CONTENTS (cont)
Page
Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
•COOLER AND FLOW DEVICES
•CONDENSER AND FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75
Optional Pumpout System Maintenance . . . . . . . . . 75
•OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE
•OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76
•RESISTANCE CHECK
•VOLTAGE DROP
•CHECK SENSOR ACCURACY
•DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76
•UNITS EQUIPPED WITH CVC
•UNITS EQUIPPED WITH ICVC
•TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 77
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
•RED LED (Labeled as STAT)
•GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88
•INPUTS
•OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88
•INPUTS
•OUTPUTS
Replacing Defective Processor Modules . . . . . . . . 88
• INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
•TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS
•SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16
INTRODUCTION
Prior to initial start-up of the 19XR unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined to familiarize those involved in the start- up, operation and maintenance of the unit with the control sys- tem before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation.
This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dis- sipate body electrostatic charge before working inside con- trol center.
Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio com- munications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Sub- part J of Part 15 of FCC Rules, which are designed to pro- vide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interfer- ence, in which case the user, at his own expense, will be required to take whatever measures may be required to cor- rect the interference.
Always store and transport replacement or defective boards in anti-static shipping bag.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
CCM | — Chiller Control Module |
CCN | — Carrier Comfort Network |
CCW | — Counterclockwise |
CVC | — Chiller Visual Controller |
CW | — Clockwise |
ECDW | — Entering Condenser Water |
ECW | — Entering Chilled Water |
EMS | — Energy Management System |
HGBP | — Hot Gas Bypass |
I/O | — Input/Output |
ICVC | — International Chiller Visual Controller |
ISM | — Integrated Starter Module |
LCD | — Liquid Crystal Display |
LCDW | — Leaving Condenser Water |
LCW | — Leaving Chilled Water |
LED | — Light-Emitting Diode |
OLTA | — Overload Trip Amps |
PIC II | — Product Integrated Controls II |
RLA | — Rated Load Amps |
SCR | — Silicon Controlled Rectifier |
SI | — International System of Units |
TXV | — Thermostatic Expansion Valve |
VFD | — Variable Frequency Drive |
Words printed in all capital letters or in italics may be viewed on the Chiller Visual Controller/International Chiller Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN, ALARM, etc.).
Words printed in both all capital letters and italics can also be viewed on the CVC/ICVC and are parameters (e.g., CON-
TROL MODE, COMPRESSOR START RELAY, ICE BUILD OPTION, etc.) with associated values (e.g., modes, tempera- tures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the CVC/ICVC control panel (e.g., ENTER ,
EXIT , INCREASE , QUIT , etc.).
