30RA402081
– 5 hp MM-V is required with this motor.
• Refer to PMB08-007
• Field Installed Motormaster V Accessory Kits have recently been updated to include single speed motor.
– Previously single speed motor had to be purchased separately for field installation. This was not clear to Sales Engineers.
Manufacture 575/3/60 380/3/60 208-230/3/60 460/3/60
Original (Leroy-Somer) HD56AZ576 HD56AZ380 HD56AZ651 HD56AZ460
Replacement (GE) HD56AK578 HD56AK382 HD56AK656 HD56AK656
30RAN Low Ambient Operation
• Reports of multiple compressor failures during low ambient
operation.
– Replace Danfoss TXV’s with Sporlan TXV’s
– Install liquid line solenoid valve(s).
• Solenoid p/n EF23JM272, 7/8 x 7/8 ODF
• Coil p/n EF19ZE024, 24vac
• Auxillary contacts p/n 3RH19211EA11 one required for each
compressor
– CCH required.
• Standard on units produced SSN2304Fnnnnn
– Install new MLV accessory p/n 30RA-900---030.
• Standard on units produced SSN 3807Qnnnnn
– Configure MMV parameter P34 to 21.0 on sizes 022-055.
– Update software to Version 5.0
30RAN Low Ambient Operation
30RAN Low Ambient Operation
Liquid line solenoid valve wiring Partial Schematic
30RAN Chilled Water Strainer
• Complaints of current #20 mesh
strainer collapsing under high
pressure differential plugging BPHE.
– Current strainer p/n:
• KH14BW001 (2”)
• KH14BW010 (2 ½”)
• New strainer will be #40 Mesh with
1/8” Perforated Plate.
– New strainer p/n:
• KH14HZ102 (2”)
• KH14HZ104 (2 ½”)
• Will be implemented 4th qtr.
Current Strainer (#20 Mesh)
New Strainer (#40 Mesh)
30RB Aquasnap Field Issues
– Compressor Failures
– Medium Temperature Brine
– High Motor Temperature Alarms
– Filter Driers
– MCHX
– Software
30RB Compressor Failures
30RB Compressor Failures
• High Differential Pressure/Low Suction
– Currently number one failure mode
– Primary cause is compressor contactor welding
• Units produced starting 0107Qnnnnn added voltage monitor
relay and contactor to prevent contactor chattering.
− Reaction time of voltage monitor relay is 300 milliseconds.
This is too slow to prevent chattering.
• Units produced starting 0108Qnnnnn have updated scroll
protection modules (SPM).
− Monitors 24 vac control voltage to SPM through the HPS
input. Shuts off compressor during low voltage situations
eliminating the need for the timer (RRT) and contactor (RRC).
− If voltage drops below 16.5 vac for 80 ms compressor output
will turn off and alarm generated.
New Version of Scroll Protection Module
30RB Compressor Failures
30RB Compressor Failures
• Two additional SPM alarms have been added.
30RB Compressor Failures
• High Differential Pressure/Low Suction (cont’d)
– New SPM is backward compatible.
– Reverse rotation contactor (RRC) and reverse rotation timer
(RRT) were eliminated.
Timer &
Contactor
Phase
Monitor
30RB Compressor Failures
MBB To All Controls
Set Primary Voltage
30RB Compressor Failures
MBB
Set Primary Voltage
RRT & RRC Removed
30RB Compressor Failures
– Beginning 1308Qnnnnn 460v
units were produced with the
Siemens 3RT10441AC20
(65A) contactor which replaced
the original Siemens
3RT10351AC20 (40A)
contactor.
– No changes made to the
208/230v or 575v units
– Manually depressing IEC style
contactors will cause them to
weld.
Warning label added
SSN 4007Qnnnnn
•High Differential Pressure/Low Suction (cont’d)
30RB Compressor Failures
– Recently I have received reports of 208/230v units
welding contactors.
– Power monitor voltage setting may not have been
properly set. 230v instead of 200v.
– People have witnessed contactors dropping out and
then immediately picking up.
– One second time delay may not be long enough.
– 100 second time delay is now setup at RCD. Part
number 3RT1916-2CG31 (5-100 sec.) replaces
3RT1916-2CG11 timer included in the rework kit
and standard on units on units produced in 2007.
– Report any occurrences encountered.
•High Differential Pressure/Low Suction (cont’d)
30RB High Motor Temperature Alarms
• Motor Protection Scheme
– Total of four PTC
thermistors connected in
series protect motor
– Steep curve in trip area –
resistance rises quickly
• SPM board trips at greater
than 4.5 kΩ and resets
below 2.5 kΩ
– A 1K resistor connected to
the SPM may be used to
temporarily bypass the PTC
for troubleshooting
30RB High Motor Temperature Alarms
• Nx.01 Motor Temperature Too High & Nx.04 Motor
Sensor PTC out of range Alarms
– Motor Temperature Too High alarms are generated when Motor
Sensor is actually out of range
• Typically caused by loose connections
• Check connections on compressor and connector on SPM. Use
dielectric grease. Connector may have to be replaced.
• Replacement SPM’s will come with dielectric grease.
– Motor Temperature Too High alarms are generated when
compressor is seized.
• This is the compressor overload protection. PTC temperature rises
rapidly shutting off compressor.
30RB Compressor Failures
• All compressor failures are analyzed by Danfoss. – Fill out compressor failure checklist
– IMPORTANT: PLEASE FAX THIS FORM TO 860-998-2135 AND RETURN FORM WITH THE FAILED COMPRESSOR
• Checklist provided with replacement compressor. Also available on HVAC Partners.
• Need to receive a checklist for every failure.
30RB Compressor Failures
• Flooding
– Units with glycol in the chilled water system for freeze
protection have to be configured for brine
(Configuration>SERV>FLUD=2).
• P.40,41,42 - Repeated Low Suction Temperature Override
– Brine freeze setpoint should be set to the freeze point of the
antifreeze solution. (Configuration>SERV>LOSP).
• Default has been increased from 14°F to 34°F.
– Don’t be afraid to raise the superheat setpoint if flooding is
witnessed (Configuration>SERV>SHP.x). Default is 7.2°F.
• Increasing the superheat to 10°F or 12°F will help.
• You should not see foaming in the oil level sightglass during
steady-state operation.
• Discharge superheat should be approximately 30°F or higher.
30RB Compressor Failures
• Flooding
– Check accuracy of thermistors and transducers. Have received
reports of inaccurate readings which may affect superheat
control.
HPS ENRV SPT
SGT
30RB Compressor Failures
• Flooding
– Check compressor oil level.
• If oil level is too high logging may occur in the cooler.
• Approach (LWT-SST) will be high >15°F.
• This may occur as the result of replacing a compressor.
Factory oil charge
is 7/8 glass.
Normal operating
level is ½ to full
glass.
View oil sight
glass
• SMB07-0014 was issued to update units in the field in
areas that were experiencing higher than normal
compressor failures.
– Not all units are included in this SMB.
– The SMB will be reissued to include units produced prior to
0107Q and shipped to high risk areas.
– Units produced prior to 0107Q not listed in the SMB should be
updated if frequent power outages or welded contactors are
encountered.
30RB Compressor Failures
• Reports of plugged liquid line filter driers
– P.40,41,42 - Repeated Low Suction Temperature Override
– Nitrogen not being used during brazing
– Drier cores not properly assembled
– Loose wing nuts
30RB Filter Drier
• Recommending changes to the current filter drier
assembly.
– Proper location of gaskets
– Better outlet gasket
– Wing-nut with lock washer
30RB Filter Drier
Current assembly Revised assembly Fender washer &
lock washer added
30RB MCHX Condenser Coil
Micro-Channel Condenser
30RB MCHX Condenser Coil
• Refrigerant leaks – Have received reports of
leaks around flange connections.
– Investigation has determined that nuts are not properly tightened.
– Torque Nuts to 12 ft-lbs +/- 3.
– Has not been necessary to replace EDPM washer.
30RB MCHX Condenser Coil
• Refrigerant leaks
– Have received reports of leaks in face and header.
• Header leaks are typically manufacturing issues.
• Leaks on the face of the coil may be due to
manufacturing, handling or corrosion.
30RB MCHX Condenser Coil
• Points of interest
– Top and bottom tubes are
inactive serving as
reinforcement.
• The cuts are designed to
prevent any failures in the
event that there is a significant
amount of thermal expansion
or contraction between the
parts.
– DO NOT USE a razor knife
to remove protective cover.
30RB MCHX Condenser Coil
• Refrigerant leaks – If a leak occurs in the face of
the coil it can be repaired in the field.
– All DOA coils should be replaced and returned for analysis.
– Be aware of corrosion issues. Coastal and Industrial corrosion are primary concern.
– New Coil Selection Guidelines are soon to be released.
– E-Coat MCHX is being tested.
Repair / Replacement
RCD Repair Kit
50TJ660007
Coil Replacement
Non-corrosive flux
Repair Wire
316 SS Mask set
Replacement Center
Instant Adhesive
30RB MCHX Condenser Coil
• Units with MCHX
condenser coils are very
sensitive to refrigerant
charge.
• One (1) pound can make the
difference between starting
or tripping on high pressure.
• Factory refrigerant charge
has been adjusted to allow
startup without generating
high pressure alarm.
• More work needed. Let us
know what you experience.
30RB MCHX Refrigerant Charge
30RB
MCHX Refrigerant Charge [lbs]
Unit
Size
A B C Total
Old New Old New Old New Old New
60 48 43 22 21 - - 70 64
70 59 43 22 21 - - 81 64
80 36 34 36 36 - - 72 70
90 51 43 40 43 - - 91 86
100 51 43 51 45 - - 102 88
110 51 46 61 56 - - 112 102
120 51 46 76 61 - - 127 107
130 71 58 61 57 - - 132 115
150 71 60 74 66 - - 145 126
160 86 86 61 59 - - 147 145
170 86 86 77 68 - - 163 154
190 86 86 93 93 - - 179 179
210 71 63 61 57 82 68 214 188
225 71 63 76 63 82 68 229 194
250 71 63 76 63 100 95 247 221
275 86 86 93 93 82 72 261 251
300 86 86 93 93 100 100 279 279
• Med Temp Brine Option (+15°F to +40°F)
• 30RBA060-100
- Special modifications not required
• 30RBA110-390
- Units with 3 or 4 compressor/ckt.
- Oil return issue at min. capacity
- Cooler has a special pass partition plate
- Hot Gas and Liquid Line solenoids added
to reduce condenser capacity under light
loads on 120 ckt B and both ckts 130 and
up.
- Special fan control routine
• MLV option not available with Brine Option
30RB Medium Temp Brine
30RB Medium Temp Brine
30RB Medium Temp Brine
If unit is configured for fluid type = Brine
Hot Gas Bypass Control (MLV) will not function
30RB Low Ambient Head Pressure Control
• Siemens Micromaster VFD Issues
– Field installed accessory and
replacement drives are not shipped
programmed.
• Follow instructions in Controls and
Troubleshooting Guide 30RB-2T to
commission drive.
– FIOP may not have proper fan motor current
programmed.
• Drive may ramp up and down quickly.
• Check motor nameplate (not unit
nameplate) for correct value.
30RB Software Change Summary (1)
• Version 2.00 key changes: SSN 2906Q
– Reduced occasional loss of configuration (rare).
– Fixes loss of communication with SPM issue (rare).
– “Black box” data management improved.
30RB Software Change Summary (2)
• Version 2.01 key changes: SSN 4406Q – If the motor temperature sensor is open circuited, alarm Nx.04
(Compressor Motor Sensor PTC Out of Range) will always be declared. Previously sometimes Nx.01(Compressor Motor Temp Too High) would be declared.
– Nuisance suction pressure transducer faults Pr.04, Pr.05, Pr.06 with the Minimum Load Valve Option have been addressed by delaying activation of the HGBP valve for 1 min. until the drop in suction pressure has been tested for.
– If saturated suction temperature is low, a compressor will not be permitted to run in Service Test.
– In order to capture Black Box data in the case of welded compressor contacts, the low SST alarms P.05, P.06, P.07 will now be declared even if a compressor is not running (per the control).
• Version 3.01 key changes: SSN 1707Q – Added welded contactor detection and management
• Welded contactor alarm is generated (Ct.01,Ct.02,Ct.03)
• EXV and Fan control shall go back to normal operation
• Unit shall shut down and remain at 0% capacity
• Cooler pump shall be controlled to ON
– The welded contactor management is cancelled if one of following conditions occur
• Cooler flow switch failure
• High pressure trip
• Cooler freeze protection alarm
– Modified “Black Box” data management
• PCDCT ver. 1.5.3 or higher required
– Improve compressor operating envelope protection.
– Improve Dual Chiller control
• If compressor is disabled algorithm will correctly declare it unavailable and allow lag chiller to start.
30RB Software Change Summary (3)
• Version 4.00 key changes: (Service Release Only) – Improve fan control especially to ensure correct SST at OAT below
57°F
– Correct a bug on fan controls introduced in version 3.01 which could cause fan cycles at low OAT
– Added configuration parameters for MCHX exchanger, desuperheater option and Danfoss VFD configuration
• Desuperheater and Danfoss VFD is not offered at this time
– Added ability to “force” pump operation from Scrolling Marquee
– Brine freeze setpoint default value is 34°F instead of 14°F
30RB Software Change Summary (4)
• Version 4.01 changes: (SSN 4407Q) – Added several config items Scrolling Marquee Display
• VLT FAN DRIVE SELECT (Not Supported)
– Configuration>UNIT>VLT.S = 0
• VLT FAN DRIVE RPM (Not Supported)
– Configuration>UNIT>RPM.F = 0
• MCHX SELECT (Must be configured to YES if unit has MCHX)
– Configuration>UNIT>MCHX = YES
• ATTACH DRIVE TO FAN x (x = Ckt. A,B,C)
– Configuration>SERV>AVFx = NO
– Added SP transducer failure condition to welded contactor logic.
30RB Software Change Summary (5)
30RB Software Change Summary (6)
• Version 5.01 changes: (SSN 3308Q) – Added dual speed fan parameter in FACTORY configuration
• This configuration is not supported.
– Corrected issue with P.14 flow switch alarm not being displayed when alarm occurred.
– Added minimum cooling setpoint parameter in SERVICE configuration for brine application.
– Improvement for MCHX application to avoid high pressure trip.
– Superheat setpoint default has been raised from 7.2°F to 9.0°F.
• Currently field testing Version 5.02 – Complaints of P.16 thru P.27 Compressor Not Started or Pressure
not established alarms. • Reduced threshold for compressor startup detection from 10 PSI to
3 PSI at start if EWT < 50°F.
30XA Aquaforce Field Issues
• Cooler Heater Failures
• Oil Separator Heater Failures
• Compressor will not start
• Software Issues
30XA Cooler Heater Failures
• Symptoms and Conditions: – Cooler Freeze Protection alarms
– Cooler Freeze-up on units not winterized or without glycol
• Root Cause – Cooler heater failure due to high watt density
• Heaters overheat and burn out (fail open)
• Heaters are rated for 500w @ 120v
• Nominal heater resistance is 28.8 +/- 1.4 ohms
– Oil Separator Heaters are also affected
• Same part as cooler heater
• Less failures due to the separator not being insulated
30XA Cooler Heater Failures
• Solution
– Beginning with s/n 1007Qnnnnn units were being shipped with 2
500w cooler heaters wired in series.
• In this configuration power is reduced to 125w for each heater
• Coolers have either 2 or 4 heaters depending on unit size
• Pump control accessory is being factory installed
• A letter is being sent to all sales offices identifying the addition of the
pump control accessory and stating that cooler freeze protection below
25°F will required pump control if the system is not protected with
antifreeze
• A stuffer will also be included with the units identifying the wiring
change and pump control requirements
30XA Cooler Heater Failures
• Solution – Beginning with serial number 2607Qnnnnn a new style belly band
heater has been incorporated.
• Each heater is rated at 400 watts vs. 500 watts previously.
• The new cooler heater design provides freeze protection to 0°F is without pump control and to -20°F with pump control.
– SMB07-0048 announced a rework
program to install insertion heaters
which will be located in the cooler
heads similar to the 30GX cooler
heaters.
– SMB08-0018 announced a rework
program to inspect units for possible
wiring error.
30XA Oil Separator Heater Failures
• Symptoms and Conditions:
– Low oil level alarms
– Compressor Locked Rotor alarms
• Root Cause
– Heater failure due to high watt density
• Same part as cooler heater
• Heaters overheat and burn out (fail open)
• Heaters are rated for 500w @ 120v
• Nominal heater resistance is 28.8 +/- 1.4
ohms
30XA Oil Separator Heater Failures
• Solution
– A new oil separator heater is now
available. Part Number is
00PPN800000300A.
• Units produced starting with
serial number 1108Qnnnnn have the new heater installed.
• Heater is still rated @ 500w.
Contains integral thermostat
with a 350°F setpoint to prevent
overheating.
• SMB08-0037 covers extended
warranty policy
30XA Software incompatibility with CPM
• All MBB software is not backward compatible with all CPM versions.
– CPM may also be referred to as TCPM.
• TCPM=Thunderbolt Compressor Protection Module.
– Testing indicates that HPS trips will not be displayed as alarms unless
unit is equipped with manual reset switch.
• 00PPG000444400A HPS w/ manual reset implemented SSN 2806Q.
– Version 4.01 software was to field tested to verify corrections.
– Units with ver. 1.0 CPM work with MBB ver. 2.06 and lower w/o replacing
HPS.
CPM rev
1.X 2.X 3.X 4.X 5.X
1.0 ok ok no** no * ok
2.0 no ok ok ok ok
3.0 no no no ok ok
** : 30XA software version 3.02 associated with CPM version 1.0 causes the EXV stay at the startup position.
* : 30XA software version 4.X associated with CPM version 1.0 can not perform the welded contactor management.
30XA sw version
30XA Software incompatibility with CPM
• 30XA’s manufactured with serial numbers between 2408Qnnnnn and 2608Qnnnnn where incorrectly shipped with MBB ver. 3.02 software and ver. 3.0 CPM’s. – The MBB will have to be upgraded to version 5.00 for proper operation.
– If the HPS trips the MBB does not recognize it. No alarm will be generated.
– Loose connection in the HPS circuit may cause eratic compressor operation.
– Beginning with serial number 2708Qnnnnn units were shipped with ver. 5.0 MBB software.
– A SMB will be issued to cover software upgrade.
• Replacement CPM’s shipped from RCD will be ver. 3.0. A MBB software upgrade to ver. 5.0 or higher will be necessary for proper operation. – CPM Software cannot be downloaded in the field because it is a UL
listed compressor protection device.
30XA Compressor will not start
• Situation: – Compressor will not run and no alarms displayed
• Units are inadvertently shipped from the factory with the
compressors disabled or incorrectly configured in the field.
– Run Status>CP.UN>x.UN = YES (No = Enable)
• Circuit is low on refrigerant. Capacity control override in effect.
– Run Status>VIEW>CAP.S = 34, 35 or 36
• Low oil level. Oil level switch is open.
– Inputs>GEN.I>OIL.x = LOW (HIGH = Closed)
• The Start/Stop button was not depressed on units equipped
with Touch Pilot.
30XA Software Change Summary (1)
• Information – The following operational issues have been reported involving
30XA software versions up to and including version 1.05 (CSA-SR-20C470105).
• When operating at low loads, under some circumstances hot gas can pass uncondensed through portions of the condenser coils. The bypassed hot gas, mixed with condensed refrigerant, may boost cooler saturated suction temperature higher than cooler water temperatures. This can generate Alarms Pr.04, Pr.05, Pr.06, “Suction Pressure Transducer Failure”. The EXV will typically be fully open or close to fully open to pass the mixed phase fluid.
• When configured for medium brine, low saturated suction temperature capacity override will be erroneously based on the default water freeze point (34°F) rather than the configured brine freeze point. Compressor will not load up.
• Does not support “Black Box” feature.
30XA Software Change Summary (2)
• Information – Version 2.01 (CSA-SR-20C470201) was released for production
with units having serial numbers beginning with 2406Qnnnnn. This version includes the following changes: • Software is modified to handle the Touch Pilot (“High Tier”) touch
screen display.
• The conditions for Suction Pressure Transducer Failure, Pr.04, Pr.05, Pr.06, now require that the EXV be less than 50% open. This eliminates declaration of these alarms under the conditions described in SITUATION above.
• When configured for medium brine, low saturated suction temperature capacity override now is based on the configured brine freeze point LO.SP.
• “Black Box” data acquisition feature now supported – Discharge gas temperatures are added to the set of points collected.
• Detection was added for swapped water temperature sensors.
30XA Software Change Summary (3)
• Information (cont’d) • EXV operation is modified for the case of discharge gas temperature
below 180°F.
• An extra 10 second delay is added before declaring a low suction
temperature alarm for brine.
– Anomalies
• Operating compressor(s) in Service Test with Navigator does not
work with Version 2.01.
• Condenser fans will start and run for short periods of time when the
unit is OFF.
30XA Software Change Summary (4)
• Information – Version 2.06 (CSA-SR-20C470206) was released for production
with units having serial numbers beginning with 1107Qnnnnn. This version includes the following changes:
• Corrected unintentional operation of condenser fans
• Modified head pressure control routine for brine applications to eliminate P.78,P.79,P.80 high discharge temperature alarms
– If LBT>28°F the condensing temperature setpoint is not allowed to increase at startup during low ambient conditions
30XA Software Change Summary (5)
• Information – Version 3.01 (CSA-SR-20C470301) was released for production
with units having serial numbers beginning with 4107Qnnnnn. This version includes the following changes:
• Improvement on compressor capacity control : at startup, 10%
increase instead of 5% allows unit to load quicker.
• Remove access to heat reclaim and heat pump parameters on
Navigator display. • Add missing CCN variables for Data Collection tool and Best ++
access (CURREN_A …) • Corrected problem with Start/Stop mode based on time schedule not
working when using Touch Pilot display.
• Improve the timing management to detect oil pressure and
economizer pressure failure
30XA Software Change Summary (6)
• Information – Version 3.02 (CSA-SR-20C470302) was released for production
with units having serial numbers beginning with 1608Qnnnnn. This version includes the following changes: • Pump 1 output is duplicated at MBB-J2B
• Corrected "slide valve unverifiable" alert and improved slide valve
reactivity. • Corrected bug on slide valve control on triple circuit : it was possible
to have 2 circuits with 30% load
• Add hydraulic kit sensors management (not supported)
• Add welded contactor management
• Change the item name "cpb_cur" into "cpc_cur" for circuit C maintenance table
• Improve capacity control (fast unloading) to protect against freeze alarm in case of quick building load decrease
• Device description change will now be saved and not over written.
30XA Software Change Summary (7)
• Information
– Version 5.00 (CSA-SR-20C470500) was released for production
with units having serial numbers beginning with 2708Qnnnnn.
This version includes the following changes:
• Allows operation with CPM version 1.
– (Backward compatibility issue. MBB ver. 3.02 would not work with CPM
ver. 1.0)
• Integrate 30XW (water-cooled) application
• Extend fastload range to 4 for future fast loading function
– (not supported)
• Change alarm text for alarms "P-37 to 39 and P-81 to P-83
30GX/HX FIELD ISSUES
• ICM to TI CPM Conversion
• Software Change Summary
30GX/HX ICM to TI CPM Conversion
• ICM Compressor Protection Module discontinued
– Used on 30HX-076 to 271 and 30GX-080 to 265 Series 0,1,2 units
– Microprocessor for ICM CPM in no longer available
– Conversion kit is to be released soon
ICM CPM p/n HN67LM100 TI CPM p/n HN67LM103
30GX/HX ICM to TI CPM Conversion
• ICM Compressor Protection Module discontinued
– There will be 2 kits
• 30HX660012 for 2 compressor units. (Includes one (1) CPM)
• 30HX660013 for 3 compressor units. (Includes two (2) CPM’s)
• All CPM’s have to be replaced during the conversion.
– One (1) HN67LM103 replaces two (2) HN67LM100 boards
• New Toroids/CT’s are required for each compressor
– Replacement toroids must be selected for unit size and voltage
– Toroids are NOT included in conversion kits. Must be ordered
separately.
– 30GX sensor harness for toroids is NOT included in 30HX660013.
» 30GX660009 required for 30GX size 205 to 265
– Furnas Overload is not required with TI CPM.
30GX/HX ICM to TI CPM Conversion
CPM
Toroid
Overload (Not req’d w/ TI)
ICM TI
30GX/HX ICM to TI CPM Conversion
• ICM Compressor Protection Module discontinued
– Software upgrade required
• PSIO1 will have to be downloaded with correct
software to recognize TI CPM.
• Use Winloader to upgrade software
– Version 15 or 17
– Select TISERV configuration file
PSIO1
30GX/HX Software Change Summary (1)
• Version 2.1
– Corrects situation of MBB loss of control of compressor protection
board (CCP).
• Symptoms of problem are failure to be able to operate outputs or read
inputs from CCP.
– Oil soienoid and motor cooling solenoid will not function
– Motor temperature indicates 0°F
• Prior to Ver. 2.1, solution was to temporarily change configured number
of Circuit A compressors from 1 to 2 then back to 1.
30GX/HX Software Change Summary (2)
• Version 2.7 (SSN 4906Qnnnnn)
– Corrects multiple problems associated with Chillervisor control
• Symptoms of problem are loss of communication and improper
indication of unit status.
• All units with Enhanced Screw software that are being controlled by a
CSM should be upgraded.
– Reduces low oil pressure alarms on 30HXA,C206 & 246
• Low oil pressure alarms reported when A2 compressor was operating
alone.
• Compressor A2 will not run as the only compressor on in the circuit
unless A1 is failed. If A2 is running alone, then the oil pump will always
be energized.
– Corrected units for DOP_A1, DOP_A2, DOP_B1, and DOP_B2
• They were specified as PSIG. They are displayed as PSIA.
30GX/HX Software Change Summary (3)
• Version 2.11 (Beta Version) DO NOT USE
– Service Test for A2 does not work for 30HX-206 and 246
• This is a problem in version 2.7 that was introduced when adding the
A2 cannot start if A1 is not running enhancement.
– Corrected problem where LWT was not checked for cooler freeze
protection.
• Only EWT was being checked.
– Corrected issue that all compressors shutdown immediately when
remote start contacts open or R-O-E switch is placed in the OFF
position.
• All loaders will be de-energized immediately for 15 seconds before
staggering the shutdown of compressor 5 seconds apart.
30GX/HX Software Change Summary (4)
• Version 2.11 (Beta Version) DO NOT USE
– EXV Starting position too small for units with 2 compressors/circuit.
• EXV calculated starting position is no longer divided by the number of
compressors in the circuit.
– MLV remains energized for 30 sec. without compressor
• Corrected problem that if the first compressor of the unit is selected to
be started and during the start process, either a “Compressor Prestart
Oil Pressure” fault or “Oil Solenoid Failure” is encountered, MLV was
energized for 30 seconds without any compressor ON.
– Corrected problem of Ckt. B EXV occasionally not moving if both
circuits were operating.
30GX/HX Software Change Summary (5)
• Version 2.11 (Beta Version) DO NOT USE
– Added reverse rotation alarm for A1, A2, B1 and B2 compressors.
• If the discharge pressure drops at the starting of the circuit, alarm will
be generated for the compressor that is starting. Alarm reset method
shall be manual.
– T051 Circuit A, Compressor 1 Failure - Reverse Rotation
– T052 Circuit A, Compressor 2 Failure - Reverse Rotation
– T055 Circuit B, Compressor 1 Failure - Reverse Rotation
– T056 Circuit B, Compressor 2 Failure - Reverse Rotation
30GX/HX Software Change Summary (6)
• Version 2.11 (Beta Version) DO NOT USE – A1 compressor always starts first
• Corrected problem introduced in version 2.07 for 30HX-206 and 246 units. Compressor A1 is always chosen to be the first compressor of the unit to be started even though A1 has more run hours than B1.
– Corrected problem with compressor oil solenoid not being energized.
• If Configuration>UNIT>CAP.A is configured for 100% B1 and B2 oil solenoids are not energized.
• If Configuration>UNIT>CAP.A is configured for 0% A1 and A2 oil solenoids are not energized.
– Anomalies
• If compressor is disabled Configuration>SERV>EN.xx and power is cycled configuration will revert to enabled.
• Nuisance Reverse Rotation alarms have been reported. Use Version 2.10 instead of 2.11.
Latest Software Versions (9/10/2008)
Product
Latest
Version*
Production
Version
Version
(HVAC Partners)
30RB 5.02 5.01 5.01
30XA 5.00 5.00 5.00
30RAN 5.0 5.0 ---
30GX,HX (series 6) 2.10 2.7 (HX only) 2.10
30GX,HX (series 4, 5) 5.3 --- 5.3
30GX,HX (series 0-3) w/ PSIO 17.7 --- 17.6
30HK, HL 4.3 4.3 4.3
30HW, 30GTN015-035 1.2 1.2 (HW only) 1.2
30GTN040-420 4.3 --- 4.3
* Including unreleased and beta versions