23XL Hermetic Screw Liquid Chillers with HCFC-22 and HFC-134a, 50/60 Hertz PIC II Controls Start-Up, Operation and Maintenance Instructions SAFETY CONSIDERATIONS Screw liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
CONTENTS Page Oil Sump Temperature Control TC (Frame 1 and 2) Chillers Only . . . . . . . . . . . . . . . . . 39 Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 40 Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Spare Safety Alarm Contacts . . . . . . . . . . . . . . . . . . . . 40 Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 40 Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 40 Condenser Freeze Protection.
CONTENTS (cont) Page Operating the Optional Pumpout Unit . . . . . . . . . . . 69 • TO READ REFRIGERANT PRESSURES Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70 • TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL • TRANSFER ALL REFRIGERANT TO CHILLER COOLER VESSEL • RETURN CHILLER TO NORMAL OPERATING CONDITIONS Chillers With Storage Tanks . . . . . . . . . . . . . . . . . . . . .
CONTENTS (cont) INTRODUCTION Page Checking Pressure Transducers. . . . . . . . . . . . . . . . . 77 • COOLER CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION • TRANSDUCER REPLACEMENT Control Algorithms Checkout Procedure . . . . . . . . 78 Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS AND EXPLANATIONS 23XL CHILLER FAMILIARIZATION (Fig.
FRONT VIEW 12 1 1 2 3 4 5 6 7 8 9 10 11 12 2 11 10 9 — — — — — — — — — — — — Power Panel Chiller Visual Controller (CVC) Cooler Refrigerant Isolation Valve ASME Nameplate, Economizer (Hidden) Service Valve Take-Apart Rabbet Fit Connector (Lower) Cooler Temperature Sensor ASME Nameplate, Condenser/Cooler Typical Waterbox Drain Port Cooler Supply/Return End Waterbox Cover Condenser Supply/Return End Waterbox Cover Compressor Nameplate (Hidden) 8 7 6 5 3 4 REAR VIEW 13 14 27 15 26 5 16 10 25
FRONT VIEW 1 2 1 2 3 4 5 6 7 — — — — — — — 8 9 10 11 12 13 14 15 — — — — — — — — 3 4 18 5 17 16 15 14 16 — 17 — 18 — 13 12 11 10 7 8 9 Compressor Nameplate (Hidden) Power Panel Chiller Visual Controller (CVC) ASME Nameplate, Cooler Cooler Vessel Separation Feet Economizer Float Valve Access Cover (Hidden) Refrigerant Charging Valve Economizer Oil Filter Assembly (Hidden) ASME Nameplate, Economizer Typical Waterbox Drain Port Take-Apart Rabbet Fit Connector ASME Nameplate, Condenser/Cooler Cool
Cooler — This vessel (also known as the evaporator) is Relatively cool (typically 65 to 85 F [18 to 29 C]) water flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid. The liquid refrigerant passes through orifices into the FLASC (Flash Subcooler) chamber (Fig. 3 and 4). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid.
(TC frame 1 and 2 chillers), and oil filter. Oil temperature is measured and displayed on the CVC default screen. During shutdown, oil temperature is maintained by the Product Integrated Control II (PIC) II). See Oil Sump Temperature Control section on page 39. NOTE: TD frame 4 chillers do not have an oil heater. Operating oil pressure must be at least 20 psi (138 kPa) for HCFC-22 [7 psi (48.3 kPa) for HFC-134a] and is dependent upon system pressure differential (lift).
HGBP LEGEND — Hot Gas Bypass Refrigerant Liquid Flow Refrigerant Vapor Flow Oil and Refrigerant Liquid Flow Oil and Refrigerant Vapor Flow Oil Flow Fig.
HGBP LEGEND — Hot Gas Bypass Refrigerant Liquid Flow Refrigerant Vapor Flow Oil and Refrigerant Vapor Flow Oil Flow Fig.
Fig. 5 — Screw Compressor Principle Fig. 6 — Slide Valve Position at Unload TO SUCTION PORT Slide Valve Principle — Oil flow to the slide piston is controlled by two solenoid valves. Each solenoid is operated by load and unload signals from the PIC II control. To unload the compressor, the unload solenoid valve is energized and the load solenoid valve is deenergized. This conducts high pressure oil to the cylinder, retracting the capacity rod, and modulating the slide valve toward the open position.
Unit-Mounted Solid-State Starter (Optional) — The 23XL chiller may be equipped with a solid-state, reducedvoltage starter (Fig. 8 and 9). This starter’s primary function is to provide on-off control of the compressor motor. This type of starter reduces the peak starting torque, reduces the motor inrush current, and decreases mechanical shock. This capability is summed up by the phrase “soft starting.” The solid-state starter is available as a 23XL option (factory supplied and installed).
CONTROLS PIC II System Components — The chiller control system is called PIC II (Product Integrated Control II). See Table 2. The PIC II controls the operation of the chiller by monitoring all operating conditions. The PIC II can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the slide valve to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on when required.
*Some 23XL chillers will have both an oil temperature sensor and an oil level safety switch (two separate components). Fig.
*Some 23XL chillers will have both an oil temperature sensor and an oil level safety switch (two separate components). Fig.
CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the 3 power panel contactor relays, CCM, and CVC. INTEGRATED STARTER MODULE (ISM) — This module is located in the starter cabinet. This module initiates commands from the CVC for starter functions such as starting and stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, 4 to 20 mA Head Pressure Reference output, and the shunt trip.
Fig. 15 — Control Panel Fig.
CVC Operation and Menus (Fig. 17-23) PRIMARY STATUS MESSAGE GENERAL • The CVC display automatically reverts to the default screen after 15 minutes if no softkey activity takes place (Fig. 17). • If a screen other than the default screen is displayed on the CVC, the name of that screen is in the upper right corner (Fig. 18). • The CVC may be set to display either English or SI units. Use the CVC configuration screen (accessed from the Service menu) to change the units.
• • 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. • • 2. Press NEXT or PREVIOUS to highlight the desired status table. The list of tables is: Press QUIT to leave the selected decision or field without saving any changes.
DEFAULT SCREEN LOCAL CCN RESET MENU (SOFTKEYS) Start Chiller In CCN Control Start Chiller in Local Control Clear Alarms Access Main Menu STATUS SCHEDULE SETPOINT 1 1 1 1 (ENTER A 4-DIGIT PASSWORD) List the Status Tables List the Service Tables Display The Setpoint Table • MAINSTAT • STARTUP • COMPRESS • HEAT_EX • POWER • ISM_STAT • CVC_PSWD Select a Status Table PREVIOUS NEXT Select a Modification Point PREVIOUS NEXT Modify a Discrete Point START STOP ON OFF Modify an Analog Point INCREASE DECR
SERVICE TABLE NEXT PREVIOUS SELECT EXIT ALARM HISTORY Display Alarm History (The table holds up to 25 alarms and alerts with the most recent alarm at the top of the screen.
SERVICE MENU CONTINUED FROM PREVIOUS PAGE ISM (STARTER) CONFIG DATA EQUIPMENT SERVICE 4 4 4 4 (ENTER A 4-DIGIT PASSWORD) Service Tables: • OPTIONS • SETUP1 • SETUP2 • LEADLAG • RAMP_DEM • TEMP_CTL Select a Service Table PREVIOUS NEXT Service Tables: • ISM (STARTER) CONFIG PASSWORD • ISM_CONF SELECT EXIT Select a Service Table Parameter SELECT PREVIOUS NEXT EXIT Modify a Service Table Parameter INCREASE DECREASE QUIT ENABLE DISABLE QUIT ENTER (ANALOG VALUES) ENTER (DISCRETE VALUES) TIME AND
TIME SCHEDULE OPERATION (Fig. 22) 1. On the Menu screen, press SCHEDULE . 2. Press SELECT to select the highlighted value. Then: For Discrete Points — Press YES select the desired state. YES or NO to 2. Press NEXT or PREVIOUS to highlight the desired schedule. NO OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03S — CCN Time Schedule For Analog Points — Press INCREASE DECREASE to select the desired value. or 3. Press SELECT to view the desired time schedule. 3.
2. There are 5 set points on this screen: BASE DEMAND LIMIT, LCW SETPOINT (leaving chilled water set point), ECW SETPOINT (entering chilled water set point), ICE BUILD SETPOINT, and TOWER FAN HIGH SETPOINT. Only one of the chilled water set points can be active at one time. The set point that is active is determined from the SERVICE menu. See the Service Operation section, page 46. The ice build (ICE BUILD) function is also activated and configured from the SERVICE menu. 3.
Table 3 — CVC Display Data 6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized names, those preceded by a dagger can also be changed (that is, written to) by the CCN, BS, and the CVC. Capitalized Reference Point Names preceded by two asterisks can be changed only from the CVC. Reference Point Names in lower case type can be viewed by CCN or BS only by viewing the whole table. 7.
Table 3 — CVC Display Data (cont) EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press STATUS ( MAINSTAT will be highlighted). 3. Press SELECT .
Table 3 — CVC Display Data (cont) EXAMPLE 4 — COMPRESS DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight COMPRESS . 4. Press SELECT .
Table 3 — CVC Display Data (cont) EXAMPLE 6 — POWER DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press STATUS . 3. Scroll down to highlight POWER . 4. Press SELECT .
Table 3 — CVC Display Data (cont) EXAMPLE 8 — SETPOINT DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SETPOINT (Base Demand Limit will be highlighted) . 3. Press SELECT . DESCRIPTION Base Demand Limit Control Point LCW Setpoint ECW Setpoint Ice Build Setpoint Tower Fan High Setpoint STATUS 40-100 UNITS % POINT DLM DEFAULT 100 10-120 15-120 15-60 55-105 DEG F DEG F DEG F DEG F lcw_sp ecw_sp ice_sp tf2_sp 50.0 60.0 40.
Table 3 — CVC Display Data (cont) EXAMPLE 10 — OVERRIDE DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5. Scroll down to highlight OVERRIDE .
Table 3 — CVC Display Data (cont) EXAMPLE 12 — ISM_HIST DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM STATUS . 4. Press SELECT . 5. Scroll down to highlight ISM_HIST .
Table 3 — CVC Display Data (cont) EXAMPLE 14 — NET_OPT DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURATION . 4. Press SELECT . 5. Scroll down to highlight NET_OPT .
Table 3 — CVC Display Data (cont) EXAMPLE 16 — OPTIONS DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight OPTIONS . DESCRIPTION Auto Restart Option Remote Contacts Open Soft Stop Amps Threshold Stall/Hot Gas Bypass Stall Limit/HGBP Option Select: Stall=0, HGBP=1 Min.
Table 3 — CVD Display Data (cont) EXAMPLE 17 — SETUP1 DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight SETUP1 .
Table 3 — CVD Display Data (cont) EXAMPLE 19 — LEAD/LAG DISPLAY SCREEN To access this display from the CVC default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight LEAD/LAG .
PIC II System Functions NOTE: Increasing either of these settings causes the slide valve to respond more slowly than they would at a lower setting. The PROPORTIONAL ECW BAND can be adjusted on the CVC display for values of 1, 2, or 3; the default setting is 2. Increase this setting to increase slide valve response to a change in entering chilled water temperature. DEMAND LIMITING — The PIC II responds to the ACTIVE DEMAND LIMIT set point by limiting the opening of the slide valve.
Default Screen Freeze — When the chiller is in an alarm state, the default CVC display “freezes,” that is, it stops updating. The first line of the CVC default screen displays a primary alarm message; the second line displays a secondary alarm message. The CVC default screen freezes to enable the operator to see the conditions of the chiller at the time of the alarm. If the value in alarm is one normally displayed on the default screen, it flashes between normal and reverse video.
Oil Sump Temperature Control TC (Frame 1 and 2) Chillers Only — The oil sump temperature con- 1. The slide is prevented from closing further, and the status line on the CVC indicates the reason for the override. 2. The slide valve is opened until the condition decreases to below the first step set point. Then the slide valve is normal capacity control. Whenever the motor current demand limit set point (ACTIVE DEMAND LIMIT) is reached, it activates a capacity override, again, with a 2-step process.
Table 5 — Capacity Overrides Table Capacity Overrides OVERRIDE CAPACITY CONTROL FIRST STAGE SET POINT OVERRIDE TERMINATION Value Value >Override Set Point +10° F (6° C) Trippoint + Override ∆T+2° F (1.
The CVC default screen indicates when the chilled water reset is active. TEMPERATURE RESET on the MAINSTAT screen indicates the amount of reset. The CONTROL POINT will be determined by adding the TEMPERATURE RESET to the SETPOINT. To activate a reset type, access the TEMP_CTL screen and input all configuration information for that reset type. Then, input the reset type number (1, 2, or 3) in the SELECT/ENABLE RESET TYPE input line.
The algorithm first determines if corrective action is necessary. This is done by checking two sets of operator configured data points, which are the MINIMUM and the MAXIMUM Load Points, (T1/P1;T2/P2). These points have default settings for each type of refrigerant, HCFC-22 or HFC-134a, as defined on the OPTIONS table, and on Table 3. These settings and the algorithm logic are graphically displayed in Fig. 24 and 25.
lead chiller monitors conditions and evaluates whether the capacity has been 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, the lag and standby chillers are also stopped.
the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s compressor motor load value MOTOR PERCENT KILOWATTS or AVERAGE LINE CURRENT on the MAINSTAT screen). This value has limits of 40% to 100%. When the lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL POINT must be modified to a value of 3º F (1.67º C) less than the lead chiller’s CONTROL POINT value. If the LOAD BALANCE OPTION is disabled, the ACTIVE DEMAND LIMIT and the CONTROL POINT are forced to the same value as the lead chiller. AUTO.
• 20 mA DEMAND LIMIT OPT (configured on RAMP_DEM screen). TERMINATION OF ICE BUILD — The ice build function terminates under the following conditions: 1. Time Schedule — When the current time on the ice build time schedule (OCCPC02S) is not set as an ice build time period. 2.
TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered. 1. From the main MENU screen, press the SERVICE softkey. The softkeys now correspond to the numerals 1, 2, 3, 4. 2. Press the four digits of the password, one at a time. An asterisk (*) appears as each digit is entered. Fig. 27 — Example of Attach to Network Device Screen NOTE: The initial factory-set password is 1-1-1-1. If the password is incorrect, an error message is displayed.
START-UP/SHUTDOWN/ RECYCLE SEQUENCE (Fig. 29) Local Start-Up — Local start-up (or a manual start-up) is days of the week field signifies that the period is applicable to a holiday. (See Fig. 22.) The broadcast function must be activated for the holidays configured on the HOLIDEF screen to work properly. Access the BRODEF screen from the EQUIPMENT CONFIGURATION table and select ENABLE to activate function.
shutdown, advances the starts in the12 hours counter by one, and displays the applicable shutdown status on the CVC display. If the water/brine temperature is high enough, the start-up sequence continues and checks the slide valve unload timer. If the unload timer has expired, the PIC II then confirms the correct refrigerant type by comparing the cooler and condenser refrigerant temperature to the leaving water temperature for each vessel.
BEFORE INITIAL START-UP The soft stop amps threshold function can be terminated and the compressor motor deenergized immediately by depressing the STOP button twice. Job Data Required • Chilled Water Recycle Mode — The chiller may cycle off and wait until the load increases to restart when the compressor is running in a lightly loaded condition. This cycling is normal and is known as “recycle.
Fig. 30 — Typical Wet-Bulb Type Vacuum Indicator 3. Leak Test Chiller — Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 31 for an outline of the leak test procedures. Refer to Fig. 24 and 25 during pumpout procedures. See the Pumpout and Refrigerant Transfer Procedures Section on page 69.
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Table 6A — HCFC-22 Pressure — Temperature (F) TEMPERATURE (F) –50 –48 –46 –44 –42 –40 –38 –36 –34 –32 –30 –28 –26 –24 –22 –20 –18 –16 –14 –12 –10 – 8 – 6 – 4 – 2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 PRESSURE (psi) Absolute Gage 11.67 6.154* 12.34 4.829* 13.00 3.445* 13.71 2.002* 14.45 0.498* 15.22 0.526 16.02 1.328 16.86 2.163 17.73 3.032 18.63 3.937 19.57 4.877 20.55 5.853 21.56 6.868 22.62 7.921 23.71 9.015 24.85 10.15 26.02 11.32 27.24 12.54 28.50 13.81 29.81 15.11 31.16 16.47 32.56 17.87 34.01 19.
Table 6C — HFC-134a Pressure — Temperature (F) TEMPERATURE, F 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 Table 6D — HFC-134a Pressure — Temperature (C) PRESSURE (psig) 6.50 7.52 8.60 9.66 10.79 11.96 13.17 14.42 15.72 17.06 18.45 19.88 21.37 22.90 24.48 26.11 27.80 29.53 31.32 33.17 35.08 37.04 39.06 41.14 43.28 45.48 47.
Chiller Dehydration — Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure. Do not start or megohm-test the compressor motor or oil pump motor, even for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result. Fig.
supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire. The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it. The negative pins must be wired to the negative pins. The signal ground pins must be wired to the signal ground pins. See installation manual.
Software Configuration attached to the starter frame near the relays. Use only the dashpot oil supplied with the starter. Do not substitute. Solid-state overload relays do not have oil. 4. Reapply starter control power (not main chiller power) to check the electrical functions. Ensure the starter (with relay 1CR closed) goes through a complete and proper start cycle. Do not operate the chiller before the control configurations have been checked and a Control Test has been satisfactorily completed.
TO CHANGE THE PASSWORD — The password may be changed from the CVC CONFIGURATION screen. 1. Press the MENU and SERVICE softkeys. Enter the current password and highlight CVC CONFIGURATION. Press the SELECT softkey. Only the last 5 entries on the CVC CONFIG screen can be changed: BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC, and PASSWORD.
Minimum Load ∆P1: 71 – 38 = 33 psid (490 – 262 = 228 kPad) Modify Minimum and Maximum Load Points (∆T1/P1; ∆ T2/P2) If NecessaryT — These pairs of chiller load points, located on the OPTIONS screen, determine when to limit guide valve travel or open the hot gas bypass valve when stall prevention is needed. These points should be set based on individual chiller operating conditions.
Perform a Control Test — Check the safety controls status by performing an automated control test. Access the CONTROL TEST table and select a test to be performed function (Table 7). The Automated Control Test checks all outputs and inputs for function. It will also set the refrigerant type. The compressor must be in the OFF mode to operate the controls test. The compressor can be put in OFF mode by pressing the STOP push-button on the CVC.
Table 7 — Control Test Menu Functions TESTS TO BE PERFORMED 1. CCM Thermistors 2. CCM Pressure Transducers 3. Pumps 4. Discrete Outputs 5. Slide Valve 6. Pumpdown Lockout 7. Terminate Lockout 8.
The full refrigerant charge on the 23XL will vary with chiller components and design conditions, as indicated on the job data specifications. An approximate charge may be determined by adding the condenser charge to the cooler charge as listed in Table 8. Do not permit water or brine that is warmer than 110 F (43 C) to flow through the cooler or condenser. Refrigerant overpressure may discharge through the relief valves and result in the loss of refrigerant charge. 7. Access the CONTROL TEST screen.
To Prevent Accidental Start-Up — A chiller STOP override setting may be entered to prevent accidental start-up during service or whenever necessary. Access the MAINSTAT screen and using the NEXT or PREVIOUS softkeys, highlight the CHILLER START/STOP parameter. Override the current START value by pressing the SELECT softkey. Press the STOP softkey followed by the ENTER softkey. The word SUPVSR! displays on the CVC indicating the override is in place.
is a good time to brush the tubes and inspect the Schrader fittings on the waterside flow devices for fouling, if necessary. Check the cooler pressure on the CVC default screen and compare it to the original holding charge that was left in the chiller. If (after adjusting for ambient temperature changes) any loss in pressure is indicated, check for refrigerant leaks. See Check Chiller Tightness section, page 49. Recharge the chiller by transferring refrigerant from the pumpout storage tank (if supplied).
Press. Temp Refrigerant In Out GPM COOLER Water Pressure SERIAL NO. REFRIGERANT TYPE CONDENSER COMPRESSOR Refrigerant Water Oil Motor ROTOR FLA Temp Pressure Temp INLET DISCHARGE Filter TEMP Press. Temp Press. Diff. Temp Level Voltage In Out In Out GPM In Out TEMP Amperage Press MODEL NO. Fig.
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES 2. To determine pumpout storage tank pressure, a 30 in. –0-400 psi (–101-0-2769 kPa) gage is attached to the storage tank. 3. Refer to Fig. 32-35, and 39 for valve locations andnumbers. Preparation — The 23XL may come equipped with an optional pumpout storage tank, pumpout system, or pumpout compressor.
Chillers with Isolation Valves e. Turn off the pumpout compressor. 2. Evacuate the refrigerant gas from the chiller condenser vessel. a. Access the PUMPDOWN LOCKOUT function accessed from the CVC CONTROL TEST table to turn on the chiller water pumps. Turn the chiller water pumps on manually if they are not controlled by the PIC II. b. Close pumpout unit valves 3 and 4; open valves 2 and 5.
Chillers with Storage Tanks — If the chiller has a k. Close valves 1a, 1b, 2, 5, 6, and 10. separate storage tank, or the chiller does not have isolation valves, refer to the following procedure. See Fig. 32-35. TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER 1. Equalize refrigerant pressure. a. Use the PIC II terminate lockout function on the PUMPDOWN LOCKOUT screen, accessed from the CONTROL TEST table to turn on the water pumps and monitor pressures.
GENERAL MAINTENANCE should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work. Refrigerant Properties — HCFC-22 and HFC-134a are the standard refrigerants in the 23XL. At normal atmospheric pressure, HCFC-22 will boil at –41 F (–40.5 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.
WEEKLY MAINTENANCE yearly oil analysis is performed, the time between oil changes may be extended. The 23XL TC frame 1 and 2 chillers use approximately 4.2 gal (15.9 L) of oil. The 23XL TD frame 4 chillers use approximately 10 gal (38 L) of oil. See Oil Specification section on page 74 for additional information. Check the Lubrication System — Mark the oil level on the sight glasses and observe the level each week while the chiller is shut down.
• • • • • 11. Add oil (approximately 4.2 gal [15.9 L]) until it can be seen at the lower edge of the oil sump sight glass. The oil sight glass will not fill completely since a small amount of gas will be trapped inside, even under vacuum conditions. 12. Open all 3 isolation valves (previously closed in Step 3). Apply power to the controls and oil heater. 13. The oil level will rise once the refrigerant gets absorbed into the oil.
1 2 3 4 5 6 7 8 — — — — — — — — temperature sensors for signs of corrosion or scale. Replace the sensor if corroded or remove any scale if found. CONDENSER — Since this water circuit is usually an opentype system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at least once per year and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors for signs of corrosion or scale.
Inspect starter contact surfaces for wear or pitting on mechanical-type starters. Do not sandpaper or file silverplated contacts. Follow the starter manufacturer’s instructions for contact replacement, lubrication, spare parts ordering, and other maintenance requirements. Periodically vacuum or blow off accumulated debris on the internal parts with a high-velocity, low-pressure blower. Power connections on newly installed starters may relax and loosen after a month of operation.
• Checking Pressure Transducers — There are 8 pressure transducers on 23XL chillers. They determine cooler, condenser, oil pressure, and cooler and condenser flow. The cooler and condenser transducers are also used by the PIC II to determine the refrigerant temperatures. The oil pressure valve (oil pressure transducer — evap pressure transducer) is calculated by the CCM. All pressure transducers should be calibrated prior to initial start-up.
Control Algorithms Checkout Procedure — 4. A high pressure point can also be calibrated between 25 and 250 psig (172.4 and 1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder).
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides A. MANUAL STOP PRIMARY MESSAGE MANUALLY STOPPED — PRESS TERMINATE PUMPDOWN MODE SECONDARY MESSAGE CCN OR LOCAL TO START TO SELECT CCN OR LOCAL SHUTDOWN IN PROGRESS SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING COMPRESSOR DEENERGIZED ICE BUILD OPERATION COMPLETE PROBABLE CAUSE/REMEDY PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary. PRIMARY MESSAGE PRESTART ALERT PRESTART ALERT SECONDARY MESSAGE STARTS LIMIT EXCEEDED HIGH MOTOR TEMPERATURE ALARM MESSAGE PRIMARY CAUSE 100->Excessive compressor starts (8 in 12 hours) 102->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*.
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) F.
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I. CHILLER PROTECT LIMIT FAULTS (cont) PRIMARY MESSAGE PROTECTIVE LIMIT SECONDARY MESSAGE OIL PRESS SENSOR FAULT ALARM MESSAGE PRIMARY CAUSE 227->Oil Delta P [VALUE] exceeded limit of [LIMIT]*. 228 PROTECTIVE LIMIT LOW OI PRESSURE 228->Oil Delta P [VALUE] exceeded limit of [LIMIT].
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) I.
Table 9 — CVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) J. CHILLER ALERTS (cont) 151 PRIMARY MESSAGE CONDENSER PRESSURE ALERT SECONDARY MESSAGE PUMP RELAY ENERGIZED ALARM MESSAGE PRIMARY CAUSE 151->High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure. 152 RECYCLE ALERT EXCESSIVE RECYCLE STARTS 152->Excessive recycle starts.
Table 10A — Thermistor Temperature (F) vs Resistance/VoltageDrop TEMPERATURE (F) –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 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 VOLTAGE RESISTANCE DROP (V) (Ohms) 4.821 98,010 4.818 94,707 4.814 91,522 4.806 88,449 4.800 85,486 4.793 82,627 4.786 79,871 4.779 77,212 4.772 74,648 4.764 72,175 4.
Table 10B — 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 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 VOLTAGE DROP (V) 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.
Control Modules — Turn controller power off before Notes on Module Operation servicing controls. This ensures safety and prevents damage to the controller. The CVC, CCM, and ISM modules perform continuous diagnostic evaluations of the hardware to determine its condition. Proper operation of all modules is indicated by LEDs (lightemitting diodes) located on the circuit board of the CVC, CCM, and ISM.
Chiller Control Module (CCM) (Fig. 43) 8. Access the MAINSTAT table and highlight the TOTAL COMPRESSOR STARTS parameter. Press the SELECT softkey. Increase or decrease the value to match the starts value recorded in Step 3. Press the ENTER softkey when you reach the correct value. Now, move the highlight bar to the COMPRESSOR ONTIME parameter. Press the SELECT softkey. Increase or decrease the run hours value to match the value recorded in Step 2. Press the ENTER softkey when the correct value is reached.
J11 DISCRETE OUTPUTS J12 DISCRETE OUTPUTS J1 24 VAC ANALOG OUT J8 SIO J7 SIO J6 SW2 V/I INPUTS J5 STAT COMM THERMISTORS J4 PRESSURE J2 DIFF PRESSURE J3 Fig. 43 — Chiller Control Module (CCM) J9 J8 J7 COM STAT INTEGRATEDSTARTERMODULE J1 FUSE J2 J3-1 J3-2 J3-3 Fig.
5. Using quarter-turn increments, alternating between clamping bolts, apply the appropriate number of whole turns referencing the table in Fig. 45. 5. Using an ohmmeter, perform the following resistance measurements and record the results: MEASURE BETWEEN T1 and T6 T2 and T4 T3 and T5 6. 7. 8. 9. 10. SCR PAIRS BEING CHECKED 3 and 6 2 and 5 1 and 4 RECORDED VALUE Care must be taken to prevent nut rotation while tightening the bolts.
Physical Data — For operator convenience during troubleshooting, additional details regarding compressor torque specifications, physical data, electrical data, and wiring schematics may be found in Tables 11-18 and Fig. 46-52.
Table 14A — 23XL Waterbox Cover Weights (Frame 1 and 2 Machines)* HEAT EXCHANGER COOLER OR CONDENSER WATERBOX DESCRIPTION NIH, 1 Pass PSI (kPa) NIH, 2 Pass (Plain) 150 (1034) NIH, 2 Pass (With Pipe Nozzles) FRAME 1 150 (1034) NIH, 3 Pass FRAME 2 lbs 118 kg 54 lbs 128 kg 58 100 46 148 67 185 84 200 91 166 76 180 82 LEGEND NIH — Nozzle-In-Head *These weights are given for reference only. They have been included in heat exchanger weights shown in Table 4.
Table 15 — Optional Storage Tank and/or Pumpout System Physical Data UNIT SIZE 28 52 TANK OUTSIDE DIAMETER in. 24.00 27.
Table 18 — 23XL Compressor Torque Specification Chart for Metric amd American Fasteners ITEM CAP SCREW SIZE AND TYPE GRADE 1. 2. 1. 2. M5 X 0.8 X 12 S.H. M6 X 1 X 16 S.H. M10 X 1.5 X 35 H.H. M10 X 1.5 X 40 S.H. M10 X 1.5 X 50 H.H. M12 X 1.75 X 40 S.H. M12 X 1.75 X 50 S.H. CAP SCREW 10.9 M12 X 1.75 X 60 S.H. M12 X 1.75 X 70 S.H. M12 X 1.75 X 80 S.H. M12 X 1.75 X 90 S.H. FRAME 1 AND 2 M16 X 2 X 55 S.H. FRAME 4 M16 X 2 X 70 S.H. M20 X 2.5 X 70 S.H. M22 X 2.5 X 80 S.H. SET SCREW M10 X 1.5 X 16 S.S.
CB CCM CVC COMPR COND DL/DP DISCH ENT — — — — — — — — Circuit Breaker Chiller Control Module Chiller Visual Controller Compressor Cond Datalink or Dataport Discharge Entering EVAP EXT GND HGBP ISM LVG PRESS REQMT — — — — — — — — ** SW TEMP TB VVI — — — — Denotes Motor Starter Panel Conn. Switch Temperature Terminal Board Variable Volume Index Denotes Power Panel Terminal Fig.
CB CCM HGBP ISM TB VVI — — — — — — * ** Denotes Component Terminal Wire Splice Option Wiring Denotes Conductor Male/Female Conn. Denotes Control Panel Conn. Denotes Motor Starter Panel Conn. Fig.
NOTE: Power factor correction capacitors (when required) are connected ahead of all current transformers for proper calibration and sensing by the ISM and IQDP4130.
Fig. 49 — Benshaw, Inc.
AUX BR CB COMM COND CPU CVC CT EVAP FU G L LL M O/L S SCR ST TB — — — — — — — — — — — — — — — — — — — Field Wiring Shield Wire Twisted Shielded Pair Twisted Pair PC Board Terminals Power Connection Terminal Strip Benshaw supplied terminal block Wire Node Symbol may have terminal block 4 3 2 “ON” “OFF” Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1. Transformer connections per transformer nameplate connection diagram.
Fig.
Fig.
LEGEND Factory Wiring Field Wiring Component Terminal Control Panel Terminal *Field supplied terminal strip must be located in the control center. Fig.
INDEX Abbreviations and Explanations, 5 After Limited Shutdown, 67 Attach to Network Device Control, 45 Automatic Soft Stop Amps Threshold, 48 Auto.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- INITIAL START-UP CHECKLIST FOR 23XL HERMETIC SCREW LIQUID CHILLER (Remove and use for job file.) MACHINE INFORMATION: NAME ADDRESS CITY JOB NO.
INSPECT WIRING AND RECORD ELECTRICAL DATA: RATINGS: Motor Voltage Motor(s) Amps Line Voltages: Motor Starter LRA Rating 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.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 23XL PIC II SETPOINT TABLE CONFIGURATION SHEET DESCRIPTION Base Demand Limit LCW Setpoint ECW Setpoint Ice Build Setpoint Tower Fan High Setpoint RANGE 40 to 100 10 to 120 15 to 120 15 to 60 55 to 105 UNITS % DEG F DEG F DEG F DEG F CVC Software Version Number: CVC Controller Identifica
23XL PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S Day Flag M T W T F S S H 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 23XL PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Day Flag M T W T F S S H 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.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 23XL PIC II ISM_CONF TABLE CONFIGURATION SHEET DESCRIPTION Starter Type (0=Full, 1=Red, 2=SS/VFD) Motor Rated Line Voltage Volt Transformer Ratio: 1 Overvoltage Threshold Undervoltage Threshold Over/Under Volt Time Voltage % Imbalance Voltage Imbalance Time Motor Rated Load Amps Motor Lock
23XL PIC II OPTIONS TABLE CONFIGURATION SHEET DESCRIPTION Auto Restart Option Remote Contacts Option Soft Stop Amps Threshold Stall/Hot Gas Bypass Stall Limit/HGBP Option Select: Stall=0, HGBP=1 Min.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 23XL PIC II SETUP1 TABLE CONFIGURATION SHEET DESCRIPTION Comp Motor Temp Override Cond Press Override Comp Discharge Alert RANGE 150 to 200 150 to 260 125 to 200 UNITS DEG F PSI DEG F DEFAULT 200 230 200 Chilled Medium Chilled Water Deadband.
23XL PIC II SETUP2 TABLE CONFIGURATION SHEET DESCRIPTION Capacity Control Proportional Inc Band Proportional Dec Band Proportional ECW Gain STATUS 2 to 10 2 to 10 1 to 3 VFD/Slide Valve Control VFD Option VFD Gain VFD Increase Step VFD Minimum Speed VFD Maximum Speed Manual SV Temp Option 0/1 0.1 to 1.5 1 to 5 20 to 100 50 to 100 0/1 UNITS DEFAULT 6.5 6.0 2.0 DSABLE/ENABLE % % % DSABLE/ENABLE CL-8 DSABLE 0.
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 23XL PIC II LEADLAG TABLE CONFIGURATION SHEET DESDRIPTION Lead Lag Control LEAD/LAG Configuration DSABLE=0, LEAD=1, LAG=2, STANDBY=3 Load Balance Option Common Sensor Option LAG Percent Capacity LAG Address LAG START Timer LAG STOP Timer PRESTART FAULT Timer STANDBY Chiller Option STANDBY
23XL PIC II RAMP_DEM TABLE CONFIGURATION SHEET DESCRIPTION Pulldown Ramp Type: Select: Temp=0, Load=1 Demand Limit + kW Ramp Demand Limit Source Select: Amps=0, kW=1 Motor Load Ramp % Min Demand Limit Prop Band Demand Limit At 20 mA 20 mA Demand Limit Opt Motor Rated Kilowatts Demand Watts Interval RANGE UNITS DEFAULT 0/1 1 0/1 0 5 to 20 3 to 15 40 to 100 0/1 50 to 9999 5 to 60 % % DSABLE/ENABLE kW MIN VALUE 10 10 40 DSABLE 145 15 23XL PIC II TEMP_CTL TABLE CONFIGURATION SHEET DESCRIPTION Contro
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 23XL BROADCAST (BRODEF) CONFIGURATION SHEET DESCRIPTION Time Broadcast Enable Daylight Savings Start Month Start Day of Week Start Week Start Time Start Advance Stop Month Stop Day of Week Stop Week Stop Time Stop Back RANGE 0/1 1 to 12 1 to 7 1 to 5 00:00 to 24:00 0 to 360 1 to 12 1 to 7
Book Tab Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 211 Catalog No. 532-306 Printed in U.S.A.
