Specifications

3
CONTENTS (cont)
Page
Power Up the Controls and Check the
Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 59
Input the Local Occupancy Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 59
• PASSWORD
• INPUT TIME AND DATE
• CHANGE ICVC CONFIGURATION IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE ICVC DISPLAY FROM ENGLISH
TO METRIC UNITS
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pressure Transducer and Optional Flow
Device Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• ZERO POINT CALIBRATION
• HIGH END CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 62
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 62
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH PUMPOUT UNIT
• CHILLER SHIPPED WITH HOLDING CHARGE
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .64,65
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check Oil Pressure and Compressor Stop . . . . . . 65
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65
Check Chiller Operating Condition . . . . . . . . . . . . . . 65
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• COMPRESSOR ASSEMBLY
• COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 66-68
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
To Start The Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• FAILURE TO STOP
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66
Preparation for Extended Shutdown . . . . . . . . . . . . 66
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-72
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Page
Operating the Optional Pumpout Unit . . . . . . . . . . . 69
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 70
• TRANSFER REFRIGERANT FROM PUMPOUT
STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .72,73
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 72
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 72
Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Test After Service, Repair, or Major Leak . . . . . . . . 72
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Refrigerant Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 73
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 73
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 73
Check the Lubrication System . . . . . . . . . . . . . . . . . . 73
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-78
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil Strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 74
Vaporizer Refrigerant Return Line Orifice . . . . . . . 74
Compressor Inlet Bearing Oil Orifice . . . . . . . . . . . . 74
Inspect Condenser Refrigerant Float System. . . . 75
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 77
Compressor Bearing Maintenance . . . . . . . . . . . . . . 77
Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . 77
Motor Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . 77
•COOLER
• CONDENSER
Water/Brine Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Water/Brine Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 77
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 78
Optional Pumpout System Maintenance. . . . . . . . . 78
• OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE
• OPTIONAL PUMPOUT SAFETY
CONTROL SETTINGS
Ordering Replacement Chiller Parts. . . . . . . . . . . . . 78
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 78-117
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Checking Display Messages . . . . . . . . . . . . . . . . . . . . 79
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 79
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . . 79
• COOLER CONDENSER PRESSURE TRANSDUCER
AND LIQUIDSIDE FLOW DEVICE CALIBRATION
• TRANSDUCER REPLACEMENT