Specifications

ManualsBrandsCarrier ManualsKitchen Appliances23XL

Start-Up, Operation, and Maintenance

Instructions

SAFETY CONSIDERATIONS

Screw liquid chillers are designed to provide safe and reli-

able service when operated within design speciﬁcations. When

operating this equipment, use good judgment and safety pre-

cautions to avoid damage to equipment and property or in-

jury to personnel.

Be sure you understand and follow the procedures and safety

precautions contained in the machine instructions, as well

as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outlet from

rupture disc or relief valve must be vented outdoors in accordance with

the latest edition of ANSI/ASHRAE 15 (American National Standards

Institute, American Society of Heating, Refrigeration, and Air Condi-

tioning Engineers), latest edition. The accumulation of refrigerant in an

enclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,

especially for enclosed and low overhead spaces. Inhalation of high

concentrations of vapor is harmful and may cause 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 test pressures. VERIFY the allowable test

pressure by checking the instruction literature and the design pressures

on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry

nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed and func-

tioning before operating any machine.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until

all refrigerant (liquid and vapor) has been removed from chiller. Traces

of vapor should be displaced with dry air or nitrogen and the work area

should be well ventilated. Refrigerant in contact with an open ﬂame

produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig machine sections or the

entire assembly.

DO NOT work on high-voltage equipment unless you are a qualiﬁed

electrician.

DO NOT WORK ON electrical components, including control centers,

switches, starters, or oil heater (if applicable) until you are sure ALL

POWER IS OFF and no residual voltage can leak from capacitors or

solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK

IS INTERRUPTED, conﬁrm that all circuits are deenergized before

resuming work.

DO NOT syphon refrigerant.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.

USE SAFETY GOGGLES. Wash any spills from the skin with soap

and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH

EYES with water and consult a physician.

NEVER APPLY an open ﬂame or live steam to a refrigerant cylinder.

Dangerous over pressure can result. When it is necessary to heat re-

frigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to

reﬁll them. It is DANGEROUS AND ILLEGAL. When cylinder is emp-

tied, evacuate remaining gas pressure, loosen the collar, and unscrew

and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the

machine. The introduction of the wrong refrigerant can cause damage

or malfunction to this machine.

Operation of this equipment with refrigerants other than those cited

herein should comply with ANSI/ASHRAE 15 (latest edition). Contact

Carrier for further information on use of this machine with other

refrigerants.

DO NOT ATTEMPT TO REMOVE ﬁttings, covers, etc., while ma-

chine 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 re-

lief devices AT LEAST ONCE A YEAR. If machine operates in a cor-

rosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief de-

vice when corrosion or build-up of foreign material (rust, dirt, scale,

etc.) is found within the valve body or mechanism. Replace the

device.

DO NOT install relief devices in series or backwards.

USE CARE when working near or in line with a compressed spring.

Sudden release of the spring can cause it and objects in its path to act

as projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about and

release refrigerant, causing personal injury.

DO NOT climb over a machine. Use platform, catwalk, or staging. Fol-

low safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move

inspection covers or other heavy components. Even if components are

light, use mechanical equipment when there is a risk of slipping or

losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE

THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead

of the starter, tower fan, or pumps. Shut off the machine or pump be-

fore servicing equipment.

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 con-

trol group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been

completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other

items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the nut

has a positive thread engagement.

PERIODICALLY INSPECT all valves, ﬁttings, and piping for corro-

sion, 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.

23XL

50/60 Hz

Hermetic Screw Liquid Chillers

With HCFC-22 and HFC-134a

Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations.

Book 2

Tab 5e

PC 211 Catalog No. 532-302 Printed U.S.A. Form 23XL-2SS Pg 1 12-94 Replaces: 23XL-1SS

Summary of content (104 pages)

PAGE 1
23XL 50/60 Hz Hermetic Screw Liquid Chillers With HCFC-22 and HFC-134a Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERATIONS Screw 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.
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CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4 23XL MACHINE FAMILIARIZATION . . . . . . . . . . . 4-7 Machine Identification Nameplate . . . . . . . . . . . . . 4 System Components . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Condenser . . . . . . . . . . . . . . . .
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CONTENTS (cont) Page Input the Local Occupied Schedule (OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Selecting Refrigerant Type . . . . . . . . . . . . . . . . . . . 53 • TO CONFIRM REFRIGERANT • TO CHANGE REFRIGERANT TYPE Input Service Configurations . . . . . . . . . . . . . . . .
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CONTENTS (cont) ABBREVIATIONS AND EXPLANATIONS Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 • RED LED • GREEN LEDs Notes on Module Operation . . . . . . . . . . . . . . . . . . 80 Processor Module (PSIO) . . . . . . . . . . . . . . . . . . . . 81 • INPUTS • OUTPUTS Starter Management Module (SMM) . . . . . . . . . . 81 • INPUTS • OUTPUTS Options Modules (8-Input) . . . . . . . . . . . . . . . . .
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FRONT VIEW 1 2 3 4 5 6 7 8 9 10 11 — — — — — — — — — — — Power Panel Local Interface Display (LID) Control Center ASME Nameplate, Cooler Cooler Refrigerant Isolation Valve ASME Nameplate, Economizer (Hidden) Service Valve Take-Apart Rabbet Fit Connector (Lower) Cooler Temperature Sensor ASME Nameplate, Condenser Typical Waterbox Drain Port Cooler Supply/Return End Waterbox Cover 12 — Condenser Supply/Return End Waterbox Cover 13 — Compressor Nameplate (Hidden) 14 15 16 17 18 19 20 21 22 — — — — — — — —
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FRONT VIEW 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 — — — — — — — — Compressor Nameplate (Hidden) Power Panel Local Interface Display (LID) Control Center ASME Nameplate, Cooler Cooler Vessel Separation Feet Economizer Float Valve Access Cover (Hidden) Refrigerant Charging Valve Economizer Oil Filter Assembly (Hidden) ASME Nameplate, Economizer Typical Waterbox Drain Port Take-Apart Rabbet Fit Connector ASME Na
PAGE 7
Relatively cool (typically 65 to 85 F [18 to 29 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 and 4). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water.
PAGE 8
bulk of the oil to drop from the refrigerant and collect at the bottom of the oil separator. A mesh screen is provided near the oil separator outlet to remove any additional oil which may still be entrained in the refrigerant vapor. The oil sump (Frame 1 and 2 machines) contains a level switch, temperature sensor, 500-watt oil heater (Frame 1 and 2 machines), and oil filter. Oil temperature is measured and displayed on the LID default screen.
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Fig.
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Fig.
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Fig. 5 — Screw Compressor Principle Fig. 7 — Slide Valve Position at Full Load In addition, the PIC Controls minimize oil loss to the cooler once the rotor inlet temperature sensor detects hot oil draining down the suction pipe. If the rotor inlet temperature increases 4 F (2.2 C) on Frame 1 and 2 machines or 8 F (4.4 C) on Frame 4 machines above the leaving chilled water temperature, the slide valve is proportionately moved in the load direction to increase suction gas velocity.
PAGE 12
These starters operate by reducing the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the voltage and the current are reduced at start-up, the starting torque is reduced as well. The objective is to reduce the starting voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage and current are then ramped up in the desired period of time.
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CONTROLS Controls Definitions PIC System Components — The Product Integrated Control (PIC) is the machine’s control system. The PIC controls the operation of the machine by monitoring all operating conditions. The PIC can also diagnose a problem with the machine. It promptly positions the slide valve to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans so that they turn on only when required.
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*Some 23XL machines will have both an oil temperature sensor and an oil level safety switch (two separate components). Fig.
PAGE 15
*Some 23XL machines will have both an oil temperature sensor and an oil level safety switch (two separate components). Fig.
PAGE 16
Fig. 13 — Control Sensors (Temperature) Fig. 14 — Control Sensors (Pressure Transducer, Typical) LEGEND 4 — 5-Volt Transducer Power Supply 2 — PSIO 5 — 6-Pack Relay Board 3 — 8-Input Module (Optional) 6 — Circuit Breakers (4) (one of two available) 1 — LID Fig.
PAGE 17
• Local Operation — By pressing the LOCAL softkey, the PIC is now in the LOCAL operation mode, and the control will accept modification to programming from the LID only. The PIC will use the Local time schedule to determine machine start and stop times. • CCN Operation — By pressing the CCN softkey, the PIC is now in the CCN operation mode. The control will accept modifications from any CCN interface or module with the proper authority, as well as the LID.
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MENU STRUCTURE — To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test. TO VIEW POINT STATUS (Fig. 19) — 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. • Press NEXT to scroll the cursor bar down in order to highlight a point or to view more points below the current screen. 2.
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Fig.
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Fig.
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For Discrete Points — Press START or STOP to select the desired state. For Analog Points — Press INCREASE DECREASE to select the desired value. 3. Press SELECT to access and view the time schedule. 4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change. or 5. Press SELECT to access the highlighted period or override. 3. Press ENTER to register new value.
PAGE 22
9. Either return to Step 4 to select another period or over ride or press EXIT again to leave the current time schedule screen and save the changes. 10. Holiday Designation may be found in the Service Operation section, page 36. 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. TO VIEW AND CHANGE SET POINTS (Fig. 23) 1. To view the Set Point table, at the Menu screen press SETPOINT . Fig.
PAGE 23
Each schedule consists of from one to 8 occupied/unoccupied time periods, set by the operator. These time periods can be enabled to be in effect (or not in effect) on each day of the week and for holidays. The day begins with 0000 hours and ends with 2400 hours. The machine is in OCCUPIED mode unless an unoccupied time period is in effect. Figure 22 shows a typical office building time schedule, with a 3-hour, off-peak cool down period from midnight to 3 a.m., following a weekend shutdown.
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Table 3 — LID Screens 3. Data appearing in the ‘‘Reference Points 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 in PSIO Software Version 13 and higher. 5. All values shall be variables available for read operation from a CCN Network. Descriptions designated (*) shall support write operations for BEST programming language, data transfer, and overriding.
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EXAMPLE 3 — STATUS03 DISPLAY SCREEN 3. Scroll down to highlight STATUS03. To access this display from the LID default screen: 1. Press MENU . 4. Press SELECT . 2. Press STATUS .
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Table 3 — LID Screens (cont) EXAMPLE 6 — LEAD/LAG CONFIGURATION DISPLAY SCREEN To access this display from the LID default screen: 4. Press SELECT . 1. Press MENU 5. Scroll down to highlight LEAD/LAG. . 6. Press SELECT . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURATION.
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EXAMPLE 8 — SERVICE2 DISPLAY SCREEN 4. Press SELECT . To access this display from the LID default screen: 1. Press MENU 5. Scroll down to highlight SERVICE2. . 6. Press SELECT . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE.
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Table 3 — LID Screens (cont) EXAMPLE 11 — MAINTENANCE (MAINT02) DISPLAY SCREEN To access this display from the LID default screen: 4. Press SELECT . 1. Press MENU 5. Scroll down to highlight MAINT02. . 6. Press SELECT . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS.
PAGE 29
NOTE: Frame 4 units do not use an oil heater. Ramp Loading Control — 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 machine is started, and the chilled water loop has to be brought down to normal design conditions. This helps reduce electrical demand charges by slowly bringing the chilled water to control point.
PAGE 30
Table 4 — Protective Limits and Control Settings MONITORED PARAMETER TEMPERATURE SENSORS OUT OF RANGE PRESSURE TRANSDUCERS OUT OF RANGE COMPRESSOR DISCHARGE TEMPERATURE LOW DISCHARGE SUPERHEAT CONDENSER FREEZE PROTECTION MOTOR WINDING TEMPERATURE PHASE REVERSAL (MOTOR ROTATION) LIMIT APPLICABLE COMMENTS −40 to 245 F (−40 to 118.3 C) Must be outside range for 3 seconds 0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds. Ratio = Input Voltage ÷ Voltage Reference .
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Table 5 — Capacity Overrides OVERRIDE CAPACITY CONTROL VIEW/MODIFY ON LID TABLE HIGH CONDENSER PRESSURE HIGH MOTOR TEMPERATURE LOW REFRIGERANT TEMPERATURE (REFRIGERANT OVERRIDE AT TEMPERATURE) MANUAL SLIDE VALVE TARGET MOTOR LOAD — ACTIVE DEMAND LIMIT EQUIPMENT SERVICE1 EQUIPMENT SERVICE1 EQUIPMENT SERVICE1 CONTROL ALGORITHM MAINT01 STATUS01 FIRST STAGE SETPOINT Default Configurable Value Range 230 psi (1586 kPa) 150 to 250 psi (1034 to 1724 kPa) .
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signal is wired to terminals J1-1(+) and J1-2(−). If the signal is internally powered, the signal is wired to terminals J13(+) and J1-2(−). Water/Brine Reset — Three types of chilled water or brine reset are available and can be viewed or modified on the Equipment Configuration menu Config table. The default screen status message indicates when the chilled water reset is active. The CONTROL POINT, on the Status01 table, indicates the machine’s reset temperature.
PAGE 33
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 option operates in CCN mode only. If any other chiller configured for lead/lag is set to the LOCAL or OFF modes, it will be unavailable for lead/lag operation.
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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 and standby chillers are running, the lead chiller will not attempt to start and will not assume the role of lead chiller until either the lag or standby chiller shuts down.
PAGE 35
ICE BUILD INITIATION — The Ice Build Time Schedule provides the means for activating ice build. The ice build time table is named OCCPC02S. If the Ice Build Time Schedule is OCCUPIED and the ICE BUILD OPTION is ENABLED, then ice build is active 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.
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CHANGING REFRIGERANT TYPES — To select refrigerant type, go to the Control Test table. Whenever the refrigerant type is changed, the ATTACH TO NETWORK DEVICE table must be used. After changing the refrigerant type in the Control Test table, move to the ATTACH TO NETWORK DEVICE table. Make sure the highlight bar is located on the LOCAL selection. Press the ATTACH softkey. The information in the PSIO module will now be uploaded. The default screen will appear.
PAGE 37
4. Press NEXT until Holidef is highlighted. This is the Holiday Definition table. 5. Press SELECT to enter 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. Fig. 27 — Example of Holiday Period Screen START-UP/SHUTDOWN/ RECYCLE SEQUENCE (Fig. 28) Local Start-Up — Local start-up (or a manual start-up) 7.
PAGE 38
When a stop signal occurs, the shutdown sequence first stops the compressor by deactivating the start relay. The slide valve decrease timer is activated for 3 minutes to open the slide valve. The condenser water pump relay is shut down 30 seconds after the compressor run contact is open and motor load is less than 10%. The service ontime and compressor ontime timers are deactivated. The 3-minute stopto-start timer will now begin to count down.
PAGE 39
When 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. RECYCLE RESTART DELTA T is an operator-configured function which defaults to 5 F (3 C). This value is viewed/modified on the Service1 screen.
PAGE 40
Leak Test Machine — Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 30 for an outline of the leak test procedures. Refer to Fig. 24 and 25 during pumpout procedures. See the Pumpout and Refrigerant Transfer Procedures Section on page 61. Refer to Tables 6A-6D for temperature/pressure relationships for HCFC-22 and HFC134a refrigerants. See Fig. 31-34. 1.
PAGE 41
Fig.
PAGE 42
Fig.
PAGE 43
Fig.
PAGE 44
Fig.
PAGE 45
Fig.
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Table 6A — HCFC-22 Pressure — Temperature (F) TEMPERATURE (F) -50 -48 -46 -44 -42 -40 -38 36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 - 8 - 6 - 4 - 2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 PRESSURE (psi) Absolute Gage 11.67 6.154* 12.34 4.829* 13.00 3.445* 13.71 2.002* 14.45 0.498* 15.22 0.526 16.02 1.328 16.86 2.163 17.73 3.032 18.63 3.937 19.57 4.877 20.55 5.853 21.56 6.868 22.62 7.921 23.71 9.015 24.85 10.15 26.02 11.32 27.24 12.54 28.50 13.81 29.81 15.11 31.16 16.47 32.56 17.87 34.01 19.
PAGE 47
Table 6C — 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 6D — 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.
PAGE 48
Do not apply greater vacuum than 29.82 in. Hg vac (.4 kPa absolute) or go below 33 F (.56 C) on the wet bulb vacuum indicator. At this temperature/pressure, isolated pockets of moisture can turn into ice. The slow rate of evaporation (sublimination) of ice at these low temperatures/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.
PAGE 49
11. Ensure that the voltage selector switch inside the power panel is switched to the incoming voltage rating. 12. On machines 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. Inspect Wiring Do not apply any kind of test voltage if the machine is under a dehydration vacuum.
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when the board is turned on its side so that 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 that so the motor is up to full speed in 8 to 10 seconds, 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 Troubleshooting Guide, Solid-State Starter section. MECHANICAL-TYPE STARTERS 1.
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CUTLER-HAMMERt SOLID-STATE STARTERS This equipment is at line voltage when ac power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on the equipment. 1. Check that all wiring connections are properly terminated to the starter. 2. Verify that the ground wire to the starter is installed properly and is of sufficient size. 3. Verify that the motor is properly grounded to the starter. 4.
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Table 7 — Potentiometer Adjustment DIAL Starting Current ADJUSTMENT RANGE Minimum Maximum (CCW) (CW) 100% 400% Ramp Time (Adjustable Current Ramp) 2 seconds 30 seconds Current Limit 100% 400% Pulse Start 0 (Off) 2 seconds Current Trip Power Saver 50% — 400% — CCW — CW — FUNCTION Sets initial starting current level. Sets time during which current ramps from the initial starting level to the maximum possible current limit setting. Sets maximum starting current.
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Configure Service1 Table — Access Service1 table to modify/ view the following to jobsite parameters: Selecting Refrigerant Type — The 23XL control must be configured for the refrigerant being used, either HCFC-22 or HFC-134a. TO CONFIRM REFRIGERANT TYPE — Confirm that the correct refrigerant type is indicated by entering the Service menu and selecting Control Test. See Fig. 21. Select Refrigerant Type. The screen will display the current refrigerant setting.
PAGE 54
Minimum Load DT1: 46.5 −44 = 2.5 F (8.1 −6.7 = 1.4 C) Minimum Load DP1: 121 − 73 = 45 psid (834 - 503 = 331 kPad) To avoid unnecessary opening of the hot gas bypass valve, add 5 psi (35 kPa) at DP1 from these conditions: DT1 = 2.5 F (1.4 C) DP1 = 50 psid (345 kPad) [30 psid (207 kPad)] If opening of the hot gas bypass valve occurs too soon or too late for the present conditions these parameters should be changed by the operator. Only the minimum load points change is required.
PAGE 55
Table 8 — Control Test Table Functions Charge Refrigerant into Machine TESTS TO BE PERFORMED 1. Automated Tests* 2. PSIO Thermistors 3. 4. 5. 6. 7. 8. 9. 10.
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Table 9 — Refrigerant Charges REFRIGERANT COOLER SIZE 10,11 20,21 40 41 42 43 ECONOMIZER NO YES NO YES NO YES NO YES NO YES NO YES HCFC-22 lb 600 650 700 750 900 1000 1000 1100 1100 1200 1200 1300 HFC-134a kg 272 295 318 340 408 454 454 499 499 544 544 590 lb * * * * 800 850 850 900 900 950 950 1000 kg * * * * 363 386 386 408 408 431 431 454 *Not available or retrofitable when using HFC-134a.
PAGE 57
If rotation is proper , allow the compressor to come up to speed. NOTE: Starters may have phase protection and will not allow a start if the phase is not correct. Instead, a ‘‘STARTER FAULT’’ message will occur if this happens. NOTES ON SOLID-STATE STARTERS 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.
PAGE 58
7. The compressor may operate at full capacity for a short time after the pulldown ramping has ended, even though the building load is small. The active electrical demand setting can be overridden to limit the compressor IKW (input kilowatt), or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate. It is accessed on the Equipment Configuration menu Config table (Table 3, Example 5).
PAGE 59
Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the oil level appears abnormally high, the oil may have absorbed refrigerant. Frame 4 machines are able to start with an abnormally high oil level. Make sure that the oil temperature is above refrigerant temperature plus 35° F (19° C) (Frame 1 and 2 machines only). NOTE: Frame 4 machines do not have an oil heater.
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Pressure Water COOLER Temp Refrigerant Pressure Water CONDENSER Temp MACHINE SERIAL NO. COMPRESSOR REFRIGERANT TYPE Oil Motor OPERROTOR DISCHARGE ATOR REMARKS Filter FLA INLET INITIALS TEMP Press. Temp Press. Temp Press. Diff. Temp Level Voltage TEMP In Out GPM In Out In Out GPM In Out Amperage Press. Refrigerant MACHINE MODEL NO. Fig.
PAGE 61
TRANSFER REFRIGERANT FROM STORAGE TANK TO MACHINE NOTE: Valve 14 is only available on Frame 1 and 2 machines. Valves 16 and 17 are only available on Frame 4 machines. 1. Equalize refrigerant pressure. PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation — The 23XL may come equipped with isolation valves and/or a pumpout system/optional storage tank for the purpose of servicing the unit. The pumpout system may come equipped with or without a storage tank. Three possibilities are available: 1.
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b. Turn on pumpout condenser water. c. Place valves in the following positions: d. Gradually crack open valve 5 to increase machine pressure to 68 psig (469 kPa) [35 psig (141 kPa)]. Slowly feed refrigerant to prevent freeze up. e. Open valve 5 fully after reaching 68 psig (469 kPa) [35 psig (141 kPa)]. Open liquid line valves 7a and 7b until refrigerant pressure equalizes. VALVE 1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17 CONDITION C C C C C d.
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6. Open valve 5 fully. g. Turn off pumpout condenser water. VALVE 1a 1b 2 3 4 5 8 11 12 13 14 15 16 17 CONDITION C C C C C C C C C C C C C C VALVE 1a 1b 2 3 4 5 8 11 12 13 14 15 16 17 CONDITION C C C C C C C C C C 7. Open valve 11 to equalize the liquid refrigerant level between vessels. 8. Close valves 1a, 1b, 3, and 5. 9. Open isolation valves 12 and 13. h. Proceed to Pumpdown test on the LID to turn off machine water pumps and lock out machine compressor.
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Refrigerant Leak Rate — ASHRAE recommends that WEEKLY MAINTENANCE 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 pumped over for other service work.
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8. Remove the oil filter retaining spring. Remove and properly discard the oil filter. 9. Insert a new oil filter. Seat the filter retaining spring against the flange stop. Install the oil sump cover with a new O-ring. Insert and tighten the 6 bolts that secure the oil sump cover. 10. Evacuate the oil sump by placing a vacuum pump on the drain valve. Follow normal evacuation procedures. Shut off the drain valve when the oil sump has been evacuated. Charge new oil through the drain valve. 11.
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Oil Specification — If oil is to be added, it must meet the following Carrier specifications: • Carrier Part Number . . . . . . . . . . . . . . . . . . . PP23BZ104 • Oil type . . . . . . . . . . . . . . . . . Inhibited polyolester-based synthetic compressor lubricant suitable for use in screw compressors where high viscosity and compatibility with HCFC 22 and HFC-134a refrigerants is required. • ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . 220 • Specific Gravity . . . . . . . . . .
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Optional Pumpout System Maintenance — For compressor maintenance details, refer to the 06D, 07D Installation, Start-Up, and Service Instructions. OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE — Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows: • HCFC-22 and HFC-134a ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Viscosity SSU 100 F (38 C). . . . . . . . . . . . . . . . . . . . 300 Carrier Part Number . . . . . . . . .
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VOLTAGE DROP — Using a digital voltmeter, the voltage drop across any energized sensor can be measured while the control is energized. Tables 11 and 12 list 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. Voltage should also be checked at the sensor plugs. Check the sensor wire at the sensor for 5 vdc if the control is powered.
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If the transducer value does not move to 0 psig (0 kPa), the transducer will return to the original reading. If the pressure is within the allowed range, check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35. For example, the condenser transducer voltage input is measured at PSIO terminals J7-1 and J7-2. The voltage ratio must be between 0.80 vdc and 0.
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LEGEND FOR TABLE 10, A - N 1CR AUX CA P CDFL CHIL S S CHWS CHWR CMPD CR AUX CRP CRT DEM LIM ERT EVFL LID MTRW — — — — — — — — — — — — — — — 1CR Compressor Start Contact Compressor Current Condenser Water Flow Chiller Start/Stop Chiller Water Supply Chiller Water Return Compressor Discharge Temperature 1CR Compressor Start Contact Condenser Refrigerant Pressure Condenser Temperature Demand Limit Evaporator Refrigerant Temperature Evaporator Water Flow Local Interface Device Motor Winding Temperature OILP
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Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) D. PRE-START FAILURES PRIMARY MESSAGE SECONDARY MESSAGE PRESTART ALERT STARTS LIMIT EXCEEDED PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT† PRESTART ALERT PRESTART ALERT PRESTART ALERT PRESTART ALERT ALARM MESSAGE/PRIMARY CAUSE STARTS EXCESSIVE Compressor Starts (8 in 12 hours) MTRW VALUE exceeded limit of [LIMIT]*. Check motor temperature.
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Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) F.
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Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/ ADDITIONAL CAUSE/REMEDY PRIMARY CAUSE UNAUTHORIZED UNIT SHOULD BE STOPPED CA P Emergency: Compressor run- Compressor is running with more than 10% OPERATION ning without control authorization. RLA and control is trying to shut it down. Throw power off to compressor if unable to stop.
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Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. NORMAL RUN OVERRIDES ACTIVE (ALERTS) PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY RUN CAPACITY LIMITED HIGH CONDENSER PRESSURE CRP VALUE exceeded limit of [LIMIT]*. Condenser pressure override. RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE MTRW VALUE exceeded limit of [LIMIT]*. Motor temperature override. See Capacity Overrides, Table 5.
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K. MACHINE PROTECT LIMIT FAULTS Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise.
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Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) L. MACHINE ALERTS PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/ ADDITIONAL CAUSE/REMEDY PRIMARY CAUSE RECYCLE ALERT HIGH AMPS AT SHUTDOWN* High Amps at Recycle: Check slide Check that slide valve is opening. Check valve. motor amps correction calibration is correct. SENSOR FAULT ALERT LEAVING COND WATER TEMP Sensor Fault: Check leaving condenser water sensor.
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Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) N. ADDITIONAL TROUBLESHOOTING INFORMATION DESCRIPTION At power-up, default screen does not appear. Instead, ‘‘Uploading Tables’’ message continually appears. Blank LID screen. Scrambled LID display screens. SMM communications failure. ‘‘Communications Failure’’ highlighted message at bottom of LID. ‘‘Control Test Disabled’’ message. Slide valve solenoid will not energize in Control Test.
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Table 11 — Thermistor Temperature (F) vs Resistance/Voltage Drop TEMPERATURE (F) −25.0 −24.0 −23.0 −22.0 −21.0 −20.0 −19.0 −18.0 −17.0 −16.0 −15.0 −14.0 −13.0 −12.0 −11.0 −10.0 −9.0 −8.0 −7.0 −6.0 −5.0 −4.0 −3.0 −2.0 −1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0 50.0 51.0 52.0 53.0 54.0 55.0 56.0 57.0 58.0 59.
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Table 12 — Thermistor Temperature (C) vs Resistance/Voltage Drop TEMPERATURE (C) −40 −39 −38 −37 −36 −35 −34 −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 38 39 40 41 42 43 44 VOLTAGE DROP (V) 4.896 4.889 4.882 4.874 4.866 4.857 4.848 4.838 4.828 4.817 4.806 4.794 4.782 4.769 4.755 4.740 4.725 4.710 4.693 4.676 4.657 4.639 4.
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If all modules indicate communications failure, check communications plug on the PSIO module for proper seating. Also check the wiring terminations (Level II — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, perform an Attach to Network Device upload of the PSIO module. The correct PSIO module address must be known to perform this function if the Attach to Network Device selection is not functioning, replace the module.
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Starter Management Module (SMM) (Fig. 47) INPUTS — Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. Application of the machine determines which terminals are used. Always refer to the individual unit’s wiring for terminal numbers. OUTPUTS — Outputs are 24 vdc and wired to strip J1. There are 2 terminals used per output. NOTE: LID address switches are factory set as follows: S1 is set at E; S2 is set at 6. Fig.
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Terminal block connections are provided on the options modules. All sensor inputs are field wired and installed. Options module number 1 can be factory or field installed. Options module 2 is shipped separately and must be field installed. For installation, refer to unit or field wiring diagrams. Be sure to address the module for the proper module number (Fig. 48) and to configure the chiller for each feature being used. INSTALLATION 1.
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Solid-State Starters — Troubleshooting guides pertaining to the operation of the solid-state starters may be found in Fig. 49-55 and Tables 13 and 14. Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables. When the power is off: • Inspect for physical damage and signs of arcing, overheating, etc.
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ELECTRONIC PROTECTION RELAY (EPR) — On CutlerHammer solid state starters, the EPR is designed to provide an alternative to conventional motor protection due to overcurrent. See Fig. 53. It performs the following functions: Test Button — The TEST button provides testing of the EPR’s ability to detect overload, test relay operation, and simulate motor load. System Ready (SYST RDY) — This light-emitting diode (LED) provides a visual indication that the EPR is functioning.
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Table 13 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide PROBLEM BIPCRS6AK board phase correct not on. PROBABLE CAUSES 1. L1 and L3 switch phases reversed. 2. Missing phase voltage. 3. Improper line voltage. BIPCRS6AK board relay not on. Ribbon cable not properly seated. 1. Improper line voltage. 2. Transformer malfunction. BIPCRS6AK board power +15 vdc not on. BIPCDVDT1/1L boards LEDs not on. 1. A short exists between line and load terminals. 2. An SCR is shorted in the phase assembly.
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Table 14 — Cutler-HammerT Solid-State Starter Troubleshooting Guide PROBLEM (CB) trips (electrically operated disconnecting means opens) as it is closed. CB trips while motor is running. CB trips when STOP is pressed. Starter does not pick up and maintain. PROBABLE CAUSE Motor is not connected. Incorrect phase sequence to the starter, 3-phase power not connected, or terminal loose. Shorted SCR. Shunt trip contact between terminals closes due to shorted SCR. Shunt trip latching relay not reset (if used).
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SCR — Silicon Control Rectifier Fig.
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Fig.
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fications, physical data, electrical data, and wiring schematics may be found in Tables 15-21 and Fig. 56-62.
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Table 18 — Optional Storage Tank and/or Pumpout System Physical Data UNIT SIZE 28 52 TANK OUTSIDE DIAMETER DRY WEIGHT in. 24.00 27.
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Table 20A — 23XL Waterbox Cover Weights (Frame 1 and 2 Machines)* HEAT EXCHANGER WATERBOX DESCRIPTION PSI (kPa) Cooler or Condenser NIH, 1 Pass NIH, 2 Pass (Plain) NIH, 2 Pass (With Pipe Nozzles) 150 (1034) NIH, 3 Pass 150 (1034) FRAME 1 lbs kg 118 54 100 46 185 84 FRAME 2 lbs kg 128 58 148 67 200 91 166 180 76 82 LEGEND NIH — Nozzle-In-Head *These weights are given for reference only. They have been included in heat exchanger weights shown in Table 15. NOTE: Add 30 lb (14 Kg) for bolts.
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Table 21 — 23XL Compressor Torque Specification Chart for Metric and American Fasteners ITEM CAP SCREW SIZE AND TYPE GRADE 1. 2. 1. 2. M5 X 0.8 X 12 S.H. M6 X 1 X 16 S.H. M10 X 1.5 X 35 H.H. M10 X 1.5 X 40 S.H. M10 X 1.5 X 50 H.H. M12 X 1.75 X 40 S.H. M12 X 1.75 X 50 S.H. CAP SCREW 10.9 M12 X 1.75 X 60 S.H. M12 X 1.75 X 70 S.H. M12 X 1.75 X 80 S.H. M12 X 1.75 X 90 S.H. FRAME 1 AND 2 M16 X 2 X 55 S.H. FRAME 4 M16 X 2 X 70 S.H. M20 X 2.5 X 70 S.H. M10 X 1.5 X 16 S.S. 10.9 M10 X 1.5 X 30 S.S.
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3.1 Chilled water and condenser water flow switch contacts, optional remote start device contacts and optional spare safety device contacts, must have 24 vdc rating. Max current is 60 ma, nominal current is 10 ma. Switches with gold plated bifurcated contacts are recommended. 3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties between these terminals. 3.
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2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Solid-state starters are provided with: A. Two (2) 0-250 MCM lugs provided per phase for power conductor terminations when compressor motor RLA is 400 amps or less. B. Three (3), 250-500 MCM lugs provided per phase for power conductor terminations when compressor motor RLA is more than 400 amps. Wye-Delta starters are provided with: A.
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Fig.
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Fig.
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Fig.
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Fig.
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Fig.
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Fig.
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Fig.
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Fig.
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INDEX 23XL Machine Familiarization, 4 Abbreviations and Explanations, 4 Adding Refrigerant, 63 Adjusting the Refrigerant Charge, 63 After Extended Shutdown, 58 After Limited Shutdown, 58 Attach To Network Device Control, 35 Automatic Soft Stop Amps Threshold, 38 Auto.
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To Stop the Machine, 58 Tower-Fan Relay, 31 Troubleshooting Guide, 68 Unit Mounted Solide-State Starter, 11 Unit Mounted Wye Delta Starter, 12 Using The Optional Storage Tank and Pumpout System, 39 Water/Brine Reset, 32 Water Leaks, 67 Water Piping (Inspect), 48 Water Treatment, 67 Weekly Maintenance, 64 Wiring (Inspect), 49 Copyright 1994 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.