Main
DANGER !DANGER
liquid and vapor
Refrigerant in contac t with an open flame produ ces toxic gases.
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PIC System Functions
Safety Controls
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Start-Up/Shutdown/Recycle Sequence
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Initial Start-Up
Operating Instruction s
Pumpout and Refrig erant Transfer Procedures
General Maintenance
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Troubleshooting Gui de
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List of Tables
Table 1 Major PIC Components and Panel Locations Table 2 LID Screens
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List of Figures
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Abbreviations and Explanations
Machine Familiarization
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Refrigeration Cycle
Motor/Oil Refri geration Cooling C ycle
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Lubrication Cycle
Click here for Figure 3 Refr igerant Motor Cooling and Oil Cooling Cycles
Summary
Details
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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)
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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)
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Click here for Figure 17 19X L Service Menu Structure
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Time Schedule Operation (Figure 18)
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To View and Change Set Points (Figure 19)
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PIC System Functions
Capacity Control
Entering Chilled Water Control
Deadband
Proportional Bands and Gain
Demand Limiting
Machine T imers
Occupancy Schedule
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Safety Controls
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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
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Demand Limit Control, Option (Requires Optional 8-Input Module)
Surge Prevention Algorithm
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Surge Protection
Lead/Lag Control
Common Point Sensor Insta llation
Machine Communication Wiring
Lead/Lag Oper ation
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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)
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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
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Safety Shutdown
Before Initial Start-Up
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Check Machine Tightness
Refrigera n t Tracer
Leak Test Machine
Click here fo r Figure 26 19XL Leak Test Pr ocedures
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Standing Vacuum Test
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Click here f or Figure 29 Dehydration Co l d Trap
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Carrier Comfort Network Inte r face
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Mechanic al-Type Star ters
not main chiller power
Benshaw, Inc. Solid-S tate Starter
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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
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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
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Estimated Minimum Loa d Conditions:
Estimated Maximu m Load Condit ions:
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Modify Equipment Configuration If Necessary
Click here fo r Table 7 Am ps Correction Fac tors for 19XL M otors
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Check Voltage Supply
Perform an Automated Control Test
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Check Optional Pumpout System Controls and Compressor
High Altitude Locations
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Click here f or Table 8 Co ntrol Test Men u Functions
19XL Machine Equalization with Pumpout Unit
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Trimming Refrigerant Charge
Click here f or Table 9 Refrigerant ( HCFC-22 or H FC-134a) Char ges
Initial Start-up
Preparation
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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
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Check Oil Pressure and Compressor Stop
Calibrate Motor Current Demand Setting
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Operating Instruc tions
Operator Duties
Prepare the Machine for Start-Up
To Start the M a chine
Do not restart
Check the Running System
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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
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Pumpout and Refrigerant Transfer Procedures
Preparation
Operating the Optional Pumpout Compressor
To Read Ref r igerant Pr es sures
Machines with Storage Tanks
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Transfer the R efrigerant fr om Machine to Storage Tank
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Machines with Isolation Valves
Transfer All R efrigerant t o Condenser Ves sel
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Transfer All R efrigerant t o Cooler/Comp ressor Vesse l
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Return R e f rigeran t to Norma l O perating Conditio ns
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General Maintenan ce
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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
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Oil Specification
Oil Changes
To Change the Oil
Refrigerant Filter
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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
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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
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Transducer Re placement
Do not pull on the transducer wir es
Control Algorithms Checkout Procedure
Control Test
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Red Led
Green LEDs
Lower LED
Upper LED
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Notes on Module Operation
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Processor Module (PSIO) (Figure 43)
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Options Modules (8-Input)
Replacing Defective Processor Modules
Click here f or Figure 45 Options Module
Installation
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Solid-State Starters
Testing Silicon Control Rec tifiers in Benshaw, Inc. Solid- State Starters
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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
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Physical Data
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*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.
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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
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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
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Figure 24 Control Sequence
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Date ________ _______
Figure 35 Refrigeration L og
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Compressor Assembly Torques
Item Description Torque ft-lb Nm
Figure 53 Compressor Fits and Clearances
Insulator Packing Nut Brass Jam Nut
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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
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19XL HERMETIC CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG
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CL-9