Start-Up, Operation, and Maintenance Instructions

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7 6 5 LEGEND 1 — RediStart MICRO Input/Output Card 2 — Fuses 1-4 (Hidden, not depicted) 3 — Circuit Breaker 2 (CB2): Machine Control and Heater Power 4 — Circuit Breaker 3 (CB3): Oil Pump Power 5 — RediStart MICRO Central Processing Unit Card (CPU) 6 — RediStart MICRO Power Card (hidden, not depicted) 7 — RediStart MICRO Bypass Card (hidden, not depicted) Fig. 5 — Solid-State Starter Box, Internal View Fig. 6 — Typical Starter External View (Solid-State Starter Shown) 1 2 3 4 10 There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter checkout. The display indicates: voltage to the SCRs SCR control voltage power indication proper phasing for rotation start circuit energized over-temperature ground fault current unbalance run state software configuration The starter is further explained in the Check Starter and Troubleshooting Guide sections, pages 54 and 76. Unit-Mounted Wye-Delta Starter (Optional) — The 19XR chiller may be equipped with a wye-delta starter mounted on the unit. This starter is used 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. Once the motor is up to speed, the starter automatically connects the phase windings into a delta configuration. Starter control, monitoring, and motor protection is provided by Carrier’s Integrated Starter Module (ISM). Unit-Mounted VFD (Optional) — The 19XRV unit will be equipped with a variable frequency drive motor controller mounted on the unit. See Fig. 7 and 8. This VFD is used with low voltage motors between 380 and 480 VAC. It reduces the starting current inrush by controlling the voltage and frequency to the compressor motor. Once the motor has accelerated to minimum speed the PIC II modulates the compressor speed and guide vane position to control chilled water temperature. The VFD is further explained in the Controls section and Troubleshooting Guide section, pages 10 and 76. There is a separate display located on the unit-mounted VFD. Operational parameters and fault codes are displayed relative to the drive. Refer to specific drive literature along with troubleshooting sections. The display is also the interface for entering specific chiller operational parameters. These parameters have been preprogrammed at the factory. An adhesive backed label on the inside of the drive has been provided for verification of the specific job parameters. See Initial Start-Up Checklist section for details. 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.) DISCRETE SIGNAL — A discrete signal is a 2-position representation of the value of a monitored source. (Example: A switch produces a discrete signal indicating whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.)
OPTIONAL METER PACKAGE INTEGRATED STARTER MODULE (ISM) OIL PUMP DISCONNECT CONTROL AND OIL HEATER DISCONNECT COMPRESSOR MOTOR DISCONNECT General — The 19XR hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the chiller (see Fig. 9). The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable flow pre-whirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor flow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. The microprocessor-based control center protects the chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required. AUTO Forward SPEED RUNNING MAN Reverse VOLTS REMOTE AMPS JOG PRO- RUN Hz AUTO GRAM JOB Kw FORWARD TORQUE REVERSE Password PROGRAM ENTER Fig. 7 — Variable Frequency Drive (VFD) LINE LOAD TXV 11 SPEED VOLTS AMPS Hz Kw TORQUE Password RUNNING MAN REMOTE PROGRAM JOG AUTO FORWARD REVERSE PROGRAM SPEED VOLTS AMPS Hz Kw TORQUE Password AUTO Forward Reverse RUN JOB ENTER AUTO RUNNING MAN REMOTE JOG PROGRAM AUTO FORWARD REVERSE PROGRAM MANUAL RESET Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View ENTER Forward Reverse RUN JOB DC BUS BAR MEASUREMENT POINT INITIAL DC BUS MEASUREMENT POINT + DANGER - HIGH VOLTAGE PIC II System Components — The chiller control system is called the PIC II (Product Integrated Control II). See Table 1. 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 guide vanes 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. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the hot gas bypass valve, if installed. The PIC II controls provide critical protection for the compressor motor and controls the motor starter. + - VFD MODULE COOLING LINES
Page 1 and 2: Start-Up, Operation, and Maintenanc
Page 3 and 4: CONTENTS (cont) Page Page Chiller D
Page 5 and 6: Factory-installed additional compon
Page 7 and 8: Factory-Mounted Starter or Variable
Page 9: MOTOR COOLING LINE TXV BULB PRESSUR
Page 13 and 14: The PIC II can interface with the C
Page 15 and 16: CVC/ICVC Operation and Menus (Fig.
Page 17 and 18: Start Chiller In CCN Control Start
Page 19 and 20: SERVICE MENU CONTINUED FROM PREVIOU
Page 21 and 22: 7. Press ENTER to register the valu
Page 23 and 24: Table 2 — CVC/ICVC Display Data (
Page 33 and 34: PIC II System Functions NOTE: Words
Page 35 and 36: Shunt Trip (Option) — The functio
Page 37 and 38: OVERRIDE CAPACITY CONTROL HIGH COND
Page 39 and 40: (see wiring diagrams or certified d
Page 41 and 42: NOTE: The lead/lag function can be
Page 43 and 44: Ice Build Control — The ice build
Page 45 and 46: Service Operation — An overview o
Page 47 and 48: Shutdown Sequence — Chiller shutd
Page 49 and 50: 49 Fig. 28 — 19XR Leak Test Proce
Page 51 and 52: Fig. 29 — Typical Optional Pumpou
Page 53 and 54: Chiller Dehydration — Dehydration
Page 55 and 56: MECHANICAL STARTER 1. Check all fie
Page 57 and 58: CHANGE THE BENSHAW INC., RediStart
Page 59 and 60: VFD Cooling System Leak Inspection
Page 61 and 62:
Protecting the VFD Configuration 1.
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Check Optional Pumpout System Contr
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Dry Run to Test Start-Up Sequence F
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Leave the oil charge in the chiller
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LEGEND C — Contactor FU — Fuse,
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2. Evacuate the refrigerant gas fro
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SCHEDULED MAINTENANCE Establish a r
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Water Treatment — Untreated or im
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TRANSDUCER REPLACEMENT — Since th
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Table 11 — CVC/ICVC Primary and S
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I. CHILLER PROTECT LIMIT FAULTS STA
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I. CHILLER PROTECT LIMIT FAULTS (co
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TEMPERATURE (F) PIC II VOLTAGE DROP
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Control Modules Turn controller pow
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ANALOG OUT J8 INTERGRATED STARTER M
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NOTES: 1. Cooler data: based on a c
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Table 14 — 19XR Additional Data f
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HEAT EXCHANGER COOLER/ CONDENSER HE
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Table 18 — Optional Pumpout Syste
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ITEM A B C D E F VIEW B — HIGH SP
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101 Fig. 45 — Allen-Bradley Wye-D
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103 LEGEND (cont) ISM — Integrate
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105 LEGEND (cont) ISM — Integrate
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107 LEGEND Denotes Component Termin
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AUX — Auxiliary C — Contactor C
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Fig. 53 — Benshaw, Inc. Solid-Sta
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LEGEND AUX — Auxiliary C — Cont
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1A LEGEND AUX — Auxiliary C — C
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117 Fig. 57 — Typical Variable Fr
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Abbreviations and Explanations, 4 A
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MACHINE INFORMATION: DESIGN CONDITI
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19XR, XRV PIC II SETPOINT TABLE CON
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CUT ALONG DOTTED LINE CUT ALONG DOT
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Copyright 2001 Carrier Corporation
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Start-Up, Operation, and Maintenance Instructions

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