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Carrier PC211 liquid and vapor, Refrigerant in contac t with an open flame produ ces toxic gases.

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DO NOT WELD OR FLAMECUT any re frigerant line or vess el until all refrigerant

(

liquid and vapor

) has been removed from chiller. Tra ces of vapor shou ld be dis-

placed with dry air or nitrogen and the work area should be well ventilated.

Refrigerant in contac t with an open flame produ ces toxic gases.

DO NOT USE eyebolts or eyeb ol t ho l es to rig machine section s or the entire

assembly.

DO NOT work on high-voltage equipment unless you are a qualified electrician.

DO NOT WORK ON electrical components, including control panels, switches,

starters, or oil he ate r unt i l y ou a r e s ur e AL L POWER IS OFF and no resi dual volt-

age can leak from capaci t or s or solid-state componen ts.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTER-

RUPTED, confirm that al l circuits are deenergi z ed before resuming work.

DO NOT siphon refriger an t.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE

SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid

refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult

a physicia n.

NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous

over pressure can resu lt. When it is necessary to heat ref r igerant, use only

warm (110 F [43 C]) water.

WARNING !WARNING

Contents

Main DANGER !DANGER liquid and vapor Refrigerant in contac t with an open flame produ ces toxic gases. Page ahead of Page Page Page Page PIC System Functions Safety Controls Page Page Start-Up/Shutdown/Recycle Sequence Page Page Page Initial Start-Up Operating Instruction s Pumpout and Refrig erant Transfer Procedures General Maintenance Page Page Troubleshooting Gui de Page Page List of Tables Table 1 Major PIC Components and Panel Locations Table 2 LID Screens Page Page Page List of Figures Page Page Page Page Page Page Abbreviations and Explanations Machine Familiarization Page Refrigeration Cycle Motor/Oil Refri geration Cooling C ycle Page Lubrication Cycle Click here for Figure 3 Refr igerant Motor Cooling and Oil Cooling Cycles Summary Details Page Oil Reclaim System Click here f or Figure 4 Lubrication System During Normal Machine Operation During Light Load Conditions Starting Equipment Unit-Mounted Solid-State Starter (Optional) Page Unit-Mounted Wye-Delta Starter (Optional) Controls Definitions Volatile memory A digital (discrete) signal An analog signal General PIC System Components Processor M odule (PSIO) Click here fo r Table 1 Ma jor PIC Compone nts and Panel Locations Starter Management Module (SMM) Local Inte rface Device (LID) Page Page Page Page Page Page Page Page Page Click here for Figure 17 19X L Service Menu Structure Page Time Schedule Operation (Figure 18) Page Page Page To View and Change Set Points (Figure 19) Page Page Page PIC System Functions Capacity Control Entering Chilled Water Control Deadband Proportional Bands and Gain Demand Limiting Machine T imers Occupancy Schedule Page Safety Controls Page Shunt Trip Default Screen Fr eez e Motor Cooling Control Ramp Loading Control SELECT RAMP TYPE PULLDOWN, LOAD PULL DO WN Temperature TEMP Capacity Override (Table 4) Click here f or Table 4 Ca pacity Overrid es High Discharge Temperature Control Oil Sump Temperature Control PSIO Software Version 08 and Lower PSIO Software Version 09 and Higher Oil Cooler Remote Start/Stop Controls Spare Safety Inputs Spare Alarm Contacts Condenser Pump Control Condenser Freeze Prevention Tower-Fan Re lay TOWER FAN RELAY CONDENSER WATER PUMP TOWER FAN RELAY Auto. Restart After Power Failure Water/Brine Reset Page Page Demand Limit Control, Option (Requires Optional 8-Input Module) Surge Prevention Algorithm Page Surge Protection Lead/Lag Control Common Point Sensor Insta llation Machine Communication Wiring Lead/Lag Oper ation Page Page Page Page Faulted Chiller Operation Load Balancing Auto. Restart After Pow er Failure Ice Build Control Ice Build Initiation Start-Up/Recyc le Operation Temperature Control During Ice Build Termination Of Ice Build Return to Non-Ice Build Operations Attach to Network Device Control Changing Refrigerant Types Attaching to Other CCN Modules Click here for Figure 22 Example of Attach to Network Device Screen Service Operation To Log On To Log Off Holiday Scheduling (Figure 23) Page Page Page Page Start-Up/Shutd own/Recycle Sequenc e ( Figure 24) Local Start- Up WATER FLOW VERIFY TIME CONTROL POINT DEADBAND Shutdown Sequence Click here f or Figure 24 Control Sequence CONDENSER REFRIGERANT TEMP CONDENSER PRESSURE O V E RRI DE ENTERING CONDENSER WATER COMPRESSOR MOTOR LOAD ENTERING CONDENSER WATER TEMP Automatic Soft Stop Amps Threshold (PSIO Software Version 09 and Higher) Chilled Water Recycle Mode Page Safety Shutdown Before Initial Start-Up Page Check Machine Tightness Refrigera n t Tracer Leak Test Machine Click here fo r Figure 26 19XL Leak Test Pr ocedures Page Page Standing Vacuum Test Page Page Page Click here f or Figure 29 Dehydration Co l d Trap Page Page Page Page Carrier Comfort Network Inte r face Page Page Mechanic al-Type Star ters not main chiller power Benshaw, Inc. Solid-S tate Starter Page Initial Start-Up Chec klist for 19XL Hermetic Centrifugal Liquid Chil ler Cutler-Hammer Solid-State Starters Click here for Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller Page Page Page Oil Charge Power Up the Controls and Check the Oil Heater Software Version Set Up Machine Control Configuration Input the Design Set Points either or Input the Local Occupied Schedule (OCCPC01S) Selecting Refrigerant Type Input Service Configurations Password Page Page Estimated Minimum Loa d Conditions: Estimated Maximu m Load Condit ions: Page Page Modify Equipment Configuration If Necessary Click here fo r Table 7 Am ps Correction Fac tors for 19XL M otors Page Check Voltage Supply Perform an Automated Control Test Page Check Optional Pumpout System Controls and Compressor High Altitude Locations Page Click here f or Table 8 Co ntrol Test Men u Functions 19XL Machine Equalization with Pumpout Unit Page Trimming Refrigerant Charge Click here f or Table 9 Refrigerant ( HCFC-22 or H FC-134a) Char ges Initial Start-up Preparation Page Manual Operation of the Guide Vanes TARGET GUIDE VANE POSITION TARGET GUIDE VANE POSITION Dry Run to Test Start-Up Sequence Check Rotation If Rotation Is Proper Page Check Oil Pressure and Compressor Stop Calibrate Motor Current Demand Setting Page Page Operating Instruc tions Operator Duties Prepare the Machine for Start-Up To Start the M a chine Do not restart Check the Running System Page To Stop the Machine Do not restart After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation TARGET GUIDE VANE POSITION Page Pumpout and Refrigerant Transfer Procedures Preparation Operating the Optional Pumpout Compressor To Read Ref r igerant Pr es sures Machines with Storage Tanks Page Page Page Transfer the R efrigerant fr om Machine to Storage Tank Page Page Machines with Isolation Valves Transfer All R efrigerant t o Condenser Ves sel Page Transfer All R efrigerant t o Cooler/Comp ressor Vesse l Page Return R e f rigeran t to Norma l O perating Conditio ns Page General Maintenan ce Page Page Refriger ant Tracer To Pressurize with Dry N itrogen Do not exceed Repair the Leak, Retest, and Apply Standing Vacuum Test Checking Guide Vane Linkage Checking the Auxiliary Switch on Guid e Vane Actuator Click here fo r Figure 38 Guide Vane Act uator Linkage Trim Refrigerant Charge Do not overcharge Weekly Maintenance Check the Lubrication System must Scheduled Maintenance Check Safety and Operating Controls Monthly Changing Oil Filter Do not con taminate this sample Page Oil Specification Oil Changes To Change the Oil Refrigerant Filter Page Replace the valve Compressor Bear i n g and Gear Ma in t en ance Inspect the Heat Exchanger Tubes Cooler Condenser Do not Water Leaks Page Page Page Optional Pumpout Compressor Oi l Charge Ordering Replacement Chiller Parts Troubleshooting Gui de Overview Checking the Display Messages Checking Temper a t ur e Sen sor s Resistance C heck Voltage Drop Check Sens or Accuracy Dual Temperature Sensors Checking Pressure Transducers Page Page Transducer Re placement Do not pull on the transducer wir es Control Algorithms Checkout Procedure Control Test Page Page Page Red Led Green LEDs Lower LED Upper LED Page Notes on Module Operation Page Processor Module (PSIO) (Figure 43) Page Options Modules (8-Input) Replacing Defective Processor Modules Click here f or Figure 45 Options Module Installation Page Solid-State Starters Testing Silicon Control Rec tifiers in Benshaw, Inc. Solid- State Starters Page Testing Silicon Control Rec tifiers (SCRs) in Cutler-Hammer Solid-State Starters Click here for Figure 46 Typical Benshaw, Inc. Sol id-State St arter (Internal View) DANGER !DANGER Page Page Page Physical Data Page Page *See Figure 5, Figure 6, Figure 8, Figure 9, Figure 10 , Figure 11, and Figure 12. Table 1 Major PIC Components and Panel Locations* Pic Component Panel Location Table 2 LID Screens Table 2, Example 1 Status01 Display Screen Table 2, Example 1 Status01 Display Screen (Continued) Description Range Units Reference Point Name (Alarm History) Example 2 Status02 Dis pl ay Screen 2. Press STATUS. 3. Scroll down to highlight STATUS02. Table 2, Example 2 Status02 Display Screen Description Point Type Units Reference Point Name (Alarm History) Input Output Example 3 Status03 Dis pl ay Screen To access this display f ro m the LID default screen: 2. Press STATUS. 3. Scroll down to highlight STATUS03. Table 2, Example 3 Status03 Display Screen Description Range Units Reference Point Na me (Alarm History) Table 2, Example 4 Setpoint Display Screen 3. Scroll down to highlight EQUIPMENT CONFIGURATION. Point Name Default 5. Scroll down to highlight CONFIG. Note: = delta degrees. Table 2, Example 5 Configuration (Config) Display Screen Description Co nfigurab le Range Units Reference Table 2, Example 6 Lead/Lag Configuration Display Screen Example 7 Service1 Disp l ay Screen To access this display f ro m the LID default screen: 3. Scroll down to highlight EQUIPMENT SERVICE. 5. Scroll down to highlight SERVICE1. Table 2, Exam ple 7 Servi c e1 Display S creen Description Configurable Range Units Reference Point Name Default Value Table 2, Exam ple 7 Servi c e1 Display S creen (Cont i nued) Description Configurable Range Units Reference Point Name Default Value Example 8 Service2 Disp l ay Screen To access this display from the LID default screen: 3. Scroll down to highlight EQUIPMENT SERVICE. Table 2, Example 8 Service2 Display Screen Description Configurable Range Units Reference Point Name Default Table 2, Example 8 Service2 Display Screen (Continued) Description Configurable Range Units Reference Point Name Default Table 2, Exa mple 9 Servi c e3 Display S creen 3. Scroll down to highlight ALGORITHM STATUS. 5. Scroll down to highlight MAINT01. Table 2, Example 10 Maintenance (Maint01) Display Screen Description Range/Status Units Referen ce Point Name Table 2, Example 11 Maintenance (Maint02) Display Screen Table 2, Example 12 Maintenance (Maint03) Display Screen Table 2, Example 13 Maintenance (Maint04) Display Screen Table 3 Protective Safety Limits and Control Settings Monitored Parameter Limit Applicable Comments Table 3 Protective Safety Limits and Control Settings (Continued) Monitored Parameter Limit Applicable Comments Table 4 Capacity Overrides Table 4 Capacity Overrides (Continued) * Inches of mercury below one at m os ph ere. Table 5A HCFC-22 Pressure Temperature (F) Temper- Pressure (psi) Temper- Pressure (psi) Absolute Gage Absolute Gage Absolute Gage Table 5B HCFC-22 Pressure Temperature (C) Temper- Pressure (kPa) Temper- Pressure (kPa) Absolute Gage Absolute Gage Absolute Gage Table 5C HF C-134a Pres su re Tempera ture (F) Temperature, F Pressure (psig) Table 5C HFC-134a Pressure Temperature (F) (Continued) Temperature, F Pressure (psig) Table 5D HFC-134a Pressure Temperature (C) Temperature, C Pressur e Gage (k Pa) Table 5D HFC-134a Pressure Temperature (C) (Continued) Temperature, C Pressur e Gage (k Pa) Table 6 Potentiometer Adjustment Table 7 Amps Correction Factors for 19XL Motors Volt/ Hz Motor Code CD CE CL CM CN CP CQ CR Table 8 Control Test Menu Functions Table 8 Control Test Menu Functions (Continued) Table 9 Refrigerant (HCFC-22 or HFC-134a) Charges Legend For Table 10, A - N Table 10A Shutdown with On/Off/Reset-Off Primary Messa ge Secondar y M e ss age P ro bable Cause/Remed y Table 10B Timing Out or Timed Out Primary Message Secondary Messa ge Probable Cause/ Remedy Table 10C In Recycle Shutdown Primary Message Secondary Messa ge Probable Cause/ Remedy Primary Message Secondary Messag e Alarm Message/Primary Cause Additional Cause/ Remedy Table 10E Normal or Auto.-Restart Table 10F Start-Up Failures: This is an alarm condition. A manual reset is required to clear. Page Table 10G Compressor Jumpstart and Refrigerant Protection Table 10H Normal Run with Reset, Temperature, or Demand Table 10I Normal Run Overrides Active (Alerts) Table 10J Out-of-Range Sensor Failures Table 10K Machine Protect Limit Faults Page Table 10K Machine Protect Limit Faults (Continued) Table 10L Machine Alerts Table 10M Spare Sens or Alert Messages Table 10N Other Problems/Malfunctions Table 10N Other Problems/Malfunctions (Continued) Table 11A Thermistor Temperature (F) vs Resistance/Voltage Drop Table 11A Thermistor Temperature (F) vs Resistance/Voltage Drop (Continued) Table 11B Thermistor Temperature (C) vs Resistance/Vol tag e Drop Temperature (C) Voltage Drop (V) Resistan ce Drop (V) Resistance (Ohms) Temperature ( C) Voltage (Ohms) Table 11B Thermistor Temperature (C) vs Resistance/Vol tag e Drop (Continued) Temperature (C) Voltage Drop (V) Resistan ce (Ohms) Drop (V) Resistance (Ohms) Temperature ( C) Voltage Table 12 Benshaw, Inc. Solid-State Starter Troubleshooting Guide Table 12 Benshaw, Inc. Solid-State Starter Troubleshooting Guide (Co ntinue d) Table 13 Cut l er-Hammer Solid-State Starter Troubleshooting G ui de Problem Probabl e Caus e Area of Correction Table 13 Cut l er-Hammer Solid-State Starter Troubleshooti ng G ui de (Continued) Problem Probabl e Caus e Area of Correction Legend CCW Counter Clockw ise CFR Current Feedback Resistor STR Shunt Trip Relay Table 13 Cut l er-Hammer Solid-State Starter Troubleshooting Gui de (Continued) Problem Probabl e Caus e Area of Correcti on Table 14 Heat Exchanger Data * Add to heat exchanger wei ghts and volumes for tot al we ight or volume. Table 15 Additional Data for Marine Waterboxes* Table 16 Compressor Weights Table 17 Compressor/Motor Weights Table 18 Waterbox Cover Weights* (English (lb)) Table 18 Waterbox Cover Weights* (SI (kg)) (Continued) Table 19 Optional Pumpout System Electrical Data Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Figure 24 Control Sequence Page Page Page Page Page Page Page Page Page Page Date ________ _______ Figure 35 Refrigeration L og Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Compressor Assembly Torques Item Description Torque ft-lb Nm Figure 53 Compressor Fits and Clearances Insulator Packing Nut Brass Jam Nut Page Page Page Page Page Page Page Page INITIAL START-UPCHECKLIST FOR 19XL HERMETIC CENTRIFUGAL LIQUID CHILLER (Remove and use for job le.) MACHINE INFORMATION: START-UPTO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS Page 19XL HERMETIC CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG Page Page Page Page Page CL-9