Manuals / Carrier / Household Appliance / Fan

Carrier XRV, 19XR Chiller Control Module CCM, Warning High Voltage, Integrated Starter Module ISM

Models: 19XR XRV

1 140

Download 140 pages 13.24 Kb

Page 89

Fig. 41 — Chiller Control Module (CCM)

	J11	J12	SW1	J1
	DISCRETE	DISCRETE		J1
	OUTPUTS	OUTPUTS		24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2
V/I INPUTS
J5
STAT	COMM	THERMISTORS	DIFF PRESSURE	PRESSURE
		J4	J3	J2

Fig. 41 — Chiller Control Module (CCM)

1

J9

+

G

+

G

1

+

G

-

COM STAT

1

J8	J7	-

TRIP PUMP	PUMP	FAN	FAN	ALARM	VFD SPARE	A B C
1CR TRANS SHUNT EVAP	COND	LO	HI	TRIP	OUT MA 20-4	COMM
CONTACTS CONTROL DISCRETE						COMM
CONTACTS CONTROL DISCRETE

INTERGRATED STARTER MODULE

CEPP130173-03-04-01			DISCONNECT POWER
ISM992519XR04012201 PCB05CEPL13025901			DISCONNECT POWER	WARNING HIGHVOLTAGE
			BEFORESERVICING





00001328























	115 VAC			FUSE
	LL1		LL2	1A

R

INTEGRATEDSTARTERMODULE

CONTACT INPUTS
SPAR ICE REM STRT 1M 2M	LINE VOLTAGES		LINE CURRENTS
SFTY BLD STRT FLT AUX AUX L1	L2	L3	IL1	IL2	IL3

WARNING HIGH VOLTAGE

DISCONNECT POWER BEFORE SERVICING

GROUND FAULTS VFD

1/4 2/5 3/6 HZ

		J5
1A	J2	J4
	J2	J6
		J6

1 + C + C + C + C + C + C

J3-1

J3-2

J3-3

1 +

-

+

-

+

- 1

1

1

J1

+

G

+

G

+

G

+

G

Fig. 42 — Integrated Starter Module (ISM)

89

Image 89

Carrier XRV, 19XR Chiller Control Module CCM, Warning High Voltage, Integrated Starter Module ISM, Integratedstartermodule

Contents

open flame produces toxic gases SAFETY CONSIDERATIONSStart-Up, Operation, and Maintenance Instructions High Discharge Temperature Control CONTENTSUsing the Optional Storage Tank ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5Power Up the Controls and CONTENTS contPUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Check Safety and Operating ControlsOrdering Replacement Chiller Parts Optional Pumpout System MaintenanceControl Algorithms Checkout Procedure INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGALFig. 1 - 19XR Identification CHILLER FAMILIARIZATION Fig. 1 andREAR VIEW Fig. 2 - Typical 19XR ComponentsFRONT VIEW Fig. 3 - Refrigerant Motor Cooling and Oil Cooling Cycles REFRIGERATION CYCLEMOTOR AND LUBRICATING OIL COOLING CYCLE LUBRICATION CYCLE VFD COOLING CYCLEFig. 4 - Lubrication System STARTING EQUIPMENTUnit-Mounted Solid-State Starter Optional CONTROLS Definitions Unit-Mounted Wye-Delta Starter OptionalFig. 5 - Solid-State Starter Box Internal View Fig. 6 - Typical Starter External View Solid-State Starter ShownFig. 8 - Variable Frequency Drive VFD Starter Internal View Fig. 7 - Variable Frequency Drive VFDTOP VIEW COMPRESSOR DETAIL Fig. 9 - 19XR Controls and Sensor LocationsPressure Transducers, Typical Fig. 10 - Control Sensors Temperature Fig. 11 - Control SensorsTable 1 - Major PIC II Components and Panel Locations Fig. 12 - Control Panel Fig. 13 - Power PanelCVC/ICVC Operation and Menus Fig Fig. 14 - CVC/ICVC Default ScreenFig. 15 - CVC/ICVC Service Screen Fig. 16 - Example of Status Screen Fig. 17 - 19XR Chiller Display Menu Structure CVC/ICVC Fig. 18 - 19XR Service Menu Structure CCN - Carrier Comfort Network CVC - Chiller Visual Controller Fig. 18 - 19XR Service Menu Structure contICVC - International Chiller Visual Controller ISM - Integrated Starter Module PIC II - Product Integrated ControlFig. 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 contTable 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 ≤ SURGE/HGBP DELTA T PIC II System FunctionsSURGE/HGBP DELTA T high bearing temperature high motor winding temperature CONDENSER FREEZE POINT configured in Table 3 - Protective Safety Limits and Control Settingstable. Adjust EVAP REFRIG TRIPPOINT for more than 152 F 66.7 C, or Value Table 4 - Capacity OverridesEvaporator 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 - TheLead/Lag System Requirements 1. Lead chiller ramp loading must be complete 20 mA DEMAND LIMIT OPT configured on RAMPDEM screen and the ICE BUILD OPTION is enabledThe CONTROL POINT is forced to the ICE BUILD SET POINT The PIC II can be configured for ice build operationFig. 24 - Example of Attach to Network Device Screen Fig. 25 - Example of Holiday Period Screen Fig. 26 - Control Sequence START-UP/SHUTDOWN RECYCLE SEQUENCE Figa recycle condition is present see Chilled Water Recycle Mode section ENTERING CONDENSER WATER temperature plus 3 F -1.6 CEquipment Required BEFORE INITIAL START-UP Job Data RequiredFig. 28 - 19XR Leak Test Procedures 1. If the pressure readings are normal for the chiller condition Page Table 5B - HFC-134a Pressure Temperature C Table 5A - HFC-134a Pressure Temperature FFig. 31 - Dehydration Cold Trap Inspect WiringCheck Starter Input the Local Occupied Schedule OCCPC01S Software Configuration5. After the last digit is changed, the CVC/ICVC goes to the Table 7 - Benshaw RediStart MICRO Menu Items Fig. 32 - Benshaw RediStart MICRO Default DisplayTable 6 - Benshaw RediStart MICRO Menu Structure 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%Set VFD TARGET VFD SPEED to 100% 5. Set TARGET VFD SPEED to 0%5. Set TARGET VFD SPEED to 100% Error RatioEstimated Maximum Load Conditions Estimated Minimum Load Conditions1724 kPa. To calibrate these transducers Table 9 - Control Test Menu Functions Charge Refrigerant into ChillerTable 10 - Refrigerant HFC-134a Charge INITIAL START-UPCheck Motor Rotation Dry Run to Test Start-Up SequenceCheck Oil Pressure and Compressor Stop Fig. 33 - Correct Motor RotationTo Stop the Chiller OPERATING INSTRUCTIONS Operator DutiesTo Start the Chiller Operating the Optional Pumpout Unit PUMPOUT AND REFRIGERANT TRANSFER PROCEDURESDATE Fig. 34 - Refrigeration LogPlant MACHINE MODEL NOFig. 36 - Optional Pumpout Unit Fig. 35 - 19XR Pumpout Unit Wiring Schematic1. Push refrigerant into the chiller condenser Chillers with Isolation ValvesTurn on the pumpout compressor to push the liquid 2. Evacuate the refrigerant gas from chiller cooler vesselTest After Service, Repair, or Major Leak - If GENERAL MAINTENANCEAccess the TERMINATE LOCKOUT function CVC ICVC from the CONTROL TEST table to view vesselFig. 37 -Guide Vane Actuator Linkage WEEKLY MAINTENANCECheck Safety and Operating Controls Monthly SCHEDULED MAINTENANCEFig. 38 - 19XR Float Valve Design Compressor Bearing and Gear MaintenanceInspect the Heat Exchanger Tubes and Flow Devices Fig. 39 - Optional Pumpout System Controls Ordering Replacement Chiller Parts - WhenChecking Pressure Transducers TROUBLESHOOTING GUIDEto calculate the chilled water/brine LEGEND TO TABLES 11A-11JTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting GuidesA. MANUAL STOP B. READY TO STARTTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides contE. START-UP IN PROGRESS F. NORMAL RUNH. OUT-OF-RANGE SENSOR ALARMS Custom Alarm/Alert Messages with Troubleshooting Guides contCheck for high condenser water temperatures or Table 11 - CVC/ICVC Primary and Secondary Messages andTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides contI. CHILLER PROTECT LIMIT FAULTS I. CHILLER PROTECT LIMIT FAULTS cont Custom Alarm/Alert Messages with Troubleshooting Guides contCVC/ICVC, release the stop signal on the STATUS01 Table 11 - CVC/ICVC Primary and Secondary Messages andI. CHILLER PROTECT LIMIT FAULTS cont Custom Alarm/Alert Messages with Troubleshooting Guides contThe refrigerant leak detector’s output wired to ISM has detected a hardware fault and has resetTable 11 - CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides contJ. CHILLER ALERTS cont Check for proper inlet guide vane and diffuserTable 12A - Thermistor Temperature F vs. Resistance/Voltage Drop Table 12B - Thermistor Temperature C vs. Resistance/Voltage Drop Notes on Module Operation Control ModulesReplacing Defective Processor Modules Chiller Control Module CCM FigIntegrated Starter Module Fig WARNING HIGH VOLTAGE Fig. 41 - Chiller Control Module CCMFig. 42 - Integrated Starter Module ISM INTEGRATEDSTARTERMODULEFig. 43 - SCR Installation Refrigerant Weight lb Table 13A - Heat Exchanger Data EnglishCooler CondenserTable 13B - Heat Exchanger Data SI Table 14 - 19XR Additional Data for Marine Waterboxes Table 15 - Compressor WeightsTable 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 Table 18 - Optional Pumpout System Electrical Data Table 19 - Additional Miscellaneous WeightsTable 20 - Motor Voltage Code 19EA47-748Fig. 44 - Compressor Fits and Clearances Compressor Assembly TorquesCOMPRESSOR, TRANSMISSION AREA VIEW A LOW SPEED SHAFT THRUST DISKVIEW B - HIGH SPEED SHAFT 19XR COMPRESSOR CLEARANCES Fig. 44 - Compressor Fits and Clearances contFig. 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 Page Page Page Fig. 48 - Power Panel Wiring Schematic Fig. 49 - Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP Disconnect Switch Fig. 50 - Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DPCircuit Breaker Current TransformerFig. 52 - Separate Metering Option Fig. 51 - Ground Fault Phase Current OptionVFD - Variable Frequency Drive Represents Twisted Wire To Door L - Main Power Supply VM - Voltmeter Represents Twisted Wire To DoorPage Page STAT - Status FU - FuseMTR - Motor PRESS - Pressure STAT - Status FU - FuseMTR - Motor PRESS - Pressure Page 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 Pressure Switch Compr Oil Pump Terminal Cartridge Fuse Earth Ground LEGEND FOR FIGResistor Chassis Ground Light Temperature Switch Common Potential Dry Contact VFD TerminalINDEX INDEX cont Remove and use for job file INITIAL START-UP CHECKLISTFOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER PIC II CAUTION 19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01SNOTE Default setting is OCCUPIED 24 hours/day NOTE Default setting is UNOCCUPIED 24 hours/dayCUT 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 MENUPage incurring obligations specifications or designsManufacturer reserves