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Carrier 17DA Air Conditioner User Manual

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2. 10 Unit Mounted Wye Delta Starter Optional 11 CONTROLS 11 39 Definitions ever ero RII DUREE CES 11 ANALOG SIGNAL DIGITAL SIGNAL VOLATILE MEMORY General 3 9 stade eet 11 PIC System Components 11 PROCESSOR MODULE PSIO STARTER MANAGEMENT MODULE SMM LOCAL INTERFACE DEVICE LID 6 PACK RELAY BOARD 8 INPUT MODULES OIL HEATER CONTACTOR 1C OIL PUMP CONTACTOR 2C HOT GAS BYPASS CONTACTOR RELAY 3C Optional CONTROL TRANSFORMERS 1 4 CONTROL AND OIL HEATER VOLTAGE SELECTOR 51 LID Operation and Menus 14 GENERAL ALARMS AND ALERTS MENU STRUCTURE TO VIEW POINT STATUS OVERRIDE OPERATIONS TIME SCHEDULE OPERATION TO VIEW AND CHANGE SET POINTS SERVICE OPERATION PIC System Functions 28 CAPACITY CONTROL ENTERING CHILLED WATER CONTROL DEADBAND PROPORTIONAL BANDS AND GAIN DEMAND LIMITING CHILLER TIMERS OCCUPANCY SCHEDULE Safety Controls 29 SHUNT TRIP Default Screen Freeze 29 Page Motor Cooling 29 Ramp Loading Control 31 Capacity Override 31 High Discharge Temperature Control 32 Oil Sump Temperature Control 32 PSIO SOFTWARE VERSIONS 08 AND LOWER PSIO S
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5. DISTRIBUTION PIPE REFRIGERANT ISOLATION VALVE COMPRESSOR BACK PRESSURE ORIFICE CONDENSER WATER CONDENSER ISOLATION VALVE TRANSMISSION DIFFUSER GUIDE VANE MOTOR GUIDE VANES IMPELLER REFRIGERANT VAPOR REFRIGERANT LIQUID VAPOR CHILLED WATER 7 COOLER ISOLATION VALVE Fig 3 Refrigerant Motor Cooling and Oil Cooling Cycles Refrigerant that flows to the oil cooling system is reg ulated by a thermostatic expansion valve There is always a minimum flow bypassing the TXV which flows through an orifice The TXV valve regulates flow into the oil refrigerant plate and frame type heat exchanger The bulb for the expansion valve controls oil temperature to the bear ings The refrigerant leaving the heat exchanger then returns to the cooler LUBRICATION CYCLE Summary The oil pump oil filter and oil cooler make up a package located partially in the transmission casting of the compressor motor assembly The oil is pumped into filter assembly to remove foreign particles and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures After the oil cooler part of the flow is directed to the gears and the high speed shaft bearings the remaining flow is directed to the motor shaft bearings Oil drains into the transmission oil sump to com plete the cycle Fig 4 Details
6. 22 134 tb kg tb kg 40 1420 640 1100 900 409 41 1490 680 1150 950 431 42 1550 700 1250 1000 454 43 1600 730 1350 1050 477 50 1850 840 1500 1100 499 51 1900 860 1600 1200 545 52 1980 900 1750 1300 590 53 2050 930 1850 1350 613 55 ue 1900 1550 704 56 2200 999 1650 749 57 2500 1135 1750 795 58 2700 1226 1900 863 Design chillers use HCFC 22 Design II chillers use either HCFC 22 or HFC 134a NOTES 1 The size of the cooler determines refrigerant charge for the entire chiller 2 Design I chillers have float chambers 3 Design 11 chillers have linear floats INITIAL START UP Preparation Before starting the chiller check that the 1 Power is on to the main starter oil pump relay tower fan starter oil heater relay and the chiller control center 2 Cooling tower water is at proper level and at or below design entering temperature 3 Chiller is charged with refrigerant and all refrigerant and oil valves are in their proper operating position 4 Oil is at the proper level in the reservoir sight glasses 5 reservoir temperature is above 140 60 C or re frigerant temperature plus 50 F 28 C 6 Valves in the evaporator and condenser water circuits are open NOTE If pumps are not automatic make sure water is circulating properly 7 Solid state starter checks The Power 15 and the Phase Corre
7. 79 INPUTS OUTPUTS Starter Management Module SMM 79 INPUTS OUTPUTS Options Modules 8 Input 79 Replacing Defective Processor Modules 80 INSTALLATION Solid State Starters 81 TESTING SILICON CONTROL RECTIFIERS IN BENSHAW INC SOLID STATE STARTERS Physical Data 85 INDEX sete Tu ee Res 98 99 INITIAL START UP CHECKLIST FOR 19XL HERMETIC CENTRIFUGAL LIQUID CHILLER CL 1 CL 12 ABBREVIATIONS AND EXPLANATIONS Frequently used abbreviations in this manual include CCN Carrier Comfort Network CCW Counterclockwise CW Clockwise ECW Entering Chilled Water ECDW Entering Condenser Water EMS Ener anagement System HGBP Hot Gas Bypass IO Input Output LCD Liquid Crystal Display LCDW Leaving Condenser Water LCW Leaving Chilled Water LED Light Emitting Diode LID Local Interface Device OLTA Overload Trip Amps PIC Product Integrated Control PSIO Processor Sensor Input Output Module RLA Rated Load Amps SCR Silicon Control Rectifier SI International System of Units SMM Starter Management Module Thermostatic Expansion Valve The 19XL chillers use HCFC 22 and HFC 134a refrig erant When referencing refrigerant charges in this manual the HCFC 22 charge will be listed first and the HFC 134a value w
8. AUX DRY CONTACT RUN AUX DRY CONTACT STARTER 0 FAULT CHILLED WATER PUMP COND WATER PUMP 4 20MA TRANSDUCER OPTIONAL BREAKER SHUNT TRIP L 8 me TOWER FAN e ALARM MOTOR CURRENT SIGNAL 0 5 RLA Fig 50 Chiller Power Panel Starter Assembly and Motor Wiring Schematic cont 95 oneuieuos 1 4 1 HUN 1g 1 1 osi n 7 Ee A ne 9 vi 1 3 21 5 1 I 1 8 o 3 a M A gt 91 534 1 010 50 42 1 L2 fug a duind 01 eounos 222 80 r Ht4 3 Jewog jueunt eseud e ZSO 150 1 yowa 1 hip 54 NE DAE dil jeuiuue INdjNO jeuuojsueJ ex LX 1 1801 5 1 JequinN X AleuuoN _ 1 amod 79 3015394 1 10 99 01d 1 5 59 uonisue4 seutua eur 6 E rte _ 39815 _ __ LONINIHOMT _ 101615 Jojeuuo f euru 91 eunsseig ubiH 1
9. BLOWN FUSE CIRCUIT PROBLEM BREAKER RETURN TO SERVICE IS PHASE IS PHASE ROTATION ES REVERSE ROTATION TWO INPUT LIGHT INES LIGHT OFF OFF NO NO HAVE THE HAS HEAT SINK TERMINAL YES ISAMBIENT COOLINGFANS No ig MOTOR NO PROTECTION TEMPERATURE STOPPED OR OVERLOADED TRIPPED TOO HIGH IS VENTILATION BLOCKED NO YES YES YES CORRECT CAUSE AND USE DE WAIT FOR UNIT OVERLOAD CHECK AND IS ASSOCIATED REPAIR ALL INTERLOCK YES SWITCHES HOLDING RELAYS SERVICE PANEL OFF INTERLOCKS ETC NO CHANGE ISTROUBLE pg CONSULT LOGIC STILL STARTER BOARD PRESENT MANUFACTURER NO RETURN TO SERVICE Fig 46 Solid State Starter Starter Fault Motor Will Not Start Troubleshooting Guide Typical 83 Table 11 Benshaw Inc Solid State Starter Troubleshooting Guide PROBABLE CAUSES 1 L1 and L3 switch phases reversed PROBLEM AK board phase correct not on 2 Missing phase voltage 3 Improper line voltage AK board relay not on AK board power 15 vdc not on 1 Improper line voltage 2 Transformer malfunction 1L boards LEDs not on A short exists between line and load terminals An SCR is shorted in the phase assembly BC board over temperature LED L3 on prior to run command Temperature switch not functioning properly 2 BC board not functioning properly BC board LEDs on prior to run command BC board LEDs not on after
10. Oil is charged into the lubrication system through a hand valve Two sight glasses in the oil reservoir permit oil level observation Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass when the compressor is shut down The oil level should be visible in at least one of the 2 sight glasses during operation Oil sump temperature is displayed on the LID default screen Oil sump temperature ranges during compressor operation between 100 to 120 F 37 to 49 C 120 to 140 F 49 to 60 C The oil pump suction is fed from the oil reservoir An oil pressure relief valve maintains 18 to 25 psid 124 to 172 kPad differential pressure in the system at the pump discharge This differential pressure can be read directly from the Local Interface Device LID default screen The oil pump discharges oil to the oil filter assembly This filter can be valved closed to permit removal of the filter without drain ing the entire oil system see Maintenance sections pages 61 to 65 for details The oil is then piped to the oil cooler This heat exchanger uses refrigerant from the condenser as the coolant The refrigerant cools the oil to a temperature between 100 and 120 F 37 to 49 C As the oil leaves the oil cooler it passes the oil pressure transducer and the thermal bulb for the refrigerant expan sion valve on the oil cooler The oil is then divided with a portion flowing to the thrust bearing forwar
11. c Leak test chiller as outlined in Steps 3 9 2 If the pressure readings are abnormal for chiller condition a Prepare to leak test chillers shipped with refrigerant Step 2h b Check for large leaks by connecting a nitrogen bottle and raising the pressure to 30 psig 207 kPa Soap test all joints If the test pressure holds for 30 minutes prepare the test for small leaks Steps 2g h Plainly mark any leaks which are found Release the pressure in the system Repair all leaks Retest the joints that were repaired After successfully completing the test for large leaks remove as much nitrogen air and moisture as pos sible given the fact that small leaks may be present in the system This can be accomplished by following the dehydration procedure outlined in the Chiller Dehydration section page 47 h Slowly raise the system pressure to a maximum of 210 psig 1448 kPa but no less than 68 psig 469 kPa for HCFC 22 35 psig 241 kPa for HFC 134a by add ing refrigerant Proceed with the test for small leaks Steps 3 9 Check the chiller carefully with an electronic leak detec tor halide torch or soap bubble solution Leak Determination If an electronic leak detector indicates a leak use a soap bubble solution if possible to confirm Total all leak rates for the entire chiller Leak age at rates greater than 1 Ib year 0 45 kg year for the entire chiller must be repair
12. 40 Automatic Soft Stop Amps Threshold PSIO Software Version 09 and Higher 40 Chilled Water Recycle Mode 40 Safety Shutdown 41 BEFORE INITIAL START UP 41 54 Job Data Required 41 Equipment Required 41 Using the Optional Storage Tank and Pumpout System 41 Remove Shipping Packaging 41 Open Oil Circuit Valves 41 Tighten All Gasketed Joints and Guide Vane Shaft Packing 41 Check Chiller Tightness 4l Refrigerant 41 Leak Test Chiller 41 Standing Vacuum Test 43 Chiller Dehydration 47 Inspect Water Piping 47 CONTENTS cont Page Check Optional Pumpout Compressor Water Piping 47 Check Relief Devices 47 Inspect Wiring 47 Carrier Comfort Network Interface 48 Check Starter ooa 48 MECHANICAL TYPE STARTERS BENSHAW INC SOLID STATE STARTER Oil Charge sx RA 50 Power Up the Controls and Check the Oil 50 SOFTWARE VERSION Set Up Chiller Control Configuration 50 Input the Design Set 50 Inpu
13. 84 Physical Data Tables 12 17 and Fig 47 51 pro clearances physical and electrical data and wiring sche vide additional information regarding compressor fits and matics for operator convenience during troubleshooting Table 12 Heat Exchanger Data COOLER RIGGING WEIGHTS VESSEL CHARGE Refrigerant HEAT NUMBER VESSEL EXCHANGER OF TUBES CODE Volume of Water HCFC 22 HFC 134a 109 115 0 0 VESSEL CHARGE NUMBER Dry Wt Refrigerant Volume OF TUBES Designi Designil Design Designi _of Water te Kg tb Kg Kc ib Ka GU VESSEL EXCHANGER 218 212 235 257 284 316 275 346 382 7775 416 _ _ s 49 423 s 49 466 8980 4073 490 222 135 513 NOTES 1 Design I chillers are equipped with a float box and chiller weight is based on a 150 psi 1034 kPa waterbox with 2 pass arrangement 2 Design Il chillers are equipped with a linear float and chiller weight is based a 300 psi 2068 kPa waterbox with 1 pass arrangement 3 Total refrigerant charge is equal to the cooler charge added to the condenser charge Table 13 Additional Data for Marine Waterboxes i5 65 5i 56 21 2059 neo 1399 o2 57 s FRAMES 2PASS 1220 54 4M 38 FRAMES 1 amp 3PASS 240 175 i7 18 107 m 68
14. QOUOMSSVd 32IAH3S NO 9399071 LON 3 Ile AS ANOdLS Hue 5 NNIW 911121445 7 6 21 6 4 Ava L XE TXT 1309135 35 e 1409135 24308135 e ISV e S318v1 1409135 VN D 2515531 318V1 LNIOd13S AdIQOW L e 5195 SNOT devil 193195 1409135 AN3W3UDNI AG 8 43915 359389349 HO 5 OL SS3Hd 80 0 UO pue 60 BIEMYOS UO FINGSHOS 07 09 39 52024220 BWIL 1v901 510254220 5 52024220 5 1 201 51024020 5318 1 1044405 S66 00d220 05 1 15 SLOVLNOO SAY T3H 205104915 SYOSN3S ANY SLNIOd 1OHINOO LOSNLVLS e S318V1 SNLVLS UNI OS TVS 313 93 37891 LNIOd A3IQOW 5 31 318 1 193138 901434 Lux 11 angy 123136 1 NI 3NIHOVW LHVLS OL 55388 AN3W 11093349
15. Thermistor Fig 48 Electronic PIC Controls Wiring Schematic For 19XL with No Backlight or with Fluorescent Backlight 90 OIL PRESS LVG FILTER EVAP ENT nj Tee LVG j TEMP c a amp COMPRESSOR 58 TEMP zt EXT 4 20 INT 4 20 COMP R THRUST BRG TEMP EXT 4 20 COMMON COMP R OIL I INT 4 20 Sue TEMP COMP R MOTOR H WINDING TEMP E 8 COND ENT 5 eo TEMP COND LVG CoAT e VW aee 8 MODULE F ADORESS 64 8 61 6 52 4 25 OPTION 1 3 sa SoS fl ep eee es WHT 8RN EXT 4 20 COMMON LL INT 4 20 C82 eto EXT 4 20 COMMON INT 4 20 EE 8 IN 2 ADORESS 72 5127 S222 OPTION 2 Fig 48 Electronic PIC Controls Wiring Schematic For 19XL with No Backlight or with Fluorescent Backlight cont 91 AUTO DEMAND RESET OPTION AUTO CHILL WATER RESET OPTION COMMON CHILL WATER SUPPLY SENSOR COMMON CHILL WATER RETURN SENSOR REMOTE TEMP RESET SENSOR SPARE TEMP 1 SPARE TEMP 2 SPARE TEMP 3 SPARE TEMP 4 SPARE TEMP 5 SPARE TEMP SPARE TEMP SPARE TEMP SPARE TEMP YEL VOLTAGE 2 12 4 2 HP PER JOB gt Guo PUMP REGM T a x eS E
16. 1110 kPa and reset at 130 psig 896 kPa Check that the water cooled condenser has been connected Loosen the compressor holddown bolts to allow free spring travel Open the compressor suction and discharge service valves Check that oil is visible in the compressor sight glass Add oil if necessary See Pumpout and Refrigerant Transfer Procedures and Optional Pumpout System Maintenance sections pages 59 and 65 for details on transfer of refrigerant oil specifica tions etc High Altitude Locations Recalibration of the pres sure transducers will be necessary as the chiller was initially calibrated at sea level Please see the calibration procedure in the Troubleshooting Guide section Charge Refrigerant into Chiller A CAUTION The transfer addition or removal of refrigerant in spring isolated chillers may place severe stress on external pip ing if springs have not been blocked in both up and down directions The standard 19XL chiller will have the refrigerant already charged in the vessels The 19XL may be ordered with a nitrogen holding charge of 15 psig 103 kPa Evacu ate the entire chiller and charge chiller from refrigerant cylinders 19XL CHILLER EQUALIZATION WITHOUT PUMP OUT UNIT A WARNING When equalizing refrigerant pressure on the 19XL chiller after service work or during the initial chiller start up do not use the discharge isolation valve to equalize The motor cooling isolation valve or charg
17. 3 conductor cable with drain wire The system elements are connected to the communication bus in a daisy chain arrangement The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it the negative pins must be wired to the negative pins the sig nal ground pins must be wired to signal ground pins 48 To attach the CCN communication bus wiring refer to the certified drawings and wiring diagrams The wire is in serted into the CCN communications plug COMMI on the PSIO module This plug also is referred to as J5 NOTE Conductors and drain wire must be 20 AWG American Wire Gage minimum stranded tinned copper Individual conductors must be insulated with PVC PVC nylon vinyl Teflon or polyethylene An aluminum polyester 10096 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operating tempera ture range of 20 C to 60 C is required See table below for cables that meet the requirements MANUFACTURER CABLE NO Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525 When connecting the CCN communication bus to a sys tem element a color code system for the entire network is recommended to simplify installation and checkout The fol lowing color code is recommended PSIO MODULE SIGNAL CCN BUS CONDUCTOR TYPE INSULATION COLOR 45 2 BLACK 3 Check Starter CAU
18. LIMIT Check discharge temperature LOW REFRIGERANT ERT VALUE exceeded limit of LIMIT TEMP Check evap pump and flow switch MTRW VALUE exceeded limit of LIMIT Check motor cooling and Solenoid HIGH MOTOR TEMPERATURE HIGH BEARING TEMPERATURE MTRB VALUE exceeded limit of LIMIT Check oil cooling control OILPD VALUE exceeded limit of LIMIT Check oil pump and LOW OIL PRESSURE 219940 Low Oil Pressure OPEN Check oil pressure switch pump and 2C aux NO MOTOR CURRENT Loss of Motor Current Check sensor POWER LOSS LOW LINE VOLTAGE V__P Power Loss Check voltage supply V P VALUE exceeded limit of LIMIT Check voltage supply VALUE exceeded limit of HIGH LINE VOLTAGE Check voltage supply ADDITIONAL CAUSE REMEDY Check discharge temperature immediately Check sen sor for accuracy check for proper condenser flow and temperature check oil reservoir temperature Check condenser for fouled tubes or air in chiller Check for proper guide vane actuator operation Check for proper amount of refrigerant charge check for proper water flow and temperatures Check for proper guide vane actuator operation Check motor temperature immediately Check sensor for accuracy Check for proper condenser flow and temperature Check motor cooling system for restric tions Check motor cooling solenoid for proper opera tion Check refrigerant filter C
19. Liquid bypass in waterbox Examine division plates and gaskets for leaks Guide vanes fail to open Use Control Test to check operation Chilled water control point too high Access control algorithm status and check chilled water control operation Guide vanes fail to open fully Be sure that the guide vane target is released Check guide vane linkage Check limit switch in actuator Check that sensor is in the proper terminals Chilled water set point set too low Access set point LID and verify Chilled water control point too low Access control algorithm status and check chilled water control for proper resets High discharge temperature keeps guide vanes open Guide vanes fail to close Be sure that guide vane target is released Check chilled water sensor accuracy Check guide vane linkage Check actuator operation Deadband too narrow Configure LID for a larger deadband Proportional bands too narrow Either INC or DEC proportional bands should be increased Loose guide vane drive Adjust chain drive Defective vane actuator Check through Control Test Defective temperature sensor Check sensor accuracy Low Oil Sump Temperature While Running Less than 100 F 38 C Check for proper oil level not enough oil Check for proper refrigerant level too much refrigerant At Power Up Default Screen Does Not Appear Tables Loading Message Continually Appears SMM Communications Failure High Oil Tempe
20. run command but before starter reaches full voltage 2 BC board not functioning properly 1L board LEDs remain on after starter reaches full voltage AREA OF CORRECTION Switch incoming phases L1 and L3 at top of CD1 or CB1 Check for missing phase voltage Verify proper line voltage applied against synchronizing transformer voltage Ribbon cable not properly Check ribbon cable for proper seating Replace board if necessary seated 1 Make sure proper line voltage is present at primary synchronizing transformer 2 Check synchronizing transformer secondary voltage as follows On the BC board measure from TB11 1 to TB11 2 and TB11 1 to TB11 3 Both readings should be within 30 to 36 vac On the BC board measure from TB11 1 to TB11 4 and TB11 2 to TB11 4 Both readings should be within 18 to 24 vac Replace synchronizing transformer if voltages are not within the specified tolerances Remove power and check resistance with ohmmeter Locate and remove stray wire strands if required Remove power Use ohmmeter to measure the resistance or each SCR phase assembly from anode to cathode The reading should be 50 000 ohm or greater If not replace phase assembly Disconnect power and check for continuity between TB11 10 and TB11 11 If no continuity exists the overtemperature switch is not functioning properly Replace defective switch if necessary Make sure BC board is functioning properly Replace bo
21. 1 PSIO Software Version 09 and higher or 180 F 82 C PSIO Software Version 08 or lower the guide vanes are propor tionally opened to increase gas flow through the compressor If the leaving chilled water temperature is then brought 5 F 2 8 C below the control set point temperature the con trols will bring the chiller into the recycle mode Oil Sump Temperature Control The oil sump tem perature control is regulated by the PIC which uses the oil heater relay when the chiller is shut down As part of the pre start checks executed by the controls oil sump temperature is compared against evaporator refrig erant temperature If the difference between these 2 tem peratures is 50 F 27 8 C or less the start up will be delayed until the oil temperature is 50 F 27 8 C or more Once this temperature is confirmed the start up continues PSIO SOFTWARE VERSION 08 AND LOWER The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 140 F 60 C or sump temperature is less than the cooler refrigerant tem perature plus 60 F 33 3 C The heater is then turned off when the oil sump temperature is 1 more than 160 F 71 1 C or 2 the sump temperature is more than 145 F 62 8 C and more than the cooler refrigerant tem perature plus 65 F 36 1 C The heater is always off dur ing start up or when the compressor is running PSIO SOFTWARE VERSION 09 AND HIGHER
22. 1410 0 4 4 147 0 23 3 532 0 56 7 1451 0 3 3 158 0 24 4 554 0 57 8 1493 0 2 2 169 0 25 6 576 0 58 9 1536 0 1 1 180 0 26 7 598 0 60 0 1980 0 0 0 192 0 27 8 621 0 1 1 204 0 28 9 645 0 2 2 216 0 30 0 669 0 3 3 229 0 31 1 694 0 4 4 242 0 32 2 720 0 5 0 248 0 33 3 746 0 5 6 255 0 34 4 773 0 6 1 261 0 35 6 800 0 6 7 269 0 36 7 828 0 7 2 276 0 37 8 857 0 7 8 284 0 38 9 886 0 8 3 290 0 40 0 916 0 8 9 298 0 41 1 946 0 9 4 305 0 42 2 978 0 45 REFRIGERANT 2 CONDENSER OPTIONAL COOLING ISOLATION HOT GAS 15 SOLENOID EL VALVE 1 LINEAR OPTIONAL COAT CONDENSER HOT GAS PT ISOLATION d VALVE Ed dod gt i t t nr _ eR COOLER E ewe COOLER 4 ISOLATION STORAGE VALVE TANK MACHINE COMPRESSO CHARGING DISCHARGE STORAGE 88 TANK LIQUID VALVE VALVE VALVE OIL COMPRESSOR SEPARATOR SUCTION NALNE CONDENSER PUMPOUT WATER SUPPLY COMPRESSOR AND RETURN PUMPOUT SERVICE VALVE ON C SERVICE VALVE ON CONDENSER PUMPOUT UNIT MACHINE MAINTAIN AT LEAST 2 FT 610 mm CLEARANCE AROUND STORAGE TANK FOR SERVICE AND OPERATION WORK m STORAGE TANK VAPOR VALVE Fig 27 Typical Optional Pumpout System Piping Schematic with Storage Tank REFRIGERANT CONDENSER OPTION
23. 2 position representation of the value of a monitored source Ex ample A switch is a digital device because it only indicates whether a value is above or below a set point or boundary by generating an on off high low or open closed signal VOLATILE MEMORY Volatile memory is memory in capable of being sustained if power is lost and subsequently restored 11 CAUTION The memory of the PSIO LID modules are volatile If the battery in a module is removed or damaged all programming will be lost General The 19XL hermetic centrifugal liquid chiller contains a microprocessor based control center that moni tors and controls all operations of the chiller The micro processor control system matches the cooling capacity of the chiller to the cooling load while providing state of the art chiller protection The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor The guide vane is a variable flow prewhirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor flow into the compressor An increase in guide vane opening increases capacity A decrease in guide vane opening decreases capacity Chiller protection is pro vided by the processor which monitors the digital and ana log inputs and executes capacity overrides or s
24. 3 705 10 250 133 1 459 217 338 50 3 679 9 979 134 1 430 218 332 51 3 653 9 717 135 1 401 219 325 52 3 627 9 461 136 1 373 220 318 53 3 600 9 213 137 1 345 221 311 54 3 575 8 973 138 1 318 222 304 55 8 547 8 739 139 1 291 223 297 56 3 520 8 511 140 1 265 224 289 57 3 493 8 291 141 1 240 225 282 58 3 464 8 076 142 1 214 76 TEMPERATURE Table 10B Thermistor Temperature C vs Resistance Voltage Drop VOLTAGE RESISTANCE DROP V Ohms 168 230 157 440 147 410 138 090 129 410 121 330 113 810 106 880 100 260 94 165 88 480 83 170 78 125 73 580 69 250 65 205 61 420 57 875 54 555 51 450 48 536 45 807 43 247 40 845 38 592 38 476 34 489 32 621 30 866 29 216 27 633 26 202 24 827 23 532 22 313 21 163 20 079 19 058 18 094 17 184 16 325 15 515 14 749 14 026 13 342 12 696 12 085 11 506 10 959 10 441 9 949 9 485 9 044 8 627 8 231 7 855 7 499 7 161 TEMPERATURE 77 VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE DROP V Ohms Control Modules CAUTION Turn controller power off before servicing controls This ensures safety and prevents damage to controller The Processor module PSIO 8 input Options mod ules Starter Management Module SMM and the Local Interface Device LID module perform continuous di agnostic evaluations of the hardware to determine its con dition See Fig 39 43 Proper operation of all modules is indicated by LED
25. 4 Open valves 2 and 5 yaive 1a 1 2 3 4 5 6 7 8 10 t1 12 13 jc cj jojo j h Turn on pumpout condenser water i Run the pumpout compressor until the storage tank pressure reaches 5 psig 34 kPa 18 in Hg 40 kPa absolute if repairing the tank off the pumpout compressor k Close valves 1a 1b 2 5 6 and 10 2 34 5 678 10 11 12 13 14 o c o o o o e e o Turn off pumpout condenser water TRANSFER THE REFRIGERANT FROM CHILLER TO STORAGE TANK Equalize refrigerant pressure a Valve positions Fave yaive ta 1b 2 3 4 5 6 7 8 10 tt 12 13 14 616 b Slowly open valve 5 and liquid line valves 7 and 10 to allow liquid refrigerant to drain by gravity into the pumpout storage tank VALVE 2 3 4 5 7 8 CONDITION 2 Transfer the remaining liquid a Turn off pumpout condenser water Place valves in the following positions VALVE _ 1a 1b 2 3 4 5 6 7 8 10 11 2 13 14 b Run the pumpout compressor for approximately30 min utes then close valve 10 VALVE 1b 2 3 4 5 6 7 8 10 11 12 13 14 06 c Turn off the pumpout compressor 3 Remove any remaining refrigerant a Turn on chiller water pu
26. 600 v It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration This occurs during the starting period when the motor is accelerating up to speed After a time de lay once the motor is up to speed the starter automatically connects the phase windings into a delta configuration 1 23 45 3 9 17 16 15 14 13 12 11 10 9 LEGEND 1 Pilot Relays 2 SMM Power Circuit Breaker and Voltage Calibration Potentiometer 3 Transistor Resistor Fault Protector TRFP 4 Transformer T2 5 Control Power Circuit Breaker 6 Oil Pump Circuit Breaker 7 Main Circuit Breaker Disconnect 8 Voltmeter Optional 9 Ammeter Optional 10 Current Transformers T1 T2 11 Phase Monitor Relay Optional 12 Overload Unit 13 Starter Management Module 14 Starter Access Door 15 Control Transformer Secondary Circuit Breaker 16 Signal Resistor 17 Field Wiring Terminal Strip TB6 Fig 7 Wye Delta Starter Internal View UM CONTROLS Definitions ANALOG SIGNAL An analog signal varies in propor tion to the monitored source It quantifies values between operating limits Example A temperature sensor is an ana log device because its resistance changes in proportion to the temperature generating many values DIGITAL SIGNAL A digital discrete signalis a
27. C min LEAD CHILLER in Control No Yes LAG CHILLER Mode Reset Off Local Run Status Timeout Recycle Startup Ramping Running Demand Override Shutdown Abnormal Pumpdown Start Stop Stop Start Retain Recovery Start Request No Yes STANDBY CHILLER Mode Reset Off Local CCN Run Status Timeout Recycle Startup Ramping Running Demand Override Shutdown Abnormal Pumpdown Start Stop Stop Start Retain Recovery Start Request No Yes NOTES REFERENCE POINT NAME leadlag loadbal lagstart lagstop preflt pull dt pull leadctrl lagmode lagstat lag__s__s lag rec stdmode stdstat std__s__s std rec 1 Only values with capital letter reference point names are variables available for read operation Forcing is not supported on this maintenance screen 2 The 4 screen is available PSIO Software Version 09 and higher 3 delta degrees 27 PIC System Functions NOTE Throughout this manual words printed in capital let ters and italics represent values that may be viewed on the LID See Table 2 for examples of LID screens Point names are listed in the Description column An overview of LID operation and menus is given in Fig 13 19 CAPACITY CONTROL The PIC controls the chiller capacity by modulating the inlet guide vanes in response to chilled water temperature changes away from the CON TROL POINT The CONTROL POINT may be changed by a CCN network device or is det
28. Configurable Range Value Value LID Screen HIGH HCFC 22 HFC 134a HCFC 22 HFC 134a gt Override CONDENSER Equipment gt Set Point lt Override Service gt 195 psig 125 psig 150 to 245 psig 90 to 200 psig 4 psig Set Point PRESSURE 1345 kPa 862 kPa 1034 to 1689 kPa 620 to 1379 kPa 28 kPa gt Override HIGH MOTOR Equipment Set Point lt Override TEMPERATURE Service 2200 F 93 3 C 150 to 200 F 66 to 93 C 10 F Set Point 6 C LOW REFRIGERANT lt Trippoint gt Trippoint TEMPERATURE Equipment lt 3 F 1 6 Override Override Refrigerant Service Above Trippoint AT 1 F AT 2 F Override Delta 0 56 C 1 2 C Temperature HCFC 22 HFC 134a HCFC 22 HFC 134a Minimum Minimum Within HIGH 0 8 C 3 C Lift Limi COMPRESSOR i i LIFT Equipment 517 kPad 345 kPad Nona Plus Surge Service HGBP Surge Maximum Maximum Deadband Prevention T2 10 F T2 10 F 0 5 to 15 F Setting 5 6 C 5 6 C 0 3 to 8 3 C to 8 3 C P2 170 psid P2 85 psid 50 to 170 psid 0 to 170 psid 1172 kPad 586 kPad 345 to 1172 kPad 207 to 1172 kPad MANUAL Control Release of GUIDE VANE Algorithm Automatic 0 to 10096 None Manual TARGET Maint01 Control MOTOR LOAD 5 of 2 Lower ACTIVE Status01 100 40 to 100 Set Point Than DEMAND LIMIT Set Point 31 High Discharge Temperature Control If the discharge temperature increases above 160 71
29. DISABLE ENABLE DISABLE ENABLE 25 75 1 236 2 60 2 60 0 30 DISABLE ENABLE 25 75 1 236 DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C EXAMPLE 5 CONFIGURATION CONFIG DISPLAY SCREEN CONFIGURABLE RANGE UNITS REFERENCE POINT NAME deg 20 res rtl res rt2 res rt restd 1 restd 2 deg chw res sel ecw opt dem 20ma dem sel astart r contact tmp ramp kw ramp ramp opt Idsgrp Idsdelta maxldstm occbrcst ibopt ibterm ibrecyc EXAMPLE 6 LEAD LAG CONFIGURATION DISPLAY SCREEN REFERENCE POINT NAME leadlag loadbal commsens lag per lag__add lagstart lagstop preflt stndopt stnd per stnd NOTE The Lead Lag Configuration table is available on PSIO Software Version 09 and higher 23 DEFAULT VALUE DISABLE 40 DISABLE DISABLE DISABLE 3 DISABLE DISABLE 0 DISABLE DEFAULT VALUE 0 DISABLE DISABLE 50 92 10 10 5 DISABLE 50 93 Table 2 LID Screens cont EXAMPLE 7 SERVICE1 DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU 2 Press SERVICE 3 Scroll down to highlight EQUIPMENT SERVICE 4 Press SELECT 5 Scroll down to highlight SERVICE1 6 Press SELECT DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE Motor Temp Override 150 200 6
30. EXIT REN Press INCREASE or DECREASE to change the time values Override values are in one hour incre ments up to 4 hours INCREASE DECREASE ENTER EXIT LJ LJ b Press ENABLE to select days in the day of week fields Press DISABLE to eliminate days from the period ENABLE DISABLE ENTER EXIT LJ LJ Press ENTER to register the values and to move horizontally left to right within a period ENABLE DISABLE ENTER EXIT J UJ Press to leave the period override PREVIOUS SELECT EXIT Either return to Step 4 to select another period or override or press EXIT again to leave the current time schedule screen and save the changes PREVIOUS SELECT EXIT Holiday Designation HOLIDEF table may be found in the Service Operation section page 38 You must assign the month day and duration for the holiday The Broad cast function in the Brodefs table also must be enabled for holiday periods to function SNOILVHNDISNOOD NOILVOIJILN3QI H3TIOHINOO 39IA30 30 LNO 907 3OIA30 4HOMA3N OL 31va AWIL 329IAH3S 1IN3WdihnO3 e NOILVENDISNOD LNAWdINOS e 501 15 1 1531 e 8318V1 939 935 81 614 34n10nu1S 3943 336 L 6 XIN 18 1 39lAH3S p QHOMSSVd LIDIC H31N3 1
31. FAULT 1CR 1M aux contacts RUN AUX CONTACT RUN__AUX Starter Contact Fault Check FAULT 1CR 1M aux contacts CHIL_S__S CCN Override Stop while CCN OVERRIDE STOP 1 GGAL run mode SRP__PL Spare Safety Fault Check contacts SPARE SAFETY DEVICE Perform pumps Control Test and verify proper switch operation Check all water valves and pump operation Check the high pressure switch Check for proper con denser pressures and condenser waterflow Check for fouled tubes Check the 2C aux contact and the oil pressure switch in the power panel This alarm is not caused by the transducer Check water flow in condenser Check for fouled tubes Transducer should be checked for accuracy This alarm is not caused by the high pressure switch 1CR auxiliary contact opened while chiller was run ning Check starter for proper operation Run auxiliary contact opened while chiller was running Check starter for proper operation has signaled chiller to stop Reset and restart when reagy If the signal was sent by the LID release the Stop signal on STATUSO1 table Spare safety input has tripped or factory installed jumper not present PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT CA VALUE exceeded limit of LIMIT High Amps Check guide vane drive EXCESSIVE MOTOR AMPS EXCESSIVE COMPR Compressor Surge Check condenser SURGE water temp and flow STR FLT Sta
32. Line kW Per job data if KW meter installed Line Frequency 50 or 60 Hz Compressor Starter Type Reduced voltage or full NOTE Cther values are left at the default values These may be changed by the operator as required Service2 and Service3 tables can be modi fied by the owner operator as required Modify Minimum and Maximum Load Points A T2 P2 If Necessary These pairs of chiller load points located on the Servicel table determine when to limit guide vane travel or to open the hot gas bypass valve when surge prevention is needed These points should be set based on individual chiller operating conditions If after configuring a value for these points surge pre vention is operating too soon or too late for conditions these parameters should be changed by the operator Example of configuration Chiller operating parameters Refrigerant used HCFC 22 Estimated Minimum Load Conditions 44 F 6 7 C LCW 45 5 F 7 5 C ECW 43 F 6 1 C Suction Temperature 70 F 21 1 C Condensing Temperature Estimated Maximum Load Conditions 44 6 7 C LCW 54 F 12 2 C ECW 42 F 5 6 C Suction Temperature 98 F 36 7 C Condensing Temperature Calculate Maximum Load To calculate maximum load points use design load condition data If the chiller full load cooler temperature difference is more than 15 F 8 3 C 51 estimate the refrigerant suction and condensing tempera tures at this difference Use the p
33. Step 1 and try logging on again md NOTE The initial factory set password is 1 1 1 1 TO LOG OFF Access the Log Out of Device table of the Service menu in order to password protect the Service menu The LID will automatically sign off and password protect itself if a key is not pressed for 15 minutes The LID default screen is then displayed HOLIDAY SCHEDULING Fig 23 The time schedules may be configured for special operation during a holiday period When modifying a time period the at the end of the days of the week field signifies that the period is ap plicable to a holiday See Fig 18 The Broadcast function must be activated for the holidays configured in the Holidef tables to work properly Access the Brodefs table in the Equipment Configuration table and answer Yes to the activated function However when the chiller is connected to a CCN Network only one chiller or CCN device can be configured to be the broadcast device The controller that is configured to be the broadcaster is the device responsible for transmitting holiday time and daylight savings dates throughout the network To view or change the holiday periods for up to 18 dif ferent holidays perform the following operation 1 At the Menu screen press SERVICE to access the Serv ice menu STATUS SCHEDULE SETPOINT n 2 If not logged on follow the instructions for To Log On or To Log Off Once
34. The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 150 F 65 6 C or the oil sump temperature is less than the cooler refrig erant temperature plus 70 F 39 C The oil heater is turned off when the oil sump temperature is either 1 more than 160 F 71 1 C or 2 the oil sump temperature is more than 155 F 68 3 C and more than the cooler refrigerant tem perature plus 75 F 41 6 C The oil heater is always off during start up or when the compressor is running When a power failure to the PSIO module has occurred for more than 3 hours 1 initial start up the oil sump is heated to 100 F 56 C above the evaporator refrigerant temperature or 190 F 88 C whichever is lower Once this temperature is reached the oil pump will be energized for 1 to 2 minutes or until the oil sump temperature cools to below 145 F 63 C The normal heating algorithm is now followed once ramp loading has been completed After a 3 hour power failure the oil temperature must rise to the higher oil temperature The controls will delay the start of the compressor until this temperature is met Oil Cooler The oil must be cooled when the compres sor is running This is accomplished through a small plate type heat exchanger located behind the oil pump The heat exchanger uses liquid condenser refrigerant as the cooling liquid A refrigerant thermostatic expansion valve TXV regu lat
35. Wire multiple inputs in series The open ing of any contact will result in a safety shutdown and LID display Refer to the certified drawings for safety contact ratings Analog temperature sensors may also be added to the options modules if installed These may be programmed to cause an alert on the CCN network but will not shut the chiller down SPARE ALARM CONTACTS Two spare sets of alarm contacts are provided within the starter The contact ratings are provided in the certified drawings The contacts are located on terminal strip TB6 terminals 5A and 5B and terminals 5C and 5D Condenser Pump Control The chiller will moni tor the CONDENSER PRESSURE and may turn on this pump if the pressure becomes too high whenever the compressor is shut down CONDENSER PRESSURE OVERRIDE is used to determine this pressure point This value is found on the Equipment Servicel LID table and has a default value Table 4 If the CONDENSER PRESSURE is greater than or equal to the CONDENSER PRESSURE OVERRIDE and the ENTERING CONDENSER WATER TEMP Temper ature is less than 115 F 46 C then the condenser pump will energize to try to decrease the pressure The pump will turn off when the condenser pressure is less than the pressure override less 5 psi 34 kPa or the CONDENSER REFRIG Refrigerant TEMP is within 3 F 2 C of the ENTERING CONDENSER WATER temperature Condenser Freeze Prevention This control algorithm helps prevent cond
36. backup wrench on the Schrader fit ting whenever removing a transducer 67 Control Algorithms Checkout Procedure The Control Algorithm Status table is in the LID Service menu The Control Algorithm Status table contains maintenance tables that may be viewed in order to see how the particular control algorithm is operating The tables are MAINTO1 Capacity This table shows all values that Control are used to calculate the chilled water brine control point MAINTO2 Override Details of all chilled water control Status override values are viewed here MAINTOS3 The surge and hot gas bypass control algorithm status is viewed from this screen All values deal ing with this control are displayed MAINT04 LEAD LAG This screen indicates LEAD LAG PSIO Status operation status Software Version 09 and Higher OCCDEFM Time The Local and CCN occupied Schedules schedules are displayed here in Status a manner that the operator can quickly determine whether the schedule is in the OCCUPIED mode or not WSMDEFME The water system manager is a CCN module which can turn on the chiller and change the chilled water control point This screen indicates the status of this system These maintenance tables are very useful in determining how the control temperature is calculated the position of the guide vane reaction from load changes control point over rides hot gas bypass reaction surge prevention etc Control Test The Contr
37. both optional 8 input modules and sensors NEXT PREVIOUS SELECT ENTER 3 Press SELECT to view the Point Status table desired PREVIOUS gO SELECT ENTER Control Mode Fig 15 Example of Point Status Screen Status01 15 4 On the Point Status table press NEXT or PREVIOUS until desired point is displayed on the screen NEXT PREVIOUS SELECT ENTER BEN OVERRIDE OPERATIONS To Override a Value or Status 1 the Point Status table press PREVIOUS to highlight the desired point NEXT PREVIOUS SELECT EXIT E qj 2 Press 5 to select the highlighted point Then PREVIOUS EXIT For Discrete Points Press START STOP to se lect the desired state SELECT START STOP RELEASE ENTER For Analog Points Press INCREASE DECREASE to select the desired value INCREASE DECREASE RELEASE ENTER RED ESI 3 Press to register new value INCREASE DECREASE RELEASE NOTE When overriding or changing metric values it is necessary to hold the softkey down for a few seconds in or der to see a value change especially on kilopascal values ENTER To Remove an Override 1 the Status table press NEXT or Point PREVIOUS to highlight the desired point NEXT PREVIOUS SELECT EXIT 2 Press 5
38. chamber between the FLASC chamber and cooler Here a float valve forms a liquid seal to keep FLASC chamber vapor from entering the cooler When liquid refrigerant passes through the valve some of it flashes to vapor in the reduced pressure on the cooler side In flashing it removes heat from the remaining liquid The refrigerant is now at a temperature and pressure at which the cycle began MOTOR OIL REFRIGERATION COOLING CYCLE The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel Fig 3 Flow of refrigerant is maintained by the pressure differential that exists due to compressor operation After the refrigerant flows past an isolation valve an in line filter and a sight glass moisture indicator the flow is split between motor cooling and oil cooling systems Flow to the motor flows through an orifice and into the motor There is also another orifice and a solenoid valve which will open if additional motor cooling is required Once past the orifice the refrigerant is directed over the motor by a spray nozzle The refrigerant collects in the bottom of the motor casing and then is drained back into the cooler through the motor refrigerant drain line A back pressure valve or an orifice in this line maintains a higher pressure in the motor shell than in the cooler oil sump The motor is protected by a temperature sensor imbedded in the stator windings Higher motor temperatures a
39. charging valve open the iso lation valves to the filter housing and turn on the power to the pump and the motor Oil Specification The 19XL compressor holds ap proximately 11 7 gal 44 3 of oil If oil is added it must meet the following Carrier specifications e Oil type for HCFC 22 Chillers only Alkyl benzene based synthetic compressor oil specifically formatted for use in HCFC 22 gear driven machines ISO Viscosity Grade e Oil Type for units using 134 Inhibited polyolester based synthetic compressor oil formatted for use with HFC gear driven hermetic compressors ISO Viscosity Grade The alkyl benzene type oil part number PP23BZ101 or the polyolester based oil part number PP23BZ103 may be ordered from your local Carrier representative Oil Changes Carrier recommends changing the oil after the first year of operation and every 3 years thereafter as a minimum in addition to a yearly oil analysis However if a continuous oil monitoring system is functioning and a yearly oil analysis is performed time between oil changes can be extended TO CHANGE THE OIL 1 Transfer the refrigerant into the condenser for isolatable vessels or a storage tank 2 Mark the existing oil level Open the control and oil heater circuit breaker When the chiller pressure is 5 psi 34 kPa or less drain the oil reservoir by opening the oil charging valve Fig 2A or Fig 2B Slow
40. condenser vessels are at 0 psig 0 kPa or are open to atmospheric pressure the trans ducers can be calibrated for zero without removing the transducer from the vessel 3 Access the Status01 table and view the particular trans ducer reading it should read 0 psi 0 kPa If the reading is not 0 psi 0 kPa but within 5 psi 35 kPa the value may be zeroed by pressing the SELECT softkey while the highlight bar is located on the transducer and then by pressing the ENTER The value will now go to zero If the transducer value is not within the calibration range the transducer will return to the original reading If the LID pressure value is within the allowed range noted above check the voltage ratio of the transducer To ob tain the voltage ratio divide the voltage dc input from the transducer by the supply voltage signal measured at the PSIO terminals J7 J34 and J7 J35 For example the condenser transducer voltage input is measured at PSIO terminals J7 1 and J7 2 The voltage ratio must be be tween 0 80 vdc and 0 11 vdc for the software to allow calibration Pressurize the transducer until the ratio is within range Then attempt calibration again 4 A high pressure point can also be calibrated between 240 and 260 psig 1655 and 1793 by attaching a regulated 250 psig 1724 kPa pressure usually from a nitrogen cylinder The high pressure point can be cali brated by accessing the transducer on the Stat
41. configuration can be downloaded from the computer Any communication wires from other chillers or CCN modules should be disconnected to prevent the new PSIO module from uploading incorrect run hours into memory To install this module first record the TOTAL COM PRESSOR STARTS and the COMPRESSOR ONTIME from the 5 01 table screen on the LID Power off the controls Remove the old PSIO DO NOT install the new PSIO at this time Turn on the control power When the LID screen re appears press the MENU softkey then press the SERVICE softkey Enter the password if applicable Move the highlight bar down to the ATTACH TO NET WORK DEVICE line Press the SELECT softkey Now press the softkey The LID will dis play UPLOADING TABLES PLEASE WAIT and then display COMMUNICATIONS FAILURE Press the EXIT softkey Turn the control power off Install the new PSIO module Turn the control power back on The LID will now automatically upload the new PSIO module Access the Status01 table and move the highlight bar down to the TOTAL COMPRESSOR STARTS line Press the softkey Increase the value to indicate the correct starts value recorded in Step 2 Press the softkey when you reach the correct value Now move the highlight bar to the COMPRESSOR ON TIME line Press the softkey Increase the run hours value to the value recorded in Step 2 Press the softkey when the c
42. cooler temperature differ ence This type of reset will add 30 16 C based on the temperature difference between entering and leaving chilled water temperature This is the only type of reset available without the need of the number one 8 input module No wir ing is required for this type as it already uses the cooler water sensors To configure Reset Type 3 enter the chilled water temperature difference the difference between enter ing and leaving chilled water at which no temperature reset occurs This chilled water temperature difference is usually the full design load temperature difference The difference in chilled water temperature at which the full amount of reset will occur is now entered on the next input line Next the amount of reset is entered Reset Type 3 can now be activated Demand Limit Control Option Requires Optional 8 Input Module The demand limit may be externally controlled with a 4 to 20 mA signal from an energy management system EMS The option is set up on the Config table When enabled the control is set for 10096 demand with 4 mA and an operator configured minimum de mand set point at 20 mA The Demand Reset input from an energy management system is hardwired into the number one 8 input module The signal may be internally powered by the module or externally powered If the signal is externally powered the signal is wired to terminals J1 1 and J1 2 If the sig nal is int
43. for cor rosion rust leaks or damage PROVIDE A DRAIN connection in the vent line near each pres sure relief device to prevent a build up of condensate or rain water Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 531 971 Book 2 PC 211 Tab 5 Printed in U S A Form 19XL 4SS Pg 1 7 96 Replaces 19XL 3SS CONTENTS Page SAFETY CONSIDERATIONS 1 INTRODUCTION 4 ABBREVIATIONS AND EXPLANATIONS 4 CHILLER FAMILIARIZATION 5 Chiller Information Plate 5 System Components 5 Cooler ee Seele dee 5 5 Motor Compressor 5 Control Center 5 Factory Mounted Starter Optional 5 Storage Vessel 5 REFRIGERATION CYCLE 5 MOTOR OIL REFRIGERATION COOLING 5 8 LUBRICATION CYCLE 8 9 Summary EXE HR ES 8 Details T ete heit 8 Reclaim System 9 DURING NORMAL CHILLER OPERATION DURING LIGHT LOAD CONDITIONS STARTING EQUIPMENT 10 11 Unit Mounted Solid State Starter Optional
44. for signs of wear REFRIGERANT The frequency of examination is determined by the hours of FROM CONDENSER chiller operation load conditions during operation and the condition of the oil and the lubrication system Excessive bearing wear can sometimes be detected through increased vibration or increased bearing temperature If either symp tom appears contact an experienced and responsible service organization for assistance REFRIGERANT TO COOLER Inspect the Heat Exchanger Tubes FLOAT BALL COOLER Inspect and clean the cooler tubes at the end of the first operating season Because these tubes have internal ridges a rotary type tube cleaning system is necessary to fully COVER clean the tubes Upon inspection the tube condition will determine the scheduled frequency for cleaning and will indicate whether water treatment is adequate in the chilled water brine circuit Inspect the entering and leaving chilled water temperature sensors for signs of corrosion or scale ASME NAMEPLATE Replace the sensor if corroded or remove any scale if found FROM CONDENSER CONDENSER Since this water circuit is usually open type system the tubes may be subject to contamination and scale Clean the condenser tubes with a rotary tube clean STRAINER ing system at least once per year and more often if the water SCREEN is contaminated Inspect the entering and leaving condenser water sensors for s
45. holddown bolts 2 Loosen guide vane sprocket adjusting bolts 3 Pry bracket upwards to remove slack then retighten the bracket holddown bolts 4 Retighten the guide vane sprocket adjusting bolts Make sure that the guide vane shaft is rotated fully in the clock wise direction in order for it to be fully closed CHECKING THE AUXILIARY SWITCH ON GUIDE VANE ACTUATOR The auxiliary switch used to activate the oil reclaim system solenoids should move to the OPEN posi tion when the actuator is 70 degrees open At this point the guide vanes should be 30 degrees open Trim Refrigerant Charge If it becomes necessary to adjust the refrigerant charge to obtain optimum chiller per formance operate the chiller at design load and then add or remove refrigerant slowly until the difference between leav ing chilled water temperature and the cooler refrigerant tem perature reaches design conditions or becomes a minimum Do not overcharge 62 ELECTRONIC VANE ACTUATOR SPROCKET ACTUATOR DRIVE CHAIN ACTUATOR BRACKET HOLDDOWN BOLTS CHAIN GUARD GUIDE VANE GUIDE SHAFT VANE SPROCKET GUIDE VANE SPROCKET ADJUSTING BOLTS Fig 36 Guide Vane Actuator Linkage Refrigerant may be added either through the storage tank or directly into the chiller as described in the Charge Refrigerant into Chiller section To remove any excess refrigerant follow the procedure in Transfer Refrigerant from Chiller to Storag
46. information Once all alarms have been cleared the default LID screens will return to normal operation The Control Algorithm Status tables will display various screens of information in order to diagnose problems with chilled water temperature control chilled water temper ature control overrides hot gas bypass surge algorithm status and time schedule operation The Control Test feature allows proper operation and test ing of temperature sensors pressure transducers the guide vane actuator oil pump water pumps tower control and other on off outputs while the compressor is stopped It also has the ability to lock off the compressor and turn on water pumps for pumpout operation The display will show the required temperatures and pressures during these operations Other Service menu tables can access configured items such as chilled water resets override set points etc If an operating fault is detected an alarm message is gen erated and displayed on the LID default screen A more detailed message along with a diagnostic message also is stored into the Alarm History table Checking the Display Messages The first area to check when troubleshooting the 19XL is the LID display If the alarm light is flashing check the primary and second ary message lines on the LID default screen Fig 13 These messages will indicate where the fault is occurring The Alarm History table on the LID Service menu will also carry
47. is from the control point Proportional gain determines how quickly the guide vanes react to how quickly the tempera ture is moving from CONTROL POINT The proportional band can be viewed modified on the LID There are two response modes one for temperature re sponse above the control point the other for response below the control point The first type is called PROPORTIONAL INC BAND and it can slow or quicken vane response to chilled water brine temperature above DEADBAND It can be adjusted from a setting of 2 to 10 the default setting is 6 5 PRO PORTIONAL DEC BAND can slow or quicken vane re sponse to chilled water temperature below deadband plus control point It can be adjusted on the LID from a setting of 2 to 10 and the default setting is 6 0 Increasing either of these set tings will cause the vanes to respond slower than at a lower setting The PROPORTIONAL ECW GAIN can be adjusted at the LID display from a setting of 1 0 to 3 0 with a default setting of 2 0 Increase this setting to increase guide vane response to a change in entering chilled water temperature The propor tional bands and gain may be viewed modified on the Equip ment Service3 table 28 DEMAND LIMITING The PIC will respond to the ACTIVE DEMAND LIMIT set point by limiting the open ing of the guide vanes It will compare the set point to either COMPRESSOR MOTOR LOAD or COMPRES SOR MOTOR CURRENT percentage depending on how the contro
48. is still not resolved consult the starter manu facturer for servicing IS MOTOR ARE POWER START ARE LINE NO WINDING No AREALL YES scrsok ANALYSIS CURRENTS GATE PULSES HERE BALANCED SHORTED PRESENT CHECK WITH GROUNDED OHMMETER YES NO SEE MOTOR WILL NOT REPAIR OR REPLACE REPLACE REPLACE LOGIC DEFECTIVE MOTOR PACKAGE SCRS START GUIDE FIG 46 RETURN TO RETURN TO RETURN TO NORMAL NORMAL NORMAL OPERATION OPERATION OPERATION CONSULT STARTER MANUFACTURER DOES MOTOR PRODUCE LOUD yEs GROWL WHEN START BUTTON IS PRESSED DOES MOTOR HAVE INTERMITTENT NO REPLACE DOES GROUND OR LOGIC PROBLEM OVERCURRENT MECHANICAL OVERLOAD CONSULT STARTER MANUFACTURER REPAIR OR RETURN TO WITH A LISTING REPLACE NORMAL OF THE MOTOR S MOTOR OPERATION RETURN TO NORMAL OPERATION LEGEND SCR Silicon Control Rectifier See test procedure described in Testing SCRs in Solid State Starters section on page 81 Fig 45 Solid State Starter General Operation Troubleshooting Guide Typical 82 START ANALYSIS HERE IS 3 PHASE SUPPLY TOO LOW OR MISSING ARE FUSES IS PROPER VOLTAGE PRESENT AT LINE SIDE OF MAIN CIRCUIT BREAKER 1 MAIN CIRCUIT BREAKER OK YES REPAIR REPLACE OR REPLACE
49. leaks are present This should only be done if all refrigerant has been evacuated from the vessel 1 Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve Never apply full cylinder pressure to the pressurizing line Follow the listed sequence 2 Open the charging valve fully 3 Slowly open the cylinder regulating valve 4 Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level Do not exceed 140 psig 965 kPa 5 Close the charging valve on the chiller Remove the cop per tube if no longer required Repair the Leak Retest and Apply Standing Vacuum Test After pressurizing the chiller test for leaks with an electronic halide leak detector soap bubble solution or an ultrasonic leak detector Bring the chiller back to atmospheric pressure repair any leaks found and retest After retesting and finding no leaks apply a standing vacuum test and then dehydrate the chiller Refer to the Standing Vacuum Test and Chiller Dehydration in the Before Initial Start Up section pages 43 and 47 Checking Guide Vane Linkage When the chiller is off the guide vanes are closed and the actuator mecha nism is in the position shown in Fig 36 If slack develops in the drive chain backlash can be eliminated as follows 1 With the machine shut down and the actuator fully closed remove the chain guard and loosen the actuator bracket
50. one chiller vessel to another without the need for an external storage tank and valve 7 stays closed See Fig 27 28 and 35 for valve locations Push refrigerant into chiller condenser a Valve positions VALE 1a 1b 2 3 5 8 t 12 13 14 je cje b Turn off chiller water pumps and pumpout unit con denser water c Turn on pumpout compressor to push liquid out of the cooler compressor d When all liquid has been pushed into the condenser close cooler isolation valve 11 e Access the Control Test Pumpdown table on the LID display to turn on the chiller water pumps f Turn off the pumpout compressor 2 Evacuate gas from cooler compressor vessel a Close pumpout valves 2 and 5 and open valves 3 and 4 VavE 1b 2 4 8 1 12 13 14 b Turn on pumpout condenser water c Run pumpout until the compressor reaches 18 in Hg vac 40 kPa abs Monitor pressures on the LID and on refrigerant gages d Close valve 1a e Turn off pumpout compressor f Close valves 1b 3 and 4 vave 2 3 4 5 v 2 13 74 Turn off pumpout condenser water Proceed to Pumpdown test on the LID to turn off chiller water pumps and lock out chiller compressor TRANSFER ALL REFRIGERANT TO CHILLER COOLER COMPRESSOR VESSEL Push refrigerant into the chiller cooler vesse
51. revert to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the Pumpdown mode Fig 13 When not in the default screen the upper right hand cor ner of the LID always displays the name of the screen that you have entered Fig 14 The LID may be configured in English or SI units through the LID configuration screen Local Operation By pressing the LOCAL softkey the PIC is now in the LOCAL operation mode The control will accept changes to set points and configurations from the LID only The PIC will use the Local Time Schedule to determine chiller start and stop times CCN Operation By pressing the softkey the PIC is now in the CCN operation mode and the control will accept modifications from any CCN interface or module with the proper authority as well as the LID The PIC will use the CCN time schedule to determine start and stop times PRIMARY STATUS COMPRESSOR DATE TIME MESSAGE ON TIME SECONDARY STATUS s MESSAGE 9 CHW IN CHW OUT EVAP REF ALARM LIGHT 55 1 44 1 40 7 ILLUMINATED CDW IN CDW OUT COND REF WHEN POWER ON 85 0 95 0 98 1 BLINKS CONTINUOUSLY OILPRESS OIL TEMP MTR AMPS ON FOR AN ALARM 21 8 132 9 93 BLINKS ONCE TO CRESET _ MEND CONFIRM A STOP STOP BUTTON HOLD FOR ONE SECOND TO STOP SOFT KEYS EACH KEY S FUNCTION IS RE DEFINED BY THE MENU DESCRIPTION ON MENU LINE ABOVE Fig
52. such as the one shown in Fig 33 provides a convenient check list for routine inspection and maintenance and provides a continuous record of chiller performance It is an aid in scheduling routine maintenance and in diagnosing chiller problems Keep a record of the chiller pressures temperatures and liquid levels on a sheet similar to that shown Automatic recording of PIC data is possible through the use of CCN devices such as the Data Collection module and a Building Supervisor Contact your Carrier representative for more information ee sjunowe epnjou peureJp pue parowa JO pappe JO 5 Ajayes uo suwopinus eieoipu SyHVIASH SMYVINAY uonisod 10 JIOAJOSOJ no e onvas dwor emsseig H3SN3QNOO S IVILINI 0553 827003 LNVH39OIH33H 1VIH3S H3TIIHO TAGOW H3TIIHO 3NIHOVIN NOILVH39IHJ33H TWONEIYLNAD DIL3INH3H 1 61 H3lHHVO 907 NOILVH3OIHHHH ejeq 58 PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation The 19XL may come equipped with an optional storage tank or pumpout system or a pump out compressor The refrigerant can be pum
53. temperature is within limits SCHEDULED MAINTENANCE Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load run hours and water quality The time intervals listed in this section are offered as guides to service only Service Ontime The LID will display a SERVICE ONTIME value on the Status01 table This value should be reset to zero by the service person or the operator each time major service work is completed so that time between serv ice can be viewed Inspect the Control Center Maintenance is lim ited to general cleaning and tightening of connections Vacuum the cabinet to eliminate dust build up In the event of chiller control malfunctions refer to the Troubleshooting Guide sec tion for control checks and adjustments CAUTION Be sure power to the control center is off when cleaning and tightening connections inside the control center Check Safety and Operating Controls Monthly ensure chiller protection the Control Test Automated Test should be done at least once per month See Table 3 for safety control settings See Table 7 for Control Test functions Changing Oil Filter Change the oil filter on a yearly basis or when the chiller is opened for repairs The 19XL has an isolatable oil filter so that the filter may be changed with the refrigerant remaining in the chiller Use the follow ing procedure 1 Make sure that the compressor is off a
54. the configured lag chiller takes the lead chiller s place as the lead chiller and the standby chiller serves as the lag chiller If the configured lead chiller does not complete the start up before the PRESTART FAULT TIMER user configured value elapses then the lag chiller shall be started and the lead chiller will shut down The lead chiller then monitors the start request from the acting lead chiller to start The PRE START FAULT TIMER is initiated at the time of a start request The PRESTART FAULT TIMER s function is to provide a timeout in the event that there is a prestart alert condition preventing the chiller from starting in a timely man ner The timer is configured under Lead Lag found in the Equipment Configuration table of the Service menu If the lag chiller does not achieve start up before the PRESTART FAULT TIMER elapses then the lag chiller shall be stopped and the standby chiller will be requested to start if configured and ready Standby Chiller Configuration and Operation The con figured standby chiller is identified as such by having the LEAD LAG SELECT configured to the value of 3 The standby chiller can only operate as a replacement for the lag chiller if one of the other two chillers is in an alarm condition as shown on the LID panel If both lead and lag chillers are in an alarm condition the standby chiller shall default to operate in CCN mode based on its configured Occupancy Schedul
55. this time is now displayed on the LID Certain conditions during shutdown will change this sequence if the COMPRESSOR MOTOR LOAD is greater than 1096 after shutdown or the starter contacts remain energized the oil pump and chilled water pump remain energized and the alarm is displayed if the ENTERING CONDENSER WATER temperature is greater than 115 F 46 C at shutdown the condenser pump will be deenergized after the 1CR compressor start relay if the chiller shuts down due to low refrigerant tempera ture the chilled water pump will stay running until the LEAVING CHILLED WATER is greater than CONTROL POINT plus 5 F 3 C Automatic Soft Stop Amps Threshold PSIO Soft ware Version 09 and Higher The SOFT STOP AMPS THRESHOLD closes the guide vanes of the com pressor automatically when a non recycle non alarm stop signal occurs before the compressor motor is deenergized 40 If the STOP button is pressed the guide vanes close to a preset amperage percent or until the guide vane is less than 2 open The compressor will then shut off If the chiller enters an alarm state or if the compressor enters a RECYCLE mode the compressor will be de energized immediately To activate SOFT STOP AMPS THRESHOLD view the bottom of Servicel table Set the SOFT STOP AMPS THRESHOLD value to the percentage amps at which the motor will shut down The default setting is 100 amps no Soft Stop When the SOFT STOP AMPS THRESHOLD is b
56. time The oil heater is energized by powering the control cir cuit This should be done several hours before start up to minimize oil refrigerant migration The oil heater is con trolled by the PIC and is powered through a contactor in the power panel Starters contain a separate circuit breaker to power the heater and the control circuit This set up allows the heater to energize when the main motor circuit breaker is off for service work or extended shutdowns The oil heater relay status can be viewed on the Status02 table on the LID Oil sump temperature can be viewed on the LID default screen When the Time Date is configured for the first time or if power is lost for more than 3 hours the oil heat algorithm will take effect before the compressor can start See the Oil Sump Temperature Control section on page 32 for addi tional information The oil pump will then energize for 1 to 2 minutes to bring the oil temperature to normal operating temperature A LOW OIL TEMPERATURE alert will show on the default LID screen if the operator has the controls set to start SOFTWARE VERSION The software version will always be labeled on the PSIO module and on the back side of the LID module On both the Controller ID and LID ID display screens the software version number will also appear Set Up Chiller Control Configuration WARNING Do not operate the chiller before the control configu rations have been checked and a Control Test has
57. tripped E NORMAL OR AUTO RESTART PRIMARY MESSAGE STARTUP IN PROGRESS STARTUP IN PROGRESS STARTUP IN PROGRESS AUTORESTART IN PROGRESS AUTORESTART IN PROGRESS AUTORESTART IN PROGRESS SECONDARY MESSAGE OCCUPIED MODE REMOTE CONTACT CLOSED START COMMAND IN EFFECT OCCUPIED MODE REMOTE CONTACT CLOSED START COMMAND IN EFFECT NOTE See Legend on page 68 69 PROBABLE CAUSE REMEDY Chiller starting Time schedule is occupied Chiller starting Remote contacts are closed Chiller starting Chiller START STOP on Status01 manu ally forced to start Chiller starting Time schedule is occupied Chiller starting Remote contacts are closed Chiller starting Chiller START STOP on Status01 manu ally forced to start Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont F START UP FAILURES This is an alarm condition A manual reset is required to clear PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START FAILURE TO START LOW OIL PRESSURE OIL PRESS SENSOR FAULT LOW CHILLED WATER FLOW LOW CONDENSER WATER FLOW STARTER FAULT STARTER OVERLOAD TRIP LINE VOLTAGE DROPOUT HIGH CONDENSER PRESSURE EXCESS ACCEL
58. 0 170 ON 160 AP 150 s 140 psi HGBP SURGE E PREVENTIONSS X 100 Ss 2005 79 ____ S 3 AT F LEGEND ECW Entering Chilled Water HGBP Hot Gas Bypass LCW Leaving Chilled Water Condenser Psi Cooler Psi ECW LCW Fig 20 19XL Hot Gas Bypass Surge Prevention AP kPa 19XL DEFAULT 8 1550 HCFC 2 pe E 282 1425 2 5 6 AP2 1172 1300 1175 HGBP SURGE PREVENTION 5 6 1172 1050 925 800 675 550 8 517 425 300 NS 2 4 6 810 2 0 3 0 4 0 5 0 6 0 AT C LEGEND ECW Entering Chilled Water HGBP Hot Gas Bypass LCW Leaving Chilled Water P Condenser kPa Cooler kPa ECW LCW Fig 21 19XL with Default Metric Settings Lead Lag System Requirements all chillers must have PSIO software capable of perform ing the lead lag function water pumps MUST be energized from the PIC controls water flows should be constant CCN Time Schedules for all chillers must be identical Operation Features 2 chiller lead lag addition of a third chiller for backup manual rotation of lead chiller load balancing if configured staggered restart of the chillers after a power failure chillers may be piped in parallel or in series chilled water flow COMMON POINT SENSOR INSTALLATION Lead lag operation does not require a common chilled water point sensor Common point sensors can be added to the 8 input opti
59. 0096 OCCUPIED if the operator wishes The schedules also can be bypassed by forcing the Start Stop command on the PIC Status screen to start The schedules also can be overridden to keep the unit in an OC CUPIED mode for up to 4 hours on a one time basis Figure 18 shows a schedule for a typical office building time schedule with a 3 hour off peak cool down period from midnight to 3 a m following a weekend shutdown Example Holiday periods are unoccupied 24 hours per day The building operates Monday through Friday 7 00 a m to 6 00 p m with a Saturday schedule of 6 00 a m to 1 00 p m and includes the Monday midnight to 3 00 a m weekend cool down schedule NOTE This schedule is for illustration only and is not in tended to be a recommended schedule for chiller operation PSIO Software Version 08 and Lower Whenever the chiller is in the LOCAL mode the chiller will start when the Occupancy Schedule 01 indicates OCCUPIED When in the CCN mode Occupancy Schedule 02 is used PSIO Software Version 09 and Higher The Local Time Schedule is still the Occupancy Schedule 01 The Ice Build Time Schedule is Schedule 02 and the CCN Default Time Schedule is Schedule 03 The CCN schedule number is de fined on the Config table in the Equipment Configuration table on page 23 The schedule number can change to any value from 03 to 99 If this schedule number is changed on the Config table the operator must use the Attach to Net wo
60. 0HZ PRI PR2 PR3 PR3 PR4 PRS ALARM PRS ALARM r w ee 6 5 5 se Te 8 e e S 8S 8 ee e 6 s All starters TO SHUNT TRIP RELAY COND HI PRESS MACHINE POWER PANEL ao OIL HEATER OIL PUMP CONTACTOR CONTACTOR 11 12 13 11 12 5 1252 WHT BLK Lo GROUND LUG REMOTE 0 DRY CONTACT EVAPORATOR WATER FLOW DRY CONTACT CONDENSER WATER FLOW DRY CONTACT SPARE SAFETY N C DRY CONTACT BLK CBRN CORN RED CLR BLK RED OIL PRESS SWITCH XXXV 3PH 50 60HZ LEGEND Main Starter Contactor PR Contactor PWR Circuit Board RLA Control Relay SMM Communications Connector TB Connector X Normally Closed Normally Open Overload 3 Phase Current Power Source h Pilot Relay Power Rated Load Amps Starter Management Module Terminal Board Variable Number Starter Cabinet Wiring Field Wiring Carrier Factory Wiring including across the line starters require 2 separate contacts for the START AUX DRY contact and RUN AUX DRY contact as shown above Fig 50 Chiller Power Panel Starter Assembly and Motor Wiring Schematic 94 MODULE 24VAC 24 28VAC C40VA 2 5VA CB 2 3 2 TRIM TO 24VAC AT RATED STARTER VOLTAGE START 1M or 1
61. 13 LID Default Screen DEVICE NAME SCREEN NAME 19XL CHLR SERVICE ATTACH TO NETWORK DEVICE CONTROLLER IDENTIFICATION EQUIPMENT CONFIGURATION CONTROLS TEST EQUIPMENT SERVICE LID CONFIGURATION TIME AND DATE CONTROL ALGORITHM STATUS LOG OUT OF DEVICE NEXT PREVIOUS SELECT EXIT Fig 14 LID Service Screen 14 ALARMS AND ALERTS Alarm and alert status are indicated on the Status tables An alarm will shut down the compressor An alert notifies the operator that an un usual condition has occurred The chiller will continue to operate when an alert is shown Alarms are indicated when the control center alarm light flashes The primary alarm message is viewed on the de fault screen and an additional secondary message and troubleshooting information are sent to the Alarm History table When an alarm is detected the LID default screen will freeze stop updating at the time of alarm The freeze en ables the operator to view the chiller conditions at the time of alarm The Status tables will show the updated informa tion Once all alarms have been cleared by pressing the softkey the default LID screen will return to nor mal operation MENU STRUCTURE To perform any of the operations described below the PIC must be powered up and have suc cessfully completed its self test The self test takes place automatically after power up e Press QUIT to leave the selected decision or field wi
62. 13 1 12 11 10 9 2 LEGEND 1 Field Wiring Terminal Strips TB2 and TB3 2 Breaker 1 2 3 4 3 Overload Unit 4 Solid State Controller 5 Silicon Controlled Rectifier SCR LED One of 6 6 Starter Fault and Run LEDs 7 Voltmeter Optional 8 Ammeter Optional 9 SCR One of 6 10 Voltage LED 11 Starter Management Module SMM 12 Pilot Relays PR1 to PR5 13 Starter Access Door Fig 5 Benshaw Inc Solid State Starter Internal View LOW SMM OPTIONAL SIDE VOLTAGE INSIDE ANALOG SERVICE ACCESS 3 PHASE ACCESS CURRENT AND PANEL VOLTMETERS POWER STARTER AIR DISCONNECT ACCESS INTAKE HANDLE DOOR LOUVERS FRONT VIEW RIGHT END VIEW Fig 6 Typical Starter External View Solid State Starter Shown There are a number of LEDs light emitting diodes that are useful in troubleshooting and starter check out on Benshaw Inc solid state starters These are used to indicate voltage to the SCRs SCR control voltage power indication proper phasing for rotation start circuit energized overtemperature ground fault current unbalance run state These LEDs are further explained in the Check Starter and Troubleshooting Guide section page 66 Unit Mounted Wye Delta Starter Optional The 19XL chiller may be equipped with a wye delta starter mounted on the unit Fig 7 This starter is intended for use with low voltage motors under
63. 19XL Hermetic Centrifugal Liquid Chillers 50 60 Hz With HCFC 22 and HFC 134a Start Up Operation and Maintenance Instructions SAFETY CONSIDERATIONS Centrifugal 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 Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide DANGER DO NOT VENT refrigerant relief valves within a building Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI ASHRAE 15 American National Standards Institute American Society of Heat ing Refrigeration and Air Conditioning Engineers The accumu lation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation PROVIDE adequate ventilation in accordance with ANSI ASHRAE 15 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 avail able for breathing Product causes eye and skin irritation Decom position products are hazardous DO NOT USE OXYGEN to purge lines or to pressurize a chil
64. 2 Temp Alert Threshold 40 245 40 118 0 2 40 245 40 118 2 40 245 40 118 40 245 40 118 0 2 0 40 245 40 118 Spare Temp 4 Enable 0 Spare Temp 4 Alert 40 118 Spare Temp 5 Enable 0 2 Spare Temp 5 Alert 40 118 Spare Temp 6 Enable Spare Temp 6 Alert 40 118 Spare Temp 7 Enable 0 Spare Temp 7 Alert 40 118 Spare Temp 8 Enable 0 2 Spare Temp 8 Alert 0 118 Spare Temp 9 Enable 0 Spare Temp 9 Alert 40 245 40 118 DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C CONFIGURABLE RANGE UNITS REFERENCE POINT NAME res 20 ma dem 20 ma chws chws chwr en chwr al 5 en rres__al spri en spri al spr2 en spr2 al spr3 en spr3 al 1 20 ma sp2 20 ma spr4 en spr4 al Spr5 Spr5 al Spr6 Spr6 al Spr7 Spr7 Spr8 en Spr8 5 9 Spr9 al DEFAULT VALUE 118 1 1 0 245 0 245 0 245 0 245 0 245 0 245 1 1 18 18 18 18 118 NOTE This screen provides the means to generate alert messages based on exceeding the Temp Alert threshold for each point listed If the Enable is set to 1 a value above the Temp Alert threshold shall generate an alert message If the Enable is s
65. 3 Add to heat exchanger weights and volumes for total weight or volume HEAT EXCHANGER FRAME PASS Water Volume L Condenser FRAME 4 2 PASS FRAME 4 1 amp 3 PASS 85 Table 14 Waterbox Cover Weights ENGLISH Ib FRAME 4 FRAME 5 WATERBOX STANDARD PES STANDARD LANGER EXCHANGER DESCRIPTION NOZZLES NOZZLES 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig 655 685 COOLERS 638 426 766 471 CS 471 373 472 413 549 368 469 428 541 NIH 3 PASS COVER 319 466 336 502 493 419 549 CONDENSERS 226 271 226 271 379 271 379 cs 590 cs 428 SI kg s EAE db EET FRAME 5 EXCHANGER DESCRIPTION NOZZLES NOZZLES 2068 kPa 297 311 COOLERS 290 193 CS 348 PLAIN COVER CS 219 CS 29 cs 24 CS 214 249 246 CONDENSERS 249 172 268 194 LEGEND These weights are for reference only To determine frame size see Fig 1 NIH Nozzle in Head NOTE For Design chillers the 150 psig 1034 kPa standard waterbox cover weights NIH 2 pass MWB Marine Waterbox cover have been included in the heat exchanger weights shown in Table 12 Design chillers are CS Contact Syracuse equipped a linear float and chiller weight is based on a 300 psig 2066 kPa waterbox with 1 pass arrangement 86 Table 15 Compressor Motor Weights ENGLISH SI SIZE Weight Ib Ib Cover Weight k
66. 3 638 6 4 540 35 313 90 3 640 174 626 7 4 527 34 231 91 3 556 175 614 8 4 514 33 185 92 3 474 176 602 9 4 501 32 176 93 3 395 177 591 10 4 487 31 202 94 3 318 178 581 11 4 472 30 260 95 3 243 179 570 12 4 457 29 351 96 3 170 180 561 13 4 442 28 473 97 3 099 181 551 14 4 427 27 624 98 3 031 182 542 15 4 413 26 804 99 2 964 183 533 16 4 397 26 011 100 2 898 184 524 17 4 381 25 245 101 2 835 185 516 18 4 366 24 505 102 2 773 186 508 19 4 348 23 789 103 2 713 187 501 20 4 330 23 096 104 2 655 188 494 21 4 313 22 427 105 2 597 189 487 22 4 295 21 779 106 2 542 190 480 23 4 278 21 153 107 2 488 191 473 24 4 258 20 547 108 2 436 192 467 25 4 241 19 960 109 2 385 193 461 26 4 223 19 393 110 2 335 194 456 27 4 202 18 843 111 2 286 195 450 28 4 184 18 311 112 2 239 196 445 29 4 165 17 796 113 2 192 197 439 30 4 145 17 297 114 2 147 198 434 31 4 125 16 814 115 2 103 199 429 32 4 103 16 346 116 2 060 200 424 33 4 082 15 892 117 2 018 201 419 34 4 059 15 453 118 1 977 202 415 35 4 037 15 027 119 1 937 203 410 36 4 017 14 614 120 1 898 204 405 37 3 994 14 214 121 1 860 205 401 38 3 968 13 826 122 1 822 206 396 39 3 948 13 449 123 1 786 207 391 40 3 927 13 084 124 1 750 208 386 41 3 902 12 730 125 1 715 209 382 42 3 878 12 387 126 1 680 210 377 43 3 854 12 053 127 1 647 211 372 44 3 828 11 730 128 1 614 212 367 45 3 805 11 416 129 1 582 213 361 46 3 781 11 112 130 1 550 214 356 47 3 757 10 816 131 1 519 215 350 48 3 729 10 529 132 1 489 216 344 49
67. 6 93 DEG F DEG C mt over 200 93 Cond Press Override S0 200 PSI kPa cp over 195 1345 125 862 Refrig Override Delta T 2 5 1 3 DEG F DEG C ref over 3A 1 6A Chilled Medium Water Brine medium WATER Brine Refrig Trippoint 8 40 13 3 4 DEG F DEG C br trip 33 1 Compr Discharge Alert 125 200 52 93 DEG F DEG C cd alert 200 93 Bearing Temp Alert 175 185 79 85 DEG F DEG C tb alert 175 79 Water Flow Verify Time MIN wflow t 5 Cil Press Verify Time SEC oilpr 1 15 Water Brine Deadband DEG F DEG C cw db 1 0 0 6 Recycle Restart Delta T DEG F DEG C rcyc dt 5 2 8 Recycle Shutdown Delta T ADEG F ADEG C rcycs__dt 1 0 0 6 Surge Limit HGBP Option srg hgbp 0 Select Surge 0 HGBP 1 Surge HGBP Delta T1 0 5 15 0 3 8 3 DEG F DEG C 1 5 0 8 50 170 345 1172 80 170 207 1172 0 5 15 0 3 8 3 50 170 345 1172 80 170 207 1172 Surge HGBP Delta P1 Min Load Points T1 P1 Surge HGBP Delta T2 Surge HGBP Delta P2 Full Load Points T2 P2 PSI hgb 75 517 50 345 DEG F DEG C PSI kPa hgb__dt2 10 5 6 hgb__dp2 170 1172 85 586 Surge HGBP Deadband 1 3 0 6 1 6 DEG F DEG C hgb dp 1 0 6 Surge Delta Percent Amps 10 50 96 surge 25 Surge Time Period 1 5 MIN surge t 2 Demand Limit Source dem src 0 Select Amps 0 Load 1 Amps Correction Factor 1 8 corfact 3 Motor Rated Load Amps 1 9999 f 200 Motor Rated Line Vol
68. 69 2830 10 580 40 70 2900 11 600 41 44 Table 5C HFC 134a Pressure Temperature F TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE F psig F psig F psig 0 6 50 60 57 46 120 171 17 2 7 52 62 60 06 122 176 45 4 8 60 64 62 73 124 181 83 6 9 66 66 65 47 126 187 32 8 10 79 68 68 29 128 192 93 10 11 96 70 71 18 130 198 66 12 13 17 72 74 14 132 204 50 14 14 42 74 77 18 134 210 47 16 15 72 76 80 30 136 216 55 18 17 06 78 83 49 138 222 76 20 18 45 80 86 17 140 229 09 22 19 88 82 90 13 24 21 37 84 93 57 26 22 90 86 97 09 28 24 48 88 100 70 30 26 11 90 104 40 32 27 80 92 108 18 34 29 53 94 112 06 36 31 32 96 116 02 38 33 17 98 120 08 40 35 08 100 124 23 42 37 04 102 128 47 44 39 06 104 132 81 46 41 14 106 137 25 48 43 28 108 141 79 50 45 48 110 146 43 52 47 74 112 151 17 54 50 07 114 156 01 56 52 47 116 160 96 58 54 93 118 166 01 Table 5D HFC 134a Pressure Temperature C TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE C GAGE kPa C GAGE kPa C GAGE kPa 18 0 44 8 10 0 314 0 43 3 1010 0 16 7 51 9 11 1 329 0 44 4 1042 0 15 6 59 3 122 345 0 45 6 1076 0 14 4 66 6 13 3 362 0 46 7 1110 0 13 3 74 4 14 4 379 0 47 8 1145 0 12 2 82 5 15 6 396 0 48 9 1180 0 11 1 90 8 16 7 414 0 50 0 1217 0 10 0 99 4 17 8 433 0 51 1 1254 0 8 9 108 0 18 9 451 0 52 2 1292 0 7 8 118 0 20 0 471 0 53 3 1330 0 6 7 127 0 21 1 491 0 54 4 1370 0 5 6 137 0 22 2 511 0 55 6
69. 924145 SNOIAddd 4LXAN 5 10965 eq JaWVWSM 430 LNNY 9Y71 0YI7 430 SNO9 DIANOO 62440920 1024148 LXAN 1252195 Se qe Soles TIN 1 aqe e qe 10 1024138 mus 1924148 6 LNAWdINOA NOLLWYHNSIANOD LNAWdINOA 39vd ShOlA3Hd NNAW 3983 19 TO VIEW AND CHANGE SET POINTS Fig 19 1 To view the Set Point table at the Menu screen press SETPOINT STATUS SCHEDULE SERVICE LJ LJ 2 There are 4 set points on this screen Base Demand Limit LCW Set Point leaving chilled water set point ECW Set Point entering chilled water set point and ICE BUILD set point PSIO Software Version 09 and higher only Only one of the chilled water set points can be active at one time and the type of set point is activated in the Serv ice menu ICE BUILD is also activated and configured in the Service menu SETPOINT Fig 19 Example of Set Point Screen 20 3 Press NEXT or PREVIOUS to highlight the desired set point entry NEXT PREVIOUS SELECT EXIT LJ LJ 4 Press to modify the highlighted set point NEXT EXIT 5 Pr
70. 9INOHL1O313 5NISn 4l N39OHLIN ed OlSd 0 OL 5534 3SlvH 0 DISd 0 1Y 73883A SI S3unssdud auoo3d S3unssdud QHOO3H Qaioadsns v31 601 DISd SL MO T38 SI SAYNSSAYd 9 d18v L 3Hn1VH3dNWa l 3unss3Hd INvH35IHJ3H 339 3unssdud INVH39IHd3H 1 6 S931 SI TASSSA H3SN3QNOO NO 3Hf18S3Hd H3HOIH HO 601 DISd 9 SI 3unss3dd H3 1005 Qa1oadsns v31 eg 0 H31V3H5 ae vc 318 1 3Hn1vH3dWa31 3HnsSs3Hd ind 04 9 59 St NVH L S831 SI SNIQVSY 3H SS38d NO 8905588 LNVH39OIB33H S3NIHOVIA SONIOV3H 39V9 1 2 13883A HOV3 OL H3TIIHO 1X6 40 1931 ANVH35IHJ3H 336 SNOLLIONOO 5 ANVH39IHd3H LY SI THSS3A H3SN30NOD 42 procedures in the Transfer Refrigerant from Storage Tank to Chiller section Steps la e page 59 WARNING Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 68 psig 469 kPa for HCFC 22 and 35 psig 241 kPa for HFC 134a Charge as a gas only with the cooler and condenser pumps running until this pressure is reached using PUMPDOWN LOCKOUT and TERMINATE LOCKOUT mode on the PIC Flash ing of liquid refrigerant at low pressures can cause tube freezeup and considerable damage
71. AL COOLING ISOLATION HOT GAS VALVE VALVE SOLENOID Mn OPTIONAL HOT GAS ISOLATION VALVE LINEAR COOLER COMPRESSOR ISOLATION MACHINE DISCHARGE VALVE CHARGING VALVE _ SEPARATOR COMPRESSOR SUCTION VALVE CONDENSER PUMPOUT WATER SUPPLY COMPRESSOR AND RETURN PUMPOUT SERVICE VALVE ON _ SERVICE VALVE ON CONDENSER PUMPOUT UNIT MACHINE Fig 28 Typical Optional Pumpout System Piping Schematic without Storage Tank 46 Chiller Dehydration Dehydration is recommended if the chiller has been open for a considerable period of time if the chiller is known to contain moisture or if there has been a complete loss of chiller holding charge or refrigerant pressure A WARNING Do not start or megohm test the compressor motor or oil pump motor even for a rotation check if the chiller is under dehydration vacuum Insulation breakdown and severe damage may result Dehydration is readily accomplished at room tempera tures Use of a cold trap Fig 29 may substantially reduce the time required to complete the dehydration The higher the room temperature the faster dehydration takes place At low room temperatures a very deep vacuum is required for boiling off any moisture If low ambient temperatures are involved contact a qu
72. ART TO SELECT CCN OR LOCAL COMPRESSOR UNLOADING COMPRESSOR DEENERGIZED OPERATION COMPLETE SECONDARY MESSAGE UNOCCUPIED MODE REMOTE CONTACTS OPEN STOP COMMAND IN EFFECT RECYCLE RESTART PENDING UNOCCUPIED MODE REMOTE CONTACTS OPEN STOP COMMAND IN EFFECT REMOTE CONTACTS CLOSED OCCUPIED MODE REMOTE CONTACTS CLOSED OCCUPIED MODE LOADSHED IN EFFECT START COMMAND IN EFFECT PROBABLE CAUSE REMEDY PIC in OFF mode press the or local softkey to start unit Enter the Control Test table and select Terminate Lockout to unlock compressor Chiller unloading before shutdown due to Soft Stop feature Chiller compressor is being commanded to stop Water pumps are deenergized within one minute Chiller shutdown from Ice Build operation PROBABLE CAUSE REMEDY Time schedule for PIC is unoccupied Chillers will start only when occupied Remote contacts have stopped chiller Close con tacts to start Chiller START STOP on Status01 manually forced to stop Release value to start Chiller in recycle mode Time schedule for PIC is UNOCCUPIED Chiller will start when occupied Make sure the time and date have been set on the Service menu Remote contacts have stopped chiller Close con tacts to start Chiller START STOP on Status01 manually forced to stop Release value to start Chiller timer counting down unit Ready for start Chiller timer counting down unit Ready for start Chiller timers com
73. ATER temperature The ECW OPTION and any temperature reset option are ignored dur ing ice build The 20 m DEMAND LIMIT OPTION is also ignored during ice build TERMINATION OF ICE BUILD Ice build termination occurs under the following conditions 1 Ice Build Time Schedule When the Ice Build Time Schedule transitions to UNOCCUPIED ice build opera tion shall terminate 2 ECW TEMPERATURE Termination of compressor operation based on temperature shall occur if the ICE BUILD TERMINATION is set to the ice build termination temperature option 0 and the ENTERING CHILLED WATER TEMPERATURE is less than the ICE BUILD SET POINT If the ICE BUILD RECYCLE OPTION is set to ENABLE a recycle shutdown occurs and recycle start up shall be based on LEAVING CHILLED WATER temperature being greater than the WATER BRINE CONTROL POINT plus RECYCLE RESTART DELTA T 3 Remote Contacts Ice Level Input Termination of compressor operation occurs when BUILD TERMI NATION is set to the contacts only option 1 and the remote contacts are open In this case the contacts are provided for ice level termination control The remote con tacts can still be opened and closed to start and stop the chiller when the Ice Build Time Schedule is UNOCCU PIED The contacts are used to stop the ICE BUILD mode when the Ice Build Time Schedule is OCCUPIED 4 ECW TEMPERATURE and Remote Contacts Termi nation of compressor operation shall occur wh
74. C during compressor operation 2 The bearing oil temperature accessed on the StatusO1 table should be 120 to 165 F 49 to 74 C If the bearing temperature reads more than 180 F 83 C with the oil pump running stop the chiller and determine the cause of the high temperature Do not restart the chiller until corrected 3 The oil level should be visible anywhere in one of the two sight glasses Foaming of the oil is acceptable as long as the oil pressure and temperature are within limits 4 The oil pressure should be between 18 and 30 psid 124 to 207 kPad as seen on the LID default screen Typically the reading will be 18 to 25 psid 124 to 172 kPad at initial start up 5 The moisture indicator sight glass on the refrigerant motor cooling line should indicate refrigerant flow and a dry condition 6 The condenser pressure and temperature varies with the chiller design conditions Typically the pressure will range between 100 and 210 psig 690 to 1450 kPa with a corresponding temperature range of 60 to 105 F 15 to 41 C The condenser entering water temperature should be controlled below the specified design entering water temperature to save on compressor kilowatt requirements 7 Cooler pressure and temperature also will vary with the design conditions Typical pressure range will be be tween 60 and 80 psig 410 and 550 kPa with temper ature ranging between 34 and 45 F 1 and 8 C 8 The compressor may operate at fu
75. CH TO NETWORK DEVICE table The Local description is always the PSIO module address of the chiller the LID is mounted on When ever the controller identification of the PSIO is changed this change is reflected on the bus and address for the LOCAL DEVICE of the ATTACH TO DEVICE screen automat ically See Fig 17 Whenever the ATTACH TO NETWORK DEVICE table is entered no information can be read from the LID on any device until you attach one of the devices listed on the display The LID erases information about the module to which it was attached to make room for information on another de vice Therefore a CCN module must be attached when this screen is entered To attach a device highlight it using the softkey and then press the softkey The message UPLOADING TABLES PLEASE WAIT dis plays The LID then uploads the highlighted device or module If the module address cannot be found the mes sage COMMUNICATION FAILURE appears The LID then reverts to the ATTACH TO DEVICE screen Try another device or check the address of the device that would not attach The upload process time for each CCN module is different In general the uploading process takes 3 to 5 minutes Before leaving the ATTACH TO NET WORK DEVICE screen select the LOCAL device Other wise the LID will be unable to display information on the local chiller CHANGING REFRIGERANT TYPES To select refrig erant type go to the Control Test table Whenever the
76. CRED 2 10 1B Gww C a 230v eme RED RED 115v 5 BLK BLK OIL HEATER 23 12000 QIMT BRIO ee BO Gc e Guo L e e MOTOR COOLING SOLENOID OL HIR c2 FOR ISO i i 1 ew po sy REDD Ly N T Pure NOTOR WINDING duo Lo LOAD NORMAL LOAD BYPASS SOLENOID OPERATING SOLENOID po CORN ACTUATOR OlL RECOVERY SOLENOIDS CHILLER POWER PANEL WIRING SEE FIG 50 es LORN M RED b B QIRT 0RND LEGEND BRG Bearing NO Normally Open Contact PSIO Processor Sensor Input CB Circuit Breaker Output Module CLR Clear RBPL Relay Board Plug COM Common S Compressor Motor Start Contactor COMM Communication Connector SMM Starter Management Module EXT External SOL Solenoid G V Guide Vane TB Terminal Board Hot aas Bypass Carrier Factory Wiring J Module Connector ee Optional Factory or Field Installed K Relay Designation 9 LID Local Interface Device Thermistor MA Milliampere t NC Normally Closed Fig 49 Elec
77. ERATION TIME STARTER TRANSITION FAULT 1CR AUX CONTACT FAULT MOTOR AMPS NOT SENSED ADDITIONAL CAUSE REMEDY Check for closed oil supply valves Check oil filter Check for low oil temperature Check transducer accuracy Check for excessive refrigerant in oil sump Run oil pump manually for 5 minutes Check transducer calibration Check cooler pressure transducer calibration Check wiring Replace transducer if necessary Check wiring to flow switch Check through Control Test for proper switch operation Check wiring to flow switch Check through Control Test for proper switch operation A starter protective device has faulted Check starter for ground fault voltage trip temperature trip etc OILPD VALUE exceeded limit of LIMIT Check oil pump system OILPD VALUE exceeded limit of LIMIT Check oil pressure sensor EVFL Evap Flow Fault Check water pump flow switch CDFL Cond Flow Fault Check water pump flow switch STR FLT Starter Fault Check Starter for Fault Source STR FLT Starter Overload Trip Check amps calibration reset overload Reset overloads before restart Check voltage supply Check transformers for supply Check with utility if voltage supply is erratic Monitor must be installed to confirm consistent single cycle drop outs Check low oil pressure switch Check the high pressure switch Check for proper condenser pressures and con denser waterflow Check for fouled tub
78. F Gage F F Gage 50 6 154 30 110 226 35 48 4 829 32 112 232 80 46 3 445 34 114 239 38 44 2 002 36 116 246 10 42 0 498 38 118 252 94 40 0 526 40 120 259 91 38 1 328 42 122 267 01 36 2 163 44 124 274 25 34 3 032 46 126 281 63 32 3 937 48 128 289 14 30 4 877 50 130 296 80 28 5 853 52 132 304 60 26 6 868 54 134 312 54 24 7 921 56 136 320 63 22 9 015 58 138 328 86 20 10 15 60 140 337 25 18 11 32 62 142 345 79 16 12 54 64 144 354 48 14 13 81 66 146 363 32 12 15 11 68 10 18 47 1 152 390 83 24 20 81 76 156 409 99 160 420 83 0 23 96 80 2 25 61 82 Inches of mercury below one atmosphere 4 27 32 84 6 29 08 86 8 30 90 88 10 32 77 90 12 34 70 92 14 36 69 94 16 38 74 96 18 40 86 98 20 43 03 100 22 45 27 102 24 47 58 104 26 49 95 106 28 52 39 108 Table 5B HCFC 22 Pressure Temperature C TEMPERATURE PRESSURE kPa TEMPERATURE TEMPERATURE PRESSURE kPa C Gage C C Gage 18 264 163 12 42 1510 17 274 173 13 43 1550 16 284 183 14 44 1590 15 296 195 15 45 1630 14 206 16 46 1670 13 217 17 47 1710 12 229 18 48 1750 11 241 19 49 1800 10 253 20 50 1840 9 266 21 51 1890 8 279 22 52 1930 7 292 23 53 1980 6 306 24 54 2030 5 320 25 55 2070 4 335 26 56 2120 3 350 27 57 2170 2 365 28 58 2220 1 381 29 59 2270 0 397 30 60 2330 1 413 31 61 2380 2 430 32 62 2430 3 447 33 63 2490 4 465 34 64 2540 5 483 35 65 2600 6 501 36 66 2660 7 520 37 67 2720 8 540 38 68 2770 9 559 39
79. For chillers with reduced voltage me chanical and solid state starters For chillers with full voltage starters Configured on Service1 table Reduced voltage starters only CONDENSER FREEZE POINT config ured in Service01 table with a default setting of 34 F 1 C CUT OUT SETTING ADJUSTMENT SCREW Ramp Loading Control The ramp loading control slows down the rate at which the compressor loads up This control can prevent the compressor from loading up during the short period of time when the chiller is started and the chilled water loop has to be brought down to normal design conditions This helps reduce electrical demand charges by slowly bringing the chilled water to control point However the total power draw during this period remains almost unchanged There are 2 methods of ramp loading with the PIC Ramp loading can be based on chilled water temperature or on mo tor load 1 Temperature ramp loading limits the rate at which either leaving chilled water or entering chilled water temper ature decreases by an operator configured rate The low est temperature ramp table will be used the first time the chiller is started at commissioning The lowest tem perature ramp rate will also be used if chiller power has been off for 3 hours or more even if the motor ramp load 15 selected 2 Motor load ramp loading limits the rate at which the compressor motor current or compressor motor load increases by an
80. GE PER JOB REGM T TO 18 56 230 115 CUN cur 2 n Yel R EVEL x 1 2 HP ee ik Om GLK x 2 13 RED CRED 21 RED RED 22 pen BLK OIL HEATER 23 1120045 _ HT e e MOTOR COOLING SOLENOID OL HIR c2 FOR SED BR i i E E na 230 WIRING on MOTOR CHILLER POWER PANEL WIRING SEE FIG 50 al do Lo LOAD BYPASS SOLENO D 91 RECOVERY SOLENOIDS OHT BRLKO NORMAL LOAD OPERATING SOLENOID po RN CORP R ACTUATOR LEGEND BRG Bearing NO PSIO CB Circuit Breaker CLR Clear RBPL COM Common S COMM Communication Connector SMM EXT External SOL G V Guide Vane TB HGBP Hot Gas Bypass INT Internal J Module Connector K Relay Designation LID Local Interface Device MA Milliampere NC Normally Closed BOP Gc e Guo M9 10 ne LORN RED 5 3 Normally Open Processor Sensor Input Output Module Relay Board Plug Compressor Motor Start Contactor Starter Management Module Solenoid Terminal Board Carrier Factory Wiring Optional Factory or Field Installed Wiring
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82. Inspect the Heat Exchanger Tubes 64 COOLER CONDENSER CONTENTS cont Page Water Leaks 64 Water Treatment 65 Inspect the Starting Equipment 65 Check Pressure Transducers 65 Optional Pumpout System Maintenance 65 OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS Ordering Replacement Chiller Parts 65 TROUBLESHOOTING GUIDE 66 97 Overview 66 Checking the Display Messages 66 Checking Temperature Sensors 66 RESISTANCE CHECK VOLTAGE DROP CHECK SENSOR ACCURACY DUAL TEMPERATURE SENSORS Checking Pressure Transducers 66 TRANSDUCER REPLACEMENT Control Algorithms Checkout Procedure 67 Control Test 67 INTRODUCTION Prior to initial start up of the 19XL unit those involved in the start up operation and maintenance should be thor oughly familiar with these instructions and other necessary job data This book is outlined so that you may become familiar with the control system before performing start up procedures Procedures in this manual are arranged in the sequence required for proper chiller start up and operation WARNING This unit uses a microprocessor control system Do not short or jumper between terminations on circuit boards or
83. LI LJ LJ ENTER EXIT 19XL CHLR HOLDY01S CONFIGURATION SELECT Holiday Start Month Start Day Duration days PREVIOUS SELECT EXIT Fig 23 Example of Holiday Period Screen 39 START UP SHUTDOWN RECYCLE SEQUENCE Fig 24 Local Start Up Local start up or a manual start up is initiated by pressing the menu softkey which is on the default LID screen Local start up can proceed when Time Schedule 01 is in OCCUPIED mode and after the in ternal 15 minute start to start and the 3 minute stop to start inhibit timers have expired on PSIO software Version 08 and lower or a 1 minute stop to start timer on PSIO Soft ware Version 09 and higher The chiller start stop status point on the Status01 table may be overridden to start regardless of the time schedule in order to locally start the unit Also the remote contacts may be enabled through the LID and closed to initiate a start up Whenever the chiller is in LOCAL control mode the PIC will wait for Time Schedule 01 to become occupied and the remote contacts to close if enabled The PIC will then per form a series of pre start checks to verify that all pre start alerts and safeties are within the limits shown in Table 3 The run status line on the LID now reads Starting If the checks are successful the chilled water brine pump relay will be energized Five seconds later the condenser pump relay is energized Thirty seconds later the PIC m
84. LID CCN address change to English or SI units and to change the password If there is more than one chiller at the jobsite change the LID address on each chiller so that each chiller has its own address Note and record the new address Change the screen to SI units as required and change the password if desired MODIFY CONTROLLER IDENTIFICATION IF NECES SARY The controller identification screen is used to change the PSIO module address Change this address for each chiller if there is more than one chiller at the jobsite Write the new address on the PSIO module for future reference Change the LID address if there is more than one chiller on the jobsite Access the LID configuration screen to view or modify this address INPUT EQUIPMENT SERVICE PARAMETERS IF NEC ESSARY The Equipment Service table has three service tables Servicel Service2 and Service3 Configure SERVICE Table Access Servicel table to modify view the following to jobsite parameters Chilled Medium Brine Refrigerant Trippoint Water or Brine Usually 3 F 1 7 C below design refrigerant temperature Surge Limiting or Hot Gas Is HGBP installed Bypass HGBP Option Minimum Load Points Per job data T1 P1 See Modify Load Points section Maximum Load Points Per job data T2 P2 See Modify Load Points section Amps Correction Factor See Table 6 Motor Rated Load Amps Per job data Motor Rated Line Voltage Per job data Motor Rated
85. Leaving condenser water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature 3 Options Thermistors Common chilled water supply sensor Common chilled water return sensor Remote reset sensor Temperature sensor Spare 1 Spare 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 9 4 Transducers Evaporator pressure Condenser pressure Oil pressure differential Oil pump pressure 5 Guide Vane Actuator Open Close All pumps or individual pumps may be activated Oil pump Confirm pressure Chilled water pump Confirm flow Condenser water pump Confirm ow All outputs or individual outputs may be energized Hot gas bypass relay Oil heater relay Motor cooling relay Tower fan relay Alarm relay Shunt trip relay 8 Pumpdown Lockout When using pumpdown lockout observe freeze up precautions when removing charge Instructs operator as to which valves to close and when Starts chilled water and condenser water pumps and confirms flows Monitors Evaporator pressure Condenser pressure Evaporator temperature during pumpout procedures Turns pumps off after pumpdown Locks out compressor 9 Terminate Lockout Starts pumps and monitors flows Instructs operator as to which values to open and when Monitors Evaporator pressure Condenser pressure Evaporator temperature during charging process Terminates compressor lockout Sets refrigeran
86. Local Occupied Schedule Input 50 Local Start Up 39 Lubrication Cycle 8 Lubrication System Check 62 Manual Guide Vane Operation 57 Manual Operation of the Guide Vanes 55 Motor Compressor 5 Motor Cooling Control 29 Motor Oil Refrigeration Cooling Cycle 5 Notes on Module Operation 78 98 Oil Changes 63 Oil Charge 50 Oil Cooler 32 Oil Pressure and Compressor Stop Check 56 Oil Reclaim Filters 63 Oil Reclaim System 9 Oil Specification 63 Oil Sump Temperature Control 32 Open Oil Circuit Valves 41 Operating Instructions 56 Operating the Optional Pumpout Compressor 59 Operator Duties 56 Optional Pumpout System Maintenance 65 Options Modules 79 Ordering Replacement Chiller Parts 65 Overview Troubleshooting Guide 66 Physical Data 85 PIC System Components 11 PIC System Functions 28 Power Up the Controls and Check the Oil Heater 50 Pumpout Compressor Water Piping Check 47 Pumpout System Controls and Compressor Check 52 Preparation Initial Start Up 55 Preparation Pumpout and Refrigerant Transfer Procedures 59 Prepare the Chiller for Start Up 56 Pressure Transducers Check 65 66 Prevent Accidential Start Up 56 Processor Module 79 Pumpout and Refrigerant Transfer Procedures 59 Ramp Loading Control 31 Refrigerant Filter 63 Refrigerant Float System Inpsect 64 Refrigerant Leak Testing 61 Refrigerant Properties 61 Refrigerant Removing 61 Refrigerant T
87. NOTE See Legend on page 68 Check oil pump voltage supply Cooler vessel pressure under vacuum Pressurize vessel Check temperature overload cutout switch 75 Table 10A Thermistor Temperature F vs Resistance Voltage Drop TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE F DROP Ohms F DROP V Ohms F DROP V Ohms 25 4 821 98 010 59 7 868 143 1 190 24 4 818 94 707 60 7 665 144 1 165 23 4 814 91 522 61 7 468 145 1 141 22 4 806 88 449 62 7 277 146 1 118 21 4 800 85 486 63 7 091 147 1 095 20 4 793 82 627 64 6 911 148 1 072 19 4 786 79 871 65 6 735 149 1 050 18 4 779 77 212 66 6 564 150 1 029 17 4 772 74 648 67 6 399 151 1 007 16 4 764 72 175 68 6 238 152 986 15 4 757 69 790 69 6 081 153 965 14 4 749 67 490 70 5 929 154 945 13 4 740 65 272 71 5 781 155 925 12 4 734 63 133 72 5 637 156 906 11 4 724 61 070 73 5 497 157 887 10 4 715 59 081 74 5 361 158 868 9 4 705 57 162 75 5 229 159 850 8 4 696 55 311 76 5 101 160 832 E 4 688 53 526 77 4 976 161 815 6 4 676 51 804 78 4 855 162 798 5 4 666 50 143 79 4 737 163 782 4 4 657 48 541 80 4 622 164 765 3 4 648 46 996 81 4 511 165 750 2 4 636 45 505 82 4 403 166 734 1 4 624 44 066 83 4 298 167 719 0 4 613 42 679 84 4 196 168 705 1 4 602 41 339 85 4 096 169 690 2 4 592 40 047 86 4 000 170 677 3 4 579 38 800 87 3 906 171 663 4 4 567 37 596 88 3 814 172 650 5 4 554 36 435 89 3 726 17
88. OFTWARE VERSIONS 09 AND HIGHER Oil Cooler 32 Remote Start Stop Controls 32 Spare Safety Inputs 32 SPARE ALARM CONTACTS Condenser Pump Control 32 Condenser Freeze Protection 32 Tower Fan Relay 33 Auto Restart After Power Failure 33 Water Brine 33 RESET TYPE 1 RESET TYPE 2 RESET TYPE 3 Demand Limit Control Option Requires Optional 8 Input Module 33 Surge Prevention Algorithm 33 Surge Protection 34 Lead Lag Control 34 COMMON POINT SENSOR INSTALLATION CHILLER COMMUNICATION WIRING LEAD LAG OPERATION FAULTED CHILLER OPERATION LOAD BALANCING AUTO RESTART AFTER POWER FAILURE Ice Build Control 36 ICE BUILD INITIATION START UP RECYCLE OPERATION TEMPERATURE CONTROL DURING ICE BUILD TERMINATION OF ICE BUILD RETURN TO NON ICE BUILD OPERATIONS Attach to Network Device Control 37 CHANGING REFRIGERANT TYPES ATTACHING TO OTHER CCN MODULES Service Operation 38 TO LOG ON TO LOG OFF HOLIDAY SCHEDULING START UP SHUTDOWN RECYCLE SEQUENCE 39 41 Local Start Up 39 Shutdown Sequence
89. ONDITION 4 Crack open valve 5 gradually increasing pressure in the evacuated vessel to 68 psig 469 kPa 35 psig 141 kPa Feed refrigerant slowly to prevent tube freeze up 5 Leak test to ensure vessel integrity 6 Open valve 5 fully vave 15 2 5 8 tt 12 13 14 151 e 15151515165 7 Open valve 11 to equalize the liquid refrigerant level between vessels 8 Close valves 1 1b 3 and 5 9 Open isolation valves 11 12 13 and 14 if present valve __ 2 3 4 5 8 11 12 13 14 jejejejeje 10 Proceed to Terminate Pumpdown Lockout test to turn off water pumps and enable the chiller compressor for start up 61 GENERAL MAINTENANCE Refrigerant Properties 22 or HFC 134a is the standard refrigerant in the 19XL At normal atmo spheric pressure HCFC 22 will boil at 41 40 C and HFC 134a will boil at 14 F 25 C and must therefore be kept in pressurized containers or storage tanks The refrig erants are practically odorless when mixed with air Both refrigerants are non combustible at atmospheric pressure Read the Material Safety Data Sheet and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of these refrigerants DANGER HCFC 22 and HFC 134a will dissolve oil and some non metallic materials dry the skin and i
90. PE 2 Remote Temp No Reset Remote Temp Full Reset Degrees Reset RESET TYPE 3 CHW Delta T No Reset CHW Delta T Full Reset Degrees Reset Select Enable Reset Type ECW CONTROL OPTION Demand Limit At 20 mA 20 mA Demand Limit Option Auto Restart Option Remote Contacts Option Temp Pulldown Deg Min Load Pulldown Select Ramp Type Temp 0 Load 1 Loadshed Group Number Loadshed Demand Delta Maximum Loadshed Time CCN Occupancy Config Schedule Number Broadcast Option ICE BUILD Option ICE BUILD TERMINATION 0 1 Contacts 2 Both ICE BUILD Recycle Option NOTE A delta degrees 30 30 17 17 0 15 0 8 0 15 0 8 30 30 217 17 0 3 DISABLE ENABLE 40 100 DISABLE ENABLE DISABLE ENABLE DISABLE ENABLE 2 10 5 20 0 1 0 99 0 60 0 120 3 99 DISABLE ENABLE DISABLE ENABLE 0 2 DISABLE ENABLE To access this display from the LID default screen Press MENU Press SERVICE Scroll down to highlight EQUIPMENT CONFIGURATION Press SELECT Scroll down to highlight Lead Lag Press SELECT DESCRIPTION LEAD LAG SELECT DISABLE 0 LEAD 1 LAG 2 STANDBY 3 Load Balance Option Common Sensor Option LAG Percent Capacity LAG Address LAG START Timer LAG STOP Timer PRESTART FAULT Timer STANDBY Chiller Option STANDBY Percent Capacity STANDBY Address LEAD LAG CONFIGURATION SCREEN CONFIGURABLE RANGE UNITS 0 3
91. PTIONAL STORAGE TANK AND PUMPOUT SYSTEM MOTOR COMPRESSOR ASSEMBLY MOTOR COMPRESSOR LUBRICATION SYSTEM CONTROL SYSTEM AUXILIARY EQUIPMENT DESCRIBE CHILLER CYCLES REVIEW MAINTENANCE SAFETY DEVICES AND PROCEDURES CHECK OPERATOR KNOWLEDGE REVIEW THE START UP OPERATION AND MAINTENANCE MANUAL Page OPERATING INSTRUCTIONS 56 58 Operator Duties 56 Prepare the Chiller for Start Up 56 To Start the Chiller 56 Check the Running System 56 To Stop the Chiller 57 After Limited Shutdown 57 Extended Shutdown 57 After Extended Shutdown 57 Cold Weather Operation 57 Manual Guide Vane Operation 57 Refrigeration Log 57 PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES 59 61 Preparation 59 Operating the Optional Pumpout 59 TO READ REFRIGERANT PRESSURES Chillers with Pumpout Storage Tanks 59 TRANSFER REFRIGERANT FROM STORAGE TANK TO CHILLER TRANSFER THE REFRIGERANT FROM CHILLER TO STORAGE TANK Chillers with Isolation Valves 60 TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL TRANSFER ALL REFRIGERANT TO CHILLER COOLER COMPRESSOR VESSEL RETURN REF
92. REFRIGERANT TYPE Confirm that the correct refrigerant type is indicated by entering the Controls Test tables on the Service menu Fig 17 Select REFRIG ERANT TYPE The screen will display the current refrig erant setting Press softkey to leave the screen with out changes TO CHANGE REFRIGERANT TYPE Enter the Con trols Test tables on the Service Menu See Fig 17 Select REFRIGERANT TYPE The screen will display the current refrigerant setting Press softkey to change the cur rent setting Next move to the ATTACH TO NETWORK DEVICE screen on the Service menu and the ATTACH TO LOCAL DEVICE to upload the new refrigerant tables Input Service Configurations The following con figurations require the LID screen to be in the Service por tion of the menu password input time and date LID configuration controller identification service parameters equipment configuration automated control test PASSWORD When accessing the Service tables a pass word must be entered LIDs are initially set for a pass word of 1 1 1 1 This password may be changed in the LID configuration screen if desired INPUT TIME AND DATE Access the Time and Date table on the Service menu Input the present time of day date and day of the week Holiday Today should only be configured to Yes if the present day is a holiday CHANGE LID CONFIGURATION IF NECESSARY The LID Configuration screen is used to view or modify the
93. RIGERANT TO NORMAL OPERATING CONDITIONS GENERAL MAINTENANCE 61 62 Refrigerant Properties 61 Adding Refrigerant 61 Removing Refrigerant 61 Adjusting the Refrigerant Charge 61 Refrigerant Leak Testing 61 Leak Rate 61 Test After Service Repair or Major Leak 61 REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGEN Repair the Leak Retest and Apply Standing Vacuum Test 62 Checking Guide Vane Linkage 62 CHECKING THE AUXILIARY SWITCH ON GUIDE VANE ACTUATOR Trim Refrigerant Charge 62 WEEKLY MAINTENANCE 62 Check the Lubrication System 62 SCHEDULED MAINTENANCE 63 65 Service Ontime 63 Inspect the Control 63 Check Safety and Operating Controls Monthly 63 Changing Oil Filter 63 Oil Specification 63 Oil Changes 63 TO CHANGE THE OIL Refrigerant 63 Oil Reclaim Filters 63 Inspect Refrigerant Float System 64 Inspect Relief Valves and Piping 64 Compressor Bearing and Gear Maintenance 64
94. RS TOO SOON OCCURS TOO LATE Increase P1 by Decrease P1 by lt 50 10 psid 70 kPad 10 psid 70 kPad Increase P2 by Decrease P2 by gt 50 10 psid 70 kPad 10 psid 70 kPad Modify Amp Correction Factors To modify the amp cor rection factor use the values listed in Table 6 Enter the appropriate amp correction factor in the Servicel table of Equipment Service Table 6 Amps Correction Factors for 19XL Motors MOTOR CODE CR 4 VOLT Hz 200 60 208 60 220 60 230 60 240 60 360 60 380 60 400 60 440 60 460 60 480 60 550 60 575 60 600 60 3300 60 2400 60 4160 60 220 50 230 50 240 50 320 50 346 50 360 50 380 50 400 50 415 50 3000 50 3300 50 amp 5 60 OO TO eor MODIFY EQUIPMENT CONFIGURATION IF NECES SARY The Equipment Configuration table has tables to select and view or modify Carrier s certified drawings will have the configuration values required for the jobsite Modify these tables only if requested Config Table Modifications Change the values in this table per job data See certified drawings for values Modifica tions include chilled water reset entering chilled water control Enable Disabl
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96. SECONDARY MESSAGE OCCUPIED MODE REMOTE CONTACT CLOSED START COMMAND IN EFFECT ICE BUILD MODE PROBABLE CAUSE REMEDY Unit in recycle mode chilled water temperature is not high enough to start Unit in recycle mode chilled water temperature is not high enough to start Chiller START STOP on Status01 manually forced to start chilled water temperature is not high enough to start Chiller in ICE BUILD mode Chilled Water Brine Tem perature is satisfied for Ice Build Setpoint temperature D PRE START ALERTS These alerts only delay start up When alert is corrected the start up will continue No reset is necessary PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE STARTS EXCESSIVE Compressor Starts 8 in 12 hours PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT STARTS LIMIT EXCEEDED HIGH MOTOR TEMPERATURE LIMIT MTRB VALUE exc HIGH BEARING TEMPERATURE temperature HIGH DISCHARGE TEMP LOW REFRIGERANT TEMP LOW OIL TEMPERATURE LOW LINE VOLTAGE HIGH LINE VOLTAGE transducer HIGH CONDENSER PRESSURE MTRW VALUE exceeded limit of Check motor temperature LIMIT Check thrust bearing CMPD VALUE exceeded limit of LIMIT Check discharge temperature ERT VALUE exceeded limit of LIMIT Check refrigerant temperature OILT VALUE exceeded limit o
97. TION BE AWARE that certain automatic start arrangements can engage the starter Open the disconnect ahead of the starter in addition to shutting off the chiller or pump Use the instruction and service manual supplied by the starter manufacturer to verify that the starter has been in stalled correctly CAUTION The main disconnect on the starter front panel may not deenergize all internal circuits Open all internal and re mote disconnects before servicing the starter Whenever a starter safety trip device activates wait at least 30 seconds before resetting the safety The microprocessor maintains its output to the ICR relay for 10 seconds to de termine the fault mode of failure MECHANICAL TYPE STARTERS 1 Check all field wiring connections for tightness clear ance from moving parts and correct connection 2 Check the contactor s to be sure they move freely Check the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time Check all other electro mechanical devices e g relays timers for free movement If the devices do not move freely contact the starter manufacturer for replacement components 3 Some dashpot type magnetic overload relays must be filled with oil on the jobsite If the starter is equipped with de vices of this type remove the fluid cups from these mag 7 netic overload relays Add dashpot oil to cups per instructions supp
98. Test before start up If the compressor oil level appears abnormally high the oil may have absorbed refrigerant Make sure that the oil tempera ture is above 140 F 60 C or cooler refrigerant temperature plus 50 F 27 C Cold Weather Operation When the entering con denser water drops very low the operator should auto matically cycle the cooling tower fans off to keep the temperature up Piping may also be arranged to bypass the cooling tower The PIC controls have a low limit tower fan relay PR3 that can be used to assist in this control Manual Guide Vane Operation Manual opera tion of the guide vanes in order to check control operation or control of the guide vanes in an emergency operation is possible by overriding the target guide vane position Access the StatusO1 table on the LID and highlight TARGET GUIDE VANE POSITION To control the position enter a percentage of guide vane opening that is desired Zero percent is fully closed 100 is fully open To re lease the guide vanes to AUTOMATIC mode press the RELEASE softkey NOTE Manual control will increase the guide vanes and override the pulldown rate during start up Motor current above the electrical demand setting capacity overrides and chilled water below control point will override the manual target and close the guide vanes For descriptions of capacity over rides and set points see the Controls section Refrigeration Log A refrigeration log
99. UNNING DEMAND LIMITED RUNNING DEMAND LIMITED RUNNING DEMAND LIMITED RUNNING DEMAND LIMITED BY 4 20MA SIGNAL BY SIGNAL BY LOADSHED REDLINE PROBABLE CAUSE REMEDY Reset program active based upon Config table setup Default method of temperature control ECW control activated on Config table Ramp loading in effect Use Service1 table to modify Ramp loading in effect Use Service1 table to modify Demand limit setpoint is lt actual demand Demand limit is active based on Config table setup RUNNING TEMP CONTROL HOT GAS BYPASS Hot Gas Bypass is energized See surge prevention in the control section RUNNING DEMAND LIMITED BY LOCAL SIGNAL Active demand limit manually overridden or Status01 table RUNNING TEMP CONTROL NOTE See Legend on page 68 ICE BUILD MODE 71 Chiller is running under Ice Build temperature control Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont NORMAL RUN OVERRIDES ACTIVE ALERTS PRIMARY MESSAGE ALARM MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY Umren MEA ERT VALUET exceeded limit of gt LM pem LIMIT is shown on the LID as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual temperature pressure
100. __ecw Water Brine Deadband 0 5 2 0 3 1 1 DEG F DEG C cwdb NOTE Overriding is not supported on this maintenance screen Active overrides show the associated point in alert Only values with capital letter reference point names are variables available for read operation EXAMPLE 11 MAINTENANCE MAINTO2 DISPLAY SCREEN To access this display from the LID default screen Press MENU Press SERVICE Scroll down to highlight CONTROL ALGORITHM STATUS Press SELECT Scroll down to highlight MAINTO2 Press SELECT DESCRIPTION OVERRIDE ALERT STATUS MOTOR WINDING TEMP Override Threshold CONDENSER PRESSURE e Co poo ics RANGE STATUS UNITS 40 245 40 118 DEG F DEG C MTRW 150 200 66 93 DEG F DEG C over 6 7 420 42 2896 PSI kPa REFERENCE POINT NAME Override Threshold 90 245 621 1689 PSI kPa EVAPORATOR REFRIG TEMP 40 245 40 118 DEG F DEG C ERT Override Threshold 2 45 1 7 2 DEG F DEG C rt over DISCHARGE TEMPERATURE 40 245 40 118 DEG F DEG C CMPD Alert Threshold 125 200 52 93 DEG F DEG C cd alert BEARING TEMPERATURE 40 245 40 118 DEG F DEG C MTRB Alert Threshold 175 185 79 85 DEG F DEG C tb alert NOTE Overriding is not supported on this maintenance screen Active overrides show the associated point in alert Only values with capital letter reference point names are variables available for read oper
101. afety shutdowns if required PIC System Components The Product Integrated Control PIC is the control system on the chiller See Table 1 The PIC controls the operation of the chiller by moni toring all operating conditions The PIC can diagnose a prob lem and let the operator know what the problem is and what to check It promptly positions the guide vanes to maintain leaving chilled water temperature It can interface with aux iliary equipment such as pumps and cooling tower fans to turn them on only when required It continually checks all safeties to prevent any unsafe operating condition It also regulates the oil heater while the compressor is off and the hot gas bypass valve if installed The PIC can be interfaced with the Carrier Comfort Net work CCN if desired It can communicate with other PIC equipped chillers and other CCN devices The PIC consists of 3 modules housed inside the 3 major components The component names and the control voltage contained in each component are listed below also see Table 1 control center all extra low voltage wiring 24 v or less power panel 230 or 115 v control voltage per job requirement up to 600 v for oil pump power starter cabinet chiller power wiring per job requirement Table 1 Major PIC Components and Panel Locations PANEL PIC COMPONENT LOCATION Processor Sensor Input Output Module PSIO Starter Management Module SMM Local In
102. alified service representative for the dehydration techniques required Perform dehydration as follows 1 Connect a high capacity vacuum pump 5 cfm 002 m s or larger is recommended to the refrigerant charging valve Fig 2A or 2B Tubing from the pump to the chiller should be as short and as large a diameter as possible to provide least resistance to gas flow 2 Usean absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum Open the shutoff valve to the vacuum indicator only when taking a reading Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum 3 Open all isolation valves if present if the entire chiller is to be dehydrated 4 With the chiller ambient temperature at 60 F 15 6 C or higher operate the vacuum pump until the manometer reads 29 8 in Hg vac ref 30 in bar 0 1 psia 100 61 kPa or a vacuum indicator reads 35 F 1 7 C Operate the pump an additional 2 hours Do not apply greater vacuum than 29 82 in Hg vac 757 4 mm Hg or go below 33 F 56 C on the wet bulb vacuum indicator At this temperature pressure isolated pockets of moisture can turn into ice The slow rate of evaporation sublimination of ice at these low temperatures pressures greatly increases dehydration time 5 Valve off the vacuum pump stop the pump and record the instrument reading 6 After a 2 hour wait take another instrument reading If the r
103. an alarm message to further expand on this alarm For a com plete listing of messages see Table 9 If the alarm light starts to flash while accessing a menu screen depress EXIT to return to the Default screen to read the failure message The compressor will not run with an alarm con dition existing unless the alarm type is an unauthorized start or a failure to shut down Checking Temperature Sensors tempera ture sensors are of the thermistor type This means that the resistance of the sensor varies with temperature All sensors have the same resistance characteristics Determine sensor temperature by measuring voltage drop if the controls are powered or resistance if the controls are powered off Com pare the readings to the values listed in Tables 10A or 10B RESISTANCE CHECK Turn off the control power and disconnect the terminal plug of the sensor in question from the module Measure sensor resistance between recep tacles designated by the wiring diagram with a digital ohm meter The resistance and corresponding temperature is listed in Tables 10A or 10B Check the resistance of both wires to ground This resistance should be infinite VOLTAGE DROP Using a digital voltmeter the voltage drop across any energized sensor can be measured while the control is energized Tables 10A or 10B lists the relation ship between temperature and sensor voltage drop volts dc measured across the energized sensor Exercise ca
104. and 3 minute inhibit tim ers are ignored during this type of start up When power is restored after the power failure and if the compressor had been running the oil pump will be ener gized for one minute prior to the evaporator pump ener gizing Auto restart will then continue like a normal start up If power to the PSIO module has been off for more than 3 hours the oil heat algorithm discussed in the Oil Sump Temperature Control section on page 32 will take effect be fore the compressor can start Refrigerant normally migrates into the oil when the oil heater is left off for extended pe riods of time The PIC operates the oil pump for 1 to 2 min utes to ensure that the oil is free of excess refrigerant Once this algorithm is completed the RESTART of the chiller will continue Water Brine Reset Three types of chilled water or brine reset are available and can be viewed or modified on the Equipment Configuration table Config selection The LID default screen status message indicates when the chilled water reset is active The Control Point tempera ture on the StatusO1 table indicates the chiller s current reset temperature To activate a reset type input all configuration informa tion for that reset type in the Config table Then input the reset type number in the SELECT ENABLE RESET TYPE input line 33 RESET 1 Reset Type requires an optional 8 input module It is an automatic chilled water temperature r
105. and terminals required for PIC refrigeration control Check certified drawings 5 Check the voltage to the following components and compare to the nameplate values oil pump contact pumpout compressor starter and power panel 6 Be sure that fused disconnects or circuit breakers have been supplied for the oil pump power panel and pumpout unit 7 Check that all electrical equipment and controls are prop erly grounded in accordance with job drawings certi fied drawings and all applicable electrical codes 8 Make sure that the customer s contractor has verified proper operation of the pumps cooling tower fans and associated auxiliary equipment This includes ensuring that motors are properly lubricated and have proper elec trical supply and proper rotation 9 For field installed starters only test the chiller compres sor motor and its power lead insulation resistance with a 500 v insulation tester such as a megohmmeter Use a 5000 v tester for motors rated over 600 v Factory mounted starters do not require a megohm test a Open the starter main disconnect switch and follow lockout tagout rules CAUTION If the motor starter is a solid state starter the motor leads must be disconnected from the starter before an insulation test is performed The voltage generated from the tester can damage the starter solid state components b With the tester connected to the motor leads take 10 second and 60 sec
106. ard if necessary BC board not functioning Board not functioning properly Replace board if necessary properly Phase assembly malfunction 1 Remove power and check SCRs Ohmmeter reading of each SCR gate to cathode resistance at terminals is 8 to 20 ohm If not replace the phase assembly 2 Replace board if necessary Imbalance between phases Check for loose SCR gate lead or open SCR gate Replace phase exists in motor terminal voltages assembly if necessary BC board run LED L5 not lit BC board not functioning Measure 24 vdc at TB11 8 to TB11 4 If voltage is present replace properly board If not present replace relay 1CR AK board power applied run command given starter at full voltage but aux LED not lit 1L boards LEDs lit Motor terminal voltage phase imbalance exists BC board LED L4 and L5 BC board not functioning not lit properly AK board not functioning Replace board properly Check motor terminal voltages for imbalance between phases If an imbalance exists check for loose SCR gate or open SCR gate Replace phase assembly if necessary Replace board BC board LED L3 lit 1 FU5 and FU6 fuses functioning properly 2 Phase assembly not functioning properly 3 Fan not functioning properly SCR phases not functioning properly Motor lead grounded BC board L2 lit BC board L1 lit 1 Check fuses FU5 and FU6 Replace if necessary 2 Verify that byp
107. arrier Comfort Network Interface section on page 48 of this manual for information on chiller communication wiring LEAD LAG OPERATION The PIC control provides the ability to operate 2 chillers in the LEAD LAG mode It also provides the additional ability to start a designated standby chiller when either the lead or lag chiller is faulted and capacity requirements are not met The lead lag option op erates in CCN mode only If any other chiller configured for lead lag is set to the LOCAL or OFF modes it will be un available for lead lag operation NOTE Lead lag configuration is viewed and edited in Lead Lag under the Equipment Configuration table of the Service menu Lead lag status during chiller operation is viewed in the MAINTO4 table in the Control Algorithm Status table Lead Lag Chiller Configuration and Operation The con figured lead chiller is identified when the LEAD LAG SELECT value for that chiller is configured to the value of 1 The configured lag chiller is identified when the LEAD LAG SELECT for that chiller is configured to the value of 2 The standby chiller is configured to a value of value of 0 disables the lead lag in that chiller To configure the LAG ADDRESS value on the LEAD LAG Configuration table always use the address of the other chiller on the system for this value Using this address will make it easier to rotate the lead and lag chillers 35 If the address ass
108. ass is pulling in by measuring the voltage drop across the contacts The reading should be 50 mV or less Replace phase assembly if necessary 3 Verify fan operation on each phase for 200 amp units Replace fan if necessary Measure resistance from anode to cathode for each SCR phase assembly Replace shorted phase if necessary Megger motor to test for motor lead going to ground Start command given Motor does not begin rotation Turn Starting Torque potentiometer RV2 clockwise until motor rotation begins Motor does not reach full speed within 25 seconds Ramp up setting is not correct Turn Ramp potentiometer RV1 counterclockwise Restart motor and verify that motor reaches full speed within 25 seconds 115 vac missing from LL1 1 CB2 is not on and LL2 2 Fuse no 4 FU4 blown SMM not responding 1 CB4 is not on 2 Potentiometer RV1 adjustment LEGEND AK Vendor Board Designation L1 L3 BC Vendor Board Designation LL2 CB Circuit Breaker RV1 CD Disconnect Switch SCR CR Control Relay SMM FU Fuse TB LED Light Emitting Diode 1 Verify CB2 is on 2 Check FUA for continuity Replace if necessary 1 Verify CB4 is on 2 jee potentiometer RV1 for 24 vac at SMM terminals J3 23 and Terminal Board Control Power Terminals Line Voltage Signal Calibration Silicon Control Rectifier Starter Management Module Terminal Board
109. ation 26 Table 2 LID Screens cont EXAMPLE 12 MAINTENANCE DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU Press SERVICE Scroll down to highlight CONTROL ALGORITHM STATUS Press SELECT Scroll down to highlight MAINTO3 Press SELECT DESCRIPTION SURGE HGBP ACTIVE Active Delta P Active Delta T 0 200 0 111 Calculated Delta T 0 200 0 111 Surge Protection Counts 0 12 o CO Inm RANGE STATUS UNITS NO YES 0 200 0 1379 PSI kPa DEG F DEG C DEG F DEG C REFERENCE POINT NAME dt a dt Spc NOTE Override is not supported on this maintenance screen Only values with capital letter reference point names are variables available for read operation EXAMPLE 13 MAINTENANCE MAINTO4 DISPLAY SCREEN To access this display from the LID default screen Press MENU Press SERVICE Scroll down to highlight CONTROL ALGORITHM STATUS Press SELECT Scroll down to highlight MAINTO4 Press SELECT DESCRIPTION LEAD LAG Configuration Current Mode Load Balance Option o RANGE STATUS DISABLE LEAD LAG STANDBY INVALID DISABLE LEAD LAG STANDBY CONFIG DISABLE ENABLE UNITS LAG Start Time 0 60 MIN LAG Stop Time 0 60 MIN Prestart Fault Time 0 30 MIN Pulldown Delta T Min 2 10 F min 1 1 5 5 C min A DEG F min Satisfied No Yes DEG
110. be made to the 24 v input to the SMM at the potentiometer located in the low voltage section to equalize the two readings PERFORM AN AUTOMATED CONTROL TEST Check the safety controls status by performing an automated con trols test Access the Control Test table and select the Automated Tests function Table 8 The Automated Control Test will check all outputs and inputs for function It will also set the refrigerant type The compressor must be in the OFF mode in order to operate the controls test and the 24 v input to the SMM must be in range per line voltage percent on StatusO1 table The OFF mode is caused by pressing the STOP pushbutton on the LID Each test will ask the operator to confirm that the operation is oc curring and whether or not to continue If an error occurs the operator has the choice to try to address the problem as the test is being done or to note the problem and proceed to the next test NOTE If during the Control Test the guide vanes do not open check to see that the low pressure alarm is not active This will cause the guide vanes to close NOTE The oil pump test will not energize the oil pump if cooler pressure is below 5 psig 35 kPa When the test is finished or the softkey is pressed the test will be stopped and the Control Test menu will be displayed If a specific automated test procedure is not completed access the particular control test to test the func tion when ready The Cont
111. been satisfactorily completed Protection by safety controls cannot be assumed until all control configurations have been confirmed As configuration of the 19XL unit is performed write down all configuration settings A log such as the one shown on pages CL 1 to CL 2 provides a convenient list for configu ration values Input the Design Set Points Access the LID set point screen and view modify the base demand limit set point and either the LCW set point or the ECW set point The PIC can control a set point to either the leaving or entering chilled water This control method is set in the Equipment Configu ration table Config table 50 Input the Local Occupied Schedule OCCPC01S Access the schedule OCCPCOIS screen on the LID and set up the occupied time schedule per the customer s requirements If no schedule is available the default is fac tory set for 24 hours occupied 7 days per week including holidays For more information about how to set up a time sched ule see the Controls section page 11 The CCN Occupied Schedule should be configured if a CCN system is being installed or if a secondary time sched ule is needed NOTE The default CCN Occupied Schedule is OCCPCO3S for Software Version 09 and above the default is OCCPCO2S for Software Version 08 and below Selecting Refrigerant Type The 19XL control must be configured for the refrigerant being used either HCFC 22 or HFC 134a TO CONFIRM
112. bove 125 51 energize a sole noid to provide additional motor cooling A further increase in temperature past the motor override set point will over ride the temperature capacity control to hold and if the motor temperature rises 10 F 5 5 C above this set point will close the inlet guide vanes If the temperature rises above the safety limit the compressor will shut down 1 23 4 5 6 7 8 9 10 11 12 LEGEND 1 Unit Mounted Starter 2 Refrigerant Filter Drier 3 Rigging Guide Bolt 28 2 4 Refrigerant Moisture Indicator 5 Motor Sight Glass 6 Refrigerant Motor Drain 9 7 Oil Filter Access Cover 8 Refrigerant Oil Cooler s 9 Oil Level Sight Glasses 10 Guide vane d 27 11 Typical Flange Connection 0 Q 5 12 Control Center 26 0 2 13 Nameplate Cooler 92900 0 14 Take Apart Rabbet Fit Connector 5 E Lower 25 o 15 Refrigerant Charging Valve o o 22999335 16 Cooler Refrigerant Isolation Valve 5 17 Cooler Pressure Schrader Fittings 18 Oil Drain Charging Valve E 19 Power Panel 24 idus 20 Retro Fit Rig in Place Beams 21 Typical Waterbox Drain Port 22 Take Apart Shell Leveling Feet 23 Cooler Return End Waterbox Cover 24 ASME Nameplate Condenser 23 25 Condenser Return End Waterbox Cover 26 Take Apart Rabbet Fit Connector Upper 27 Protect
113. cer locations Schrader fittings waterboxes and tubes and vents and drains OPTIONAL STORAGE TANK AND PUMPOUT SYS TEM Transfer valves and pumpout system refrigerant charging and pumpdown procedure and relief devices 56 MOTOR COMPRESSOR ASSEMBLY Guide vane actuator transmission motor cooling system oil cool ing system temperature and pressure sensors oil sight glasses integral oil pump isolatable oil filter extra oil and motor temperature sensors synthetic oil and compressor serviceability MOTOR COMPRESSOR LUBRICATION SYSTEM Oil pump cooler filter oil heater oil charge and specification operating and shutdown oil level temperature and pressure and oil charging connections CONTROL SYSTEM CCN and Local start reset menu softkey functions LID operation occupancy schedule set points safety controls and auxiliary and optional controls AUXILIARY EQUIPMENT Starters and disconnects sepa rate electrical sources pumps and cooling tower DESCRIBE CHILLER CYCLES Refrigerant motor cool ing lubrication and oil reclaim REVIEW MAINTENANCE Scheduled routine and ex tended shutdowns importance of a log sheet importance of water treatment and tube cleaning and importance of main taining a leak free chiller SAFETY DEVICES AND PROCEDURES Electrical dis connects relief device inspection and handling refrigerant CHECK OPERATOR KNOWLEDGE Start stop and shut dow
114. compressor serv ice valves OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS Fig 38 The optional pumpout system high pressure switch should open at 220 5 psig 1517 34 kPa and should reset automatically on pressure drop to 190 psig 1310 kPa for HCFC 22 chillers For chillers using HFC 134a the switch opens at 161 psig 1110 kPa and closes at 130 psig 896 kPa Check the switch setting by operating the pumpout compressor and slowly throttling the pumpout condenser water HIGH PRESSURE FUSE ON STOP SWITCH GROUND CONNECTION X ci COMPRESSOR TERMINAL CONTACTOR Fig 38 Optional Pumpout System Controls Ordering Replacement Chiller Parts When ordering Carrier specified parts the following information must accompany an order chiller model number and serial number name quantity and part number of the part required delivery address and method of shipment TROUBLESHOOTING GUIDE Overview The PIC has many features to aid the operator and the technician in troubleshooting a 19XL chiller By using the LID display the chiller actual operating con ditions can be viewed while the unit is running When an alarm occurs the default LID screen will freeze at the time of alarm The freeze enables the operator to view the chiller conditions at the time of alarm The Status tables will still show the current
115. configured is started Lag Chiller Shutdown Requirements The following con ditions must be met in order for the lag chiller to be stopped 1 Lead chiller COMPRESSOR MOTOR LOAD value is less than the lead chiller percent capacity plus 15 NOTE Lead chiller percent capacity 100 LAG PER CENT CAPACITY The LAG PERCENT CAPACITY value is configured on the Lead Lag Configuration screen 2 The lead chiller chilled water temperature is less than the CONTROL POINT plus of the WATER BRINE DEADBAND 3 The configured LAG STOP TIMER entry has elapsed The LAG STOP TIMER is started when the CHILLED WATER TEMPERATURE is less than the CHILLED WATER CONTROL POINT plus of the WATER BRINE DEADBAND and the lead chiller COMPRESSOR MOTOR LOAD is less than the lead chiller percent capacity plus 15 The timer is ignored if the chilled water temperature reaches 3 F 1 67 C below the CON TROL POINT and the lead chiller COMPRESSOR MOTOR LOAD value is less than the lead chiller percent capacity plus 15 FAULTED CHILLER OPERATION If the lead chiller shuts down on an alarm condition it stops communica tion to the lag and standby chillers After 30 seconds the lag chiller will now become the acting lead chiller and will start and stop the standby chiller if necessary Ifthe lag chiller faults when the lead chiller is also faulted the standby chiller reverts to a stand alone CCN mode of operation If the lead chill
116. creen Status message states Ready for Start press the softkey start up checks will be made by the control 3 When the starter is energized and the motor begins to turn Check for clockwise rotation Fig 32 IF ROTATION IS PROPER allow the compressor to come up to speed IF THE MOTOR ROTATION IS NOT CLOCKWISE as viewed through the sight glass reverse any 2 of the 3 incoming power leads to the starter and recheck rotation NOTE Solid state starters have phase protection and will not allow a start if the phase is not correct Instead a Starter Fault message will occur if this happens CAUTION Do not check motor rotation during coastdown Rota tion may have reversed during equalization of vessel pressures Py CORRECT MOTOR ROTATION IS CLOCKWISE WHEN VIEWED THROUGH MOTOR SIGHT GLASS TO CHECK ROTATION ENERGIZE COMPRESSOR MOTOR MOMENTARILY DO NOT LET MACHINE DEVELOP CONDENSER PRESSURE CHECK ROTATION IMMEDIATELY ALLOWING CONDENSER PRESSURE TO BUILD OR CHECKING ROTATION WHILE MACHINE COASTS DOWN MAY GIVE A FALSE INDICATION DUE TO GAS PRESSURE EQUALIZING THROUGH COMPRESSOR Fig 32 Correct Motor Rotation NOTES ON SOLID STATE STARTERS Benshaw Inc 1 When the compressor is energized to start by the ICR relay confirm that the Relay On LED is lit on the starter SCR control board The compressor motor should start to turn immediately when this light comes on If not adjust the start torque
117. ct LEDs must be lit before the starter will energize If the Power 15 LED is not on incoming voltage is not present or is incorrect If the Phase Correct LED is not lit rotate any 2 incoming phases to correct the phasing A WARNING Do not permit water or brine that is warmer than 110 F 43 C to flow through the cooler or con denser Refrigerant overpressure may discharge through the relief devices and result in the loss of refrigerant charge 8 Press to automate the chiller start stop value on the Status01 table to enable the chiller to start The initial factory setting of this value is overridden to stop in order to prevent accidental start up Manual Operation of the Guide Vanes Manual operation of the guide vanes is helpful to establish a steady motor current for calibration of the motor amps value In order to manually operate the guide vanes it is nec essary to override the TARGET GUIDE VANE POSITION value which is accessed on the Status01 table Manual con trol is indicated by the word flashing after the target value position Manual control is also indicated on the default screen on the run status line 1 Access the Status01 table and look at the target guide vane position Fig 16 If the compressor is off the value will read zero 2 Move the highlight bar to the TARGET GUIDE VANE POSITION line and press the softkey 3 Press ENTER to override the auto
118. ctive action mode If the actual values are below the line the algorithm takes no action Modification of the default set points of the MINIMUM and MAXIMUM load points is described in the Input Service Configuration section on page 50 Corrective action can be taken by making one of 2 choices If a hot gas bypass line is present and the hot gas is con figured on the Servicel table then the hot gas bypass valve can be energized If a hot gas bypass if not present then the action taken is to hold the guide vanes See Table 4 Capacity Overrides Both of these corrective actions will reduce the lift experienced by the compressor and help to prevent a surge condition Surge is a condition when the lift becomes so high that the gas flow across the impeller reverses This condition can eventually cause chiller dam age The surge prevention algorithm is intended to notify the operator that chiller operating conditions are marginal and to take action to help prevent chiller damage such as low ering entering condenser water temperature Surge Protection Surging of the compressor be determined by the PIC through operator configured settings Surge will cause amperage fluctuations of the compressor motor The PIC monitors these amperage swings and if the swing is greater than the configurable setting in one sec ond then one surge count has occurred The SURGE DELTA PERCENT AMPS setting is displayed and configured on the Servicel scr
119. d pinion bear ing and gear spray The balance then lubricates the motor shaft bearings and the rear pinion bearing The oil temper ature is measured as the oil leaves the thrust and forward REAR MOTOR BEARING ERE FILTER ISOLATION VALVE FILTER OIL DRAIN OIL COOLER OIL PRESSURE TRANSDUCER OIL THERMAL EXPANSION FILTER VALVE BULB ISOLATION VALVE ESN PRESSURE RELIEF VALVE FWD MOTOR BEARING REAR PINION BEARING DEMISTOR OIL SPRAY FWD PINION AND THRUST BEARING SIGHT GLASSES OIL HEATER STRAINER CHECK VALVE GUIDE VANE OIL RECLAIM LINE SOLENOID VALVES STRAINER E FILTER o OIL RECLAIM LINE EDUCTOR OIL CHARGE VALVE Fig 4 Lubrication System journal bearings within the bearing housing The oil then drains into the oil reservoir at the base of the compressor The PIC Product Integrated Control measures the temperature of the oil in the sump and maintains the temperature during shut down see Oil Sump Temperature Control section page 32 This temperature is read on the LID default screen During the chiller start up the PIC will energize the oil pump and provide 15 seconds of prelubrication to the bear ings after pressure is verified before starting the compressor During shutdown the oil pump will run for 60 seconds to post lubricate after the compressor shuts down The oil pu
120. d through the LID screen or Fig 40 LID Module Rear View and LED Locations Processor Module PSIO Fig 41 INPUTS Each input channel has 3 terminals only 2 of the terminals are used Application of chiller determines which terminals are normally used Always refer to individual unit wiring for terminal numbers OUTPUTS Output is 20 vdc There are 3 terminals per output only 2 of which are used depending on the appli cation Refer to the unit wiring diagram CHASSIS GROUND REAR UPPER CCN BUS CONNECTOR J5 COMM 1 FORWARD LOWER SENSOR BUS CONNECTOR J8 COMM 3 SLINANI 21 O6 X00 Sg 0O vo oo0 oum 0000000000 5109110 9 NOTE Address switches on this module be at any position Addresses are only changed through the LID screen or Fig 41 Processor PSIO Module 79 Starter Management Module SMM Fig 42 INPUTS Inputs on strips J2 and J3 are a mix of analog and discrete on off inputs Application of the chiller de termines which terminals are used Always refer to the individual unit wiring diagram for terminal numbers OUTPUTS Outputs are 24 vdc and wired to strip J1 There are 2 terminals used per output SENSOR BUS CONNECTOR CHASSIS GROUND POWER CONNECTOR ADDRESS 1 SWITCHES AQ 52 J2 NOTE SMM address switches should be set as follows S1 set at 3 S2 set at 2 Fig 42 Starter Managem
121. den nated to the starter 8 SCR Indicator LEDs Hidden 2 Verify that the ground wire to the starter is installed prop Scc Reset erly and is of sufficient size Fig 30 Benshaw Inc Solid State Starter 3 Verify that the motors are properly grounded to the starter Power Stack 4 Check that all of the relays are properly seated in their sockets 5 Verify that the proper ac input voltage is brought into the starter per the certified drawings 6 Verify the initial factory settings of the starting torque and MIN MAX ramp potentiometers are set per the note on the schematic for the starters NOTE The potentiometers are located at the lower left hand corner on the circuit board mounted in front of the starter power stack Fig 30 and 31 The starting torque potentiometer should be set so that when the PIC calls for the motor to start the rotor should SECONDS SECONDS just start to turn The nominal dial position for a 60 Hz 0 100 motor is approximately the 11 30 position The nominal dial position for a 50 Hz motor is approximately in the 9 30 position because the board is turned on its side so STARTING TORQUE that the 9 00 o clock position is located where the 6 00 o clock position would normally be located The ramp NOTE Adjustments potentiometer should be set so that the motor is up to full Starting torque 096 to 10096 rated motor torque speed in 15 to 20 seconds the bypass contactors have Ramp time t
122. e Y 7 2 SSSA oN 3 RY OR ESSE 5777 LER NOTES 1 Dimensions are in inches with rotor in the thrust position 2 All clearances listed are new chiller tolerances 3 All radial clearances are diametrical DESIGN I MOTOR REAR LABYRINTH DESIGN II MOTOR REAR LABYRINTH NOTE Radial clearances shown are diametrical Fig 47 Compressor Fits and Clearances 88 COMPRESSOR ASSEMBLY TORQUES TORQUE ITEM DESCRIPTION Nem 1 Oil Heater Grommet Nut 14 2 Impeller Retaining Bolt 60 62 3 Bull Gear Retaining Bolt 108 115 4 Motor Terminals Low Voltage 68 5 Demister Bolts 20 26 6 Guide Vane Shaft Seal Nut 34 7 Motor Terminals High Voltage Insulator 2 7 5 4 Packing Nut 6 8 Brass Jam Nut 13 6 LEGEND Nem Newton Meters Not shown ITEM2 Zra 2 p IMPELLER SHIMMING TO BE DETERMINED AT ASSEMBLY LL LA KO table lists Z clearances for each compressor code Figure 1 shows the location on the chiller information plate of the compressor code for each chiller 203 204 223 274 283 307 321 377 381 397 410 469 470 499 COMPRESSOR COMPRESSOR ODE ODE 516 517 546 547 518 519 548 549 526 527 556 557 528 529 558 559 536 537 566 567 538 539 568 569 Fig 47 Compressor Fits and Clearances cont 89 VOLTA
123. e 4 20 mA demand limit auto restart option Enable Disable remote contact option Enable Disable Owner Modified CCN Tables The following tables are de scribed for reference only Occdef Table Modifications The Occdef tables contain the Local and CCN time schedules which can be modified here or in the Schedule screen as described previously Holidef Table Modifications The Holidef tables configure the days of the year that holidays are in effect See the holi day paragraphs in the Controls section for more details Brodefs Table Modifications The Brodefs table defines the outside air temperature sensor and humidity sensor if one is to be installed It will define the start and end of day light savings time Enter the dates for the start and end of daylight savings if required for the location Brodefs also will activate the Broadcast function which enables the holi day periods that are defined on the LID Other Tables The Alarmdef Cons def and Runt def con tain tables for use with a CCN system See the applicable CCN manual for more information on these tables These tables can only be defined through a CCN Building Supervisor CHECK VOLTAGE SUPPLY Access the Status 01 screen and read the actual line voltage This reading should be equal 52 to the incoming power to the starter Use a voltmeter to check incoming power at the starter power leads If the readings are not equal an adjustment can
124. e Some safety shutdown logic resides in the SMM in case communications are lost between the 2 modules The PSIO monitors conditions using input ports on the PSIO the SMM and the 8 input modules Outputs are con trolled by the PSIO and SMM as well 3 Power is supplied to modules within the control panel via 21 power sources The transformers are located within the power panel with the exception of the SMM which operates from a 24 vac power source and has its own 24 vac transformer located within the starter Within the power panel T1 supplies power to the LID the PSIO and the 5 vac power supply for the transduc ers The other 21 vac transformer is T4 which supplies power to both 8 input modules if present T4 is capable of supplying power to two modules if additional mod ules are added another power supply will be required Power is connected to Terminals 1 and 2 of the power input connection on each module GREEN COMMI RED LEDS COMMUNICATION LED CONNECTOR o O o o o 1000 009000000000000 000000000000000000 Fig 39 PSIO Module Address Selector Switch Locations and LED Locations LID DISPLAY CONTRAST ADJUSTMENT ADDRESS SWITCHES 2 GREEN LEDS BATTERY STOP BUTTON DO NOT ALARM LIGHT REMOVE CONNECTION NOTE Address switches on this module can be at any position Addresses are only change
125. e Tank section Steps la and b page 60 WEEKLY MAINTENANCE Check the Lubrication System Mark the oil level on the reservoir sight glass and observe the level each week while the chiller is shut down If the level goes below the lower sight glass the oil reclaim system will need to be checked for proper operation If additional oil is required add it through the oil drain charging valve Fig 2A or Fig 2B A pump is required for adding oil against refrigerant pressure The oil charge is approximately 8 gallons 30 L The added oil must meet Carrier specifications for the 19XL Refer to Changing Oil Filter and Oil Changes sections on page 63 Any additional oil that is added should be logged by noting the amount and date Any oil that is added due to oil loss that is not related to service will eventually return to the sump It must be removed when the level is high A 1200 watt oil heater is controlled by the PIC to main tain oil temperature see the Controls section when the compressor is off The LID Status02 table displays whether the heater is energized or not If the PIC shows that the heater is energized but the sump is not heating up the power to the oil heater may be off or the oil level may be too low Check the oil level the oil heater contactor voltage and oil heater resistance The PIC will not permit compressor start up if the oil temperature is too low The control will continue with start up only after the
126. e and a filter on the cooler scavaging line Replace these filters once per year or more often if filter condition indicates a need for more frequent replacement Change these filters by transferring the refrig erant charge to a storage vessel or the condenser Inspect Refrigerant Float System Perform Compressor Bearing and Gear inspection every 5 years or when the condenser is opened ance The key to good bearing and gear maintenance is for service Transfer the refrigerant into the cooler vessel or proper lubrication Use the proper grade of oil maintained into a storage tank Remove the float access cover Clean the at recommended level temperature and pressure Inspect the chamber and valve assembly thoroughly Be sure that the lubrication system regularly and thoroughly valve moves freely Make sure that all openings are free of obstructions Examine the cover gasket and replace if nec essary See Fig 37 for views of both float valve designs On the linear float valve design inspect orientation of the float slide pin It must be pointed toward the bubbler tube for proper operation To inspect the bearings a complete compressor teardown is required Only a trained service technician should remove and examine the bearings The cover plate on older com pressor bases was used for factory test purposes and is not usable for bearing or gear inspection The bearings and gears should be examined on a scheduled basis
127. e and remote contacts input Lag Chiller Start Up Requirements Before the lag chiller can be started the following conditions must be met 1 Lead chiller ramp loading must be complete 2 Lead chiller CHILLED WATER temperature must be greater than the CONTROL POINT plus 1 2 the WATER BRINE DEADBAND NOTE The chilled water temperature sensor may be the leaving chilled water sensor the return water sensor the common supply water sensor or the common return water sensor depending on which options are configured and enabled 3 Lead chiller ACTIVE DEMAND LIMIT value must be greater than 9596 of full load amps 4 Lead chiller temperature pulldown rate of the CHILLED WATER temperature is less than 0 5 F 0 27 C per minute The lag chiller status indicates it is in CCN mode and is not faulted If the current lag chiller is in an alarm con dition then the standby chiller becomes the active lag chiller if it is configured and available 6 The configured LAG START TIMER entry has elapsed The LAG START TIMER shall be started when the lead chiller ramp loading is completed The LAG START TIMER entry is accessed by selecting Lead Lag from the Equip ment Configuration table of the Service menu When all of the above requirements have been met the lag chiller is forced to a START mode The PIC control then monitors the lag chiller for a successful start If the lag chiller fails to start the standby chiller if
128. e upper left hand corner of the LID screen See Fig 22 When the CCN device has been viewed the ATTACH TO NETWORK DEVICE table should now be used to attach to the PIC that is on the chiller Move to the ATTACH TO NETWORK DEVICE table and press the ATTACH softkey to upload the LOCAL device The PSIO for the 19XL will now be uploaded NOTE The LID will not automatically reattach to the PSIO module on the chiller Press the ATTACH softkey to attach to LOCAL DEVICE and view the chiller PSIO NAME DESCRIPTOR TABLE NAME ALWAYS THE PSIO MODULE 19XL CHIR ATTACH TO NETWORK DEVICE ON THE 19XL Bee prog NUMERICAL OTHER CCN DEVICE H 9 LOCATION MODULES DEVICE3 0 0 OF DEVICE 4 0 0 DEVICES M M MODULE DEVICE 0 DEVICE8 0 0 DEVICE 9 0 0 MENU LINE SELECT ATTACH Fig 22 Example of Attach to Network Device Screen Service Operation overview of the menu driven programs available for Service Operation is shown in Fig 17 TO LOG ON 1 On the Menu screen press SERVICE The keys now correspond to the numerals 1 2 3 4 2 Press the four digits of your password one at a time An asterisk appears as you enter each digit ENTER 4 DIGIT PASSWORD m TOUO The menu bar Next Previous Select Exit is displayed to indicate that you have successfully logged on PREVIOUS SELECT EXIT 38 If the password is entered incorrectly an error message is displayed If this occurs return to
129. eading has not changed dehydration is complete If the reading indicates vacuum loss repeat Steps 4 and 5 7 If the reading continues to change after several attempts perform a leak test up to the maximum 230 psig 1585 kPa pressure Locate and repair the leak and re peat dehydration TO VACUUM FROM ast iuh PUMP SYSTEM 7 MOISTURE MIXTURE OF CONDENSES DRY ICE AND METHYL ALCOHOL ON COLD SURFACES Fig 29 Dehydration Cold Trap Inspect Water Piping Refer to piping diagrams pro vided in the certified drawings and the piping instructions in the 19XL Installation Instructions manual Inspect the piping to the cooler and condenser Be sure that flow direc tions are correct and that all piping specifications have been met Piping systems must be properly vented with no stress on waterbox nozzles and covers Water flows through the cooler and condenser must meet job requirements Measure the pres sure drop across cooler and across condenser CAUTION Water must be within design limits clean and treated to ensure proper chiller performance and reduce the potential of tubing damage due to corrosion scaling or erosion Carrier assumes no responsibility for chiller dam age resulting from untreated or improperly treated water Check Optional Pumpout Compressor Water Pip ing If the optional storage tank and or pumpout system are installed check to ensure the pumpout condenser water has been p
130. ed Note total chiller leak rate on the start up report If noleak is found during initial start up procedures com plete the transfer of refrigerant gas from the storage tank to the chiller see Pumpout and Refrigerant Transfer Pro cedures Transfer Refrigerant from Storage Tank to Chiller section Step le page 59 Retest 43 If no leak is found after a retest a Transfer the refrigerant to the storage tank and perform a standing vacuum test as outlined in the Standing Vacuum Test section this page b If the chiller fails this test check for large leaks Step 2b c Dehydrate the chiller if it passes the standing vacuum test Follow the procedure in the Chiller Dehydration section Charge chiller with refrigerant see Pumpout and Refrigerant Transfer Procedures Transfer Refrig erant from Storage Tank to Chiller section Steps 1a e or page 59 If aleak is found pump the refrigerant back into the stor age tank or if isolation valves are present pump into the non leaking vessel see Pumpout and Refrigerant Trans fer procedures section Transfer the refrigerant until chiller pressure is at 18 in Hg 40 kPa absolute Repair the leak and repeat the procedure beginning from Step 2h to ensure a leaktight repair If chiller is opened to the atmosphere for an extended period evacuate it be fore repeating leak test Standing Vacuum Test When performing the stand ing vacuum test or chiller d
131. een It has a default setting of 25 amps SURGE PROTECTION COUNTS can be monitored on the Maint03 table A surge protection shutdown of the chiller will occur when ever the surge protection counter reaches 12 counts with in an operator specified time known as the SURGE TIME PERIOD The SURGE TIME PERIOD is displayed and configured on the Servicel screen It has a default of 2 minutes Lead Lag Control NOTE Lead lag control is only available on chillers with PSIO Software Version 09 or higher Lead lag is a control system process that automatically starts and stops a lag or second chiller in a 2 chiller water system Refer to Fig 16 and 17 for menu table and screen selection information On chillers that have PSIO software with Lead Lag capability it is possible to utilize the PIC controls to perform the lead lag function on 2 chillers A third chiller can be added to the lead lag system as a standby chiller to start up in case the lead or lag chiller in the system has shut down during an alarm condition and additional cooling is required NOTE Lead lag configuration is viewed and edited under Lead Lag in the Equipment Configuration table located in the Service menu Lead lag status during chiller operation is viewed in MAINTO04 table in the Control Algorithm Status table See Table 2 34 19XL DEFAULTS AT1 1 5 HCFC 22 AP1 75 psid AT2 10 AP2 170 psid 200 190 180 HGBP SURGE PREVENTION _ 10 17
132. ehydration use a manometer or a wet bulb indicator Dial gages cannot indicate the small amount of acceptable leakage during a short period of time 1 2 5 Attach an absolute pressure manometer or wet bulb in dicator to the chiller Evacuate the vessel see Pumpout and Refrigerant Trans fer Procedures section page 59 to at least 18 in Hg vac ref 30 in bar 41 kPa using a vacuum pump or the pumpout unit Valve off the pump to hold the vacuum and record the manometer or indicator reading If the leakage rate is less than 0 05 in Hg 17 kPa in 24 hours the chiller is sufficiently tight b If the leakage rate exceeds 0 05 in Hg 17 kPa in 24 hours repressurize the vessel and test for leaks If refrigerant is available in the other vessel pressurize by following Steps 2 10 of Return Refrigerant To Normal Operating Conditions section page 61 If not use nitrogen and a refrigerant tracer Raise the vessel pressure in increments until the leak is detected If refrigerant is used the maximum gas pressure is approximately 120 psig 827 kPa for HCFC 22 70 psig 483 kPa for HFC 134a at normal ambient temperature If nitrogen is used limit the leak test pres sure to 230 psig 1585 kPa maximum Repair leak retest and proceed with dehydration Table 5A HCFC 22 Pressure Temperature F TEMPERATURE PRESSURE psi TEMPERATURE PRESSURE psi TEMPERATURE PRESSURE psi
133. eing applied a status message SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING is shown Chilled Water Recycle Mode The chiller may cycle off and wait until the load increases to restart again when the compressor is running in a lightly loaded condition This cycling of the chiller is normal and is known as recycle A recycle shutdown is initiated when any of the following con ditions are true when in LCW control the difference between the LEAV ING CHILLED WATER temperature and ENTERING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T found in the Servicel table and the LEAVING CHILLED WATER TEMP is below the CONTROL POINT and the CONTROL POINT has not increased in the last 5 minutes when ECW CONTROL OPTION is enabled the difference between the ENTERING CHILLED WATER temperature and the LEAVING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T found in the Servicel table and the ENTERING CHILLED WATER TEMPERATURE is below the CONTROL POINT and the CONTROL POINT has not increased in the last 5 minutes when the LEAVING CHILLED WATER temperature is within 3 F 2 C of the BRINE REFRIG TRIPPOINT When the chiller is in RECYCLE mode the chilled water pump relay remains energized so that the chilled water tem perature can be monitored for increasing load The recycle control uses RECYCLE RESTART DELTA T to check when the compressor should be restarted This is an operator configured f
134. emperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual temperature pressure voltage etc at which the control tripped RECYCLE ALERT HIGH AMPS AT SHUTDOWN HIGH BEARING SENSOR ALERT TEMPERATURE RECYCLE ALERT EXCESSIVE RECYCLE STARTS Excessive recycle starts M SPARE SENSOR ALERT MESSAGES PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SPARE SENSOR ALERT Brie sensor Spare 1 SPARE SENSOR ALENT pee a SPARE SENSOR ALEM ILU NOTE See Legend on page 68 74 Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont N OTHER PROBLEMS MALFUNCTIONS DESCRIPTION MALFUNCTION Chilled Water Brine Temperature Too High Machine Running Chilled Water Brine Temperature Too Low Machine Running Chilled Water Temperature Fluctuates Vanes Hunt PROBABLE CAUSE REMEDY Chilled water set point set too high Access set point on LID and verify Capacity override or excessive cooling load chiller at design capacity Check LID status messages Check for outside air infiltration into conditioned space Condenser temperature too high Check for proper flow examine cooling tower operation check for air or water leaks check for fouled tubes Refrigerant level low Check for leaks add refrigerant and trim charge
135. en BUILD TERMINATION is set to both the temperature and contacts 2 option and the previously described condi tions for ENTERING CHILLED WATER temperature and remote contacts have occurred 37 NOTE Overriding the CHILLER START STOP WATER BRINE CONTROL POINT and ACTIVE DEMAND LIMIT variables by CCN devices with a priority less than 4 during the ice build period is not possible However over riding can be accomplished with CCN during two chiller lead lag RETURN TO NON ICE BUILD OPERATIONS Upon termination of ice build the chiller shall return to normal temperature control and start stop schedule operation If the CHILLER START STOP or WATER BRINE CONTROL POINT has been forced with a priority less than 4 prior to entering ice build operation then chiller START STOP and WATER BRINE CONTROL POINT forces will be removed Attach to Network Device Control On the Serv ice menu one of the selections is ATTACH TO NETWORK DEVICE This table serves the following purposes to upload new parameters when switching the controller to HFC 134a refrigerant to upload the Occupancy Schedule Number if changed for OCCPCO3S software version 09 and later as defined in the 01 table to attach the LID to any CCN device if the chiller has been connected to a CCN Network This may include other PIC controlled chillers to change to a new PSIO or LID module or upgrade software Figure 22 illustrates the ATTA
136. en at the starter if there is a difference Highlight the amps value then press SELECT Press INCREASE or to bring the value to that indicated on the ammeter Press ENTER when equal 4 Make sure that the target guide vane position is released into AUTOMATIC mode To Prevent Accidental Start Up The PIC can be set up so that start up of the unit is more difficult than just pressing LOCAL or softkeys during chiller serv ice or when necessary By accessing the Status01 table and highlighting the chiller Start Stop line the value can be over ridden to stop by pressing SELECT and then the STOP and softkeys SUPVSR will appear after the value When attempting to restart remember to release the override The default chiller message line will also state that the Start Stop has been set to Start or Stop when the value is overridden Check Chiller Operating Condition Check to be sure that chiller temperatures pressures water flows and oil and refrigerant levels indicate that the system 1 func tioning properly Instruct the Customer Operator Check to be sure that the operator s understand all operating and main tenance procedures Point out the various chiller parts and explain their function as part of the complete system COOLER CONDENSER Float chamber relief devices refrigerant charging valve temperature sensor locations pres sure transdu
137. enser operates at a higher temperature pressure than the cooler and has water flowing through its internal tubes in order to remove heat from the refrigerant Motor Compressor This component maintains sys tem temperature pressure differences and moves the heat carrying refrigerant from the cooler to the condenser Control Center The control center is the user inter face for controlling the chiller It regulates the chiller s capacity as required to maintain proper leaving chilled water temperature The control center registers cooler condenser and lubricating system pressures shows chiller operating condition and alarm shutdown conditions records the total chiller operating hours sequences chiller start stop and recycle under micro processor control provides access to other CCN Carrier Comfort Network devices Factory Mounted Starter Optional The starter allows the proper start and disconnect of electrical energy for the compressor motor oil pump oil heater and control panels Storage Vessel Optional There are 2 sizes of storage vessels available The vessels have double relief valves a magnetically coupled dial type refrigerant level gage a one inch drain valve and 1 2 in male flare vapor connection for the pumpout unit A 30 in 0 400 psi 101 0 2750 kPa gage also is supplied with each unit NOTE If a storage vessel is not used at the jobsite factory installed isolation va
138. enser tube freeze up by ener gizing the condenser pump relay If the pump is controlled by the PIC starting the pump will help prevent the water in the condenser from freezing Condenser freeze prevention can occur whenever the chiller is not running except when it is either actively in pumpdown or in Pumpdown Lockout with the freeze prevention disabled refer to Control Test table Pumpdown Terminate Lockout tables When the CONDENSER REFRIG TEMP is less than or equal to the CONDENSER FREEZE POINT or the ENTERING CONDENSER WATER temperature is less than or equal to the CONDENSER FREEZE POINT then the CONDENSER WATER PUMP shall be energized until the CONDENSER REFRIG TEMP is greater than the CON DENSER FREEZE POINT plus 5 F 2 7 C An alarm will be generated if the chiller is in PUMPDOWN mode and the pump is energized An alert will be generated if the chiller is not in PUMPDOWN mode and the pump is energized If in recycle shutdown the mode shall transition to a non recycle shutdown Tower Fan Relay Low condenser water tempera ture can cause the chiller to shut down on low refrigerant temperature The tower fan relay located in the starter is controlled by the PIC to energize and deenergize as the pres sure differential between cooler and condenser vessels changes in order to prevent low condenser water temperature and to maximize chiller efficiency The tower fan relay can only accomplish this if the relay has been added to
139. ent Module SMM Options Modules 8 Input The options modules are optional additions to the PIC and are used to add tem perature reset inputs spare sensor inputs and demand limit inputs Each option module contains 8 inputs each input meant for a specific duty See the wiring diagram for exact module wire terminations Inputs for each of the options modules available include the following OPTIONS MODULE 1 4 to 20 mA Auto Demand Reset 4 to 20 mA Auto Chilled Water Reset Common Chilled Water Supply Temperature Common Chilled Water Return Temperature Remote Temperature Reset Sensor Spare Temperature 1 Spare Temperature 2 Spare Temperature 3 OPTIONS MODULE 2 4 to 20 mA Spare 1 4 to 20 mA Spare 2 Spare Temperature 4 Spare Temperature 5 Spare Temperature 6 Spare Temperature 7 Spare Temperature 8 Spare Temperature 9 Terminal block connections are provided on the options modules All sensor inputs are field wired and installed Options module number 1 can be factory or field installed Options module 2 is shipped separately and must be field installed For installation refer to the unit or field wiring diagrams Be sure to address the module for the proper mod ule number Fig 43 and to configure the chiller for each feature being used SENSOR BUS POWER CONNECTOR CONNECTOR 2 CHASSIS GROUND ADDRESS 0 51 SWITCHES PR S2 SWITCH OPTIONS SETTING MODULE 2 S1 7 2 2 Fig 43 Options M
140. er connections on each vessel by removing the pres sure transducer 2 To determine storage tank pressure a 30 in 0 400 psi 101 0 2760 kPa gage is attached to the vessel 3 Refer to Fig 27 28 and 35 for valve locations and numbers A CAUTION Transfer addition or removal of refrigerant in spring isolated chillers may place severe stress on external pip ing if springs have not been blocked in both up and down directions Chillers with Pumpout Storage Tanks If the chiller has isolation valves leave them open for the follow ing procedures The letter describes a closed valve See Fig 16 17 27 and 28 TRANSFER REFRIGERANT FROM STORAGE TANK TO CHILLER 1 Equalize refrigerant pressure a Use the Control Test Terminate Lockout to turn on water pumps and monitor pressures b Close pumpout unit storage tank valves 2 4 5 8 and 10 and close chiller charging valve 7 open chiller iso lation valves 11 12 13 and 14 if present c Open pumpout unit storage tank valves 3 and 6 open chiller valves 1a and 1b 59 Li COMPR MOTOR C OL L C OL 2 E C OL BLU HSV 50 60 HZ ON STOP 5 FU 3A YEL A 47 RED CN dE 5 HL Y RED ES OMS T oL HP LEGEND Contactor Fuse 3 Amps High Pressure Cutout Compressor Overload Internal Thermostat Compressor Termi
141. er is in an alarm condition as shown on the LID panel the RESET softkey is pressed to clear the alarm and the chiller is placed in the CCN mode the lead chiller will now communicate and monitor the RUN STATUS of the lag and standby chillers If both the lag and standby chillers are running the lead chiller will not attempt to start and will not assume the role of lead chiller until either the lag or standby chiller shuts down If only one chiller is running the lead chiller will wait for a start request from the operating chiller When the configured lead chiller starts it assumes its role as lead chiller LOAD BALANCING When the LOAD BALANCE OPTION is enabled the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller s COM PRESSOR MOTOR LOAD value This value has limits of 40 to 100 When setting the lag chiller ACTIVE DEMAND LIMIT the CONTROL POINT will be modi fied to a value of 3 F 1 67 C less than the lead chiller s CONTROL POINT value If the LOAD BALANCE OPTION 36 is disabled the ACTIVE DEMAND LIMIT and the CON TROL POINT are forced to the same value as the lead chiller AUTO RESTART AFTER POWER FAILURE When an auto restart condition occurs each chiller may have a delay added to the start up sequence depending on its lead lag configuration The lead chiller does not have a delay The lag chiller has a 45 second delay The standby chiller has a 90 second delay T
142. erator monitors and modifies configura tions in the microprocessor through the 4 softkeys and the LID Communication with the LID and the PSIO is accomplished through the CCN bus The communication between the PSIO SMM and both 8 input modules is accomplished through the sensor bus which is a 3 wire cable On sensor bus terminal strips Terminal 1 of PSIO mod ule is connected to Terminal 1 of each of the other modules Terminals 2 and 3 are connected in the same manner See Fig 39 43 If a Terminal 2 wire is connected to Terminal 1 the system does not work 2 If a green LED is solid on check communication wiring If a green LED is off check the red LED operation If the 78 red LED 1 normal check the module address switches Fig 39 43 Proper addresses are MODULE ADDRESS SMM Starter Management Module 8 input Options Module 1 8 input Options Module 2 If all modules indicate communications failure check com munications plug on the PSIO module for proper seating Also check the wiring CCN bus 1 2 wht 3 blk Sensor bus 1 2 blk 3 clr wht If a good connec tion is assured and the condition persists replace the PSIO module If only one 8 input module or SMM indicates commu nication failure check the communications plug on that module If a good connection is assured and the condi tion persists replace the module system operating intelligence rests in the PSIO mod ul
143. ermined by the PIC adding any active chilled water reset to the ECW Entering Chilled Water SET POINT LCW SET POINT The PIC uses the PROPORTIONAL INC Increase BAND PROPORTIONAL DEC Decrease BAND and the PROPORTIONAL ECW GAIN to determine how fast or slow to respond CONTROL POINT may be viewed overridden on the Status table StatusO1 selection ENTERING CHILLED WATER CONTROL If this op tion is enabled the PIC uses ENTERING CHILLED WATER temperature to modulate the vanes instead of LEAV ING CHILLED WATER temperature ENTERING CHILLED WATER control option may be viewed modified on the Equip ment Configuration table Config table DEADBAND This is the tolerance on the chilled water brine temperature CONTROL POINT If the water temper ature goes outside of the DEADBAND the PIC opens or closes the guide vanes in response until it is within tolerance The PIC may be configured with a 0 5 to 2 F 0 3 to 1 1 C dead band DEADBAND may be viewed or modified on the Equip ment Servicel table For example a 1 F 0 6 C deadband setting controls the water temperature within 0 5 0 3 C of the con trol point This may cause frequent guide vane movement if the chilled water load fluctuates frequently A value of 1 F 0 6 C is the default setting PROPORTIONAL BANDS AND GAIN Proportional band is the rate at which the guide vane position is corrected in proportion to how far the chilled water brine temperature
144. ernally powered the signal is wired to terminals J1 3 and J1 2 When enabled the control is set for 100 demand with 4 mA and an operator configured mini mum demand set point at 20 mA Surge Prevention Algorithm This is an operator configurable feature which can determine if lift conditions are too high for the compressor and then take corrective action Lift is defined as the difference between the pressure at the impeller eye and the impeller discharge The maxi mum lift that a particular impeller can perform varies with the gas flow across the impeller and the size of the impeller The algorithm first determines if corrective action is nec essary This is done by checking 2 sets of operator con figured data points which are the MINIMUM and the MAXIMUM Load Points T1 P1 T2 P2 These points have default settings for each type of refrigerant HCFC 22 or HFC 134a as defined on the Servicel table or on Table 4 These settings and the algorithm function are graphically displayed in Fig 20 and 21 The two sets of load points on this graph default settings are shown describe a line which the algorithm uses to determine the maximum lift of the com pressor Whenever the actual differential pressure between the cooler and condenser and the temperature difference between the entering and leaving chilled water are above the line on the graph as defined by the MINIMUM and MAXI MUM Load Points the algorithm will go into a corre
145. es Check the 2C aux contact and the oil pressure switch in the power panel This alarm is not caused by the transducer Check water flow in condenser Check for fouled tubes Transducer should be checked for accuracy This alarm is not caused by the high pressure switch Check that guide vanes are closed at start up Check starter for proper operation Reduce unit pressure if possible Check starter for proper operation Run contact failed to close Check starter for proper operation Start contact failed to close Check for proper motor amps signal to SMM Check wiring from SMM to current transformer Check main motor circuit breaker for trip V P Single Cycle Dropout Detected Check voltage supply High Condenser Pressure OPENJ Check switch oil pressure contact and water temperature flow High Condenser Pressure VALUE Check switch water flow and transducer Excess Acceleration Check guide vane closure at start up RUN AUX Starter Transition Fault Check 1CR 1M Interlock mechanism 1CR AUX Starter Contact Fault Check 1CR 1M aux contacts __ Motor Amps Not Sensed Check motor load signal FAILURE TO START FAILURE TO START CHECK REFRIGERANT TYPE LOW OIL PRESSURE Pressures at transducers indicate another refrigerant type in Control Test Make sure to access the ATTACH TO NETWORK DEVICE table after changing refrigerant type The oil pressure differential sw
146. es refrigerant flow to control oil temperature entering the bearings There is always a flow of refrigerant bypassing the thermostatic TXV The bulb for the expansion valve is strapped to the oil supply line leaving the heat exchanger and the valve 15 set to maintain 110 F 43 C NOTE The TXV is not adjustable Oil sump temperature may be at a lower temperature Remote Start Stop Controls remote device such as a time clock which uses a set of contacts may be used to start and stop the chiller However the device should not be programmed to start and stop the chiller in excess of 2 or 32 3 times every 12 hours If more than 8 starts in 12 hours occur then an Excessive Starts alarm is displayed prevent ing the chiller from starting The operator must reset the alarm at the LID in order to override the starts counter and start the chiller If Automatic Restart After a Power Failure is not activated when a power failure occurs and the remote con tact 1 closed the chiller will indicate an alarm because of the loss of voltage The contacts for Remote Start are wired into the starter at terminal strip TB5 terminals 8A and 8B See the certified drawings for further details on contact ratings The contacts must be dry no power Spare Safety Inputs Normally closed NC digital inputs for additional field supplied safeties may be wired to the spare protective limits input channel in place of the factory installed jumper
147. eset based on a 4 to 20 mA input signal This type permits up to 30 F 16 C of automatic reset to the chilled water or brine temperature set point based on the input from a 4 to 20 mA signal This signal is hardwired into the number one 8 input module If the 4 20 mA signal is externally powered from the 8 input module the signal is wired to terminals J1 5 and J1 6 If the signal is to be internally powered by the 8 input mod ule for example when using variable resistance the signal is wired to J1 7 and J1 6 The PIC must now be con figured on the Service2 table to ensure that the appropriate power source is identified RESET TYPE 2 Reset Type requires an optional 8 input module It is an automatic chilled water temperature reset based on a remote temperature sensor input This reset type permits 30 F 16 C of automatic reset to the set point based on a temperature sensor wired to the number one 8 input module see wiring diagrams or certified drawings The tem perature sensor must be wired to terminal J1 19 and J1 20 To configure Reset Type 2 enter the temperature of the remote sensor at the point where no temperature reset will occur Next enter the temperature at which the full amount of reset will occur Then enter the maximum amount of re set required to operate the chiller Reset Type 2 can now be activated RESET TYPE 3 Reset Type 3 is an automatic chilled water temperature reset based on
148. ess INCREASE or DECREASE to change the se lected set point value PREVIOUS SELECT INCREASE DECREASE QUIT ENTER LJ LJ 6 Press to save the changes and return to the previous screen INCREASE DECREASE QUIT EMEND SERVICE OPERATION To view the menu driven pro grams available for Service Operation see Service Opera tion section page 38 For examples of LID display screens see Table 2 ENTER Table 2 LID Screens NOTES Only 12 lines of information appear on the LID screen at any given time Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen The LID may be configured in Fnglish or SI units as required through the LID configuration screen Data appearing in the Reference Point Names column is used for operations only i with ICE BUILD Lead Lag Occupancy Configuration and Soft Stopping are only available on PSIO Software ersion 9 and higher ROP EXAMPLE 1 STATUSO1 DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU 2 Press STATUS STATUSO1 will be highlighted 3 Press SELECT REFERENCE POINT NAME ALARM HISTORY Reset Off Local CCN MODE Timeout Recycle Startup DESCRIPTION Control Mode Run Status Ramping Running Demand Override STATUS Shutdown Abnormal Pumpdown Occupied No Yes OCC Alarm State Normal A
149. et to 2 a value below the Temp Alert threshold shall generate an alert message If the Enable is set to 0 alert generation is disabled 1 Press SERVICE Scroll down to highlight EQUIPMENT SERVICE Press SELECT Scroll down to highlight SERVICES a A O EXAMPLE 9 SERVICE3 DISPLAY SCREEN To access this display from the LID default screen Press MENU DESCRIPTION Proportional Inc Band 2 10 Proportional Dec Band 2 10 Proportional ECW Gain 1 3 Guide Vane Travel Limit 30 100 CONFIGURABLE RANGE UNITS 25 REFERENCE POINT NAME DEFAULT VALUE 6 5 6 0 2 0 50 Table 2 LID Screens cont EXAMPLE 10 MAINTENANCE MAINTO1 DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU Press SERVICE Scroll down to highlight ALGORITHM STATUS Press SELECT 2 3 4 5 Scroll down to highlight MAINTO1 DESCRIPTION REFERENCE POINT NAME CAPACITY CONTROL Control Point 10 120 12 2 48 9 DEG C Leaving Chilled Water 40 245 40 118 LOW Entering Chilled Water 40 245 40 118 DEG C ECW Control Point Error 99 99 55 55 DEG C cperr ECW Delta T DEG C ecwdt ECW Reset DEG C ecwres LCW Reset Icwres Total Error Resets DEG C error Guide Vane Delta gvd Target Guide Vane Pos GV TRG Actual Guide Vane Pos GV ACT Proportional Inc Band Proportional Dec Band Proportional ECW Gain gv
150. f LIMIT Check oil temperature V P VALUE exceeded limit of LIMIT Check voltage suppy V P VALUE exceeded limit of LIMIT Check voltage supply CRP VALUE exceeded limit of LIMIT Check condenser water and ADDITIONAL CAUSE REMEDY Depress the RESET softkey if addi tional start is required Reassess start up requirements Check motor cooling line for proper operation Check for excessive starts within a short time span Check oil heater for proper opera tion check for low oil level partially closed oil supply valves etc Check sensor accuracy Check sensor accuracy Allow dis charge temperature to cool Check for excessive starts Check transducer accuracy Check for low chilled water brine supply temperature Check oil heater power oil heater relay Check oil level Check voltage supply Check volt age transformers Consult power utility if voltage is low Adjust voltage potentiometer in starter for SMM voltage input Check voltage supply Check volt age transformers Consult power utility if voltage is low Adjust voltage potentiometer in starter for SMM voltage input Check for high condenser water temperature Check transducer accuracy eeded limit of LIMIT is shown on the LID as temperature pressure voltage etc predefined or selected by the operator as an override or an alert VALUE is the actual temperature pressure voltage etc at which the control
151. g kg Cover 60 Hz 50 Hz 60 Hz 50 Hz Ib kg 60 Hz 50 Hz 60 Hz 50 Hz CB 114 cc 2660 1143 1150 197 239 250 1208 518 522 90 109 114 CE Ha cL Ha Ha CN 2660 1278 isi 263 279 250 120 59 60 no te 4 114 ca 114 CR 2660 1335 1384 22 204 20 1208 6 628 128 133 114 NOTE For medium voltage motors add 85 Ibs 39 kg to above for 60 Hz motors and 145 Ibs 66 kg for 50 Hz motors Total compressor motor weight is the sum of the compressor stator rotor and end bell cover weight Compressor weight includes suction and discharge elbow weights Table 16 Compressor Weights Table 17 Optional Pumpout System WEIGHT Electrical Data SUCTION ELBOW 25 UNIT RLA DISCHARGE ELBOW 23 3 8 23 0 TRANSMISSION 730 331 10 9 63 5 SUCTION HOUSING 350 159 95 57 5 IMPELLER SHROUD 80 36 400 460 3 50 60 7 288 COMPRESSOR BASE 476 LEGEND DIFFUSER 70 32 LRA Locked Rotor Amps OIL PUMP 150 68 RLA Rated Load Amps MISCELLANEOUS 61 m 87 4 VIEW A ITEM5 ZEN c u rt cem SSSR N 7277777777 1 Ook p ITEM 3 SEE VIEW B Rp SS 2222277 BZ TS Z EE NN 52 j A 0000 E 2001 Ge 0010 24 b NIZA zm 5 E 4 p
152. gerant Transfer Procedures section page 59 for pumpout system prepara tion refrigerant transfer and chiller evacuation Remove Shipping Packaging Remove any packaging material from the control center power panel guide vane actuator motor cooling and oil reclaim solenoids motor and bearing temperature sensor covers and the factory mounted starter Open Oil Circuit Valves Check that the oil filter isolation valves Fig 4 are open by removing the valve cap and checking the valve stem Tighten All Gasketed Joints and Guide Vane Shaft Packing Gaskets and packing normally relax by the time the chiller arrives at the jobsite Tighten all gasketed joints and guide vane shaft packing to ensure a leak tight chiller Check Chiller Tightness Figure 26 outlines the proper sequence and procedures for leak testing 19XL chillers are shipped with the refrigerant contained in the condenser shell and the oil charge shipped in the compressor The cooler will have a 15 psig 103 kPa refrigerant charge Units may be ordered with the refrigerant shipped separately along with a 15 psig 103 kPa nitrogen holding charge in each vessel To determine if there are any leaks the chiller should be charged with refrigerant Use an electronic leak detector to check all flanges and solder joints after the chiller is pressurized If any leaks are detected fol low the leak test procedure If the chiller is spring isolated keep all
153. he delay time is added after the chiller water flow verification The PIC controls ensure that the guide vanes are closed After the guide vane position is confirmed the delay for lag and standby chiller occurs prior to ener gizing the oil pump The normal start up sequence then continues The auto restart delay sequence occurs whether the chiller is in CCN or LOCAL mode and is intended to stagger the compressor motors from being energized simul taneously This will help reduce the inrush demands on the building power system Ice Build Control IMPORTANT The Ice Build control option is only avail able on chillers with PSIO Software Version 09 and higher Ice build control automatically sets the chilled WATER BRINE CONTROL POINT of the chiller to a temperature where an ice building operation for thermal storage can be accomplished The PIC can be configured for ice build operation Con figuration of ice build control is accomplished through entries in the Config table Ice Build Setpoint table and the Ice Build Time Schedule table Figures 16 and 17 show how to access each entry The Ice Build Time Schedule defines the period during which ice build is active if the ice build option is ENABLED If the Ice Build Time Schedule overlaps other schedules defining time then the Ice Build Time Schedule shall take priority During the ice build period the WATER BRINE CONTROL POINT is set to the ICE BUILD SET POINT for temperature c
154. heck for throttled oil supply isolation valves Valves should be wide open Check oil cooler thermal expan sion valve Check sensor accuracy Check journal and thrust bearings Check refrigerant filter Check for ex cessive oil sump level Check power to oil pump and oil level Check for dirty filters or oil foaming at start up Check for thermal overload cutout Reduce ramp load rate if foaming noted NOTE This alarm is not related to pressure switch problems Check the oil pressure switch for proper operation Check oil pump for proper pressure Check for exces sive refrigerant in oil system Check wiring Check torque setting on solid state starter Check for main circuit breaker trip Check power supply to PSIO module Check 24 vdc input sensor on the SMM adjust potenti ometer if necessary Check transformers to SMM Check power to PSIO module Check distribution bus Consult power company PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT LOW CHILLED EVFL Flow Fault Check evap pump flow WATER FLOW switch LOW CONDENSER CDFL Flow Fault Check cond pump WATER FLOW flow switch High Cond Pressure Check Switch oil pressure contact and water temp flow HIGH CONDENSER PRESSURE High Cond Pressure VALUE Check Switch water flow and transducer 1CR AUX CONTACT 1CR Starter Contact Fault Check
155. ible injury to personnel these vention or removal Consult a water treatment specialist devices must be kept in peak operating condition for proper treatment As a minimum the following maintenance is required 1 At least once a year disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust dirt scale leakage etc 2 If corrosion or foreign material is found do not attempt to repair or recondition Replace the valve CAUTION gt the chiller is installed in a corsive atmosphere othe Chiller must be dehydrated after repair of water leaks See Chiller Dehydration section page 47 valve inspections at more frequent intervals 64 Water Leaks Water is indicated during chiller opera tion by the refrigerant moisture indicator Fig 2A or 2B on the refrigerant motor cooling line Water leaks should be re paired immediately Water Treatment Untreated or improperly treated wa ter may result in corrosion scaling erosion or algae The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program A CAUTION Water must be within design flow limits clean and treated to ensure proper chiller performance and reduce the potential of tubing damage due to corrosion scaling ero sion and algae Carrier assumes no responsibility for chiller damage resulting from un
156. igerant Oil Cooler Oil Filter Access Cover Oil Level Sight Glasses Guide Vane Actuator Typical Flange Connection Control Center Cooler Pressure Schrader Fitting Hidden ASME Nameplate Cooler Cooler Take Apart Rabbet Fit Connector Lower Refrigerant Charging Valve Oil Drain Charging Valve Power Panel Cooler Waterbox Cover Cooler In Out Temperature Sensors Condenser In Out Temperature Sensors Condenser Waterbox Cover Take Apart Rabbet Fit Connector Upper Refrigerant Cooling Isolation Valve Hidden LEGEND 25 Cooler Relief Valve 26 Chiller Identification Plate 27 Suction Elbow 28 Transmission Vent Line 29 Condenser Relief Valves 30 Low Voltage Access Door Starter 31 Medium Voltage Access Door Starter 32 Amp Volt Gages 33 Condenser Isolation Valve 34 Linear Float Valve Chamber 35 Condenser Pressure Transducer 36 Discharge Pressure Switch and Discharge Pressure Transducer 37 Cooler Refrigerant Isolation Valve 38 Condenser Return End Waterbox Cover 39 Typical Waterbox Drain Port 40 Cooler Return End Waterbox Cover 41 Cooler Pressure Transducer 42 Pumpdown Valve Fig 2B Typical 19XL Components Design FLASC CHAMBER FLOAT VALVE CHAMBER 1 a COOLING MOTOR COOLING SOLENOID FILTER STATOR DRIER MOISTURE INDICATOR ORIFICES OIL FILTER ORIFICE THERMOSTATIC EXPANSION VALVE TXV
157. ignments placed into the LAG ADDRESS and STANDBY ADDRESS values conflict the lead lag will be disabled and an alert message will occur For example if the LAG ADDRESS matches the lead chiller s address the lead lag will be disabled and an alert message will occur The lead lag maintenance screen MAINT04 will display the message INVALID CONFIG in the LEAD LAG CONFIGURATION and CURRENT MODE fields The lead chiller responds to normal start stop controls such as occupancy schedule forced start stop and remote start contact inputs After completing start up and ramp loading the PIC evaluates the need for additional capacity If addi tional capacity is needed the PIC initiates the start up of the chiller configured at the LAG ADDRESS If the lag chiller is faulted in alarm or is in the OFF or LOCAL modes then the chiller at the STANDBY ADDRESS if configured is requested to start After the second chiller is started and is running the lead chiller shall monitor conditions and evalu ate whether the capacity has reduced enough for the lead chiller to sustain the system alone If the capacity is reduced enough for the lead chiller to sustain the CONTROL POINT temperatures alone then the operating lag chiller is stopped If the lead chiller is stopped in CCN mode for any reason other than an alarm condition then the lag and standby chillers are stopped If the configured lead chiller stops for and alarm condition then
158. igns of corrosion or scale Replace the AT SUDE sensor if corroded or remove any scale if found Higher than normal condenser pressures together with the inability to reach full refrigeration load usually indicate dirty l ___ FLOAT NEM CHAMBER tubes or air in the chiller If the refrigeration log indicates I i rise above normal condenser pressures check the condenser f AHIT n BUBBLER d SNNT LS lt i TUBE refrigerant temperature against the leaving condenser water N temperature If this reading is more than what the design SOVER difference is supposed to be then the condenser tubes may ORIFICE CONDENSER be dirty or water flow may be incorrect Because HCFC 22 REFRIGERANT GAS INLET f TO COOLER and 134 are high pressure refrigerants air usually does not enter the chiller rather the refrigerant leaks out During the tube cleaning process use brushes especially Fig 37 19XL Float Valve Designs designed to avoid scraping and scratching the tube wall Con tact your Carrier representative to obtain these brushes Do not use wire brushes DESIGN II LINEAR FLOAT Inspect Relief Valves and Piping The relief valves on this chiller protect the system against the potentially dan CAUTION gerous effects of overpressure To ensure against damage Hard scale may require chemical treatment for its pre to the equipment and poss
159. ill be shown next to it in brackets Words printed in all capital letters and italics represent val ues that may be viewed on the LID The PSIO software version number of your 19XL unit will be located on the front cover CHILLER FAMILIARIZATION Fig 1 2A and 2B Chiller Information Plate The information plate is located on the right side of the chiller control center panel 19XL 53 53 462 CQ Model Description Hermetic Centrifugal Liquid Chiller Cooler Size 40 43 Frame 4 50 53 Frame 5 55 58 Frame 5 Motor Size Compressor Size Condenser Size 40 43 Frame 4 50 53 Frame 5 55 58 Frame 5 MODEL NUMBER NOMENCLATURE 94 20 J 43758 Unique Number Place of Manufacture SERIAL NUMBER BREAKDOWN Fig 1 19XL Identification Year of Manufacture Week of Year System Components The components include the cooler and condenser heat exchangers in separate vessels motor compressor lubrication package control center and motor starter connections from pressure vessels have ex ternal threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly Cooler This vessel also known as the evaporator is located underneath the compressor The cooler is main tained at lower temperature pressure so that evaporating refrigerant can remove heat from water flowing through its internal tubes Condenser The cond
160. in the power panel Fig 12 It operates all 200 to 575 v oil pumps The PIC energizes the contactor to turn on the oil pump as necessary HOT GAS BYPASS CONTACTOR RELAY 3C Op tional This relay located in the power panel Item 5 Fig 12 controls the opening of the hot gas bypass valve The PIC energizes the relay during low load high lift conditions CONTROL TRANSFORMERS 1 4 These trans formers convert incoming control voltage to either 21 vac power for the PSIO module and options modules or 24 vac power for 3 power panel contactor relays 3 control solenoid valves and the guide vane actuator They are located in the power panel See Fig 12 CONTROL AND OIL HEATER VOLTAGE SELECTOR 51 It is possible to use either 115 v or 230 v incoming con trol power in the power panel The switch is set to the volt age used at the jobsite HODHA LEGEND 1 T2 24 vac Power Transformer for Hot Gas Bypass Relay Oil Pump Relay Oil Heater Relay Motor Cooling Solenoid Oil Reclaim Solenoid 2 Oil Pressure Switch 3 T4 24 vac Optional 8 Input Module Transformer T1 24 vac Control Center Transformer 3C Hot Gas Bypass Relay Location Oil Pump Terminal Block Factory Terminal Connections T3 24 vac Guide Vane Actuator Transformer ONO Fig 12 Power Panel with Options 13 LID Operation and Menus Fig 13 19 GENERAL The LID display will automatically
161. ing hose con nected between pumpout valves on top of cooler and condenser is to be used as the equalization valve To equalize the pressure differential on a refrigerant isolated 19XL chiller use the TERMINATE LOCKOUT function of the Control Test in the SERVICE menu This will help to turn on pumps and advise the proper procedure The following procedure describes how to equalize refrig erant pressure on an isolated 19XL chiller without a pump out unit 1 Access TERMINATE LOCKOUT function on the Con trol Test 2 Turn on the chilled water and condenser water pumps to ensure against freezing 3 Slowly open the refrigerant cooling isolation valve The chiller cooler and condenser pressures will grad ually equalize This process will take approximately 15 minutes 4 Once the pressures have equalized the cooler isolation valve the condenser isolation valve and the hot gas by pass isolation valve may now be opened Refer to Fig 27 and 28 valves 11 12 and 14 A WARNING Whenever turning the discharge isolation valve be sure to reattach the valve locking device This will prevent the valve from opening or closing during serv ice work or during chiller operation Table 7 Control Test Menu Functions TESTS TO BE PERFORMED 1 Automated Tests DEVICES TESTED Operates the second through seventh tests 2 PSIO Thermistors Entering chilled water Leaving chilled water Entering condenser water
162. iped in Check for field supplied shutoff valves and controls as specified in the job data Check for refrig erant leaks on field installed piping See Fig 27 and 28 Check Relief Devices Be sure that relief devices have been piped to the outdoors in compliance with the lat est edition of ANSI ASHRAE Standard 15 and applicable local safety codes Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing 19XL relief valves are set to relieve at the 300 psig 2068 kPa chiller design pressure Inspect Wiring WARNING Do not check voltage supply without proper equipment and precautions Serious injury may result Follow power company recommendations CAUTION Do not apply any kind of test voltage even for a rota tion check if the chiller is under a dehydration vacuum Insulation breakdown and serious damage may result Examine wiring for conformance to job wiring dia grams and to all applicable electrical codes 2 On low voltage compressors 600 v or less connect voltmeter across the power wires to the compressor starter and measure the voltage Compare this reading with the voltage rating on the compressor and starter nameplates 3 Compare the ampere rating on the starter nameplate with the compressor nameplate The overload trip amps must be 108 to 120 of the rated load amps 4 The starter for a centrifugal compressor motor must con tain the components
163. itch is open when the compressor tried to START Check the switch for proper operation Also check the oil pump interlock 2C aux in the power panel and the high condenser pressure switch Current Refrigerant Properties Abnormal Check Selection of refrigerant type Low Oil Pressure LIMIT Check oil pressure switch pump and 2C aux LIMIT is shown on the LID as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped DPEN indicates that an input circuit is open NOTE See Legend on page 68 70 Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont G COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE UNIT SHOULD BE PRIMARY MESSAGE UNAUTHORIZED OPERATION STOPPED POTENTIAL FREEZE UP TOO LOW FAILURE TO STOP EVAP PRESS TEMP DISCONNECT POWER NECT POWER Emergency Compressor running without control authorization ERT Emergency Freeze up prevention RUN AUX Emergency DISCON ADDITIONAL CAUSE REMEDY Compressor is running with more than 1096 RLA and control is trying to shut it down Throw power off to compressor if unable to stop Determine cause before repowering Determine cause If pumping refrigerant ou
164. ive Truck Holddown Lugs e0 16 19 18 28 Refrigerant Cooling Isolation Valve Hidden 19XL FRONT VIEW 29 30 31 3233 34 35 36 37 38 39 LEGEND 29 Pumpdown System Connection 30 Cooler Relief Valves 31 Chiller Identification Nameplate 32 Cooler Pressure Transducer 33 Suction Elbow 34 Transmission Vent Line 35 Discharge Pressure Switch and Discharge Pressure Transducer 36 Condenser Isolation Valve 37 Low Voltage Access Door Starter 057555 38 Medium Voltage Access Door Starter o 39 Amp Volt Gages 40 Refrigerant Supply Sump CELER 41 Condenser Pressure Transducer 42 Liquid Seal Float Chamber 43 ASME Nameplate Float Chamber 44 Condenser Relief Valves 45 Condenser In Out Temperature Sensors 46 Cooler In Out Temperature Sensors 46 45 44 43 42 41 40 19XL REAR VIEW Fig 2A Typical 19XL Components Design 10 11 0 12 13 b 04 Lou 0 eee 21 20 19 18 17 16 15 14 19XL FRONT VIEW 28 29 30 7 T 31 ANS g 55 oo x lt 32 37 36 35 34 33 15 19XL REAR VIEW dali mi 2 adi AO 15 LEGEND Unit Mounted Starter Refrigerant Filter Drier Rigging Guide Bolt Motor Sight Glass Refrigerant Moisture Indicator Refr
165. l a Valve positions VALVE 1a 1b 2 3 4 s 8 1 12 13 14 jej eje b Turn off chiller water pumps and pumpout condenser water c Turn on pumpout compressor to push refrigerant out of the condenser d When all liquid is out of the condenser close cooler isolation valve 11 e Turn off the pumpout compressor 2 Evacuate gas from the chiller condenser vessel a Access the Control Test Pumpdown table on the LID display to turn on the chiller water pumps b Close pumpout valves 3 and 4 open valves 2 and 5 VALVE 4 5 8 1 12 13 14 15151 15161615615 Turn on pumpout condenser water d Run the pumpout compressor until the chiller com pressor reaches 18 in Hg vac 40 kPa abs Monitor pressure at the LID and refrigerant gages e Close valve 1b f Turn off pumpout compressor g Close valves 1a 2 and 5 VALVE __ 2 4 5 8 1 12 13 h Turn off pumpout condenser water 1 Proceed to the Pumpdown test on the LID to turn off chiller water pumps and lockout chiller compressor RETURN REFRIGERANT TO NORMAL OPERATING CONDITIONS 1 Be sure that the chiller vessel that was opened has been evacuated 2 Access the Control Test Terminate Lockout table to view vessel pressures and turn on chiller water pumps 3 Open valves 1a 1b and 3 VALVE 2 5 8 11 12 13 14 C
166. l is configured for the DEMAND LIMIT SOURCE which is accessed on the SERVICEI table The default set ting is current limiting CHILLER TIMERS The PIC maintains 2 runtime clocks known as COMPRESSOR ONTIME and SERVICE ON TIME COMPRESSOR ONTIME indicates the total life time compressor run hours This timer can register up to 500 000 hours before the clock turns back to zero The SERVICE ONTIME is a resettable timer that can be used to indicate the hours since the last service visit or any other reason The time can be changed through the LID to whatever value is desired This timer can register up to 32 767 hours before it rolls over to zero The chiller also maintains a start to start timer and a stop to start timer These timers limit how soon the chiller can be started See the Start Up Shutdown Recycle Sequence sec tion page 39 for operational information OCCUPANCY SCHEDULE This schedule determines when the chiller is either occupied or unoccupied Each schedule consists of from one to 8 occupied unoccupied time periods set by the operator These time periods can be enabled to be in effect or not in effect on each day of the week and for holidays The day begins with 0000 hours and ends with 2400 hours The chiller is in OCCUPIED mode unless an unoccupied time period is in effect The chiller will shut down when the schedule goes to UN OCCUPIED These schedules can be set up to follow the building schedule or to be 1
167. larm ALM Chiller Start Stop Stop Start CHIL_S__S Base Demand Limit 40 100 DLM Active Demand Limit 40 100 DEM__LIM Compressor Motor Load 0 999 CA_L Current 0 999 CA Amps 0 999 Target Guide Vane Pos 0 100 GV TRG Actual Guide Vane Pos 0 100 GV Water Brine Setpoint 10 120 12 2 48 9 P Control Point 10 120 12 2 48 9 LCW__STPT Entering Chilled Water 40 245 40 118 ECW Leaving Chilled Water 40 245 40 118 LCW Entering Condenser Water 40 245 40 118 ECDW Leaving Condenser Water 40 245 40 118 LCDW Evaporator Refrig Temp 40 245 40 118 DEG F DEG C ERT Evaporator Pressure 6 7 420 46 2896 PSI kPa ERP Condenser Refrig Temp 40 245 40 118 CRT Condenser Pressure 6 7 420 46 2896 CRP Discharge Temperature 40 245 40 118 DEG F DEG C CMPD Bearing Temperature 40 245 40 118 DEG F DEG MTRB Motor Winding Temp 40 245 40 118 DEG F DEG MTRW Oil Sump Temperature 40 245 40 118 DEG F DEG C OILT Oil Pressure Transducer 6 7 420 46 2896 PSI kPa OILP Pressure 6 7 420 46 2896 kPad OILPD Line Voltage Percent 0 999 V Actual 0 9999 VOLTS Remote Contacts Input Off On REMCON Total Compressor Starts 0 65535 C starts Starts in 12 Hours 0 8 STARTS Compressor Ontime 0 500000 0 C hrs Service Ontime 0 32767 S HRS Compressor Motor kW 0 9999 CKW NOTE All values are variables available for read operation to a CCN Descripti
168. ld 40 Auto Restart After Power Failure 33 Before Initial Start Up 41 Calibrate Motor Current 56 Capacity Override 31 Carrier Comfort Network Interface 48 Changing Oil Filter 63 Charge Refrigerant Into Chiller 53 Chilled Water Recycle Mode 40 Chiller Dehydration 47 Chiller Familiarization 5 Chiller Information Plate 5 Chiller Operating Condition Check 56 Chiller Tightness Check 41 Chillers with Isolation Valves 60 Chillers with Pumpout Storage Tanks 59 Cold Weather Operation 57 Compressor Bearing and Gear Maintenance 64 Condenser 5 Condenser Freeze Prevention 32 Condenser Pump Control 32 Control Algorithms Checkout Procedure 67 Control Center 5 63 Control Modules 78 Control Test 67 Controls 11 Cooler 5 Default Screen Freeze 29 Definitions Controls 11 Demand Limit Control Option 33 Design Set Points Input 50 Details Lubrication Cycle 8 Display Messages Check 66 Dry Run to Test Start Up Sequence 55 Equipment Required 41 Extended Shutdown 57 Factory Mounted Starter 5 General Controls 11 General Maintenance 61 Guide Vane Linkage Check 62 Heat Exchanger Tubes Inspect 64 High Altitude Locations 53 High Discharge Temperature Control 32 Ice Build Control 36 Initial Start Up 55 Instruct the Customer Operator 56 Introduction 4 Job Data Required 41 Lead Lag Control 34 Leak Rate 61 Leak Test Chiller 41 LID Operation and Menus 14
169. ler 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 and functioning before operating any chiller 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 or nitrogen and the work area should be well ventilated Refrigerant in contact with an open flame produces toxic gases DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly DO NOT work on high voltage equipment unless you are a quali fied electrician DO NOT WORK ON electrical components including control pan els switches starters or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servicing IF WORK IS INTERRUPTED confirm that all circuits are deenergized be fore resuming work AVOID SPILLING liquid refrigerant on skin or getting it into the eyes USE SAFETY GOGGLES Wash any spills from the skin with soap and wa
170. less than 50 000 ohms remove connecting bus heatsink between SCR3 and SCR6 and check anode to cathode of SCR3 and SCR6 separately to determine which device is defective See Fig 44 Replace defective device and retest controller 3 Repeat Steps 1 and 2 across terminals L2 and T2 for SCRs 2 and 5 4 Repeat Steps 1 and 2 across terminals L3 and T3 for SCRs 1 and 4 If the SCRs tested were not defective but the problem still persists refer to the following Steps 5 and 6 5 Disconnect the SCR1 from the white gate and red cath ode wires on the AK control logic card With an ohm meter set on Rx1 check between white and red wires 81 AK BOARD SCR2 GATE G6 CATHODE RESET BUTTON CONNECTING BUS 1L BOARD ONE OF BC BOARD THREE HEATSINK 24 ANODE A CONNECTION AT END OF SCR4 SCR BLOCK CONNECTING BUS SCR1 LEGEND SCR Silicon Control Rectifier Fig 44 Typical Benshaw Inc Solid State Starter internal View Resistance should normally be between 8 and 20 ohms average Excessively high or low resistance may be indicative of a defective logic card Replace and retest 6 Repeat Step 5 for SCR leads 2 through 6 Care should be taken to ensure that the gate and cathode wires are replaced exactly as they were white wire to gate G1 through G6 red wire to cathode K1 through K6 CAUTION Damage to the starter may result if wires are reversed If the problem
171. lied with the starter The oil is usually shipped in a small container attached to the starter frame near the re lays Use only dashpot oil supplied with the starter Do 8 not substitute Factory filled dashpot overload relays need oil at start up 4 9 and solid state overload relays do not have oil 4 4 Reapply starter control power not main chiller power to check electrical functions When using a reduced voltage starter such as a wye delta type check the transition timer for proper setting The factory setting is 30 seconds 5 seconds timed closing The timer is adjustable in a 1 range between 0 and 60 seconds and settings other than the nominal 30 seconds may be chosen as needed typi cally 20 to 30 seconds are used When the timer has been set check that the starter with relay 1CR closed goes through a complete and proper start cycle LEGEND 1 Phase Voltage Indicator BENSHAW INC SOLID STATE STARTER 2 Sana Fault and Run LEDs 5 Overtemp Ground Fault A WARNING Current Unbalance CUB This equipment is at line voltage when AC power is HAUS IY ee NR connected Pressing the STOP button does not remove Run Start Initiated voltage Use caution when adjusting the potentiometers 1 Starting dote Ramp Up Potentiometer on the equipment 5 Phase Correct LED 6 Relay On LED 1 Check that all wiring connections are properly termi in RUN State LEDs Hid
172. ll capacity for a short time after the pulldown ramping has ended even though the building load is small The active electrical demand setting can be overridden to limit the compressor or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation Pulldown rate can be based on load rate or temperature rate It is accessed on the Equipment Con figuration Config table Table 2 Example 5 To Stop the Chiller 1 The occupancy schedule will start and stop the chiller automatically once the time schedule is set up 2 By pressing the STOP button for one second the alarm light will blink once to confirm that the button has been pressed then the compressor will follow the normal shut down sequence as described in the Controls section The chiller will not restart until the or LOCAL soft key is pressed The chiller is now in the OFF mode If the chiller fails to stop in addition to action that the PIC will initiate the operator should close the guide vanes by overriding the guide vane target to zero to re duce chiller load then by opening the main disconnect Do not attempt to stop the chiller by opening an isolating knife switch High intensity arcing may occur Do not re start the chiller until the problem is diagnosed and corrected After Limited Shutdown No special preparations should be necessary Follow the regular preliminary checks and starting procedures E
173. logged on press NEXT un til Equipment Configuration is highlighted SERVICE NEXT PREVIOUS SELECT EXIT Ea WEN E 3 Once Equipment Configuration is highlighted press SELECT to access PREVIOUS EXIT NEN E 4 Press NEXT until Holidef is highlighted This is the Holiday Definition table SELECT NEXT PREVIOUS SELECT EXIT 5 Press to enter the Data Table Select screen This screen lists 18 holiday tables PREVIOUS EXIT L SELECT 10 11 12 Press NEXT to highlight the holiday table that you wish to view or change Each table is one holiday pe riod starting on a specific date and lasting up to 99 days NEXT PREVIOUS SELECT EXIT O O Press SELECT to access the holiday table The Con figuration Select table now shows the holiday start month and day and how many days the holiday period will last NEXT PREVIOUS EXIT O LJ Press NEXT PREVIOUS to highlight the month day or duration SELECT NEXT PREVIOUS SELECT EXIT LJ LJ Press SELECT to modify the month day duration NEXT PREVIOUS SELECT EXIT O Press INCREASE DECREASE to change the se lected value INCREASE DECREASE QUIT ENTER Press to save the changes INCREASE DECREASE QUIT EJ Press EXIT to return to the previous menu NEXT PREVIOUS SELECT
174. lves on the chiller may be used to iso late the chiller charge in either the cooler or condenser An optional pumpout compressor system is used to transfer refrigerant from vessel to vessel REFRIGERATION CYCLE The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening As the compressor suction reduces the pressure in the cooler the remaining refrigerant boils at a fairly low temperature typically 38 to 42 F 3 to 6 C The energy required for boiling is obtained from the water flowing through the cooler tubes With heat energy removed the water becomes cold enough for use in an air conditioning circuit or process liq uid cooling After taking heat from the water the refrigerant vapor is compressed Compression adds still more heat energy and the refrigerant is quite warm typically 98 to 102 F 37 to 40 C when it is discharged from the compressor into the condenser Relatively cool typically 65 to 90 F 18 to 32 C water flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid The liquid refrigerant passes through orifices into the FLASC Flash Subcooler chamber Fig 3 Since the FLASC chamber is at a lower pressure part of the liquid refrigerant flashes to vapor thereby cooling the remaining liquid The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water The liquid drains into a float
175. ly open the valve against refrigerant pressure 5 Change the oil filter at this time See Changing Oil Filter section 6 Change the refrigerant filter at this time see the next sec tion Refrigerant Filter 7 Charge the chiller with oil Charge until the oil level is equal to the oil level marked in Step 2 Turn on the power to the oil heater and let the PIC warm it up to at least 140 F 60 C Operate the oil pump manually through the Control Test for 2 minutes The oil level should be full in the lower sight glass for shutdown conditions If the oil level is above full in the upper sight glass remove the excess oil The oil level should now be equal to the amount shown in Step 2 Refrigerant Filter refrigerant filter drier located on the refrigerant cooling line to the motor Fig 2A or 2B should be changed once a year or more often if filter condition indicates a need for more frequent replacement Change the filter with the chiller pressure at 0 psig 0 kPa by transferring the refrigerant to the condenser vessel if iso lation valves are present or a storage tank A moisture indicator sight glass is located beyond this filter to indicate the volume and moisture in the refrigerant If the moisture indicator dry eye indicates moisture locate the source of water immediately by performing a thorough leak check Oil Reclaim Filters The oil reclaim system has a strainer on the eductor suction lin
176. matic target The screen wil now read a value of zero and the word will flash 4 Press SELECT softkey and then press RELEASE softkey to release the vanes to AUTO MATIC mode After few seconds the SUPVSR will disappear Dry Run to Test Start Up Sequence 1 Disengage the main motor disconnect on the starter front panel This should only disconnect the motor power Power to the controls oil pump and starter control circuit should still be energized 2 Look at the default screen on the LID the Status mes sage in the upper left hand corner will read Manually Stopped Press CCN or Local to start If the chiller 55 controls do not go into start mode go to the Schedule screen and override the schedule or change the oc cupied time Press LOCAL softkey to begin the start up sequences 3 Check that chilled water and condenser water pumps energize 4 Check that the oil pump starts and pressurizes the lubri cation system After the oil pump has run about 11 sec onds the starter will be energized and go through its start up sequence 5 Check the main contactor for proper operation 6 The PIC will eventually show an alarm for motor amps not sensed Reset this alarm and continue with the initial start up Check Rotation 1 Engage the main motor disconnect on the front of the starter panel The motor is now ready for rotation check 2 After the default s
177. mechanism Replace the device DO NOT install relief devices in series or backwards USE CARE when working near or in line with a compressed spring Sudden release of the spring can cause it and objects in its path to act as projectiles CAUTION DO NOT STEP on refrigerant lines Broken lines can whip about and release refrigerant causing personal injury DO NOT climb over a chiller Use platform catwalk or staging Follow safe practices when using ladders USE MECHANICAL EQUIPMENT crane hoist etc to lift or move inspection covers or other heavy components Even if com ponents are light use mechanical equipment when there is a risk of slipping or losing your balance BE AWARE that certain automatic start arrangements CAN EN GAGE THE STARTER TOWER FAN OR PUMPS Open the disconnect ahead of the starter tower fans or pumps USE only repair or replacement parts that meet the code require ments of the original equipment DO NOT VENT OR DRAIN waterboxes containing industrial brines liquid gases or semisolids without the permission of your process control group DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained DOUBLE CHECK that coupling nut wrenches dial indicators or other items have been removed before rotating any shafts DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement PERIODICALLY INSPECT all valves fittings and piping
178. modules control or board failure may result Be aware of electrostatic discharge static electricity when handling or making contact with circuit boards or mod ule connections Always touch a chassis grounded part to dissipate body electrostatic charge before working inside control center Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs Cir cuit boards can easily be damaged Always hold boards by the edges and avoid touching components and connections This equipment uses and can radiate radio frequency energy If not installed and used in accordance with the instruction manual it may cause interference to radio communications It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Federal Com munication Commission Rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Operation of this equipment in a residential area is likely to cause interference in which case the user at his own expense will be required to take whatever measures may be re quired to correct the interference Always store and transport replacement or defective boards in anti static shipping bag Page Control Modules 78 RED LED GREEN LEDs Notes on Module Operation 78 Processor Module PSIO
179. motor temperature is below 100 F 37 8 C Note that there is always a minimum flow of refrigerant when the compressor is operating for motor cool ing the relay only controls additional refrigerant to the motor Table 3 Protective Safety Limits and Control Settings MONITORED PARAMETER TEMPERATURE SENSORS OUT OF RANGE PRESSURE TRANSDUCERS OUT OF RANGE LIMIT 40 to 245 F 40 to 118 3 C 0 08 to 0 98 Voltage Ratio APPLICABLE COMMENTS Must be outside range for 2 seconds Must be outside range for 2 seconds Ratio Input Voltage Voltage Reference COMPRESSOR DISCHARGE TEMPERATURE 220 104 4 C Preset alert setting configurable MOTOR WINDING TEMPERATURE BEARING TEMPERATURE 2220 104 4 C 7185 F 85 C 33 F for water chilling 0 6 C EVAPORATOR REFRIGERANT TEMPERATURE lt Brine Refrigerant Trippoint set point adjustable from 0 to 40 F 718 to 4 C for brine chilling TRANSDUCER VOLTAGE CONDENSER PRESSURE SWITCH CONTROL OIL PRESSURE SWITCH 4 5 vdc gt 5 5 vdc 2263 7 psig 1813 48 kPa reset at 180 10 1241 69 kPa 7 260 psig 1793 kPa for HCFC 22 215 psig 1482 kPa for HFC 134a Cutout 11 psid 76 kPad 1 5 psid 10 3 kPad Cut in 716 5 psid 114 kPad 4 psid 27 5 kPad CONTROL Alert 18 psid 124 kPad LINE VOLTAGE HIGH LOW SINGLE CYCLE 711096 for 30 seconds lt 10 with compressor running gt 10
180. mp can also be energized for testing purposes in the Control Test Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start up If the guide vanes open quickly the sudden drop in suction pressure can cause any refrigerant in the oil to flash The resulting oil foam cannot be pumped efficiently therefore oil pressure falls off and lubrication is poor If oil pressure falls below 15 psid 103 kPad differential the PIC will shut down the compressor Oil Reclaim System The oil reclaim system oper ates to return oil back to the oil reservoir by recovering it from 2 areas on the chiller The primary area of recovery is from the guide vane housing Oil also is recovered along with refrigerant from the cooler Any refrigerant that enters the oil reservoir transmission area is flashed into gas The demister line at the top of the casing will vent this refrigerant into the suction of the com pressor Oil entrained in the refrigerant is eliminated by the demister filter DURING NORMAL CHILLER OPERATION oil is entrained with the refrigerant As the compressor pulls the refrigerant into the guide vane housing to be com pressed the oil will normally drop out at this point and fall to the bottom of the housing where it accumulates Us ing discharge gas pressure to power an eductor the oil is vacuumed from the housing by the eductor and is dis charged into the oil reservoir Oil and refrigerant are also rec
181. mps using the Control Test Pumpdown b Turn on pumpout condenser water c Place valves in the following positions VALVE 2 5 6 7 8 10 11 CONDITION d Run the pumpout compressor until the chiller pres sure reaches 65 psig 448 kPa 30 psig 207 kPa 60 then shut off the pumpout compressor Warm con denser water will boil off any entrapped liquid refrig erant and chiller pressure will rise e When the pressure rises to 70 psig 483 kPa 40 psig 276 kPa turn on the pumpout compressor until the pressure again reaches 65 psig 448 kPa 30 psig 207 kPa and then turn off the compressor Repeat this process until the pressure no longer rises then turn on the pumpout compressor and pump out until the pressure reaches 18 in Hg 40 kPa absolute f Close valves 1b 3 4 6 and 7 yaive ta 1b 2 3 4 5 6 7 8 10 11 12 13 14 cowomon c c c o o o e e o o g Turn off the pumpout condenser water and continue with the Control Test for Pumpdown which will lock out the chiller compressor for operation 4 Establish vacuum for service a In order to conserve refrigerant operate the pump out compressor until the chiller pressure is reduced to 18 in Hg vac ref 30 in bar 40 kPa abs following Step 3e Chillers with Isolation Valves TRANSFER ALL REFRIGERANT TO CHILLER CON DENSER VESSEL For chillers with isolation valves re frigerant can be transferred from
182. n heavy con centrations may displace enough oxygen to cause asphyxiation When handling this refrigerant protect the hands and eyes and avoid breathing fumes Adding Refrigerant Follow the procedures de scribed in Trimming Refrigerant Charge section page 54 WARNING Always use the compressor Pumpdown function in the Control Test table to turn on the evaporator pump and lock out the compressor when transferring refrigerant Liquid refrigerant may flash into a gas and cause pos sible freeze up when the chiller pressure is below 65 psig 448 kPa 30 psig 207 kPa Removing Refrigerant If the optional pumpout unit is used the 19XL refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels Follow procedures in the Pumpout and Refrigerant Transfer Procedures section when removing refrigerant from the pumpout storage tank to the chiller vessel Adjusting the Refrigerant Charge If the addi tion or removal of refrigerant is required for improved chiller performance follow the procedures given under the Trim Refrigerant Charge section page 62 Refrigerant Leak Testing Because HCFC 22 and HFC 134a are above atmospheric pressure at room tempera ture leak testing can be performed with refrigerant in the chiller Use an electronic halide leak detector soap bubble solution or ultra sonic leak detector Be sure that the room is well ventilated and free fr
183. n procedures safety and operating controls refrigerant and oil charging and job safety REVIEW THE START UP OPERATION AND MAINTE NANCE MANUAL OPERATING INSTRUCTIONS Operator Duties 1 Become familiar with refrigeration chiller and related equip ment before operating the chiller 2 Prepare the system for start up start and stop the chiller and place the system in a shutdown condition 3 Maintain a log of operating conditions and document any abnormal readings 4 Inspect the equipment make routine adjustments and per form a Control Test Maintain the proper oil and refrig erant levels 5 Protect the system from damage during shutdown periods 6 Maintain the set point time schedules and other PIC functions Prepare the Chiller for Start Up Follow the steps described in the Initial Start Up section page 55 To Start the Chiller 1 Start the water pumps if they are not automatic 2 On the LID default screen press the softkey to start the system If the chiller is in the OCCUPIED mode and the start timers have expired the start sequence will start Follow the procedure de scribed in the Start Up Shutdown Recycle section page 39 Check the Running System After the compres sor starts the operator should monitor the LID display and observe the parameters for normal operating conditions 1 The oil reservoir temperature should be above 140 60 C during shutdown and above 100 F 38
184. nal Contactor Terminal Overload Terminal Pumpout Unit Terminal Bimetal thermal protector imbedded in motor winding Fig 34 19XL Pumpout Unit Wiring Schematic OILRETURN DISCHARGE VENTVALVE8 LIN SERVICE CONNECTION VALVE SUETON COMPRESSOR SERVICE VALVE VALVE 2 VALVE 3 gt VANES T PUMPOUT C KS STARTER VALVE 4 A lt PANEL 77 0 OIL SIGHT HOE 4 MTG SPRINGS GLASS CONDENSER ND REFRIGERANT CONDENSER WATER INLET VALVE CONNECTIONS Fig 35 Optional Pumpout Unit VALVE __ 19 2 3 4 5 6 7 8 10 t1 12 13 14 coNpmoN fej ele eleje d Gradually crack open valve 5 to increase chiller pres sure to 68 psig 469 kPa 35 psig 141 kPa Slowly feed refrigerant to prevent freeze up e Open valve 5 fully after the pressure rises above the freeze point of the refrigerant Open liquid line valves 7 and 10 until refrigerant pressure equalizes VALVE a 1b 2 3 4 56 78 10 11 12 13 14 2 Transfer remaining refrigerant a Close valve 5 and open valve 4 VALVE __ 1b 2 3 4 5 6 7 8 10 11 12 13 14 CONDITION d b Turn off the chiller water pumps through the LID Turn off the pumpout condenser water and turn on the pumpout compressor to push liquid out of the storage tank Close liquid line valve 7 Turn off the pumpout compressor Close valves 3 and
185. nd the disconnect for the compressor is open 2 Disconnect the power to the oil pump 3 Close the oil filter isolation valves Fig 4 4 Connect an oil charging hose from the oil charging valve Fig 4 and place the other end in a clean container suitable for used oil The oil drained from the filter hous ing should be used as an oil sample to be sent to a labo ratory for proper analysis Do not contaminate this sample 5 Slowly open the charging valve to drain the oil from the housing CAUTION The oil filter housing is at a high pressure Relieve this pressure slowly 6 Once all oil has been drained place some rags or ab sorbent material under the oil filter housing to catch any drips once the filter is opened Remove the 4 bolts from the end of the filter housing and remove the filter cover 7 Remove the filter retainer by unscrewing the retainer nut The filter may now be removed and disposed of properly 8 Replace the old filter with a new filter Install the filter retainer and tighten down the retainer nut Install the fil ter cover and tighten the 4 bolts 9 Evacuate the filter housing by placing a vacuum pump on the charging valve Follow the normal evacuation pro cedures Shut the charging valve when done and recon nect the valve so that new oil can be pumped into the filrer housing Fill with the same amount that was removed then close the charging valve 63 10 Remove the hose from the
186. ng Inspect 47 Water Treatment 65 Weekly Maintenance 62 Wiring Inspect 47 Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 PC 211 Catalog No 531 971 Printed in U S A Form 19XL 4SS Pg 100 7 96 Replaces 19XL 3SS Tab 5
187. o full motor voltage 0 5 seconds to energized and the auxiliary LCD is energized 60 seconds 7 Proceed to apply power to the starter Fig 31 Ramp Up and Starting Torque 8 The Power 15 and Phase Correct LEDs should be on If Potentiometers not see the starter Troubleshooting Guide section 49 Oil Charge The 19XL compressor holds approxi mately 8 gal 30 L of oil The chiller will be shipped with oil in the compressor When the sump is full the oil level should be no higher than the middle of the upper sight glass and minimum level is the bottom of the lower sight glass Fig 2A or 2B If oil is added it must meet Carrier s speci fication for centrifugal compressor usage as described in the Oil Specification section on page 63 Charge the oil through the oil charging valve located near the bottom of the trans mission housing Fig 2A or Fig 2B The oil must be pumped from the oil container through the charging valve due to higher refrigerant pressure The pumping device must be able to lift from 0 to 200 psig 0 to 1380 kPa or above unit pressure Oil should only be charged or removed when the chiller is shut down Power Up the Controls and Check the Oil Heater Ensure that an oil level is visible in the compressor before energizing controls A circuit breaker in the starter energizes the oil heater and the control circuit When first powered the LID should display the default screen within a short period of
188. odule Replacing Defective Processor Modules The replacement part number is printed in a small label on front of the PSIO module The model and serial numbers are printed on the unit nameplate located on an exterior corner post The proper software is factory installed by Carrier in the replacement module When ordering a replacement proces sor module PSIO specify complete replacement part number full unit model number and serial number This new unit requires reconfiguration to the original chiller data by the installer Follow the procedures described in the Set Up Chiller Control Configuration section on page 50 CAUTION Electrical shock can cause personal injury Disconnect all electrical power before servicing 80 INSTALLATION 1 11 Verify that the existing PSIO module is defective by us ing the procedure described in the Troubleshooting Guide section page 66 and Control Modules section page 78 Do not select the Attach to Network Device table if the LID displays communication failure Data regarding the PSIO configuration should have been recorded and saved This data will have to be recon figured into the LID If this data is not available follow the procedures described in the Set Up Chiller Control Configuration section If a CCN Building Supervisor or Service Tool is present the module configuration should have already been uploaded into memory then when the new module is installed the
189. of refrigeration gages to the cooler and condenser Schrader fittings Compare the two readings If there is a difference in readings the transducer can be calibrated as described in the Troubleshooting Guide section Optional Pumpout System Maintenance For compressor maintenance details refer to the 06D 07D Installation Start Up and Service Instructions OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE The pumpout compressor uses oil with the same specifi cations as the centrifugal compressor oil For more details on oil selection see Oil Specification section page 63 The total oil charge 4 5 pints 2 6 L consists of 3 5 pints 2 0 L for the compressor and one additional pint 0 6 L for the oil separator 65 Oil should be visible in one of the compressor sight glasses both during operation and at shutdown Always check the oil level before operating the compressor Before adding or changing oil relieve the refrigerant pressure as follows 1 Attach a pressure gage to the gage port of either com pressor service valve Fig 35 2 Close the suction service valve and open the discharge line to the storage tank or the chiller 3 Operate the compressor until the crankcase pressure drops to 2 psig 13 kPa 4 Stop the compressor and isolate the system by closing the discharge service valve 5 Slowly remove the oil return line connection Fig 35 Add oil as required 6 Replace the connection and reopen the
190. off control of the compressor motor as its primary function Using this type of starter reduces the peak starting torque reduces the motor inrush current and decreases mechanical shock This is summed up by the phrase starting Two varieties of solid state starters are available as a 19XL option factory supplied and installed When a unit mounted optional solid state starter is purchased with the 19XL a Benshaw Inc solid state starter will be shipped with the unit See Fig 5 The solid state starter s manufacturer name will be located inside the starter access door See Fig 6 These starters operate by reducing the starting voltage The starting torque of a motor at full voltage is typically 125 to 175 of the running torque When the voltage and the current are reduced at start up the starting torque is reduced as well The object is to reduce the starting voltage to just the voltage necessary to develop the torque required to get the motor moving The voltage and current are then ramped up in a desired period of time The voltage is reduced through the use of silicon controlled rectifiers SCR Once full volt age is reached a bypass contactor is energized to bypass the SCRs WARNING When voltage is supplied to the solid state circuitry the heat sinks within the starter are at line voltage Do not touch the heat sinks while voltage is present or serious injury will result 10
191. ol Test feature can check all of the thermistor temperature sensors including those on the Options modules pressure transducers pumps and their associated flow switches the guide vane actuator and other control outputs such as hot gas bypass The tests can help to determine whether a switch is defective or a pump relay is not operating among other useful troubleshooting tests During pumpdown operations the pumps are energized to prevent freeze up and the vessel pressures and temperatures are displayed The lockout feature will prevent start up of the compressor when no refrigerant is present in the chiller or if the vessels are isolated The lockout is then terminated by the operator by using the Terminate Lockout function after the pumpdown procedure is reversed and refrigerant is added Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides A SHUTDOWN WITH ON OFF RESET OFF B PRIMARY MESSAGE MANUALLY STOPPED PRESS TERMINATE PUMPDOWN MODE SHUTDOWN IN PROGRESS SHUTDOWN IN PROGRESS ICE BUILD TIMING OUT OR TIMED OUT PRIMARY MESSAGE READY TO START IN XX MIN READY TO START IN XX MIN READY TO START IN XX MIN READY TO START IN XX MIN READY TO START READY TO START READY TO START READY TO START IN XX MIN READY TO START IN XX MIN READY TO START READY TO START STARTUP INHIBITED READY TO START IN XX MIN SECONDARY MESSAGE OR LOCAL TO ST
192. om concentration of refrigerant to keep false readings to a minimum Before making any necessary repairs to a leak transfer all refrigerant from the leaking vessel Leak Rate ASHRAE recommends that chillers should be immediately taken off line and repaired if the refrigerant leakage rate for the entire chiller is more than 10 of the operating refrigerant charge per year Additionally Carrier recommends that leaks totalling less than the above rate but more than a rate of 1 Ib 0 5 kg per year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work Test After Service Repair or Major Leak 1f all refrigerant has been lost or if the chiller has been opened for service the chiller or the affected vessels must be pres sured and leak tested Refer to the Leak Test Chiller section to perform a leak test WARNING HCFC 22 and HFC 134a should not be mixed with air or oxygen and pressurized for leak testing In gen eral neither refrigerant should not be allowed to be pre sent with high concentrations of air or oxygen above atmospheric pressures as the mixture can undergo combustion REFRIGERANT TRACER Use an environmentally acceptable refrigerant as a tracer for leak test procedures TO PRESSURIZE WITH DRY NITROGEN Another method of leak testing is to pressurize with nitrogen only and use a soap bubble solution or an ultrasonic leak detector to determine if
193. on module if desired Refer to the certified drawings for termination of sensor leads NOTE If the common point sensor option is chosen on a chilled water system both chillers should have their own 8 input option module and common point sensor installed Each chiller will use its own common point sensor for control when that chiller is designated as the lead chiller The PIC cannot read the value of common point sensors installed on other chill ers in the chilled water system When installing chillers in series a common point sensor should be used If a common point sensor is not used the leaving chilled water sensor of the upstream chiller must be moved into the leaving chilled water pipe of the downstream chiller If return chilled water control is required on chillers piped in series the common point return chilled water sensor should be installed If this sensor is not installed the return chilled water sensor of the downstream chiller must be relocated to the return chilled water pipe of the upstream chiller To properly control the common supply point temperature sensor when chillers are piped in parallel the water flow through the shutdown chillers must be isolated so that no water by pass around the operating chiller occurs The common point sensor option must not be used if water bypass around the operating chiller is occurring CHILLER COMMUNICATION WIRING Refer to the chiller s Installation Instructions or to the C
194. ond megohm readings as follows 6 Lead Motor Tie all 6 leads together and test be tween the lead group and ground Next tie leads in pairs 1 and 4 2 and 5 and 3 and 6 Test between each pair while grounding the third pair 3 Lead Motor Tie terminals 1 2 and 3 together and test between the group and ground c Divide the 60 second resistance reading by the 10 second reading The ratio or polarization index must be one or higher Both the 10 and 60 second readings must be at least 50 megohms If the readings on a field installed starter are unsat isfactory repeat the test at the motor with the power leads disconnected Satisfactory readings in this sec ond test indicate the fault is in the power leads NOTE Unit mounted starters do not have to be meg ohm tested 10 Tighten up all wiring connections to the plugs on the SMM 8 input and PSIO modules 11 Ensure that the voltage selector switch inside the power panel is switched to the incoming voltage rating 12 On chillers with free standing starters inspect the power panel to ensure that the contractor has fed the wires into the bottom of the panel Wiring into the top of the panel can cause debris to fall into the contactors Clean and inspect the contactors if this has occurred Carrier Comfort Network Interface The Carrier Comfort Network CCN communication bus wiring is sup plied and installed by the electrical contractor It consists of shielded
195. onitors the chilled water and condenser water flow switches and waits until the WATER FLOW VERIFY TIME operator configured default 5 minutes to confirm flow After flow is verified the chilled water brine temperature is compared to CONTROL POINT plus DEADBAND If the temperature is less than or equal to this value the PIC will turn off the condenser pump relay 0 MACHINE SAFETIES EVAPORATOR PUMP CONDENSER WATER PUMP WATER FLOW CHILLED WATER TEMP GUIDE VANES OIL PUMP TOWER FAN CONTROL OIL PRESSURE COMPRESSOR COMPRESSOR ONTIME SERVICE ONTIME START INITIATED Prestart checks made evaporator pump started Condenser water pump started 5 seconds after A Water flows verified 30 seconds to 5 minutes maximum after B Chilled water temperatures checked against con trol point Guide vanes checked for closure Oil pump started tower fan control enabled Oil pressure verified 30 seconds minimum 300 seconds maximum after C Compressor motor starts compressor ontime and serv ice ontime start 15 minute inhibit timer starts 10 seconds after D total compressor starts advances by one number of starts over a 12 hour period advances by one SHUTDOWN INITIATED Compressor motor stops com pressor ontime and service ontime stops 3 minute inhibit timer starts on PSIO Software Version 08 and lower and 1 minute inhibit timer starts for PSIO Software Version 09 and higher Oil pump and evaporator pum
196. ons shown with support write operations for BEST programming language data transfer and overriding 21 1 2 3 4 Press MENU Press STATUS Scroll down to highlight STATUSO2 Press SELECT DESCRIPTION Hot Gas Bypass Relay Chilled Water Pump Chilled Water Flow Condenser Water Pump Condenser Water Flow Compressor Start Relay Compressor Start Contact Compressor Run Contact Starter Fault Contact Pressure Trip Contact Single Cycle Dropout Oil Pump Relay Oil Heater Relay Motor Cooling Relay Tower Fan Relay Compr Shunt Trip Relay Alarm Relay Spare Prot Limit Input Table 2 LID Screens cont EXAMPLE 2 STATUSO2 DISPLAY SCREEN To access this display from the LID default screen POINT TYPE INPUT OUTPUT X X X X UNITS OFF ON OFF ON NO YES OFF ON NO YES OFF ON OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN CLOSED NORMAL ALARM OFF ON OFF ON OFF ON OFF ON OFF ON NORMAL ALARM ALARM NORMAL REFERENCE POINT NAME ALARM HISTORY NOTE All values are variables available for read operation to a CCN Descriptions shown with support write operations from the LID only 1 2 3 4 Press MENU Press STATUS Scroll down to highlight STATUSO3 Press SELECT DESCRIPTION OPTIONS BOARD 1 Demand Limit 4 20 mA Temp Reset 4 20 mA Common CHWS Sensor Common CHWR Sensor Remote Reset Sensor Temp Sensor Spare 1 Temp Sens
197. ontrol The JCE BUILD RECYCLE OPTION and ICE BUILD TERMINATION entries from a screen in the Config configuration table provide options for chiller recycle and termination of ice build cycle respec tively Termination of ice build can result from the ENTER ING CHILLED WATER BRINE temperature being less than the CE BUILD SET POINT opening of the REMOTE CON TACT inputs from an ice level indicator or reaching the end of the Ice Build Time Schedule ICE BUILD INITIATION The Ice Build Time Schedule provides the means for activating ice build The ice build time table is named OCCPCO2S If the Ice Build Time Schedule is OCCUPIED and the CE BUILD OPTION is ENABLED then ice build 1 active and the following events automatically take place unless over ridden by a higher authority CCN device 1 Force CHILLER START STOP to START 2 Force WATER BRINE CONTROL POINT to the ICE BUILD SET POINT 3 Remove any force Auto on theACTIVE DEMAND LIMIT NOTE Items 1 3 shown above shall not occur if the chiller is configured and operating as a lag or standby chiller for lead lag and is actively controlled by a lead chiller The lead chiller communicates the BUILD SET POINT desired CHILLER START STOP state and ACTIVE DEMAND LIMIT to the lag or standby chiller as required for ice build if con figured to do so START UP RECYCLE OPERATION If the chiller is not running when ice build activates then the PIC checks the follo
198. operator configured rate The TEMP Temperature PULLDOWN LOAD PULL DOWN and SELECT RAMP TYPE may be viewed modified on the LID Equipment Configuration table Config table see Table 2 Motor load is the default type Capacity Override Table 4 Capacity overrides can prevent some safety shutdowns caused by exceeding motor amperage limit refrigerant low temperature safety limit motor high temperature safety limit and condenser high pres sure limit In all cases there are 2 stages of compressor vane control 1 The vanes are held from opening further and the status line on the LID indicates the reason for the override 2 The vanes are closed until condition decreases below the first step set point and then the vanes are released to nor mal capacity control Whenever the motor current demand limit set point is reached it activates a capacity override again with a 2 step process Exceeding 110 of the rated load amps for more than 30 seconds will initiate a safety shutdown The compressor high lift surge prevention set point will cause a capacity override as well When the surge preven tion set point is reached the controller normally will only hold the guide vanes from opening If so equipped the hot gas bypass valve will open instead of holding the vanes Table 4 Capacity Overrides SECOND OVERRIDE OVERRIDE FIRST STAGE SET POINT SE AONT TERMINATION CAPACITY CONTROL View Modify Default Value
199. or Spare 2 Temp Sensor Spare 3 OPTIONS BOARD 2 4 20 mA Spare 1 4 20 mA Spare 2 Temp Sensor Spare 4 Temp Sensor Spare 5 Temp Sensor Spare 6 Temp Sensor Spare 7 Temp Sensor Spare 8 Temp Sensor Spare 9 EXAMPLE 3 STATUSO03 DISPLAY SCREEN To access this display from the LID default screen DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C REFERENCE POINT NAME ALARM HISTORY DEM 5 CHWS CHWR RESET SPARE1 SPARE2 SPARE3 SPARE1__M SPARE2__M SPARE4 SPARES SPARE6 SPARE7 SPARE8 SPARE9 NOTE All values shall be variables available for read operation to a CCN network Descriptions shown with support write operations for BEST programming language data transfer and overriding Base Demand Limit LCW Setpoint ECW Setpoint ICE BUILD Setpoint DESCRIPTION EXAMPLE 4 SETPOINT DISPLAY SCREEN To access this display from the LID default screen 1 Press MENU 2 Press SETPOINT CONFIGURABLE RANGE UNITS 22 REFERENCE POINT NAME DEFAULT VALUE Table 2 LID Screens cont To access this display from the LID default screen 1 Press MENU Oo Press SERVICE Scroll down to highlight EQUIPMENT CONFIGURATION Press SELECT Scroll down to highlight CONFIG Press SELECT DESCRIPTION RESET TYPE 1 Degrees Reset at 20 mA RESET TY
200. orrect value is reached Complete the PSIO installation Following the instruc tions in the Start up Operation and Maintenance manual input all the proper configurations such as time date etc Re calibrate the motor amps and check the pres sure transducer calibrations PSIO installation is now complete Solid State Starters Troubleshooting guides and in formation pertaining to the operation of the solid state starter may be found in Fig 44 46 and Table 11 Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting table When the power is off nspect for physical damage and signs of arcing overheat ing etc Is the wiring to the starter correct Are all connections in the starter tight Is the current feedback resistor properly adjusted and installed Is a heater coil installed in each leg of the motor Is the control transformer fuse blown Is the motor connected to the starter TESTING SILICON CONTROL RECTIFIERS IN BENSHAW INC SOLID STATE STARTERS If a sili con control rectifier SCR is suspected of being defective use the following procedure as part of a general trouble shooting guide IMPORTANT Before performing the SCR check be low remove power from the starter and disconnect the motor terminals T1 T2 and T3 1 Connect ohmmeter across terminals L1 and 1 Resis tance reading should be greater than 50 000 ohms 2 If reading is
201. ot advance the starts in 12 hours counter Any failure after the 1CR relay has energized re sults in a safety shutdown energizes the alarm light and dis plays the applicable shutdown status on the LID display Shutdown Sequence Shutdown of the chiller can occur if any of the following events happen the STOP button is pressed for at least one second the alarm light will blink once to confirm stop command recycle condition is present see Chilled Water Recycle Mode section time schedule has gone into UNOCCUPIED mode chiller protective limit has been reached and chiller is in alarm the start stop status is overridden to stop from the CCN network or the LID When a stop signal occurs the shutdown sequence first stops the compressor by deactivating the start relay status message of SHUTDOWN IN PROGRESS COMPRES SOR DEENERGIZED is displayed Compressor and service ontime stop The guide vanes are then brought to the closed position The oil pump relay and the chilled water brine pump relay are shut down 60 seconds after the com pressor stops The condenser water pump will be shut down when the CONDENSER REFRIGERANT TEMP is less than the CONDENSER PRESSURE OVERRIDE minus 5 psi 34 kPa or is less than or equal to the ENTERING CONDENSER WATER TEMP plus 3 F 2 C The stop to start timer will now begin to count down If the start to start timer is still greater than the value of the start to stop timer then
202. overed from the top of the cooler refrigerant level and are discharged into the guide vane housing The oil will drop to the bottom of the guide vane housing and be recovered by the eductor system DURING LIGHT LOAD CONDITIONS the suction gas into the compressor does not have enough velocity to return oil which is floating in the cooler back to the compressor In addition the eductor may not have enough power to pull the oil from the guide vane housing back into the oil reservoir due to extremely low pressure at the guide vanes Two so lenoids located on the oil reclaim piping are operated so that the eductor can pull oil and refrigerant directly from the cooler and discharge the mixture into the oil reservoir The oil reclaim solenoids are operated by an auxiliary contact integral to the guide vane actuator This switchover of the solenoids occurs when the guide vanes are opened beyond 30 degrees from the closed position STARTING EQUIPMENT The 19XL requires a motor starter to operate the centrif ugal hermetic compressor motor the oil pump and various auxiliary equipment The starter serves as the main field wiring interface for the contractor Three types of starters are available from Carrier Cor poration solid state wye delta and across the line starters See Carrier Specification Z 375 for specific starter require ments All starters must meet these specifications in order to properly start and satisfy mechanical safety req
203. ped for service work to either the cooler compressor vessel or the condenser vessel by using the optional pumpout system If a storage tank is supplied the refrigerant can be isolated in the external storage tank The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuations Operating the Optional Pumpout Compressor 1 Be sure that the suction and the discharge service valves on the optional pumpout compressor are open back seated during operation Rotate the valve stem fully coun terclockwise to open Frontseating the valve closes the refrigerant line and opens the gage port to compressor pressure 2 Make sure that the compressor holddown bolts have been loosened to allow free spring travel 3 Open the refrigerant inlet valve on the pumpout compressor 4 Oil should be visible in the pumpout compressor sight glass under all operating conditions and during shut down If oil is low add oil as described under Optional Pumpout System Maintenance section page 65 The pumpout unit control wiring schematic is detailed in Fig 34 TO READ REFRIGERANT PRESSURES during pumpout or leak testing 1 The LID display on the chiller control center is suitable for determining refrigerant side pressures and low soft vacuum For evacuation or dehydration measurement use a quality vacuum indicator or manometer to ensure the desired range and accuracy This can be placed on the Schrad
204. perator also can define alert limits on vari ous monitored inputs Safety contact and alert limits are defined in Table 3 Alarm and alert messages are listed in the Troubleshooting Guide section page 66 SHUNT TRIP The shunt trip function of the PIC is a safety trip The shunt trip is wired from an output on the SMM to a shunt trip equipped motor circuit breaker If the PIC tries to shut down the compressor through normal shutdown pro cedure but is unsuccessful for 30 seconds the shunt trip out put is energized and causes the circuit breaker to trip off If ground fault protection has been applied to the starter the ground fault trip will also energize the shunt trip to trip the circuit breaker Default Screen Freeze Whenever an alarm occurs the LID default screen will freeze displaying the condition of the chiller at the time of alarm Knowledge of the operating state of the chiller at the time an alarm occurs is useful when troubleshooting Current chiller information can be viewed on the Status tables Once all existing alarms are cleared by pressing the softkey the default LID will return to normal operation Motor Cooling Control Motor temperature is reduced by refrigerant entering the motor shell and evap orating The refrigerant is regulated by the motor cooling relay This relay will energize when the compressor is run ning and motor temperature is above 125 F 51 7 C The relay will close when
205. plete unit start will commence Chiller timers complete unit start will commence loadshed module commanding chiller to stop Chiller START STOP on Status01 has been manually forced to start Chiller will start regard less of time schedule or remote contact status Q1CR AUX Compressor Start Contact _ CCN CDFL CHIL S S CHW CHWS CHWR CMPD CRP CRT Compressor Current Carrier Comfort Network Condenser Water Flow Chiller Start Stop Chilled Water Chilled Water Supply Chiller Water Return Discharge Temperature Condenser Pressure Condenser Refrigerant Temperature LEGEND ECW Entering Chilled Water PSIO Processor Sensor ERT Evaporator Refrigerant Input Output Module Temperature RLA Rated Load Amps EVFL Chilled Water Flow RUN _ Compressor Run Contact GV Target Guide Vane Position SPR PL 1 Input LID Local Interface Device Module anagemen MTRB Bearing Temperature STR FLT Starter Fault MTRW Motor Winding Temperature TXV Thermostatic Expansion OILPD Oil Pressure Valve OILT Oil Sump Temperature Line Voltage Percent PIC Product Integrated Control V REF Voltage Reference 68 Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont C IN RECYCLE SHUTDOWN PRIMARY MESSAGE RECYCLE RESTART PENDING RECYCLE RESTART PENDING RECYCLE RESTART PENDING RECYCLE RESTART PENDING
206. potentiometer in a clockwise direction 2 Observe that all 6 gate LEDs are lit on the starter SCR control board 3 The factory setting should bring the motor to full voltage in 15 to 30 seconds If the setting is not correct adjust the ramp potentiometer counterclockwise for a shorter time clockwise for a longer time See Fig 5 for starter com ponent placement Check Oil Pressure and Compressor Stop 1 When the motor is up to full speed note the differential oil pressure reading on the LID default screen It should be between 18 and 30 psid 124 to 206 kPad 2 Press the Stop button and listen for any unusual sounds from the compressor as it coasts to a stop Calibrate Motor Current 1 Make sure that the compressor motor rated load amps in the Servicel table has been configured Place an ammeter on the line that passes through the motor load current trans fer on the motor side of the power factor correction ca pacitors if provided 2 Start the compressor and establish a steady motor current value between 7096 and 10096 RLA by manually over riding the guide vane target value on the LID and setting the chilled water set point to a low value Do not exceed 105 of the nameplate RLA 3 When a steady motor current value in the desired range is met compare the compressor motor amps value on the StatusO1 table to the actual amps shown on the ammeter on the starter Adjust the amps value on the LID to the actual value se
207. ps deenergized 60 seconds after F Condenser pump and tower fan control may con tinue to operate if condenser pressure is high Evaporator pump may continue if in RECYCLE mode Restart permitted both inhibit timers expired minimum of 15 minutes after E minimum of 3 minutes after F on PSIO Software Version 08 and lower minimum of 1 minute after F on PSIO Software Version 09 and higher Fig 24 Control Sequence O A and go into a RECYCLE mode If the water brine tempera ture is high enough the start up sequence continues on to check the guide vane position If the guide vanes are more than 6 open the start up waits until the PIC closes the vanes If the vanes are closed and the oil pump pressure is less than 3 psid 21 kPad the oil pump relay will then be en ergized The PIC then waits until the OIL PRESS Pressure VERIFY TIME operator configured default 15 seconds for oil pressure to reach 18 psid 124 kPad After oil pressure is verified the PIC waits 15 seconds and then the compres sor start relay is energized to start the compressor Compressor ontime and service ontime timers start and the compressor starts counter and the number of starts over a 12 hour period counter are advanced by one Failure to verify any of the requirements up to this point will result in the PIC aborting the start and displaying the applicable pre start mode of failure on the LID default screen A pre start failure does n
208. r for proper operation LEAVING COND WATER Sensor Fault Check leaving condenser SENSOREEAUETAPEBT _ Check sensor See sensor test ENTERING COND WATER Sensor Fault Check entering condenser Procedure LOW OIL PRESSURE Check oil filter Check for improper ALERT CHECK OIL FILTER Low Oil Pressure Alert Check oil oil level or temperature AUTORESTART PENDING POWER LOSS Power Loss Check voltage supply V VALUE exceeded limit of AUTORESTART PENDING LOW LINE VOLTAGE Check power supply if there are ex volage SY cessive compressor starts occurring exceeded limit o AUTORESTART PENDING HIGH LINE VOLTAGE LIMIT Check voltage supply Discharge temperature exceeded SENSOR ALERT HIGH DISCHARGE TEMP VALUET exceeded limit of ure the alert threshold Check entering 9 condenser water temperature Thrust bearing temperature Cheek ceeded the alert threshold Check for closed valves improper oil level temperature or temperatures CRP High Condenser Pressure m CONDENSER PRESSURE Check ambient conditions Check ALERT PUMP RELAY ENERGIZED Pump energized to reduce condenser pressure for accuracy The chiller load is too small to keep the chiller on line and there have been more than 5 restarts in 4 hours Increase chiller load adjust hot gas bypass increase RECYCLE RESTART DELTA T LIMIT is shown on the LID as the t
209. racer 41 Refrigeration Cycle 5 Refrigeration Log 57 Relief Devices Check 47 Relief Valves and Piping Inspect 64 Remote Start Stop Controls 32 Repair the Leak Retest and Apply Standing Vacuum Test 62 Replacing Defective Processor Modules 80 Rotation Check 55 Running System Check 56 Safety and Operating Controls Check Monthly 63 Safety Considerations 1 Safety Controls 29 Safety Shutdown 41 Scheduled Maintenance 63 Selecting Refrigerant Type 50 Service Configuration Input 50 Service Ontime 63 Service Operation 38 Set Up Chiller Control Configuration 50 Shipping Packaging Remove 41 Shutdown Sequence 40 Solid State Starters 81 Spare Safety Inputs 32 Standing Vacuum Test 43 Starter Check 48 Starter Management Module 79 Starting Equipment 10 65 Start Up Shutdown Recycle Sequence 39 Start the Chiller 56 Stop the Chiller 57 Storage Vessel 5 Summary Lubrication Cycle 8 Surge Prevention Algorithm 33 Surge Protection 34 System Components 5 Temperature Sensors Check 66 Test After Service Repair or Major Leak 61 Tighten All Gasketed Joints and Guide Vane Shaft Packing 41 Tower Fan Relay 33 Trim Refrigerant Charge 62 INDEX cont 99 Troubleshooting Guide 66 Unit Mounted Solid State Starter 10 Unit Mounted Wye Delta Starter 11 Using the Optional Storage Tank and Pumpout System 41 Water Brine Reset 33 Water Leaks 64 Water Pipi
210. rature While Running Blank LID Screen Communications Failure Highlighted Message At Bottom of LID Screen Controls Test Disabled Check for proper communications wiring on PSIO module Check that the COMM1 communications wires from the LID are terminated to the COMM PSIO connection Check that PSIO communication plugs are connected correctly Check SMM communication plug Check for proper SMM power supply See Control Modules section on page 78 Check for proper oil level too much oil Check that TXV valve is operating properly Increase contrast potentiometer See Fig 40 Check red LED on LID for proper operation power supply If LED is blinking but green LED s are not replace LID module memory failure LID is not properly addressed to the PSIO Make sure that Attach to Network Device Local Device is set to read the PSIO address Check LED s on PSIO Is red LED operating properly Are green LED s blinking See control module troubleshooting section Press the Stop pushbutton The PIC must be in the OFF mode for the controls test to operate Clear all alarms Check line voltage percent on Status01 screen The percent must be within 90 to 110 Check voltage input to SMM calibrate starter voltage potentiometer for accuracy Vanes Will Not Open In Control Test Low pressure alarm is active Put chiller into pumpdown mode or equalize pressure Check guide vane actuator wiring Oil Pump Does Not Run
211. re when measuring voltage to prevent damage to the sensor leads connector plugs and modules Sensors should also be checked 66 at the sensor plugs Check the sensor wire at the sensor for 5 vdc if the control is powered CAUTION Relieve all refrigerant pressure or drain the water prior to replacing the temperature sensors CHECK SENSOR ACCURACY Place the sensor in a medium of a known temperature and compare that temper ature to the measured reading The thermometer used to determine the temperature of the medium should be of lab oratory quality with 0 5 F 25 C graduations The sensor in question should be accurate to within 2 F 1 2 C See Fig 8 for sensor locations The sensors are immersed directly in the refrigerant or water circuits The wiring at each sensor is easily disconnected by unlatching the connector These connectors allow only one way connection to the sensor When installing a new sensor apply a pipe sealant or thread sealant to the sensor threads DUAL TEMPERATURE SENSORS There are 2 sensors each on the bearing and motor temperature sensors for servicing convenience In case one of the dual sensors is damaged the other one can be used by moving a wire The number 2 terminal in the sensor terminal box is the common line To use the second sensor move the wire from the number 1 position to the number 3 position Checking Pressure Transducers There are 3 pressure transducers on
212. reakers 4 Fig 11 Control Center Front View with Options Module Fig 10 Control Sensors Pressure Transducer Typical oOuhOn 12 PROCESSOR MODULE PSIO The PSIO is the brain of the PIC Fig 11 This module contains all the operating software needed to control the chiller The 19 XL uses 3 pres sure transducers and 8 thermistors to sense pressures and tem peratures These are connected to the PSIO module The PSIO also provides outputs to the guide vane actuator oil pump oil heater hot gas bypass optional motor cooling solenoid and alarm contact The PSIO communicates with the LID the SMM and the optional 8 input modules for user inter face and starter management STARTER MANAGEMENT MODULE SMM This mod ule is located within the starter cabinet This module ini tiates PSIO commands for starter functions such as start stop of the compressor start stop of the condenser and chilled water pumps start stop of the tower fan spare alarm con tacts and the shunt trip The SMM monitors starter inputs such as flow switches line voltage remote start contact spare safety condenser high pressure oil pump interlock motor current signal starter and run contacts and kW trans ducer input optional The SMM contains logic capable of safely shutting down the machine if communications with the PSIO are lost LOCAL INTERFACE DEVICE LID The LID is mounted to the control center and allo
213. refrigerant type is changed the ATTACH TO NETWORK DEVICE table must be used After changing the refrigerant type in the Control Test table move to the ATTACH TO NET WORK DEVICE table Make sure the highlight bar is located on the LOCAL selection Press the soft key The information in the PSIO module will now be up loaded The default screen will appear The new refrigerant type change for the controller is complete ATTACHING TO OTHER CCN MODULES If the chiller PSIO has been connected to a CCN Network or other PIC controlled chillers through CCN wiring the LID can be used to view or change parameters on the other controllers Other PIC chillers can be viewed and set points changed if the other unit is in CCN control if desired from this particular LID module To view the other devices move to the ATTACH TO NETWORK DEVICE table Move the highlight bar to any device number Press the softkey to change the bus number and address of the module to be viewed Press EXIT softkey to move back to the ATTACH TO NET WORK DEVICE table If the module number is not valid the COMMUNICATION FAILURE message will show and a new address number should be entered or the wiring checked If the model is communicating properly the LOAD IN PROGRESS message will flash and the new mod ule can now be viewed Whenever there is a question regarding which module on the LID is currently being shown check the device name descriptor on th
214. rk Device table to upload the new number into the Sched ule screen See Fig 17 Safety Controls The PIC monitors all safety control inputs and if required shuts down the chiller or limits the guide vanes to protect the chiller from possible damage from any of the following conditions high bearing temperature high motor winding temperature high discharge temperature low oil pressure low cooler refrigerant temperature pressure condenser high pressure or low pressure inadequate water brine cooler and condenser flow high low or loss of voltage excessive motor acceleration time excessive starter transition time lack of motor current signal excessive motor amps excessive compressor surge temperature and transducer faults Starter faults or optional protective devices within the starter can shut down the chiller These devices are dependent on what has been purchased as options A CAUTION If compressor motor overload occurs check the motor for grounded or open phases before attempting a restart If the controller initiates a safety shutdown it displays the fault on the LID display with a primary and a secondary message and energizes an alarm relay in the starter and blinks the alarm light on the control center The alarm is stored in memory and can be viewed in the PIC alarm table along with a message for troubleshooting 29 To give a better warning as to the operating condition of the chiller the o
215. rol Test menu is described as follows Automated Tests As described above a complete control test Check of all PSIO thermistors only Check of all options boards thermistors PSIO Thermistors Options Thermistors Transducers Check of all transducers Guide Vane Actuator Check of the guide vane operation Pumps Check operation of pump outputs either all pumps can be activated or individual pumps The test will also test the associated input such as flow or pressure Activation of all on off outputs or individually Pumpdown prevents the low refrig erant alarm during evacuation so refrigerant can be removed from the unit locks the compressor off and starts the water pumps To charge refrigerant and enable the chiller to run after pumpdown lockout Sets type of refrigerant used HCFC 22 or HFC 134a Make sure to Attach to Local Device after changing refrigerant type Refer to Selecting Refrigerant Type section on page 50 Discrete Outputs Pumpdown Lockout Terminate Lockout Refrigerant Type Check Optional Pumpout System Controls and Compressor Controls include an on off switch a 3 amp fuse the compressor overloads an internal thermostat a com pressor contactor and a refrigerant high pressure cutout The high pressure cutout is factory set to open at 220 5 psig 1250 34 kPa and automatically reset at 185 0 7 psig 1280 0 48 kPa with HCFC 22 HFC 134a units open at 161 psig
216. roper saturated pressure and temperature for the particular refrigerant used Suction Temperature 42 F 5 6 C z 71 5 psig 521 kPa saturated refrigerant pressure HCFC 22 Condensing Temperature 98 36 7 C 190 psig 1310 kPa saturated refrigerant pressure HCFC 22 Maximum Load AT2 54 44 10 12 2 6 7 5 5 C Maximum Load AP2 190 71 5 118 5 psid 1310 521 789 kPad To avoid unnecessary surge prevention add about 10 psid 70 kPad to AP2 from these conditions 2 10 5 5 C AP2 130 psid 900 kPad Calculate Minimum Load To calculate minimum load con ditions estimate the temperature difference that the cooler will have at 1096 load then estimate what the suction and condensing temperatures will be at this point Use the proper saturated pressure and temperature for the particular refrig erant used Suction Temperature 43 6 1 C 73 psig 503 saturated refrigerant pressure HCFC 22 Condensing Temperature 70 F 21 1 C 121 psig 834 kPa saturated refrigerant pressure HCFC 22 Minimum Load ATI 45 5 44 1 5 F 7 5 6 7 0 8 C Minimum Load 121 73 45 psid 834 503 331 kPad Again to avoid unnecessary surge prevention add 10 psid 70 kPad at 1 from these conditions ATI 1 5 F 0 8 C 60 psid 410 kPad If surge prevention occurs too soon or too late LOAD SURGE PREVENTION SURGE PREVENTION OCCU
217. rter Fault Check starter for fault source STR FLT Starter Overload Trip Check amps calibration reset overload REF VALUE exceeded limit of LIMIT Check transducer power supply STARTER FAULT STARTER OVERLOAD TRIP TRANSDUCER VOLTAGE FAULT Check motor current for proper calibration Check guide vane drive and actuator for proper operation Check condenser flow and temperatures Check con figuration of surge protection Check starter for possible ground fault reverse rota tion voltage trip etc Reset overloads and reset alarm Check motor current calibration or overload calibration do not field calibrate overloads Check transformer power 5 vdc supply to trans ducers Power must be 4 5 to 5 5 vdc LIMIT is shown on the LID as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual temperature pressure voltage etc at which the control tripped OPEN indicates that an input circuit is open NOTE See Legend on page 68 73 Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont L CHILLER ALERTS PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY Check that guide vanes are closing High Amps at Recycle Check guide vane Check motor amps correction cali drive bration is correct Check actuato
218. s light emitting diodes located on the side of the LID and on the top horizontal surface of the PSIO SMM and 8 input modules RED LED If the LED is blinking continuously at 2 second rate it is indicating proper operation If it is lit continuously it indicates a problem requiring replacement of the module Off continuously indicates that the power should be checked If the red LED blinks 3 times per sec ond a software error has been discovered and the module must be replaced If there is no input power check fuses and the circuit breaker If fuse is good check for shorted sec ondary of transformer or if power is present to the module replace the module GREEN LEDs There are one or 2 green LEDs on each type of module These LEDs indicate communication status between different parts of the controller and the network mod ules as follows LID Module Upper LED Communication with CCN network if present blinks when communication occurs Lower LED Communication with PSIO module must blink every 5 to 8 seconds when the LID default screen is displayed PSIO Module Green LED Closest to Communications Connection Com munication with SMM and 8 input module must blink continuously Other Green LED Communication with LID must blink every 3 to 5 seconds 8 Input Modules and SMM Green LED Communication with PSIO module will blink continuously Notes on Module Operation 1 The chiller op
219. s and design conditions indicated on the job data specifications An approximate charge may be found by adding the condenser charge to the cooler charge listed in Table 8 Always operate the condenser and chilled water pumps during charging operations to prevent freeze ups Use the Control Test Terminate Lockout to monitor conditions and start the pumps If the chiller has been shipped with a holding charge the refrigerant will be added through the refrigerant charging valve Fig 27 and 28 valve 7 or to the pumpout charging con nection First evacuate the nitrogen holding charge from the 54 vessels Charge the refrigerant as a gas until the system pres sure exceeds 68 psig 469 kPa 35 psig 141 kPa After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all of the recommended refrigerant charge has been added TRIMMING REFRIGERANT CHARGE The 19XL is shipped with the correct charge for the design duty of the chiller Trimming the charge can be best accomplished when design load is available To trim check the temperature difference between leaving chilled water temperature and cooler refrigerant temperature at full load design conditions If necessary add or remove refrigerant to bring the tempera ture difference to design conditions or minimum differential Table 8 Refrigerant Charges 19XL TOTAL REFRIGERANT CHARGE Design Il COOLER Design SIZE Chiller
220. springs blocked in both directions in order to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process or any time refrigerant is transferred Adjust the springs when the refrigerant is in operating condition and when the water circuits are full Refrigerant Tracer Carrier recommends the use of an environmentally acceptable refrigerant tracer for leak test ing with an electronic detector or halide torch Ultrasonic leak detectors also can be used if the chiller is under pressure A WARNING Do not use air or oxygen as a means of pressurizing the chiller Some mixtures of HCFC 22 or HFC 134a and air can undergo combustion Leak Test Chiller Due to regulations regarding refrigerant emissions and the difficulties associated with sepa rating contaminants from refrigerant Carrier recommends the following leak test procedures See Fig 26 for an outline of the leak test procedures Refer to Fig 27 and 28 during pumpout procedures and Tables 5A B C and D for refrig erant pressure temperature values 1 If the pressure readings condition are normal for chiller a Evacuate the holding charge from the vessels if present b Raise the chiller pressure if necessary by adding re frigerant until pressure is at equivalent saturated pres sure for the surrounding temperature Follow the pumpout SXV310N 1931 V
221. t of chiller stop operation and go over pumpout procedures Starter and run and start contacts are energized while control tried to shut down Disconnect power to starter LOSS OF COMMUNCIATION STARTER CONTACT FAULT WITH STA ABNORMAL 1CR OR 1CR__AUX Starter Contact Fault RUN AUX Check 1 aux contacts POTENTIAL FREEZE U TOO LOW LIMIT is shown on the LID as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or P COND PRESS TEMP RTER Check chiller prevention Loss of Communication with Starter CRT VALUE exceeded limit of LIMIT Emergency Freeze up Check wiring from PSIO to SMM Check SMM module troubleshooting procedures Starter run and start contacts energized while chiller was off Disconnect power The condenser pressure transducer is reading a pressure that could freeze the water in the condenser tubes Check for condenser refrigerant leaks bad trans ducers or transferred refrigerant Place the unit in Pumpdown mode to eliminate ALARM if vessel is evacuated alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped H NORMAL RUN WITH RESET TEMPERATURE OR DEMAND PRIMARY MESSAGE RUNNING RESET ACTIVE RUNNING RESET ACTIVE RUNNING RESET ACTIVE RUNNING TEMP CONTROL RUNNING TEMP CONTROL RUNNING TEMP CONTROL RUNNING DEMAND LIMITED R
222. t the Local Occupied Schedule OCCPCO1S 50 Selecting Refrigerant Type 50 TO CONFIRM REFRIGERANT TYPE TO CHANGE REFRIGERANT TYPE Input Service Configurations 50 PASSWORD INPUT TIME AND DATE CHANGE LID CONFIGURATION IF NECESSARY MODIFY CONTROLLER IDENTIFICATION IF NECESSARY EQUIPMENT SERVICE PARAMETERS IF NECESSARY MODIFY EQUIPMENT CONFIGURATION IF NECESSARY CHECK VOLTAGE SUPPLY PERFORM AN AUTOMATED CONTROL TEST Check Optional Pumpout System Controls and 52 High Altitude Locations 53 Charge Refrigerant Into Chiller 53 19XL CHILLER EQUALIZATION WITHOUT PUMPOUT UNIT 19XL CHILLER EQUALIZATION WITH PUMPOUT UNIT TRIMMING REFRIGERANT CHARGE INITIAL START UP 55 56 Preparation 55 Manual Operation of the Guide Vanes 55 Dry Run to Test Start Up Sequence 55 Check Rotation 55 IF ROTATION IS PROPER IF THE MOTOR ROTATION IS NOT CLOCKWISE NOTES ON SOLID STATE STARTERS Benshaw Inc Check Oil Pressure and Compressor Stop 56 Calibrate Motor Current 56 To Prevent Accidental Start Up 56 Check Chiller Operating Condition 56 Instruct the Customer Operator 56 COOLER CONDENSER O
223. t type used HCFC 22 or HFC 134a NOTE Be sure to ATTACH TO LOCAL DEVICE after changing refrigerant type See Attach to Network Device Control section page 37 6 Pumps 7 Discrete Outputs 10 Refrigerant Type During any of the tests that are not automated an out of range read ing will have an asterisk next to the reading and a message will be displayed 19XL CHILLER EQUALIZATION WITH PUMPOUT UNIT The following procedure describes how to equal ize refrigerant pressure on an isolated 19XL chiller using the pumpout unit 1 Access the TERMINATE LOCKOUT mode in the Con trol Test 2 Turn on the chilled water and condenser water pumps to prevent possible freezing 3 Open valve 4 on the pumpout unit and open valves la and 1b on the chiller cooler and condenser Fig 27 and 28 Slowly open valve 2 on the pumpout unit to equalize the pressure This process will take approximately 15 minutes 4 Once the pressures have equalized the discharge isola tion valve cooler isolation valve optional hot gas bypass isolation valve and the refrigerant isolation valve can be opened Close valves 1 and 1b and all pumpout unit valves A WARNING Whenever turning the discharge isolation valve be sure to reattach the valve locking device This will prevent the valve from opening or closing during serv ice work or during chiller operation The full refrigerant charge on the 19XL will vary with chiller component
224. tage 1 9999 460 Meter Rated Line kW 1 9999 600 Line Frequency 0 1 0 Select 0 60 Hz 1 50 Hz Compr Starter Type REDUCE FULL starter REDUCE Condenser Freeze Point 20 35 28 9 1 7 DEG F DEG C cdfreeze 34 1 Soft Stop Amps Threshold 40 100 96 softstop 100 NOTES 1 Condenser Freeze Point and Softstop Amps Threshold are only selectable readable on PSIO Software Versions 09 and higher 2 Values in indicate HFC 134a values 3 A delta degrees 24 o nm Table 2 LID Screens cont EXAMPLE 8 SERVICE2 DISPLAY SCREEN To access this display from the LID default screen Press MENU Press SERVICE Scroll down to highlight EQUIPMENT SERVICE Press SELECT Scroll down to highlight SERVICE2 Press SELECT DESCRIPTION OPTIONS BOARD 1 20 mA POWER CONFIGURATION External 0 Internal 1 RESET 20 mA Power Source DEMAND 20 mA Power Source SPARE ALERT ENABLE Disable 0 Low 1 High 2 Temp Alert Threshold CHWS Temp Enable 0 2 CHWS Temp Alert 40 245 40 118 CHWR Temp Enable 0 2 CHWR Temp Alert 40 245 40 118 Reset Temp Enable 0 2 Reset Temp Alert Spare Temp 1 Enable Spare Temp 1 Alert Spare Temp 2 Enable Spare Temp 2 Alert Spare Temp 3 Enable Spare Temp 3 Alert OPTIONS BOARD 2 20 mA POWER CONFIGURATION External 0 Internal 1 SPARE 1 20 mA Power Source SPARE 2 20 mA Power Source SPARE ALERT ENABLE Disable 0 Low 1 High
225. ter If liquid refrigerant enters the eyes IMME DIATELY FLUSH EYES with water and consult a physician NEVER APPLY an open flame or live steam to a refrigerant cylinder Dangerous over pressure can result When it is necessary to heat refrigerant use only warm 110 F 43 C water DO NOT REUSE disposable nonreturnable cylinders or attempt to refill them It is DANGEROUS AND ILLEGAL When cylinder is emptied evacuate remaining gas pressure loosen the collar and unscrew and discard the valve stem DO NOT INCINERATE CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller The introduction of the wrong refrigerant can cause dam age or malfunction to this chiller Operation of this equipment with refrigerants other than those cited herein should comply with ANSI ASHRAE 15 latest edi tion Contact Carrier for further information on use of this chiller with other refrigerants DO NOT ATTEMPT TO REMOVE fittings covers etc while chiller is under pressure or while chiller is running Be sure pressure is at 0 psig 0 kPa before breaking any refrigerant connection CAREFULLY INSPECT all relief devices rupture discs and other relief devices AT LEAST ONCE A YEAR If chiller 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
226. terface Device LID 6 Pack Relay Board 8 Input Modules Optional Control Center Starter Cabinet Control Center Control Center Control Center Oil Heater Contactor 1C Power Panel Oil Pump Contactor 2C Power Panel Hot Gas Bypass Relay 3C Optional Power Panel Control Transformers T1 T4 Power Panel Control and Oil Heater Voltage Selector S1 Power Panel Temperature Sensors See Fig 8 Pressure Transducers See Fig 8 See Fig 5 6 and Fig 8 12 OIL MOTOR STARTER DISCHARGE TEMPERATURE CONDENSER PRESSURE TEMPERATURE TEMPERATURE CABINET SENSOR AND PRESSURE TRANSDUCER SENSOR SENSOR SWITCH BELOW DISCHARGE CONNECTION LINE CONDENSER TEMPERATURE SENSOR o 259 o AN n EM MEM goes duds CONDENSER L TEMPERATURE SENSOR LER EVAPORATOR TEMPERATURE SENSOR Es s 7 n 7 1 Som 7 y EVAPORATOR TEMPERATURE SENSOR THRUST POWER OIL BEARING PANEL GUIDE COOLER PRESSURE SENSOR VANE PRESSURE TRANSDUCER CONNECTION ACTUATOR TRANSDUCER CONTROL CENTER Fig 8 19XL Controls and Sensor Locations i CONNECTOR ee inm RECEPTACLE 6 35 1 4 in 18 WATERPROOF SEAL Fig 9 Control Sensors Temperature 1 4 SAE FEMALE FLARE WITH INTEGRAL SCHRADER DEFLATOR LEGEND LID PSIO 8 Input Module One of 2 Available 5 Volt Transducer Power Supply 6 Pack Relay Board Circuit B
227. th out saving any changes INCREASE DECREASE QUIT ENTER O O Press ENTER to leave the selected decision or field and save changes INCREASE DECREASE QUIT ENTER O LJ LJ Press to scroll the cursor bar down in order to highlight a point or to view more points below the current screen NEXT PREVIOUS SELECT EXIT e Press PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen NEXT PREVIOUS SELECT EXIT L LJ LJ Press SELECT to view the next screen level high lighted with the cursor bar or to override if allowable the highlighted point value NEXT PREVIOUS SELECT EXIT e Press EXIT to return to the previous screen level PREVIOUS SELECT e Press INCREASE or DECREASE to change the high lighted point value EXIT INCREASE DECREASE QUIT ENTER en TO VIEW POINT STATUS Fig 15 Point Status is the actual value of all of the temperatures pressures relays and actuators sensed and controlled by the PIC On the Menu screen press STATUS to view the list of Point Status tables STATUS SCHEDULE SETPOINT SERVICE EJ Wah ed 2 Press NEXT or PREVIOUS to highlight the desired status table The list of tables is Status01 Status of control points and sensors Status02 Status of relays and contacts Status03 Status of
228. that the RESET softkey be pressed in order to clear the alarm If the alarm is still present the alarm light will continue to blink Once the alarm is cleared the operator must press the Or LOCAL softkeys to restart the chiller CAUTION Do not reset starter loads or any other starter safety for 30 seconds after the compressor has stopped Voltage output to the compressor start signal is maintained for 10 seconds to determine starter fault BEFORE INITIAL START UP Job Data Required list of applicable design temperatures and pressures pro duct data submittal chiller certified prints starting equipment details and wiring diagrams diagrams and instructions for special controls or options 19XL Installation Instructions pumpout unit instructions Equipment Required mechanic s tools refrigeration digital volt ohmmeter DVM clamp on ammeter electronic leak detector absolute pressure manometer or wet bulb vacuum indica tor Fig 25 500 v insulation tester megohmmeter for compressor motors with nameplate voltage of 600 v or less or a 5000 v insulation tester for compressor motor rated above 600 v PLUG FLARE NUT INSULATION THERMOMETER 203 mm WICK SIGHT GLASS DISTILLED WATER OR METHYL ALCOHOL 2 12 63 5 Fig 25 Typical Wet Bulb Type Vacuum Indicator 41 Using the Optional Storage Tank and Pumpout System Refer to Pumpout and Refri
229. the 19XL These determine cooler condenser and oil pressure The cooler and condenser trans ducers also are used by the PIC to determine the refrigerant temperatures All 3 can be calibrated if necessary It is not usually necessary to calibrate at initial start up However at high altitude locations calibration of the transducer will be necessary to ensure the proper refrigerant temperature pressure relationship Each transducer is supplied with 5 vdc power from a power supply If the power supply fails a transducer voltage reference alarm will occur If the trans ducer reading is suspected of being faulty check the supply voltage It should be 5 vdc 5 v If the supply voltage is correct the transducer should be recalibrated or replaced IMPORTANT Whenever the oil pressure or the cooler pressure transducer is calibrated the other sensor should be calibrated to prevent problems with oil differential pressure readings Calibration can be checked by comparing the pressure readings from the transducer against an accurate refrig eration gage These readings are all viewed or calibrated from the Status01 table on the LID The transducer can be checked and calibrated at 2 pressure points These calibration points are 0 psig 0 kPa and between 240 and 260 psig 1655 to 1793 kPa To calibrate these transducers 1 Shut down the compressor 2 Disconnect the transducer in question from its Schrader fitting NOTE If the cooler or
230. the cooling tower temperature controller The TOWER FAN RELAY is turned on whenever the CONDENSER WATER PUMP is running flow is verified and the difference between cooler and condenser pressure is more than 45 psid 310 kPad 30 psid 207 kPad or entering condenser water temper ature is greater than 85 F 29 C The TOWER FAN RELAY is deenergized when the condenser pump is off flow is lost the evaporator refrigerant temperature is less than the over ride temperature or the differential pressure is less than 40 psid 279 kPad 28 psid 193 kPad and entering con densing water is less than 80 F 27 C IMPORTANT A field supplied water temperature con trol system for condenser water should be installed The system should maintain the leaving condenser wa ter temperature at a temperature that is 20 F 11 C above the leaving chilled water temperature CAUTION The tower fan relay control is not a substitute for a con denser water temperature control When used with a Water Temperature Control system the tower fan relay control can be used to help prevent low condenser wa ter temperatures Auto Restart After Power Failure This option may be enabled or disabled and may be viewed modified in the Config table of Equipment Configuration If enabled the chiller will start up automatically after a single cycle drop out low high or loss of voltage has occurred and the power is within 10 of normal The 15
231. to access the highlighted point PREVIOUS SELECT EXIT 3 Press RELEASE to remove the override and return the point to the PIC s automatic control INCREASE DECREASE RELEASE ENTER O LJ Override Indication An override value is indicated by SUPVSR SERVC or BEST flashing next to the point value on the Status table TIME SCHEDULE OPERATION Fig 16 1 On the Menu screen press SCHEDULE STATUS SCHEDULE SETPOINT SERVICE LJ LJ 2 Press NEXT or PREVIOUS to highlight the de sired schedule PSIO Software Version 08 and lower OCCPCOIS LOCAL Time Schedule OCCPCO2S CCN Time Schedule PSIO Software Version 09 and higher OCCPCOIS LOCAL Time Schedule 25 ICE BUILD Time Schedule 3 995 CCN Time Schedule Actual number is defined in Config table NEXT PREVIOUS SELECT EXIT 3 Press to access view the time schedule NEXT PREVIOUS SELECT EXIT 19XL CHLR OCC PCO1S TIME PERIOD SELECT PERIOD ON MTWTFSSH 0700 XXXXX 00 x x NEXT PREVIOUS SELECT Fig 16 Example of Time Schedule Operation Screen 16 4 10 Press or PREVIOUS to highlight the de sired period or override that you wish to change NEXT PREVIOUS SELECT EXIT LJ LJ Press SELECT to access the highlighted period or override PREVIOUS SELECT
232. treated or improperly treated water Inspect the Starting Equipment Before work ing on any starter shut off the chiller and open all discon nects supplying power to the starter A WARNING The disconnect on the starter front panel does not de energize all internal circuits Open all internal and re mote disconnects before servicing the starter A WARNING Never open isolating knife switches while equipment is operating Electrical arcing can cause serious injury Inspect starter contact surfaces for wear or pitting on mechanical type starters Do not sandpaper or file silver plated contacts Follow the starter manufacturer s instruc tions for contact replacement lubrication spare parts order ing and other maintenance requirements Periodically vacuum or blow off accumulated debris on the internal parts with a high velocity low pressure blower Power connections on newly installed starters may relax and loosen after a month of operation Turn power off and retighten Recheck annually thereafter A CAUTION Loose power connections can cause voltage spikes over heating malfunctioning or failures Check Pressure Transducers Once a year the pressure transducers should be checked against a pressure gage reading Check all three transducers oil pressure con denser pressure cooler pressure Note the evaporator and condenser pressure readings on the StatusO1 table on the LID Attach an accurate set
233. tronic PIC Controls Wiring Schematic For 19XL with Halogen Backlight 92 any CONDENSER EVAPORATOR PRESSURE OIL PRESS LYG FILTER EVAP ENT Tbe LYG p COMPRESSOR EXT 4 20 DISCH TEMP PA Coe RESET OPTION INT 4 20 COMM REAR UPPER 2g COMP R THRUST 2 BRG quo DUI Sue TEMP LK EXT 4 20 m AUTO CHILL WA RESET OPTION 2B I INT 4 20 COMMON CHILL WATER SUPPLY SENSOR 27 COMP R MOTOR v WINDING TOP WwW COMMON CHILL VATER 1 CONO ENT onn 28 A L SENSOR 20 TEP t 30 REMDTE fo Tee RESET SSOR RED 34 LO eae TEP v10 36 GRY IN MODULE 2 ADORESS 64 2 FIG SPARE TEMP 3 2 OPTION 01 Sos baw a des Low A ExT 4 20 P common INT 4 20 EXT 4 20 FM 4 como AE INT 4 20 _ SPARE 4 SPARE TEMP 5 sre 8 IN MODULE NY SPARE Tene ADORESS 72 5197 522 SPARE OPTION 02 Fig 49 Electronic PIC Controls Wiring Schematic For 19XL with Halogen Backlight cont 93 115V 1PH 50 6
234. u s HA HINd obe ompun 25 550 eseud 10 5 550 eseud ueuM puooes euo 10 dui si 4 41 401281049 10151591 uonisueJ 72 pexoo iejur pue Z SJ01961002 71 SALON SQ 82 NO t X 1 1 L 835 aanva m r 4 30151538 801 vi 6 310N I Tm N45 1 13 QO 401 ETOILE es H3MOd v luo 2235 Orem ONO Wi 02 sor S S J a gt goi E es MOLINO ei 193NNO99 f Joi lt ZO 101 HDI ptem uses ao 23 mors 6 310N C Noi 21 Su nee 1 us lu 0 41 JQwawooas v6 M3ANHOJSNVHL 5 Fae 3 1NVIS 7051405 voz ve 3 ay OMA SEE Q 581 10000004 ix 97 INDEX Abbreviations and Explanations 4 Adding Refrigerant 61 Adjusting the Refrigerant Charge 61 After Extended Shutdown 57 After Limited Shutdown 57 Attach to Network Device Control 37 Automatic Soft Stop Amps Thresho
235. uirements Starters may be supplied as separate free standing units or may be mounted directly on the chiller unit mounted for low voltage units only Inside the starter are 3 separate circuit breakers Circuit breaker CB1 is the compressor motor circuit breaker The disconnect switch on the starter front cover is connected to this breaker Circuit breaker CB1 supplies power to the com pressor motor WARNING The main circuit breaker CB1 on the front of the starter disconnects the main motor current only Power is still energized for the other circuits Two more circuit break ers inside the starter must be turned off to disconnect power to the oil pump PIC controls and oil heater Circuit breaker CB2 supplies power to the control center oil heater and portions of the starter controls Circuit breaker CB3 supplies power to oil pump Both of these circuit break ers are wired in parallel with CB1 so that power is supplied to them if the disconnect is open starters are shipped with a Carrier control module called the Starter Management Module SMM This module controls and monitors all aspects of the starter See the Con trols section on page 11 for additional SMM information starter replacement parts are supplied by the starter manufacturer Unit Mounted Solid State Starter Optional The 19XL may be equipped with a solid state reduced voltage starter Fig 5 and 6 This starter provides on
236. unction which defaults to 5 F 3 C This value is viewed modified on the Servicel table The compressor will restart when in LCW CONTROL the LEAVING CHILLED WATER tem perature is greater than the CONTROL POINT plus the RECYCLE RESTART DELTA T or in ECW CONTROL the ENTERING CHILLED WATER temperature is greater than the CONTROL POINT plus the RECYCLE RESTART DELTA T Once these conditions are met the compressor will ini tiate a start up with a normal start up sequence An alert condition may be generated if 5 or more RECYCLE STARTUPs occur in less than 4 hours This excessive recycling can reduce chiller life Compressor re cycling due to extremely low loads should be reduced To reduce compressor recycling use the time schedule to shut the chiller down during low load operation or increase the chiller load by running the fan systems If the hot gas bypass is installed adjust the values to ensure that hot gas is ener gized during light load conditions Increase the RECYCLE RESTART DELTA T on the Servicel table to lengthen the time between restarts The chiller should not be operated below design mini mum load without a hot gas bypass installed on the chiller Safety Shutdown safety shutdown is identical to a manual shutdown with the exception that the LID will dis play the reason for the shutdown the alarm light will blink continuously and the spare alarm contacts will be ener gized A safety shutdown requires
237. usO1 screen highlighting the transducer pressing the SELECT soft key and then increasing or decreasing the value to the exact pressure on the refrigerant gage Press ENTER to finish High altitude locations must compensate the pressure so that the temperature pressure relationship is correct If the transducer reading returns to the previous value and the pressure is within the allowed range check the volt age ratio of the transducer Refer to Step 3 above The voltage ratio for this high pressure calibration must be between 0 585 and 0 634 vdc to allow calibration Change the pressure at the transducer until the ratio is within the acceptable range Then attempt calibrate to the new pres sure input The PIC will not allow calibration if the transducer is too far out of calibration A new transducer must be installed and re calibrated TRANSDUCER REPLACEMENT Since the transduc ers are mounted on Schrader type fittings there is no need to remove refrigerant from the vessel Disconnect the trans ducer wiring by pulling up on the locking tab while pulling up on the weather tight connecting plug from the end of the transducer Do not pull on the transducer wires Unscrew the transducer from the Schrader fitting When installing a new transducer do not use pipe sealer which can plug the sensor Put the plug connector back on the sensor and snap into place Check for refrigerant leaks WARNING Make sure to use a
238. v31 NHOdH3d DISd edi DISd 04 22 04OH SI SHNSSAHd JILNN SY9 1NVH3OIHA3H 518553 31Vnov 3 ANY N3OOHLIN 3SV3 13H AHOLOV3 01 DISd 91 1v SI 3Hn SS3Hd N39OHLIN HLIM S3NIHOVIN 1591 497 71 61 92 614 ANIHOVW 313 1dWOO H3MO1 HO 5 9IH3HdSOMLIV LY 739932 13663 31VHOAH3G TY 13883A SHSM 3SOHL AINO 193 13H I1NVHU3OIHJ3H SXV31TIV 43400934 13883A NI 3unssddd 1 3SV3 IHH SNIGNVLS WHO3H3d S3ounos ONY S3ounos TV 31700 ONY 31700 T3SS3A SXVY310ON Y0193130 13 SOINOSVHI TCI NOLLN1OS 3 188n8 d VOS ONISN 1531 3V31INHOdHH3d 1931 3V31WHOJH3d ed Lvz DISd 1 ed 0189 04 22 040 3AO8V SI SHNSS3Yd 1NVH35IHJ3H ONnOZ3 SXV310N 1531 V3lIWNHOdU3d H3SN3ONCO 3Hn ssS3ud HAZMWNOA LOH SI QNY NO SI H31V3H TIO AYNSNA OL STOHINOO H3MOd H3SN3QNOO ANY 931009 N33M138 3HnSS3Hd H3ZITvno3 LOH 51110 NO SI H31V3H 3HhISN3 OL STOHLNOO H3MOd MON SV u3ovulL 40103130
239. voltage etc at which the control tripped J OUT OF RANGE SENSOR FAILURES PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SENSOR FAULT LEAVING CHW TEMPERATURE Sensor Fault Check leaving CHW SENSOR FAULT ENTERING CHW TEMPERATURE Sensor Fault Check entering CHW Sensor Fault Check condenser SENSOR FAULT CONDENSER PRESSURE Sensor Fault Check evaporator SENSOR FAULT EVAPORATOR PRESSURE 5 ee sensor test procedure SENSOR FAULT BEARING TEMPERATURE Sansor fault check sensors for proper operation emperature sensor and wiring SENSOR FAULT MOTOR WINDING TEMP Sensor Fault ecm motortemperature Sensor Fault Check discharge SENSOR FAULT DISCHARGE TEMPERATURE Sensor Fault Check oil sump SENSOR FAULT OIL SUMP TEMPERATURE Sensor Fault Check oil pressure SENSOR FAULT OIL PRESSURE TRANSDUCER NOTE See Legend on page 68 72 Table 9 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides cont K CHILLER PROTECT LIMIT FAULTS WARNING Excessive numbers of the same fault can lead to severe chiller damage Seek service expertise PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE PRIMARY CAUSE PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT HIGH DISCHARGE CMPD VALUE exceeded limit of TEMP
240. wing parameters based on the BUILD TERMINA TION value to avoid starting the compressor unnecessarily if ICE BUILD TERMINATION is set to the temperature only option zero and the ENTERING CHILLED WATER temperature is less than or equal to the BUILD SET POINT if ICE BUILD TERMINATION is set to the contacts only option 1 and the remote contacts are open if the BUILD TERMINATION is set to the both tem perature and contacts option 2 and ENTERING CHILLED WATER temperature is less than or equal to the BUILD SET POINT and remote contacts are open The BUILD RECYCLE OPTION determines whether or not the PIC will go into a RECYCLE mode If the BUILD RECYCLE OPTION is set to DSABLE disable when the ice build terminates the PIC will revert back to normal temperature control duty If the BUILD RECYCLE OPTION 1 set to ENABLE when ice build terminates the PIC will go into an ICE BUILD RECYCLE mode and the chilled water pump relay will remain energized to keep the chilled water flowing If the entering CHILLED WATER BRINE TEMPERATURE increases above the ICE BUILD SET POINT plus the RECYCLE RESTART DELTA T value the compressor will restart and control the CHILLED WATER BRINE TEMPERATURE to the ICE BUILD SET POINT TEMPERATURE CONTROL DURING ICE BUILD During ice build the capacity control algorithm uses the WATER BRINE CONTROL POINT minus 5 F 2 7 C to con trol the LEAVING CHILLED W
241. with compressor off gt 10 seconds Energizes condenser pump relay if condenser refrigerant temperature or condenser entering water temperature is below the configured con COMPRESSOR MOTOR LOAD STARTER ACCELERATION TIME Determined by inrush current going below 100 compressor motor load STARTER TRANSITION CONDENSER FREEZE PROTECTION Flow Switches Field Supplied Operate water pumps with chiller off Manually reduce water flow and observe switch for proper cutout Safety shutdown occurs when cutout time exceeds 3 seconds Cutout lt 15 psid 103 kPad denser freeze point temperature Deenergizes when the temperature is 5 F 3 C above con denser freeze point temperature NO ADJUSTMENTS ARE TO BE MADE ON THIS SETSCREW FACTORY ADJUSTED ONLY ES COM WIRE FLOW SWITCH TO STARTER TERMINAL STRIP TB 5 FOR FLOW INDICATIONS 30 Preset alert setting configurable Preset alert setting configurable Preset configure chilled medium for water Service1 table Configure chilled medium for brine Service1 table Adjust brine refrigerant trippoint for proper cutout Preset Preset Preset Preset no calibration needed Preset Preset based on transformed line volt age to 24 vac rated input to the Starter Management Module Also monitored at PSIO power input Preset Preset Preset
242. ws the operator to interface with the PSIO or other CCN devices Fig 11 It is the input cen ter for all local chiller set points schedules set up func tions and options The LID has a STOP button an alarm light 4 buttons for logic inputs and a display The function of the 4 buttons or softkeys are menu driven and are shown on the display directly above the key 6 PACK RELAY BOARD This device is a cluster of 6 pilot relays located in the control center Fig 11 It is energized by the PSIO for the oil pump oil heater alarm optional hot gas bypass relay and motor cooling solenoid ey DT PAT OIL HEATER CONTACTOR 12 23 8 INPUT MODULES One optional module is factory in stalled in the control center panel when ordered Fig 11 There can be up to 2 of these modules per chiller with 8 spare inputs each They are used whenever chilled water reset demand reset or reading a spare sensor is required The sensors or 4 to 20 mA signals are field installed The spare temperature sensors must have the same temperature resistance curve as the other temperature sen sors on this unit These sensors are 5 000 ohm at 75 F 25 C OIL HEATER CONTACTOR 1C This contactor is lo cated in the power panel Fig 12 and operates the heater at either 115 or 230 v It is controlled by the PIC to maintain oil temperature during chiller shutdown OIL PUMP CONTACTOR 2C This contactor is located
243. xtended Shutdown The refrigerant should be trans ferred into the storage vessel if supplied see Pumpout and Refrigerant Transfer Procedures in order to reduce chiller pressure and possibility of leaks Maintain a holding charge 57 of 5 to 10 Ibs 2 27 to 4 5 kg of refrigerant to prevent air from leaking into the chiller If freezing temperatures are likely to occur in the chiller area drain the chilled water condenser water and the pumpout condenser water circuits to avoid freeze up Keep the waterbox drains open Leave the oil charge in the chiller with the oil heater and controls energized to maintain the minimum oil reser voir temperature After Extended Shutdown Be sure that the water system drains are closed It may be advisable to flush the water circuits to remove any soft rust which may have formed This is a good time to brush the tubes if necessary Check the cooler pressure on the LID default screen and compare to the original holding charge that was left in the chiller If after adjusting for ambient temperature changes any loss in pressure is indicated check for refrigerant leaks See Check Chiller Tightness section page 41 Recharge the chiller by transferring refrigerant from the storage tank if supplied Follow the Pumpout and Refrig erant Transfer Procedures section page 59 Observe freeze up precautions Carefully make all regular preliminary and running sys tem checks Perform a Control

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