Contents
Safety Considerations
Start-Up, Operation, and Maintenance Instructions
Contents
Contents
Abbreviations and Explanations
Introduction
Refrigeration Cycle
Chiller Familiarization
MOTOR/OIL Refrigeration Cooling Cycle
19XL Rear View
Cooler In/Out Temperature Sensors
Take-Apart Rabbet Fit Connector
Condenser In/Out Temperature Sensors
Cooler Pressure Schrader Fitting
Refrigerant Motor Cooling and Oil Cooling Cycles
Lubrication Cycle
Lubrication System
Unit-Mounted Solid-State Starter Optional
Starting Equipment
Controls
Denitions
Major PIC Components Panel Locations
PIC Component Panel
Pressure Transducer, Typical
19XL Controls and Sensor Locations
Control and OIL Heater Voltage Selector S1
Power Panel with Options
General
LID Operation and Menus Fig
Select
Override Operations
− Example of Point Status Screen Status01
Example of Time Schedule Operation Screen
19XL Menu Structure
19XL Service Menu Structure
19XL Service Menu Structure
Example of Set Point Screen
Setpoint
LID Screens
Description Range Units Reference Point Name Alarm History
Example 1 Ð STATUS01 Display Screen
Menu Status Select
Example 3 Ð STATUS03 Display Screen
Example 2 Ð STATUS02 Display Screen
Example 4 Ð Setpoint Display Screen
Menu
Example 6 Ð LEAD/LAG Configuration Display Screen
Example 5 Ð Configuration Config Display Screen
ECW Control Option
ICE Build Termination
Example 7 Ð SERVICE1 Display Screen
Spare Alert Enable
Example 8 Ð SERVICE2 Display Screen
Example 9 Ð SERVICE3 Display Screen
Menu Service
Example 11 Ð Maintenance MAINT02 Display Screen
Example 10 Ð Maintenance MAINT01 Display Screen
Discharge Temperature
Bearing Temperature
Example 13 Ð Maintenance MAINT04 Display Screen
Example 12 Ð Maintenance MAINT03 Display Screen
Description RANGE/STATUS Units Reference Point Name
PIC System Functions
Page
Protective Safety Limits and Control Settings
Capacity Overrides
Page
Page
ECW
Lead/Lag Control
Hgbp
Hot Gas Bypass
Page
Cent Capacity
Ice Build Control
Page
To LOG on
Example of Attach to Network Device Screen
Sequence Fig
START-UP/SHUTDOWN/RECYCLE
Recycle Restart Delta T
Before Initial START-UP
Using the Optional Storage Tank and Pumpout
Job Data Required
Equipment Required
19XL Leak Test Procedures
Page
Ð HCFC-22 Pressure Ð Temperature C
Ð HCFC-22 Pressure Ð Temperature F
Ð HFC-134a Pressure Ð Temperature C
Ð HFC-134a Pressure Ð Temperature F
Temperature Pressure
Page
Check Optional Pumpout Compressor Water Pip
Inspect Wiring
MECHANICAL-TYPE Starters
Check Starter
BENSHAW, INC. SOLID-STATE Starter
Benshaw, Inc. Solid-State Starter Power Stack
Set Up Chiller Control Conguration
Power Up the Controls and Check the Oil Heater
Load Surge Prevention Occurs TOO Soon Occurs TOO Late
Volt Motor Code
Amps Correction Factors For 19XL Motors
19XL Chiller Equalization Without PUMP- OUT Unit
Charge Refrigerant into Chiller
Control Test Menu Functions
Tests to be Devices Tested Performed
19XL Total Refrigerant Charge
Refrigerant Charges
Cooler
Size
Dry Run to Test Start-Up Sequence
Initial START-UP
Check Rotation
Calibrate Motor Current
Check Oil Pressure and Compressor Stop
Operating Instructions
Operator Duties
To Stop the Chiller
Plant
Operating the Optional Pumpout Compressor
Pumpout and Refrigerant Transfer Procedures
Transfer Refrigerant from Storage Tank to Chiller
Tstat
Transfer the Refrigerant from Chiller to Storage Tank
Chillers with Isolation Valves
Test After Service, Repair, or Major Leak Ð If
General Maintenance
Return Refrigerant to Normal Operating Conditions
Guide Vane Actuator Linkage
Weekly Maintenance
Check Safety and Operating Controls Monthly
Scheduled Maintenance
To Change the OIL
Inspect the Heat Exchanger Tubes
Compressor Bearing and Gear Mainten
Optional Pumpout System Controls
Troubleshooting Guide
MAINT02
MAINT01
MAINT03
MAINT04
Timing OUT or Timed OUT
Shutdown with ON/OFF/RESET-OFF
Normal or AUTO.-RESTART
Recycle Shutdown
Autorestart in Progress
LOW Chilled Water
Compressor Jumpstart and Refrigerant Protection
Normal RUN with RESET, TEMPERATURE, or Demand
OUT-OF-RANGE Sensor Failures
Normal RUN Overrides Active Alerts
Limited
Protective Limit
Chiller Protect Limit Faults
Spare Sensor Alert Messages
Chiller Alerts
DESCRIPTION/MALFUNCTION Probable CAUSE/REMEDY
Other PROBLEMS/MALFUNCTIONS
Temperature Voltage Resistance Drop
Ð Thermistor Temperature F vs Resistance/Voltage Drop
Ð Thermistor Temperature C vs Resistance/Voltage Drop
Module Address
Control Modules
Input Options Module
Processor Module Psio Fig
Starter Management Module SMM Fig
Options Module
Switch Options Setting Module
Installation
Typical Benshaw, Inc. Solid-State Starter internal View
Page
Page
Problem Probable Causes Area of Correction
Benshaw, Inc. Solid-State Starter Troubleshooting Guide
RV1
SCR
Additional Data for Marine Waterboxes
Heat Exchanger Data
Cooler
Condenser
Coolers
Waterbox Cover Weights
Condensers
1034 kPa
Compressor Weights
Compressor/Motor Weights
Optional Pumpout System Electrical Data
Compressor Fits and Clearances
Description Torque
Compressor Assembly Torques
Ft-lb
``Z
COM
CLR
Comm
EXT
Page
CLR
Page
Chiller Power Panel, Starter Assembly Motor Wiring Schematic
Chiller Power Panel, Starter Assembly Motor Wiring Schematic
POT
PMR
GFR
HPS
Typical Wye-Delta Unit Mounted Starter Wiring Schematic
Index
Index
Copyright 1996 Carrier Corporation