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Carrier PC211, Start-Up, Operation And Maintenance Instructions Manual

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Carrier PC211 Start-Up, Operation And Maintenance Instructions Manual Download Page 302

116
117
118
119
120
121
122
123
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125
126
127
128
129
130
131
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139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159

1.822
1.792
1.771
1.748
1.724
1.702
1.676
1.653
1.630
1.607
1.585
1.562
1.538
1.517
1.496
1.474
1.453
1.431
1.408
1.389
1.369
1.348
1.327
1.308
1.291
1.289
1.269
1.250
1.230
1.211
1.192
1.173
1.155
1.136
1.118
1.100
1.082
1.064
1.047
1.029
1.012
0.995
0.978
0.962

2,060
2,018
1,977
1,937
1,898
1,860
1,822
1,786
1,750
1,715
1,680
1,647
1,614
1,582
1,550
1,519
1,489
1,459
1,430
1,401
1,373
1,345
1,318
1,291
1,265
1,240
1,214
1,190
1,165
1,141
1,118
1,095
1,072
1,050
1,029
1,007

1,

986

1,

965

1,

945

1,

925

1,

906

1,

887

1,

868

1,

850

160
161
162
163
164
165
166
167
168
169
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183
184
185
186
187
188
189
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191
192
193
194
195
196
197
198
199
200
201
202
203

0.945
0.929
0.914
0.898
0.883
0.868
0.853
0.838
0.824
0.810
0.797
0.783
0.770
0.758
0.745
0.734
0.722
0.710
0.700
0.689
0.678
0.668
0.659
0.649
0.640
0.632
0.623
0.615
0.607
0.600
0.592
0.585
0.579
0.572
0.566
0.560
0.554
0.548
0.542
0.537
0.531
0.526
0.520
0.515

832
815
798
782
765
750
734
719
705
690
677
663
650
638
626
614
602
591
581
570
561
551
542
533
524
516
508
501
494
487
480
473
467
461
456
450
445
439
434
429
424
419
415
410

204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225

0.510
0.505
0.499
0.494
0.488
0.483
0.477
0.471
0.465
0.459
0.453
0.446
0.439
0.432
0.425
0.417
0.409
0.401
0.393
0.384
0.375
0.366

405
401
396
391
386
382
377
372
367
361
356
350
344
338
332
325
318
311
304
297
289
282

Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop (Continued)

Temperature 
(F)

Voltage
Drop 
(V)

Resistance
(Ohms)

Temperature
(F)

Voltage
Drop 
(V)

Resistance
(Ohms)

Temperature
(F)

Voltage
Drop 
(V)

Resistance
(Ohms)

Summary of Contents for PC211

Page 1: ... 94 Form 19XL 3SS Replaces 19XL 2SS Copyright Carrier Corporation 1994 Safety Considerations Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications When operating this equipment use good judgement and safety precautions to avoid damage to equipment and property or injury to personnel Be sure you understand and follow the procedures ...

Page 2: ... heart irregularities unconsciousness or death Misuse can be fatal Vapor is heavier than air and reduces the amount of oxygen available for breathing Product causes eye and skin irritation Decomposition products are hazardous DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose Oxygen gas reacts violently with oil grease and other common substances NEVER EXCEED specified tes...

Page 3: ...starters or oil heater until you are sure ALL POWER IS OFF and no residual volt age can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servicing IF WORK IS INTER RUPTED confirm that all circuits are deenergized before resuming work DO NOT siphon refrigerant AVOID SPILLING liquid refrigerant on skin or getting it into the eyes USE SAFETY GOGGLES Wash any...

Page 4: ...er refrigerants DO NOT ATTEMPT TO REMOVE fittings covers etc while machine is under pressure or while machine 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 machine operates in a corrosive atmosphere inspect the devices at more frequent intervals DO NOT ATT...

Page 5: ...automatic start arrangements CAN ENGAGE THE STARTER TOWER FAN OR PUMPS Open the disconnect ahead of the starter tower fan and pumps USE only repair or replacement parts that meet the code requirements 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 bol...

Page 6: ...N PERIODICALLY INSPECT all valves fittings and piping for corrosion rust leaks or damage PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build up of condensate or rain water ...

Page 7: ... Safety Considerations Introduction Abbreviations and Explanations Machine Familiarization Machine Information Plate System Components Cooler Condenser Motor Compressor Control Center Factory Mounted Starter Optional Storage Vessel Optional ...

Page 8: ...ing Cycle Lubrication Cycle Summary Details Oil Reclaim System During Normal Machine Operation During Light Load Conditions Starting Equipment Unit Mounted Solid State Starter Optional Unit Mounted Wye Delta Starter Optional Controls Definitions Analog Signal ...

Page 9: ...rter 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 T1 T4 Control and Oil Heater Voltage Selector S1 LID Operation and Menus General Alarm and Alerts ...

Page 10: ...tions Time Schedule Operation To View and Change Set Points Service Operation PIC System Functions Capacity Control Entering Chilled Water Control Deadband Proportional Bands and Gain Demand Limiting Machine Timers Occupancy Schedule Safety Controls Shunt Trip ...

Page 11: ...city Override High Discharge Temperature Control Oil Sump Temperature Control PSIO Software Versions 08 and Lower PSIO Software Versions 09 and Higher Oil Cooler Remote Start Stop Controls Spare Safety Inputs Spare Alarm Contacts Condenser Pump Control Condenser Freeze Protection ...

Page 12: ...l Option Requires Optional 8 Input Module Surge Prevention Algorithm Surge Protection Lead Lag Control Common Point Sensor Installation Machine Communication Wiring Lead Lag Operation Faulted Chiller Operation Load Balancing Auto Restart After Power Failure Ice Build Control Ice Build Initiation ...

Page 13: ...on ice Build Operations Attach to Network Device Control Changing Refrigerant Types Attaching to Other CCN Modules Service Operation To Log On To Log Off Holiday Scheduling Start Up Shutdown Recycle Sequence Local Start Up Shutdown Sequence Automatic Soft Stop Amps Threshold PSIO Software Version 09 and Higher ...

Page 14: ...nitial Start Up Job Data Required Equipment Required Using the Optional Storage Tank and Pumpout System Remove Shipping Packaging Open Oil Circuit Valves Torque All Gasketed Joints Check Machine Tightness Refrigerant Tracer Leak Test Machine Standing Vacuum Test ...

Page 15: ...lief Devices Inspect Wiring Carrier Comfort Network Interface Check Starter Mechanical Type Starters Benshaw Inc Solid State Starter Cutler Hammer Solid State Starters Oil Charge Power Up the Controls and Check the Oil Heater Software Version Set Up Machine Control Configuration Input the Design Set Points ...

Page 16: ...onfigurations Password Input Time and Date Change LID Configuration If Necessary Modify Controller Identification If Necessary Input Equipment Service Parameters If Necessary Modify Equipment Configuration If Necessary Check Voltage Supply Perform an Automated Control Test Check Optional Pumpout System Controls and Compressor High Altitude Locations ...

Page 17: ...efrigerant Charge Initial Start Up Preparation Manual Operation of the Guide Vanes Dry Run to Test Start Up Sequence Check Rotation If Rotation Is Proper If the Motor Rotation Is Not Clockwise Notes on Solid State Starters Benshaw Inc Check Oil Pressure and Compressor Stop Calibrate Motor Current Demand Setting To Prevent Accidental Start Up ...

Page 18: ...Tank and Pumpout System 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 Operator Duties ...

Page 19: ...tem To Stop the Machine After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation Refrigeration Log Pumpout and Refrigerant Transfer Procedures Preparation Operating the Optional Pumpout Compressor To Read Refrigerant Pressures ...

Page 20: ...e Tank Machines with Isolation Valves Transfer All Refrigerant to Condenser Vessel Transfer All Refrigerant to Cooler Compressor Vessel Return Refrigerant to Normal Operating Conditions General Maintenance Refrigerant Properties Adding Refrigerant Removing Refrigerant Adjusting the Refrigerant Charge Refrigerant Leak Testing Leak Rate ...

Page 21: ...d Apply Standing Vacuum Test Checking Guide Vane Linkage Checking the Auxiliary Switch on Guide Vane Actuator Trim Refrigerant Charge Weekly Maintenance Check the Lubrication System Scheduled Maintenance Service Ontime Inspect the Control Center Check Safety and Operating Controls Monthly Changing Oil Filter Oil Specification ...

Page 22: ...il Reclaim Filters Inspect Refrigerant Float System Inspect Relief Valves and Piping Compressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes Cooler Condenser Water Leaks Water Treatment Inspect the Starting Equipment Check Pressure Transducers ...

Page 23: ...Control Settings Ordering Replacement Chiller Parts Troubleshooting Guide Overview Checking the Display Messages Checking Temperature Sensors Resistance Check Voltage Drop Check Sensor Accuracy Dual Temperature Sensors Checking Pressure Transducers Transducer Replacement Control Algorithms Checkout Procedure ...

Page 24: ...st Control Modules Red LED Green LEDs Notes on Module Operation Processor Module PSIO Inputs Outputs Starter Management Module SMM Inputs Outputs Options Modules 8 Input Replacing Defective Processor Modules Installation ...

Page 25: ...ontrol Rectifiers in Benshaw Inc Solid State Starters Testing Silicon Control Rectifiers SCRs in Cutler Hammer Solid State Starters Electronic Protection Relay EPR Physical Data Initial Start Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller ...

Page 26: ...4 Setpoint Display Screen Example 5 Configuration Config Display Screen Example 6 Lead Lag Configuration Display Screen Example 7 Service1 Display Screen Example 8 Service2 Display Screen Example 9 Service3 Display Screen Example 10 Maintenance Maint01 Display Screen Example 11 Maintenance Maint02 Display Screen Example 12 Maintenance Maint03 Display Screen Example 13 Maintenance Maint04 Display S...

Page 27: ...perature F Table 5D HFC 134a Pressure Temperature C Table 6 Potentiometer Adjustment Table 7 Amps Correction Factors for 19XL Motors Table 8 Control Test Menu Functions Table 9 Refrigerant HCFC 22 or HFC 134a Charges Table 10 LID Primary and Secondary Messages and Custom Alarm Alert Messages with Troubleshooting Guides A Shutdown with On Off Reset Off B Timing Out or Timed Out C In Recycle Shutdow...

Page 28: ...ant Protection H Normal Run with Reset Temperature or Demand I Normal Run Overrides Active Alerts J Out Of Range Sensor Failures K Machine Protect Limit Faults L Machine Alerts M Spare Sensor Alert Messages N Other Problems Malfunctions Table 11A Thermistor Temperature F vs Resistance Voltage Drop Table 11B Thermistor Temperature C vs Resistance Voltage Drop Table 12 Benshaw Inc Solid State Starte...

Page 29: ...tarter Troubleshooting Guide Table 14 Heat Exchanger Data Table 15 Additional Data for Marine Waterboxes Table 16 Compressor Weights Table 17 Compressor Motor Weights Table 18 Waterbox Cover Weights Table 19 Optional Pumpout System Electrical Data ...

Page 30: ...ication System Figure 5 Cutler Hammer Solid State Starter Internal View Figure 6 Benshaw Inc Solid State Starter Internal View Figure 7 Typical Starter Front View Solid State Starter Shown Figure 8 19XL Controls and Sensor Locations Figure 9 Control Sensors Temperature Figure 10 Control Sensors Pressure Transducer Typical Figure 11 Control Panel Front View with Options Module Figure 12 Power Panel...

Page 31: ...igure 18 Example of Time Schedule Operation Screen Figure 19 Example of Set Point Screen Figure 20 19XL Hot Gas Bypass Surge Prevention Figure 21 19XL with Default Metric Settings Figure 22 Example of Attach to Network Device Screen Figure 23 Example of Holiday Period Screen Figure 24 Control Sequence Figure 25 Typical Wet Bulb Type Vacuum Indicator Figure 26 19XL Leak Test Procedures ...

Page 32: ...30 Benshaw Inc Solid State Starter Power Stack Figure 31 Ramp Up and Starting Torque Potentiometers Figure 32 Typical Potentiometer Adjustment Figure 33 Typical Cutler Hammer Solid State Starter Figure 34 Correct Motor Rotation Figure 35 Refrigeration Log Figure 36 19XL Pumpout Unit Wiring Schematic Figure 37 Optional Pumpout System Figure 38 Guide Vane Actuator Linkage Figure 39 19XL Float Valve ...

Page 33: ...essor PSIO Module Figure 44 Starter Management Module SSM Figure 45 Options Module Figure 46 Typical Benshaw Inc Solid State Starter Internal View Figure 47 Resistance Check Figure 48 SCR and Power Poles Figure 49 Typical Cutler Hammer Solid State Starter Internal View Figure 50 Cutler Hammer Terminal Functions Figure 51 Solid State Starter General Operation Troubleshooting Guide Typical ...

Page 34: ...ressor Fits and Clearances Figure 54 Compressor Fits and Clearances Continued Figure 55 Compressor Fits and Clearances Continued Figure 56 Electronic PIC Controls Wiring Schematic Figure 57 Machine Power Panel Starter Assembly and Motor Wir ing Schematic Figure 58 Typical Wye Delta Unit Mounted Starter Wiring Schematic ...

Page 35: ...ance should be thoroughly 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 machine start up and operation ...

Page 36: ... 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 Rules which are designed to provide reasonable protection ag...

Page 37: ...ly used abbreviations in this manual include CCN Carrier Comfort Network LID Local Interface Device CCW Counterclockwise LCW Leaving Chilled Water CW Clockwise OLTA Overload Trip Amps ECW Entering Chilled Water PIC Product Integrated Control ECDW Entering Condenser Water PSIO Processor Sensor Input Output Module EMS Energy Management System RLA Rated Load Amps HGBP Hot Gas Bypass SCR Silicon Contr...

Page 38: ...ol center and motor starter All connections from pressure vessels have external 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 maintained at lower temperature pressure so that evaporating refrigerant can remove heat from water flowing through i...

Page 39: ... machine operating condition and alarm shutdown conditions records the total machine operating hours sequences machine start stop and recycle under microprocessor control provides access to other CCN Carrier Comfort Network devices Factory Mounted Starter Optional The starter allows for the proper starting and disconnecting of the electrical energy for the compressor motor oil pump oil heater and ...

Page 40: ...airly 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 liquid cooling After taking heat from the water the refrigerant vapor is compressed Compression adds still more heat energy and the refrigerant is quit...

Page 41: ...ooling Cycle The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel Figure 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...

Page 42: ...s If the temperature rises above the safety limit the compressor will shut down Refrigerant that flows to the oil cooling system is regulated 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 temperat...

Page 43: ...t bearings Oil drains into the transmission oil sump to complete the cycle Figure 4 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 top of the lower sight glass when the compressor is shut down The oil level should be visible in at leas...

Page 44: ...nd the thermal bulb for the refrigerant expansion valve on the oil cooler The oil is then divided with a portion flowing to the thrust bearing forward pinion bearing and gear spray The balance then lubricates the motor shaft bearings and the rear pinion bearing The oil temperature is measured as the oil leaves the thrust and forward journal bearings within the bearing housing The oil then drains i...

Page 45: ...n oil back to the oil reservoir by recovering it from 2 areas on the machine 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 compressor Oil entrained...

Page 46: ...gh 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 solenoids located on the oil reclaim piping are operated so that the eductor can pull oil and refrigerant directly from the cooler and discharge...

Page 47: ...l safety requirements 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 compress...

Page 48: ...arter Figure 5 Figure 6 Figure 7 This starter provides on 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 soft starting Two varieties of solid state starters are available as a 19XL option factory supplied and installed When a unit ...

Page 49: ...d a bypass contactor is energized to bypass the SCRs There are a number of LEDs light emitting diodes that are useful in troubleshooting and starter checkout 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 When voltage is supplied to the solid sta...

Page 50: ...arting 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 delay once the motor is up to speed the starter automatically connects the phase windings into a delta configuration Click here for Figure 5 Cutler Hammer Solid State Starter Internal View Click here for Figure ...

Page 51: ...te signal is a 2 position representation of the value of a monitored source Example 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 incapable of being sustained if power is lost and subsequently restored CAUTION CAUTION The memory of the ...

Page 52: ...t vapor flow into the compressor An increase in guide vane opening increases capacity A decrease in guide vane opening decreases capacity Machine protection is provided by the processor which monitors the digital and analog inputs and executes capacity overrides or safety shutdowns if required PIC System Components The Product Integrated Control PIC is the control system on the machine See Table 1...

Page 53: ...or 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 machine power wiring per job requirement Processor Module PSIO The PSIO is the brain of the PIC This module contain...

Page 54: ... pumps start stop of the tower fan spare alarm contacts 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 1M and run contacts and kW transducer input optional The SMM contains logic capable of safely shutting down the machine if communications with the PSIO ...

Page 55: ... 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 sensors on this unit These sensors are 5 000 ohm at 75 F 25 C Oil Heater Contactor 1C This contactor is located in the power panel and operates the heater at either 115 or 230 v It is controlled by ...

Page 56: ...ol 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 Click here for Figure 8 19XL Controls and Sensor Locations Click here for Figure 9 Control Sensors Temperature Click here for Figure 10 Control Sensors Pressure Transducer Typical Click...

Page 57: ...in the Pumpdown mode Figure 13 When not in the default screen the upper right hand corner of the LID always dis plays the name of the screen that you have entered Figure 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 and the control will accept modification to programm...

Page 58: ... indicated when the control center alarm light flashes The primary alarm message is viewed on the default 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 enables the operator to view the machine conditions at the time of alarm The...

Page 59: ...C must be powered up and have successfully completed its self test Press QUIT to leave the selected decision or field without saving any changes Press ENTER to leave the selected decision or field and save changes INCREASE DECREASE QUIT ENTER INCREASE DECREASE QUIT ENTER ...

Page 60: ...ress PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen Press SELECT to view the next screen level highlighted with the cursor bar or to override if allowable the highlighted point value NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 61: ... To View Point Status Figure 15 Point Status is the actual value of all of the temperatures pressures relays and actuators sensed and controlled by the PIC 1 On the Menu screen press STATUS to view the list of Point Status tables NEXT PREVIOUS SELECT EXIT INCREASE DECREASE QUIT ENTER STATUS SCHEDULE SETPOINT SERVICE ...

Page 62: ...us02 Status of relays and contacts Status03 Status of both optional 8 input modules and sensors 3 Press SELECT to view the desired Point Status table desired 4 On the Point Status table press NEXT or PREVIOUS until desired point is displayed on the screen NEXT PREVIOUS SELECT ENTER NEXT PREVIOUS SELECT ENTER NEXT PREVIOUS SELECT ENTER ...

Page 63: ...table press NEXT or PREVIOUS to highlight the desired point 2 Press SELECT to select the highlighted point Then NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT Click here for Figure 15 Example of Point Status Screen Status 01 Click here for Figure 16 19XL Menu Structure ...

Page 64: ...r DECREASE to select the desired value 3 Press ENTER to register new value Note When overriding or changing metric values it is necessary to hold the softkey down for a Click here for Figure 17 19XL Service Menu Structure START STOP RELEASE ENTER INCREASE DECREASE RELEASE ENTER NEXT PREVIOUS SELECT EXIT ...

Page 65: ...e desired point 2 Press SELECT to access the highlighted point 3 Press RELEASE to remove the override and return the point to the PIC s automatic control Override Indication An override value is indicated by SUPVSR SERVC or BEST flashing next to the point value on the Status table NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT INCREASE DECREASE RELEASE ENTER ...

Page 66: ...edule PSIO Software Version 08 and lower OCCPC01S LOCAL Time Schedule OCCPC02S CCN Time Schedule PSIO Software Version 09 and higher OCCPC01S LOCAL Time Schedule OCCPC02S ICE BUILD Time Schedule OCCPC03 99S CCN Time Schedule Actual number is defined in Config table STATUS SCHEDULE SETPOINT SERVICE NEXT PREVIOUS SELECT EXIT ...

Page 67: ...me schedule 4 Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change 5 Press SELECT to access the highlighted period or override NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 68: ...ments up to 4 hours b Press ENABLE to select days in the day of week fields Press DISABLE to eliminate days from the period 7 Press ENTER to register the values and to move horizontally left to right within a period INCREASE DECREASE ENTER EXIT ENABLE DISABLE ENTER EXIT ENABLE DISABLE ENTER EXIT ...

Page 69: ... save the changes 10 Holiday Designation HOLIDEF table may be found in the Service Operation section You must assign the month day and duration for the holiday The Broadcast function in the Brodefs table also must be enabled for holiday periods to function NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT Click here for Figure 18 Example of Time Schedule Operation Screen ...

Page 70: ...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 Service menu ICE BUILD is also activated and configured in the Service menu 3 Press NEXT or PREVIOUS to highlight the desired set point entry STATUS SCHEDULE SETPOINT SERVICE NEXT PRE...

Page 71: ...CREASE or DECREASE to change the selected set point value 6 Press ENTER to save the changes and return to the previous screen NEXT PREVIOUS SELECT EXIT INCREASE DECREASE QUIT ENTER INCREASE DECREASE QUIT ENTER Click here for Figure 19 Example of Set Point Screen ...

Page 72: ... current screen 2 The LID may be configured in English or SI units as required through the LID configuration screen 3 Data appearing in the Reference Point Names column is used for CCN operations only 4 All options associated with ICE BUILD Lead Lag CCN Occupancy Configuration and Soft Stopping are only available on PSIO Software Version 9 and higher Click on an example to view Example 1 Status01 ...

Page 73: ...lay Screen Example 7 Service1 Display Screen Example 8 Service2 Display Screen Example 9 Service3 Display Screen Example 10 Maintenance Maint01 Display Screen Example 11 Maintenance Maint02 Display Screen Example 12 Maintenance Maint03 Display Screen Example 13 Maintenance Maint04 Display Screen ...

Page 74: ...e CONTROL POINT The CONTROL POINT may be changed by a CCN network device or is determined by the PIC adding any active chilled water reset to the chilled water SET POINT The PIC uses the PROPORTIONAL INC Increase BAND PROPORTIONAL DEC Decrease BAND and the PROPORTIONAL ECW Entering Chilled Water GAIN to determine how fast or slow to respond CONTROL POINT may be viewed overridden on the Status tabl...

Page 75: ... 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 is from the control point Proportional gain determines how quickly the guide vanes react to how quickly the temperature is moving from CONTROL POINT The proportional band can be viewed modified on the LID Ther...

Page 76: ...ll respond to the ACTIVE DEMAND LIMIT set point by limiting the opening of the guide vanes It will compare the set point to either COMPRESSOR MOTOR LOAD or COMPRESSOR MOTOR CURRENT percentage depending on how the control is configured for the DEMAND LIMIT SOURCE which is accessed on the SERVICE1 table The default setting is current limiting Machine Timers The PIC maintains 2 runtime clocks known a...

Page 77: ...The machine is in OCCUPIED mode unless an unoccupied time period is in effect The machine will shut down when the schedule goes to UNOCCUPIED These schedules can be set up to follow the building schedule or to be 100 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...

Page 78: ...upancy 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 defined on the Config table in the Equipment Configuration table The schedule number can change to any value from 03 to 99 If this schedule number is changed o...

Page 79: ...sure 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 th...

Page 80: ...ge for troubleshooting To give a better warning as to the operating condition of the machine the operator also can define alert limits on various monitored inputs Safety contact and alert limits are defined in Table 3 Alarm and alert messages are listed in the Troubleshooting Guide section CAUTION CAUTION If compressor motor overload occurs check the motor for grounded or open phases before attemp...

Page 81: ... at the time of alarm Knowledge of the operating state of the chiller at the time an alarm occurs is useful when troubleshooting Current machine information can be viewed on the Status tables Once all existing alarms are cleared by pressing the RESET softkey the default LID will return normal operation Motor Cooling Control Motor temperature is reduced by refrigerant entering the motor shell and e...

Page 82: ...perature or on motor load 1 Temperature ramp loading limits the rate at which either leaving chilled water or entering chilled water temperature decreases by an operator configured rate The lowest temperature ramp table will be used the first time the machine is started at commissioning The lowest temperature ramp rate will also be used if machine power has been off for 3 hours or more even if the...

Page 83: ...es below the first step set point and then the vanes are released to normal 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 ...

Page 84: ...the controls oil sump temperature is compared against evaporator refrigerant temperature If the difference between these 2 temperatures 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 o...

Page 85: ...eated 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 ...

Page 86: ...stop the machine in excess of 2 or 3 times every 12 hours If more than 8 starts in 12 hours occur then an Excessive Starts alarm is displayed preventing the machine from starting The operator must reset the alarm at the LID in order to override the starts counter and start the machine If Automatic Restart After a Power Failure is not activated when a power failure occurs and the remote contact is ...

Page 87: ...p TB6 terminals 5A and 5B and terminals 5C and 5D Condenser Pump Control The machine will monitor 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 Service1 LID table and has a default value Table 4 If the CONDENSER PRESSURE ...

Page 88: ...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 CONDENSER FREEZE POINT plus 5 F 2 7 C An alarm will be generated if the machine is in PUMPDOWN mode and the pump is energized An alert will be generated if the machine is not in PUMPDOWN mode and the pump is energized If in recycle shutdown the mode shall...

Page 89: ...nt temperature is less than the override temperature or the differential pressure is less than 40 psid 279 kPad 28 psid 193 kPad for HFC 134a and entering condensing water is less than 80 F 27 C IMPORTANT A field supplied water temperature control system for condenser water should be installed The system should maintain the leaving condenser water tempera ture at a temperature that is 20 F 11 C ab...

Page 90: ... normal start up If power to the PSIO module has been off for more than 3 hours the PIC will raise the oil temperature 100 F 56 C above the evaporator temperature Refrigerant normally migrates into the oil when the oil heater is left off for extended periods of time The PIC operates the oil pump for 1 to 2 minutes to ensure that the oil is free of excess refrigerant Once this algorithm is complete...

Page 91: ...ly powered by the 8 input module for example when using variable resistance the signal is wired to J1 7 and J1 6 The PIC must now be configured on the Service2 table to ensure that the appropriate power source is identified 2 Reset Type 2 Requires optional 8 input module Automatic chilled water temperature reset based on a remote temperature sensor input This type permits 30 F 16 C of automatic re...

Page 92: ...dule No wiring 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 entering 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 whi...

Page 93: ...1 2 If the signal is internally 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 minimum 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 d...

Page 94: ...gorithm takes no action Modification of the default set points of the MINIMUM and MAXIMUM load points is described in Figure 21 Corrective action can be taken by making one of 2 choices If a hot gas bypass line is present and the hot gas is configured on the Service1 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 v...

Page 95: ...ing is displayed and configured on the Service1 screen It has a default setting of 25 amps SURGE PROTECTION COUNTS can be monitored on the Maint03 table A surge protection shutdown of the machine will occur whenever the surge protection counter reaches 12 counts within an operator specified time known as the SURGE TIME PERIOD The SURGE TIME PERIOD is displayed and configured on the Service1 screen...

Page 96: ...n 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 Configura tion table located in the Service menu Lead lag status during machine operation is viewed in the MAINT04 table in the Con...

Page 97: ...common point sensor option is chosen on a chilled water system both machines should have their own 8 input option module and common point sensor installed Each machine will use its own common point sensor for control when that machine is desig nated as the lead chiller The PIC cannot read the value of common point sensors installed on other machines in the chilled water system When installing chil...

Page 98: ...e s Installation Instructions Carrier Comfort Network Interface section for information on machine 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 optio...

Page 99: ...o 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 machine 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 respo...

Page 100: ...hiller 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 PRESTART FAULT TIMER is initiated at the time of a start request The PRESTART ...

Page 101: ... 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 c...

Page 102: ...arted Lag Chiller Shutdown Requirements The following conditions 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 PERCENT CAPACITY The LAG PERCENT CAPACITY value is configured on the Lead Lag Configuration screen 2 The lead chiller chilled water tempera...

Page 103: ...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 chiller 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 an...

Page 104: ...ndition 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 The 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 ...

Page 105: ...o 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 SETPOINT for temperature control The ICE BUILD RECYCLE OPTIO...

Page 106: ...and the following events automatically take place unless overridden by a higher authority CCN device 1 Force CHILLER START STOP to START 2 Force WATER BRINE CONTROL POINT to the ICE BUILD SETPOINT 3 Remove any force Auto on the ACTIVE 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 controlle...

Page 107: ... WATER temperature is less than or equal to the ICE BUILD SETPOINT and remote contacts are open The ICE BUILD RECYCLE OPTION determines whether or not the PIC will go into a RECYCLE mode If the ICE 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 ICE BUILD RECYCLE OPTION is set to ENABLE when ice build te...

Page 108: ...ressor operation based on temperature shall occur if the ICE BUILD TERMINATION is set to the ICE BUILD TERMINATION TEMP option and the ENTERING CHILLED WATER temperature is less than the ICE BUILD SETPOINT 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 POI...

Page 109: ...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 overriding can be accomplished with CCN during two chiller lead lag Return to Non Ice Build Operations Upon termination of ice build the machine shall return to normal temperature control and start stop schedule operation If the CHILL...

Page 110: ...achine the LID is mounted on Whenever 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 automatically See Figure 17 Whenever the ATTACH TO NETWORK DEVICE table is entered the LID erases information on the module to which it was attached in order to make room for another device Therefore it is the...

Page 111: ...ange for the controller is complete Attaching to Other CCN Modules If the machine 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 machines 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 othe...

Page 112: ...e 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 machine 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 re attach to the PSIO module on the machine Press the ATTACH softkey to attach to L...

Page 113: ...nd 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 The menu bar Next Previous Select Exit is displayed to indicate that you have successfully logged on If the password is entered incorrectly an error message is displayed If this occurs return to ENTER A 4 DIGIT PASSWORD 1 2 3 4 NEXT PREVIOUS SELECT EXIT ...

Page 114: ...ay be configured for special operation during a holiday period When modifying a time period the H at the end of the days of the week field signifies that the period is applicable to a holiday See Figure 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 ac...

Page 115: ...erent holidays perform the following operation 1 At the Menu screen press SERVICE to access the Service menu 2 If not logged on follow the instructions for To Log On or To Log Off Once logged on press NEXT until Equipment Configuration is highlighted 3 Once Equipment Configuration is highlighted press SELECT to access STATUS SCHEDULE SETPOINT SERVICE NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT ...

Page 116: ...the Data Table Select screen This screen lists 18 holiday tables 6 Press NEXT to highlight the holiday table that you wish to view or change Each table is one holiday period starting on a specific date and lasting up to 99 days NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 117: ... shows the holiday start month and day and how many days the holiday period will last 8 Press NEXT or PREVIOUS to highlight the month day or duration 9 Press SELECT to modify the month day or duration NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT ...

Page 118: ... the selected value 11 Press ENTER to save the changes 12 Press EXIT to return to the previous menu INCREASE DECREASE QUIT ENTER INCREASE DECREASE QUIT ENTER NEXT PREVIOUS SELECT EXIT Click here for Figure 23 Example of Holiday Period Screen ...

Page 119: ...nabled 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 perform 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...

Page 120: ...pressure is verified the PIC waits 10 seconds and then the compressor start relay 1CR is energized to start the compressor 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 not advance the starts in 12 hours counter Any failure after the 1CR ...

Page 121: ...ssor 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 this time is now displayed...

Page 122: ...to a preset amperage percent or until the guide vane is less than 2 open The compressor will then shut off If the machine enters an alarm state or if the compressor enters a RECYCLE mode the compressor will be deenergized immediately To activate SOFT STOP AMPS THRESHOLD view the bottom of Service1 table Set the SOFT STOP AMPS THRESHOLD value to the percentage amps at which the motor will shut down...

Page 123: ... the machine is in RECYCLE mode the chilled water pump relay remains energized so that the chilled water temperature 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 function which defaults to 5 F 3 C This value is viewed modified on the Service1 table The compressor will restart wh...

Page 124: ...rvice1 table to lengthen the time between restarts The machine should not be operated below design minimum load without a hot gas bypass installed on the machine Safety Shutdown A safety shutdown is identical to a manual shutdown with the exception that the LID will display the reason for the shutdown the alarm light will blink continuously and the spare alarm contacts will be energized A safety s...

Page 125: ...pecial 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 CAUTION 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 main tained for 10 seconds to ...

Page 126: ...hine 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 Figure 4 are open by removing the valve cap and checking the valve stem Torque All Gasket...

Page 127: ...to check all flanges and solder joints after the machine is pressurized If any leaks are detected follow the leak test procedure If the machine is spring isolated keep all 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 spr...

Page 128: ...mperature values 1 If the pressure readings are normal for machine condition a Evacuate the holding charge from the vessels if present b Raise the machine pressure if necessary by adding refrigerant until pressure is at equivalent saturated pressure for the surrounding temperature Follow the pumpout procedures in the Transferring Refrigerant from Storage Tank to Machine section Steps 1a e Do not u...

Page 129: ...Steps 2g h c Plainly mark any leaks which are found d Release the pressure in the system e Repair all leaks f Retest the joints that were repaired Never charge liquid refrigerant into the machine if the pressure in the machine 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 usi...

Page 130: ...ctor halide torch or soap bubble solution 4 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 machine Leakage at rates greater than 1 lb year 0 45 kg year for the entire machine must be repaired Note total machine leak rate on the start up report 5 If no leak is found during initial start up proc...

Page 131: ... Hg 40 kPa absolute 9 Repair the leak and repeat the procedure beginning from Step 2h to ensure a leaktight repair If machine is opened to the atmosphere for an extended period evacuate it before repeating leak test Standing Vacuum Test When performing the standing vacuum test or machine dehydration use a manometer or a wet bulb indicator Dial gages cannot indicate the small amount of acceptable l...

Page 132: ...ogen 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 pressure to 230 psig 1585 kPa maximum 5 Repair leak retest and proceed with dehydration Click here for Figure ...

Page 133: ...own to contain moisture or if there has been a complete loss of machine holding charge or refrigerant pressure Click here for Table 5A HCFC 22 Pressure Temperature F Click here for Table 5B HCFC 22 Pressure Temperature C Click here for Table 5C HFC 134a Pressure Temperature F Click here for Table 5D HFC 134a Pressure Temperature C ...

Page 134: ...ump 5 cfm 002 m 3 s or larger is recommended to the refrigerant charging valve Figure 2A or Figure 2B Tubing from the pump to the machine should be as short and as large a diameter as possible to provide least resistance to gas flow 2 Use an 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 Lea...

Page 135: ...erature pressure isolated pockets of mois ture can turn into ice The slow rate of evaporation sublimination of ice at these low tem peratures 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 reading has not changed dehydration is complete If the reading indicates vac...

Page 136: ... drop across cooler and across condenser Check Optional Pumpout Compressor Water Piping If the optional storage tank and or pumpout system are installed check to ensure the pumpout condenser water has been piped in Check for field supplied shutoff valves and controls as specified in the job data Check for refrigerant leaks on field installed piping See Figure 27 and Figure 28 CAUTION CAUTION Water...

Page 137: ...s are set to relieve at the 300 psig 2068 kPa machine design pressure Inspect Wiring 1 Examine wiring for conformance to job wiring diagrams and to all applicable electrical codes Do not check voltage supply without proper equipment and precautions Serious injury may result Follow power company recommendations WARNING WARNING CAUTION CAUTION Do not apply any kind of test voltage even for a rotatio...

Page 138: ... 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 properly grounded in accordance with job drawings certified drawings and all applicable electrical codes 8 Make sure that the customer s contractor has verified proper operation of the pumps ...

Page 139: ...d 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 unsatisfactory repeat the test at the motor with the power leads disconnected Satisfactory readings in this second test indicate the fault is in the power lea...

Page 140: ... Network CCN communication bus wiring is supplied and installed by the electrical contractor It consists of shielded 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 m...

Page 141: ...C is required See table below for cables that meet the requirements When connecting the CCN communication bus to a system element a color code system for the entire network is recommended to simplify installation and checkout The following color code is recommended Manufacturer Cable No Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525 Signal Type CCN Bus Conductor Insulation Color PSI...

Page 142: ...roprocessor maintains its output to the 1CR relay for 10 seconds to determine the fault mode of failure CAUTION CAUTION BE AWARE that certain automatic start arrangements can engage the starter Open the disconnect ahead of the starter in addition to shutting off the machine or pump CAUTION CAUTION The main disconnect on the starter front panel may not deenergize all internal circuits Open all inte...

Page 143: ...quipped with devices of this type remove the fluid cups from these magnetic overload relays Add dashpot oil to cups per instructions supplied with the starter The oil is usually shipped in a small container attached to the starter frame near the relays Use only dashpot oil supplied with the starter Do not substitute Factory filled dashpot overload relays need no oil at start up and solid state ove...

Page 144: ... 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 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...

Page 145: ...t the 9 00 o clock position is located where the 6 00 o clock position would normally be located The ramp potentiometer should be set so that the motor is up to full speed in 15 to 20 sec onds the bypass contactors have energized and the auxiliary LCD is energized 7 Proceed to apply power to the starter 8 The Power 15 and Phase Correct LEDs should be on If not see the starter Troubleshooting Guide...

Page 146: ... to the starter 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 Refer to the certified drawings The order in which the solid state control module adjustment potentiometers are set is Click here for Initial Start Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller This equipment is at line voltage when a...

Page 147: ...ers are nearly linear To make an initial setting determine the percentage of the potentiometer rotation Use the following formula to calculate the percent of rotation See Figure 32 and Figure 33 Example Starting current is adjustable between 100 and 400 of motor full load current The initial setting for 200 starting current is as follows of rotation desired setting minimum setting maximum setting ...

Page 148: ...table from 100 to 400 FLA and is factory set at 100 If quick acceleration is desired set the starting current at a higher level CAUTION CAUTION Do not adjust any potentiometer beyond its stops This type of adjustment will result in damage to the potentiometer Click here for Table 6 Potentiometer Adjustment Click here for Figure 32 Typical Potentiometer Adjustment Click here for Figure 33 Typical C...

Page 149: ...at a reduced level during motor start The current limit is adjustable from 100 to 400 of the motor full load current value The current limit is factory set at 250 Pulse Start A pulse start is not used on this machine It is set to the OFF position Current Trip A control contact closes when the motor reaches a factory set value of 175 of full load amps This signal is used as an interlock to shut dow...

Page 150: ...is correct If the motor is found to be rotating in the wrong direction interchange any two phases to the motor Start the unit When unit reaches full speed monitor the running current to ensure that the motor is not overloaded Oil Charge The 19XL compressor holds approximately 8 gal 30 L of oil The machine will be shipped with oil in the compressor When the sump is full the oil level should be no h...

Page 151: ...circuit This should be done several hours before start up to minimize oil refrigerant migration The oil heater is controlled 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 shutdown...

Page 152: ... software version number will also appear Set Up Machine Control Configuration 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 configuration values Do not operate the machine before the control configurations have been checked and a Control Test has been satisfactorily completed Pr...

Page 153: ...uirements If no schedule is available the default is factory set for 24 hours occupied 7 days per week including holidays For more information about how to set up a time schedule see the Controls section The CCN Occupied Schedule OCCPC03S should be configured if a CCN system is being installed or if a secondary time schedule is needed Selecting Refrigerant Type The 19XL control must be configured ...

Page 154: ... on the Service menu and the ATTACH TO LOCAL DEVICE to upload the new refrigerant tables Input Service Configurations The following configurations require the LID screen to be in the Service portion 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 passw...

Page 155: ...achine 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 Necessary The controller identification screen is used to change the PSIO module address Change this address for each machine if there is more than one machine at the jobsite Write the new address on the PSIO module for future r...

Page 156: ...lve when surge prevention is needed These points should be set based on individual machine operating conditions Chilled Medium Brine Refrigerant Trippoint Surge Limiting or Hot Gas Bypass Option Minimum Load Points T1 P1 Maximum Load Points T2 P2 Amps Correction Factor Motor Rated Load Amps Motor Rated Line Voltage Motor Rated Line kW Line Frequency Compressor Starter Type Water or Brine Usually 3...

Page 157: ...he operator Example of configuration Machine operating parameters Refrigerant used HCFC 22 Estimated Minimum Load Conditions 44 F 6 7 C LCW 45 5 F 7 5 C EWC 43 F 6 1 C Suction Temperature 70 F 21 1 C Condensing Temperature Estimated Maximum Load Conditions 44 F 6 7 C LCW 54 F 12 2 C ECW 42 F 5 6 C Suction Temperature 98 F 36 7 C Condensing Temperature ...

Page 158: ...ated pressure and temperature for the particular refrigerant used Suction Temperature 42 F 5 6 C 71 5 psig 521 kPa saturated refrigerant pressure HCFC 22 Condensing Temperature 98 F 36 7 C 190 psig 1310 kPa saturated refrigerant pressure HCFC 22 Maximum Load T2 54 44 10 F 12 2 6 7 5 5 C Maximum Load P2 190 71 5 118 5 psid 1310 521 789 kPad To avoid unnecessary surge prevention add about 10 psid 70...

Page 159: ... and temperature for the particular refrigerant used Suction Temperature 43 F 6 1 C 73 psig 503 kPa saturated refrigerant pressure HCFC 22 Condensing Temperature 70 F 21 1 C 121 psig 834 kPa saturated refrigerant pressure HCFC 22 Minimum Load T1 45 5 44 1 5 F 7 5 6 7 0 8 C Minimum Load P1 121 73 45 psid 834 503 331 kPad Again to avoid unnecessary surge prevention add 10 psid 70 kPad at P1 from the...

Page 160: ...uipment 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 Load Surge Prevention Occurs Too Soon Surge Prevention Occurs Too Late At low loads 50 Increase P1 by 10 psid 70 kPad Decrease P1 by 10 psid 70 kPad At high loads 50 Increase P2 by 10 psid 70 kPad Decrease...

Page 161: ...e Schedule screen as described previously Holidef Table Modifications The Holidef tables configure the days of the year that holidays are in effect See the holiday paragraphs in the Controls section for more details Brodefs Table Modifications The Brodefs screen defines the outside air temperature sensor and humidity sensor if one is to be installed It will define the start and end of daylight sav...

Page 162: ...cess 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 Status01 table The OFF mode is caused by pressing the STOP p...

Page 163: ...cers Guide Vane Actuator Pumps Discrete Outputs Pumpdown Lockout Terminate Lockout Refrigerant Type As described above a complete control test Check of all PSIO thermistors only Check of all options boards thermistors Check of all transducers Check of the guide vane operation Check operation of pump outputs either all pumps can be activated or individual pumps The test will also test the associate...

Page 164: ...ck 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 for details on transfer of refrigerant oil specifi...

Page 165: ...ON The transfer addition or removal of refrigerant in spring isolated machines may place severe stress on external piping if springs have not been blocked in both up and down directions When equalizing refrigerant pressure on the 19XL machine after service work or during the initial machine start up do not use the discharge isolation valve to equalize The motor cooling isolation valve or charging ...

Page 166: ...ensure against freezing 3 Slowly open the refrigerant cooling isolation valve The machine cooler and condenser pressures will gradually equalize This process will take approximately 15 minutes 4 Once the pressures have equalized the condenser isolation valve the optional hot gas isolation valve and cooler isolation valve may now be opened Refer to Figure 27 and Figure 28 Valves 11 12 and 14 Whenev...

Page 167: ...he pressure This process will take approximately 15 minutes 4 Once the pressures have equalized the discharge isolation 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 charge on the 19XL will vary with machine components and design conditions indicated on t...

Page 168: ...a holding charge the refrigerant will be added through the refrigerant charging valve Figure 27 and Figure 28 valve 7 or to the pumpout charging connection First evacuate the nitrogen holding charge from the vessels Charge the refrigerant as a gas until the system pressure exceeds 68 psig 469 kPa for HCFC 22 35 psig 141 kPa for HFC 134a After the machine is beyond this pressure the refrigerant sho...

Page 169: ... the temperature difference to design conditions or minimum differential Initial Start up Preparation Before starting the machine check that the 1 Power is on to the main starter oil pump relay tower fan starter oil heater relay and the machine control center 2 Cooling tower water is at proper level and at or below design entering temperature 3 Machine is charged with refrigerant and all refrigera...

Page 170: ...coming voltage is not present or is incorrect If the Phase Correct LED is not lit rotate any 2 incoming phases to correct the phasing 8 Press RELEASE 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 Do not permit water or brine that is warmer than 110...

Page 171: ...01 table and look at the target guide vane position Figure 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 SELECT softkey 3 Press ENTER to override the automatic target The screen will now read a value of zero and the word SUPVSR will flash 4 Press the SELECT softkey and0 then press RELEASE softkey to release the va...

Page 172: ... seconds 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 screen S...

Page 173: ...ers Benshaw Inc 1 When the compressor is energized to start by the 1CR 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 potentiometer in a clockwise direction 2 Observe that all 6 gate LEDs are lit on the starter SCR control board CAUTION CAUTION Do not check mot...

Page 174: ... ammeter on the line that passes through the motor load current transfer on the motor side of the power factor correction capacitors if provided 2 Start the compressor and establish a steady motor current value between 70 and 100 RLA by manually overriding 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 s...

Page 175: ...ne will also state that the Start Stop has been set to Start or Stop when the value is overridden Check Machine Operating Condition Check to be sure that machine temperatures pressures water flows and oil and refrigerant levels indicate that the system is functioning properly Instruct the Customer Operator Check to be sure that the operator s understand all operating and maintenance procedures Poi...

Page 176: ...rs 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 Auxilia...

Page 177: ...d operating controls refrigerant and oil charging and job safety Review the Start Up Operation and Maintenance Manual Operating Instructions Operator Duties 1 Become familiar with refrigeration machine and related equipment before operating the machine 2 Prepare the system for start up start and stop the machine and place the system in a shutdown condition 3 Maintain a log of operating conditions ...

Page 178: ...uence will start Follow the procedure described in the Start Up Shutdown Recycle section Check the Running System After the compressor 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 F 60 C during shutdown and above 100 F 38 C during compressor operation 2 The bearing oil temperature a...

Page 179: ...n 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 between 60 and 80 psig 410 and 55...

Page 180: ...trols section The machine will not restart until the CCN or LOCAL softkey is pressed The machine is now in the OFF mode If the machine 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 reduce machine load then by opening the main disconnect Do not attempt to stop the machine by opening an isolatin...

Page 181: ...the oil heater and controls energized to maintain the minimum oil reservoir 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...

Page 182: ... Guide Vane Operation Manual operation 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 Status01 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 i...

Page 183: ...n scheduling routine maintenance and in diagnosing machine problems Keep a record of the machine 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 Click here for Figure 35 Refrigerati...

Page 184: ...he Optional Pumpout Compressor 1 Be sure that the suction and the discharge service valves on the optional pumpout compressor are open backseated during operation Rotate the valve stem fully counterclockwise 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...

Page 185: ... To determine storage tank pressure a 30 in 0 400 psi 101 0 2760 kPa gage is attached to the vessel 3 Refer to Figure 27 Figure 28 and Figure 37 for valve locations and numbers Machines with Storage Tanks If the machine has isolation valves leave them open for the following procedures The letter C describes a closed valve Valves 9 and 10 on the storage tank are always closed See Figure 16 Figure 1...

Page 186: ... machine isolation valves 11 12 13 and 14 if present c Open pumpout storage tank valves 3 and 6 open machine valves 1a and 1b d Gradually crack open valve 5 to increase machine pressure to 68 psig 469 kPa for HCFC 22 35 psig 141 kPa for HFC 134a Slowly feed refrigerant to prevent freeze up Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C C C Click here for Figure 36 19XL Pumpout Unit Wiring S...

Page 187: ...t a Close valve 5 and open valve 4 b Turn off the water pumps through the LID c Turn off the pumpout condenser water and turn on the pumpout compressor to push liquid out of the storage tank d Close liquid line valve 7 e Turn off the pumpout compressor f Close valves 3 and 4 Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C ...

Page 188: ...tank pressure reaches 5 psig 34 kPa 18 in Hg 40 kPa absolute if repairing the tank j Turn off the pumpout compressor k Close valves 1a 1b 2 5 and 6 l Turn off pumpout condenser water Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C C Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C C C C C C C ...

Page 189: ...ve 7 to allow liquid refrigerant to drain by gravity into the storage tank 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 11 12 13 14 Condition C C C C C Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C Valve 1a 1b 2 3 4 5 6 7 8 11 12 13 14 Condition C C C ...

Page 190: ...ompressor until the machine pressure reaches 65 psig 448 kPa for HCFC 22 30 psig 207 kPa for HFC 134a then shut off the pumpout Warm condenser water will boil off any entrapped liquid refrigerant and machine pressure will rise e When the pressure rises to 70 psig 483 kPa for HCFC 22 40 psig 276 kPa for HFC 134a turn on the pumpout compressor until the pressure again reaches 65 psig Valve 1a 1b 2 3...

Page 191: ...te f Close valves 1a 1b 3 4 and 6 g Turn off the pumpout condenser water and continue with the Control Test for Pumpdown which will lock out the machine compressor for operation 4 Establish vacuum for service a In order to conserve refrigerant operate the pumpout compressor until the machine pressure is reduced to 18 in Hg vac ref 30 in bar 40 kPa abs following Step 3e Valve 1a 1b 2 3 4 5 6 7 8 11...

Page 192: ...umpout condenser 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 machine water pumps f Turn off the pumpout compressor Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C ...

Page 193: ...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 g Turn off pumpout condenser water h Proceed to Pumpdown test on the LID to turn off machine water pumps and lock out machine compressor Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C C Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C C C C C C ...

Page 194: ... 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 condenser vessel a Access the Control Test Pumpdown table on the LID display to turn on the machine water pumps b Close pumpout valves 3 and 4 open valves 2 and 5 Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C Valve 1a 1b 2 3 4 5 8 11 12 13 ...

Page 195: ...ressure at the LID and refrigerant gages e Close valve 1b f Turn off pumpout compressor g Close valves 1a 2 and 5 h Turn off pumpout condenser water i Proceed to Pumpdown test on the LID to turn off machine water pumps and lockout machine compressor Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C C C C C C ...

Page 196: ...nd 3 4 Crack open valve 5 gradually increasing pressure in the evacuated vessel to 68 psig 469 kPa for HCFC 22 35 psig 141 kPa for HFC 134a Feed refrigerant slowly to prevent tube freeze up 5 Leak test to ensure vessel integrity 6 Open valve 5 fully 7 Open valve 11 to equalize the liquid refrigerant level between vessels Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C C C Valve 1a 1b 2 3 4...

Page 197: ...d 5 9 Open isolation valves 12 13 and 14 if present 10 Proceed to Terminate Pumpdown Lockout test to turn off water pumps and enable the machine compressor for start up Valve 1a 1b 2 3 4 5 8 11 12 13 14 Condition C C C C C C C ...

Page 198: ...y 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 HCFC 22 and HFC 134a will dissolve oil and some nonmetallic materials dry the skin and in heavy concentrations may displace enough oxygen to cause asph...

Page 199: ... the storage tank to the machine Adjusting the Refrigerant Charge If the addition or removal of refrigerant is required for improved machine performance follow the procedures given under the Trim Refrigerant Charge section Always use the compressor Pumpdown function in the Control Test table to turn on the evaporator pump and lock out the compressor when transferring refriger ant Liquid refrigeran...

Page 200: ...ASHRAE recommends that machines should be immediately taken off line and repaired if the refrigerant leakage rate for the entire machine 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 lb 0 5 kg per year should be repaired during annual maintenance or whenever the refrigerant is pum...

Page 201: ...he 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 machine and close the regulating valve when the pressure reaches test level Do not exceed 140 psig 965 kPa HCFC 22 and HFC 134a should not be mixed with air...

Page 202: ...achine Dehydration in the Before Initial Start Up section Checking Guide Vane Linkage When the machine is off the guide vanes are closed and the actuator mechanism is in the position shown in Figure 38 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 holddown ...

Page 203: ... operate the machine at design load and then add or remove refrigerant slowly until the difference between leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions or becomes a minimum Do not overcharge Refrigerant may be added either through the storage tank or directly into the machine as described in the section entitled Refrigerant Charging To remove a...

Page 204: ...ional 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 maintain oil temperature see the Controls section when the compressor is off The LID Status02 table displays whether the heater is e...

Page 205: ...e reset to zero by the service person or the operator each time major service work is completed so that time between service can be viewed Inspect the Control Center Maintenance is limited to general cleaning and tightening of connections Vacuum the cabinet to eliminate dust build up In the event of machine control malfunctions refer to the Troubleshooting Guide section for control checks and adju...

Page 206: ...with the refrigerant remaining in the machine Use the following procedure 1 Make sure that the compressor is off and the disconnect for the compressor is open 2 Disconnect the power to the oil pump 3 Close the oil filter isolation valves Figure 4 4 Connect an oil charging hose from the oil charging valve Figure 4 and place the other end in a clean container suitable for used oil The oil drained fr...

Page 207: ...and tighten down the retainer nut Install the filter cover and tighten the 4 bolts 9 Evacuate the filter housing by placing a vacuum pump on the charging valve Follow the normal evacuation procedures Shut the charging valve when done and reconnect the valve so that new oil can be pumped into the filter housing Fill with the same amount that was removed then close the charging valve 10 Remove the h...

Page 208: ...lkyl benzene type oil part number PP23BZ101 or the polyolester based oil P N PP23BZ103 may be ordered from your local Carrier representative Oil Changes Carrier recommends changing the oil after the first year of operation and every three 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 perf...

Page 209: ...ower sight glass for shutdown conditions If the oil level is above 1 2 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 A refrigerant filter drier located on the refrigerant cooling line to the motor Figure 2A or Figure 2B should be changed once a year or more often if filter condition indicates a need for more f...

Page 210: ...ve the float access cover Clean the chamber and valve assembly thoroughly Be sure that the valve moves freely Make sure that all openings are free of obstructions Examine the cover gasket and replace if necessary See Figure 39 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 opera...

Page 211: ... is proper lubrication Use the proper grade of oil maintained at recommended level temperature and pressure Inspect the lubrication system regularly and thoroughly 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 compressor bases was used for factory test purposes and is not usable f...

Page 212: ...or signs of corrosion or scale Replace the sensor if corroded or remove any scale if found Condenser Since this water circuit is usually an open type system the tubes may be subject to contamination and scale Clean the condenser tubes with a rotary tube cleaning system at least once per year and more often if the water is contaminated Inspect the entering and leaving condenser water sensors for si...

Page 213: ...be cleaning process use brushes especially designed to avoid scraping and scratching the tube wall Contact your Carrier representative to obtain these brushes Do not use wire brushes Water Leaks Water is indicated during machine operation by the refrigerant moisture indicator Figure 2A or Figure 2B on the refrigerant motor cooling line Water leaks should be repaired immediately CAUTION CAUTION Har...

Page 214: ...program CAUTION CAUTION Machine must be dehydrated after repair of water leaks See Machine Dehydration section CAUTION CAUTION Water must be within design flow limits clean and treated to ensure proper machine performance and reduce the potential of tubing damage due to corro sion scaling erosion and algae Carrier assumes no responsibility for chiller damage resulting from untreated or improperly ...

Page 215: ...aintenance 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 The disconnect on the starter front panel does not deenergize all internal circuits Open all internal and remot...

Page 216: ...tach an accurate set 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 CAUTION CAUTION Loose powe...

Page 217: ...utdown 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 compressor service valve Figure 37 2 Close the suction service valve and open the discharge line to the storage tank or the machine 3 Operate the compressor until the crankcase pressure drops to 2 psig 13 kPa...

Page 218: ... 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 Ordering Replacement Chiller Parts When ordering Carrier specified parts the following information must accompany an order machine model number and serial number name quantity and part number of the part required delivery address and me...

Page 219: ... chilled water temperature control chilled water tem perature control overrides hot gas bypass surge algorithm status and time schedule operation The Control Test feature allows proper operation and testing 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 o...

Page 220: ...the failure message The compressor will not run with an alarm condition existing unless the alarm type is an unauthorized start or a failure to shut down Checking Temperature Sensors All temperature 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 vo...

Page 221: ...xercise care when measuring voltage to prevent damage to the sensor leads connector plugs and modules Sensors should also be checked at the sensor plugs Check the sensor wire at the sensor for 5 vdc if the control is powered Check Sensor Accuracy Place the sensor in a medium of a known temperature and compare that temperature to the measured reading The thermometer used to determine the temperatur...

Page 222: ...inal 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 the 19XL These determine cooler condenser and oil pressure The cooler and condenser transducers also are used by the PIC to determine the refrigerant temperatures All 3 can be calibrated if necessary It is not usual...

Page 223: ...connect the transducer in question from its Schrader fitting Note If the cooler or condenser vessels are at 0 psig 0 kPa or are open to atmospheric pres sure the transducers can be calibrated for zero without removing the transducer from the vessel 3 Access the Status01 table and view the particular transducer reading it should read 0 psi 0 kPa If the reading is not 0 psi 0 kPa but within 5 psi 35...

Page 224: ...ween 240 and 260 psig 1655 and 1793 kPa by attaching a regulated 250 psig 1724 kPa pressure usually from a nitrogen cylinder The high pressure point can be calibrated by accessing the transducer on the Status01 screen highlighting the transducer pressing the SELECT softkey and then increasing or decreasing the value to the exact pressure on the refrigerant gage Press ENTER to finish High altitude ...

Page 225: ...nsducer 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 Make sure ...

Page 226: ...ol Override Status Surge HGBP Status LEAD LAG Status Time Schedules Status Water System Manager Status This table shows all values that are used to calculate the chilled water brine control point Details of all chilled water control override values are viewed here The surge and hot gas bypass control algorithm status is viewed from this screen All values dealing with this control are displayed Thi...

Page 227: ...n 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 machine 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 ad...

Page 228: ... Table 10D Pre Start Alerts Click here for Table 10E Normal or Auto Restart Click here for Table 10F Start Up Failures Click here for Table 10G Compressor Jumpstart and Refrigerant Protection Click here for Table 10H Normal Run with Reset Temperature or Demand ...

Page 229: ...rts Click here for Table 10J Out of Range Sensor Failures Click here for Table 10K Machine Protect Limit Faults Click here for Table 10L Machine Alerts Click here for Table 10M Spare Sensor Alert Messages Click here for Table 10N Other Problems Malfunctions ...

Page 230: ...on of all modules is indicated by LEDs light emitting diodes located on the side of the LID and on the top horizontal surface of the PSIO SMM and 8 input modules Click here for Table 11A Thermistor Temperature F vs Resistance Voltage Drop Click here for Table 11B Thermistor Temperature C vs Resistance Voltage Drop CAUTION CAUTION Turn controller power off before servicing controls This ensures saf...

Page 231: ... is no input power check fuses and the circuit breaker If fuse is good check for shorted secondary 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 modules as follows LID Module Upper LED Communication with CCN netw...

Page 232: ...ations connection Communication 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 ...

Page 233: ...odule is connected to Terminal 1 of each of the other modules Terminals 2 and 3 are connected in the same manner See Figure 41 Figure 42 Figure 43 Figure 44 and Figure 45 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 red LED is normal check the module address ...

Page 234: ...dules The PSIO monitors conditions using input ports on the PSIO the SMM and the 8 input modules Outputs are controlled by the PSIO and SMM as well 3 Power is supplied to modules within the control panel via 21 vac 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 with...

Page 235: ...o 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 application Refer to the unit wiring diagram Click here for Figure 41 PSIO Module Address Selector Switch Locations and LED Locations Click here for Figure 42 LID Module Rear View and LED Locations Click here for Figure 43 Processor PSIO Module ...

Page 236: ...discrete on off inputs Application of the machine determines 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 Click here for Figure 44 Starter Management Module SSM ...

Page 237: ...s Inputs for each of the options modules available include the following Option 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 Option Module 2 4 to 20 mA Spare 1 4 to 20 mA Spare 2 Spare Temperature 4 ...

Page 238: ...mber 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 processor module PSIO specify complete replacement part number full unit model number and serial number This new unit requires reconfig...

Page 239: ...ploaded into memory then when the new module is installed the con figuration can be downloaded from the computer Any communication wires from other machines or CCN modules should be disconnected to prevent the new PSIO module from uploading incorrect run hours into memory 3 Check that all power to the unit is off Carefully disconnect all wires from the defective module by unplugging the 6 connecto...

Page 240: ...s the Attach to Network Device table on the LID Service menu Set the local device address to Bus 0 Address 90 Press the ATTACH softkey to upload the PSIO into the LID 11 Change the address of the PSIO in the Controller Identification table back to the previous value Write the address on the PSIO 12 Use the configuration sheets to input setpoint configuration and schedule information into the PSIO ...

Page 241: ...leshooting tables When the power is off Inspect for physical damage and signs of arcing overheating 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 R...

Page 242: ...ctive but the problem still persists refer to the following Steps 5 and 6 5 Disconnect the SCR1 from the white gate and red cathode wires on the AK control logic card With an ohmmeter set on Rx1 check between white and red wires Resistance should normally be between 8 and 20 ohms average Excessively high or low resistance may be indicative of a defective device Replace and retest 6 Repeat Step 5 f...

Page 243: ...esistance reading Resistance reading should be greater than 10 000 ohms 2 Connect ohmmeter across terminals L2 and T2 Check the resistance reading Resistance reading should be greater than 10 000 ohms 3 Connect ohmmeter across terminals L3 and T3 Check the resistance reading Resistance reading should be greater than 10 000 ohms If the SCRs tested were not defective but the problem persists refer t...

Page 244: ...tly less one or both SCRs in the power pole may be shorted See Figure 48 7 If a shorted SCR is detected check for possible shorted connections system grounds or any other condition that might be causing the short Replacement of SCRs or power poles without determining the cause of the failure may result in repeated failure of the SCRs 8 When the starter is running measure the voltage from the line ...

Page 245: ...p to speed any current unbalance in the motor is caused by the motor or an unbalanced line voltage Electronic Protection Relay EPR On Cutler Hammer solid state starters the EPR is designed to provide an alternative to conventional motor protection due to overcurrent See Figure 50 It performs the following functions Test Button The TEST button provides testing of the EPR s ability to detect overloa...

Page 246: ...ovides a visual indication that the EPR has detected an overload condition and tripped Fault FLT LED The FLT LED is an indicator light Reset Button The RESET button allows for the manual reset of the EPR Trip Common COM and FLA Test Terminals The Trip COM and FLA test terminals provide for Digital Voltmeter DVM calibration Terminal 1 TB1 Terminal 1 is the 120 vac connection to power the EPR Termin...

Page 247: ... red light and the SYST RDY LED is a solid green light the overload has tripped because of a phase unbalance Click here for Figure 50 Cutler Hammer Terminal Functions Click here for Figure 51 Solid State Starter General Operation Troubleshooting Guide Typical Click here for Figure 52 Solid State Starter Starter Fault Motor Will Not Start Troubleshooting Guide Typical Click here for Table 12 Bensha...

Page 248: ...garding compressor fits and clearances physical and electrical data and wiring schematics for operator convenience during troubleshooting Click here for Table 13 Cutler Hammer Solid State Starter Troubleshooting Guide Click here for Table 14 Heat Exchanger Data Click here for Table 15 Additional Data for Marine Waterboxes Click here for Table 16 Compressor Weights ...

Page 249: ...Waterbox Cover Weights Click here for Table 19 Optional Pumpout System Electrical Data Click here for Figure 53 Compressor Fits and Clearances Click here for Figure 54 Compressor Fits and Clearances continued Click here for Figure 55 Compressor Fits and Clearances continued ...

Page 250: ...gure 56 Electronic PIC Controls Wiring Schematic Click here for Figure 57 Machine Power Panel Starter Assembly and Motor Wiring Schematic Click here for Figure 58 Typical Wye Delta Unit Mounted Starter Wiring Schematic ...

Page 251: ...M Local Interface Device LID 6 Pack Relay Board 8 Input Modules Optional Oil Heater Contactor 1C Oil Pump Contactor 2C Hot Gas Bypass Relay 3C Optional Control Transformers T1 T4 Control and Oil Heater Voltage Selector S1 Temperature Sensors Pressure Transducers Control Center Starter Cabinet Control Center Control Center Control Center Power Panel Power Panel Power Panel Power Panel Power Panel S...

Page 252: ...en To access this display from the LID default screen 1 Press MENU 2 Press STATUS STATUS01 will be highlighted 3 Press SELECT Table 2 Example 1 Status01 Display Screen Description Range Units Reference Point Name Alarm History Control Mode Run Status Occupied Alarm State Chiller Start Stop Base Demand Limit Active Demand Limit Compressor Motor Load Current Amps Target Guide Vane Pos Actual Guide V...

Page 253: ...r Starts Starts in 12 Hours Compressor Ontime Service Ontime Compressor Motor kW 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 6 7 420 46 2896 40 245 40 118 6 7 420 46 2896 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 6 7 420 46 2896 6 7 420 46 2896 0 999 0 9999 Off On 0 65535 0 8 0 500000 0 0 32767 0 9999 DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG C DEG F DEG...

Page 254: ...led 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 X X X X X X X X X X X X X X X X X X OFF ON OFF ON NO YES OFF O...

Page 255: ...or Common CHWR Sensor Remote Reset Sensor Temp Sensor Spare 1 Temp Sensor 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 4 20 4 20 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 40 245 40 118 4 20 4 20 40 245 40 118 40 245 40 11...

Page 256: ...e 2 Example 4 Setpoint Display Screen Description Configurable Range Units Reference Point Name Default Value Base Demand Limit LCW Setpoint ECW Setpoint ICE BUILD Setpoint 40 100 20 120 6 7 48 9 20 120 6 7 48 9 20 60 6 7 15 6 DEG F DEG C DEG F DEG C DEG F DEG C DLM lcw sp ecw sp ice sp 100 50 0 10 0 60 0 15 6 40 0 4 4 ...

Page 257: ...ldown Deg Min Load Pulldown Min 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 Temp 1 Contacts 2 Both ICE BUILD Recycle Option 30 30 17 17 40 245 40 118 40 245 40 118 30 30 17 17 0 15 0 8 0 15 0 8 30 30 17 17 0 3 DISABLE ENABLE 40 100 DISABLE ENABLE DISAB...

Page 258: ...uration Display Screen Description Configurable Range Units Reference Point Name Default Value 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 0 3 DISABLE ENABLE DISABLE ENABLE 25 75 1 236 2 60 2 60 0 30 DISAB...

Page 259: ...d Recycle Restart Delta T Surge Limit HGBP Option Select Surge 0 HGBP 1 Surge HGBP Delta T1 Surge HGBP Delta P1 Min Load Points T1 P1 Surge HGBP Delta T2 150 200 66 93 150 245 1034 1689 90 200 620 1379 2 5 1 3 Water Brine 8 40 13 3 4 125 200 52 93 175 185 79 85 0 5 5 15 300 0 5 2 0 0 3 1 1 2 0 10 0 1 1 5 6 0 1 0 5 15 0 3 8 3 50 170 345 1172 30 170 207 1172 0 5 15 0 3 8 3 50 170 345 1172 DEG F DEG ...

Page 260: ...Rated Line Voltage Meter Rated Line KW Line Frequency Select 0 60 Hz 1 50 Hz Compr Starter Type Condenser Freeze Point Soft Stop Amps Threshold 30 170 207 1172 1 3 0 6 1 6 10 50 1 5 0 1 1 8 1 9999 1 9999 1 9999 0 1 REDUCE FULL 20 35 28 9 1 7 40 100 PSI kPa DEG F DEG C MIN AMPS VOLTS kW HZ DEG F DEG C hgb dp2 hgb dp surge a surge t dem src corfact a fs v fs kw fs freq starter cdfreeze softstop 170 ...

Page 261: ...NABLE Disable 0 Low 1 High 2 Temp Alert Threshold CHWS Temp Enable CHWS Temp Alert CHWR Temp Enable CHWR Temp Alert Reset Temp Enable 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 DISABLE ENABLE DISABLE ENABLE 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 4...

Page 262: ...d Spare Temp 4 Enable Spare Temp 4 Alert Spare Temp 5 Enable Spare Temp 5 Alert Spare Temp 6 Enable Spare Temp 6 Alert Spare Temp 7 Enable Spare Temp 7 Alert Spare Temp 8 Enable Spare Temp 8 Alert Spare Temp 9 Enable Spare Temp 9 Alert DISABLE ENABLE DISABLE ENABLE 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 40 118 0 2 40 245 0 118 0 2 40 245 40 118 DEG F DEG C DEG F DEG C DEG...

Page 263: ...ght EQUIPMENT SERVICE 4 Press SELECT 5 Scroll down to highlight SERVICE3 Table 2 Example 9 Service3 Display Screen Description Configurable Range Units Reference Point Name Default Value Proportional Inc Band Proportional Dec Band Proportional ECW Gain Guide Vane Travel Limit 2 10 2 10 1 3 30 100 gv inc gv de gv ecw gv lim 6 5 6 0 2 0 50 ...

Page 264: ...ription Range Status Units Reference Point Name CAPACITY CONTROL Control Point Leaving Chilled Water Entering Chilled Water Control Point Error ECW Delta T ECW Reset LCW Reset Total Error Resets Guide Vane Delta Target Guide Vane Pos Actual Guide Vane Pos Proportional Inc Band Proportional Dec Band Proportional ECW Gain Water Brine Deadband 10 120 12 2 48 9 40 245 40 118 40 245 40 118 99 99 55 55 ...

Page 265: ...era tion Table 2 Example 11 Maintenance Maint02 Display Screen Description Range Status Units Reference Point Name OVERRIDE ALERT STATUS MOTOR WINDING TEMP Override Threshold CONDENSER PRESSURE Override Threshold EVAPORATOR REFRIG TEMP Override Threshold DISCHARGE TEMPERATURE Alert Threshold BEARING TEMPERATURE Alert Threshold 40 245 40 118 150 200 66 93 6 7 420 42 2896 90 245 621 1689 40 245 40 1...

Page 266: ...e Override is not supported on this maintenance screen Only values with capital letter reference point names are variables available for read operation Table 2 Example 12 Maintenance Maint03 Display Screen Description Range Status Units Reference Point Name SURGE HGBP ACTIVE Active Delta P Active Delta T Calculated Delta T Surge Protection Counts NO YES 0 200 0 1379 0 200 0 111 0 200 0 111 0 12 PS...

Page 267: ...figuration Current Mode Load Balance Option LAG Start Time LAG Stop Time Prestart Fault Time Pulldown Delta T Min Satisfied LEAD CHILLER in Control LAG CHILLER Mode Run Status Start Stop Recovery Start Request STANDBY CHILLER Mode Run Status Start Stop Recovery Start Request DISABLE LEAD LAG STANDBY INVALID DISABLE LEAD LAG STANDBY CONFIG DISABLE ENABLE 0 60 0 60 0 30 x xx No Yes No Yes Reset Off ...

Page 268: ...nt adjustable from 0 to 40 F 18 to 4 C for brine chilling Configure chilled medium for brine Service1 table Adjust brine refrigerant trippoint for proper cutout Transducer Voltage 4 5 vdc 5 5 vdc Preset Condenser Pressure Switch Control 263 7 psig 1813 48 kPa reset at 180 10 1241 69 kPa Preset 260 psig 1793 kPa for HCFC 22 215 psig 1482 kPa for HFC 134a Preset Oil Pressure Switch Control Cutout 11...

Page 269: ... full voltage starters Configured on Service1 table Starter Transition 75 seconds Reduced voltage starters only Condenser Freeze Protection Energizes condenser pump relay if condenser refrigerant temperature or condenser entering water tempera ture is below the configured con denser freeze point temperature Deenergizes when the temperature is 5 F 3 C above condenser freeze point temperature CONDEN...

Page 270: ...erride Delta Temperature Equip ment Service1 3 F 1 6 C Above Trippoint 2 to 5 F 1 to 3 C Trippoint Override T 1 F 0 56 C Trippoint Override T 2 F 1 2 C High Compressor Lift Surge Prevention Equip ment Service1 HCFC 22 HFC 134a HCFC 22 HFC 134a None Within Lift Limits Plus Surge HGBP Deadband Setting Min T1 1 5 F 0 8 C P1 75 psid 517 kPad Max T2 10 F 5 6 C P2 170 psid 1172 kPad Min T1 1 5 F 0 8 C P...

Page 271: ...40 to 100 5 of Set Point 2 Lower Than Set Point Table 4 Capacity Overrides Continued Override Capacity Control First Stage Setpoint Second Stage Setpoint Override Termination View Modify on LID Screen Default Value Configurable Range Value Value ...

Page 272: ... 50 254 08 260 79 267 63 226 35 232 80 239 38 246 10 252 94 20 18 16 14 12 24 85 26 02 27 24 28 50 29 81 10 15 11 32 12 54 13 81 15 11 50 52 54 56 58 98 73 102 07 105 50 109 02 112 62 84 03 87 38 90 81 94 32 97 93 120 122 124 126 128 274 60 281 71 288 95 296 33 303 84 259 91 267 01 274 25 281 63 289 14 10 8 6 4 2 31 16 32 56 34 01 35 51 37 06 16 47 17 87 19 32 20 81 22 36 60 62 64 66 68 116 31 120...

Page 273: ...8 7 6 5 367 380 393 407 421 266 279 292 306 320 21 22 23 24 25 936 962 989 1020 1040 835 861 888 919 939 51 52 53 54 55 1980 2030 2080 2130 2170 1890 1930 1980 2030 2070 4 3 2 1 0 436 451 466 482 498 335 350 365 381 397 26 27 28 29 30 1070 1100 1130 1160 1190 969 1000 1030 1060 1090 56 57 58 59 60 2220 2270 2320 2370 2430 2120 2170 2220 2270 2330 1 2 3 4 5 514 531 548 566 584 413 430 447 465 483 3...

Page 274: ...52 8 60 9 66 10 79 10 12 14 16 18 11 96 13 17 14 42 15 72 17 06 20 22 24 26 28 18 45 19 88 21 37 22 90 24 48 30 32 34 36 38 26 11 27 80 29 53 31 32 33 17 40 42 44 46 48 35 08 37 04 39 06 41 14 43 28 50 52 54 56 58 45 48 47 74 50 07 52 47 54 93 60 62 64 66 68 57 46 60 06 62 73 65 47 68 29 ...

Page 275: ...06 116 02 120 08 100 102 104 106 108 124 23 128 47 132 81 137 25 141 79 110 112 114 116 118 146 43 151 17 156 01 160 96 166 01 120 122 124 126 128 171 17 176 45 181 83 187 32 192 93 130 132 134 136 138 140 198 66 204 50 210 47 216 55 222 76 229 09 Table 5C HFC 134a Pressure Temperature F Continued Temperature F Pressure psig ...

Page 276: ...66 6 74 4 12 2 11 1 10 0 8 9 7 8 82 5 90 8 99 4 108 0 118 0 6 7 5 6 4 4 3 3 2 2 127 0 137 0 147 0 158 0 169 0 1 1 0 0 1 1 2 2 3 3 180 0 192 0 204 0 216 0 229 0 4 4 5 0 5 6 6 1 6 7 242 0 248 0 255 0 261 0 269 0 7 2 7 8 8 3 8 9 9 4 276 0 284 0 290 0 298 0 305 0 10 0 11 1 12 2 13 3 14 4 314 0 329 0 345 0 362 0 379 0 ...

Page 277: ... 34 4 35 6 36 7 720 0 746 0 773 0 800 0 828 0 37 8 38 9 40 0 41 1 42 2 857 0 886 0 916 0 946 0 978 0 43 3 44 4 45 6 46 7 47 8 1010 0 1042 0 1076 0 1110 0 1145 0 48 9 50 0 51 1 52 2 53 3 1180 0 1217 0 1254 0 1292 0 1330 0 54 4 55 6 56 7 57 8 58 9 60 0 1370 0 1410 0 1451 0 1493 0 1536 0 1580 0 Table 5D HFC 134a Pressure Temperature C Continued Temperature C Pressure Gage kPa ...

Page 278: ...mp Time Adjust able Current Ramp 2 seconds 30 seconds Sets time during which cur rent ramps from the initial starting level to the maxi mum possible current limit setting 15 seconds Current Limit 100 400 Sets maximum starting cur rent 250 Pulse Start 0 Off 2 seconds Sets duration of 400 cur rent pulse Pulse is used to break load free OFF Current Trip 50 400 Sets running current trip 175 Power Save...

Page 279: ...1 2 4 440 60 460 60 480 60 550 60 2 3 4 3 2 2 3 2 1 2 3 1 1 2 3 2 1 2 3 3 1 2 3 2 3 5 7 2 4 6 8 2 575 60 600 60 3300 60 2400 60 4 6 4 3 2 4 1 3 2 3 2 2 3 4 3 3 4 6 3 2 3 5 3 2 3 4 2 3 3 4 2 3 4160 60 220 50 230 50 240 50 3 2 2 5 3 2 3 4 2 2 2 3 3 3 4 5 2 2 3 3 2 1 2 3 3 1 1 2 3 1 1 2 320 50 346 50 360 50 380 50 2 3 4 3 2 3 4 3 1 3 4 3 1 2 2 2 1 1 2 4 1 2 2 2 3 3 8 2 3 4 8 2 400 50 415 50 3000 50 3...

Page 280: ...water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature 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 Evaporator pressure Condenser pressure Oil pressure differential Oil pump pressure Open Close All pumps or individual pumps ...

Page 281: ...ch valves to close and when Starts chilled water and condenser water pumps and con firms flows Monitors Evaporator pressure Condenser pressure Evaporator temperature during pumpout procedures Turns pumps off after pumpdown Locks out compressor Starts pumps and monitors flows Instructs operator as to which values to open and when Monitors Evaporator pressure Condenser pressure Evaporator temperatur...

Page 282: ... Table 9 Refrigerant HCFC 22 or HFC 134a Charges Cooler Size 19XL Total Refrigerant Charge Design I Machine Design II Machine lb kg lb kg 40 1420 640 1270 1576 41 1490 680 1340 1607 42 1550 700 1400 1635 43 1600 730 1450 1658 50 1850 840 1650 1748 51 1900 860 1700 1771 52 1980 900 1780 1807 53 2050 930 1850 1839 55 2330 1057 56 2400 1089 57 2510 1139 58 2610 1184 ...

Page 283: ...arter Fault MTRB Bearing Temperature TXV Thermostatic Expansion Valve MTRW Motor Winding Temperature V P Line Voltage Percent V REF Voltage Reference Table 10A Shutdown with On Off Reset Off Primary Message Secondary Message Probable Cause Remedy Manually Stopped Press CCN or Local to Start PIC in OFF mode press the CCN or local softkey to start unit Terminate Pumpdown Mode To Select CCN or Local ...

Page 284: ...t on the Service menu Ready To Start Remote Contacts Open Remote contacts have stopped machine Close contacts to start Ready To Start Stop Command In Effect Chiller START STOP on Status01 manually forced to stop Release value to start Ready To Start In XX Min Remote Contacts Closed Machine timer counting down unit Ready for start Ready To Start In XX Min Occupied Mode Machine timer counting down u...

Page 285: ...tart Pending Remote Contact Closed Unit in recycle mode chilled water temperature is not high enough to start Recycle Restart Pending Start Command In Effect Chiller START STOP on Status01 manually forced to start chill water temperature is not high enough to start Recycle Restart Pending Ice Build Mode Machine in ICE BUILD mode Chilled Water Brine Tem perature is satisfied for Ice Build Setpoint ...

Page 286: ...art Alert High Discharge Temp CMPD VALUE exceeded limit of LIMIT Check discharge tem perature Check sensor accuracy Allow discharge temperature to cool Check for excessive starts Prestart Alert Low Refrigerant Temp ERT VALUE exceeded limit of LIMIT Check refrigerant tem perature Check transducer accuracy Check for low chilled water brine supply temperature Prestart Alert Low Oil Temperature OILT V...

Page 287: ...te contacts are closed Startup in Progress Start Command In Effect Machine starting Chiller START STOP on Status01 manually forced to start AutoRestart in Progress Occupied Mode Machine starting Time schedule is occupied AutoRestart in Progress Remote Contact Closed Machine starting Remote contacts are closed AutoRestart in Progress Start Command In Effect Machine starting Chiller START STOP on St...

Page 288: ...ch Check through Control Test for proper switch operation Failure To Start Starter Fault STR FLT Starter Fault Check Starter for Fault Source A starter protective device has faulted Check starter for ground fault voltage trip temperature trip etc Failure To Start Starter Overload Trip STR FLT Starter Overload Trip Check amps calibration reset overload Reset overloads before restart Failure To Star...

Page 289: ...ps signal to SMM Check wiring from SMM to cur rent transformer Check main motor cir cuit breaker for trip Failure To Start Check Refriger ant Type Current Refrigerant Properties Abnormal Check Selection of refrigerant type Pressures at transducers indicate another refrigerant type in Control Test Make sure to access the ATTACH TO NETWORK DEVICE table after chang ing refrigerant type Failure To Sta...

Page 290: ...efrigerant out of machine stop operation and go over pumpout procedures Failure To Stop Disconnect Power RUN AUX Emergency DIS CONNECT POWER Starter and run and start con tacts are energized while control tried to shut down Disconnect power to starter Loss Of Communciation With Starter Loss of Communication with Starter Check machine Check wiring from PSIO to SMM Check SMM module trou bleshooting ...

Page 291: ...ading in effect Use Service1 table to modify Running Demand Limited By Demand Ramp Loading Ramp loading in effect Use Service1 table to modify Running Demand Limited By Local Demand Setpoint Demand limit setpoint is actual demand Running Demand Limited By 4 20MA Signal Demand limit is active based on Config table setup Running Demand Limited By CCN Signal Running Demand Limited By LoadShed Redline...

Page 292: ...gh Condenser Pres sure CRP VALUE exceeded limit of LIMIT Condenser pressure override See Capacity Over rides Table 4 Correct operating condition modify setpoint or release override Run Capacity Lim ited High Motor Temperature MTRW VALUE exceeded limit of LIMIT Motor temperature over ride Run Capacity Lim ited Low Evap Refrig Temp ERT VALUE exceeded limit of LIMIT Check refrigerant charge level Run...

Page 293: ...r Fault Condenser Pressure Sensor Fault Check condenser pressure transducer Sensor Fault Evaporator Pressure Sensor Fault Check evaporator pressure transducer Sensor Fault Bearing Temperature Sensor Fault Check bearing tem perature sensor Sensor Fault Motor Winding Temp Sensor Fault Check motor temper ature sensor Sensor Fault Discharge Temperature Sensor Fault Check discharge tem perature sensor ...

Page 294: ...flow and temperature Check motor cooling system for restric tions Check motor cooling solenoid for proper operation Check refrigerant filter Protective Limit High Bearing Tem perature MTRB VALUE exceeded limit of LIMIT Check oil cool ing control Check for throttled oil supply isolation valves Valves should be wide open Check oil cooler thermal expansion valve Check sensor accuracy Check journal an...

Page 295: ...nser pressures and con denser 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 Protective Limit High Condenser Pressure High Cond Pressure VALUE Check switch water flow and trans ducer Check water flow in condenser Check for fouled tubes Transducer should be checked for accuracy This alarm is not cau...

Page 296: ...denser flow and temperatures Check configuration of surge protection Protective Limit Starter Fault STR FLT Starter Fault Check starter for fault source Check starter for possible ground fault reverse rotation voltage trip etc Protective Limit Starter Overload Trip STR FLT Starter Over load Trip Check amps calibration reset over load Reset overloads and reset alarm Check motor current calibration ...

Page 297: ...r Loss V P Power Loss Check voltage supply Check power supply if there are excessive compressor starts occurring AutoRestart Pending Low Line Voltage V P VALUE exceeded limit of LIMIT Check voltage supply AutoRestart Pending High Line Voltage V P VALUE exceeded limit of LIMIT Check voltage supply Sensor Alert High Discharge Temp CMPD VALUE exceeded limit of LIMIT Check dis charge temperature Disch...

Page 298: ...1 Sensor Fault Check temperature sen sor Spare 1 Spare Sensor Alert Temp Sensor Spare 2 Sensor Fault Check temperature sen sor Spare 2 Spare Sensor Alert Temp Sensor Spare 3 Sensor Fault Check temperature sen sor Spare 3 Spare Sensor Alert Temp Sensor Spare 4 Sensor Fault Check temperature sen sor Spare 4 Spare Sensor Alert Temp Sensor Spare 5 Sensor Fault Check temperature sen sor Spare 5 Spare S...

Page 299: ...erminals ChilledWater Brine Temperature Too Low Machine Running Chilled water set point set too low Access set point on 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 a...

Page 300: ...cal 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 trou bleshooting section Controls Test Disabled 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 S...

Page 301: ... 55 0 56 0 57 0 58 0 59 0 60 0 61 0 62 0 63 0 64 0 65 0 66 0 67 0 68 0 69 0 70 0 4 278 4 258 4 241 4 223 4 202 4 184 4 165 4 145 4 125 4 103 4 082 4 059 4 037 4 017 3 994 3 968 3 948 3 927 3 902 3 878 3 854 3 828 3 805 3 781 3 757 3 729 3 705 3 679 3 653 3 627 3 600 3 575 3 547 3 520 3 493 3 464 3 437 3 409 3 382 3 353 3 323 3 295 3 267 3 238 3 210 3 181 3 152 3 123 21 153 20 547 19 960 19 393 18 ...

Page 302: ...188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 0 945 0 929 0 914 0 898 0 883 0 868 0 853 0 838 0 824 0 810 0 797 0 783 0 770 0 758 0 745 0 734 0 722 0 710 0 700 0 689 0 678 0 668 0 659 0 649 0 640 0 632 0 623 0 615 0 607 0 600 0 592 0 585 0 579 0 572 0 566 0 560 0 554 0 548 0 542 0 537 0 531 0 526 0 520 0 515 832 815 798 782 765 750 734 719 705 690 677 663 650 638 626 614 602 591 ...

Page 303: ... 143 247 140 845 138 592 138 476 134 489 132 621 130 866 129 216 127 633 126 202 124 827 123 532 122 313 121 163 120 079 119 058 118 094 117 184 116 325 115 515 114 749 114 026 113 342 112 696 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 3 860 3 816 3 771 3 726 3 680 3 633 3 585 3 537 3 487 3 438 3 387 3 3...

Page 304: ... 1 006 971 938 906 876 836 805 775 747 719 693 669 645 623 602 583 564 547 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 100 101 102 103 104 105 106 107 0 648 0 632 0 617 0 603 0 590 0 577 0 566 0 555 0 545 0 535 0 525 0 515 0 506 0 496 0 486 0 476 0 466 0 454 0 442 0 429 0 416 0 401 0 386 0 370 531 516 502 489 477 466 456 446 436 427 419 410 402 393 385 376 367 357 346 335 324 3...

Page 305: ...ay wire strands if required 2 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 BC board over temper ature LED L3 on prior to run command 1 Temperature switch not functioning properly 2 BC board not functioning properly 1 Disconnect power and check for continuity between TB1...

Page 306: ...y 3 Verify fan operation on each phase for 200 amp units Replace fan if necessary BC board L2 lit SCR phases not function ing properly Measure resistance from anode to cathode for each SCR phase assembly Replace shorted phase if necessary BC board L1 lit Motor lead grounded Megger motor to test for motor lead going to ground Start command given Motor does not begin rota tion Turn Starting Torque p...

Page 307: ... SCR looks like shorted SCR Check SCR Starter does not pick up and maintain Line voltage is not applied Check incoming lines for proper voltage Overload is not reset Reset overload 120 v control voltage is not present Check control transformer fuse Check control circuits Heatsink overtemperature switches are open Check for continuity through overtemper ature switches Check that all fans are rotati...

Page 308: ...g SCR Check gate lead wiring to SCRs Defective motor Check motor for shorts opens and grounds Mechanical shock to machine Current increases too quickly Decrease starting current counterclock wise If necessary increase ramp time clockwise End of limit contact does not close Starter is in current limit Perform SCR full voltage test Current trip contact does not close when current goes above the trip...

Page 309: ...when starting symptom in troubleshoot ing table Excessive starting time current limit may be set too low Increase current limit setting clockwise Overload relay trips when running Incorrect heater coils melting alloy Check heater coil rating Mechanical problems Check machinery for binding or exces sive loading Single phasing See Starter or motor is noisy or vibrates when starting problem in troubl...

Page 310: ... 649 196 363 53 445 7375 3350 7770 3524 1650 748 1500 680 104 394 55 201 8510 3860 1840 834 104 395 56 227 8845 4012 1910 860 115 438 57 257 9205 4175 2020 916 128 486 58 290 9575 4343 2120 962 140 531 Condenser 40 218 5050 2100 4855 2202 1400 181 1350 159 156 212 41 246 5200 2350 5010 2272 1400 181 1350 159 162 235 42 279 5375 2450 5180 2350 1400 181 1350 159 168 257 43 315 5575 2525 5370 2436 14...

Page 311: ... English SI Rigging Wt lb Water Volume gal Rigging Wt kg Water Volume L Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser Frame 4 2 Pass 1115 1660 169 151 1506 300 261 193 Frame 4 1 3 Pass 2030 1160 138 101 1922 527 524 384 Frame 5 2 Pass 1220 1935 188 164 1554 424 331 243 Frame 5 1 3 Pass 2240 1705 175 128 1017 774 663 486 ...

Page 312: ...Kg Suction Elbow 1155 1125 Discharge Elbow 1150 1123 Transmission 1730 1331 Suction Housing 1350 1159 Impeller Shroud 1180 1136 Compressor Base 1050 1476 Diffuser 1170 1132 Oil Pump 1150 1168 Miscellaneous 1135 1161 Total Weight Less Motor 2660 1207 ...

Page 313: ...b End Bell Cover lb Compressor Weight lb Stator Weight kg Rotor Weight kg End Bell Cover lb 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz CD 2660 1153 1213 234 252 250 1208 523 551 106 114 114 CE 2660 1162 1227 237 255 250 1208 528 557 108 116 114 CL 2660 1202 1283 246 270 250 1208 546 582 112 123 114 CM 2660 1225 1308 254 275 250 1208 556 594 115 125 114 CN 2660 1276 1341 263 279 250 1208 579 6...

Page 314: ...150 psig 300 psig 150 psig 300 psig Coolers NIH 1 Pass Cover 284 414 324 491 412 578 452 655 NIH 2 Pass Cover 285 411 341 523 410 573 466 685 NIH 3 Pass Cover 292 433 309 469 423 602 440 638 NIH Plain End Cover 243 292 243 292 304 426 304 426 MWB Cover CS 621 CS 621 CS 766 CS 766 Plain End Cover CS 482 CS 482 CS 471 CS 471 Condensers NIH 1 Pass Cover 306 446 346 523 373 472 413 549 NIH 2 Pass Cove...

Page 315: ...a 1034 kPa 2068 kPa 1034 kPa 2068 kPa Coolers NIH 1 Pass Cover 129 188 147 223 187 262 205 297 NIH 2 Pass Cover 129 187 155 237 186 260 212 311 NIH 3 Pass Cover 133 197 140 213 192 273 200 290 NIH Plain End Cover 110 133 110 133 138 193 138 193 MWB Cover CS 282 CS 282 CS 348 CS 348 Plain End Cover CS 219 CS 219 CS 214 CS 214 Condensers NIH 1 Pass Cover 139 202 157 237 169 214 188 249 NIH 2 Pass Co...

Page 316: ...d Amps Table 19 Optional Pumpout System Electrical Data Motor Code Condenser Unit Volts PH HZ Max RLA LRA 1 19EA47 748 575 3 60 13 8 23 0 4 19EA42 748 200 208 3 60 10 9 63 5 5 19EA44 748 230 3 60 19 5 57 5 6 19EA46 748 400 460 3 50 60 14 7 28 8 ...

Page 317: ...Figure 1 19XL Identification ...

Page 318: ...Figure 2A Front View Typical 19XL Components Design I See next page for Rear View ...

Page 319: ...Figure 2A Rear View Typical 19XL Components Design I ...

Page 320: ...Figure 2B Front View Typical 19XL Components Design II See next page for Rear View ...

Page 321: ...Figure 2B Rear View Typical 19XL Components Design II ...

Page 322: ...Figure 3 Refrigerant Motor Cooling and Oil Cooling Cycles ...

Page 323: ...Figure 4 Lubrication System ...

Page 324: ...Figure 5 Cutler Hammer Solid State Starter Internal View ...

Page 325: ...Figure 6 Benshaw Inc Solid State Starter Internal View ...

Page 326: ...Figure 7 Typical Starter Front View Solid State Starter Shown ...

Page 327: ...Figure 8 19XL Controls and Sensor Locations ...

Page 328: ...Figure 9 Control Sensors Temperature ...

Page 329: ...Figure 10 Control Sensors Pressure Transducer Typical ...

Page 330: ...Figure 11 Control Panel Front View with Options Module ...

Page 331: ...Figure 12 Power Panel with Options ...

Page 332: ...Figure 13 LID Default Screen ...

Page 333: ...Figure 14 LID Service Screen ...

Page 334: ...Figure 15 Example of Point Status Screen Status01 ...

Page 335: ...Figure 16 19XL Menu Structure ...

Page 336: ...Figure 17 19XL Service Menu Structure ...

Page 337: ...Figure 18 Example of Time Schedule Operation Screen ...

Page 338: ...Figure 19 Example of Set Point Screen ...

Page 339: ...Figure 20 19XL Hot Gas Bypass Surge Prevention ...

Page 340: ...Figure 21 19XL with Default Metric Settings ...

Page 341: ...Figure 22 Example of Attach to Network Device Screen ...

Page 342: ...Figure 23 Example of Holiday Period Screen ...

Page 343: ...onds after D F SHUTDOWN INITIATED Compressor motor stops compressor 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 G Oil pump and evaporator pumps deenergized 60 seconds after F Condenser pump and tower fan control may continue to operate if condenser pressure is high Evap...

Page 344: ...Figure 25 Typical Wet Bulb Type Vacuum Indicator ...

Page 345: ...Figure 26 19XL Leak Test Procedures ...

Page 346: ...Figure 27 Typical Optional Pumpout System Piping Schematic with Storage Tank ...

Page 347: ...Figure 28 Typical Optional Pumpout System Piping Schematic without Storage Tank ...

Page 348: ...Figure 29 Dehydration Cold Trap ...

Page 349: ...Figure 30 Benshaw Inc Solid State Starter Power Stack ...

Page 350: ...Figure 31 Ramp Up and Starting Torque Potentiometers ...

Page 351: ...Figure 32 Typical Potentiometer Adjustment ...

Page 352: ...Figure 33 Typical Cutler Hammer Solid State Starter ...

Page 353: ...Figure 34 Correct Motor Rotation ...

Page 354: ...n safety controls repairs made oil or refrigerant added or removed air exhausted and water drained from dehydrator Include amounts Figure 35 Refrigeration Log DATE ______ COOLER CONDENSOR COMPRESSOR OPER ATOR INITIALS REMARKS TIME Refrigerant Water Refrigerant Water BEARING TEMP Oil Motor Press Temp Pressure Temp Press Temp Pressure Temp Press Diff Temp reservior Level FLA ______ In Out GPM In Out...

Page 355: ...9XL Pumpout Unit Wiring Schematic Compressor Terminal Contactor Terminal Overload Terminal Pumpout Unit Terminal C Contactor Fu Fuse 3 Amps HP High Pressure Cutout OL Compressor Overload T stat Internal Thermostat ...

Page 356: ...Figure 37 Optional Pumpout System ...

Page 357: ...Figure 38 Guide Vane Actuator Linkage ...

Page 358: ...Figure 39 19XL Float Valve Designs ...

Page 359: ...Figure 40 Optional Pumpout System Controls ...

Page 360: ...Figure 41 PSIO Module Address Selector Switch Locations and LED Locations ...

Page 361: ...Figure 42 LID Module Rear View and LED Locations ...

Page 362: ...Figure 43 Processor PSIO Module ...

Page 363: ...Figure 44 Starter Management Module SSM ...

Page 364: ...Switch Setting Option Module 1 Option Module 2 S1 S2 6 4 7 2 Figure 45 Options Module ...

Page 365: ...Figure 46 Typical Benshaw Inc Solid State Starter Internal View ...

Page 366: ...Figure 47 Resistance Check ...

Page 367: ...Figure 48 SCR and Power Poles ...

Page 368: ...Figure 49 Typical Cutler Hammer Solid State Starter Internal View ...

Page 369: ...Figure 50 Cutler Hammer Terminal Functions ...

Page 370: ...Figure 51 Solid State Starter General Operation Troubleshooting Guide Typical ...

Page 371: ...Figure 52 Solid State Starter Starter Fault Motor Will Not Start Troubleshooting Guide Typical ...

Page 372: ...peller Retaining Bolt Bull Gear Retaining Bolt Motor Terminals Low Voltage Demister Bolts Guide Vane Shaft Seal Nut Motor Terminals High Voltage Insulator Packing Nut Brass Jam Nut 10 44 46 80 85 50 15 19 25 2 4 5 10 14 60 62 108 115 68 20 26 34 2 7 5 4 6 8 13 6 Figure 53 Compressor Fits and Clearances ...

Page 373: ...Figure 54 Compressor Fits and Clearances Continued ...

Page 374: ...Figure 55 Compressor Fits and Clearances Continued ...

Page 375: ...Figure 56 Electronic PIC Controls Wiring Schematic page 1 of 2 Legend Carrier Factory Wiring Optional Factory or Field Installed Wiring ...

Page 376: ...Legend Carrier Factory Wiring Optional Factory or Field Installed Wiring Figure 56 Electronic PIC Controls Wiring Schematic page 2 of 2 ...

Page 377: ...Legend Starter Cabinet Wiring Field Wiring Carrier Factory Wiring Figure 57 Machine Power Panel Starter Assembly and Motor Wiring Schematic page 1 of 2 ...

Page 378: ...Legend Starter Cabinet Wiring Field Wiring Carrier Factory Wiring Figure 57 Machine Power Panel Starter Assembly and Motor Wiring Schematic page 2 of 2 ...

Page 379: ...ional features are indicated by bold dotted boxes Caution Yellow wires remain energized when main disconnect is off Dry Contact Figure 58 Typical Wye Delta Unit Mounted Starter Wiring Schematic page 1 of 2 ...

Page 380: ...ure 58 Typical Wye Delta Unit Mounted Starter Wiring Schematic page 2 of 2 Optional features are indicated by bold dotted boxes Caution Yellow wires remain energized when main disconnect is off Dry contact ...

Page 381: ... JOB DATA REQUIRED 1 Machine Installation Instructions Yes M No M 2 Machine Assembly Wiring and Piping Diagrams Yes M No M 3 Starting Equipment Details and Wiring Diagrams Yes M No M 4 Applicable Design Data see above Yes M No M 5 Diagrams and Instructions for Special Controls Yes M No M INITIAL MACHINE PRESSURE YES NO Was Machine Tight If Not Were Leaks Corrected Was Machine Dehydrated After Repa...

Page 382: ...D IN THE STARTER IN ACCORDANCE WITH CERTIFIED DRAWINGS Yes RUN MACHINE Do these safeties shut down machine Condenser Water Flow Switch Yes M No M Chilled Water Flow Switch Yes M No M Pump Interlocks Yes M No M INITIAL START Line Up All Valves in Accordance With Instruction Manual Start Water Pumps and Establish Water Flow Oil Level OK and Oil Temperature OK Check Oil Pump Rotation Pressure Check C...

Page 383: ...GE UNITS DEFAULT VALUE Base Demand Limit 40 to 100 100 0 LCW Setpoint 20 to 120 6 7 to 48 9 DEG F DEG C 50 0 ECW Setpoint 20 to 120 6 7 to 48 9 DEG F DEG C 60 0 ICE BUILD Setpoint 20 to 60 6 7 to 15 6 DEG F DEG C 40 0 PSIO Software Version Number LID Software Version Number PSIO Controller Identification BUS ADDRESS LID Identification BUS ADDRESS CL 3 ...

Page 384: ...TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag Occupied Unoccupied M T W T F S S H Time Time Period 1 Period 2 Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 NOTE Default setting is UNOCCUPIED 24 hours day 19XL PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC S Day Flag Occupied Unoccupied M T W T F S S H Time Time Period 1 Period 2 Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 NOTE...

Page 385: ...ct Enable Reset Type 0 to 3 0 ECW Control Option Disable Enable Disable Demand Limit at 20 mA 40 to 100 40 20 mA Demand Limit Option Disable Enable Disable Auto Restart Option Disable Enable Disable Remote Contacts Option Disable Enable Disable Temp Pulldown Deg Min 2 to 10 3 Load Pulldown Min 5 to 20 10 Select Ramp Type Temp 0 Load 1 0 1 1 Loadshed Group Number 0 to 99 0 Loadshed Demand Delta 0 t...

Page 386: ...alance Option Disable Enable Disable Common Sensor Option Disable Enable Disable LAG Percent 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 0 to 30 Min 5 STANDBY Chiller Option Disable Enable Disable STANDBY Percent Capacity 25 to 75 50 STANDBY Address 1 to 236 93 CL 6 ...

Page 387: ...0 SEC 15 Water Brine Deadband 0 5 to 2 0 0 3 to 1 1 DEG F DEG C 1 0 0 6 Recycle Restart Delta T 2 0 to 10 1 1 to 5 5 DEG F DEG C 5 2 8 Surge Limit HGBP Option Surge 0 HGBP 1 0 1 0 Surge HGBP Delta T1 0 5 to 15 0 3 to 8 3 DEG F DEG C 1 5 0 8 Surge HGBP Delta P1 50 to 170 345 to 1172 30 to 170 206 to 1172 psi kPa 75 517 50 345 Surge HGBP Delta T2 0 5 to 15 0 0 3 to 8 3 DEG F DEG C 10 5 6 Surge HGBP ...

Page 388: ...oad Amps 1 to 9999 AMPS 200 Motor Rated Line Voltage 1 to 9999 VOLTS 460 Meter Rated Line kW 1 to 9999 kW 600 Line Frequency 0 60 Hz 1 50 Hz 0 1 0 Compressor Starter Type REDUCE FULL REDUCE Condenser Freeze Point 20 to 35 28 9 to 1 7 DEG F DEG C 34 1 1 Soft Stop Amps Threshold 40 to 100 100 CL 8 ...

Page 389: ...EG F DEG C 245 118 Spare Temp 3 Enable 0 to 2 0 DISABLE 1 HIGH 2 LOW 0 Spare Temp 3 Alert 40 to 245 40 to 118 DEG F DEG C 245 118 SPARE 1 20 mA Power Source 0 1 0 EXTERNAL 1 INTERNAL 0 SPARE 2 20 mA Power Source 0 1 0 EXTERNAL 1 INTERNAL 0 Spare Temp 4 Enable 0 to 2 0 DISABLE 1 HIGH 2 LOW 0 Spare Temp 4 Alert 40 to 245 40 to 118 DEG F DEG C 245 118 Spare Temp 5 Enable 0 to 2 0 DISABLE 1 HIGH 2 LOW...

Page 390: ...VICE3 TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT VALUE Proportional Inc Band 2 to 10 6 5 Proportional Dec Band 2 to 10 6 0 Proportional ECW Gain 1 to 3 2 0 Guide Vane Travel Limit 30 to 100 50 CL 10 ...

Page 391: ...ON SHEET HOLIDEF S DESCRIPTION RANGE UNITS VALUE Holiday Start Month 1 to 12 Start Day 1 to 31 Duration 0 to 99 DAYS HOLIDAY HOLIDEF CONFIGURATION SHEET HOLIDEF S DESCRIPTION RANGE UNITS VALUE Holiday Start Month 1 to 12 Start Day 1 to 31 Duration 0 to 99 DAYS NOTE There are no HOLIDAYS defined on the default menu HOLIDAY dates must be updated yearly if they are used 13 ...

Page 392: ...nt Number 0 to 239 SE s 0 OARH Broadcast Controller Name 8 characters Text Bus Number 0 to 239 Bus s 0 Element Number 0 to 239 SE s 0 Daylight Savings Start Month 1 to 12 4 Day 1 to 31 15 Time 00 00 to 23 59 HH MM 02 00 Minutes To Add 1 to 1440 MIN 60 Daylight Savings Stop Month 1 to 12 10 Day 1 to 31 15 Time 00 00 to 23 59 HH MM 02 00 Minutes To Subtract 1 to 1440 MIN 60 15 ...

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