CONTROLS MANUALTouch Pilot Control30KAVOriginal document

CONTENTS1 - .SAFETY CONSIDERATIONS. 51.1 - Safety guidelines. 51.2 - Safety precautions. 52 - .CONTROL OVERVIEW. 52.1 - System functionalities. 52.2 - Touch Pilot components. 52.3 - Operating modes. 53 - .HARDWARE DESCRIPTION. 63.1 - Control boards. 63.2 - Power supply to boards. 63.3 - Light emitting diodes on boards. 63.4 - Connections of the main controller. 63.5 - Pressure transducers. 63.6 - Temperature sensors. 73.7 - Actuators. 73.8 - Connections at the customer terminal block. 84 - .HOW TO USE TOUCH PILOT USER INTERFACE. 94.1 - User interface. 94.2 - Touch Pilot buttons. 94.3 - Menu structure. 105 - .SETTING UP TOUCH PILOT CONTROL. 115.1 - General description. 115.2 - Welcome screen. 115.3 - Synoptic screen. 115.4 - Unit start/stop. 125.5 - Display settings. 125.6 - Main menu. 135.7 - Configuration menu. 145.8 - System configuration override. 145.9 - Trending. 145.10 - Schedule setting. 156 - .WEB CONNECTION. 166.1 - Web server connection. 166.2 - Web interface. 166.3 - Web browser settings. 166.4 - Technical documentation. 167 - .TOUCH PILOT CONTROL: DETAILED MENU STRUCTURE. 177.1 - Main menu. 177.2 - Configuration menu. 237.3 - Alarms menu. 278 - .TOUCH PILOT CONTROL OPERATION. 288.1 - Start / Stop control. 288.2 - Pumps control. 298.3 - Control point. 308.4 - Ramp loading. 318.5 - Capacity limitation. 318.6 - Capacity control. 328.7 - Night mode. 328.8 - Low noise mode. 328.9 - Head pressure control. 322

8.10 - Refrigerant gas leak detection (option 159). 328.11 - Automatic refrigerant leak detection. 328.12 - BACnet (option 149). 328.13 - Circuit lead/lag selection. 328.14 - Circuit capacity loading sequence. 338.15 - Master/Slave assembly (option 58). 338.16 - Energy Management Module (option 156). 339 - .DIAGNOSTICS. 349.1 - E-mail notifications. 349.2 - Control diagnostics. 349.3 - Displaying current alarms. 349.4 - Resetting alarms. 349.5 - Alarm history. 349.6 - Alarms description. 3510 - 6MAINTENANCE. 42The cover photos are solely for illustration and form no part of any offer for sale or any sale contract. The manufacturerreserves the right to change the design at any time without notice.3

PREFACEThe goal of this manual is to give a broad overview of themain functions of the Touch Pilot control system used tocontrol and monitor the operation of 30KAV air-cooledchillers using screw compressor technology.Instructions in this manual are given as a guide to goodpractice in the installation, start-up and operation of thecontrol system. This document does not contain full serviceprocedures for the correct operation of the equipment.The support of a qualified Carrier Service Engineer isstrongly recommended to ensure optimal operation of theequipment as well as the optimization of all availablefunctionalities.Note that this document may refer to optional componentsand certain functions, options or accessories may not beavailable for the specific unit.IMPORTANT: All screenshots of the user interface providedin this manual include text in English. After changing thelanguage of the system, all labels will be in the languageselected by the user.Please read all instructions prior to proceeding with anywork. Pay attention to all safety warnings.The information provided herein is solely for the purpose ofallowing customers to operate and service Carrier-manufacturedequipment and it is not to be reproduced, modified or used forany other purpose without the prior consent of CarrierCorporation.4AbbreviationsIn this manual, the refrigerant circuits are called circuit A andcircuit B. Compressor in circuit A is labelled A1 andcompressor in circuit B is labelled B1. The followingabbreviations are used frequently:BMSBuilding Management SystemDGTDischarge Gas TemperatureCCNEMMEXVLEDLENLONSCTSSTCarrier Comfort NetworkEnergy Management ModuleElectronic Expansion ValveLight Emitting DiodeSensor Bus (internal communication bus linking thebasic board to slave boards)Local Operating NetworkSaturated Condensing TemperatureSaturated suction Temperature

1 - SAFETY CONSIDERATIONS2 - CONTROL OVERVIEW1.1 - Safety guidelinesInstallation, start-up and servicing of equipment can behazardous if certain factors particular to the installation arenot considered: operating pressures, presence of electricalcomponents and voltages and the installation site (elevatedplinths and built-up structures).2.1 - System functionalitiesThe Touch Pilot system controls the start-up of thecompressors needed to maintain the desired heat exchangerentering and leaving water temperature.Only properly qualified installation engineers and highlyqualified installers and technicians, fully trained for theproduct, are authorised to install and start-up the equipmentsafely.During all servicing operations all instructions andrecommendations which appear in the installation andservice instructions for the product, as well as on tags andlabels fixed to the equipment and components andaccompanying parts supplied separately, must be read,understood and followed.Failure to comply with the instructions provided by themanufacturer may result in injury or product damage. Apply all standard safety codes and practices.Wear safety glasses and gloves.Use the proper tools to move heavy objects.Move units carefully and set them down gently.1.2 - Safety precautionsOnly personnel qualified in accordance with IEC (InternationalElectrotechnical Commission) recommendations may bepermitted access to electrical components.It is particularly recommended that all sources of electricityto the unit be shut off before any work is begun. Shut off themain power supply at the main circuit breaker or isolator.IMPORTANT: This equipment conforms to all applicablecodes regarding electromagnetic compatibility.RISK OF ELECTROCUTION! Even when the main circuitbreaker or isolator is switched off, specific circuits may stillbe energised as they may be connected to a separate powersource.RISK OF BURNS! Electrical currents may causecomponents to get hot. Handle the power cable, electricalcables and conduits, terminal box covers and motor frameswith great care.The control panel serves as a user interface and a configurationtool for controlling the operation of the unit. Touch Pilotconstantly monitors safety devices that protect the unit againstfailure and guarantee its optimal functioning.2.2 - Touch Pilot componentsThe controller manages a number of mechanisms that allowthe unit to operate effectively, including the following: Compressor start-up to control the water loop(screw compressor technology) 7’’ touch screen as standard (Touch Pilot) BMS connection Diagnostics, e-mail transmission Web connectivity Energy Management Module (optional) Hydronic module, variable-speed pump control (optional) External fixed-speed or variable-speed pump control Remote unit management Energy optimization, power/energy monitoring Maintenance schedule management Communication protocols (CCN, BACnet, Jbus, LON)2.3 - Operating modesThe control system can operate in three independent modes: Local mode: The unit is controlled by commands fromthe user interface. Remote mode: The unit is controlled by dry contacts. Network mode: The unit is controlled by networkcommands (CCN or BACnet). Data communicationcable is used to connect the unit to the RS485communication bus or IP connection.When the control operates autonomously (Local or Remote),it retains all of its control capabilities but does not offer anyfeatures of the Network.IMPORTANT: Emergency stop!The Network emergency stop command stops the unitregardless of its active operating type.5

3 - HARDWARE DESCRIPTION3.1 - Control boardsEach circuit is by default fitted with one SIOB board usedto manage all inputs and outputs of the controller. At thesame time, Energy Management Module (EMM) requiresan additional SIOB board to be installed. The control alsoincludes up to four AUX1 boards used to control refrigerantleak detection option, master/slave assembly control, andinternal or external pumps’ control.All boards communicate via an internal LEN bus.3.4 - Connections of the main controllerConnections are located on the bottom side of the maincontroller.The controller comes with two RS485 ports, where the firstport is used to connect to CCN (Carrier Comfort Network)and the second RS485 port is used for internal communication(LEN). The Ethernet port allows for TCP/IP communicationor BMS (Building Management System) connection thanksto BACnet/IP communication.Touch Pilot continuously monitors the information receivedfrom various pressure and temperature probes andaccordingly starts the program that controls the unit.The unit is equipped with the Touch Pilot user interface(7- inch colour LCD touch screen).The electrical box includes all boards controlling the unitand the user interface.3.2 - Power supply to boardsAll boards are supplied from a common 24 VAC supplyreferred to earth.In the event of a power supply interrupt, the unit restartsautomatically without the need for an external command.However, any faults active when the supply is interruptedare saved and may in certain cases prevent the unit fromrestarting.CAUTION: Maintain correct polarity when connecting thepower supply to the boards, otherwise the boards may bedamaged.3.3 - Light emitting diodes on boardsAll boards continuously check and indicate the properoperation of their electronic circuits. A light emitting diode(LED) lights on each board when it is operating properly. The red LED flashing for a two-second period on theSIOB board indicates correct operation. A differentrate indicates a board or a software failure. The green LED flashes continuously on all boards toshow that the board is communicating correctly over itsinternal bus. If the green LED is not flashing, thisindicates a LEN bus wiring problem.Legend:1. USB connector2. Ethernet connector3. CCN connector (RS485)4. LEN internal bus (RS485)5. Power supply connector (24 VAC)123453.5 - Pressure transducersTwo types of electronic sensors (high and low pressure) areused to measure various pressures in each circuit.These electronic sensors deliver 0 to 5 VDC. The sensorsare connected to the slave boards.Suction pressure sensors (low pressure type)These sensors measure the suction pressure in each circuit.They are used for EXV control. Suction pressure sensors arelocated on the suction piping of each circuit.Discharge pressure sensors (high pressure type)These sensors measure the discharge pressure in each circuit.They are used to control head pressure or high pressure loadshedding. Discharge pressure sensors are mounted on thedischarge line piping of each circuit.Oil pressure sensors (high pressure type)These sensors measure the oil pressure of each compressor.Oil pressure sensors are located at the oil port of thecompressor. The economizer pressure is subtracted fr