Carrier AquaEdge 19XR series Start-Up, Operation And Maintenance Instructions Manual Download Page 147

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147

Fig. 59 — Compressor Fits and Clearances — Two-Stage Compressors (cont)

VIEW E

VIEW D

REAR, HIGH SPEED SHAFT BEARING

–0.0007-0.0007

[0/017-0.017]

0.003-0.0011

[0.008-0.027]

Interference fit

THRUST

VIEW A2

LOW SPEED SHAFT THRUST DISK

a19-1637

Summary of Contents for AquaEdge 19XR series

Page 1: ...a solid state or wye delta mechanical starter is used Open the power supply disconnect before touching motor leads or terminals WARNING Failure to follow these procedures may result in personal injury or death DO NOT USE TORCH to remove any component System contains oil and refrigerant under pressure To remove a component wear protective gloves and gog gles and proceed as follows a Shut off electr...

Page 2: ...hiller 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 mechanism Replace the device DO NOT install relief devices in series or backwards USE CARE when working near or in line with a com pressed spring Sudden...

Page 3: ...EVICE TIME BROADCAST ENABLE HOLIDAY SCHEDULING DAYLIGHT SAVING TIME CONFIGURATION START UP SHUTDOWN RECYCLE SEQUENCE 64 67 Local Start Up 64 Shutdown Sequence 66 Automatic Soft Stop Amps Threshold 66 Page Chilled Water Recycle Mode 66 Safety Shutdown 67 BEFORE INITIAL START UP 67 86 Job Data Required 67 Equipment Required 67 Using the Optional Storage Tank and Pumpout System 67 Remove Shipping Pac...

Page 4: ...THOUT REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGEN Repair the Leak Retest and Apply Standing Vacuum Test 94 Checking Guide Vane Linkage 94 Trim Refrigerant Charge 95 Page WEEKLY MAINTENANCE 95 Check the Lubrication System 95 SCHEDULED MAINTENANCE 95 98 Service Ontime 95 Inspect the Control Panel 95 Check Safety and Operating Controls Monthly 95 Changing Oil Filter 95 Oil Specification 96 Oil...

Page 5: ...handling or making contact with circuit boards or module connections Always touch a chassis grounded part to dis sipate body electrostatic charge before working inside con trol center Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs Circuit boards can easily be damaged Always hold boards by the edges and avoid touching components and connections ...

Page 6: ... 60 64 460 3 60 65 575 3 60 66 2400 3 60 67 3300 3 60 68 4160 3 60 69 6900 3 60 50 230 3 50 52 400 3 50 53 3000 3 50 54 3300 3 50 55 6300 3 50 5A 5B 6A 6B 6C 10000 3 50 11000 3 50 11000 3 60 11000 3 60 13800 3 60 Special Order Indicator Standard S Special Order Description 19XR High Efficiency Semi Hermetic Centrifugal Liquid Chiller 19XRV High Efficiency Semi Hermetic Centrifugal Liquid Chiller w...

Page 7: ...ces and energy management systems Languages that may be pre installed at factory include English Chinese Japanese and Korean International language translator ILT is available for conversion of extended ASCII characters Economizer Optional An economizer along with a two stage compressor allows for higher lift applica tions The economizer is a separate vessel in the flow path after the condenser th...

Page 8: ...ser Auto Reset Relief Valves 17 Motor Circuit Breaker 18 Solid State Starter Control Display 19 Unit Mounted Starter or VFD Optional Solid State Starter Shown 20 Motor Sight Glass 21 Cooler Return End Waterbox Cover 22 ASME Nameplate One Hidden 23 Typical Waterbox Drain Port 24 Condenser Return End Waterbox Cover 25 Refrigerant Moisture Flow Indicator 26 Refrigerant Filter Drier 27 Liquid Line Iso...

Page 9: ...Housing LEGEND 17 Damper Valve 18 Cooler Auto Reset Relief Valves 19 Solid State Starter Control Display Optional 20 Unit Mounted Starter Optional 21 Motor Sight Glass 22 Cooler Return End Waterbox Cover 23 ASME Nameplate 24 Vessel Take Apart Connector 25 Typical Waterbox Drain Port 26 Condenser Return End Waterbox Cover 27 Refrigerant Moisture Flow Indicator 28 Refrigerant Filter Drier 29 Liquid ...

Page 10: ...forms a liquid seal to keep FLASC chamber vapor from entering the cooler When liquid refriger ant 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 tempera ture and pressure at which the cycle began Refrigerant from the condenser also cools the oil and optional variable s...

Page 11: ...N VALVE ROTOR TRANSMISSION ORIFICE FITTING DAMPER VALVE REFRIGERANT ISOLATION VALVE HOT GAS BYPASS OPTIONAL FLOAT VALVE CHAMBER CONDENSER WATER FLASC CHAMBER ISOLATION VALVE REFRIGERANT LIQUID REFRIGERANT VAPOR REFRIGERANT LIQUID VAPOR MOTOR Fig 5 Refrigeration Cycle 19XR XRV Two Stage Compressor IMPORTANT To avoid adverse effects on chiller opera tion considerations must be made to condenser wate...

Page 12: ...cted to the gears and the high speed shaft bearings the re maining flow is directed to the motor shaft bearings Oil drains into the transmission oil sump to complete the cycle Fig 6 and 7 Details 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 ...

Page 13: ...ING SIGHT GLASS FLOW OIL FILTER REAR MOTOR BEARING STRAINER Fig 6 Single Stage Lubrication System a19 1965 OIL PUMP AND MOTOR OIL HEATER OIL PRESS REGULATOR OIL COOLER ISOLATION VALVES PRESSURE TRANSDUCER TXV BULB MOTOR COOLING LINE REAR HIGH SPD BRG OIL FILTER FLOW EDUCTORS SIGHT GLASS STRAINERS FILTER SIGHT GLASS OIL SKIMMER LINE COOLER LABYRINTH GAS LINE OIL SUPPLY TO FORWARD HIGH SPEED BEARING...

Page 14: ... to the rotor includes a babbitted thrust face which opposes the normal axial forces which tend to pull the assembly towards the transmission The bearing closer to the bull gear includes a smaller babbitted thrust face designed to handle counterthrust forces For compressors equipped with hydrodynamic bearings the high speed shaft assembly is supported by two journal bearings located at the transmi...

Page 15: ...tanding VFDs must include a Carrier control module called the Integrated Starter Module ISM ex cluding the Benshaw solid state and wye delta MX3 starters This module controls and monitors all aspects of the starter See the Controls section following for additional ISM infor mation Contact Carrier s Replacement Component Division RCD for replacement parts Unit Mounted Solid State Starter Optional T...

Page 16: ...the Controls section and Troubleshooting Guide sections pages 17 and 99 Typically three separate circuit breakers are inside the start er This includes 1 the VFD circuit breaker 2 a circuit breaker which provides power to the chiller controls and the the oil heater provided at 115 vac and 3 a circuit breaker that provides power at the line voltage to the oil pump The controls oil heater and oil pu...

Page 17: ...by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns if re quired PIC II System Components The chiller control system is called the PIC II Product Integrated Control II See Table 1 The PIC II controls the operation of the chiller by monitoring all operating conditions The PIC II can diagnose a problem and let the operator know what the problem is and wha...

Page 18: ...on the back of the ICVC See Fig 13 English is the default language Three other programmed languages are available as options Chinese Japanese Korean NOTE Pressing any one of the four softkey buttons will acti vate the backlight display without implementing a softkey function INTEGRATED STARTER MODULE ISM This mod ule is located in the starter cabinet This module initiates com mands from the ICVC f...

Page 19: ...TIONAL This relay located in the power panel con trols the opening of the hot gas bypass valve The PIC II ener gizes the relay during low load high lift conditions CONTROL TRANSFORMERS T1 T2 These trans formers convert incoming control voltage to 24 vac power for the 3 power panel contactor relays CCM and ICVC SENSORS Three types of temperature sensors are used Figure 15 shows a typical temperatur...

Page 20: ...RONT VIEW CONTROL PANEL DISPLAY FRONT VIEW Fig 13 Control Panel a19 1855 a19 1897 a19 1956 OIL HEATER CONDUIT CONTROL PANEL POWER CONDUIT OPTIONAL HOT GAS BYPASS CONDUIT 3C HOT GAS BYPASS RELAY OPTIONAL T2 24 VAC POWER TRANSFORMER FOR ICVC AND CCM T1 24 VAC POWER TRANSFORMER FOR HOT GAS BYPASS RELAY OIL PUMP CONTACTOR AND OIL HEATER CONTACTOR T1 T2 OIL HEATER CONTACTOR 11 12 13 21 22 23 11 12 13 2...

Page 21: ...u pancy schedule to determine chiller start and stop times The PIC II can be placed in the local operating mode by pressing the LOCAL softkey When RUN STATUS is READY the chiller will attempt to start up CCN In CCN mode the PIC II accepts input from any CCN interface or module with the proper authority as well as from the local ICVC The PIC II uses the CCN time occupancy schedule to determine star...

Page 22: ...ws viewing and modification of the local and CCN time schedules and Ice Build time schedules The SETPOINT menu allows set point adjustments such as the entering chilled water and leaving chilled water set points The SERVICE menu can be used to view or modify information on the Alarm History Control Test Control Algorithm Status Equipment Configuration ISM Starter Configuration data Equipment Servi...

Page 23: ... Status of motor starter ICVC_PSWD Service menu password forcing access screen 3 Press to view the desired point status table 4 On the point status table press or until the desired point is displayed on the screen OVERRIDE OPERATIONS Manual Overrides To Force Manually Override a Value or Status 1 From any point status screen press or to highlight the desired value 2 Press to select the highlighted...

Page 24: ...Build Setpoint Tower Fan High Setpoint EXIT SELECT PREVIOUS NEXT Select a Schedule 1 2 3 4 5 6 7 8 Override ENABLE DISABLE EXIT SELECT PREVIOUS NEXT Select a Time Period Override Modify a Schedule Time ENTER EXIT INCREASE DECREASE ENTER EXIT ANALOG VALUES DISCRETE VALUES Add Eliminate a Day 1 1 1 Select a Status Table NEXT PREVIOUS SELECT EXIT START ON STOP OFF RELEASE ENTER EXIT NEXT PREVIOUS SEL...

Page 25: ...S DISCRETE VALUES Select a Parameter NEXT PREVIOUS SELECT EXIT Modify a Parameter ENTER ENABLE DISABLE QUIT DECREASE INCREASE ENTER QUIT NEXT PREVIOUS SELECT EXIT Select a Table EQUIPMENT CONFIGURATION List the Equipment Configuration Tables CAPACITY Capacity Control Algorithm OVERRIDE Override Status LL_MAINT LEADLAG Status WSMCHLRE Water System Manager Control Status Maintenance Table Data NEXT ...

Page 26: ...rk Devices Local Device 1 Device 2 Device 3 Device 4 Device 5 Device 6 Device 7 Device 8 Attach to any Device Service Tables OPTIONS SETUP1 SETUP2 LEADLAG RAMP_DEM TEMP_CTL EQUIPMENT SERVICE ISM STARTER CONFIG DATA Service Tables ISM STARTER CONFIG PASSWORD ISM_CONF ENTER A 4 DIGIT PASSWORD VALUES SHOWN AT FACTORY DEFAULT 4 4 4 4 ICVC CONFIGURATION EXIT INCREASE DECREASE ENTER ICVC Configuration T...

Page 27: ...e 8 a Press or to change the time values Override values are in one hour increments up to 4 hours b Press to select days in the day of week fields Press to eliminate days from the period 9 Press to register the values and to move horizon tally left to right within a period 10 Press to leave the period or override 11 Either return to Step 4 to select another period or over ride or press again to le...

Page 28: ...tion section page 63 The ice build ICE BUILD function is also activated and configured from the SER VICE menu 3 Press or to highlight the desired set point entry 4 Press to modify the highlighted set point 5 Press or to change the select ed set point value 6 Press to save the changes and return to the previ ous screen SERVICE OPERATION To view the menu driven pro grams available for Service Operat...

Page 29: ...clamation point in the far right field of the ICVC screen indi cates an alert state The asterisk or exclamation point indi cates that the value on that line has exceeded or is approaching a limit For more information on alarms and alerts see the Alarms and Alerts section page 22 9 Index of all ICVC parameters is shown in Appendix A 10 An abbreviation in the column to the right of POINT STATUS indi...

Page 30: ...eted ramp loading following start up Demand The chiller is prevented from loading further because it has reached the an AVERAGE LINE CURRENT Limit or a MOTOR KILOWATTS Limit Ramping The chiller has started and is slowly increasing its load to control electrical demand charges Autorest The chiller is starting back up due to a power failure and auto restart is enabled Override The chiller is prevent...

Page 31: ...1 OPEN CLOSED 1M_AUX Starter Trans Relay 0 1 OFF ON CMPTRANS Compressor Run Contact 0 1 OPEN CLOSED 2M_AUX Tower Fan Relay Low 0 1 OFF ON TFR_LOW Tower Fan Relay High 0 1 OFF ON TFR_HIGH Starter Fault 0 1 ALARM NORMAL STR_FLT Spare Safety Input 0 1 ALARM NORMAL SAFETY Shunt Trip Relay 0 1 OFF ON TRIPR ISM Fault Status 0 255 ISMFLT MENU STATUS STARTUP SELECT DESCRIPTION STATUS UNITS POINT Actual Gu...

Page 32: ...ter 40 245 F ECDW Leaving Condenser Water 40 245 F LCDW Condenser Refrig Temp 40 245 F CRT Condenser Pressure 6 7 420 PSI CRP Condenser Approach 0 99 F COND_APP Hot Gas Bypass Relay 0 1 OFF ON HGBYPASS Surge Prevention Active 0 1 NO YES SHG_ACT Actual Guide Vane Pos 0 100 GV_POS Active Delta Tsat 0 200 F CDW_DT Surge Line Delta Tsat 0 200 F DELTA_TX Head Pressure Reference 0 100 HPR MENU STATUS HE...

Page 33: ...S Overvoltage 0 1 NORMAL ALARM OV_VOLT Undervoltage 0 1 NORMAL ALARM UN_VOLT Current Imbalance 0 1 NORMAL ALARM AMP_UNB Voltage Imbalance 0 1 NORMAL ALARM VOLT_UNB Overload Trip 0 1 NORMAL ALARM OVERLOAD Locked Rotor Trip 0 1 NORMAL ALARM LRATRIP Starter LRA Trip 0 1 NORMAL ALARM SLRATRIP Ground Fault 0 1 NORMAL ALARM GRND_FLT Phase Reversal 0 1 NORMAL ALARM PH_REV Frequency Out of Range 0 1 NORMA...

Page 34: ... Chilled Water 40 245 DEG F ECW Leaving Chilled Water 40 245 DEG F LCW Capacity Control Control Point 10 120 DEG F ctrlpt Control Point Error 99 99 F cperr ECW Delta T 99 99 F ecwdt ECW Reset 99 99 F ecwres LCW Reset 99 99 F lcwres Total Error Resets 99 99 F error Guide Vane Delta 2 0 2 0 gvd Target Guide Vane Pos 0 100 GV_TRG Actual Guide Vane Pos 0 100 GV_POS Target VFD Speed 0 100 VFD_OUT Actua...

Page 35: ...SCRIPTION STATUS UNITS POINT LeadLag Control LEADLAG Configuration NOTE 1 leadlag Current Mode NOTE 2 llmode Load Balance Option 0 1 DSABLE ENABLE loadbal LAG START Time 2 60 MIN lagstart LAG STOP Time 2 60 MIN lagstop Prestart Fault Time 2 30 MIN preflt Pulldown Time 2 30 MIN pulldown Pulldown Delta T Min x xx F pull_dt Satisfied 0 1 NO YES pull_sat LEAD CHILLER in Control 0 1 NO YES leadctrl LAG...

Page 36: ...d Change in Effect 0 5 SPD_CHG VFD Speed Factor 0 000 1 000 VFD_SPD Surge Counts 0 99 SC Surge Protection Counts 0 4 SPC Ramp Loading Active 0 1 No Yes RAMP_ACT VFD Rampdown Active 0 1 No Yes VFD_RAMP HGBP VFD Active 0 2 HGBP_VFD VFD Load Factor 0 00 1 20 VFD_RAT Hot Gas Bypass Relay 0 1 Off On HGBYPASS Surge Limit HGBP Option 0 2 HGBP_OPT Override Inhibit Active 0 1 No Yes VANE_INH Override Decre...

Page 37: ...or write operation DESCRIPTION STATUS UNITS POINT WSM Active 0 1 NO YES WSMSTAT Chilled Water Temp 0 0 99 9 DEG F CHWTEMP Equipment Status 0 1 OFF ON CHWRST Commanded State XXXXXXXX TEXT CHLRENA CHW setpt Reset Value 0 0 25 0 DEG F CHWRVAL Current CHW Set Point 0 0 99 9 DEG F CHWSTPT DESCRIPTION STATUS UNITS POINT DEFAULT Loadshed Function Group Number 0 99 ldsgrp 0 Demand Limit Decrease 0 60 ldsd...

Page 38: ...0 Voltage Imbalance Time 1 10 SEC vu_time 5 Motor Rated Load Amps 10 5000 AMPS rla 200 Motor Locked Rotor Trip 100 60000 AMPS mot_lra 1000 Locked Rotor Start Delay 1 10 cycles lrs_del 5 Starter LRA Rating 100 60000 AMPS str_lra 2000 Motor Current CT Ratio 1 10 1000 ct_ratio 100 Current Imbalance 5 40 c_unbal 15 Current Imbalance Time 1 10 SEC cu_time 5 Grnd Fault CT s 0 1 NO YES gf_cts YES Ground ...

Page 39: ... 1 85 Surge Line High Offset 0 1 3 0 SP_HIGH 1 0 Surge HGBP Deadband 0 5 3 F hgb_db 1 HGBP On Delta T 0 5 10 0 F Hgb_ton 2 0 HGBP Off Delta T 0 5 10 0 F Hgb_toff 4 0 Surge Protection Surge Delta Amps 5 40 surge_a 20 Surge Time Period 7 10 MIN surge_t 8 Surge Delay Time 0 120 SEC SURG_DEL 0 Ice Build Control Ice Build Option 0 1 DSABLE ENABLE Ibopt DSABLE Ice Build Termination 0 2 Ibterm 0 0 Temp 1...

Page 40: ...band 0 5 2 0 F CWDB 1 0 Evap Refrig Trippoint 0 0 40 0 DEG F ERT_TRIP 33 Refrig Override Delta T 2 0 5 0 F REF_OVER 3 Evap Approach Alert 0 5 30 0 F EVAP_AL 5 Cond Approach Alert 0 5 30 0 F COND_AL 6 Condenser Freeze Point 20 35 DEG F CDFREEZE 34 Flow Delta P Display 0 1 DSABLE ENABLE FLOWDISP DSABLE Evap Flow Delta P Cutout 0 5 50 0 PSI EVAP_CUT 5 0 Cond Flow Delta P Cutout 0 5 50 0 PSI COND_CUT ...

Page 41: ... Control VFD Option 0 1 DSABLE ENABLE vfd_opt DSABLE VFD Gain 0 1 1 5 vfd_gain 0 75 VFD Increase Step 1 5 vfd_step 2 VFD Minimum Speed 65 100 vfd_min 70 VFD Maximum Speed 90 110 vfd_max 100 VFD Start Speed 65 100 vfd_str 100 VFD Surge Line Gain 2 0 3 5 vfd_slg 2 0 VFD Current Limit 0 99999 amps VFDLIM_T 250 DESCRIPTION STATUS UNITS POINT DEFAULT Lead Lag Control LEAD LAG Configuration 0 3 leadlag ...

Page 42: ...0 20 mA Demand Limit Opt 0 1 DSABLE ENABLE dem_sel DSABLE Motor Rated Kilowatts 50 9999 kW motor_kw 145 Demand Watts Interval 5 60 MIN dw_int 15 DESCRIPTION STATUS UNITS POINT DEFAULT Control Point ECW Control Option 0 1 DSABLE ENABLE ecw_opt DSABLE Temp Pulldown Deg Min 2 10 F tmp_ramp 3 Temperature Reset RESET TYPE 1 Degrees Reset At 20 mA 30 30 F deg_20ma 10 RESET TYPE 2 Remote Temp No Reset 40...

Page 43: ...n the Alarm History Alert History Control Test Control Algorithm Status Equipment Configura tion ISM Starter Configuration data Equipment Service Time and Date Attach to Network Device Log Out of Network Device and ICVC Configuration screens For more information on the menu structures refer to Fig 20 and 21 Press the softkey that corresponds to the menu structure to be viewed STATUS SCHEDULE SETPO...

Page 44: ...if no reset function is config ured the CONTROL POINT will equal the SETPOINT CON TROL POINT may be viewed or manually overridden from the MAINSTAT screen Minor adjustments to the rate of capacity adjustment can be made by changing PROPORTIONAL INC Increase BAND PROPORTIONAL DEC Decrease BAND and PROPOR TIONAL ECW Entering Chilled Water GAIN in the SER VICE EQUIPMENT SERVICE SETUP2 screen Increasi...

Page 45: ...ter brine temperature control point If the water temperature goes outside the CHILLED WATER DEADBAND the PIC II opens or closes the guide vanes until the temperature is within tolerance The PIC II may be config ured with a 0 5 to 2 F 0 3 to 1 1 C deadband CHILLED WATER DEADBAND may be viewed or modified on the SET UP1 screen which is accessed from the EQUIPMENT SER VICE table For example a 1 F 0 6...

Page 46: ... produced by the Carrier s chiller selection program and are en tered into the VDO_SRD screen The starting point diffuser schedule consists of guide vane and diffuser positions for three points designated as the 25 50 and 75 Load Points In order for the schedule to be valid the guide vane values must be ascending and the diffuser values must be descending for the three points Figure 25 shows the s...

Page 47: ...lay of average demand power in kilowatts in the POWER screen This value is continuously updated and averaged over the preceding time interval specified as DEMAND WATTS INTERVAL in the SERVICE EQUIPMENT SERVICE RAMP_DEM screen CHILLER TIMERS AND STARTS COUNTER The PIC II maintains two run time clocks COMPRESSOR ONTIME and SERVICE ONTIME COMPRESSOR ONTIME indicates the total lifetime compressor run ...

Page 48: ... the alarm light on the control panel The alarm is stored in memory and can be viewed on the ALARM HISTORY and ISM_HIST screens on the ICVC along with a message for troubleshooting If the safety shutdown was also initiated by a fault detected in the motor starter the conditions at the time of the fault will be stored in ISM_HIST To give more precise information or warnings on the chiller s operati...

Page 49: ... Water Chilling CALC EVAP SAT TEMP or EVAP REFRIG LIQUID TEMP 33 deg F REFRIG OVERRIDE DELTA T Brine Chilling CALC EVAP SAT TEMP or EVAP REFRIG LIQUID TEMP EVAP REFRIG TRIP POINT Prestart Alert Configure REFRIG OVER RIDE DELTA T EVAP REFRIG TRIP POINT and CHILLED MEDIUM in SETUP1 screen TRANSDUCER VOLTAGE FAULT 239 Voltage Reference 4 5 VDC or 5 5 VDC Preset Alarm HIGH CONDENSER PRESSURE CONTROL 2...

Page 50: ...NT SINGLE CYCLE DROPOUT 210 144 Line Voltage on 2 Phases 50 for 1 Cycle Preset Alarm Prestart Alert Configure SINGLE CYCLE DROPOUT in ISM_CONF screen CURRENT IMBALANCE 215 Line Current Imbalance CURRENT IMBAL ANCE for CURRENT IMBALANCE TIME Configure CURRENT IMBALANCE and CURRENT IMBALANCE TIME in ISM_ CONF screen POWER LINE FREQUENCY OUT OF RANGE 222 LINE FREQUENCY 56 Hz or 64 Hz 60 Hz LINE FREQU...

Page 51: ...D LOAD AMPS 203 PERCENT LOAD CURRENT 100 at 45 sec after 1CR closes reduced voltage Preset Alarm PERCENT LOAD CUR RENT AVERAGE LOAD CURRENT MOTOR RATED LOAD AMPS AMPS NOT SENSED 202 PERCENT LOAD CURRENT 15 w 1M 2M closed Preset Alarm PERCENT LOAD CUR RENT AVERAGE LOAD CURRENT MOTOR RATED LOAD AMPS AMPS WHEN STOPPED 205 Amp signal 10 w 1M 2M open preset alarm FAILURE TO STOP 204 1M 2M contacts fail...

Page 52: ...ide Region See Table 7 2 When the value of interest is in the Override Region and further crosses the Second Stage Set Point the guide vanes are closed until the value meets the Override Ter mination Condition The PIC II controls resume normal capacity control operation after the override termination condition has been satisfied In the case of high dis charge superheat there is an intermediate sta...

Page 53: ...C NOTE EVAP SAT OVERRIDE TEMP EVAP REFRIG TRIPPOINT REFRIG OVERRIDE DELTA T CALC EVAP SAT TEMP EVAP SAT OVERRIDE TEMP 2 F 1 1 C HIGH COMPRESSOR LIFT SURGE PREVENTION TSMIN IGVMIN TSMAX IGVMAX SHAPEFAC OPTIONS Tsmain 45 F IGVmin 5 Tsmax 70 F IGVmax 100 shapefac 0 04 0 to 150 F 0 to 110 0 to 150 F 0 to 110 1 to 0 None Active Tsat Surge Line Tsat Dead band Setting MANUAL GUIDE VANE TARGET TARGET GUID...

Page 54: ...the CCM module terminal J5 5 and J5 6 for a refrigerant leak detector Enabling REFRIGERANT LEAK OP TION OPTIONS screen will allow the PIC II controls to go into an alarm state at a user configured level REFRIGERANT LEAK ALARM mA The input is configured for 4 to 20 mA by setting the DIP switch 1 on SW2 at the ON position or config ured for 1 to 5 vdc by setting switch 1 at the OFF position The outp...

Page 55: ...d CONDENSER PRESSURE is more than 30 psid 206 8 kPad and ENTERING COND WATER temperature is greater than the TOWER FAN HIGH SETPOINT SETPOINT menu default 75 F 23 9 C The TOWER FAN RELAY HIGH is turned off when the CONDENSER WATER PUMP is off or the EVAPORATOR REFRIG TEMP is less than the EVAP REF OVERRIDE TEMP and ENTERING CONDENSER WATER is less than 70 F 21 1 C or the difference between EVAPORA...

Page 56: ...atic chilled water temperature reset based on cooler temperature difference Reset Type 3 adds 30 F 16 C based on the temperature difference between the entering and leaving chilled water temperature To configure Reset Type 3 enter the chilled water tempera ture difference the difference between entering and leaving chilled water at which no temperature reset occurs CHW DELTA T NO RESET This chille...

Page 57: ...urn to zero or the En tering Condenser Water Temperature decreases by 1 degree or the Leaving Chilled Water Temperature increases by 1 degree If the machine has a split ring diffuser a correction its posi tion will be made simulatneously The threshold at which a current fluctuation is interpreted as a surge can be adjusted from the OPTIONS screen Scroll to the SURGE DELTA AMPS parameter and use th...

Page 58: ...ng to the SURGE DELTA AMPS parameter and adjusting it with the INCREASE or DE CREASE softkeys The default setting is 10 The SURGE TIME PERIOD can be adjusted from the OPTIONS screen Scroll to the SURGE TIME PERIOD parameter and use the INCREASE or DECREASE softkey to adjust the surge count time interval The default setting is 8 minutes SURGE PROTECTION COUNTS are displayed in the COMPRESS screen B...

Page 59: ...If ENTERING CHILLED WATER control is required on chillers piped in series either a common point sensor should be used preferred or the ENTERING CHILLED WATER sensor of the downstream chiller must be relocated to the ENTERING CHILLED WATER pipe of the upstream chiller In this applica tion the COMMON SENSOR OPTION should only be enabled for the downstream chiller if that chiller is configured as the...

Page 60: ...r depending on which options are configured and enabled 6 Lead chiller temperature pulldown rate TEMP PULL DOWN DEG MIN on the TEMP_CTL screen of the chilled water temperature is less than 0 5 F 0 27 C per minute for a cumulative duration greater than the PULL DOWN TIMER setting in the LEAD LAG screen When all the above requirements have been met the lag chiller is commanded to a STARTUP mode indi...

Page 61: ...e has limits of 40 to 100 In addition the CONTROL POINT for the lag chiller will be mod ified to a value of 3 F 1 67 C less than the lead chiller s CONTROL POINT value If the LOAD BALANCE OPTION is disabled the ACTIVE DEMAND LIMIT and the CONTROL POINT are both forced to the same value as the lead chiller AUTO RESTART AFTER POWER FAILURE When an auto restart condition occurs each chiller may have ...

Page 62: ... CONTROL OPTION and any temperature reset options configured on TEMP_CTL screen 20 mA DEMAND LIMIT OPT configured on RAMP_DEM screen TERMINATION OF ICE BUILD The ice build function terminates under the following conditions 1 Time Schedule When the current time on the ice build time schedule OCCPC02S is not set as an ice build time period 2 Entering Chilled Water Temperature Ice build opera tion te...

Page 63: ...ration Service Operation An overview of the tables and screens available for the SERVICE function is shown in Fig 21 TO ACCESS THE SERVICE SCREENS When the SERVICE screens are accessed a password must be entered 1 From the main MENU screen press the softkey The softkeys now correspond to the numerals 1 2 3 4 2 Press the four digits of the password one at a time An asterisk appears as each digit is...

Page 64: ...l HOLIDAYS is highlighted This is the Holiday Definition table 5 Press to enter the Data Table Select screen This screen lists 18 holiday tables 6 Press to highlight the holiday table that is to be viewed or changed Each table is one holiday period starting on a specific date and lasting up to 99 days 7 Press to access the holiday table The Configu ration Select table now shows the holiday start m...

Page 65: ...this value the PIC II turns off the condenser pump relay and goes into a RECYCLE mode NOTE The 19XR units equipped with ICVC are not available with factory installed chilled water or condenser water flow devices available as an accessory for use with the CCM con trol board In place of the cooler and condenser water pressure inputs on the CCM is a 4300 ohm resistor and a jumper lead If the water br...

Page 66: ... alarm state or if the compressor enters a RECYCLE mode the compressor deenergizes immediately To activate the soft stop amps threshold feature scroll to the bottom of OPTIONS screen on the ICVC Use the or softkey to set the SOFT STOP AMPS THRESHOLD parameter to the percent of amps at which the motor will shut down The default setting is 100 amps no soft stop The range is 40 to 100 When the soft s...

Page 67: ... Using the Optional Storage Tank and Pum pout System Refer to Positive Pressure Chillers with Storage Tanks section page 90 for pumpout system prepara tion refrigerant transfer and chiller evacuation Remove Shipping Packaging Remove any pack aging material from the control center power panel guide vane actuator motor cooling and oil reclaim solenoids motor and bearing temperature sensor covers and...

Page 68: ...tec tor or soap bubble solution 4 Leak Determination If an electronic leak detector indi cates a leak use a soap bubble solution if possible to confirm Total all leak rates for the entire chiller Leakage at rates greater than 0 1 of the total charge per year must be repaired Note the total chiller leak rate on the start up report 5 If no leak is found during the initial start up procedures complet...

Page 69: ...69 Fig 33 19XR Leak Test Procedures a19 1625 ...

Page 70: ...192 93 130 198 66 132 204 50 134 210 47 136 216 55 138 222 76 140 229 09 TEMPERATURE C PRESSURE KPA 18 0 44 8 16 7 51 9 15 6 59 3 14 4 66 6 13 3 74 4 12 2 82 5 11 1 90 8 10 0 99 4 8 9 108 0 7 8 118 0 6 7 127 0 5 6 137 0 4 4 147 0 3 3 158 0 2 2 169 0 1 1 180 0 0 0 192 0 1 1 204 0 2 2 216 0 3 3 229 0 4 4 242 0 5 0 248 0 5 6 255 0 6 1 261 0 6 7 269 0 7 2 276 0 7 8 284 0 8 3 290 0 8 9 298 0 9 4 305 0 ...

Page 71: ...contact a qualified service representative for the dehydration techniques required Perform dehydration as follows 1 Connect a high capacity vacuum pump 5 cfm 002 m3 s or larger is recommended to the refrigerant charging valve Fig 2 and 3 Tubing from the pump to the chiller should be as short in length and as large in diameter as possible to provide least resistance to gas flow 2 Use an absolute pr...

Page 72: ...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 di...

Page 73: ...vel should be no higher than the middle of the upper sight glass and minimum level is the bottom of the lower sight glass Fig 2 and 3 If oil is added it must meet Carrier s specification for centrifugal compressor use as de scribed in the Oil Specification section Charge the oil through the oil charging valve located near the bottom of the transmis sion housing Fig 2 and 3 The oil must be pumped f...

Page 74: ... IMP METRIC and PASSWORD 2 Use the softkey to scroll to PASSWORD The first digit of the password is highlighted on the screen 3 To change the digit press the or softkey When the desired digit is seen press the softkey 4 The next digit is highlighted Change it and the third and fourth digits in the same way the first was changed 5 After the last digit is changed the ICVC goes to the BUS NUMBER para...

Page 75: ...SM_CONF Per chiller nameplate data RL AMPS on compressor nameplate Motor Locked Rotor Trip ISM_CONF Per chiller identification name plate Starter LRA Rating ISM_CONF Enter value from nameplate in starter cabinet MAXIMUM FUSE This value shall always be 9999 for Benshaw RediStart MX3 wye delta and solid state starters Motor Current CT Ratio ISM_CONF Enter ratio reduced to a ratio to 1 of current tra...

Page 76: ... Only Located on the right side of the VFD as viewed from its front See Fig 36 ISM MENU CFN MENU FUN MENU FL MENU E MENU Shows parameters entered on the ISM_CONF screen on the ICVC Initial Current as RLA Meter 1 display Fault Log 9 faults Event Log 99 events Max Current As LRA Meter 2 display Ramp Time seconds CT Ratio Time Date Format Time Date Passcode DESCRIPTION BENSHAW PARAMETER RANGE UNITS D...

Page 77: ...y the VFD disconnect switch is in the open position 5 Close and latch the doors of the VFD enclosure 6 Apply power to the VFD enclosure Remove lock outs and close all disconnects 7 Verify that the ICVC display powers up and goes to the default screen 8 Close the VFD disconnect switch The VFD is configured to attempt an automatic reset of mi nor faults every 30 seconds After a total of 10 failed at...

Page 78: ...omatic mode Refer to Override Operations Sec tion on page 23 VFD CONTROL VERIFICATION Running Preparation 1 Disconnect power to the VFD Verify that the branch dis connects or other local disconnects are open and properly tagged out 2 Connect a voltmeter and ampmeter to the line side of the VFD Locate meters safely away from the power cables 3 Reconnect power to the VFD 4 Measure the voltage on the...

Page 79: ...e Line Speed Factor 1 85 Surge Line High Offset 1 0 Surge HGBP Deadband 1 Calculate Surge HGBP Delta Tsmin Convert design suc tion temp to pressure using an R 134a pressure temperature chart Min Cond Pressure suction pressure ΔP minimum Convert Min Cond Pressure to Min Cond Temperature using a saturation pressure temperature chart for R 134a Surge HGBP Tsmin Min Cond Temp design suc tion temperatu...

Page 80: ...N is greater than 60 then increase SURGE HGBP DELTA TSMAX in steps of 2º F until cooling capacity is reached or one of conditions listed above no longer applies Do not change SURGE HGBP DELTA TSMIN If ACTUAL GUIDE VANE POSITION is more than 30 AND less than 60 then 1 Increase SURGE HGBP DELTA TSMIN in steps of 2º F 2 Increase SURGE HGBP DELTA TSMAX in steps of 2º F 3 Repeat Steps 1 and 2 until one...

Page 81: ... when viewing the compressor from the suction end Units with VFD On units with VFD further adjustments can be made if response to surge prevention or protection is not functioning as desired VFD GAIN and VFD INCREASE STEP can be adjusted to allow for more aggressive changes in speed when surge prevention or protection is active MODIFY EQUIPMENT CONFIGURATION IF NECES SARY The EQUIPMENT SERVICE tab...

Page 82: ...not contain ComfortWORKS controls or a Building Supervisor Autodial Gateway or APIM to serve as an alarm acknowledger set all digits in this decision to 0 in order to prevent unnecessary activity on the CCN Communication Bus Allowable Entries 00000000 to 11111111 0 Disabled 1 Enabled Default Value 10000000 Fig 41 Alarm Control and Alarm Routing a19 1627 TESTS TO BE PERFORMED DEVICES TESTED 1 CCM T...

Page 83: ...flow de vice view the particular reading CHILLED WATER DELTA P and CONDENSER WATER DELTA P on the HEAT_EX screen and OIL PUMP DELTA P on the COMPRESS screen 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 set to zero by pressing the softkey while the appropriate transducer parameter is highlighted on the ICVC screen Then press the softkey The v...

Page 84: ...er cooler and condenser Fig 43 and 44 Slowly open valve 2 on the pumpout unit to equalize the pressure This process takes 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 1a and 1b and all pumpout unit valves The full refrigerant c...

Page 85: ...If necessary add or remove refrigerant to bring the 6 10 7 1a 11 8 1b 5 3 4 2 PUMPOUT COMPRESSOR RELIEF VALVE PUMPOUT CONDENSER CHECK VALVE CONDENSER COOLER STORAGE VESSEL OIL SEPARATOR Fig 43 Typical Optional Pumpout System Piping Schematic with Storage Tank a19 2434 NOTE Maintain at least 2 ft 610 mm clearance around storage tank for service and operation work 7 1a 11 8 1b 5 3 4 2 PUMPOUT COMPRE...

Page 86: ...UP display screen and verify the chilled water and condenser water pumps have energized 4 Verify the oil pump has started and is pressurizing the lubrication system After the oil pump has run about 11 seconds the starter energizes COMPRESSOR START CONTACT is closed and goes through its start up sequence 5 The PIC II eventually shows an alarm for motors amps not sensed Reset this alarm and continue...

Page 87: ...arging and job safety REVIEW THE START UP OPERATION AND MAINTE NANCE MANUAL OPERATING INSTRUCTIONS Operator Duties 1 Become familiar with the chiller and related equipment 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 equ...

Page 88: ...rature drops very low the operator should automatically cycle the cooling tower fans off to keep the tem perature up Piping may also be arranged to bypass the cooling tower The PIC II controls have a low limit tower fan output that can be used to assist in this control terminal J9 11 and J9 12 on ISM Manual Guide Vane Operation It is possible to manually operate the guide vanes in order to check c...

Page 89: ...trols repairs made and oil or refrigerant added or removed Include amounts Fig 46 Refrigeration Log DATE COOLER CONDENSER COMPRESSOR OPERATOR INITIALS REMARKS TIME REFRIGERANT WATER REFRIGERANT WATER BEARING TEMP OIL MOTOR PRESS TEMP PRESSURE TEMP PRESS TEMP PRESSURE TEMP PRESS DIFF TEMP RESER VOIR LEVEL FLA IN OUT GPM IN OUT IN OUT GPM IN OUT AMPERAGE OR VANE POSITION DATE ...

Page 90: ... of the valves DANGER During transfer of refrigerant into and out of the optional storage tank carefully monitor the storage tank level gage Do not fill the tank more than 90 of capacity to allow for refrigerant expansion Overfilling may result in damage to the tank or the release of refrigerant which will result in personal injury or death CAUTION Do not mix refrigerants from chillers that use di...

Page 91: ...and 10 to allow liquid refriger ant to drain by gravity 2 Push remaining liquid followed by refrigerant vapor re moval from chiller a To prepare for liquid push turn off the pumpout condenser water Place valves in the following positions b Run the pumpout compressor in manual until all liquid is pushed out of the chiller approximately 45 minutes Close valves 2 5 7 and 10 then stop compressor c Tur...

Page 92: ... to removal q Turn off pumpout condenser water r Turn off chiller water pumps and lockout chiller compressor Transfer Refrigerant from Condenser to Cooler a Turn off chiller water pumps and pumpout con denser water supply if applicable It is assumed that the starting point is as shown in the following table and that pressures in both vessels are above 35 psig 241 kPa b Set valves as shown below to...

Page 93: ...nk pressure reaches 5 psig 34 kPa 18 in Hg vacuum 41 kPa absolute in Manual or Automatic mode e Turn off the pumpout compressor f Close valves 1a 1b 2 5 and 6 g Turn off pumpout condenser water 4 Drain the contaminants from the bottom of the storage tank into a container Dispose of contaminants safely GENERAL MAINTENANCE Refrigerant Properties The standard refrigerant for the 19XR chiller is HFC 1...

Page 94: ...re reaches test level Do not exceed 140 psig 965 kPa 5 Close the charging valve on the chiller Remove the cop per tube if it is 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 solu tion or an ultrasonic leak detector Bring the chiller back to at mospheric pressure repair any l...

Page 95: ...s value should be reset to zero by the service person or the operator each time major service work is completed so that the time between ser vice can be viewed and tracked Inspect the Control Panel Maintenance consists of general cleaning and tightening of connections Vacuum the cabinet to eliminate dust build up If the chiller control mal functions refer to the Troubleshooting Guide section for c...

Page 96: ...once every 5 years or when the machine is opened for service This filter does not contain desiccant for moisture removal so changing the filter will not change the moisture indicator status Change the filter by closing the filter isolation valves and slowly opening the flare fitting with a wrench and back up wrench to relieve the pressure Change the strainers once every 5 years or whenever refrige...

Page 97: ...illed water brine circuit is adequate Inspect the entering and leaving chilled water temperature sensors and flow devices for signs of corrosion or scale Replace a sensor or Schrader fitting if corroded or remove any scale if found CONDENSER AND OPTIONAL FLOW DEVICES Since this water circuit is usually an open type system the tubes may be subject to contamination and scale Clean the condenser tube...

Page 98: ...c mode for one minute or until the vacuum switch is satisfied and com pressor shuts off 3 Move the pumpout selector switch to OFF Pumpout compressor shell should now be under vacuum 4 Oil can be added to the shell with a hand oil pump through the access valve in the compressor base Current compressor units do not have a sump access valve Add oil through 3 8 in oil recovery line between compressor ...

Page 99: ... on the ICVC default screen Fig 17 These messages will indicate where the fault is occurring These messages contain the alarm message with a specified code This code or state appears with each alarm and alert mes sage The ALARM and ALERT HISTORY tables on the ICVC SERVICE menu also contain an alarm or alert message to fur ther expand on the alarm or alert For a complete list of possi ble alarm mes...

Page 100: ... MAINSTAT manually forced to START Release SUPERVISOR force to start under normal control READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller is in recycle mode READY TO START UNOCCUPIED MODE Time schedule for PIC II is UNOCCUPIED in OCCPC01S screen Chiller will start when state changes to OCCUPIED Make sure the CURRENT TIME and DATE are correct in the TIME AND DATE screen READY TO START REMO...

Page 101: ...re sensor to cool Check compressor discharge temperature sensor wiring and accuracy to CCM J4 17 and J4 18 Check Resistance of thermistor vs temperature Check for excessive starts Check COMP DISCHARGE ALERT setting in SETUP1 screen 104 PRESTART ALERT LOW REFRIGERANT TEMP 104 Evaporator Refrig Temp VALUE exceeded limit of LIMIT Check EVAPORATOR PRESSURE CALC EVAP SAT TEMP and EVAP REFRIG LIQUID TEM...

Page 102: ...D on either side of the CONTROL POINT See TEMP_CTL screen RUNNING TEMP CONTROL TEMPERATURE RAMP LOADING Ramp Loading based on LEAVING CHILLED WATER or ENTERING CHILLED WATER is in effect PULLDOWN RAMP TYPE 0 Capacity inhibit is in effect because LEAVING CHILLED WATER or ENTERING CHILLED WATER has fallen below the ramping temperature pulldown Setpoint See RAMP_DEM screen RUNNING DEMAND LIMITED BY D...

Page 103: ...eck COMP MOTOR TEMP OVERRIDE setting in SETUP1 Check refrigerant filter drier 122 RUN CAPACITY LIMITED LOW EVAP REFRIG TEMP 122 Evaporator Refrig Temp VALUE exceeded limit of LIMIT Check refrigerant charge Check that optional cooler liquid line isolation valve is fully open Check for excessive condenser flow or low chilled water flow Check for low entering cooler water tempera ture Check that cond...

Page 104: ...7A or 17B Check for proper wiring between COMP DIS CHARGE TEMP Sensor and CCM J4 17 and J4 18 Check for disconnected grounded or shorted wiring 267 SENSOR FAULT OIL SUMP TEMP 267 Sensor Fault Check Oil Sump Temp Sensor Check sensor resistance or voltage drop against Table 17A or 17B Check for proper wiring between OIL SUMP TEMP and CCM J4 21 and J4 22 Check for disconnected grounded or shorted wir...

Page 105: ...ER FLOW VERIFY TIME settings Check load resistors optional water flow switches or water flow delta P transducer calibration and wir ing to CCM J3 13 through J3 18 Check for 5 0 V reference voltage between CCM J3 13 and J3 15 and J3 16 and J3 18 Activate Pumpdown Mode in CONTROLS TEST screen before removing refrig erant charge 230 PROTECTIVE LIMIT LOW CONDENSER WATER FLOW 230 Low Condenser Water Fl...

Page 106: ...n plate gasket bypass or plugged condenser water strainers Check for noncondensables in condenser Check CONDENSER PRESSURE transducer wiring and accuracy to CCM J2 4 through J2 6 Configure COND PRESS OVERRIDE in SETUP1 screen This Alarm is not caused by the High Condenser Pressure Switch 236 PROTECTIVE LIMIT COMPRESS SURGE LOW SPEED 236 Compressor Surge Check con denser water temp and flow Surge p...

Page 107: ...TRIPPOINT Check for proper refrigerant charge Check float valve operation Confirm that optional refrigerant liquid line isolation valve is open Check for proper Chilled Water flow and tempera ture Confirm that condenser water enters bottom row of condenser tubes first reversed condenser water flow may cause refrigerant to stack in the condenser Check EVAPORATOR PRESSURE transducer and EVAP REFRIG ...

Page 108: ...nter ISM_CONF screen and then immediately exit ISM_CONF screen by pressing EXIT then CAN CEL Next re enter the ISM_CONF screen a sec ond time so parameters stored in the ISM will be uploaded into the ICVC Confirm that the settings in the ISM_CONF screen are correct Press EXIT then SAVE to store the ISM_CONF screen set tings in both the ICVC and ISM 252 Not Used Not Used 252 Not Used 253 PROTECTIVE...

Page 109: ...ISM_HIST screen Check wiring leading to ISM terminals J1 LL1 and J1 LL2 Check control power circuit breaker control power transformer and control power circuit fuses Monitor chiller utility power for disruptions Improve ISM ground connection apply measures to reduce electrical noise to ISM Consult power company 148 AUTORESTART PENDING POWER LOSS 148 Control Power Loss When Running AUTO RESTART OPT...

Page 110: ...E 2 159 Spare Temperature 2 VALUE exceeded limit of LIMIT Check component that SPARE TEMPERATURE 2 is monitoring Check SPARE TEMP 2 ENABLE and SPARE TEMP 2 LIMIT in SET UP1 screen Check SPARE TEMPERATURE 2 sensor resistance or voltage drop Check SPARE TEMPERATURE 2 wiring to CCM J4 27 and J4 28 160 Not Used Not Used 160 Not Used 161 LOSS OF COMMUNICATION WITH WSM 161 WSM Cool Source Loss of Commun...

Page 111: ... Contactors and Aux The 1M aux or 2M aux contacts are closed during power up or the 1M aux or 2M aux contacts remain closed for an excessive delay following a STOP command Check wiring and dry contacts leading to ISM J2 9 and J2 10 and J2 11 and J2 12 205 FAILURE TO STOP MOTOR AMPS WHEN STOPPED 205 Motor Amps When Stopped Average Line Current VALUE High line current measured on any phase after pow...

Page 112: ...VOLTAGE for an excessive amount of time Check LINE VOLTAGE in ISM_HIST screen Check MOTOR RATED LINE VOLTAGE and UNDERVOLTAGE THRESHOLD in ISM_CONF screen Check phase to phase and phase to ground distribution bus voltage Check connec tions to ISM terminal block J3 Consult power com pany Medium voltage applications only Check voltage potential transformers and VOLT TRANS FORMER RATIO in ISM_CONF sc...

Page 113: ...fter the GROUND FAULT START DELAY has expired Check these settings and GROUND FAULT CT RATIO in ISM_CONF screen Check ISM_HIST screen Confirm that ground fault current transformer ori entation is correct and that the correct motor leads have been routed through the ground fault current transformers in the right direction Check for con densation on motor terminals or inside of motor leads Check mot...

Page 114: ... 98 1 644 3 049 99 1 619 2 981 100 1 595 2 914 101 1 570 2 849 102 1 546 2 786 103 1 523 2 724 104 1 499 2 663 105 1 476 2 605 106 1 453 2 547 107 1 430 2 492 108 1 408 2 437 109 1 386 2 384 110 1 364 2 332 111 1 343 2 282 112 1 321 2 232 113 1 300 2 184 114 1 279 2 137 115 1 259 2 092 116 1 239 2 047 117 1 219 2 003 118 1 200 1 961 119 1 180 1 920 120 1 161 1 879 121 1 143 1 840 122 1 124 1 801 1...

Page 115: ...914 3 861 32 1 865 3 701 33 1 816 3 549 34 1 768 3 404 35 1 721 3 266 36 1 675 3 134 37 1 629 3 008 38 1 585 2 888 39 1 542 2 773 40 1 499 2 663 41 1 457 2 559 42 1 417 2 459 43 1 377 2 363 TEMPERATURE C PIC III VOLTAGE DROP V RESISTANCE OHMS 44 1 338 2 272 45 1 300 2 184 46 1 263 2 101 47 1 227 2 021 48 1 192 1 944 49 1 158 1 871 50 1 124 1 801 51 1 091 1 734 52 1 060 1 670 53 1 029 1 609 54 0 99...

Page 116: ... 0 kPa and between 25 and 250 psig 173 and 1724 kPa To calibrate these transducers 1 Shut down the compressor cooler and condenser pumps NOTE There should be no flow through the heat exchangers 2 Disconnect the transducer in question from its Schrader fitting for cooler or condenser transducer calibration For oil pressure or flow device calibration leave the transduc er in place NOTE If the cooler...

Page 117: ...green LED is on continuously check the communica tion wiring If a green LED is off check the red LED op eration If the red LED is normal check the module ad dress switches SW1 Fig 54 and 55 Confirm all switches are in OFF position All system operating intelligence resides in the ICVC Outputs are controlled by the CCM as well 3 Power is supplied to the modules within the control panel via 24 vac po...

Page 118: ...118 CCN INTERFACE CONNECTION SW1 BACK OF CVC MODULE PART NUMBER SOFTWARE PART NUMBER J7 SIO J1 POWER CCN J8 SERVICE ICVC Fig 54 Rear of ICVC International Chiller Visual Controller a19 1868 ...

Page 119: ... VOLTAGES L1 L2 L3 IL1 LINE CURRENTS GROUND FAULTS IL2 IL3 1 4 2 5 3 6 VFD HZ INTEGRATEDSTARTERMODULE INTERGRATED STARTER MODULE 1A J1 1 1 C C C C C C J2 J3 1 J3 2 J3 3 J4 1 J5 1 G G G G 1 J6 STAT COM J7 G 1 G G J8 1 J9 1 COMM C B A 4 20 MA OUT SPARE VFD TRIP ALARM HI FAN LO FAN COND PUMP EVAP PUMP SHUNT TRIP DISCRETE CONTROL CONTACTS TRANS 1CR R WARNING HIGH VOLTAGE DISCONNECT POWER BEFORE SERVIC...

Page 120: ...elease the force on SERVICE ONTIME after the desired value has been set 9 Perform the guide vane calibration procedure in Control Test Check and recalibrate pressure transducer readings refer to pages 98 and 99 Check that the CURRENT TIME and DATE in the TIME AND DATE screen are correct Solid State Starters Troubleshooting information per taining to the Benshaw Inc solid state starter may be found...

Page 121: ...or washer s which are under the nut s in the center of the loader bar becomes loose indicating that the clamp is tight See Fig 57 On the loader bars with two indicator washers it may be necessary to tighten or loos en one side of the clamp to get both indicator washers free Reconnect the red cathode wire from the SCR and the white anode gate wire to the appropriate location on the firing card i e ...

Page 122: ... 726 338 863 915 2228 2288 330 153 392 415 41 5078 5232 783 338 930 995 2305 2375 355 153 422 452 42 5226 5424 840 338 990 1074 2373 2462 381 153 449 488 45 5363 5602 821 383 938 998 2435 2543 373 174 426 453 46 5559 5824 874 383 1014 1088 2524 2644 397 174 460 494 47 5730 6044 949 383 1083 1179 2601 2744 431 174 492 535 50 5713 6090 897 446 1101 1225 2594 2765 407 202 500 556 51 5940 6283 974 446...

Page 123: ...81 1057 1182 74 10790 11775 1584 840 2366 2622 4899 5346 719 381 1074 1190 75 10840 11859 1599 950 2183 2431 4921 5384 726 431 991 1104 76 11289 12345 1747 950 2361 2619 5125 5605 793 431 1072 1189 77 11638 12814 1869 950 2501 2801 5284 5818 849 431 1135 1272 78 11738 12949 1849 950 2548 2864 5329 5879 839 431 1157 1300 79 11828 12994 1806 950 2592 2885 5370 5899 820 431 1177 1310 7K 8728 1047 194...

Page 124: ... 5039 560 338 863 915 2226 2286 254 153 391 415 41 5078 5232 630 338 930 995 2303 2373 286 153 422 451 42 5226 5424 690 338 990 1074 2370 2460 313 153 449 487 45 5363 5602 640 383 938 998 2433 2541 290 174 425 453 46 5559 5824 720 383 1014 1088 2522 2642 327 174 460 494 47 5730 6044 790 383 1083 1179 2599 2742 358 174 491 535 50 5713 6090 750 446 1101 1225 2591 2762 340 202 499 556 51 5940 6283 84...

Page 125: ...4 381 1057 1182 74 10790 11775 1440 840 2366 2622 4899 5346 654 381 1074 1190 75 10840 11859 1365 950 2183 2431 4917 5379 619 431 990 1103 76 11289 12345 1505 950 2361 2619 5121 5600 683 431 1071 1188 77 11638 12814 1625 950 2501 2801 5279 5812 737 431 1134 1271 78 11738 12949 1625 950 2548 2864 5329 5879 738 431 1157 1300 79 11828 12994 1625 950 2592 2885 5370 5899 738 431 1177 1310 7K 8728 1047 ...

Page 126: ...E 5 2 PASS 1223 1195 61 60 555 542 231 226 FRAME 6 1 AND 3 PASS 2860 139 1297 524 FRAME 6 2 PASS 1430 1443 69 69 649 655 262 262 FRAME 7 1 AND 3 PASS 3970 309 1801 1170 FRAME 7 2 PASS 1720 1561 155 123 780 708 585 465 FRAME 8 1 AND 3 PASS 5048 364 2290 1376 FRAME 8 2 PASS 2182 1751 182 141 990 794 688 532 FRAME 2 1 AND 3 PASS 300 860 84 2068 390 318 FRAME 2 2 PASS 430 430 42 42 195 195 159 159 FRA...

Page 127: ...ER 35 16 67 30 130 59 130 59 350 159 N A N A OIL PUMP 125 57 150 68 150 68 150 68 185 84 125 57 HIGH SPEED SHAFT ASSEMBLY 15 7 12 5 30 14 30 14 65 29 94 43 IMPELLER 5 2 8 4 15 7 15 7 50 23 10 avg 5 avg INTAKE WALL 89 40 DISCHARGE WALL 85 39 DIAPHRAGM 87 39 MISCELLANEOUS Incl Low Speed Gear 135 61 135 61 144 65 200 91 235 107 390 177 TOTAL COMPRESSOR WEIGHT Less Motor and Elbows 2300 1043 2816 1277...

Page 128: ...05 122 635 130 124 CQS 2816 1353 276 1408 290 274 1277 614 125 639 132 124 CRS 2816 1259 321 274 1277 571 146 124 CRS 380V 2816 1328 346 274 1277 602 157 124 HIGH EFFICIENCY MOTORS LOW VOLTAGE 200 575 V CBH 2816 1235 239 1290 254 274 1277 560 108 585 115 124 CCH 2816 1260 249 1295 259 274 1277 572 113 587 117 124 CDH 2816 1286 258 1358 273 274 1277 583 117 616 124 124 CEH 2816 1305 265 1377 279 27...

Page 129: ... BELL COVER WEIGHT LB COMPRESSOR WEIGHT KG 60 HZ 50 HZ END BELL COVER WEIGHT KG STATOR WEIGHT LB ROTOR WEIGHT LB STATOR WEIGHT LB ROTOR WEIGHT LB STATOR WEIGHT KG ROTOR WEIGHT KG STATOR WEIGHT KG ROTOR WEIGHT KG HIGH EFFICIENCY MOTORS MEDIUM VOLTAGE 2400 4160 V CBH 2816 1114 242 1156 255 274 1277 505 110 524 116 124 CCH 2816 1129 247 1163 257 274 1277 512 112 528 117 124 CDH 2816 1155 253 1190 263...

Page 130: ...4211 1524 296 1637 327 236 1554 1910 691 134 743 148 107 DCS 3425 4211 1569 307 1685 354 236 1554 1910 712 139 764 161 107 DDS 3425 4211 1588 313 1713 357 236 1554 1910 720 142 777 162 107 DES 3425 4211 1613 324 1746 360 236 1554 1910 732 147 792 163 107 DFS 3425 4211 1675 347 1811 381 236 1554 1910 760 157 821 173 107 DGS 3425 4211 1704 355 1998 422 236 60 Hz 318 50 Hz 1554 1910 773 161 906 191 1...

Page 131: ...1 197 144 LFH 3425 4211 2096 434 2133 444 318 1554 1910 951 197 968 201 144 LGH 3425 4211 2133 444 2199 458 318 1554 1910 968 201 997 208 144 LHH 3425 4211 2199 458 2066 437 318 1554 1910 997 208 937 198 144 HIGH EFFICIENCY MOTORS MEDIUM VOLTAGE 2400 4160V DBH 3425 4211 1950 405 1950 405 318 1554 1910 885 184 885 184 144 DCH 3425 4211 1950 405 2025 429 318 1554 1910 885 184 919 195 144 DDH 3425 42...

Page 132: ... 282 188 STANDARD EFFICIENCY MOTORS MEDIUM VOLTAGE 2400 4160 V EHS 7285 2744 706 2818 741 414 3304 1245 320 1278 336 188 EJS 7285 2816 741 2892 775 414 3304 1277 336 1312 352 188 EKS 7285 2816 741 2930 775 414 3304 1277 336 1329 352 188 ELS 7285 2808 741 3005 810 414 3304 1274 336 1363 367 188 EMS 7285 2892 775 3005 810 414 3304 1322 352 1363 367 188 ENS 7285 2997 775 3143 879 414 3304 1359 352 14...

Page 133: ... 414 3304 1393 334 188 HIGH EFFICIENCY MOTORS MEDIUM VOLTAGE 2400 4160 V EHH 7285 2939 776 2997 810 414 3304 1333 352 1359 367 188 EJH 7285 2999 810 3108 862 414 3304 1360 367 1410 391 188 EKH 7285 2988 810 3102 862 414 3304 1355 367 1407 391 188 ELH 7285 2981 810 3065 872 414 3304 1352 367 1390 396 188 EMH 7285 3031 855 3077 872 414 3304 1375 388 1396 396 188 ENH 7285 3075 872 3260 974 414 3304 1...

Page 134: ...2 1359 367 188 6L 4853 2932 775 2997 810 414 2201 1330 352 1359 367 188 6M 4853 2986 810 3096 862 414 2201 1354 367 1404 391 188 6N 4853 2986 810 3203 914 414 2201 1354 367 1453 415 188 6P 4853 2986 810 3203 914 414 2201 1354 367 1453 415 188 STANDARD EFFICIENCY MOTORS MEDIUM VOLTAGE 2400 4160 V 6H 4853 2744 706 2818 741 414 2201 1245 320 1278 336 188 6J 4853 2816 741 2892 775 414 2201 1277 336 13...

Page 135: ...1392 334 188 MF 4853 3034 724 3153 791 414 2201 1376 328 1430 359 188 MG 4853 3071 737 414 2201 1393 334 188 HIGH EFFICIENCY MOTORS MEDIUM VOLTAGE 2400 4160 V EH 4853 2939 776 2997 810 414 2201 1333 352 1359 367 188 EJ 4853 2999 810 3108 862 414 2201 1360 367 1410 391 188 EK 4853 2988 810 3102 862 414 2201 1355 367 1407 391 188 EL 4853 2981 810 3065 872 414 2201 1352 367 1390 396 188 EM 4853 3031 ...

Page 136: ... 300 psig 253 288 433 468 433 468 NIH Plain End Cover 300 psig 175 175 291 291 291 291 MWB End Cover 300 psig 619 619 619 619 MWB Return Cover 300 psig 445 445 445 445 WATERBOX DESCRIPTION CONDENSER FRAME 1 FRAME 2 FRAME 3 STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED NIH 1 Pass Cover 150 psig 177 204 260 297 260 297 NIH 2 Pass Cover 150 psig 185 218 265 318 265 318 NI...

Page 137: ...8 1053 NIH 2 Pass Cover 300 psig 626 689 761 867 927 1078 NIH 3 Pass Cover 300 psig 660 694 795 830 997 1050 NIH MWB End Cover 300 psig 522 522 658 658 834 834 WATERBOX DESCRIPTION CONDENSER FRAME 4 FRAME 5 FRAME 6 STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED NIH 1 Pass Cover 150 psig 148 185 168 229 187 223 NIH 2 Pass Cover 150 psig 191 245 224 298 245 330 NIH 3 Pass...

Page 138: ...9 2523 NIH 2 Pass Cover 300 psig 1662 1908 2369 2599 NIH 3 Pass Cover 300 psig 1724 1807 2353 2516 NIH MWB End Cover 300 psig 1378 1378 1951 1951 WATERBOX DESCRIPTION CONDENSER FRAME 7 FRAME 8 STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED NIH 1 Pass Cover 150 psig 329 441 417 494 NIH 2 Pass Cover 150 psig 404 520 508 662 NIH 3 Pass Cover 150 psig 1222 1280 1469 1527 MWB End Cover 150 psig 781 ...

Page 139: ...2068 kPa 115 131 196 212 196 212 NIH Plain End Cover 2068 kPa 79 79 132 132 132 132 MWB End Cover 2068 kPa 281 281 281 281 MWB Return Cover 2068 kPa 202 202 202 202 WATERBOX DESCRIPTION CONDENSER FRAME 1 FRAME 2 FRAME 3 STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED NIH 1 Pass Cover 1034 kPa 80 92 118 135 118 135 NIH 2 Pass Cover 1034 kPa 84 99 120 144 120 144 NIH 3 Pas...

Page 140: ...4 478 NIH 2 Pass Cover 2068 kPa 284 313 345 394 420 489 NIH 3 Pass Cover 2068 kPa 299 315 361 376 452 476 NIH MWB End Cover 2068 kPa 237 237 298 298 378 378 WATERBOX DESCRIPTION CONDENSER FRAME 4 FRAME 5 FRAME 6 STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED NIH 1 Pass Cover 1034 kPa 67 84 76 104 85 101 NIH 2 Pass Cover 1034 kPa 87 111 102 135 111 150 NIH 3 Pass Cover 1...

Page 141: ...7 854 1070 1144 NIH 2 Pass Cover 2068 kPa 754 865 1075 1179 NIH 3 Pass Cover 2068 kPa 782 820 1067 1141 NIH MWB End Cover 2068 kPa 625 625 885 885 WATERBOX DESCRIPTION CONDENSER FRAME 7 FRAME 8 STANDARD NOZZLES FLANGED STANDARD NOZZLES FLANGED NIH 1 Pass Cover 1034 kPa 149 200 189 224 NIH 2 Pass Cover 1034 kPa 183 236 230 300 NIH 3 Pass Cover 1034 kPa 554 580 666 693 MWB End Cover 1034 kPa 354 354...

Page 142: ... 460 V 605 680 A 1600 726 1600 726 STD TIER VFD 380 400 AND 460 V 765 A 1600 726 STD TIER VFD 380 400 AND 460 V 855 960 1070 A 1600 726 1600 726 1600 726 STD TIER VFD 380 400 AND 460 V 1275 A 3000 1361 3000 1361 3000 1361 STD TIER VFD 380 400 AND 460 V 1530 A 3000 1361 3000 1361 LIQUIFLO 2 VFD 380 400 AND 460 V 442 A 1600 726 1600 726 LIQUIFLO 2 VFD 380 400 AND 460 V 608 A 1600 726 1600 726 LIQUIF...

Page 143: ...Low Speed Journal Motor End 0050 0040 0050 0040 0053 0043 0053 0043 0065 0055 0065 0055 C1 Low Speed Labyrinth to Thrust Disk 0115 0055 N A 010 005 N A N A N A C2 Labyrinth to Low Speed Shaft N A 010 005 0095 0055 0095 0055 013 009 013 009 D Low Speed Shaft Thrust Float 020 008 020 008 023 008 023 008 020 008 020 008 E Impeller Eye to Shroud F1 Impeller Bore to Shaft Rear 0020 0005 0025 0010 0014 ...

Page 144: ...SPEED SHAFT THRUST DISK FRAME 2 COMPRESSORS VIEW A2 LOW SPEED SHAFT THRUST DISK FRAME 3 4 AND 5 COMPRESSORS a19 1636 a19 1637 P O F1 H E F2 K I J IMPELLER SHIMMING TO BE DETERMINED AT ASSEMBLY SEE VIEW C THRUST SEE NOTE 5 G L VIEW B HIGH SPEED SHAFT ORIGINAL DESIGN OIL FILM BEARINGS AND IMPELLER SECTION a19 1639 ...

Page 145: ...ERFERENCE 0 0011 0 0013 INTERFERENCE 0 0007 0 0007 0 0050 0 0020 0 0012 0 0004 VIEW B HIGH SPEED SHAFT WITH ROLLING ELEMENT BEARINGS Fig 58 Compressor Fits and Clearances Single Stage Compressors cont a19 1640 N M VIEW C HIGH SPEED SHAFT RING SEAL a19 1641 ...

Page 146: ...NT BEARINGS A Low Speed Journal Gear End 0069 0059 B Low Speed Journal Motor End 0065 0059 C1 Low Speed labyrinth to thrust Disk N A C2 Labyrinth to Low Speed Shaft 013 009 D Low Speed Shaft thrust Float 20 008 LEGEND 1 Oil Heater Retaining Nut 2 Bull Gear Retaining Bolt 3 Demister Bolts 4 First Impeller Nut Inner 5 Second Impeller Nut Outer 6 Guide Vane Shaft Seal Not Shown ...

Page 147: ...or Fits and Clearances Two Stage Compressors cont VIEW E VIEW D REAR HIGH SPEED SHAFT BEARING 0 0007 0 0007 0 017 0 017 0 003 0 0011 0 008 0 027 Interference fit THRUST C1 C2 B VIEW A2 LOW SPEED SHAFT THRUST DISK a19 1637 ...

Page 148: ...AST FOUR LAYERS OF APPROPRIATE ELECTRICAL INSULATING TAPE 1 2 3 12 6 4 5 MOTOR LEAD INSTALLATION LABELS 19XR XRV COMPRESSOR ASSEMBLY TORQUES FRAME 2 5 Not shown 19XR XRV COMPRESSOR ASSEMBLY TORQUES FRAME E Fig 60 Compressor Assembly Torques Single and Two Stage Compressors ITEM COMPRESSOR FRAME 2 FRAME 3 FRAME 4 FRAME 5 CODE 201 299 2ZZ 321 389 3ZZ 32E 38H 421 487 4B1 4W7 501 599 1 Oil Heater Reta...

Page 149: ...l Conn Denotes Motor Starter Panel Conn Fig 61 Power Panel Wiring Schematic FR Frame G Ground GRD Ground GVA Guide Vane Actuator HGBP Hot Gas Bypass HT EXCH Heat Exchanger ISM Integrated Starter Module L Main Supply Power N O Normally Open PRESS Pressure REQM T Requirement T Transformer TB Terminal Board Denotes Component Terminal Wire Splice Denotes Conductor Male Female Conne Option Wiring LEGEN...

Page 150: ...150 Fig 62 PIC II Control Panel Wiring Schematic Frame 2 3 4 and E Compressors without Split Ring Diffuser a19 1870 ...

Page 151: ...151 Fig 62 PIC II Control Panel Wiring Schematic Frame 2 3 4 and E Compressors without Split Ring Diffuser cont a19 1870 ...

Page 152: ...152 a19 1871 Fig 63 PIC II Control Panel Wiring Schematic Frame 4 and 5 Compressors with Split Ring Diffuser ...

Page 153: ...ator EXT External FR Frame GND Ground G V Guide Vane HGBP Hot Gas Bypass HT EXCH Heat Exchanger ICVC International Chiller Visual Controller ISM Integrated Starter Module L Main Supply Power LVG Leaving N O Normally Open PRESS Pressure REQM T Requirement TEMP Temperature TB Terminal Board UPC UPC Open Controller Denotes Control Panel Terminal Denotes Oil Pump Terminal Denotes Power Panel Terminal ...

Page 154: ...154 Fig 64 Benshaw Inc Wye Delta Unit Mounted Starter Wiring Schematic Low Voltage a19 1873 ...

Page 155: ... terminal block Terminal Strip Power Connection PC Board Terminals Twisted Pair Twisted Shielded Pair Shield Wire Field Wiring LEGEND NOTES LED status with power applied and prior to run command Transformer T1 primary fuses FU1 FU2 value dependent on system voltage and model per Chart 1 Transformer connections per transformer nameplate connection diagram MOVs are used on power stack assemblies for...

Page 156: ...ormer T1 primary fuses FU1 FU2 value dependent on system voltage and model per Chart 1 Transformer connec tions per transformer nameplate connection diagram CT1 CT3 are sized per Chart 2 Optional for all starters CT7 CTI2 are optional for all starters Circuit breaker CB2 rated at 30 amps for models 19XRA 19XRC 19XTR 1 2 3 4 5 6 ON OFF 7 8 9 ...

Page 157: ...0 3900 1 601 740 3900 1 741 855 5760 1 856 1250 5760 1 CHART 3 STARTER RLA RANGE L1 L2 L3 CONDUCTORS PER PHASE LOAD SIDE 95 205 262 MCM DLO BLK 1 cond per phase 206 259 373 MCM DLO BLK 1 cond per phase 260 298 373 MCM DLO BLK 1 cond per phase 299 398 262 MCM DLO BLK 2 cond per phase 399 501 262 MCM DLO BLK 2 cond per phase 502 597 373 MCM DLO BLK 2 cond per phase 598 687 373 MCM DLO BLK 2 cond per...

Page 158: ...High Pressure Relay ISM Integrated Starter Module L Main Power Supply LL Control Power Supply LVG Leaving M Contactor MTR Motor PRESS Pressure PT Power Transformer ST Shunt Trip STAT Status TB Terminal Block TRANS Transition VFD Variable Frequency Drive VL Wire Label Starter Vendor Power Wiring Starter Vendor Control Wiring Field Installed Power Wiring supplied by others Field Installed Control Wi...

Page 159: ...High Pressure Relay ISM Integrated Starter Module L Main Power Supply LL Control Power Supply LVG Leaving M Contactor MTR Motor PRESS Pressure PT Power Transformer ST Shunt Trip STAT Status TB Terminal Block TRANS Transition VFD Variable Frequency Drive VL Wire Label Starter Vendor Power Wiring Starter Vendor Control Wiring Field Installed Power Wiring supplied by others Field Installed Control Wi...

Page 160: ...sformer HPR High Pressure Relay ISM Integrated Starter Module L Main Power Supply LL Control Power Supply MTR Motor PRESS Pressure PT Power Transformer ST Shunt Trip STAT Status TB Terminal Block TC Transition Clear TRANS Transition VFD Variable Frequency Drive VL Wire Label Starter Vendor Power Wiring Starter Vendor Control Wiring Field Installed Power Wiring supplied by others Field Installed Co...

Page 161: ...161 Fig 69 Typical Low Voltage Variable Frequency Drive VFD Wiring Schematic 575 v ...

Page 162: ...162 Fig 69 Typical Low Voltage Variable Frequency Drive VFD Wiring Schematic 575 v cont ...

Page 163: ...163 Fig 69 Typical Low Voltage Variable Frequency Drive VFD Wiring Schematic 575 v cont a19 1880 ...

Page 164: ...ariable Frequency Drive 1C Compressor Oil Heater Contactor 1M Start Contactor 2C Oil Pump Contactor 3C Hot Gas Bypass Relay Field Control Wiring Field Power Wiring Factory Wiring Shielded Cable Twisted Pair Wiring Male Female Connector Terminal Block Connection Wire Splice or Junction Cam Switch Component Terminal Thermistor Transducer Fusible Link Potentiometer Pressure Switch Compr Oil Pump Term...

Page 165: ...ge 2 System Feeder Short Circuit Ground Fault and Protection A Evaporator Liquid Pump Starter Disconnect B Evaporator Liquid Pump Motor Starter C Condenser Liquid Pump Starter Disconnect D Condenser Liquid Pump Motor Starter E Cooling Tower Fan Motor Starter Disconnect Low Fan 1 F Cooling Tower Fan Motor Starter Low Fan 1 G Cooling Tower Fan Motor Starter Disconnect High Fan 2 H Cooling Tower Fan ...

Page 166: ...166 Fig 70 19XR Typical Wiring with Unit Mounted Variable Frequency Drive with ISM Integrated Starter Module a19 2078 NOTE See Legend on page 165 ...

Page 167: ...167 Fig 70 19XR Typical Wiring with Unit Mounted Variable Frequency Drive with ISM Integrated Start Module cont a19 1714 ...

Page 168: ...e an inner diameter of 23 4 in Caution should be taken when selecting power wiring so that all power cables can pass through the CTs III CONTROL WIRING 3 0 Field supplied control conductors to be at least 18 AWG or larger 3 1 Ice build start terminate device contacts remote start stop device contacts and spare safety device contacts devices not supplied by Carrier must have 24 VAC rating MAX curre...

Page 169: ... Surge Suppressor ST Shunt Trip VFD Variable Frequency Drive VSBx Voltage Sensing Board WRN Warning Relay XIOx External Inputs Outputs 1M Start Relay 66 Carrier ISM to be programmed by Carrier before start up Relay contacts shown without signal power applied 71 Calibrate for 4 20 mA 0 5 vdc Default 0 10 vdc 100 WARNING Ground must be connected to prevent high voltages from being applied to drive c...

Page 170: ...OOLING FAN MAIN FAN CONTACTOR MAIN FAN MOTOR PROTECTOR DISCONNECT SWITCH 1 CONTROL POWER TRANSFORMER ISOLATED GATE DRIVE POWER SUPPLY LINE VOLTAGE SEE JOBSHEET FIELD SUPPLIED FOR VFD USE ONLY CHILLER CONTROL POWER MUST BE FIELD SUPPLIED SEPARATELY 3 LV AND 1 115 V POWER SUPPLY IS REQUIRED AND MUST BE FIELD SUPPLIED WITH BRANCH CIRCUIT PROTECTION 8 kVA MINIMUM REQUIRED Fig 71 Typical Medium Voltage...

Page 171: ...T2 OIL HEATER CONTACTOR 11 12 13 21 22 23 11 12 13 21 22 23 3 1 6 5 4 2 51 50 43 17 C B A OIL PUMP CONTACTOR CHILLER POWER PANEL 115 V 230 V 1 PH FIELD SUPPLIED 1 5 KVA MINIMUM 3 PH FIELD SUPPLIED OIL PUMP POWER FIELD SUPPLIED GROUND FIELD SUPPLIED GROUND FIELD SUPPLIED GROUND LINE VOLTAGE FIELD SUPPLIED Fig 71 Typical Medium Voltage Variable Frequency Drive VFD Wiring Schematic cont a19 2065 ...

Page 172: ...NTROL PANEL DRIVE INPUT CONTACTOR TERMINAL BLOCK VFD UNIT SECTION 1A FIELD USE WIRE TO DRIVE TERMINAL BLOCK 1 12 AWG WIRE TO DRIVE TERMINAL BLOCK 1 12 AWG WIRE TO DRIVE TERMINAL BLOCK 1 12 AWG TO CARRIER CHILLER POWER PANEL WIRE TO DRIVE INPUT CONTACTOR TERMINAL BLOCK DRIVE TERMINAL BLOCK VFD UNIT SECTION 5A DRIVE TERMINAL BLOCK 2 VFD UNIT SECTION 3A TO DRIVE UNIT SECTION 5A Fig 71 Typical Medium ...

Page 173: ...MER IS FOR VFD CONTROL POWER ONLY CHILLER CONTROL POWER MUST BE PROVIDED AS A SEPARATE SOURCE FIELD SUPPLIED VFD UNIT SECTION 1A MODULE WIRING Fig 71 Typical Medium Voltage Variable Frequency Drive VFD Wiring Schematic cont a19 2062 ...

Page 174: ...174 CHILLER MOTOR FIELD SUPPLIED GROUND Fig 71 Typical Medium Voltage Variable Frequency Drive VFD Wiring Schematic cont a19 2063 ...

Page 175: ...175 MAIN COOLING FAN FIELD SUPPLIED GROUND FIELD SUPPLIED WITH BRANCH CIRCUIT PROTECTION 8 kVa MINIMUM REQUIRED Fig 71 Typical Medium Voltage Variable Frequency Drive VFD Wiring Schematic cont a19 2061 ...

Page 176: ...176 CONTINUED ON NEXT PAGE Fig 71 Typical Medium Voltage Variable Frequency Drive VFD Wiring Schematic cont a19 2064 ...

Page 177: ...177 CONTINUED FROM PREVIOUS PAGE Fig 71 Typical Medium Voltage Variable Frequency Drive VFD Wiring Schematic cont a19 2066 ...

Page 178: ...ut signal is designed for controllers with a non grounded 4 20 mA input signal and a maximum input impedance of 500 ohms IV POWER WIRING BETWEEN FREE STANDING VFD AND COMPRESSOR MOTOR 4 0 Medium voltage over 600 volts compressor motors have 3 terminals Connections are 9 16 in threaded stud A compression lug with a single 9 16 in diameter hole can be connected directly to the stud or 3 adapters are...

Page 179: ...uting SERVICE EQUIPMENT CONFIGURATION NET_OPT x Amps or KW Ramp Min SERVICE EQUIPMENT SERVICE RAMP_DEM X Amps KW Ramp SERVICE CONTROL ALGORITHM STATUS CAPACITY Auto Chilled Water Reset STATUS MAINSTAT Auto Demand Limit Input STATUS MAINSTAT Auto Restart Option SERVICE EQUIPMENT SERVICE OPTIONS X Average Line Current STATUS MAINSTAT Average Line Current STATUS POWER Average Line Voltage STATUS POWE...

Page 180: ... Approach STATUS HEAT_EX Condenser Freeze Point SERVICE EQUIPMENT SERVICE SETUP1 X Condenser Pressure STATUS HEAT_EX Condenser Pressure SERVICE CONTROL ALGORITHM STATUS OVERRIDE Condenser Refrig Temp STATUS HEAT_EX Condenser Refrig Temp SERVICE CONTROL ALGORITHM STATUS OVERRIDE Condenser Water Delta P STATUS HEAT_EX Condenser Water Flow STATUS STARTUP Control Mode STATUS MAINSTAT Control Point STA...

Page 181: ...LGORITHM STATUS ISM_HIST Ground Fault Phase 3 STATUS POWER Ground Fault Phase 3 SERVICE CONTROL ALGORITHM STATUS ISM_HIST Ground Fault Protection SERVICE ISM STARTER CONFIG DATA ISM_CONF X Ground Fault Start Delay SERVICE ISM STARTER CONFIG DATA ISM_CONF X Group Number SERVICE EQUIPMENT CONFIGURATION NET_OPT x Guide Vane 25 Load 2 SERVICE EQUIPMENT SERVICE VDO_SRD X Guide Vane 50 Load 2 SERVICE EQ...

Page 182: ...ICE VDO_SRD X Line Current Phase 1 STATUS POWER Line Current Phase 1 SERVICE CONTROL ALGORITHM STATUS ISM_HIST Line Current Phase 2 STATUS POWER Line Current Phase 2 SERVICE CONTROL ALGORITHM STATUS ISM_HIST Line Current Phase 3 STATUS POWER Line Current Phase 3 SERVICE CONTROL ALGORITHM STATUS ISM_HIST Line Frequency SERVICE CONTROL ALGORITHM STATUS ISM_HIST Line Frequency Faulting SERVICE ISM ST...

Page 183: ...EQUIPMENT SERVICE SETUP2 X Proportional Inc Band SERVICE EQUIPMENT SERVICE SETUP2 X Pulldown Ramp Type SERVICE EQUIPMENT SERVICE RAMP_DEM X PULLDOWN Time SERVICE CONTROL ALGORITHM STATUS LL_MAINT PULLDOWN Timer SERVICE EQUIPMENT SERVICE LEADLAG X Pulldown Delta T Min SERVICE CONTROL ALGORITHM STATUS LL_MAINT Pulldown Satisfied SERVICE CONTROL ALGORITHM STATUS LL_MAINT Ramp Loading Active SERVICE C...

Page 184: ...arter Trans Relay STATUS STARTUP Starter Type SERVICE ISM STARTER CONFIG DATA ISM_CONF X Starts In 12 Hours STATUS MAINSTAT Superheat Required SERVICE CONTROL ALGORITHM STATUS OVERRIDE Surge Counts SERVICE CONTROL ALGORITHM STATUS SURGEPREV Surge Delay Time SERVICE EQUIPMENT SERVICE OPTIONS X Surge Delta Amps SERVICE EQUIPMENT SERVICE OPTIONS X Surge Limit HGBP Option SERVICE CONTROL ALGORITHM STA...

Page 185: ...ctor SERVICE CONTROL ALGORITHM STATUS SURGEPREV VFD Maximum Speed SERVICE EQUIPMENT SERVICE SETUP2 X VFD Minimum Speed SERVICE EQUIPMENT SERVICE SETUP2 X VFD Option SERVICE EQUIPMENT SERVICE SETUP2 X VFD Rampdown Active SERVICE CONTROL ALGORITHM STATUS SURGEPREV VFD Speed Factor SERVICE CONTROL ALGORITHM STATUS SURGEPREV VFD Start Speed SERVICE EQUIPMENT SERVICE SETUP2 X VFD Surge Line Gain SERVIC...

Page 186: ...186 APPENDIX B LEAD LAG WIRING 19XR Lead Lag Schematic Series Cooler Flow a19 1655 ...

Page 187: ...187 APPENDIX B LEAD LAG WIRING cont 19XR Lead Lag Schematic Parallel Cooler Flow a19 1717 ...

Page 188: ...for analysis Change oil if required by analysis Leak test CONTROLS Perform general cleaning Tighten connections Check pressure transducers Confirm accuracy of thermistors COOLER Inspect and clean cooler tubes Inspect relief valves Leak test Verify water pressure dif ferential Inspect water pumps and cooling tower STARTER Perform general cleaning Tighten connections Change VFD refrigerant strainer ...

Page 189: ...k Test PPM Record Water Pressure Differential PSI PSI Inspect Water Pumps yes no Eddy Current Test yes no CONDENSER Leak Test PPM Inspect and Clean Condenser Tubes yes no Record Water Pressure Differential PSI PSI Inspect Water Pumps and Cooling Tower yes no Inspect Relief Valves yes no Replace Refrigerant Filter Drier yes no Inspect Float Valve and Strainer yes no Eddy Current Test yes no CONTROL...

Page 190: ...quirements are not covered under warranty MONTH 1 2 3 4 5 6 7 8 9 10 11 12 DATE OPERATOR UNIT SECTION ACTION ENTRY COOLER Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes CONDENSER Isolate and Drain Waterbox Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes CONTROLS Do Not Disconnect Control Power ...

Page 191: ...d the arrow on the Ones 1 s switch to 5 BACNET DEVICE INSTANCE ADDRESS The UPC Open controller also has a BACnet Device Instance address This Device Instance MUST be unique for the complete BAC net system in which the UPC Open controller is installed The Device Instance is auto generated by default and is derived by adding the MAC address to the end of the Network Number The Network Number of a ne...

Page 192: ...ntroller communicates using BACnet on an MS TP network segment communications at 9600 bps 19 2 kbps 38 4 kbps or 76 8 kbps Wire the controllers on an MS TP network segment in a dai sy chain configuration Wire specifications for the cable are 22 AWG American Wire Gage or 24 AWG low capacitance twisted stranded shielded copper wire The maximum length is 2000 ft Install a BT485 terminator on the firs...

Page 193: ...MMMENDATION CABLE Single twisted pair low capacitance CL2P 22 AWG 7x30 TC foam FEP plenum rated cable CONDUCTOR 22 or 24 AWG stranded copper tin plated INSULATION Foamed FEP 0 015 in 0 381 mm wall 0 060 in 1 524 mm O D COLOR CODE Black White TWIST LAY 2 in 50 8 mm lay on pair 6 twists foot 20 twists meter nominal SHIELDING Aluminum Mylar shield with 24 AWG TC drain wire JACKET SmokeGard Jacket Smo...

Page 194: ...oth the ComfortLink and UPC Open configurations must be changed The following configurations are used to set the CCN Ad dress and Bus number in the ComfortLink control These con figurations can be changed using the scrolling marquee display or accessory Navigator handheld device Configuration CCN CCN A CCN Address Configuration CCN CCN B CCN Bus Number The following configurations are used to set ...

Page 195: ...pen controller is protected by internal solid state polyswitches on the incoming power and network connections These polyswitches are not replaceable and will reset themselves if the condition that caused the fault returns to normal RX Lights when the controller receives data from the network segment there is an Rx LED for Ports 1 and 2 TX Lights when the controller transmits data to the network s...

Page 196: ...stpt_1 Cond Water Flow CDW_FLOW R BV 6 cdw_flow_1 Cond Water Pump CDP R BV 7 cdp_1 Current CHW Setpoint CHWSTPT R F AV 25 chwstpt_1 Demand Level 1 N A R AV 1 dmv_lvl_1_perct_ 1 Demand Level 2 N A R AV 2 dmv_lvl_2_perct_ 1 Demand Level 3 N A R AV 3 dmv_lvl_3_perct_ 1 Element Communications Alarm N A R BV 20 com m_lost_alm_1 Element Comm Status N A R BV 2999 element_stat_1 Emergency Stop EMSTOP R BV...

Page 197: ..._out_1 Twr Fan Relay High TFR_LOW R BV 13 tfr_high_1 Twr Fan Relay Low TFR_HIGH R BV 14 tfr_low_1 User Defined Analog 1 N A R AV 2901 user_analog_1_1 User Defined Analog 2 N A R AV 2902 user_analog_2_1 User Defined Analog 3 N A R AV 2903 user_analog_3_1 User Defined Analog 4 N A R AV 2904 user_analog_4_1 User Defined Analog 5 N A R AV 2905 user_analog_5_1 User Defined Binary 1 N A R BV 2911 user_b...

Page 198: ...otation Check 86 Notes on Module Operation 117 Oil Changes 96 Oil Charge 73 Oil Cooler 54 Oil Pressure and Compressor Stop Check 86 Oil Reclaim Filter 96 Oil Reclaim System 14 Oil Specification 96 Oil Sump Temperature and Pump Control 52 Open Oil Circuit Valves 67 Operating Instructions 87 88 Operating the Optional Pumpout Unit 90 Operator Duties 87 Optional Pumpout Compressor Water Piping Check 7...

Page 199: ... No 4 Applicable Design Data see above Yes No 5 Diagrams and Instructions for Special Controls Yes No INITIAL MACHINE PRESSURE NOTE To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start up checklist use good judgment follow safe practices and adhere to the safety considerations information as outlined in preceding sec tions of this Sta...

Page 200: ...Refrigerant section B Complete any remaining control calibration and record under Controls section C Take at least two sets of operational log readings and record D After machine has been successfully run and set up shut down and mark shutdown oil and refrigerant levels E Give operating instructions to owner s operating personnel Hours Given Hours F Call your Carrier factory representative to repo...

Page 201: ...BUS ADDRESS DESCRIPTION RANGE UNITS DEFAULT VALUE Base Demand Limit 40 to 100 100 LCW Setpoint 10 to 120 9 4 to 48 9 DEG F DEG C 50 0 10 0 ECW Setpoint 15 to 120 12 2 to 48 9 DEG F DEG C 60 0 15 6 Ice Build Setpoint 15 to 60 9 4 to 15 6 DEG F DEG C 40 0 4 4 Tower Fan High Setpoint 55 to 105 13 to 41 DEG F DEG C 75 24 ...

Page 202: ...pied Time M T W T F S S H Period 1 Period 2 Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 ICE BUILD 19XR XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag Occupied Time Unoccupied Time M T W T F S S H Period 1 Period 2 Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 19XR XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S Day Flag Occupied Time Unoccupied Time M T W T ...

Page 203: ...C 5 Motor Rated Load Amps 10 to 5000 AMPS 200 Motor Locked Rotor Trip 100 to 60000 AMPS 1000 Locked Rotor Start Delay 1 to 10 cycles 5 Starter LRA Rating 100 to 60000 AMPS 2000 Motor Current CT Ratio 1 10 to 1000 100 Current Imbalance 5 to 40 15 Current Imbalance Time 1 to 10 SEC 5 Grnd Fault CT s 0 1 NO YES YES Ground Fault CT Ratio 1 150 150 Ground Fault Current 1 to 25 AMPS 15 Ground Fault Star...

Page 204: ...GBP Delta Tsmax 0 0 to 150 0 ˆF 70 Surge HGBP IGVmax 0 0 to 110 0 5 0 Surge Line Shape Factor 1 000 to 0 000 0 040 Surge Line Speed Factor 0 00 to 3 00 1 85 Surge Line High Offset 0 1 to 3 0 1 0 Surge HGBP Deadband 0 5 to 3 ˆF 1 HGBP On Delta T 0 5 to 10 0 ˆF 2 0 HGBP Off Delta T 0 5 to 10 0 ˆF 4 0 Surge Protection Surge Delta Amps 5 to 40 20 Surge Time Period 7 to 10 MIN 8 Surge Delay Time 0 to 1...

Page 205: ...n mA 15 to 22 mA 18 0 Guide Vane 25 Load 2 0 to 83 6 4 Guide Vane 50 Load 2 0 to 83 22 9 Guide Vane 75 Load 2 0 to 83 41 3 SRD 25 Load 1 0 to 100 73 5 SRD 50 Load 1 0 to 100 35 1 SRD 75 Load 1 0 to 100 19 5 Lift 25 Load 1 0 to 100 0 to 55 6 F C 52 4 29 1 Lift 100 Load 1 0 to 100 0 to 55 6 F C 67 5 37 5 Lift 25 Load 2 0 to 100 0 to 55 6 F C 27 2 15 1 SRD IGV Offset Select 1 to 5 3 Low Lift Profile ...

Page 206: ...ap Approach Alert 0 5 to 15 1 1 to 2 8 ˆF ˆC 5 2 8 Cond Approach Alert 0 5 to 15 0 3 to 8 3 ˆF ˆC 6 3 3 Condenser Freeze Point 20 to 35 28 9 to 1 7 DEG F DEG C 34 1 1 Flow Delta P Display 0 1 DSABLE ENABLE DSABLE Evap Flow Delta P Cutout 0 5 to 50 0 3 4 to 344 8 ˆPSI ˆkPa 5 0 34 5 Cond Flow Delta P Cutout 0 5 to 50 0 3 4 to 344 8 ˆPSI ˆkPa 5 0 34 5 Cond Hi Flow Alarm Option 0 1 DSABLE ENABLE DSABL...

Page 207: ...C Band 2 to 10 6 0 Proportional ECW Gain 1 to 3 2 0 Guide Vane Travel Limit 30 to 100 80 VFD Speed Control VFD Option 0 1 DSABLE ENABLE DSABLE VFD Gain 0 1 to 1 5 0 75 VFD Increase Step 1 to 5 2 VFD Minimum Speed 65 to 100 70 VFD Maximum Speed 90 to 100 100 VFD Start Speed 65 to 100 100 VFD Surge Line Gain 2 0 to 3 5 2 0 VFD Current Limit 0 to 99999 amps 250 ...

Page 208: ... LAG 2 STANDBY 3 0 to 3 0 Load Balance Option 0 1 DSABLE ENABLE DSABLE Common Sensor Option 0 1 DSABLE ENABLE DSABLE LAG Capacity 25 to 75 50 LAG Address 1 to 236 92 LAG START Timer 2 to 60 MIN 10 LAG STOP Timer 2 to 60 MIN 10 PRESTART FAULT Timer 2 to 30 MIN 5 PULLDOWN Timer 1 to 30 MIN 2 STANDBY Chiller Option 0 1 DSABLE ENABLE DSABLE STANDBY Capacity 25 to 75 50 STANDBY Address 1 to 236 93 ...

Page 209: ...99 kW 145 Demand Watts Interval 5 to 60 MIN 15 DESCRIPTION RANGE UNITS DEFAULT VALUE Control Point ECW Control Option 0 1 DSABLE ENABLE DSABLE Temp Pulldown Deg Min 2 to 10 0 6 to 5 6 ˆF ˆC 3 1 7 Temperature Reset RESET TYPE 1 Degrees Reset At 20 mA 30 to 30 17 to 17 ˆF ˆC 10 6 RESET TYPE 2 Remote Temp No Reset 40 to 245 40 to 118 DEG F DEG C 85 29 Remote Temp Full Reset 40 to 245 40 to 118 DEG F ...

Page 210: ...UE Time Broadcast Enable DSABLE ENABLE DSABLE Daylight Savings Start Month 1 to 12 4 Start Day of Week 1 to 7 7 Start Week 1 to 5 3 Start Time 00 00 to 24 00 HH MM 02 00 Start Advance 0 to 360 MIN 60 Stop Month 1 to 12 10 Stop Day of Week 1 to 7 7 Stop Week 1 to 5 3 Stop Time 00 00 to 24 00 02 00 Stop Back 0 to 360 MIN 60 ...

Page 211: ... 13 DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE SECONDARY MESSAGE DATE TIME COMPRESSOR ONTIME CHW IN OILPRESS CHW OUT OIL TEMP CDW IN CDW OUT EVAP REF COND REF AMPS COMMUNICATION MESSAGE ...

Page 212: ...3190045 01 Printed in U S A Form 19XR XRV CLT 10SS Pg CL 14 12 16 Replaces 19XR XRV CLT 9SS Carrier Corporation 2016 CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE SECONDARY MESSAGE DATE TIME COMPRESSOR ONTIME CHW IN OILPRESS CHW OUT OIL TEMP CDW IN CDW OUT EVAP REF COND REF AMPS COMMUNICATION MESSAGE ...

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Summary of Contents for AquaEdge 19XR series

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Carrier AquaEdge 19XR series, Start-Up, Operation And Maintenance Instructions Manual, Page: 147 / 212

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Summary of Contents for AquaEdge 19XR series

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