SAFETY CONSIDERATIONS
Start-Up, Operation, and Maintenance Instructions
open flame produces toxic gases
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5
CONTENTS
High Discharge Temperature Control
Using the Optional Storage Tank
Check Safety and Operating Controls
CONTENTS cont
Power Up the Controls and
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL
Optional Pumpout System Maintenance
Ordering Replacement Chiller Parts
Control Algorithms Checkout Procedure
Fig. 1 - 19XR Identification
CHILLER FAMILIARIZATION Fig. 1 and
Fig. 2 - Typical 19XR Components
FRONT VIEW
REAR VIEW
REFRIGERATION CYCLE
MOTOR AND LUBRICATING OIL COOLING CYCLE
Fig. 3 - Refrigerant Motor Cooling and Oil Cooling Cycles
LUBRICATION CYCLE
VFD COOLING CYCLE
STARTING EQUIPMENT
Unit-Mounted Solid-State Starter Optional
Fig. 4 - Lubrication System
Fig. 6 - Typical Starter External View Solid-State Starter Shown
Unit-Mounted Wye-Delta Starter Optional
CONTROLS Definitions
Fig. 5 - Solid-State Starter Box Internal View
Fig. 8 - Variable Frequency Drive VFD Starter Internal View
Fig. 7 - Variable Frequency Drive VFD
TOP VIEW COMPRESSOR DETAIL
Fig. 9 - 19XR Controls and Sensor Locations
Fig. 10 - Control Sensors Temperature Fig. 11 - Control Sensors
Table 1 - Major PIC II Components and Panel Locations
Pressure Transducers, Typical
Fig. 12 - Control Panel
Fig. 13 - Power Panel
Fig. 14 - CVC/ICVC Default Screen
Fig. 15 - CVC/ICVC Service Screen
CVC/ICVC Operation and Menus Fig
Fig. 16 - Example of Status Screen
Fig. 17 - 19XR Chiller Display Menu Structure CVC/ICVC
Fig. 18 - 19XR Service Menu Structure
ISM - Integrated Starter Module PIC II - Product Integrated Control
Fig. 18 - 19XR Service Menu Structure cont
CCN - Carrier Comfort Network CVC - Chiller Visual Controller
ICVC - International Chiller Visual Controller
Fig. 19 - Example of Time Schedule Operation Screen
Fig. 20 - Example of Set Point Screen
Table 2 - CVC/ICVC Display Data
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
ISMSTAT
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
Table 2 - CVC/ICVC Display Data cont
PIC II System Functions
SURGE/HGBP DELTA T
≤ SURGE/HGBP DELTA T
high bearing temperature high motor winding temperature
Table 3 - Protective Safety Limits and Control Settings
table. Adjust EVAP REFRIG TRIPPOINT for
CONDENSER FREEZE POINT configured in
more than 152 F 66.7 C, or
Value
Table 4 - Capacity Overrides
Evaporator Freeze Protection ICVC only - A
Demand Limit Control Option - The demand limit control option 20 mA DEMAND LIMIT OPT is externally controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy management system EMS. The option is set up on the RAMPDEM screen. When enabled, 4 mA is the 100% de- mand set point with an operator-configured minimum demand at a 20 mA set point DEMAND LIMIT AT 20 mA
Fig. 23 - Head Pressure Reference Output
Surge Protection Fixed Speed Chiller - The
Lead/Lag System Requirements
1. Lead chiller ramp loading must be complete
The PIC II can be configured for ice build operation
and the ICE BUILD OPTION is enabled
20 mA DEMAND LIMIT OPT configured on RAMPDEM screen
The CONTROL POINT is forced to the ICE BUILD SET POINT
Fig. 24 - Example of Attach to Network Device Screen
Fig. 25 - Example of Holiday Period Screen
Fig. 26 - Control Sequence
START-UP/SHUTDOWN RECYCLE SEQUENCE Fig
a recycle condition is present see Chilled Water Recycle Mode section
ENTERING CONDENSER WATER temperature plus 3 F -1.6 C
Equipment Required
BEFORE INITIAL START-UP Job Data Required
Fig. 28 - 19XR Leak Test Procedures
1. If the pressure readings are normal for the chiller condition
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Table 5B - HFC-134a Pressure Temperature C
Table 5A - HFC-134a Pressure Temperature F
Fig. 31 - Dehydration Cold Trap
Inspect Wiring
Check Starter
Input the Local Occupied Schedule OCCPC01S
Software Configuration
5. After the last digit is changed, the CVC/ICVC goes to the
Fig. 32 - Benshaw RediStart MICRO Default Display
Table 6 - Benshaw RediStart MICRO Menu Structure
Table 7 - Benshaw RediStart MICRO Menu Items
Accessing Password Protected Parameters - Although the VFD controller has been preconfigured as the factory, the user will need to be able to access the parameters to verify the job specific parameters are correct, tune the controller or correct a problem. The two passwords protecting the VFD configuration are Parameter Set Display password and Program Disable password. The Parameter Set Display password restricts view- ing. P.nnn parameters above 007 and all H.nnn and R.nnn screens. The password can be accessed at parameter P.006 and will switch between enabled and disabled each time the pass- word 107 is entered. The Program Disable password restricts the changing of the drive parameter set. To enable or disable changes select parameter P.051 and enter the password
VFD Cooling System Leak Inspection
Set TARGET VFD SPEED to 0%
Error Ratio
5. Set TARGET VFD SPEED to 0%
Set VFD TARGET VFD SPEED to 100%
5. Set TARGET VFD SPEED to 100%
Estimated Maximum Load Conditions
Estimated Minimum Load Conditions
1724 kPa. To calibrate these transducers
Table 9 - Control Test Menu Functions
Charge Refrigerant into Chiller
Table 10 - Refrigerant HFC-134a Charge
INITIAL START-UP
Fig. 33 - Correct Motor Rotation
Dry Run to Test Start-Up Sequence
Check Motor Rotation
Check Oil Pressure and Compressor Stop
OPERATING INSTRUCTIONS Operator Duties
To Start the Chiller
To Stop the Chiller
Operating the Optional Pumpout Unit
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES
MACHINE MODEL NO
Fig. 34 - Refrigeration Log
DATE
Plant
Fig. 36 - Optional Pumpout Unit
Fig. 35 - 19XR Pumpout Unit Wiring Schematic
2. Evacuate the refrigerant gas from chiller cooler vessel
Chillers with Isolation Valves
1. Push refrigerant into the chiller condenser
Turn on the pumpout compressor to push the liquid
ICVC from the CONTROL TEST table to view vessel
GENERAL MAINTENANCE
Test After Service, Repair, or Major Leak - If
Access the TERMINATE LOCKOUT function CVC
Fig. 37 -Guide Vane Actuator Linkage
WEEKLY MAINTENANCE
Check Safety and Operating Controls Monthly
SCHEDULED MAINTENANCE
Compressor Bearing and Gear Maintenance
Inspect the Heat Exchanger Tubes and Flow Devices
Fig. 38 - 19XR Float Valve Design
Fig. 39 - Optional Pumpout System Controls
Ordering Replacement Chiller Parts - When
Checking Pressure Transducers
TROUBLESHOOTING GUIDE
to calculate the chilled water/brine
LEGEND TO TABLES 11A-11J
B. READY TO START
Custom Alarm/Alert Messages with Troubleshooting Guides
Table 11 - CVC/ICVC Primary and Secondary Messages and
A. MANUAL STOP
F. NORMAL RUN
Custom Alarm/Alert Messages with Troubleshooting Guides cont
Table 11 - CVC/ICVC Primary and Secondary Messages and
E. START-UP IN PROGRESS
Table 11 - CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides cont
H. OUT-OF-RANGE SENSOR ALARMS
Check for high condenser water temperatures or
Custom Alarm/Alert Messages with Troubleshooting Guides cont
I. CHILLER PROTECT LIMIT FAULTS
Table 11 - CVC/ICVC Primary and Secondary Messages and
Table 11 - CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides cont
I. CHILLER PROTECT LIMIT FAULTS cont
CVC/ICVC, release the stop signal on the STATUS01
ISM has detected a hardware fault and has reset
Custom Alarm/Alert Messages with Troubleshooting Guides cont
I. CHILLER PROTECT LIMIT FAULTS cont
The refrigerant leak detector’s output wired to
Check for proper inlet guide vane and diffuser
Custom Alarm/Alert Messages with Troubleshooting Guides cont
Table 11 - CVC/ICVC Primary and Secondary Messages and
J. CHILLER ALERTS cont
Table 12A - Thermistor Temperature F vs. Resistance/Voltage Drop
Table 12B - Thermistor Temperature C vs. Resistance/Voltage Drop
Notes on Module Operation
Control Modules
Chiller Control Module CCM Fig
Integrated Starter Module Fig
Replacing Defective Processor Modules
INTEGRATEDSTARTERMODULE
Fig. 41 - Chiller Control Module CCM
WARNING HIGH VOLTAGE
Fig. 42 - Integrated Starter Module ISM
Fig. 43 - SCR Installation
Condenser
Table 13A - Heat Exchanger Data English
Refrigerant Weight lb
Cooler
Table 13B - Heat Exchanger Data SI
Table 14 - 19XR Additional Data for Marine Waterboxes
Table 15 - Compressor Weights
Table 16 - 19XR Motor Weights Standard and High Efficiency Motors
Table 17A - 19XR Waterbox Cover Weights - English lb
Table 17B - 19XR Waterbox Cover Weights - SI kg
19EA47-748
Table 19 - Additional Miscellaneous Weights
Table 18 - Optional Pumpout System Electrical Data
Table 20 - Motor Voltage Code
VIEW A LOW SPEED SHAFT THRUST DISK
Compressor Assembly Torques
Fig. 44 - Compressor Fits and Clearances
COMPRESSOR, TRANSMISSION AREA
VIEW B - HIGH SPEED SHAFT 19XR COMPRESSOR CLEARANCES
Fig. 44 - Compressor Fits and Clearances cont
Fig. 45 - Allen-Bradley Wye-Delta Unit-Mounted Starter
Fig. 45 - Allen-Bradley Wye-Delta Unit-Mounted Starter cont
Fig. 45 - Allen-Bradley Wye-Delta Unit-Mounted Starter cont
AUX - Auxiliary BRG - Bearing C - Contactor
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Fig. 48 - Power Panel Wiring Schematic
Fig. 49 - Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP
Current Transformer
Fig. 50 - Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP
Disconnect Switch
Circuit Breaker
L - Main Power Supply VM - Voltmeter Represents Twisted Wire To Door
Fig. 51 - Ground Fault Phase Current Option
Fig. 52 - Separate Metering Option
VFD - Variable Frequency Drive Represents Twisted Wire To Door
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FU - Fuse
MTR - Motor PRESS - Pressure
STAT - Status
FU - Fuse
MTR - Motor PRESS - Pressure
STAT - Status
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Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic
Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont
Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont
Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont
Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont
Fig. 57 - Typical Variable Frequency Drive VFD Wiring Schematic cont
Dry Contact VFD Terminal
LEGEND FOR FIG
Pressure Switch Compr Oil Pump Terminal Cartridge Fuse Earth Ground
Resistor Chassis Ground Light Temperature Switch Common Potential
INDEX
INDEX cont
INITIAL START-UP CHECKLIST
FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
Remove and use for job file
PIC II CAUTION
19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET
NOTE Default setting is UNOCCUPIED 24 hours/day
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S
NOTE Default setting is OCCUPIED 24 hours/day
CUT ALONG DOTTED LINECUT ALONG DOTTED LINE
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET
19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET
19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET
19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET
19XR, XRV PIC II RAMPDEM TABLE CONFIGURATION SHEET
BROADCAST BRODEF CONFIGURATION SHEET
Variable by job - refer to component nameplates and labels
LOCAL
CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
MENU
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specifications or designs
incurring obligations
Manufacturer
