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CONTENTS (cont)
Page
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
• CHECK VOLTAGE SUPPLY
• PERFORM AN AUTOMATED
CONTROLS TEST
High Altitude Locations
. . . . . . . . . . . . . . . . . . . . . 44
Charge Refrigerant Into Machine
. . . . . . . . . . . . . 44
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP
. . . . . . . . . . . . . . . . . . . . . . . . . 45,46
Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Manual Operation of the Guide Vanes
. . . . . . . . 45
Dry Run to Test Start-Up Sequence
. . . . . . . . . . 45
Check Rotation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• IF ROTATION IS PROPER
• IF THE MOTOR ROTATION IS NOT CLOCKWISE
Check Oil Pressure and Compressor Stop
. . . . 46
Calibrate Motor Current Demand Setting
. . . . . 46
To Prevent Accidental Start-Up
. . . . . . . . . . . . . . 46
Check Machine Operating Condition
. . . . . . . . . 46
Instruct the Customer Operator
. . . . . . . . . . . . . . 46
• COOLER-CONDENSER
• ECONOMIZER
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE MACHINE CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION,
AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS
. . . . . . . . . . . . . . . 47,48
Operator Duties
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prepare the Machine for Start-Up
. . . . . . . . . . . . 47
To Start the Machine
. . . . . . . . . . . . . . . . . . . . . . . . 47
Check the Running System
. . . . . . . . . . . . . . . . . . 47
To Stop the Machine
. . . . . . . . . . . . . . . . . . . . . . . . 47
After Limited Shutdown
. . . . . . . . . . . . . . . . . . . . . 47
Extended Shutdown
. . . . . . . . . . . . . . . . . . . . . . . . . 47
After Extended Shutdown
. . . . . . . . . . . . . . . . . . . 48
Cold Weather Operation
. . . . . . . . . . . . . . . . . . . . . 48
Manual Guide Vane Operation
. . . . . . . . . . . . . . . 48
Refrigeration Log
. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REFRIGERANT TRANSFER PROCEDURE
. . . . . 48
Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
GENERAL MAINTENANCE
. . . . . . . . . . . . . . . . . . . 50
Refrigerant Properties
. . . . . . . . . . . . . . . . . . . . . . . 50
Adding Refrigerant
. . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removing Refrigerant
. . . . . . . . . . . . . . . . . . . . . . . 50
Adjusting the Refrigerant Charge
. . . . . . . . . . . . 50
Refrigerant Leak Testing
. . . . . . . . . . . . . . . . . . . . 50
Refrigerant Leak Rate
. . . . . . . . . . . . . . . . . . . . . . . 50
Test After Service, Repair, or Major Leak
. . . . . 50
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Page
Repair the Leak, Retest, and Apply
Standing Vacuum Test
. . . . . . . . . . . . . . . . . . . . 50
Checking Guide Vane Linkage
. . . . . . . . . . . . . . . 50
Trim Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . 50
WEEKLY MAINTENANCE
. . . . . . . . . . . . . . . . . . . 50,51
Check the Lubrication System
. . . . . . . . . . . . . . . 50
SCHEDULED MAINTENANCE
. . . . . . . . . . . . . . 51-53
Service Ontime
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspect the Control Center
. . . . . . . . . . . . . . . . . . . 51
Check Safety and Operating Controls
Monthly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Change Oil and Oil Filter
. . . . . . . . . . . . . . . . . . . . 51
Oil Specification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Oil Changes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Refrigerant Filter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Change Refrigerant Filter or Strainer
. . . . . . . . . 52
Inspect Refrigerant Float System
. . . . . . . . . . . . 52
Inspect Relief Valves and Piping
. . . . . . . . . . . . . 52
Compressor Bearing and Gear Maintenance
. . 52
Inspect the Heat Exchanger Tubes
. . . . . . . . . . . 52
• COOLER
• CONDENSER
Water Leaks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Water Treatment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Inspect the Starting Equipment
. . . . . . . . . . . . . . 52
Check Pressure Transducers
. . . . . . . . . . . . . . . . 53
Ordering Replacement Chiller Parts
. . . . . . . . . . 53
TROUBLESHOOTING GUIDE
. . . . . . . . . . . . . . . 53-71
Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking the Display Messages
. . . . . . . . . . . . . 53
Checking Temperature Sensors
. . . . . . . . . . . . . . 53
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers
. . . . . . . . . . . . . 53
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure
. . . . . 54
Control Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control Modules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• RED LED
• GREEN LEDs
Notes on Module Operation
. . . . . . . . . . . . . . . . . . 63
Processor Module (PSIO)
. . . . . . . . . . . . . . . . . . . . 64
• INPUTS
• OUTPUTS
Starter Management Module (SMM)
. . . . . . . . . . 64
• INPUTS
• OUTPUTS
Options Modules (8-Input)
. . . . . . . . . . . . . . . . . . . 64
Replacing Defective Processor Modules
. . . . . . 65
• INSTALLATION OF NEW PSIO MODULE
Physical Data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INITIAL START-UP CHECKLIST FOR
19EF HERMETIC CENTRIFUGAL
LIQUID CHILLER
. . . . . . . . . . . . . . . . . . . CL-1-CL-12
3
Summary of Contents for 19EF Series
Page 10: ...Fig 5 19EF Controls and Sensor Locations cont 10...
Page 13: ...Fig 12 19EF Menu Structure 13...
Page 14: ...Fig 13 19EF Service Menu Structure 14...
Page 38: ...Fig 24 19EF Leak Test Procedures 38...
Page 69: ...Fig 36 Electronic PIC Controls Wiring Schematic 69...
Page 70: ...Fig 36 Electronic PIC Controls Wiring Schematic cont 70...
Page 71: ...Fig 37 Machine Power Panel Starter Assembly and Motor Wiring Schematic 71...