9XR,XRV Hermetic Centrifugal Liquid Chillers 50/60 Hz With PIC II Controls and HFC-134a Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
CONTENTS Page Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 High Discharge Temperature Control . . . . . . . . . . . . 36 Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36 Oil Cooler . . . . . . . . . . . . . .
CONTENTS (cont) Page Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Check Optional Pumpout Compressor Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Carrier Comfort Network Interface. . . . . .
CONTENTS (cont) Page Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74 Compressor Bearing and Gear Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Inspect the Heat Exchanger Tubes and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 • COOLER AND FLOW DEVICES • CONDENSER AND FLOW DEVICES Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Water Treatment . . . . . . . . . . . . . . . . . . . .
through its internal tubes in order to remove heat from the refrigerant. Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed additional components are referred to as accessories. The chiller software part number of the 19XR unit is located on the back of the CVC/ICVC. Motor-Compressor — This component maintains system temperature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser.
FRONT VIEW 1 2 3 4 5 17 6 16 7 8 15 14 13 12 LEGEND 1 — Guide Vane Actuator 2 — Suction Elbow 3 — Chiller Visual Controller/ International Chiller Visual Control (CVC/ICVC) 4 — Chiller Identification Nameplate 5 — Cooler, Auto Reset Relief Valves 6 — Cooler Pressure Transducer 7 — Condenser In/Out Temperature Thermistors 8 — Condenser Waterflow Device (ICVC Inputs available) 9 — Cooler In/Out Temperature Thermistors 10 — Cooler Waterflow Device (ICVC Inputs available) 11 — Refrigerant Charging Valve 12
Factory-Mounted Starter or Variable Frequency Drive (Optional) — The starter allows for the refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) when it is discharged from the compressor into the condenser. Relatively cool (typically 65 to 90 F [18 to 32 C]) water flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid. The liquid refrigerant passes through orifices into the FLASC (Flash Subcooler) chamber (Fig. 3).
LUBRICATION CYCLE cooler heat exchanger. The oil cooler uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a temperature between 120 and 140 F (49 to 60 C). As the oil leaves the oil cooler, it passes the oil pressure transducer and the thermal bulb for the refrigerant expansion valve on the oil cooler. The oil is then divided. Part of the oil flows to the thrust bearing, forward pinion bearing, and gear spray.
REAR MOTOR BEARING FWD MOTOR BEARING LABYRINTH GAS LINE OIL SUPPLY TO FORWARD HIGH SPEED BEARING MOTOR COOLING LINE ISOLATION VALVE TXV BULB PRESSURE TRANSDUCER OIL PUMP ISOLATION VALVE OIL COOLER OIL PUMP MOTOR FILTER OIL HEATER EDUCTOR FILTER SIGHT GLASS SIGHT GLASS ISOLATION VALVE OIL SKIMMER LINE Fig. 4 — Lubrication System solid-state starters. This module controls and monitors all aspects of the starter. See the Controls section on page 10 for additional ISM information.
There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter checkout. The display indicates: • voltage to the SCRs • SCR control voltage • power indication • proper phasing for rotation • start circuit energized • over-temperature • ground fault • current unbalance • run state • software configuration The starter is further explained in the Check Starter and Troubleshooting Guide sections, pages 54 and 76.
SPEED VOLTS AMPS Hz RUNNING AUTO MAN Forward Reverse REMOTE JOG AUTO PROGRAM RUN JOB Kw TORQUE FORWARD REVERSE Password PROGRAM SPEED RUNNING VOLTS AMPS Hz REMOTE JOG AUTO Kw TORQUE FORWARD REVERSE Password PROGRAM AUTO MAN Forward Reverse PROGRAM RUN JOB ENTER ENTER OPTIONAL METER PACKAGE MANUAL RESET Fig.
FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE WATER SENSOR CABLES WATER SENSOR CABLES COOLER PRESSURE TRANSDUCER CONNECTION CONDENSER PRESSURE CABLE SCHRADER FITTING (HIDDEN) CONDENSER PRESSURE TRANSDUCER CONNECTION CONDENSER SERVICE VALVE DISCHARGE ISOLATION VALVE (OPTIONAL) COMPRESSOR DISCHARGE ELBOW JOINTS TOP VIEW COMPRESSOR DETAIL Fig.
ground fault, remote start contact, spare safety, condenser high pressure, oil pump interlock, starter 1M, and run contacts. The ISM contains logic capable of safety shutdown. It shuts down the chiller if communications with the CVC/ICVC are lost. The ISM can also act as the interface for PIC II to the VFD controller. CHILLER CONTROL MODULE (CCM) — This module is located in the control panel. The CCM provides the input and outputs necessary to control the chiller.
Fig. 12 — Control Panel Fig.
CVC/ICVC Operation and Menus (Fig. 14-20) For more information menu structures, PRIMARY STATUS on the COMPRESSOR DATE refer TIMEto ON TIME Fig. 17. MESSAGE GENERAL • The CVC/ICVC display automatically reverts to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the pumpdown mode (Fig. 14). • If a screen other than the default screen is displayed on the CVC/ICVC, the name of that screen is in the upper right corner (Fig. 15).
• Press QUIT to leave the selected decision or field without saving any changes. 2. Press NEXT or PREVIOUS to highlight the desired status table.
• DEFAULT SCREEN LOCAL CCN RESET MENU (SOFTKEYS) Start Chiller In CCN Control Start Chiller in Local Control Clear Alarms Access Main Menu STATUS SCHEDULE SETPOINT 1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) List the Status Tables List the Service Tables Display The Setpoint Table • MAINSTAT • STARTUP • COMPRESS • HEAT_EX • POWER • ISM_STAT • CVC_PSWD Select a Status Table PREVIOUS NEXT Select a Modification Point PREVIOUS NEXT Modify a Discrete Point START STOP ON OFF
• SERVICE TABLE NEXT PREVIOUS SELECT EXIT ALARM HISTORY Display Alarm History (The table holds up to 25 alarms and alerts with the most recent alarm at the top of the screen.
SERVICE MENU CONTINUED FROM PREVIOUS PAGE ISM (STARTER) CONFIG DATA EQUIPMENT SERVICE 4 4 4 4 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) Service Tables: • OPTIONS • SETUP1 • SETUP2 • LEADLAG • RAMP_DEM • TEMP_CTL Select a Service Table PREVIOUS NEXT Service Tables: • ISM (STARTER) CONFIG PASSWORD • ISM_CONF SELECT EXIT Select a Service Table Parameter SELECT PREVIOUS NEXT EXIT Modify a Service Table Parameter INCREASE DECREASE QUIT ENABLE DISABLE QUIT ENTER (ANALOG VALUES) E
OCCPC02S — ICE BUILD Time Schedule OCCPC03S — CCN Time Schedule For Discrete Points — Press START or STOP to select the desired state. For Analog Points — Press INCREASE DECREASE to select the desired value. or 3. Press SELECT to view the desired time schedule. 4. Press NEXT or PREVIOUS to highlight the desired period or override to change. 3. Press ENTER to register the new value.
2. There are 5 set points on this screen: BASE DEMAND LIMIT, LCW SETPOINT (leaving chilled water set point), ECW SETPOINT (entering chilled water set point), ICE BUILD SETPOINT, and TOWER FAN HIGH SETPOINT. Only one of the chilled water set points can be active at one time. The set point that is active is determined from the SERVICE menu. See the Service Operation section, page 45. The ice build (ICE BUILD) function is also activated and configured from the SERVICE menu. 3.
Table 2 — CVC/ICVC Display Data 6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized names, those preceded by a dagger can also be changed (that is, written to) by the CCN, BS, and the CVC/ICVC. Capitalized Reference Point Names preceded by two asterisks can be changed only from the CVC/ICVC. Reference Point Names in lower case type can be viewed by CCN or BS only by viewing the whole table. 7.
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. Press STATUS ( MAINSTAT will be highlighted). 3. Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 4 — COMPRESS DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight COMPRESS . 4. Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 6 — POWER DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight POWER . 4. Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 8 — CVC/ICVC_PSWD DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight CVC .or ICVC 4. Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 11 — OVERRIDE DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight OVERRIDE . Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 13 — ISM_HIST DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight CONTROL ALGORITHM STATUS . Press SELECT . Scroll down to highlight ISM_HIST . Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 15 — NET_OPT DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURATION . 4. Press SELECT . 5. Scroll down to highlight NET_OPT . 6. Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 17 — OPTIONS DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight OPTIONS . Press SELECT . DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold Surge / Hot Gas Bypass Surge Limit/HGBP Option Select: Surge=0, HGBP=1 Min.
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 19 — SETUP2 DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight SETUP2 . Press SELECT .
Table 2 — CVC/ICVC Display Data (cont) EXAMPLE 21 — RAMP_DEM DISPLAY SCREEN To access this display from the CVC/ICVC default screen: 1. Press MENU . 2. 3. 4. 5. 6. Press SERVICE . Scroll down to highlight EQUIPMENT SERVICE . Press SELECT . Scroll down to highlight RAMP_DEM . Press SELECT .
PIC II System Functions display screen. The TARGET VFD SPEED can be manually overridden by the operator from the COMPRESS screen. The VFD MINIMUM SPEED, MAXIMUM SPEED, VFD GAIN and INCREASE STEP can be viewed and modified in the SETUP2 display screen. TARGET and ACTUAL VFD SPEED can be viewed in the COMPRESS screen. ECW CONTROL OPTION — If this option is enabled, the PIC II uses the ENTERING CHILLED WATER temperature to modulate the vanes instead of the LEAVING CHILLED WATER temperature.
ICE BUILD mode, it uses Occupancy Schedule 02 (OCCPC02S). When the chiller is in CCN mode, it uses Occupancy Schedule 03 (OCCPC03S). The CCN SCHEDULE NUMBER is configured on the NET_OPT display screen, accessed from the EQUIPMENT CONFIGURATION table. See Table 2, Example 15. SCHEDULE NUMBER can be changed to any value from 03 to 99. If this number is changed on the NET_OPT screen, the operator must go to the ATTACH TO NETWORK DEVICE screen to upload the new number into the SCHEDULE screen. See Fig. 18.
Table 3 — Protective Safety Limits and Control Settings MONITORED PARAMETER TEMPERATURE SENSORS OUT OF RANGE PRESSURE TRANSDUCERS OUT OF RANGE COMPRESSOR DISCHARGE TEMPERATURE MOTOR WINDING TEMPERATURE BEARING TEMPERATURE EVAPORATOR REFRIGERANT TEMPERATURE LIMIT –40 to 245 F (–40 to 118.3 C) APPLICABLE COMMENTS Must be outside range for 2 seconds 0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds. Ratio = Input Voltage ÷ Voltage Reference Preset, alert setting configurable >220 F (104.
Ramp Loading — The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the chiller is started and the chilled water loop has to be brought down to CONTROL POINT. This helps reduce electrical demand charges by slowly bringing the chilled water to CONTROL POINT. The total power draw during this period remains almost unchanged. There are two methods of ramp loading with the PIC II.
Table 4 — Capacity Overrides FIRST STAGE SET POINT OVERRIDE CAPACITY CONTROL SECOND STAGE SET POINT OVERRIDE TERMINATION View/Modify on CVC/ICVC Screen Default Value Configurable Range Value Value HIGH CONDENSER PRESSURE SETUP1 125 psig (862 kPa) 90 to 165 psig (620 to 1138 kPa) >Override Set Point +2.4 psid (16.5 kPad) 200 F (93.
Condenser Freeze Prevention — This control algo- The TOWER FAN RELAY LOW and HIGH parameters are accessed from the STARTUP screen. rithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. The PIC II controls the pump and, by starting it, helps to prevent the water in the condenser from freezing. The PIC II can perform this function whenever the chiller is not running except when it is either actively in pumpdown or in pumpdown/lockout with the freeze prevention disabled.
where the HOT GAS BYPASS/SURGE PREVENTION is off, the point must pass through the deadband region to the line determined by the configured values before the HOT GAS BYPASS/SURGE PREVENTION will be turned on. As the point moves from the region where the HOT GAS BYPASS/ SURGE PREVENTION is on, the point must pass through the deadband region before the HOT GAS BYPASS/SURGE PREVENTION is turned off.
Capacity Overrides. Both of these corrective actions try to reduce the lift experienced by the compressor and help prevent a surge condition. parameter, and use the INCREASE or DECREASE softkey to adjust the amount of time. The default setting is 8 minutes. Access the display screen (COMPRESS) to monitor the surge count (SURGE PROTECTION COUNTS).
LEAD/LAG OPERATION — The PIC II not only has the ability to operate 2 chillers in lead/lag, but it can also start a designated standby chiller when either the lead or lag chiller is faulted and capacity requirements are not met. The lead/lag option only operates when the chillers are in CCN mode. If any other chiller configured for lead/lag is set to the LOCAL or OFF modes, it will be unavailable for lead/lag operation.
NOTE: Lead chiller percent capacity = 115 – LAG % CAPACITY. The LAG % CAPACITY parameter is on the LEADLAG screen, which is accessed from the EQUIPMENT SERVICE table on the SERVICE menu. FAULTED CHILLER OPERATION — If the lead chiller shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the lag chiller becomes the acting lead chiller and starts and stops the standby chiller, if necessary.
Ice Build Control — The ice build control option automatically sets the CONTROL POINT of the chiller to a temperature that allows ice building for thermal storage. NOTE: For ice build control to operate properly, the PIC II must be in CCN mode. NOTE: See Fig. 17 and 18 for more information on ice buildrelated menus. The PIC II can be configured for ice build operation. • From the SERVICE menu, access the EQUIPMENT SERVICE table.
stop the chiller when a specific time period on the ice build schedule is not set for ice build. 4. Entering Chilled Water Temperature and ICE BUILD Contacts — Compressor operation terminates when the ICE BUILD TERMINATION parameter is set to 2 (BOTH) and the conditions described above in items 2 and 3 for entering chilled water temperature and remote contacts have occurred.
Service Operation — An overview of the tables and screens available for the SERVICE function is shown in Fig. 18. TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered. 1. From the main MENU screen, press the SERVICE softkey. The softkeys now correspond to the numerals 1, 2, 3, 4. HOLIDAY SCHEDULING (Fig. 25) — The time schedules may be configured for special operation during a holiday period.
START-UP/SHUTDOWN/ RECYCLE SEQUENCE (Fig. 26) Local Start-Up — Local start-up (or a manual start-up) is NOTE: Units equipped with ICVC are not available with factory installed chilled water or condenser water flow devices (available as an accessory for use with the CCM Control board). If the water/brine temperature is high enough, the start-up sequence continues and checks the guide vane position. If the guide vanes are more than 4% open, the start-up waits until the PIC II closes the vanes.
Shutdown Sequence — Chiller shutdown begins if any of the following occurs: • the STOP button is pressed for at least one second (the alarm light blinks once to confirm the stop command) • a recycle condition is present (see Chilled Water Recycle Mode section) • the time schedule has gone into unoccupied mode • the chiller protective limit has been reached and chiller is in alarm • the start/stop status is overridden to stop from the CCN network or the CVC/ICVC When a stop signal occurs, the shutdown sequen
BEFORE INITIAL START-UP To determine if there are any leaks, the chiller should be charged with refrigerant. Use an electronic leak detector to check all flanges and solder joints after the chiller is pressurized. If any leaks are detected, follow the leak test procedure.
Fig.
Leak Test Chiller — Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from the refrigerant, Carrier recommends the following leak test procedure. See Fig. 28 for an outline of the leak test procedure. Refer to Fig. 29 and 30 during pumpout procedures and Tables 5A and 5B for refrigerant pressure/ temperature values. 1. If the pressure readings are normal for the chiller condition: a. Evacuate the holding charge from the vessels, if present. b.
Fig. 29 — Typical Optional Pumpout System Piping Schematic with Storage Tank Fig.
Table 5A — HFC-134a Pressure — Temperature (F) TEMPERATURE, F 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 Table 5B — HFC-134a Pressure — Temperature (C) PRESSURE (psig) 6.50 7.52 8.60 9.66 10.79 11.96 13.17 14.42 15.72 17.06 18.45 19.88 21.37 22.90 24.48 26.11 27.80 29.53 31.32 33.17 35.08 37.04 39.06 41.14 43.28 45.48 47.
Chiller Dehydration — Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure. Do not start or megohm-test the compressor motor or oil pump motor, even for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result. Fig.
11. On chillers with free-standing starters, inspect the power panel to ensure that the contractor has fed the wires into the bottom of the panel. Wiring into the top of the panel can cause debris to fall into the contactors. Clean and inspect the contactors if this has occurred. 2. On low-voltage compressors (600 v or less) connect a voltmeter across the power wires to the compressor starter and measure the voltage. Compare this reading to the voltage rating on the compressor and starter nameplates. 3.
MECHANICAL STARTER 1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection. 2. Check the contactor(s) to ensure they move freely. Check the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time. Check all other electro-mechanical devices, such as relays, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components. 3.
address for each chiller if there is more than one chiller at the jobsite. Write the new address on the CVC/ICVC module for future reference. INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The EQUIPMENT SERVICE table has six service tables. Configure SERVICE Tables — Access the SERVICE tables, shown in Table 2, to modify or view job site parameters: NOTE: Because a schedule is integral to the chiller control sequence, the chiller will not start until the time and date have been set.
CHANGE THE BENSHAW INC., RediStart MICRO™ SOFTWARE CONFIGURATION IF NECESSARY — Benshaw starter configurations are checked and modified from the menus in the Benshaw Redistart MICRO Default Display. See Fig. 32 and Table 6 for default display and menu items. To access the menus to perform checks and modifications, the Benshaw starter must be powered up and its self-test must have been successfully completed. The self-test takes place automatically after power-up.
VERIFY VFD CONFIGURATION PARAMETERS IF NECESSARY AND Accessing Password Protected Parameters — Although the VFD controller has been preconfigured as the factory, the user will need to be able to access the parameters to verify the job specific parameters are correct, tune the controller or correct a problem. The two passwords protecting the VFD configuration are Parameter Set Display password and Program Disable password. The Parameter Set Display password restricts viewing. P.
Configure Chiller Visual Controller Parameter — The chiller controller must have its job specific parameters set as defined by the job sheet or installed nameplates. Below are the job specific parameters that must be set: To access the ISM_CONF screen: 1. Press ENTER . 2. Press SERVICE . 3. Enter the password 1111. 4. Select ISM (CONFIG STARTER DATA) 5. Scroll down and select the ISM_CONF DATA screen to modify or view the ISM parameters: VFD Cooling System Leak Inspection 1.
2. Press STATUS . 3. Press COMPRESS . 4. Press SELECT . 5. Set TARGET VFD SPEED to 0%. Verify that the ACTUAL VFD SPEED shown on the VFD display is within 0 to 1 Hz. 1. Press the ENTER softkey on the VFD keypad until all LEDs on the left side of the keypad are illuminated. NOTE: The value displayed is the frequency at which the VFD is being commanded to operate. 2. Adjust VFD parameter P.009 (Input Offset) if outside the tolerance.
Calculate Minimum Load — To calculate the minimum load conditions, estimate the temperature difference the cooler will have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated pressure and temperature for the particular refrigerant used. Suction Temperature: 43 F (6.1 C) = 38 psig (262 kPa) saturated refrigerant pressure (HFC-134a) Condensing Temperature: 70 F (21.
Owner-Modified CCN Tables — The following EQUIPMENT CONFIGURATION screens are described for reference only. OCCDEFCS — The OCCDEFCS screen contains the Local and CCN time schedules, which can be modified here or on the SCHEDULE screen as described previously. HOLIDAYS — From the HOLIDAYS screen, the days of the year that holidays are in effect can be configured. See the holiday paragraphs in the Controls section for more details. BRODEF — The BRODEF screen defines the start and end of daylight savings time.
Check Optional Pumpout System Controls and Compressor — Controls include an on/off switch, High Altitude Locations — Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the pressure transducers if the chiller has been moved to a high altitude location. See the calibration procedure in the Troubleshooting Guide section. a 3-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout.
Table 10 — Refrigerant (HFC-134a) Charge CHILLER EQUALIZATION WITH PUMPOUT UNIT — The following steps describe how to equalize refrigerant pressure on an isolated 19XR chiller using the pumpout unit. 1. Access the terminate lockout function on the CONTROL TEST screen. 2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing. COOLER CODE 10 11 12 15 16 17 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 55 56 57 60 61 62 65 66 67 70 71 72 75 76 77 80 81 82 85 86 87 3.
Dry Run to Test Start-Up Sequence For electro-mechanical starters. 1. Disengage the main motor disconnect (CB1) on the starter front panel. This should only disconnect the motor power. Power to the controls, oil pump, and starter control circuit should still be energized. 2. Observe the default screen on the CVC/ICVC: the status message in the upper left-hand corner reads, “Manually Stopped,” Press the CCN or LOCAL softkey to start.
OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices. MOTOR COMPRESSOR ASSEMBLY — Guide vane actuator, transmission, motor cooling system, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil filter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.
tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuations. Leave the oil charge in the chiller with the oil heater and controls energized to maintain the minimum oil reservoir temperature. After Extended Shutdown — Ensure the water system drains are closed. It may be advisable to flush the water circuits to remove any soft rust which may have formed.
Press. Temp Refrigerant In Water Out GPM Pressure COOLER In Out Temp MACHINE MODEL NO. Press. Temp Refrigerant In Out GPM Pressure Water CONDENSER In Out Temp MACHINE SERIAL NO. BEARING TEMP Fig. 34 — Refrigeration Log REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts. TIME DATE Plant Press. Diff.
the CONTROL TEST table to turn on the water pumps and monitor pressures. If the chilled water and condenser water pumps are not controlled by the PIC II, these pumps must be started and stopped manually at the appropriate times during the refrigerant transfer procedure. b. Close pumpout unit valves 2, 4, 5, 8, and 10, and close chiller charging valve 7; open chiller isolation valves 11, 12, 13, and 14 (if present). c. Open pumpout unit/storage tank valves 3 and 6, open chiller valves 1a and 1b.
Chillers with Isolation Valves TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK 1. Equalize refrigerant pressure. a. Valve positions: VALVE CONDITION TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL — For chillers with isolation valves, refrigerant can be stored in one chiller vessel or the other without the need for an external storage tank. 1. Push refrigerant into the chiller condenser. a. Valve positions: 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14 C C C C C b. Slowly open valve 5.
GENERAL MAINTENANCE 2. Evacuate the refrigerant gas from the chiller condenser vessel. a. Access the PUMPDOWN LOCKOUT function accessed from the CVC/ICVC CONTROL TEST table to turn on the chiller water pumps. Turn the chiller water pumps on manually if they are not controlled by the PIC II. b. Close pumpout unit valves 3 and 4; open valves 2 and 5. VALVE 1a 1b 2 CONDITION 3 4 C C 5 Refrigerant Properties — The standard refrigerant for the 19XR chiller is HFC-134a.
HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be present with high concentrations of air or oxygen above atmospheric pressures, because the mixture can undergo combustion. TESTING WITH REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures. Use dry nitrogen to raise the machine pressure to leak testing levels.
SCHEDULED MAINTENANCE 10. Remove the hose from the charging valve, open the isolation valves to the filter housing, and turn on the power to the pump and the motor. Establish a regular maintenance schedule based on your actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are offered as guides to service only. Oil Specification — If oil is added, it must meet the following Carrier specifications: Oil Type for units using R-134a . . . .
Inspect Refrigerant Float System — Perform this Compressor Bearing and Gear Maintenance — inspection every 5 years or when the condenser is opened for service. 1. Transfer the refrigerant into the cooler vessel or into a pumpout storage tank. 2. Remove the float access cover. 3. Clean the chamber and valve assembly thoroughly. Be sure the valve moves freely. Ensure that all openings are free of obstructions. 4. Examine the cover gasket and replace if necessary. See Fig.
Water Treatment — Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program. OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE — Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows: ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Carrier Part Number . . . . . . . .
TROUBLESHOOTING GUIDE VOLTAGE DROP — The voltage drop across any energized sensor can be measured with a digital voltmeter while the control is energized. Table 12A or 12B lists the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Sensors should also be checked at the sensor plugs.
Control Test — The Control Test feature can check all the TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring. 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.
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides A. MANUAL STOP PRIMARY MESSAGE MANUALLY STOPPED — PRESS TERMINATE PUMPDOWN MODE SECONDARY MESSAGE CCN OR LOCAL TO START TO SELECT CCN OR LOCAL SHUTDOWN IN PROGRESS SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING COMPRESSOR DEENERGIZED ICE BUILD OPERATION COMPLETE PROBABLE CAUSE/REMEDY PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary. PRIMARY MESSAGE PRESTART ALERT PRESTART ALERT SECONDARY MESSAGE STARTS LIMIT EXCEEDED HIGH BEARING TEMPERATURE ALARM MESSAGE PRIMARY CAUSE 100->Excessive compressor starts (8 in 12 hours) 101->Comp Thrust Bearing Temp [VALUE] exceeded limit of [LIMIT]*.
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) G. NORMAL RUN WITH OVERRIDES STATE 120 121 122 123 124 125 PRIMARY MESSAGE RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED SECONDARY MESSAGE HIGH CONDENSER PRESSURE HIGH MOTOR TEMPERATURE ALARM MESSAGE PRIMARY CAUSE 120->Condenser Pressure [VALUE] exceeded limit of [LIMIT]*.
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECT LIMIT FAULTS (cont) PRIMARY MESSAGE PROTECTIVE LIMIT SECONDARY MESSAGE OIL PRESS SENSOR FAULT ALARM MESSAGE PRIMARY CAUSE 227->Oil Pump Delta P [VALUE] exceeded limit of [LIMIT]*. 228 PROTECTIVE LIMIT LOW OIL PRESSURE 228->Oil Pump Delta P [VALUE] exceeded limit of [LIMIT].
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J.
Table 12A — Thermistor Temperature (F) vs. Resistance/Voltage Drop TEMPERATURE (F) –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 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 52 53 54 55 56 57 58 59 PIC II RESISTANCE VOLTAGE (Ohms) DROP (V) 4.700 98,010 4.690 94,707 4.680 91,522 4.670 88,449 4.659 85,486 4.648 82,627 4.637 79,871 4.625 77,212 4.613 74,648 4.
Table 12B — Thermistor Temperature (C) vs. Resistance/Voltage Drop TEMPERATURE (C) –33 –32 –31 –30 –29 –28 –27 –26 –25 –24 –23 –22 –21 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 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 PIC II VOLTAGE DROP (V) 4.722 4.706 4.688 4.670 4.650 4.630 4.608 4.586 4.562 4.538 4.512 4.486 4.458 4.429 4.399 4.368 4.336 4.303 4.269 4.233 4.196 4.158 4.119 4.079 4.037 3.994 3.951 3.906 3.861 3.
Control Modules Notes on Module Operation 1. The chiller operator monitors and modifies configurations in the microprocessor by using the 4 softkeys and the CVC/ICVC. Communications between the CVC/ ICVC and the CCM is accomplished through the SIO (Sensor Input/Output) bus, which is a phone cable. The communication between the CCM and ISM is accomplished through the sensor bus, which is a 3-wire cable. 2. If a green LED is on continuously, check the communication wiring.
Chiller Control Module (CCM) (Fig. 41) 7. The CVC/ICVC now automatically attaches to the local network device. 8. Access the MAINSTAT table and highlight the TOTAL COMPRESSOR STARTS parameter. Press the SELECT softkey. Increase or decrease the value to match the starts value recorded in Step 3. Press the ENTER softkey when you reach the correct value. Now, move the highlight bar to the COMPRESSOR ONTIME parameter. Press the SELECT softkey.
J11 DISCRETE OUTPUTS SW1 J12 DISCRETE OUTPUTS J1 24 VAC ANALOG OUT J8 SIO J7 SIO J6 SW2 V/I INPUTS J5 COMM STAT THERMISTORS J4 PRESSURE J2 DIFF PRESSURE J3 Fig.
5. Using quarter-turn increments, alternating between clamping bolts, apply the appropriate number of whole turns referencing the table in Fig. 43. 5. Using an ohmmeter, perform the following resistance measurements and record the results: MEASURE BETWEEN T1 and T6 T2 and T4 T3 and T5 6. 7. 8. 9. 10. SCR PAIRS BEING CHECKED 3 and 6 2 and 5 1 and 4 RECORDED VALUE Care must be taken to prevent nut rotation while tightening the bolts.
Table 13A — Heat Exchanger Data (English) NUMBER OF TUBES CODE 10 11 12 15 16 17 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 5A 5B 5C 55 56 57 5F 5G 5H 60 61 62 65 66 67 70 71 72 75 76 77 80 81 82 85 86 87 ENGLISH Dry (Rigging) Weight (lb) Cooler Condenser Cooler Only 142 161 180 142 161 180 200 240 282 200 240 280 200 240 280 324 364 400 324 364 400 431 485 519 225 241 258 431 485 519 225 241 258 557 599 633 557 599 633 644 726 790 644 726 790 829 901 976 829 901 976 180 200 225 180 200 22
Table 13B — Heat Exchanger Data (SI) NUMBER OF TUBES CODE 10 11 12 15 16 17 20 21 22 30 31 32 35 36 37 40 41 42 45 46 47 50 51 52 5A 5B 5C 55 56 57 5F 5G 5H 60 61 62 65 66 67 70 71 72 75 76 77 80 81 82 85 86 87 SI Dry (Rigging) Weight (kg) Cooler Condenser Cooler Only 142 161 180 142 161 180 200 240 282 200 240 280 200 240 280 324 364 400 324 364 400 431 485 519 225 241 258 431 485 519 225 241 258 557 599 633 557 599 633 644 726 790 644 726 790 829 901 976 829 901 976 180 200 225 180 200 225 218 266
Table 14 — 19XR Additional Data for Marine Waterboxes* HEAT EXCHANGER FRAME, PASS FRAME 2, 1 AND 2 PASS FRAME 2, 2 PASS FRAME 3, 1 AND 2 PASS FRAME 3, 2 PASS FRAME 4, 1 AND 3 PASS FRAME 4, 2 PASS FRAME 5, 1 AND 3 PASS FRAME 5, 2 PASS FRAME 6, 1 AND 3 PASS FRAME 6, 2 PASS FRAME 7, 1 AND 3 PASS FRAME 7, 2 PASS FRAME 8, 1 AND 3 PASS FRAME 8, 2 PASS FRAME 2, 1 AND 3 PASS FRAME 2, 2 PASS FRAME 3, 1 AND 3 PASS FRAME 3, 2 PASS FRAME 4, 1 AND 3 PASS FRAME 4, 2 PASS FRAME 5, 1 AND 3 PASS FRAME 5, 2 PASS FRAME 6, 1 A
Table 16 — 19XR Motor Weights Standard and High Efficiency Motors MOTOR SIZE BD BE BF BG BH CD CE CL CM CN CP CQ DB DC DD DE DF DG DH DJ EH EJ EK EL EM EN EP Stator Weight* (lb) 60 Hz 50 Hz 1030 1030 1070 1070 1120 1120 1175 1175 1175 1175 1286 1358 1305 1377 1324 1435 1347 1455 1358 1467 1401 1479 1455 1479 1665 1725 1681 1737 1977 2069 2018 2089 2100 2139 2187 2153 2203 2207 2228 2305 3060 3120 3105 3250 3180 3250 3180 3370 3270 3370 3270 3520 3340 3520 ENGLISH Rotor Weight† (lb) 60 Hz 50 Hz 240 240 250
Table 17A — 19XR Waterbox Cover Weights — English (lb) HEAT EXCHANGER WATERBOX DESCRIPTION COOLER/ CONDENSER NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig NIH, 3 Pass Cover, 150 psig NIH/MWB End Cover, 150 psig NIH, 1 Pass Cover, 300 psig NIH, 2 Pass Cover, 300 psig NIH, 3 Pass Cover, 300 psig NIH/MWB End Cover, 300 psig HEAT EXCHANGER WATERBOX DESCRIPTION COOLER/ CONDENSER NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig NIH, 3 Pass Cover, 150 psig NIH/MWB End Cover, 150 psig NIH, 1
Table 17B — 19XR Waterbox Cover Weights — SI (kg) HEAT EXCHANGER WATERBOX DESCRIPTION COOLER/ CONDENSER NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig NIH, 3 Pass Cover, 150 psig NIH/MWB End Cover, 150 psig NIH, 1 Pass Cover, 300 psig NIH, 2 Pass Cover, 300 psig NIH, 3 Pass Cover, 300 psig NIH/MWB End Cover, 300 psig HEAT EXCHANGER WATERBOX DESCRIPTION COOLER/ CONDENSER NIH, 1 Pass Cover, 150 psig NIH, 2 Pass Cover, 150 psig NIH, 3 Pass Cover, 150 psig NIH/MWB End Cover, 150 psig NIH, 1 Pass
Table 20 — Motor Voltage Code Table 18 — Optional Pumpout System Electrical Data MOTOR CODE 1 4 5 6 CONDENSER UNIT 19EA47-748 19EA42-748 19EA44-748 19EA46-748 VOLTS-PH-Hz 575-3-60 200/208-3-60 230-3-60 400/460-3-50/60 MAX RLA 3.8 10.9 9.5 4.7 Code 60 61 62 63 64 65 66 67 68 69 50 51 52 53 54 55 LRA 23.0 63.5 57.5 28.
COMPRESSOR, TRANSMISSION AREA Compressor Assembly Torques ITEM 1* 2 3 4 5* 6* 7* DESCRIPTION Oil Heater Retaining Nut Bull Gear Retaining Bolt Demister Bolts Impeller Retaining Bolt Motor Terminals (Low Voltage) Guide Vane Shaft Seal Nut Motor Terminals (High Voltage) — Insulator — Packing Nut — Brass Jam Nut TORQUE ft.-lb N•m 20 28 80-85 108-115 15-19 20-26 44-46 60-62 50 68 25 34 2-4 5 10 2.7-5.4 6.8 13.6 LEGEND N•m — Newton meters *Not shown. NOTES: 1.
VIEW B — HIGH SPEED SHAFT 19XR COMPRESSOR CLEARANCES ITEM A B C D E F G 221-299 .0050 .0040 .0050 .0040 .0115 .0055 .0190 .0040 –.002 –.0005 .0050 .0040 —* COMPRESSOR CODE 321-389 421-489 .0050 .0055 .0040 .0043 .0050 .0053 .0040 .0043 .0115 .0100 .0080 .0050 .022 .027 .012 .017 –.0020 –.0029 –.0005 –.0014 .0050 .0048 .0040 .0038 —* —* *Depends on impeller size, contact your Carrier Service Representative for more information. NOTE: All clearances for cylindrical surfaces are diametrical. Fig.
Fig.
Fig.
C CB CP CT DS FU GRD HPR ISM L — — — — — — — — — — LL M OP PFCC RES S ST TB TC VL LEGEND — — — — — — — — — — Control Power Supply Contactor Oil Pump Power Factor Correction Capacitor Resistor Contactor Shunt Trip Terminal Block Transition Contactor Wire Label PRIMARY H1-H3 H1-H4 416 480 400 460 380 440 H1-H5 600 575 550 500 SECONDARY X1-X2 X1-X3 X1-X4 99 120 130 95 115 125 91 110 120 85 100 110 3.
— — — — — — — — — — — — — — — — — — — ** ISM L LVG N.O. PRESS REQM’T TEMP TB Fig. 46A — Electronic PIC II Control Panel Wiring Schematic For CVC (Frame 2, 3, 4 Compressor) AUX BRG C CB CCM CCN COMP’R COND CVC DISCH DL/DP ENT EVAP EXT FR GND G.V.
— — — — — — — — — — — — — — — — — — — ** ISM L LVG N.O. PRESS REQM’T TEMP TB Fig. 46B — Electronic PIC II Control Panel Wiring Schematic For ICVC (Frame 2, 3, 4 Compressor) AUX BRG C CB CCM CCN COMP’R COND DISCH DL/DP ENT EVAP EXT FR GND G.V.
— — — — — — — — — — — — — — — — — — — LEGEND Auxiliary Bearing Contactor Circuit Breaker Chiller Control Module Carrier Comfort Network Compressor Condenser Chiller Visual Controller Discharge Datalink or Dataport Entering Evaporator External Frame Ground Guide Vane Hot Gas Bypass Heat Exchanger ** — — — — — — — — Denotes Motor Starter Panel Conn.
— — — — — — — — — — — — — — — — — — — — LEGEND Auxiliary Bearing Contactor Circuit Breaker Chiller Control Module Carrier Comfort Network Compressor Condenser Discharge Datalink or Dataport Entering Evaporator External Frame Ground Guide Vane Hot Gas Bypass Heat Exchanger International Chiller Visual Controller Integrated Starter Module ** L LVG N.O. PRESS REQM’T TEMP TB — — — — — — — Denotes Motor Starter Panel Conn.
AUX C CB CCM COMM COMPR DISCH — — — — — — — Auxiliary Contactor Circuit Breaker Chiller Control Module Communication Compressor Discharge FR G GRD GVA HGBP HT EXCH ISM — — — — — — — Frame Ground Ground Guide Vane Actuator Hot Gas Bypass Heat Exchanger Integrated Starter Module — — — — — — Main Supply Power Normally Open Pressure Requirement Transformer Terminal Board LEGEND * ** Option Wiring Denotes Conductor Male/Female Connector Wire Splice Denotes Power Panel Terminal Denotes Mach.
LEGEND AUX C CB CT DS FU G — — — — — — — Auxiliary Contactor Circuit Breaker Current Transformer Disconnect Switch Fuse Ground HPR ISM L LL M RES S TB — — — — — — — — High Pressure Relay Integrated Starter Module Main Supply Power Control Power Supply Contactor Resistor Contactor Terminal Block NOTES: 1. Power factor correction capacitors (when required) are connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130. 2.
LEGEND AUX C CB CT DS FU G — — — — — — — Auxiliary Contactor Circuit Breaker Current Transformer Disconnect Switch Fuse Ground HPR ISM L LL M RES S TB — — — — — — — — High Pressure Relay Integrated Starter Module Main Supply Power Control Power Supply Contactor Resistor Contactor Terminal Block NOTES: 1. Power factor correction capacitors (when required) are connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130. 2. For metering option see Fig. 52. Fig.
CT ISM VFD LEGEND — Current Transformer — Integrated Starter Module — Variable Frequency Drive Represents Twisted Wire To Door Fig. 51 — Ground Fault Phase Current Option AM CT L VM — — — — LEGEND Ammeter Current Transformer Main Power Supply Voltmeter Represents Twisted Wire To Door Fig.
Fig. 53 — Benshaw, Inc.
LEGEND AUX BR CB COND CPU CVC/ ICVC CT EVAP FU GND — — — — — — Auxiliary Bridge Rectifier Circuit Breaker Condenser Central Processing Unit Chiller Visual Controller — — — — Current Transformer Evaporator Fuse Ground L LL M O/L PFCC — — — — — RLA SCR ST TB — — — — Main Supply Power Control Power Supply Contactor Overload Reset Power Factor Correction Capacitor Rated Load Amps Silicone Controller Rectifier Shunt Trip Terminal Block NOTES: 1 LED status with power applied and prior to run command.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
LEGEND FOR FIG.
INDEX Motor and Lubricating Oil Cooling Cycle, 7 Motor-Compressor, 5 Motor Rotation (Check), 65 Notes on Module Operation, 87 Oil Changes, 73 Oil Charge, 55 Oil Cooler, 36 Oil Pressure and Compressor Stop (Check), 65 Oil Reclaim Filter, 73 Oil Reclaim System, 8 Oil Specification, 73 Oil Sump Temperature Control, 36 Open Oil Circuit Valves, 48 Operating Instructions, 66 Operating the Optional Pumpout Unit, 67 Operator Duties, 66 Optional Pumpout Compressor Water Piping (Check), 53 Optional Pumpout System Con
INDEX (cont) Start-Up/Shutdown/Recycle Sequence, 46 Start the Chiller, 66 Stop the Chiller, 66 Storage Vessel, 7 Summary (Lubrication Cycle), 8 Surge Prevention Algorithm (Fixed Speed Chiller), 39 Surge Prevention Algorithm with VFD, 40 Surge Protection (Fixed Speed Chillers), 40 Surge Protection VFD Units, 40 System Components, 5 Temperature Sensors (Check), 76 Test After Service, Repair, or Major Leak, 71 Tighten All Gasketed Joints and Guide Vane Packing, 48 Tower Fan Relay Low and High, 38 Trim Refriger
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER (Remove and use for job file.) MACHINE INFORMATION: NAME JOB NO.
INSPECT WIRING AND RECORD ELECTRICAL DATA: RATINGS: Motor(s) Amps Motor Voltage Line Voltages: Motor Oil Pump Voltage Oil Pump Starter LRA Rating Controls/Oil Heater FIELD-INSTALLED STARTERS ONLY: Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state starters; disconnect leads to motor and megger the leads.
19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET DESCRIPTION Base Demand Limit ECW Setpoint LCW Setpoint Ice Build Setpoint Tower Fan High Setpoint CVC/ICVC Number: CVC/ICVC Identification: BUS: Software RANGE 40 to 100 10 to 120 15 to 120 15 to 60 55 to 105 UNITS % DEG F DEG F DEG F DEG F DEFAULT 100 60.0 50.0 40.
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S Day Flag M T W T F S S H Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is OCCUPIED 24 hours/day. ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag M T W T F S S H Occupied Time Unoccupied 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.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - 19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET DESCRIPTION Starter Type (0=Fu
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold Surge/Hot Gas Bypass Surge Limit/HGBP Option Select: Surge=0, HGBP=1 Min.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - 19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET DESCRIPTION Comp Motor Temp Over
19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET DESCRIPTION Capacity Control Proportional Inc Band Proportional DEC Band Proportional ECW Gain STATUS UNITS DEFAULT 2 to 10 2 to 10 1 to 3 Guide Vane Travel Limit 30 to 100 % 80 Diffuser Control Diffuser Option Guide Vane 25% Load Pt Diffuser 25% Load Point Guide Vane 50% Load Pt Diffuser 50% Load Point Guide Vane 75% Load Pt Diffuser 75% Load Point Diffuser Full Span mA 0 to 1 0 to 78 0 to 100 0 to 78 0 to 100 0 to 78 0 to 100 15 to 22 DSABLE/ENA
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - 19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET DESCRIPTION Lead Lag Control LE
19XR, XRV PIC II RAMP_DEM TABLE CONFIGURATION SHEET DESCRIPTION Pulldown Ramp Type: Select: Temp=0, Load=1 Demand Limit + kW Ramp Demand Limit Source Select: Amps=0, kW=1 Motor Load Ramp% Min Demand Limit Prop Band Demand Limit At 20 mA 20 mA Demand Limit Opt Motor Rated Kilowatts Demand Watts Interval RANGE UNITS DEFAULT 0/1 1 0/1 0 5 to 20 3 to 15 40 to 100 0/1 50 to 9999 5 to 60 % % DSABLE/ENABLE kW MIN VALUE 10 10 40 DSABLE 145 15 19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET DESCRIPTI
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - BROADCAST (BRODEF) CONFIGURATION SHEET DESCRIPTION Time Broadcast Enable Daylight
UNIT-MOUNTED VFD CONFIGURATION SHEET DESCRIPTION Maximum Speed Speed Display Scaling Motor Voltage Frequency Motor Amps Line Voltage Over Frequency Limit PARAMETER P.004 P.028 H.000 H.001 H.002 H.021 H.022 RANGE 15 to H.022 10 to 999 100 to 690 30 to 200 Power Module Dependent 300 to 565 30 to 210 *Variable by job — refer to component nameplates and labels.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE: DATE: SE
CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET PRIMARY MESSAGE: DATE: SECONDARY MESSAGE: COMPRESSOR ONTIME: TIME: CHW IN CHW OUT EVAP REF CDW IN CDW OUT COND REF OILPRESS OIL TEMP AMPS % COMMUNICATION MESSAGE CCN LOCAL RESET CL-14 MENU
Book Tab Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. 2 PC 211 Catalog No. 531-982 Printed in U.S.A.
