Specifications

4
CONTENTS (cont)
Page
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 95
Checking Guide Vane Linkage. . . . . . . . . . . . . . . . . . . 95
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 96
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 96
Check the Lubrication System. . . . . . . . . . . . . . . . . . . 96
SCHEDULED MAINTENANCE. . . . . . . . . . . . . . . . . 96-99
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Inspect the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . 96
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect Refrigerant Float System. . . . . . . . . . . . . . . . 97
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 97
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 98
Recalibrate Pressure Transducers. . . . . . . . . . . . . . . 99
Optional Pumpout System Maintenance . . . . . . . . . 99
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 99
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 99-165
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Checking Display Messages. . . . . . . . . . . . . . . . . . . . 100
Checking Temperature Sensors . . . . . . . . . . . . . . . . 100
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . 100
• TRANSDUCER REPLACEMENT
• COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND OPTIONAL WATERSIDE FLOW
DEVICE CALIBRATION
Control Algorithms Checkout Procedure . . . . . . . 117
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 118
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 118
•INPUTS
• OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . 118
•INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . 120
•INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
• TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
APPENDIX A — ICVC PARAMETER INDEX . .166-176
Page
APPENDIX B — LEAD/LAG WIRING . . . . . . . . 177,178
APPENDIX C — MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 179-181
APPENDIX D — OPTIONAL BACNET
COMMUNICATIONS WIRING. . . . . . . . . . . . . . 182-188
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
INITIAL START-UP CHECKLIST FOR
19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . . CL-1 to CL-16
INTRODUCTION
Prior to initial start-up of the 19XR unit, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the start-
up, operation and maintenance of the unit with the control sys-
tem before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
CAUTION
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dis-
sipate body electrostatic charge before working inside con-
trol center.
Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.
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 com-
munications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Sub-
part J of Part 15 of FCC Rules, which are designed to pro-
vide reasonable protection against such interference when
operated in a commercial environment. Operation of this
equipment in a residential area is likely to cause interfer-
ence, in which case the user, at his own expense, will be
required to take whatever measures may be required to cor-
rect the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
CAUTION
Do NOT punch holes or drill into the top surface of the
VFD (variable frequency drive) enclosure for field wiring.
Knockouts are provided on the side of the VFD enclosure
for field wiring connections. The top panel of the enclosure
must be removable for servicing the power module.
CAUTION
PROVIDE MACHINE PROTECTION. Store machine
and starter indoors, protected from construction dirt and
moisture. Inspect under shipping tarps, bags or crates to be
sure water has not collected during transit. Keep protective
shipping covers in place until machine is ready for
installation.