® 19XL 50/60 Hz Hermetic Centrifugal Liquid Chillers with HCFC–22 and HFC–134a Start-Up, Operation, and Maintenance Instructions Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 211 Catalog No.
DANGER ! DANGER DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
WARNING ! WARNING DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases. DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire assembly. DO NOT work on high-voltage equipment unless you are a qualified electrician.
WARNING ! WARNING DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar, and unscrew and discard the valve stem. DO NOT INCINERATE. CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The introduction of the wrong refrigerant can cause machine damage or malfunction to this machine.
CAUTION ! CAUTION DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury. DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders. USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
CAUTION ! CAUTION PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage. PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.
Contents List of Tables List of Figures Safety Considerations Introduction Abbreviations and Explanations Machine Familiarization Machine Information Plate System Components Cooler Condenser Motor-Compressor Control Center Factory-Mounted Starter (Optional) Storage Vessel (Optional)
Contents Refrigeration Cycle Motor/Oil Refrigeration Cooling Cycle Lubrication Cycle Summary Details Oil Reclaim System During Normal Machine Operation During Light Load Conditions Starting Equipment Unit Mounted Solid-State Starter (Optional) Unit Mounted Wye-Delta Starter (Optional) Controls Definitions Analog Signal
Contents Digital Signal Volatile Memory General PIC System Components Processor Module (PSIO) Starter Management Module (SMM) Local Interface Device (LID) 6-Pack Relay Board 8-Input Modules Oil Heater Contactor (1C) Oil Pump Contactor (2C) Hot Gas Bypass Contactor Relay (3C) (Optional) Control Transformers (T1-T4) Control and Oil Heater Voltage Selector (S1) LID Operation and Menus General Alarm and Alerts
Contents Menu Structure To View Point Status Override Operations Time Schedule Operation To View and Change Set Points Service Operation PIC System Functions Capacity Control Entering Chilled Water Control Deadband Proportional Bands and Gain Demand Limiting Machine Timers Occupancy Schedule Safety Controls Shunt Trip
Contents Default Screen Freeze Motor Cooling Control Ramp Loading Control Capacity Override High Discharge Temperature Control Oil Sump Temperature Control PSIO Software Versions 08 and Lower PSIO Software Versions 09 and Higher Oil Cooler Remote Start/Stop Controls Spare Safety Inputs Spare Alarm Contacts Condenser Pump Control Condenser Freeze Protection
Contents Tower Fan Relay Auto.
Contents Start-Up/Recycle 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 Service Operation To Log On To Log Off Holiday Scheduling Start-Up/Shutdown/Recycle Sequence Local Start-Up Shutdown Sequence Automatic Soft-Stop Amps Threshold (PSIO Software Version 09 and Higher)
Contents Chilled Water Recycle Mode Safety Shutdown Before Initial Start-Up Job Data Required Equipment Required Using the Optional Storage Tank and Pumpout System Remove Shipping Packaging Open Oil Circuit Valves Torque All Gasketed Joints Check Machine Tightness Refrigerant Tracer Leak Test Machine Standing Vacuum Test
Contents Machine Dehydration Inspect Water Piping Check Optional Pumpout Compressor Water Piping Check Relief Devices Inspect Wiring Carrier Comfort Network Interface Check Starter Mechanical-Type Starters Benshaw, Inc.
Contents Input the Local Occupied Schedule (OCCPC01S) Selecting Refrigerant Type To Confirm Refrigerant Type To Change Refrigerant Type Input Service Configurations Password Input Time and Date Change LID Configuration If Necessary Modify Controller Identification If Necessary Input Equipment Service Parameters If Necessary Modify Equipment Configuration If Necessary Check Voltage Supply Perform an Automated Control Test Check Optional Pumpout System Controls and Compressor High Altitude Locations
Contents Charge Refrigerant into Machine 19XL Machine Equalization without Pumpout Unit 19XL Machine Equalization with Pumpout Unit Trimming Refrigerant Charge Initial Start-Up Preparation Manual Operation of the Guide Vanes Dry Run to Test Start-Up Sequence Check Rotation If Rotation Is Proper If the Motor Rotation Is Not Clockwise Notes on Solid-State Starters (Benshaw, Inc.
Contents Check Machine Operating Condition Instruct the Customer Operator Cooler-Condenser Optional Storage Tank and Pumpout System Motor Compressor Assembly Motor Compressor Lubrication System Control System Auxiliary Equipment Describe Machine Cycles Review Maintenance Safety Devices and Procedures Check Operator Knowledge Review the Start-Up, Operation, and Maintenance Manual Operating Instructions Operator Duties
Contents Prepare the Machine for Start-Up To Start the Machine Check the Running System To Stop the Machine After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation Refrigeration Log Pumpout and Refrigerant Transfer Procedures Preparation Operating the Optional Pumpout Compressor To Read Refrigerant Pressures
Contents Machines with Storage Tanks Transfer Refrigerant from Storage Tank to Machine Transfer the Refrigerant from Machine to Storage Tank Machines with Isolation Valves Transfer All Refrigerant to Condenser Vessel Transfer All Refrigerant to Cooler/Compressor Vessel Return Refrigerant to Normal Operating Conditions General Maintenance Refrigerant Properties Adding Refrigerant Removing Refrigerant Adjusting the Refrigerant Charge Refrigerant Leak Testing Leak Rate
Contents Test After Service, Repair, or Major Leak Refrigerant Tracer To Pressurize with Dry Nitrogen Repair the Leak, Retest, and Apply Standing Vacuum Test Checking Guide Vane Linkage Checking the Auxiliary Switch on Guide Vane Actuator Trim Refrigerant Charge Weekly Maintenance Check the Lubrication System Scheduled Maintenance Service Ontime Inspect the Control Center Check Safety and Operating Controls Monthly Changing Oil Filter Oil Specification
Contents Oil Changes To Change the Oil Refrigerant Filter Oil Reclaim Filters Inspect Refrigerant Float System Inspect Relief Valves and Piping Compressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes Cooler Condenser Water Leaks Water Treatment Inspect the Starting Equipment Check Pressure Transducers
Contents Optional Pumpout System Maintenance Optional Pumpout Compressor Oil Charge Optional Pumpout Safety Control Settings Ordering Replacement Chiller Parts Troubleshooting Guide Overview Checking the Display Messages Checking Temperature Sensors Resistance Check Voltage Drop Check Sensor Accuracy Dual Temperature Sensors Checking Pressure Transducers Transducer Replacement Control Algorithms Checkout Procedure
Contents Control Test Control Modules Red LED Green LEDs Notes on Module Operation Processor Module (PSIO) Inputs Outputs Starter Management Module (SMM) Inputs Outputs Options Modules (8-Input) Replacing Defective Processor Modules Installation
Contents Solid-State Starters Testing Silicon Control Rectifiers in Benshaw, Inc.
Contents List of Tables Table 1 — Major PIC Components and Panel Locations Table 2 — LID Screens Example 1 — Status01 Display Screen Example 2 — Status02 Display Screen Example 3 — Status03 Display Screen Example 4 — Setpoint Display Screen Example 5 — Configuration (Config) Display Screen Example 6 — Lead/Lag Configuration Display Screen Example 7 — Service1 Display Screen Example 8 — Service2 Display Screen Example 9 — Service3 Display Screen Example 10 — Maintenance (Maint01) Displa
Contents Table 3 — Protective Safety Limits and Control Settings Table 4 — Capacity Overrides Table 5A — HCFC-22 Pressure — Temperature (F) Table 5B — HCFC-22 Pressure — Temperature (C) Table 5C — HFC-134a Pressure — Temperature (F) Table 5D — HFC-134a Pressure — Temperature (C) Table 6 — Potentiometer Adjustment Table 7 — Amps Correction Factors for 19XL Motors Table 8 — Control Test Menu Functions Table 9 — Refrigerant (HCFC-22 or HFC-134a) Charges Table 10 — LID Primary and Secondary Messages
Contents Table 10 — LID Primary and Secondary Messages and Custom Alarm/ Alert Messages with Troubleshooting Guides (Continued) D. Pre-Start Alerts E. Normal or Auto.-Restart F. Start-Up Failures G. Compressor Jumpstart and Refrigerant Protection H. Normal Run with Reset, Temperature, or Demand I. Normal Run Overrides Active (Alerts) J. Out-Of-Range Sensor Failures K. Machine Protect Limit Faults L. Machine Alerts M. Spare Sensor Alert Messages N.
Contents Table 13 — Cutler-Hammer® Solid-State Starter Troubleshooting Guide Table 14 — Heat Exchanger Data Table 15 — Additional Data for Marine Waterboxes Table 16 — Compressor Weights Table 17 — Compressor/Motor Weights Table 18 — Waterbox Cover Weights Table 19 — Optional Pumpout System Electrical Data
Contents List of Figures Figure 1 — 19XL Identification Figure 2A— Typical 19XL Components — Design I Figure 2B— Typical 19XL Components — Design II Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles Figure 4 — Lubrication System Figure 5 — Cutler-Hammer Solid-State Starter, Internal View Figure 6 — Benshaw, Inc.
Contents Figure 13 — LID Default Screen Figure 14 — LID Service Screen Figure 15 — Example of Point Status Screen (Status01) Figure 16 — 19XL Menu Structure Figure 17 — 19XL Service Menu Structure Figure 18 — Example of Time Schedule Operation Screen Figure 19 — Example of Set Point Screen Figure 20 — 19XL Hot Gas Bypass/Surge Prevention Figure 21 — 19XL with Default Metric Settings Figure 22 — Example of Attach to Network Device Screen Figure 23 — Example of Holiday Period Screen Figure 24 — Control Sequen
Contents Figure 27 — Typical Optional Pumpout System Piping Schematic with Storage Tank Figure 28 — Typical Optional Pumpout System Piping Schematic without Storage Tank Figure 29 — Dehydration Cold Trap Figure 30 — Benshaw, Inc.
Contents Figure 40 — Optional Pumpout System Controls Figure 41 — PSIO Module Address Selector Switch Locations and LED Locations Figure 42 — LID Module (Rear View) and LED Locations Figure 43 — Processor (PSIO) Module Figure 44 — Starter Management Module (SSM) Figure 45 — Options Module Figure 46 — Typical Benshaw, Inc.
Contents Figure 52 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical) Figure 53 — Compressor Fits and Clearances Figure 54 — Compressor Fits and Clearances (Continued) Figure 55 — Compressor Fits and Clearances (Continued) Figure 56 — Electronic PIC Controls Wiring Schematic Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic Figure 58 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic
Introduction Prior to initial start-up of the 19XL 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 so that you may become familiar with the control system before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper machine start-up and operation.
WARNING ! WARNING 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 dissipate body electrostatic charge before working inside control center.
Abbreviations and Explanations Frequently used abbreviations in this manual include: CCN — Carrier Comfort Network LID — Local Interface Device CCW — Counterclockwise LCW — Leaving Chilled Water CW — Clockwise OLTA — Overload Trip Amps ECW — Entering Chilled Water PIC — Product Integrated Control ECDW — Entering Condenser Water PSIO — Processor Sensor Input/Output Module EMS — Energy Management System RLA — Rated Load Amps HGBP — Hot Gas Bypass SCR — Silicon Control Rectifier I/O
Machine Familiarization (Figure 1, Figure 2A (Front View) (Rear View), and Figure 2B (Front View) (Rear View) Machine Information Plate The information plate is located on the right side of the machine control center panel. Click here for Figure 1 — 19XL Identification System Components The components include the cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control center, and motor starter.
flowing through its internal tubes in order to remove heat from the refrigerant. Motor-Compressor This component maintains system temperature/pressure differences and moves the heat carrying refrigerant from the cooler to the condenser. Control Center The control center is the user interface for controlling the machine. It regulates the machine’s capacity as required to maintain proper leaving chilled water temperature.
also is supplied with each unit. Note: If a storage vessel is not used at the jobsite, factory-installed isolation valves on the chiller may be used to isolate the machine charge in either the cooler or condenser. An optional pumpout compressor system is used to transfer refrigerant from vessel to vessel. Refrigeration Cycle The compressor continuously draws refrigerant vapor from the cooler, at a rate set by the amount of guide vane opening.
(Figure 3). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid drains into a float chamber between the FLASC chamber and cooler. Here a float valve forms a liquid seal to keep FLASC chamber vapor from entering the cooler.
in the motor shell than in the cooler/oil sump. The motor is protected by a temperature sensor imbedded in the stator windings. Higher motor temperatures (above 125 F [51 C]) energize a solenoid to provide additional motor cooling. A further increase in temperature past the motor override set point will override the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set point, will close the inlet guide vanes.
Click here for Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles Lubrication Cycle Summary The oil pump, oil filter, and oil cooler make up a package located partially in the transmission casting of the compressor-motor assembly. The oil is pumped into a filter assembly to remove foreign particles, and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures.
The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to 172 kPad) differential pressure in the system at the pump discharge. This differential pressure can be read directly from the Local Interface Device (LID) default screen. The oil pump discharges oil to the oil filter assembly. This filter is capable of being valved closed to permit removal of the filter without draining the entire oil system (see Maintenance sections for details).
of post-lubrication. The oil pump can also be energized for testing purposes in the Control Test. Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to flash. The resulting oil foam cannot be pumped efficiently, therefore oil pressure falls off and lubrication is poor.
discharge gas pressure to power an eductor, the oil is vacuumed from the housing by the eductor and is discharged into the oil reservoir. Oil and refrigerant are also recovered from the top of the cooler refrigerant level and are discharged into the guide vane housing. The oil will drop to the bottom of the guide vane housing and be recovered by the eductor system.
Starting Equipment The 19XL requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxiliary equipment. The starter serves as the main field wiring interface for the contractor. Three types of starters are available from Carrier Corporation: solid-state, wye-delta, and across-the-line starters. See Carrier Specification Z-375 for specific starter requirements.
Circuit breaker CB2 supplies power to the control center, oil heater, and portions of the starter controls. Circuit breaker CB3 supplies power to oil pump. Both of these circuit breakers are wired in parallel with CB1 so that power is supplied to them if the CB1 disconnect is open. All starters are shipped with a Carrier control module called the Starter Management Module (SMM). This module controls and monitors all aspects of the starter. See the Controls section for additional SMM information.
reduced at start-up, the starting torque is reduced as well. The object is to reduce the starting voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage and current are then ramped up in a desired period of time. The voltage is reduced through the use of silicon controlled rectifiers (SCR). Once full voltage is reached, a bypass contactor is energized to bypass the SCRs.
• current unbalance • run state These LEDs are further explained in the Check Starter and Troubleshooting Guide sections. Unit-Mounted Wye-Delta Starter (Optional) The 19XL machine may be equipped with a wye-delta starter mounted on the unit. This starter is intended for use with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration. This occurs during the starting period when the motor is accelerating up to speed.
Controls Definitions Analog Signal An analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.) Digital Signal A digital (discrete) signal is a 2-position representation of the value of a monitored source.
General The 19XL hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the machine. The microprocessor control system matches the cooling capacity of the machine to the cooling load while providing state-of-the-art machine protection.
also regulates the oil heater while the compressor is off, and the hot gas bypass valve, if installed. The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PIC-equipped chillers and other CCN devices. The PIC consists of 3 modules housed inside the 3 major components.
to control the machine. The 19XL uses 3 pressure transducers and 8 thermistors to sense pressures and temperatures. These are connected to the PSIO module. The PSIO also provides outputs to the: guide vane actuator; oil pump; oil heater; hot gas bypass (optional); motor cooling solenoid; and alarm contact. The PSIO communicates with the LID, the SMM, and the optional 8-input modules for user interface and starter management. Starter Management Module (SMM) This module is located within the starter cabinet.
6-Pack Relay Board This device is a cluster of 6 pilot relays located in the control center. It is energized by the PSIO for the oil pump, oil heater, alarm, optional hot gas bypass relay, and motor cooling solenoid. 8-Input Modules One optional module is factory installed in the control center panel when ordered. There can be up to 2 of these modules per chiller with 8 spare inputs each. They are used whenever chilled water reset, demand reset, or reading a spare sensor is required.
Hot Gas Bypass Contactor Relay (3C) (Optional) This relay, located in the power panel, controls the opening of the hot gas bypass valve. The PIC energizes the relay during low load, high lift conditions. Control Transformers (T1-T4) These transformers convert incoming control voltage to either 21 vac power for the PSIO module and options modules, or 24 vac power for 3 power panel contactor relays, 3 control solenoid valves, and the guide vane actuator. They are located in the power panel.
Click here for Figure 12 — Power Panel with Options Control and Oil Heater Voltage Selector (S1) It is possible to use either 115 v or 230 v incoming control power in the power panel. The switch is set to the voltage used at the job site.
mode, and the control will accept modifications from any CCN interface or module (with the proper authority), as well as the LID. The PIC will use the CCN time schedule to determine start and stop times. Alarms and Alerts Alarm (*) and alert (!) status are indicated on the Status tables. An alarm (*) will shut down the compressor. An alert (!) notifies the operator that an unusual condition has occurred. The machine will continue to operate when an alert is shown.
Menu Structure To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test. • Press QUIT to leave the selected decision or field without saving any changes. INCREASE DECREASE • QUIT ENTER Press ENTER to leave the selected decision or field and save changes.
• Press NEXT to scroll the cursor bar down in order to highlight a point or to view more points below the current screen. NEXT • SELECT EXIT Press PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen. NEXT • PREVIOUS PREVIOUS SELECT EXIT Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable) the highlighted point value.
• Press EXIT to return to the previous screen level. NEXT • PREVIOUS SELECT EXIT Press INCREASE or DECREASE to change the highlighted point value. INCREASE DECREASE QUIT ENTER To View Point Status (Figure 15) Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC. 1. On the Menu screen, press STATUS to view the list of Point Status tables.
2. Press NEXT or PREVIOUS to highlight the desired status table. The list of tables is: • • • Status01 — Status of control points and sensors Status02 — Status of relays and contacts Status03 — Status of both optional 8-input modules and sensors NEXT PREVIOUS SELECT ENTER 3. Press SELECT to view the desired Point Status table desired. NEXT PREVIOUS SELECT ENTER 4. On the Point Status table press NEXT or PREVIOUS until desired point is displayed on the screen.
Override Operations To Override a Value or Status 1. On the Point Status table press NEXT or PREVIOUS to highlight the desired point. NEXT PREVIOUS SELECT EXIT 2. Press SELECT to select the highlighted point.
Click here for Figure 17 — 19XL Service Menu Structure For Discrete Points — Press START or STOP to select the desired state. START STOP RELEASE ENTER For Analog Points — Press INCREASE or DECREASE to select the desired value. INCREASE DECREASE RELEASE ENTER 3. Press ENTER to register new value.
few seconds in order to see a value change, especially on kilopascal values. To Remove an Override 1. On the Point Status table press NEXT or PREVIOUS to highlight the desired point. NEXT PREVIOUS SELECT EXIT SELECT EXIT 2. Press SELECT to access the highlighted point. NEXT PREVIOUS 3. Press RELEASE to remove the override and return the point to the PIC’s automatic control.
Time Schedule Operation (Figure 18) 1. On the Menu screen, press SCHEDULE. STATUS SCHEDULE SETPOINT SERVICE 2. Press NEXT or PREVIOUS to highlight the desired schedule. PSIO Software Version 08 and lower: OCCPC01S — LOCAL Time Schedule OCCPC02S — CCN Time Schedule PSIO Software Version 09 and higher: OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03-99S — CCN Time Schedule (Actual number is defined in Config table.
3. Press SELECT to access and view the time schedule. NEXT PREVIOUS SELECT EXIT 4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change. NEXT PREVIOUS SELECT EXIT 5. Press SELECT to access the highlighted period or override.
6. a. Press INCREASE or DECREASE to change the time values. Override values are in onehour increments, up to 4 hours. INCREASE DECREASE ENTER EXIT b. Press ENABLE to select days in the day-of-week fields. Press DISABLE to eliminate days from the period. ENABLE DISABLE ENTER EXIT 7. Press ENTER to register the values and to move horizontally (left to right) within a period.
8. Press EXIT to leave the period or override. NEXT PREVIOUS SELECT EXIT 9. Either return to Step 4 to select another period or override, or press EXIT again to leave the current time schedule screen and save the changes. NEXT PREVIOUS SELECT EXIT Click here for Figure 18 — Example of Time Schedule Operation Screen 10. Holiday Designation (HOLIDEF table) may be found in the Service Operation section. You must assign the month, day, and duration for the holiday.
To View and Change Set Points (Figure 19) 1. To view the Set Point table, at the Menu screen press SETPOINT. STATUS SCHEDULE SETPOINT SERVICE 2. There are 4 set points on this screen: Base Demand Limit; LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point (PSIO Software Version 09 and higher only). Only one of the chilled water set points can be active at one time, and the type of set point is activated in the Service menu.
4. Press SELECT to modify the highlighted set point. NEXT PREVIOUS SELECT EXIT 5. Press INCREASE or DECREASE to change the selected set point value. INCREASE DECREASE QUIT ENTER 6. Press ENTER to save the changes and return to the previous screen.
Service Operation To view the menu-driven programs available for Service Operation, see Service Operation section. For examples of LID display screens, see Table 2 (begins on this page). Table 2 — LID Screens Note: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be configured in English or SI units, as required, through the LID configuration screen. 3.
Table 2 — LID Screens (Continued) Click on an example to view: Example 6 — Lead/Lag Configuration Display Screen Example 7 — Service1 Display Screen Example 8 — Service2 Display Screen Example 9 — Service3 Display Screen Example 10 — Maintenance (Maint01) Display Screen Example 11 — Maintenance (Maint02) Display Screen Example 12 — Maintenance (Maint03) Display Screen Example 13 — Maintenance (Maint04) Display Screen
PIC System Functions Note: Throughout this manual, words printed in capital letters and italics are values that may be viewed on the LID. See Table 2 for examples of LID screens. Point names are listed in the Description column. An overview of LID operation and menus is given in Figure 13, Figure 14, Figure 15, Figure 16, Figure 17, Figure 18, and Figure 19.
Deadband This is the tolerance on the chilled water/ brine temperature CONTROL POINT. If the water temperature goes outside of the DEADBAND, the PIC opens or closes the guide vanes in response until it is within tolerance. The PIC may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. DEADBAND may be viewed or modified on the Equipment Service1 table. For example, a 1° F (0.6° C) deadband setting controls the water temperature within ±0.5° F (0.3° C) of the control point.
vane response to chilled water temperature below deadband plus control point. It can be adjusted on the LID from a setting of 2 to 10, and the default setting is 6.0. Increasing either of these settings will cause the vanes to respond slower than a lower setting. The PROPORTIONAL ECW GAIN can be adjusted at the LID display from a setting of 1.0 to 3.0, with a default setting of 2.0. Increase this setting to increase guide vane response to a change in entering chilled water temperature.
register up to 32,767 hours before it rolls over to zero. The chiller also maintains a start-to-start timer and a stop-to-start timer. These timers limit how soon the machine can be started. See the Start-Up/Shutdown/Recycle Sequence section for operational information. Occupancy Schedule This schedule determines when the chiller is either occupied or unoccupied. Each schedule consists of from one to 8 occupied/unoccupied time periods, set by the operator.
midnight to 3:00 a.m. weekend cool-down schedule. Note: This schedule is for illustration only, and is not intended to be a recommended schedule for chiller operation. PSIO Software Version 08 and Lower Whenever the chiller is in the LOCAL mode, the machine will start when the Occupancy Schedule 01 indicates OCCUPIED. When in the CCN mode, Occupancy Schedule 02 is used. PSIO Software Version 09 and Higher The Local Time Schedule is still the Occupancy Schedule 01.
Safety Controls The PIC monitors all safety control inputs, and if required, shuts down the machine or limits the guide vanes to protect the machine from possible damage from any of the following conditions: • high bearing temperature • high motor winding temperature • high discharge temperature • low oil pressure • low cooler refrigerant temperature/pressure • condenser high pressure or low pressure • inadequate water/brine cooler and condenser flow • high, low, or loss of voltage • excessive motor acceler
CAUTION ! CAUTION If compressor motor overload occurs, check the motor for grounded or open phases before attempting a restart. If the controller initiates a safety shutdown, it displays the fault on the LID display with a primary and a secondary message, and energizes an alarm relay in the starter and blinks the alarm light on the control center. The alarm is stored in memory and can be viewed in the PIC alarm table along with a message for troubleshooting.
Shunt Trip The shunt trip function of the PIC is a safety trip. The shunt trip is wired from an output on the SMM to the motor circuit breaker. If the PIC tries to shut down the compressor through normal shutdown procedure but is unsuccessful for 30 seconds, the shunt trip output is energized and causes the circuit breaker to trip off. If ground fault protection has been applied to the starter, the ground fault trip will also energize the shunt trip to trip the circuit breaker.
Ramp Loading Control The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the machine is started, and the chilled water loop has to be brought down to normal design conditions. This helps reduce electrical demand charges by slowly bringing the chilled water to control point. However, the total power draw during this period remains almost unchanged.
Capacity Override (Table 4) These can prevent some safety shutdowns caused by exceeding motor amperage limit, refrigerant low temperature safety limit, motor high temperature safety limit, and condenser high pressure limit. In all cases there are 2 stages of compressor vane control. 1. The vanes are held from opening further, and the status line on the LID indicates the reason for the override. 2.
High Discharge Temperature Control If the discharge temperature increases above 160 F (71.1 C) (PSIO Software Version 09 and higher) or 180 F (82 C) (PSIO Software Version 08 or lower), the guide vanes are proportionally opened to increase gas flow through the compressor. If the leaving chilled water temperature is then brought 5° F (2.8° C) below the control set point temperature, the controls will bring the machine into the recycle mode.
PSIO Software Version 09 and Higher The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 150 F (65.6 C) or the oil sump temperature is less than the cooler refrigerant temperature plus 70° F (39° C). The oil heater is turned off when the oil sump temperature is either 1) more than 160 F (71.1 C); or 2) the oil sump temperature is more than 155 F (68.3 C) and more than the cooler refrigerant temperature plus 75° F (41.6° C).
regulates refrigerant flow to control oil temperature entering the bearings. There is always a flow of refrigerant bypassing the thermal expansion valve (TXV). The bulb for the expansion valve is strapped to the oil supply line leaving the heat exchanger and the valve is set to maintain 110 F (43 C). Note: The expansion valve is not adjustable. Oil sump temperature may be at a lower temperature.
spare protective limits input channel in place of the factory-installed jumper. (Wire multiple inputs in series.) The opening of any contact will result in a safety shutdown and LID display. Refer to the certified drawings for safety contact ratings. Analog temperature sensors may also be added to the options modules, if installed. These may be programmed to cause an alert on the CCN network, but will not shut the machine down.
Condenser Freeze Prevention This control algorithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. If the pump is controlled by the PIC, starting the pump will help prevent the water in the condenser from freezing. Condenser freeze prevention can occur whenever the machine is not running except when it is either actively in pumpdown or in Pumpdown Lockout with the freeze prevention disabled (refer to Control Test table, Pumpdown/Terminate Lockout tables).
relay can only accomplish this if the relay has been added to the cooling tower temperature controller. The TOWER FAN RELAY is turned on whenever the CONDENSER WATER PUMP is running, flow is verified, and the difference between cooler and condenser pressure is more than 45 psid (310 kPad) (30 psid [207 kPad] for HFC-134a) or entering condenser water temperature is greater than 85 F (29 C).
Auto. Restart After Power Failure This option may be enabled or disabled, and may be viewed/modified in the Config table of Equipment Configuration. If enabled, the chiller will start up automatically after a single cycle dropout, low, high, or loss of voltage has occurred, and the power is within ±10% of normal. The 15- and 3-minute inhibit timers are ignored during this type of start-up.
To activate a reset type, input all configuration information for that reset type in the Config table. Then input the reset type number in the SELECT/ENABLE RESET TYPE input line. 1. Reset Type 1 (Requires optional 8-input module) — Automatic chilled water temperature reset based on a 4 to 20 mA input signal. This type permits up to ±30° F (±16° C) of automatic reset to the chilled water or brine temperature set point, based on the input from a 4 to 20 mA signal.
Reset Type 2 can now be activated. 3. Reset Type 3 — Automatic chilled water temperature reset based on cooler temperature difference. This type of reset will add ±30° F (±16° C) based on the temperature difference between entering and leaving chilled water temperature. This is the only type of reset available without the need of the number one 8-input module. No wiring is required for this type as it already uses the cooler water sensors.
Demand Limit Control, Option — (Requires Optional 8-Input Module) The demand limit may be externally controlled with a 4 to 20 mA signal from an energy management system (EMS). The option is set up on the Config table. When enabled, the control is set for 100% demand with 4 mA and an operator configured minimum demand set point at 20 mA. The Demand Reset input from an energy management system is hardwired into the number one, 8-input module.
Points, (T1/P1;T2/P2). These points have default settings for each type of refrigerant, HCFC-22 or HFC-134a, as defined on the Service1 table, or on Table 4. These settings and the algorithm function are graphically displayed in Figure 20. The two sets of load points on this graph (default settings are shown) describe a line which the algorithm uses to determine the maximum lift of the compressor.
Surge Protection Surging of the compressor can be determined by the PIC through operator configured settings. Surge will cause amperage fluctuations of the compressor motor. The PIC monitors these amperage swings, and if the swing is greater than the configurable setting in one second, then one surge count has occurred. The SURGE DELTA PERCENT AMPS setting is displayed and configured on the Service1 screen. It has a default setting of 25% amps, SURGE PROTECTION COUNTS can be monitored on the Maint03 table.
Lead/Lag Control Note: Lead/lag control is only available on machines with PSIO Software Version 09 or higher. Lead/lag is a control system process that automatically starts and stops a lag or second chiller in a 2-chiller water system. Refer to Figure 16 and Figure 17 for menu, table, and screen selection information. On machines that have PSIO software with Lead/Lag capability, it is possible to utilize the PIC controls to perform the lead/lag function on 2 machines.
Operation Features: • • • • • • 2 chiller lead/lag addition of a third chiller for backup manual rotation of lead chiller load balancing if configured staggered restart of the chillers after a power failure chillers may be piped in parallel or in series chilled water flow Common Point Sensor Installation Lead/lag operation does not require a common chilled water point sensor. Common point sensors can be added to the 8-input option module, if desired.
chilled water sensor should be installed. If this sensor is not installed, the return chilled water sensor of the downstream chiller must be relocated to the return chilled water pipe of the upstream machine. To properly control the common supply point temperature sensor when chillers are piped in parallel, the water flow through the shutdown chillers must be isolated so that no water bypass around the operating chiller occurs.
Lead/Lag Chiller Configuration and Operation The configured lead chiller is identified when the LEAD/LAG SELECT value for that chiller is configured to the value of ‘‘1.’’ The configured lag chiller is identified when the LEAD/LAG SELECT for that chiller is configured to the value of ‘‘2.’’ The standby chiller is configured to a value of ‘‘3.’’ A value of ‘‘0’’ disables the lead/lag in that chiller.
requested to start. After the second chiller is started and is running, the lead chiller shall monitor conditions and evaluate whether the capacity has reduced enough for the lead chiller to sustain the system alone. If the capacity is reduced enough for the lead chiller to sustain the CONTROL POINT temperatures alone, then the operating lag chiller is stopped. If the lead chiller is stopped in CCN mode for any reason other than an alarm (*) condition, then the lag and standby chillers are stopped.
Standby Chiller Configuration and Operation The configured standby chiller is identified as such by having the LEAD/LAG SELECT configured to the value of ‘‘3.’’ The standby chiller can only operate as a replacement for the lag chiller if one of the other two chillers is in an alarm (*) condition (as shown on the LID panel).
6. The configured LAG START TIMER entry has elapsed. The LAG START TIMER shall be started when the lead chiller ramp loading is completed. The LAG START TIMER entry is accessed by selecting Lead/Lag from the Equipment Configuration table of the Service menu. When all of the above requirements have been met, the lag chiller is forced to a START mode. The PIC control then monitors the lag chiller for a successful start. If the lag chiller fails to start, the standby chiller, if configured, is started.
COMPRESSOR MOTOR LOAD is less than the lead chiller percent capacity plus 15%. The timer is ignored if the chilled water temperature reaches 3° F (1.67° C) below the CONTROL POINT and the lead chiller COMPRESSOR MOTOR LOAD value is less than the lead chiller percent capacity plus 15%. Faulted Chiller Operation If the lead chiller shuts down on an alarm (*) condition, it stops communication to the lag and standby chillers.
Load Balancing When the LOAD BALANCE OPTION is enabled, the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s COMPRESSOR MOTOR LOAD value. This value has limits of 40% to 100%. When setting the lag chiller ACTIVE DEMAND LIMIT, the CONTROL POINT shall be modified to a value of 3° F (1.67° C) less than the lead chiller’s CONTROL POINT value.
Ice Build Control IMPORTANT: The Ice Build control option is only available on machines with PSIO Software Version 09 and higher. Ice build control automatically sets the chilled WATER/ BRINE CONTROL POINT of the machine to a temperature where an ice building operation for thermal storage can be accomplished. Note: For ice build control to properly operate, the PIC controls must be placed in CCN mode. See Figure 16 and Figure 17. The PIC can be configured for ice build operation.
temperature being less than the ICE BUILD SETPOINT, opening of the REMOTE CONTACT inputs from an ice level indicator, or reaching the end of the Ice Build Time Schedule. Ice Build Initiation The Ice Build Time Schedule provides the means for activating ice build. The ice build time table is named OCCPC02S.
Start-Up/Recycle Operation If the machine is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINATION value, to avoid starting the compressor unnecessarily: • if ICE BUILD TERMINATION is set to the TEMPERATURE ONLY OPTION and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SETPOINT; • if ICE BUILD TERMINATION is set to the CONTACTS ONLY OPTION and the remote contacts are open; • if the ICE BUILD TERMINATION is set t
Temperature Control During Ice Build During ice build, the capacity control algorithm uses the WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to control the LEAVING CHILLED WATER temperature. The ECW OPTION and any temperature reset option are ignored during ice build. The 20 mA DEMAND LIMIT OPTION is also ignored during ice build. Termination Of Ice Build Ice build termination occurs under the following conditions: 1.
Schedule is UNOCCUPIED. The contacts are used to stop the ICE BUILD mode when the Ice Build Time Schedule is OCCUPIED. 4. ECW TEMPERATURE and Remote Contacts — Termination of compressor operation shall occur when ICE BUILD TERMINATION is set to BOTH (temperature and contacts) option and the previously described conditions for ECW TEMPERATURE and remote contacts have occurred.
Attach to Network Device Control On the Service menu, one of the selections is ATTACH TO NETWORK DEVICE. This table serves the following purposes: • • to upload new parameters when switching the controller to HFC-134a refrigerant. to upload the Occupancy Schedule Number (if changed) for OCCPC03S, as defined in the Service01 table • to attach the LID to any CCN device, if the machine has been connected to a CCN Network. This may include other PIC controlled chillers.
various CCN modules is different for each module. In general, the uploading process will take 3 to 5 minutes. Changing Refrigerant Types To select refrigerant type, go to the Control Test table. Whenever the refrigerant type is changed, the ATTACH TO NETWORK DEVICE table must be used. After changing the refrigerant type in the Control Test table, move to the ATTACH TO NETWORK DEVICE table. Make sure the highlight bar is located on the LOCAL selection. Press the ATTACH softkey.
checked. If the model is communicating properly, the ‘‘UPLOAD IN PROGRESS’’ message will flash and the new module can now be viewed. Whenever there is a question regarding which module on the LID is currently being shown, check the device name descriptor on the upper left hand corner of the LID screen. See Figure 22. When the CCN device has been viewed, the ATTACH TO NETWORK DEVICE table should now be used to attach to the PIC that is on the machine.
Service Operation An overview of the menu-driven programs available for Service Operation is shown in Figure 17. To Log On 1. On the Menu screen, press SERVICE. The keys now correspond to the numerals 1, 2, 3, 4. 2. Press the four digits of your password, one at a time. An asterisk (*) appears as you enter each digit. ENTER A 4 DIGIT PASSWORD:* 1 2 3 4 The menu bar (Next-Previous-Select-Exit) is displayed to indicate that you have successfully logged on.
Step 1 and try logging on again. 1 INVALID PASSWORD 2 3 4 Note: The initial factory set password is 1-1-1-1. To Log Off Access the Log Out of Device table of the Service menu in order to password-protect the Service menu. The LID will automatically sign off and password-protect itself if a key is not pressed for 15 minutes. The LID default screen is then displayed. Holiday Scheduling (Figure 23) The time schedules may be configured for special operation during a holiday period.
that is configured to be the broadcaster is the device responsible for transmitting holiday, time, and daylight-savings dates throughout the network. To view or change the holiday periods for up to 18 different holidays, perform the following operation: 1. At the Menu screen, press SERVICE to access the Service menu. STATUS SCHEDULE SETPOINT SERVICE 2. If not logged on, follow the instructions for To Log On or To Log Off. Once logged on, press NEXT until Equipment Configuration is highlighted.
4. Press NEXT until Holidef is highlighted. This is the Holiday Definition table. NEXT PREVIOUS SELECT EXIT 5. Press SELECT to enter the Data Table Select screen. This screen lists 18 holiday tables. NEXT PREVIOUS SELECT EXIT 6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday period, starting on a specific date, and lasting up to 99 days.
7. Press SELECT to access the holiday table. The Configuration Select table now shows the holiday start month and day, and how many days the holiday period will last. NEXT PREVIOUS SELECT EXIT 8. Press NEXT or PREVIOUS to highlight the month, day, or duration. NEXT PREVIOUS SELECT EXIT 9. Press SELECT to modify the month, day, or duration.
10. Press INCREASE or DECREASE to change the selected value. INCREASE DECREASE QUIT ENTER QUIT ENTER 11. Press ENTER to save the changes. INCREASE DECREASE 12. Press EXIT to return to the previous menu.
Start-Up/Shutdown/Recycle Sequence (Figure 24) Local Start-Up Local start-up (or a manual start-up) is initiated by pressing the LOCAL menu softkey which is on the default LID screen. Local start-up can proceed when Time Schedule 01 is in OCCUPIED mode, and after the internal 15 minute start-to-start and the 3 minute stop-to-start inhibit timers have expired (on PSIO software Version 08 and lower or a 1 minute stop-to-start timer on PSIO Software Version 09 and higher).
than or equal to this value, the PIC will turn off the condenser pump relay and go into a RECYCLE mode. If the water/brine temperature is high enough, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 3 psid (21 kPad), the oil pump relay will then be energized.
confirm stop command) recycle condition is present (see Chilled Water Recycle Mode section) time schedule has gone into UNOCCUPIED mode (machine protective limit has been reached and machine is in alarm) • the start/stop status is overridden to stop from the CCN network or the LID When a stop signal occurs, the shutdown sequence first stops the compressor by deactivating the start relay. A status message of ‘‘SHUTDOWN IN PROGRESS, COMPRESSOR DEENERGIZED’’ is displayed.
• if the machine shuts down due to low refrigerant temperature, the chilled water pump will stay running until the LEAVING CHILLED WATER is greater than CONTROL POINT, plus 5° F (3° C) Automatic Soft Stop Amps Threshold (PSIO Software Version 09 and Higher) The SOFT STOP AMPS THRESHOLD closes the guide vanes of the compressor automatically when a non-recycle, non-alarm stop signal occurs before the compressor motor is deenergized.
compressor is running in a lightly loaded condition. This cycling of the chiller is normal and is known as recycle.
hours. This excessive recycling can reduce machine life. Compressor recycling due to extremely low loads should be reduced. To reduce compressor recycling, use the time schedule to shut the machine down during low load operation or increase the machine load by running the fan systems. If the hot gas bypass is installed, adjust the values to ensure that hot gas is energized during light load conditions. Increase the RECYCLE RESTART DELTA T on the Service1 table to lengthen the time between restarts.
CAUTION ! CAUTION Do not reset starter loads or any other starter safety for 30 seconds after the compressor has stopped. Voltage output to the compressor start signal is maintained for 10 seconds to determine starter fault.
• • absolute pressure manometer or wet-bulb vacuum indicator (Figure 25) 500 v insulation tester (megohmmeter) for compressor motors with nameplate voltage of 600 v or less, or a 5000-v insulation tester for compressor motor rated above 600 v Using the Optional Storage Tank and Pumpout System Refer to Pumpout and Refrigerant Transfer Procedures section for: pumpout system preparation, refrigerant transfer, and machine evacuation.
Check Machine Tightness Figure 26 outlines the proper sequence and procedures for leak testing. 19XL chillers are shipped with the refrigerant contained in the condenser shell and the oil charge shipped in the compressor. The cooler will have a 15 psig (103 kPa) refrigerant charge. Units may be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogen-holding charge in each vessel. To determine if there are any leaks, the machine should be charged with refrigerant.
WARNING ! WARNING Do not use air or oxygen as a means of pressurizing the machine. Some mixtures of HCFC-22 or HFC-134a and air can undergo combustion. Click here for Figure 26 — 19XL Leak Test Procedures Leak Test Machine Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Figure 26 for an outline of the leak test procedures.
WARNING ! WARNING Never charge liquid refrigerant into the machine if the pressure in the machine is less than 68 psig (469 kPa) for HCFC-22 and 35 psig (241 kPa) for HFC-134a. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN LOCKOUT and TERMINATE LOCKOUT mode on the PIC. Flashing of liquid refrigerant at low pressures can cause tube freezeup and considerable damage. c. Leak test machine as outlined in Steps 3 - 9. 2.
g. After successfully completing the test for large leaks, remove as much nitrogen, air, and moisture as possible, given the fact that small leaks may be present in the system. This can be accomplished by following the dehydration procedure, outlined in the Machine Dehydration section. h. Slowly raise the system pressure to a maximum of 210 psig (1448 kPa) but no less than 68 psig (469 kPa) for HCFC-22, 35 psig (241 kPa) for HFC-134a by adding refrigerant. Proceed with the test for small leaks (Steps 3-9).
b. If the machine fails this test, check for large leaks (Step 2b). c. Dehydrate the machine if it passes the standing vacuum test. Follow the procedure in the Machine Dehydration section. Charge machine with refrigerant (see Pumpout and Refrigerant Transfer Procedures, Machines with Storage Tanks section, Steps 1a-e). 7.
4. a. If the leakage rate is less than 0.05 in. Hg (.17 kPa) in 24 hours, the machine is sufficiently tight. b. If the leakage rate exceeds 0.05 in. Hg (.17 kPa) in 24 hours, repressurize the vessel and test for leaks. If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Refrigerant to Normal Operating Conditions section. If not, use nitrogen and a refrigerant tracer. Raise the vessel pressure in increments until the leak is detected.
Click here for Table 5A — HCFC-22 Pressure — Temperature (F) Click here for Table 5B — HCFC-22 Pressure — Temperature (C) Click here for Table 5C — HFC-134a Pressure — Temperature (F) Click here for Table 5D — HFC-134a Pressure — Temperature (C) Machine Dehydration Dehydration is recommended if the machine has been open for a considerable period of time, if the machine is known to contain moisture, or if there has been a complete loss of machine holding charge or refrigerant pressure.
WARNING ! WARNING Do not start or megohm test the compressor motor or oil pump motor, even for a rotation check, if the machine is under dehydration vacuum. Insulation breakdown and severe damage may result. Dehydration is readily accomplished at room temperatures. Use of a cold trap (Figure 29) may substantially reduce the time required to complete the dehydration. The higher the room temperature, the faster dehydration takes place.
3. Open all isolation valves (if present), if the entire machine is to be dehydrated. 4. With the machine ambient temperature at 60 F (15.6 C) or higher, operate the vacuum pump until the manometer reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C). Operate the pump an additional 2 hours. Do not apply greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb vacuum indicator.
Inspect Water Piping Refer to piping diagrams provided in the certified drawings, and the piping instructions in the 19XL Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that flow directions are correct and that all piping specifications have been met. Piping systems must be properly vented, with no stress on waterbox nozzles and covers. Water flows through the cooler and condenser must meet job requirements.
Check Relief Devices Be sure that relief devices have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing. 19XL relief valves are set to relieve at the 300 psig (2068 kPa) machine design pressure. Inspect Wiring WARNING ! WARNING Do not check voltage supply without proper equipment and precautions. Serious injury may result.
2. On low-voltage compressors (600 v or less) connect voltmeter across the power wires to the compressor starter and measure the voltage. Compare this reading with the voltage rating on the compressor and starter nameplates. 3. Compare the ampere rating on the starter nameplate with the compressor nameplate. The overload trip amps must be 108% to 120% of the rated load amps. 4. The starter for a centrifugal compressor motor must contain the components and terminals required for PIC refrigeration control.
a. Open the starter main disconnect switch and follow lockout/tagout rules. CAUTION ! CAUTION If the motor starter is a solid-state starter, the motor leads must be disconnected from the starter before an insulation test is performed. The voltage generated from the tester can damage the starter solid-state components. b.
Note: Unit-mounted starters do not have to be megohm tested. 10. Tighten up all wiring connections to the plugs on the SMM, 8-input, and PSIO modules. 11. Ensure that the voltage selector switch inside the power panel is switched to the incoming voltage rating. 12. On machines with freestanding starters, inspect the power panel to ensure that the contractor has fed the wires into the bottom of the panel. Wiring into the top of the panel can cause debris to fall into the contactors.
tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl or Teflon with a minimum operating temperature range of –20 C to 60 C is required. See table below for cables that meet the requirements. Manufacturer Cable No.
Check Starter CAUTION ! CAUTION BE AWARE that certain automatic start arrangements can engage the starter. Open the disconnect ahead of the starter in addition to shutting off the machine or pump. Use the instruction and service manual supplied by the starter manufacturer to verify that the starter has been installed correctly. CAUTION ! CAUTION The main disconnect on the starter front panel may not deenergize all internal circuits.
Mechanical-Type Starters 1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection. 2. Check the contactor(s) to be sure they move freely. Check the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time. Check all other electro-mechanical devices, e.g., relays, timers, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components. 3.
seconds may be chosen as needed (typically 20 to 30 seconds are used). When the timer has been set, check that the starter, (with relay 1CR closed, goes through a complete and proper start cycle. Benshaw, Inc. Solid-State Starter WARNING ! WARNING This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on the equipment. 1. Check that all wiring connections are properly terminated to the starter. 2.
The starting torque potentiometer should be set so that when the PIC calls for the motor to start, the rotor should just start to turn. The nominal dial position for a 60 Hz motor is approximately the 11:30 position. The nominal dial position for a 50 Hz motor is approximately in the 9:30 position because the board is turned on its side, so that the 9:00 o’clock position is located where the 6:00 o’clock position would normally be located.
Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller (Print and use for job file) Click here for Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller Cutler-Hammer® Solid-State Starters WARNING ! WARNING This equipment is at line voltage when ac power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on the equipment. 1. Check that all wiring connections are properly terminated to the starter. 2.
important because of the interdependency of these functions. See Table 6. The settings should be made in the following sequence: Potentiometer Adjustment Note: All potentiometers are factory set. The following information is provided for reference. Adjustment potentiometers are nearly linear. To make an initial setting, determine the percentage of the potentiometer rotation. Use the following formula to calculate the percent of rotation. See Figure 32 and Figure 33.
CAUTION ! CAUTION Do not adjust any potentiometer beyond its stops. This type of adjustment will result in damage to the potentiometer. Starting Current The torque required to start a machine (initial torque) varies from one application to another. Starting current may be adjusted to match the initial motor torque of the application. The starting current value is adjustable from 100% to 400% FLA and is factory set at 100%. If quick acceleration is desired, set the starting current at a higher level.
Ramp Time (Adjustable Current Ramp) The motor current is ramped up from the starting current value over a timed period set by the ramp time potentiometer (adjustable from 2 to 30 seconds at 400% current limit setting). The 19XL is factory set at 15 seconds. However, based on jobsite conditions, a range of ±5 seconds is acceptable. Current Limit This protection limits motor current to a set value and holds motor torque at a reduced level during motor start.
Voltage Measurements Consider the following when checking voltage measurements: • • • • • • • • Before energizing the starter, check the incoming lines for properly balanced voltages. Close the circuit breaker to apply power to the starter. Verify the 120 vac control voltage. Visually check to ensure that all fans are running (if applicable). Verify phase sequence at line terminals. Incorrect phase sequence will result in a shunt trip of the circuit breaker.
located near the bottom of the transmission housing (Figure 2A or Figure 2B). The oil must be pumped from the oil container through the charging valve due to higher refrigerant pressure. The pumping device must be able to lift from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil should only be charged or removed when the machine is shut down. Power Up the Controls and Check the Oil Heater Ensure that an oil level is visible in the compressor before energizing controls.
normal operating temperature. A LOW OIL TEMPERATURE alert will show on the default LID screen if the operator has the controls set to start. Software Version The software version will always be labeled on the PSIO module, and on the back side of the LID module. On both the Controller ID and LID ID display screens, the software version number will also appear.
Input the Design Set Points Access the LID set point screen and view/modify the base demand limit set point, and either the LCW set point or the ECW set point. The PIC can control a set point to either the leaving or entering chilled water. This control method is set in the Equipment Configuration table, Config table. Input the Local Occupied Schedule (OCCPC01S) Access the schedule OCCPC01S screen on the LID and set up the occupied time schedule per the customer’s requirements.
refrigerant setting. Press EXIT softkey to leave the screen without changes. To Change Refrigerant Type Enter the Controls Test tables on the Service Menu. See Figure 17. Select REFRIGERANT TYPE. The screen will display the current refrigerant setting. Press YES softkey to change the current setting. Next, move to the ATTACH TO NETWORK DEVICE screen on the Service menu and the ATTACH TO LOCAL DEVICE to upload the new refrigerant tables.
Input Time and Date Access the Time and Date table on the Service menu. Input the present time of day, date, and day of the week. ‘‘Holiday Today’’ should only be configured to ‘‘Yes’’ if the present day is a holiday. Change Lid Configuration If Necessary The LID Configuration screen is used to view or modify the LID CCN address, change to English or SI units, and to change the password.
Configure SERVICE1 Table Access Service1 table to modify/view the following to jobsite parameters: Chilled Medium Brine Refrigerant Trippoint Surge Limiting or Hot Gas Bypass Option Minimum Load Points (T1/P1) Maximum Load Points (T2/P2) Amps Correction Factor Motor Rated Load Amps Motor Rated Line Voltage Motor Rated Line kW Line Frequency Compressor Starter Type Water or Brine? Usually 3° F (1.
If, after configuring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed by the operator. Example of configuration: Machine operating parameters Refrigerant used: HCFC-22 Estimated Minimum Load Conditions: 44 F (6.7 C) LCW 45.5 F (7.5 C) EWC 43 F (6.1 C) Suction Temperature 70 F (21.1 C) Condensing Temperature Estimated Maximum Load Conditions: 44 F (6.7 C) LCW 54 F (12.2 C) ECW 42 F (5.6 C) Suction Temperature 98 F (36.
Calculate Maximum Load To calculate maximum load points, use design load condition data. If the machine full load cooler temperature difference is more than 15° F (8.3 C), estimate the refrigerant suction and condensing temperatures at this difference. Use the proper saturated pressure and temperature for the particular refrigerant used. Suction Temperature: 42 F (5.6 C) = 71.5 psig (521 kPa) saturated refrigerant pressure (HCFC-22) Condensing Temperature: 98 F (36.
Calculate Minimum Load To calculate minimum load conditions, estimate the temperature difference that the cooler will have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated pressure and temperature for the particular refrigerant used. Suction Temperature: 43 F (6.1 C) = 73 psig (503 kPa) saturated refrigerant pressure (HCFC-22) Condensing Temperature: 70 F (21.
If surge prevention occurs too soon or too late: Load Surge Prevention Occurs Too Soon Surge Prevention Occurs Too Late At low loads (<50%) Increase P1 by 10 psid (70 kPad) Decrease P1 by 10 psid (70 kPad) At high loads (>50%) Increase P2 by 10 psid (70 kPad) Decrease P2 by 10 psid (70 kPad) Modify Amp Correction Factors To modify the amp correction factor, use the values listed in Table 7. Enter the appropriate amp correction factor in the Service1 table of Equipment Service.
Config Table Modifications Change the values in this table per job data. See certified drawings for values. Modifications include: • • • • • chilled water reset entering chilled water control (Enable/Disable) 4-20 mA demand limit auto restart option (Enable/Disable) remote contact option (Enable/Disable) Owner-Modified CCN Tables The following tables are described for reference only.
system. See the applicable CCN manual for more information on these tables. These tables can only be defined through a CCN Building Supervisor. Check Voltage Supply Access the Status 01 screen and read the actual line voltage. This reading should be equal to the incoming power to the starter. Use a voltmeter to check incoming power at the starter power leads.
Note: The oil pump test will not energize the oil pump if cooler pressure is below –5 psig (–35 kPa). When the test is finished, or the EXIT softkey is pressed, the test will be stopped and the Control Test menu will be displayed. If a specific automated test procedure is not completed, access the particular control test to test the function when ready. The Control Test menu is described as follows.
Check Optional Pumpout System Controls and Compressor Controls include an on/off switch, a 3-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 220 ± 5 psig (1250 ± 34 kPa), and automatically reset at 185 +0,–7 (1280 +0,–48 kPa) with HCFC-22. HFC-134a units open at 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Check that the water-cooled condenser has been connected.
Charge Refrigerant into Machine ! CAUTION CAUTION The transfer, addition, or removal of refrigerant in spring isolated machines may place severe stress on external piping if springs have not been blocked in both up and down directions. The standard 19XL machine will have the refrigerant already charged in the vessels. The 19XL may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Evacuate the entire machine, and charge machine from refrigerant cylinders.
To equalize the pressure differential on a refrigerant isolated 19XL machine, use the TERMINATE LOCKOUT function of the Control Test in the SERVICE menu. This will help to turn on pumps and advise the proper procedure. The following procedure describes how to equalize refrigerant pressure on an isolated 19XL machine without a pumpout unit: 1. Access TERMINATE LOCKOUT function on the Control Test. 2. Turn on the chilled water and condenser water pumps to ensure against freezing. 3.
19XL Machine Equalization with Pumpout Unit The following procedure describes how to equalize refrigerant pressure on an isolated 19XL machine using the pumpout unit: 1. Access the TERMINATE LOCKOUT mode in the Control Test. 2. Turn on the chilled water and condenser water pumps to prevent possible freezing. 3. Open valve 4 on the pumpout unit and open valves 1a and 1b on the cooler and condenser, Figure 27 and Figure 28. Slowly open valve 2 on the pumpout unit to equalize the pressure.
adding the condenser charge to the cooler charge listed in Table 9. Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups. Use the Control Test Terminate Lockout to monitor conditions and start the pumps. If the machine has been shipped with a holding charge, the refrigerant will be added through the refrigerant charging valve (Figure 27 and Figure 28, valve 7) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the vessels.
Trimming Refrigerant Charge The 19XL is shipped with the correct charge for the design duty of the machine. Trimming the charge can be best accomplished when design load is available. To trim, check the temperature difference between leaving chilled water temperature and cooler refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the temperature difference to design conditions or minimum differential.
5. Oil reservoir temperature is above 140 F (60 C) or refrigerant temperature plus 50° F (28° C). 6. Valves in the evaporator and condenser water circuits are open. Note: If pumps are not automatic, make sure water is circulating properly. 7. Solid-state starter checks: The Power +15 and the Phase Correct LEDs must be lit before the starter will energize. If the Power +15 LED is not on, incoming voltage is not present or is incorrect.
Manual Operation of the Guide Vanes Manual operation of the guide vanes is helpful to establish a steady motor current for calibration of the motor amps value. In order to manually operate the guide vanes, it is necessary to override the TARGET GUIDE VANE POSITION value which is accessed on the Status01 table. Manual control is indicated by the word ‘‘SUPVSR!’’ flashing after the target value position. Manual control is also indicated on the default screen on the run status line. 1.
2. Look at the default screen on the LID: the Status message in the upper left-hand corner will show a ‘‘Manually Stopped’’ message. Press CCN or Local to start. If not, go to the Schedule screen and override the schedule or change the occupied time. Press the LOCAL softkey to begin the start-up sequences. 3. Check that chilled water and condenser water pumps energize. 4. Check that the oil pump starts and pressurizes the lubrication system.
If the Motor Rotation Is Not Clockwise (as viewed through the sight glass), reverse any 2 of the 3 incoming power leads to the starter and recheck rotation. Note: Solid-state starters have phase protection and will not allow a start if the phase is not correct. Instead, a Starter Fault message will occur if this happens. CAUTION ! CAUTION Do not check motor rotation during coastdown. Rotation may have reversed during equalization of vessel pressures.
3. The factory setting should bring the motor to full voltage in 15 to 30 seconds. If the setting is not correct, adjust the ramp potentiometer counterclockwise for a shorter time, clockwise for a longer time. (See Figure 6 for starter component placement.) Check Oil Pressure and Compressor Stop 1. When the motor is up to full speed, note the differential oil pressure reading on the LID default screen. It should be between 18 and 30 psid (124 to 206 kPad). 2.
To Prevent Accidental Start-Up The PIC can be set up so that start-up of the unit is more difficult than just pressing the LOCAL or CCN softkeys during machine service or when necessary. By accessing the Status01 table, and highlighting the chiller Start/Stop line, the value can be overridden to stop by pressing SELECT and then the STOP and ENTER softkeys. ‘‘SUPVSR’’ will appear after the value. When attempting to restart, remember to release the override.
Optional Storage Tank and Pumpout System Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices. Motor Compressor Assembly Guide vane actuator, transmission, motor cooling system, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil filter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.
Review Maintenance Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importance of maintaining a leak-free machine. Safety Devices and Procedures Electrical disconnects, relief device inspection, and handling refrigerant. Check Operator Knowledge Start, stop, and shutdown procedures, safety and operating controls, refrigerant and oil charging, and job safety.
5. Protect the system from damage during shutdown periods. 6. Maintain the set point, time schedules, and other PIC functions. Prepare the Machine for Start-Up Follow the steps described in the Initial Start-Up section. To Start the Machine 1. Start the water pumps, if they are not automatic. 2. On the LID default screen, press the LOCAL or CCN softkey to start the system. If the machine is in the OCCUPIED mode, and the start timers have expired, the start sequence will start.
3. The oil level should be visible anywhere in one of the two sight glasses. Foaming of the oil is acceptable as long as the oil pressure and temperature are within limits. 4. The oil pressure should be between 18 and 30 psid (124 to 207 kPad) differential, as seen on the LID default screen. Typically the reading will be 18 to 25 psid (124 to 172 kPad) at initial start-up. 5. The moisture indicator sight glass on the refrigerant motor cooling line should indicate refrigerant flow and a dry condition. 6.
based on load rate or temperature rate. It is accessed on the Equipment Configuration, Config table (Table 2, Example 5). To Stop the Machine 1. The occupancy schedule will start and stop the machine automatically once the time schedule is set up. 2. By pressing the STOP button for one second, the alarm light will blink once to confirm that the button has been pressed, then the compressor will follow the normal shutdown sequence as described in the Controls section.
Extended Shutdown The refrigerant should be transferred into the storage vessel (if supplied; see Pumpout and Refrigerant Transfer Procedures) in order to reduce machine pressure and possibility of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant to prevent air from leaking into the machine. If freezing temperatures are likely to occur in the machine area, drain the chilled water, condenser water, and the pumpout condenser water circuits to avoid freeze-up.
Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the compressor oil level appears abnormally high, the oil may have absorbed refrigerant. Make sure that the oil temperature is above 140 F (60 C) or cooler refrigerant temperature plus 50° F (27° C). Cold Weather Operation When the entering condenser water drops very low, the operator should automatically cycle the cooling tower fans off to keep the temperature up.
Refrigeration Log A refrigeration log, such as the one shown in Figure 35, provides a convenient checklist for routine inspection and maintenance and provides a continuous record of machine performance. It is an aid in scheduling routine maintenance and in diagnosing machine problems. Keep a record of the machine pressures, temperatures, and liquid levels on a sheet similar to that shown.
Pumpout and Refrigerant Transfer Procedures Preparation The 19XL may come equipped with an optional storage tank or pumpout system, or a pumpout compressor. The refrigerant can be pumped for service work to either the cooler/ compressor vessel, or the condenser vessel by using the optional pumpout system. If a storage tank is supplied, the refrigerant can be isolated in the external tank.
To Read Refrigerant Pressures during pumpout or leak testing: 1. The LID display on the machine control center is suitable for determining refrigerant-side pressures and low (soft) vacuum. For evacuation or dehydration measurement, use a quality vacuum indicator or manometer to ensure the desired range and accuracy. This can be placed on the Schrader connections on each vessel (Figure 8) by removing the pressure transducer. 2. To determine storage tank pressure, a 30 in.
Transfer Refrigerant from Storage Tank to Machine 1. Equalize refrigerant pressure. a. Use the Control Test Terminate Lockout to turn on water pumps and monitor pressures. b. Close pumpout/storage tank valves 2, 4, 5, and 8, and close machine charging valve 7; open machine isolation valves 11, 12, 13, and 14 (if present). c. Open pumpout/storage tank valves 3 and 6, open machine valves 1a and 1b.
e. Open valve 5 fully after the pressure rises above the freeze point of the refrigerant. Open liquid line valve 7 until refrigerant pressure equalizes. Valve 1a 1b 2 3 C Condition 4 5 6 7 C 8 11 12 13 14 11 12 13 14 C 2. Transfer remaining refrigerant. a. Close valve 5 and open valve 4. Valve 1a 1b Condition 2 3 C 4 5 C 6 7 8 C b. Turn off the water pumps through the LID. c.
g. Open valves 2 and 5. Valve 1a 1b 2 Condition 3 4 C C 5 6 7 8 C C 11 12 13 14 h. Turn on pumpout condenser water. i. Run the pumpout compressor until the storage tank pressure reaches 5 psig (34 kPa) (18 in. Hg [40 kPa absolute] if repairing the tank). j. Turn off the pumpout compressor. k. Close valves 1a, 1b, 2, 5, and 6. l. Turn off pumpout condenser water.
Transfer the Refrigerant from Machine to Storage Tank 1. Equalize refrigerant pressure. a. Valve positions: Valve 1a 1b 2 3 C Condition 4 5 C C 6 7 8 C C 11 12 13 14 b. Slowly open valve 5 and liquid line valve 7 to allow liquid refrigerant to drain by gravity into the storage tank. Valve 1a 1b 2 3 C Condition 4 5 6 7 C 8 11 12 13 14 C 2. Transfer the remaining liquid. a. Turn off pumpout condenser water.
b. Run the pumpout compressor for 30 minutes then close valve 7. c. Turn off the pumpout compressor. Valve 1a 1b 2 Condition 3 4 C C 5 6 7 8 C C 11 12 13 14 13 14 3. Remove any remaining refrigerant. a. Turn on water pumps through the use of the Control Test Pumpdown. b. Turn on pumpout condenser water. c. Place valves in the following positions: Valve Condition 1a 1b 2 C 3 4 5 C 6 7 8 C C 11 12 d.
(448 kPa) for HCFC-22, 30 psig (207 kPa) for HFC-134a, and then turn off the compressor. Repeat this process until the pressure no longer rises, then turn on the pumpout compressor and pumpout until the pressure reaches 18 in. Hg. (40 kPa absolute). f. Close valves 1a, 1b, 3, 4, and 6. Valve Condition 1a 1b 2 3 4 5 6 7 8 C C C C C C C C C 11 12 13 14 g.
Machines with Isolation Valves Transfer All Refrigerant to Condenser Vessel 1. Push refrigerant into condenser. a. Valve positions: Valve 1a 1b 2 Condition 3 4 C C 5 8 11 C 12 13 14 C C C b. Turn off machine water pumps and pumpout condenser water. c. Turn on pumpout compressor to push liquid out of the cooler/compressor. d. When all liquid has been pushed into the condenser, close cooler isolation valve 11. e.
2. Evacuate gas from cooler/compressor vessel. a. Close pumpout valves 2 and 5, and open valves 3 and 4. Valve 1a 1b 2 3 4 C Condition 5 8 11 12 13 14 C C C C C C b. Turn on pumpout condenser water. c. Run pumpout until the compressor reaches 18 in. Hg vac (40 kPa abs.). Monitor pressures on the LID and on refrigerant gages. d. Close valve 1a. e. Turn off pumpout compressor. f. Close valves 1b, 3, and 4. g. Turn off pumpout condenser water.
Transfer All Refrigerant to Cooler/Compressor Vessel 1. Push refrigerant into the cooler vessel. a. Valve positions: Valve 1a 1b 2 3 4 C Condition 5 8 C C 11 12 13 14 C C C b. Turn off machine water pumps and pumpout condenser water. c. Turn on pumpout compressor to push refrigerant out of the condenser. d. When all liquid is out of the condenser, close cooler isolation valve 11. e. Turn off the pumpout compressor. 2. Evacuate gas from the condenser vessel. a.
c. Turn on pumpout condenser water. d. Run the pumpout until the compressor reaches 18 in. Hg vac (40 kPa abs.). Monitor pressure at the LID and refrigerant gages. e. Close valve 1b. f. Turn off pumpout compressor. g. Close valves 1a, 2, and 5. Valve Condition 1a 1b 2 3 4 5 8 11 12 13 14 C C C C C C C C C C C h. Turn off pumpout condenser water. i. Proceed to Pumpdown test on the LID to turn off machine water pumps and lockout machine compressor.
Return Refrigerant to Normal Operating Conditions 1. Be sure that the vessel that was opened has been evacuated. 2. Access the Control Test Terminate Lockout table to view vessel pressures and turn on machine water pumps. 3. Open valves 1a, 1b, and 3. Valve 1a 1b 2 3 C Condition 4 5 8 11 12 13 14 C C C C C C C 4. Crack open valve 5, gradually increasing pressure in the evacuated vessel to 68 psig (469 kPa), for HCFC-22, 35 psig (141 kPa) for HFC-134a.
8. Close valves 1a, 1b, 3, and 5. 9. Open isolation valves 12, 13, and 14 (if present). Valve Condition 1a 1b 2 3 4 5 8 C C C C C C C 11 12 13 14 10. Proceed to Terminate Pumpdown Lockout test to turn off water pumps and enable the machine compressor for start-up.
General Maintenance Refrigerant Properties HCFC-22 or HFC-134a is the standard refrigerant in the 19XL. At normal atmospheric pressure, HCFC-22 will boil at –41 F (–40 C) and HFC-134a will boil at –14 F (–25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerants are practically odorless when mixed with air. Both refrigerants are non-combustible at atmospheric pressure.
Adding Refrigerant Follow the procedures described in Trimming Refrigerant Charge section. WARNING ! WARNING Always use the compressor Pumpdown function in the Control Test table to turn on the evaporator pump and lock out the compressor when transferring refrigerant. Liquid refrigerant may flash into a gas and cause possible freeze-up when the machine pressure is below 65 psig (448 kPa), for HCFC-22, 30 psig (207 kPa) for HFC-134a.
Refrigerant Leak Testing Because HCFC-22 and HFC-134a are above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the machine. Use an electronic, halide leak detector, soap bubble solution, or ultra-sonic leak detector. Be sure that the room is well ventilated and free from concentration of refrigerant to keep false readings to a minimum. Before making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.
WARNING ! WARNING HCFC-22 and HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, neither refrigerant should not be allowed to be present with high concentrations of air or oxygen above atmospheric pressures, as the mixture can undergo combustion. Refrigerant Tracer Use an environmentally acceptable refrigerant as a tracer for leak test procedures.
5. Close the charging valve on the machine. Remove the copper tube if no longer required. Repair the Leak, Retest, and Apply Standing Vacuum Test After pressurizing the machine, test for leaks with an electronic, halide leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the machine back to atmospheric pressure, repair any leaks found, and retest. After retesting and finding no leaks, apply a standing vacuum test, and then dehydrate the machine.
Checking the Auxiliary Switch on Guide Vane Actuator The auxiliary switch used to activate the oil reclaim system solenoids should move to the OPEN position when the actuator is 70 degrees open. (At this point the guide vanes should be 30 degrees open.
Weekly Maintenance Check the Lubrication System Mark the oil level on the reservoir sight glass, and observe the level each week while the machine is shut down. If the level goes below the lower sight glass, the oil reclaim system will need to be checked for proper operation. If additional oil is required, add it through the oil drain charging valve (Figure 2A or Figure 2B). A pump is required for adding oil against refrigerant pressure. The oil charge is approximately 8 gallons (30 L).
Scheduled Maintenance Establish a regular maintenance schedule based on the actual machine requirements such as machine load, run hours, and water quality. The time intervals listed in this section are offered as guides to service only. Service Ontime The LID will display a SERVICE ONTIME value on the Status01 table. This value should be reset to zero by the service person or the operator each time major service work is completed so that time between service can be viewed.
Check Safety and Operating Controls Monthly To ensure machine protection, the Control Test Automated Test should be done at least once per month. See Table 3 for safety control settings. See Table 8 for Control Test functions. Changing Oil Filter Change the oil filter on a yearly basis or when the machine is opened for repairs. The 19XL has an isolatable oil filter so that the filter may be changed with the refrigerant remaining in the machine. Use the following procedure: 1.
CAUTION ! CAUTION The oil filter housing is at a high pressure. Relieve this pressure slowly. 6. Once all oil has been drained, place some rags or absorbent material under the oil filter housing to catch any drips once the filter is opened. Remove the 4 bolts from the end of the filter housing and remove the filter cover. 7. Remove the filter retainer by unscrewing the retainer nut. The filter may now be removed and disposed of properly. 8. Replace the old filter with a new filter.
Oil Specification If oil is to be added, it must meet the following Carrier specifications: • Oil type for HCFC-22 Machines only... Alkyl-benzene-based synthetic compressor oil specifically formatted for use in HCFC-22 gear-driven machines ISO Viscosity Grade ..................................................................................................86 • Oil Type for units using R-134a............
4. When the machine pressure is 5 psi (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Figure 2A or Figure 2B). Slowly open the valve against refrigerant pressure. 5. Change the oil filter at this time. See Changing Oil Filter section. 6. Change the refrigerant filter at this time, see the next section, Refrigerant Filter. 7. Charge the machine with oil. Charge until the oil level is equal to the oil level marked in Step 2.
Oil Reclaim Filters The oil reclaim system has a strainer on the eductor suction line and a filter on the cooler scavaging line. Replace these filters once per year, or more often if filter condition indicates a need for more frequent replacement. Change these filters by transferring the refrigerant charge to a storage vessel or the condenser. Inspect Refrigerant Float System Perform inspection every 5 years or when the condenser is opened for service.
As a minimum, the following maintenance is required. 1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt, scale, leakage, etc. 2. If corrosion or foreign material is found, do not attempt to repair or recondition. Replace the valve. 3.
symptom appears, contact an experienced and responsible service organization for assistance. Inspect the Heat Exchanger Tubes Cooler Inspect and clean the cooler tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes. Upon inspection, the tube condition will determine the scheduled frequency for cleaning, and will indicate whether water treatment is adequate in the chilled water/brine circuit.
leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes may be dirty, or water flow may be incorrect. Because HCFC-22 and HFC134-a are high-pressure refrigerants, air usually does not enter the machine, rather, the refrigerant leaks out. During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes.
CAUTION ! CAUTION Machine must be dehydrated after repair of water leaks. See Machine Dehydration section. Water Treatment Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program.
Inspect the Starting Equipment Before working on any starter, shut off the machine, and open all disconnects supplying power to the starter. WARNING ! WARNING The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter. WARNING ! WARNING Never open isolating knife switches while equipment is operating. Electrical arcing can cause serious injury.
CAUTION ! CAUTION Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures. Check Pressure Transducers Once a year, the pressure transducers should be checked against a pressure gage reading. Check all three transducers: oil pressure, condenser pressure, cooler pressure. Note the evaporator and condenser pressure readings on the Status01 table on the LID. Attach an accurate set of refrigeration gages to the cooler and condenser Schrader fittings.
Optional Pumpout Compressor Oil Charge Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows: ISO Viscosity........................................................68 Carrier Part Number ............................. PP23BZ103 The total oil charge, 4.5 pints (2.6 L), consists of 3.5 pints (2.0 L) for the compressor and one additional pint (0.6 L) for the oil separator.
Optional Pumpout Safety Control Settings (Figure 40) The optional pumpout system high-pressure switch should open at 220 ± 5 psig (1517 ± 34 kPa) and should reset automatically on pressure drop to 190 psig (1310 kPa) for HCFC-22 machines. For machines using HFC-134a, the switch opens at 161 psig (1110 kPa) and closes at 130 psig (896 kPa). Check the switch setting by operating the pumpout compressor and slowly throttling the pumpout condenser water.
Troubleshooting Guide Overview The PIC has many features to aid the operator and the technician in troubleshooting a 19XL machine. • By using the LID display, the chiller actual operating conditions can be viewed while the unit is running. • When an alarm occurs, the default LID screen will freeze at the time of alarm. The freeze enables the operator to view the machine conditions at the time of alarm. The Status tables will still show the current information.
Checking the Display Messages The first area to check when troubleshooting the 19XL is the LID display. If the alarm light is flashing, check the primary and secondary message lines on the LID default screen (Figure 13). These messages will indicate where the fault is occurring. The Alarm History table on the LID Service menu will also carry an alarm message to further expand on this alarm. For a complete listing of messages, see Table 10.
a digital ohmmeter. The resistance and corresponding temperature is listed in Table 11A or Table 11B. Check the resistance of both wires to ground. This resistance should be infinite. Voltage Drop Using a digital voltmeter, the voltage drop across any energized sensor can be measured while the control is energized. Table 11A or Table 11B lists the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor).
See Figure 8 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconnected by unlatching the connector. These connectors allow only one-way connection to the sensor. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads. Dual Temperature Sensors There are 2 sensors each on the bearing and motor temperature sensors for servicing convenience.
faulty, check the supply voltage. It should be 5 vdc ± .5 v. If the supply voltage is correct, the transducer should be recalibrated or replaced. IMPORTANT: Whenever the oil pressure or the cooler pressure transducer is calibrated, the other sensor should be calibrated to prevent problems with oil differential pressure readings. Calibration can be checked by comparing the pressure readings from the transducer against an accurate refrigeration gage.
If the transducer value is not within the calibration range, the transducer will return to the original reading. If the LID pressure value is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35. For example, the condenser transducer voltage input is measured at PSIO terminals J7-1 and J7-2.
The PIC will not allow calibration if the transducer is too far out of calibration. A new transducer must be installed and recalibrated. Transducer Replacement Since the transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel. Disconnect the transducer wiring by pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do not pull on the transducer wires.
Control Algorithms Checkout Procedure In the LID Service menu, one of the tables is Control Algorithm Status. This table contains 4 maintenance tables which may be viewed in order to see how the particular control algorithm is operating.
Control Test The Control Test feature can check all of the thermistor temperature sensors, including those on the Options modules, pressure transducers, pumps and their associated flow switches, the guide vane actuator, and other control outputs, such as hot gas bypass. The tests can help to determine whether a switch is defective, or a pump relay is not operating, among other useful troubleshooting tests.
Click here for Table 10C — In Recycle Shutdown Click here for Table 10D — Pre-Start Alerts Click here for Table 10E — Normal or Auto.
Click here for Table 10I — Normal Run Overrides Active (Alerts) Click here for Table 10J — Out-of-Range Sensor Failures Click here for Table 10K — Machine Protect Limit Faults Click here for Table 10L — Machine Alerts Click here for Table 10M — Spare Sensor Alert Messages Click here for Table 10N — Other Problems/Malfunctions
Click here for Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop Click here for Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop Control Modules CAUTION ! CAUTION Turn controller power off before servicing controls. This ensures safety and prevents damage to controller.
Red Led If the LED is blinking continuously at a 2-second rate, it is indicating proper operation. If it is lit continuously it indicates a problem requiring replacement of the module. Off continuously indicates that the power should be checked. If the red LED blinks 3 times per second, a software error has been discovered and the module must be replaced. If there is no input power, check fuses and the circuit breaker.
PSIO Module Green LED closest to communications connection — Communication with SMM and 8-input module; must blink continuously. Other Green LED — Communication with LID; must blink every 3 to 5 seconds. 8-Input Modules and SMM Green LED — Communication with PSIO module; will blink continuously.
Notes on Module Operation 1. The machine operator monitors and modifies configurations in the microprocessor through the 4 softkeys and the LID. Communication with the LID and the PSIO is accomplished through the CCN bus. The communication between the PSIO, SMM, and both 8-input modules is accomplished through the sensor bus, which is a 3-wire cable. On sensor bus terminal strips, Terminal 1 of PSIO module is connected to Terminal 1 of each of the other modules.
If all modules indicate communications failure, check communications plug on the PSIO module for proper seating. Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, replace the PSIO module. If only one 8-input module or SMM indicates communication failure, check the communications plug on that module. If a good connection is assured and the condition persists, replace the module.
Click here for Figure 41 — PSIO Module Address Selector Switch Locations and LED Locations Click here for Figure 42 — LID Module (Rear View) and LED Locations Processor Module (PSIO) (Figure 43) Inputs Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines which terminals are normally used. Always refer to individual unit wiring for terminal numbers. Outputs Output is 20 vdc.
Starter Management Module (SMM) (Figure 44) Inputs Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. Application of the machine determines which terminals are used. Always refer to the individual unit wiring diagram for terminal numbers. Outputs Outputs are 24 vdc and wired to strip J1. There are 2 terminals used per output.
Options Modules (8-Input) The options modules are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, and demand limit inputs. Each option module contains 8 inputs, each input meant for a specific duty. See the wiring diagram for exact module wire terminations. Inputs for each of the options modules available include the following: Option Module 1 4 to 20 mA Auto. Demand Reset 4 to 20 mA Auto.
Terminal block connections are provided on the options modules. All sensor inputs are field wired and installed. Options module number 1 can be factory or field-installed. Options module 2 is shipped separately and must be field installed. For installation, refer to the unit or field wiring diagrams. Be sure to address the module for the proper module number (Figure 45) and to configure the chiller for each feature being used.
Installation 1. Verify if the existing PSIO module is defective, by using the procedure described in the Troubleshooting Guide section, and Control Modules section. Do not select the Attach to Network Device table if the LID displays communication failure. 2. Data regarding the PSIO configuration should have been recorded and saved. This data will have to be reconfigured into the LID. If this data is not available, follow the procedures described in the Set Up Machine Control Configuration section.
6. Mount the new module in the unit control box using a long-shaft Phillips screwdriver and the screw saved in Step 4 above. Make sure that the green grounding wire is reinstalled along with the mounting screw. 7. Connect the LID communication wires (CCN bus) and the power wires. If CCN wiring has been attached to the CCN bus, disconnect the wires. Attach the sensor bus plug and the input and output plugs. 8. Carefully check all wiring connections before restoring power. 9.
14. Restore chiller to normal operation, calibrate motor amps. Solid-State Starters Troubleshooting guides and information pertaining to the operation of the solid-state starter may be found in Figure 46, Figure 47, Figure 48, Figure 49, Figure 50, Figure 51, Figure 52, Table 12, and Table 13. Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables.
IMPORTANT: Before performing the SCR check below, remove power from the starter and disconnect the motor terminals T1, T2, and T3. 1. Connect ohmmeter across terminals L1 and T1. Resistance reading should be greater than 50,000 ohms. 2. If reading is less than 50,000 ohms, remove connecting bus heatsink between SCR3 and SCR6 and check anode to cathode of SCR3 and SCR6 separately to determine which device is defective. See Figure 46. Replace defective device and retest controller. 3.
CAUTION ! CAUTION Damage to the starter may result if wires are reversed. If problem is still not resolved, consult the starter manufacturer for servicing. Testing Silicon Control Rectifiers (SCRs) in Cutler-Hammer® Solid-State Starters To check for a shorted SCR refer to Steps 1-3 and Figure 47, Figure 48, and Figure 49. Note: Do not megger (high voltage insulation test) the starter. 1. Connect ohmmeter across terminals L1 and T1. Check the resistance reading.
4. Connect the T1, T2, and T3 terminals on the starter to the motor. 5. Disconnect one of the wires to the shunt trip contact on the starter. This wire is disconnected to prevent the shorted SCR detection from operating the disconnect device while this test is being performed. 6. Close the disconnect breaker. Check the voltage from the starter line terminal to load terminal on each phase. The measured voltage should be approximately 0.58 times the system line-to-line voltage.
If one of the voltages is higher than 2 v, but the voltages of the 3 power poles are approximately equal, the starter is probably still in current limit. If the voltage is higher than 2 v on only 1 or 2 power poles, not all SCRs are firing properly. Make sure the gate lead connections are tight.
System Ready (SYST RDY) — This light-emitting diode (LED) provides a visual indication that the EPR is functioning. Trip Time Potentiometer — The Trip Time potentiometer has 50 selectable overload trip classes ranging from 1 to 50 seconds. Reset Time Potentiometer — The Reset Time potentiometer has 5 to 120 minutes of motor cooling reset. Full Load Amperes (FLA) — The FLA potentiometer is adjustable from 1 to 1,500 amps, based on overload frame size.
light and the fault indicator (FLT) is a flashing red light, the a motor overload trip is approaching. When the FLT LED is a solid red light and the SYST RDY LED is a flashing green light, a motor overload trip has occurred. When the FLT LED is a solid red light and the SYST RDY LED is a solid green light, the overload has tripped because of a phase unbalance.
Click here for Table 13 — Cutler-Hammer® Solid-State Starter Troubleshooting Guide Physical Data Table 14, Table 15, Table 16, Table 17, Table 18, Table 19, Figure 53, Figure 54, Figure 55, Figure 56, Figure 57, and Figure 58 provide additional information regarding compressor fits and clearances, physical and electrical data, and wiring schematics for operator convenience during troubleshooting.
Click here for Table 17 — Compressor/Motor Weights Click here for Table 18 — Waterbox Cover Weights Click here for Table 19 — Optional Pumpout System Electrical Data Click here for Figure 53 — Compressor Fits and Clearances Click here for Figure 54 — Compressor Fits and Clearances (continued) Click here for Figure 55 — Compressor Fits and Clearances (continued)
Click here for Figure 56 — Electronic PIC Controls Wiring Schematic Click here for Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic Click here for Figure 58 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic
Table 1 — Major PIC Components and Panel Locations* Pic Component Panel Location Processor Sensor Input/Output Module (PSIO) Starter Management Module (SMM) Local Interface Device (LID) 6-Pack Relay Board 8-Input Modules (Optional) Oil Heater Contactor (1C) Oil Pump Contactor (2C) Hot Gas Bypass Relay (3C) (Optional) Control Transformers (T1-T4) Control and Oil Heater Voltage Selector (S1) Temperature Sensors Pressure Transducers Control Center Starter Cabinet Control Center Control Center Control Center
Table 2 — LID Screens Notes: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be configured in English or SI units, as required, through the LID configuration screen. 3. Data appearing in the Reference Point Names column is used for CCN operations only. 4.
Table 2, Example 1 — Status01 Display Screen (Continued) Description Range Entering Chilled Water Leaving Chilled Water Entering Condenser Water Leaving Condenser Water Evaporator Refrig Temp Evaporator Pressure Condenser Refrig Temp Condenser Pressure Discharge Temperature Bearing Temperature Motor Winding Temp Oil Sump Temperature Oil Pressure Transducer Oil Pressure Line Voltage: Percent Actual *Remote Contacts Input Total Compressor Starts Starts in 12 Hours Compressor Ontime *Service Ontime *Compress
Example 2 — Status02 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press STATUS. 3. Scroll down to highlight STATUS02. 4. Press SELECT.
Example 3 — Status03 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press STATUS. 3. Scroll down to highlight STATUS03. 4. Press SELECT.
Example 4 — Setpoint Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SETPOINT. Table 2, Example 4 — Setpoint Display Screen Description Configurable Range Units Reference Point Name Default Value Base Demand Limit LCW Setpoint ECW Setpoint ICE BUILD Setpoint 40-100 20-120 (–6.7-48.9) 20-120 (–6.7-48.9) 20- 60 (–6.7-15.6) % DEG F (DEG C) DEG F (DEG C) DEG F (DEG C) DLM lcw sp ecw sp ice sp 100 50.0 (10.0) 60.0 (15.6) 40.0 ( 4.
Example 5 — Configuration (Config) Display Screen To access this display from the LID default screen: 1. 2. 3. 4. 5. 6. Press MENU. Press SERVICE. Scroll down to highlight EQUIPMENT CONFIGURATION. Press SELECT. Scroll down to highlight CONFIG. Press SELECT.
Example 6 — Lead/Lag Configuration Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT CONFIGURATION. 4. Press SELECT. 5. Scroll down to highlight Lead/Lag. 6. Press SELECT.
Example 7 — Service1 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT. 5. Scroll down to highlight SERVICE1. 6. Press SELECT.
Table 2, Example 7 — Service1 Display Screen (Continued) Description Surge/HGBP Delta P2 Full Load Points (T2/P2) Surge/HGBP Deadband Surge Delta Percent Amps Surge Time Period Demand Limit Source Select: Amps=0, Load=1 Amps Correction Factor Motor Rated Load Amps Motor Rated Line Voltage Meter Rated Line KW Line Frequency Select: 0=60 Hz, 1=50 Hz Compr Starter Type Condenser Freeze Point Soft Stop Amps Threshold Units Reference Point Name Default Value [30-170 (207-1172)] PSI (kPa) hgb dp2 170 (1172
Example 8 — Service2 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT. 5. Scroll down to highlight SERVICE2. 6. Press SELECT.
Table 2, Example 8 — Service2 Display Screen (Continued) Description OPTIONS BOARD 2 20 mA POWER CONFIGURATION External = 0, Internal = 1 SPARE 1 20 mA Power Source SPARE 2 20 mA Power Source SPARE ALERT ENABLE Disable = 0, Low = 1, High = 2 Temp = Alert Threshold Spare Temp 4 Enable Spare Temp 4 Alert Spare Temp 5 Enable Spare Temp 5 Alert Spare Temp 6 Enable Spare Temp 6 Alert Spare Temp 7 Enable Spare Temp 7 Alert Spare Temp 8 Enable Spare Temp 8 Alert Spare Temp 9 Enable Spare Temp 9 Alert Configurable
Example 9 — Service3 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT. 5. Scroll down to highlight SERVICE3. Table 2, Example 9 — Service3 Display Screen Description Configurable Range Proportional Inc Band Proportional Dec Band Proportional ECW Gain Guide Vane Travel Limit 2-10 2-10 1-3 30-100 Units % Reference Point Name gv gv gv gv inc de ecw lim Default Value 6.5 6.0 2.
Example 10 — Maintenance (Maint01) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT01.
Example 11 — Maintenance (Maint02) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT02. 6. Press SELECT.
Example 12 — Maintenance (Maint03) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT03. 6. Press SELECT.
Example 13 — Maintenance (Maint04) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT04. 6. Press SELECT.
Table 3 — Protective Safety Limits and Control Settings Monitored Parameter Limit Applicable Comments Temperature Sensors Out Of Range –40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds Pressure Transducers Out Of Range 0.08 to 0.98 Voltage Ratio Must be outside range for 2 seconds. Ratio = Input Voltage ÷ Voltage Reference Compressor Discharge Temperature >220 F (104.4 C) Preset, alert setting configurable Motor Winding Temperature >220 F (104.
Table 3 — Protective Safety Limits and Control Settings (Continued) Monitored Parameter Limit Applicable Comments Starter Acceleration Time (Determined by inrush current going below 100% compressor motor load) >45 seconds For machines with reduced voltage mechanical and solid-state starters >10 seconds For machines with full voltage starters (Configured on Service1 table) Starter Transition >75 seconds Reduced voltage starters only CONDENSER FREEZE POINT configured in Service01 table with a defaul
Table 4 — Capacity Overrides First Stage Setpoint Override Capacity Control High Condenser Pressure View/ Modify Default Value on LID Screen HCFC-22 Equip>195 psig ment Service1 (1345 kPa) Equip- Configurable Range HFC-134a 125 psig (862 kPa) >200 F High Motor ment (93.3 C) Temperature Service1 Equip<3° F (1.6° C) Low ment (Above Trippoint) Refrigerant Temperature Service1 (Refrigerant Override Delta Temperature) High Compressor Lift (Surge Prevention) EquipHCFC-22 ment Service1 Min: T1 — 1.5° F (0.
Table 4 — Capacity Overrides (Continued) Second Stage Setpoint Override Termination Configurable Range Value Value 40 to 100% >5% of Set Point 2% Lower Than Set Point First Stage Setpoint Override Capacity Control View/ Modify Default Value on LID Screen 100% Motor Load Status01 — Active Demand Limit
Table 5A — HCFC-22 Pressure – Temperature (F) Temperature (F) Pressure (psi) Absolute Gage -50 -48 -46 -44 -42 11.67 12.34 13.00 13.71 14.45 6.154* 4.829* 3.445* 2.002* 0.498* -40 -38 -36 -34 -32 15.22 16.02 16.86 17.73 18.63 -30 -28 -26 -24 -22 Temperature (F) Pressure (psi) Absolute Gage 20 22 24 26 28 57.73 59.97 62.27 64.64 67.08 43.03 45.27 47.58 49.95 52.39 0.526 1.328 2.163 3.032 3.937 30 32 34 36 38 69.59 72.17 74.82 77.54 80.34 19.57 20.55 21.56 22.62 23.71 4.877 5.853 6.868 7.
Table 5B — HCFC-22 Pressure – Temperature (C) Temperature (C) Pressure (kPa) Absolute Gage -18 -17 -16 -15 264 274 284 296 163 173 183 195 -14 -13 -12 -11 -10 307 318 330 342 354 -9 -8 -7 -6 -5 Temperature (C) Pressure (kPa) Absolute Gage 11 12 13 14 15 701 723 744 766 789 600 622 643 665 688 206 217 229 241 253 16 17 18 19 20 812 836 860 885 910 367 380 393 407 421 266 279 292 306 320 21 22 23 24 25 -4 -3 -2 -1 0 436 451 466 482 498 335 350 365 381 397 1 2 3 4 5 514 531 548 566 584
Table 5C — HFC-134a Pressure – Temperature (F) Temperature, F Pressure (psig) 0 2 4 6 8 6.50 7.52 8.60 9.66 10.79 10 12 14 16 18 11.96 13.17 14.42 15.72 17.06 20 22 24 26 28 18.45 19.88 21.37 22.90 24.48 30 32 34 36 38 26.11 27.80 29.53 31.32 33.17 40 42 44 46 48 35.08 37.04 39.06 41.14 43.28 50 52 54 56 58 45.48 47.74 50.07 52.47 54.93 60 62 64 66 68 57.46 60.06 62.73 65.47 68.
Table 5C — HFC-134a Pressure – Temperature (F) (Continued) Temperature, F Pressure (psig) 70 72 74 76 78 71.18 74.14 77.18 80.30 83.49 80 82 84 86 88 86.17 90.13 93.57 97.09 100.70 90 92 94 96 98 104.40 108.18 112.06 116.02 120.08 100 102 104 106 108 124.23 128.47 132.81 137.25 141.79 110 112 114 116 118 146.43 151.17 156.01 160.96 166.01 120 122 124 126 128 171.17 176.45 181.83 187.32 192.93 130 132 134 136 138 140 198.66 204.50 210.47 216.55 222.76 229.
Table 5D — HFC-134a Pressure – Temperature (C) Temperature, C Pressure Gage (kPa) -18.0 -16.7 -15.6 -14.4 -13.3 44.8 51.9 59.3 66.6 74.4 -12.2 -11.1 -10.0 -8.9 -7.8 82.5 90.8 99.4 108.0 118.0 -6.7 -5.6 -4.4 -3.3 -2.2 127.0 137.0 147.0 158.0 169.0 -1.1 0.0 1.1 2.2 3.3 180.0 192.0 204.0 216.0 229.0 4.4 5.0 5.6 6.1 6.7 242.0 248.0 255.0 261.0 269.0 7.2 7.8 8.3 8.9 9.4 276.0 284.0 290.0 298.0 305.0 10.0 11.1 12.2 13.3 14.4 314.0 329.0 345.0 362.0 379.
Table 5D — HFC-134a Pressure – Temperature (C) (Continued) Temperature, C Pressure Gage (kPa) 15.6 16.7 17.8 18.9 20.0 396.0 414.0 433.0 451.0 471.0 21.1 22.2 23.3 24.4 25.6 491.0 511.0 532.0 554.0 576.0 26.7 27.8 28.9 30.0 31.1 598.0 621.0 645.0 669.0 694.0 32.2 33.3 34.4 35.6 36.7 720.0 746.0 773.0 800.0 828.0 37.8 38.9 40.0 41.1 42.2 857.0 886.0 916.0 946.0 978.0 43.3 44.4 45.6 46.7 47.8 1010.0 1042.0 1076.0 1110.0 1145.0 48.9 50.0 51.1 52.2 53.3 1180.0 1217.0 1254.0 1292.0 1330.0 54.
Table 6 — Potentiometer Adjustment Adjustment Range Dial Function Factory Setting Minimum (CCW) Maximum (CW) Starting Current 100% 400% Sets initial starting current level. 100% Ramp Time (Adjustable Current Ramp) 2 seconds 30 seconds Sets time during which current ramps from the initial starting level to the maximum possible current limit setting. 15 seconds Current Limit 100% 400% Sets maximum starting current. 250% Pulse Start 0 (Off) 2 seconds Sets duration of 400% current pulse.
Table 7 — Amps Correction Factors for 19XL Motors Motor Code Volt/ Hz CD CE CL CM CN CP CQ CR 200/60 208/60 220/60 230/60 3 5 2 4 6 8 2 4 3 4 2 3 2 2 3 5 3 4 1 2 2 2 1 2 2 2 1 2 2 2 1 2 240/60 360/60 380/60 400/60 4 4 6 8 4 2 4 4 3 2 4 4 8 2 5 5 2 1 3 3 2 1 2 2 2 1 2 3 2 1 2 4 440/60 460/60 480/60 550/60 2 3 4 3 2 2 3 2 1 2 3 1 1 2 3 2 1 2 3 3 1 2 3 2 3 5 7 2 4 6 8 2 575/60 600/60 3300/60 2400/60 4 6 4 3 2 4 1 3 2 3 2 2 3 4 3 3 4 6 3 2 3 5 3 2 3 4 2 3 3 4 2 3 4160
Table 8 — Control Test Menu Functions Tests To Be Performed Devices Tested 1. Automated Tests* Operates the second through seventh tests 2. PSIO Thermistors Entering chilled water Leaving chilled water Entering condenser water Leaving condenser water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature 3.
Table 8 — Control Test Menu Functions (Continued) Tests To Be Performed Devices Tested 7. Discrete Outputs All outputs or individual outputs may be energized: Hot gas bypass relay Oil heater relay Motor cooling relay Tower fan relay Alarm relay 8.
Table 9 — Refrigerant (HCFC-22 or HFC-134a) Charges 19XL Total Refrigerant Charge Cooler Size Design I Machine Design II Machine lb kg lb kg 40 1420 640 1270 1576 41 1490 680 1340 1607 42 1550 700 1400 1635 43 1600 730 1450 1658 50 1850 840 1650 1748 51 1900 860 1700 1771 52 1980 900 1780 1807 53 2050 930 1850 1839 55 — — 2330 1057 56 — — 2400 1089 57 — — 2510 1139 58 — — 2610 1184 Notes: 1.
Legend For Table 10, A - N 1CR AUX — Compressor Start Contact OILPD — Oil Pressure CA P — Compressor Current OILT — Oil Sump Temperature CDFL — Condenser Water Flow PIC — Product Integrated Control CHIL S S — Chiller Start/Stop PRS TRIP — Pressure Trip Contact CMPD — Discharge Temperature PSIO — Processor Sensor Input/Output Module CRP — Condenser Pressure RLA — Rated Load Amps ERT — Evaporator Refrigerant Temperature RUN AUX — Compressor Run Contact EVFL — Chille
Table 10B — Timing Out or Timed Out Primary Message Secondary Message Probable Cause/Remedy Ready To Start In XX Min Unoccupied Mode Time schedule for PIC is unoccupied. Machines will start only when occupied. Ready To Start In XX Min Remote Contacts Open Remote contacts have stopped machine. Close contacts to start. Ready To Start In XX Min Stop Command In Effect Chiller START/STOP on Status01 manually forced to stop. Release value to start.
Table 10C — In Recycle Shutdown Primary Message Secondary Message Probable Cause/Remedy Recycle Restart Pending Occupied Mode Unit in recycle mode, chilled water temperature is not high enough to start. Recycle Restart Pending Remote Contact Closed Unit in recycle mode, chilled water temperature is not high enough to start. Recycle Restart Pending Start Command In Effect Chiller START/STOP on Status01 manually forced to start, chill water temperature is not high enough to start.
Table 10D — Prestart Alerts: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary. Alarm Message/Primary Cause Additional Cause/ Remedy Starts Limit Exceeded STARTS EXCESSIVE Compressor Starts (8 in 12 hours) Depress the RESET softkey if additional start is required. Reassess start-up requirements. Prestart Alert High Motor Temperature MTRW VALUE exceeded limit of [LIMIT]*. Check motor temperature. Check motor cooling line for proper operation.
Table 10E — Normal or Auto.-Restart Primary Message Secondary Message Probable Cause/Remedy Startup in Progress Occupied Mode Machine starting. Time schedule is occupied. Startup in Progress Remote Contact Closed Machine starting. Remote contacts are closed. Start Command In Effect Machine starting. Chiller START/STOP on Status01 manually forced to start. AutoRestart in Progress Occupied Mode Machine starting. Time schedule is occupied.
Table 10F — Start-Up Failures: This is an alarm condition. A manual reset is required to clear. Primary Message Secondary Message Alarm Message/Primary Cause Additional Cause/Remedy Failure To Start Low Oil Pressure OILPD [VALUE] exceeded limit of [LIMIT]*. Check oil pump system. Check for closed oil supply valves. Check oil filter. Check for low oil temperature. Check transducer accuracy. Oil Press Sensor Fault OILPD [VALUE] exceeded limit of [LIMIT]*. Check oil pressure sensor.
Table 10F — Start-Up Failures: This is an alarm condition. A manual reset is required to clear. (Continued) Primary Message Failure To Start Failure To Start Failure To Start Failure To Start Failure To Start Secondary Message Alarm Message/Primary Cause Starter Transition Fault RUN AUX Starter Transition Fault: Check 1CR/1M/Interlock mechanism. Check starter for proper operation. Run contact failed to close. 1CR AUX Contact Fault 1CR AUX Starter Contact Fault: Check 1CR/1M aux. contacts.
Table 10G — Compressor Jumpstart and Refrigerant Protection Primary Message Secondary Message Alarm Message/Primary Cause Unit Should Be Stopped CA P Emergency: Compressor running without control authorization. Compressor is running with more than 10% RLA and control is trying to shut it down. Throw power off to compressor if unable to stop. Determine cause before repowering. Evap Press/Temp Too Low ERT Emergency: Freeze-up prevention. Determine cause.
Table 10H — Normal Run with Reset, Temperature, or Demand Primary Message Secondary Message Probable Cause/Remedy Running — Reset Active 4-20MA Signal Running — Reset Active Remote Sensor Control Running — Reset Active CHW Temp Difference Running — Temp Control Leaving Chilled Water Default method of temperature control. Running — Temp Control Entering Chilled Water ECW control activated on Config table. Running — Temp Control Temperature Ramp Loading Ramp loading in effect.
Table 10I — Normal Run Overrides Active (Alerts) Alarm Message/Primary Cause Primary Message Secondary Message Run Capacity Limited High Condenser Pressure CRP [VALUE]* exceeded limit of [LIMIT]*. Condenser pressure override. Run Capacity Limited High Motor Temperature MTRW [VALUE]* exceeded limit of [LIMIT]*. Motor temperature override. Run Capacity Limited Low Evap Refrig Temp ERT [VALUE]* exceeded limit of [LIMIT]*. Check refrigerant charge level.
Table 10J — Out-of-Range Sensor Failures Primary Message Secondary Message Alarm Message/Primary Cause Sensor Fault Leaving CHW Temperature Sensor Fault: Check leaving CHW sensor. Sensor Fault Entering CHW Temperature Sensor Fault: Check entering CHW sensor. Sensor Fault Sensor Fault Sensor Fault Sensor Fault Sensor Fault Sensor Fault Sensor Fault Condenser Pressure Sensor Fault: Check condenser pressure transducer. Evaporator Pressure Sensor Fault: Check evaporator pressure transducer.
Table 10K — Machine Protect Limit Faults WARNING ! WARNING Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise. Primary Message Secondary Message Alarm Message/ Primary Cause High Discharge Temp CMPD [VALUE] exceeded limit of [LIMIT]*. Check discharge temperature. Check discharge temperature immediately. Check sensor for accuracy; check for proper condenser flow and temperature; check oil reservoir temperature.
Table 10K — Machine Protect Limit Faults (Continued) WARNING ! WARNING Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise. Primary Message Secondary Message Alarm Message/ Primary Cause Protective Limit Power Loss V P Power Loss: Check voltage supply. Low Line Voltage V P [VALUE] exceeded limit of [LIMIT]*. Check voltage supply. High Line Voltage V P [VALUE] exceeded limit of [LIMIT]*. Check voltage supply.
Table 10K — Machine Protect Limit Faults (Continued) WARNING ! WARNING Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise. Primary Message Secondary Message Alarm Message/ Primary Cause CCN Override Stop CHIL S S CCN Override Stop while in LOCAL run mode. CCN has signaled machine to stop. Reset and restart when ready. If the signal was sent by the LID, release the Stop signal on STATUS01 table.
Table 10L — Machine Alerts Primary Message Secondary Message Alarm Message/ Primary Cause Recycle Alert High Amps at Shutdown High Amps at Recycle: Check that guide vanes are closing. Check Check guide vane drive. motor amps correction calibration is correct. Check actuator for proper operation. Sensor Fault Alert Leaving Cond Water Temp Sensor Fault: Check leaving condenser water sensor. Sensor Fault Alert Entering Cond Water Temp Sensor Fault: Check entering condenser water sensor.
Table 10M — Spare Sensor Alert Messages Primary Message Secondary Message Alarm Message/Primary Cause Spare Sensor Alert Common CHWS Sensor Sensor Fault: Check common CHWS sensor. Spare Sensor Alert Common CHWR Sensor Sensor Fault: Check common CHWR sensor. Spare Sensor Alert Remote Reset Sensor Sensor Fault: Check remote reset temperature sensor. Spare Sensor Alert Temp Sensor — Spare 1 Sensor Fault: Check temperature sensor — Spare 1.
Table 10N — Other Problems/Malfunctions Description/ Malfunction Probable Cause/Remedy Chilled Water/Brine Temperature Too High (Machine Running) Chilled water set point set too high. Access set point on LID and verify. Capacity override or excessive cooling load (machine at design capacity). Check LID status messages. Check for outside air infiltration into conditioned space. Condenser temperature too high.
Table 10N — Other Problems/Malfunctions (Continued) Description/ Malfunction Probable Cause/Remedy SMM Communications Failure Check that PSIO communication plugs are connected correctly. Check SMM communication plug. Check for proper SMM power supply. See Control Modules section. High Oil Temperature While Running Check for proper oil level (too much oil). Check that TXV valve is operating properly.
Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop Temperature (F) -25.0 -24.0 -23.0 -22.0 -21.0 -20.0 -19.0 -18.0 -17.0 -16.0 -15.0 -14.0 -13.0 -12.0 -11.0 -10.0 -9.0 -8.0 -7.0 -6.0 -5.0 -4.0 -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 Voltage Drop (V) Resistance (Ohms) 4.821 4.818 4.814 4.806 4.800 4.793 4.786 4.779 4.772 4.764 4.757 4.749 4.740 4.734 4.724 4.715 4.705 4.696 4.688 4.676 4.666 4.657 4.648 4.636 4.
Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop (Continued) Temperature (F) 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 Voltage Drop (V) Resistance (Ohms) 1.822 1.792 1.771 1.748 1.724 1.702 1.676 1.653 1.630 1.607 1.585 1.562 1.538 1.517 1.496 1.474 1.453 1.431 1.408 1.389 1.369 1.348 1.327 1.308 1.291 1.289 1.269 1.250 1.230 1.211 1.192 1.173 1.155 1.
Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop Temperature (C) -40 -39 -38 -37 -36 -35 -34 -33 -32 -31 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 Voltage Drop (V) Resistance (Ohms) 4.896 4.889 4.882 4.874 4.866 4.857 4.848 4.838 4.828 4.817 4.806 4.794 4.782 4.769 4.755 4.740 4.725 4.710 4.693 4.676 4.657 4.639 4.619 4.598 4.577 4.554 4.531 4.507 4.482 4.456 4.428 4.400 4.371 4.341 4.310 4.278 4.245 4.
Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop (Continued) Temperature (C) 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 Voltage Drop (V) 1.594 1.553 1.513 1.474 1.436 1.399 1.363 1.327 1.291 1.258 1.225 1.192 1.160 1.129 1.099 1.069 1.040 1.012 0.984 0.949 0.920 0.892 0.865 0.838 0.813 0.789 0.765 0.743 0.722 0.702 0.683 0.
Table 12 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide Problem Probable Causes Area of Correction AK board phase correct not on. 1. L1 and L3 switch 1. Switch incoming phases L1 and L3 at top of CD1 or phases reversed. 2. Missing phase voltage. 3. Improper line voltage. 2. Check for missing phase voltage. 3. Verify proper line voltage applied against synchronizing CB1. transformer voltage. AK board relay not on. Ribbon cable not properly seated. Check ribbon cable for proper seating.
Table 12 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide (Continued) Problem Probable Causes Area of Correction AK board power applied, run command given, starter at full voltage, but aux LED not lit. AK board not functioning properly. Replace board. 1L boards LEDs lit. Motor terminal voltage phase imbalance exists. Check motor terminal voltages for imbalance between phases. If an imbalance exists, check for loose SCR gate or open SCR gate. Replace phase assembly, if necessary.
Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide Problem Probable Cause Area of Correction CB trips (electrically operated disconnecting means opens) as it is closed. Motor is not connected. Connect motor to starter. Incorrect phase sequence to the starter, 3phase power not connected, or terminal loose. Switch two incoming power leads. The 50 and 51 corresponding motor leads must also be switched to maintain the same motor rotation. Shorted SCR. Perform shorted SCR check.
Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide (Continued) Problem Probable Cause Area of Correction Motor accelerates too quickly. Current limit is too high. Decrease current limit setting counterclockwise. Improper current feedback. Check current calibrator for proper resistance value. Pulse start setting is too long. Decrease pulse start time counterclockwise. Broken current feedback transformer wire. Check for a broken current feedback transformer wire.
Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide (Continued) Problem Probable Cause Area of Correction Overload relay trips when starting. Incorrect heater coils (melting allow). Check heater coil rating. Loose heater coil. Tighten heater coil. Long starting time (high inertia applications may require slow trip overload and oversize starter). Motor and starter thermal capabilities must be evaluated before extending overload trip times. Mechanical problems.
Table 14 — Heat Exchanger Data Vessel Cooler Condenser Heat Exchanger Code Number of Tubes Rigging Weights Vessel Charge Dry Wt.
Table 15 — Additional Data for Marine Waterboxes* Heat Exchanger Frame, Pass English SI Rigging Wt (lb) Water Volume (gal) Rigging Wt (kg) Water Volume (L) Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser Frame 4, 2 Pass 1115 1660 169 151 1506 300 261 193 Frame 4, 1 & 3 Pass 2030 1160 138 101 1922 527 524 384 Frame 5, 2 Pass 1220 1935 188 164 1554 424 331 243 Frame 5, 1 & 3 Pass 2240 1705 175 128 1017 774 663 486 * Add to heat exchanger w
Table 16 — Compressor Weights Weight Component Lb Kg Suction Elbow 1155 1125 Discharge Elbow 1150 1123 Transmission 1730 1331 Suction Housing 1350 1159 Impeller Shroud 1180 1136 Compressor Base 1050 1476 Diffuser 1170 1132 Oil Pump 1150 1168 Miscellaneous 1135 1161 Total Weight (Less Motor) 2660 1207
Table 17 — Compressor/Motor Weights English Motor Size Compressor Weight (lb) SI Stator Weight (lb) Rotor Weight (lb) 60 Hz 50 Hz 60 Hz 50 Hz End Bell Cover (lb) Compressor Weight (lb) Stator Weight (kg) Rotor Weight (kg) 60 Hz 50 Hz 60 Hz 50 Hz End Bell Cover (lb) CD 2660 1153 1213 234 252 250 1208 523 551 106 114 114 CE 2660 1162 1227 237 255 250 1208 528 557 108 116 114 CL 2660 1202 1283 246 270 250 1208 546 582 112 123 114 CM 2660 1225 1308 254
Table 18 — Waterbox Cover Weights* (English (lb)) Heat Exchanger Coolers Condensers Frame 4, Std. Nozzles Frame 4, Flanged Frames, Std.
Table 18 — Waterbox Cover Weights* (SI (kg)) (Continued) Heat Exchanger Coolers Condensers Frame 4, STD. Nozzles Frame 4, Flanged Frames, STD.
Table 19 — Optional Pumpout System Electrical Data Motor Code Condenser Unit Volts-PH-HZ Max RLA LRA 1 19EA47-748 575-3-60 13.8 23.0 4 19EA42-748 200/208-3-60 10.9 63.5 5 19EA44-748 230-3-60 19.5 57.5 6 19EA46-748 400/460-3-50/60 14.7 28.
Figure 1 — 19XL Identification
Figure 2A (Front View) — Typical 19XL Components — Design I (See next page for Rear View)
Figure 2A (Rear View) — Typical 19XL Components — Design I
Figure 2B (Front View) — Typical 19XL Components — Design II (See next page for Rear View)
Figure 2B (Rear View) — Typical 19XL Components — Design II
Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
Figure 4 — Lubrication System
Figure 5 — Cutler-Hammer Solid-State Starter, Internal View
Figure 6 — Benshaw, Inc.
Figure 7 — Typical Starter Front View (Solid-State Starter Shown)
Figure 8 — 19XL Controls and Sensor Locations
Figure 9 — Control Sensors (Temperature)
Figure 10 — Control Sensors (Pressure Transducer, Typical)
Figure 11 — Control Panel (Front View), with Options Module
Figure 12 — Power Panel with Options
Figure 13 — LID Default Screen
Figure 14 — LID Service Screen
Figure 15 — Example of Point Status Screen (Status01)
Figure 16 — 19XL Menu Structure
Figure 17 — 19XL Service Menu Structure
Figure 18 — Example of Time Schedule Operation Screen
Figure 19 — Example of Set Point Screen
Figure 20 — 19XL Hot Gas Bypass/Surge Prevention
Figure 21 — 19XL with Default Metric Settings
Figure 22 — Example of Attach to Network Device Screen
Figure 23 — Example of Holiday Period Screen
A B C — START INITIATED — Prestart checks made; evaporator pump started — Condenser water pump started (5 seconds after A) — Water flows verified (30 seconds to 5 minutes maximum after B). Chilled water temperatures checked against control point. Guide vanes checked for closure. Oil pump started; tower fan control enabled.
Figure 25 — Typical Wet-Bulb Type Vacuum Indicator
Figure 26 — 19XL Leak Test Procedures
Figure 27 — Typical Optional Pumpout System Piping Schematic with Storage Tank
Figure 28 — Typical Optional Pumpout System Piping Schematic without Storage Tank
Figure 29 — Dehydration Cold Trap
Figure 30 — Benshaw, Inc.
Figure 31 — Ramp Up and Starting Torque Potentiometers
Figure 32 — Typical Potentiometer Adjustment
Figure 33 — Typical Cutler-Hammer® Solid-State Starter
Figure 34 — Correct Motor Rotation
Date _______________ REFRIGERATION LOG CARRIER 19XL HERMETIC CENTRIFUGAL REFRIGERATION MACHINE Plant ______________ DATE ______ MACHINE MODEL NO. ______________ COOLER Refrigerant CONDENSOR Water Pressure TIME Press. Temp In Out MACHINE SERIAL NO. _______________ GPM Refrigerant In Out Pressure Press. COMPRESSOR Water Temp Temp In Out GPM REFRIGERANT TYPE ______________ Oil Temp In BEARING TEMP Out Motor FLA ______ Press.
C — Contactor Fu — Fuse, 3 Amps HP — High-Pressure Cutout OL — Compressor Overload T’stat — Internal Thermostat Compressor Terminal Contactor Terminal Overload Terminal Pumpout Unit Terminal Figure 36 — 19XL Pumpout Unit Wiring Schematic
Figure 37 — Optional Pumpout System
Figure 38 — Guide Vane Actuator Linkage
Figure 39 — 19XL Float Valve Designs
Figure 40 — Optional Pumpout System Controls
Figure 41 — PSIO Module Address Selector Switch Locations and LED Locations
Figure 42 — LID Module (Rear View) and LED Locations
Figure 43 — Processor (PSIO) Module
Figure 44 — Starter Management Module (SSM)
Switch Setting Option Module 1 Option Module 2 S1 S2 6 4 7 2 Figure 45 — Options Module
Figure 46 — Typical Benshaw, Inc.
Figure 47 — Resistance Check
Figure 48 — SCR and Power Poles
Figure 49 — Typical Cutler-Hammer® Solid-State Starter (Internal View)
Figure 50 — Cutler-Hammer® Terminal Functions
Figure 51 — Solid-State Starter, General Operation Troubleshooting Guide (Typical)
Figure 52 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical)
Compressor Assembly Torques Torque Item 1* 2 3 4 5 6* 7* Description Oil Heater Grommet Nut Impeller Retaining Bolt Bull Gear Retaining Bolt Motor Terminals (Low Voltage) Demister Bolts Guide Vane Shaft Seal Nut Motor Terminals (High Voltage) – Insulator – Packing Nut – Brass Jam Nut ft-lb N•m 10 44-46 80-85 50 15-19 25 14 60-62 108-115 68 20-26 34 2-4 5 10 2.7-5.4 6.8 13.
Figure 54 — Compressor Fits and Clearances (Continued)
Figure 55 — Compressor Fits and Clearances (Continued)
Legend Carrier Factory Wiring Optional (Factory or Field-Installed) Wiring Figure 56 — Electronic PIC Controls Wiring Schematic (page 1 of 2)
Legend Carrier Factory Wiring Optional (Factory or Field-Installed) Wiring Figure 56 — Electronic PIC Controls Wiring Schematic (page 2 of 2)
Legend Starter Cabinet Wiring Field Wiring Carrier Factory Wiring Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic (page 1 of 2)
Legend Starter Cabinet Wiring Field Wiring Carrier Factory Wiring Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic (page 2 of 2)
Optional features are indicated by bold dotted boxes. Caution: Yellow wires remain energized when main disconnect is off.
Optional features are indicated by bold dotted boxes. Caution: Yellow wires remain energized when main disconnect is off.
INITIAL START-UP CHECKLIST FOR 19XL HERMETIC CENTRIFUGAL LIQUID CHILLER (Remove and use for job file.) MACHINE INFORMATION: NAME JOB NO.
INSPECT WIRING AND RECORD ELECTRICAL DATA: RATINGS: Motor(s) Amps Motor Voltage Line Voltages: Motor Oil Pump Voltage Oil Pump Starter Amps Controls/Oil Heater FIELD-INSTALLED STARTERS ONLY: Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state starters, disconnect leads to motor and megger the leads.
19XL HERMETIC CENTRIFUGAL LIQUID CHILLER CONFIGURATION SETTINGS LOG (Remove and use for job file.) 19XL SET POINT TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT Base Demand Limit 40 to 100 % LCW Setpoint 20 to 120 (–6.7 to 48.9) DEG F (DEG C) 50.0 ECW Setpoint 20 to 120 (–6.7 to 48.9) DEG F (DEG C) 60.0 ICE BUILD Setpoint 20 to 60 (–6.7 to 15.6) DEG F (DEG C) 40.
19XL PIC TIME SCHEDULE CONFIGURATION SHEET Day Flag M T W T F S S H OCCPC01S Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is OCCUPIED 24 hours/day. ICE BUILD 19XL PIC TIME SCHEDULE CONFIGURATION SHEET Day Flag M T W T F S S H OCCPC02S Occupied Time Unoccupied Time Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is UNOCCUPIED 24 hours/day.
19XL PIC CONFIG TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT –30 to 30 (–17 to 17) DEG F (DEG C) 10 (6) Remote Temp (No Reset) –40 to 245 (–40 to 118) DEG F (DEC C) 85 (29) Remote Temp (Full Reset) –40 to 245 (–40 to 118) DEG F (DEG C) 65 (18) Degrees Reset –30 to 30 (–17 to 17) DEG F (DEG C) 10 (6) CHW Temp (No Reset) 0 to 15 (0 to 8) DEG F (DEG C) 10 (6) CHW Temp (Full Reset) 0 to 15 (0 to 8) DEG F (DEG C) 0 (0) Degrees Reset –30 to 30 (–17 to 17) DEG F (DEG C) 5
19XL PIC LEAD/LAG TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT LEAD/LAG SELECT DISABLE =0, LEAD =1, LAG =2, STANDBY =3 0, 1, 2, 3 Load Balance Option Disable/Enable Disable Common Sensor Option Disable/Enable Disable LAG Percent Capacity 25 to 75 LAG Address 1 to 236 LAG START Timer 2 to 60 Min 10 LAG STOP Timer 2 to 60 Min 10 PRESTART FAULT Timer 0 to 30 Min 5 STANDBY Chiller Option Disable/Enable STANDBY Percent Capacity 25 to 75 STANDBY Address 1 to 236 0 %
19XL PIC SERVICE1 TABLE CONFIGURATION SHEET DESCRIPTION Motor Temp Override RANGE UNITS DEFAULT 150 to 200 (66 to 93) DEG F (DEG C) 200 (93) Cond Pressure Override 150 to 245 (1034 to 1639) [90 to 200 (620 to 1379)] Refrig Override Delta T 2 to 5 (1 to 3) psig (kPa) DEG F (DEG C) 195 (1345) [125 (862)] 3 (1.6) Chilled Medium Water/Brine Brine Refrig Trippoint 8 to 40 (–13.
19XL PIC SERVICE1 TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT Motor Rated Load Amps 1 to 9999 AMPS 200 Motor Rated Line Voltage 1 to 9999 VOLTS 460 Meter Rated Line kW 1 to 9999 kW 600 Line Frequency 0=60 Hz/1=50 Hz 0/1 Compressor Starter Type REDUCE/FULL Condenser Freeze Point –20 to 35 (–28.9 to 1.7) DEG F (DEG C) 34 (1.
19XL PIC SERVICE2 TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT RESET 20 mA Power Source 0/1 0 =EXTERNAL, 1 =INTERNAL 0 DEMAND 20 mA Power Source 0/1 0 =EXTERNAL, 1 =INTERNAL 0 CHWS Temp Enable 0 to 2 0 =DISABLE, 1 =HIGH, 2 =LOW 0 CHWS Temp Alert –40 to 245 (–40 to 118) DEG F (DEG C) CHWR Temp Enable 0 to 2 0 =DISABLE, 1 =HIGH, 2 =LOW CHWR Temp Alert –40 to 245 (–40 to 118) DEG F (DEG C) Reset Temp Enable 0 to 2 0 =DISABLE, 1 =HIGH, 2 =LOW Reset Temp Alert –40 to 245
19XL PIC SERVICE3 TABLE CONFIGURATION SHEET DESCRIPTION RANGE UNITS DEFAULT Proportional Inc Band 2 to 10 6.5 Proportional Dec Band 2 to 10 6.0 Proportional ECW Gain 1 to 3 2.
HOLIDAY (HOLIDEF) CONFIGURATION SHEET DESCRIPTION RANGE Holiday Start Month 1 to 12 Start Day 1 to 31 Duration 0 to 99 1 to 12 Start Day 1 to 31 Duration 0 to 99 1 to 12 Start Day 1 to 31 Duration 0 to 99 S VALUE DAYS RANGE Holiday Start Month HOLIDEF UNITS HOLIDAY (HOLIDEF) CONFIGURATION SHEET DESCRIPTION VALUE DAYS RANGE Holiday Start Month S UNITS HOLIDAY (HOLIDEF) CONFIGURATION SHEET DESCRIPTION HOLIDEF HOLIDEF S UNITS DAYS NOTE: There are no HOLIDAYS defined on the
BROADCAST (BRODEFS) CONFIGURATION SHEET DESCRIPTION Activate RANGE UNITS Yes/No DEFAULT No OAT Broadcast Controller Name 8 characters Text Bus Number 0 to 239 Bus #s 0 Element Number 0 to 239 SE #s 0 Controller Name 8 characters Text Bus Number 0 to 239 Bus #s 0 Element Number 0 to 239 SE #s 0 OARH Broadcast Daylight Savings Start Month 1 to 12 4 Day 1 to 31 15 Time 00:00 to 23:59 HH:MM Minutes To Add 1 to 1440 MIN 02:00 60 Daylight Savings Stop Month 1 to 12 10 D