Main
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
19XL Hermetic Centrifugal Liquid Chillers
50/60 Hz
With HCFC-22 and HFC-134a
CONTENTS
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CONTENTS (cont)
INTRODUCTION
ABBREVIATIONSAND EXPLANATIONS
CHILLER FAMILIARIZATION (Fig. 1, 2A, and 2B) Chiller Information Plate
SystemComponents
Cooler
Condenser
Motor-Compressor
Fig. 2A Typical19XL Components Design I
19XL REAR VIEW
19XL FRONT VIEW
Fig. 2B Typical 19XLComponents Design II
19XL REAR VIEW
LUBRICATION CYCLE Summary
Details
Oil Reclaim System
STARTING EQUIPMENT
Unit-Mounted Solid-State Starter (Optional)
Unit-MountedWye-Delta Starter (Optional)
CONTROLS Denitions
General
PICSystem Components
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LID Operation and Menus (Fig. 13-19)
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Table 2 LID Screens
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PIC System Functions
SafetyControls
Default Screen Freeze
Motor Cooling Control
Table 3 Protective Safety Limits and Control Settings
Ramp Loading Control
Capacity Override (Table 4)
High Discharge Temperature Control
OilSump Temperature Control
OilCooler
RemoteStart/Stop Controls
Spare Safety Inputs
Tower Fan Relay
Auto. Restart After Power Failure
Water/Brine Reset
Demand Limit Control, Option (Requires Optional 8-Input Module)
Surge PreventionAlgorithm
SurgeProtection
Lead/Lag Control
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Ice Build Control
Attachto Network Device Control
Service Operation
START-UP/SHUTDOWN/RECYCLE SEQUENCE (Fig. 24) Local Start-Up
Shutdown Sequence
AutomaticSoft Stop Amps Threshold (PSIO Soft- ware Version 09 and Higher)
ChilledWater Recycle Mode
Safety Shutdown
BEFORE INITIAL START-UP Job Data Required
Equipment Required
Using the Optional Storage Tankand Pumpout System
Remove Shipping Packaging
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StandingVacuum Test
Table 5A HCFC-22 Pressure Temperature (F)
Table 5B HCFC-22 Pressure Temperature(C)
Table 5C HFC-134a Pressure Temperature(F)
Table 5D HFC-134a Pressure Temperature(C)
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Chiller Dehydration
InspectWater Piping
CheckOptional Pumpout Compressor Water Pip- ing
Check Relief Devices
Inspect Wiring
CarrierComfort Network Interface
Check Starter
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Oil Charge
PowerUp the Controls and Check the Oil Heater
Set Up Chiller Control Conguration
Input the Design Set Points
Inputthe Local Occupied Schedule (OCCPC01S)
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CheckOptional Pumpout System Controls and Compressor
HighAltitude Locations
Charge Refrigerant into Chiller
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INITIAL START-UP Preparation
ManualOperation of the Guide Vanes
Dry Run to Test Start-Up Sequence
Check Rotation
Check Oil Pressure and Compressor Stop
Calibrate Motor Current
ToPrevent Accidental Start-Up
Check Chiller Operating Condition
Instructthe Customer Operator
To Stop the Chiller
After Limited Shutdown
ExtendedShutdown
After Extended Shutdown
Cold Weather Operation
REFRIGERATION LOG CARRIER 19XT HERMETIC CENTRIFUGALREFRIGERATION MACHINE
Plant CHILLER MODEL NO. CHILLER SERIAL NO. REFRIGERANT TYPE
Fig. 33 Refrigeration Log
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation
Operating the Optional Pumpout Compressor
Chillers with Pumpout Storage Tanks
Chillers with Isolation Valves
GENERAL MAINTENANCE Refrigerant Properties
Adding Refrigerant
RemovingRefrigerant
Adjusting the Refrigerant Charge
Refrigerant Leak Testing
Repair the Leak, Retest, and Apply Standing Vacuum Test
CheckingGuide Vane Linkage
TrimRefrigerant Charge
WEEKLYMAINTENANCE Checkthe Lubrication System
SCHEDULED MAINTENANCE
Service Ontime
Inspect the Control Center
Check Safety and Operating Controls Monthly
ChangingOil Filter
Inspect Refrigerant Float System
InspectRelief Valves and Piping
Compressor Bearing and Gear Mainten- ance
Inspect the Heat Exchanger Tubes
WaterLeaks
WaterTreatment
Inspect the Starting Equipment
Check Pressure Transducers
Optional Pumpout System Maintenance
Ordering Replacement Chiller Parts
TROUBLESHOOTING GUIDE Overview
Checking the Display Messages
Checking Temperature Sensors
Checking Pressure Transducers
ControlAlgorithms Checkout Procedure
Control Test
with Troubleshooting Guides
A. SHUTDOWN WITH ON/OFF/RESET-OFF
B. TIMING OUT OR TIMED OUT
LEGEND
C. IN RECYCLE SHUTDOWN
E. NORMAL OR AUTO.-RESTART
F. START-UP FAILURES:This is an alarm condition. A manual reset is required to clear.
G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION
H. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND
I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)
J. OUT-OF-RANGE SENSOR FAILURES
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L. CHILLER ALERTS
M. SPARE SENSOR ALERT MESSAGES
N. OTHER PROBLEMS/MALFUNCTIONS
Table 10A Thermistor Temperature (F) vs Resistance/Voltage Drop
Table 10B Thermistor Temperature(C) vs Resistance/Voltage Drop
Control Modules
Notes on Module Operation
Processor Module (PSIO) (Fig. 41)
Starter Management Module (SMM) (Fig. 42)
Options Modules (8-Input)
ReplacingDefective Processor Modules
Solid-StateStarters
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Table 11 Benshaw, Inc. Solid-State Starter Troubleshooting Guide
Physical Data
matics for operator convenience during troubleshooting. Table 12 Heat Exchanger Data
COOLER
CONDENSER
Table 13 Additional Data for Marine Waterboxes*
Table 14 WaterboxCover Weights*
ENGLISH (lb)
SI (kg)
Table 15 Compressor/Motor Weights
Table 16 Compressor Weights
Table 17 Optional Pumpout System Electrical Data
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COMPRESSORASSEMBLY TORQUES
Fig. 47 Compressor Fits and Clearances (cont)
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Fig. 49 Electronic PIC Controls Wiring Schematic (For 19XL with Halogen Backlight)
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Fig. 50 Chiller Power Panel, Starter Assembly, and Motor Wiring Schematic
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Fig. 51 Typical Wye-DeltaUnit Mounted Starter Wiring Schematic
Fig. 51 Typical Wye-DeltaUnit Mounted Starter Wiring Schematic (cont)
INDEX
INDEX (cont)
Table 10B — Thermistor Temperature(C) vs Resistance/Voltage Drop