Start-Up, Operation, and Maintenance Instructions

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Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5 CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7 Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Factory-Mounted Starter or Variable Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7 Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7 REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7 MOTOR AND LUBRICATING OIL COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8 VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9 Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • PRIMARY OIL RECOVERY MODE SECONDARY OIL RECOVERY METHOD STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10 Unit-Mounted Solid-State Starter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unit-Mounted Wye-Delta Starter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ANALOG SIGNAL DISCRETE SIGNAL General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 11 CHILLER VISUAL CONTROLLER (CVC) INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC) INTEGRATED STARTER MODULE (ISM) CHILLER CONTROL MODULE (CCM) OIL HEATER CONTACTOR (1C) OIL PUMP CONTACTOR (2C) HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) CONTROL TRANSFORMERS (T1, T2) OPTIONAL TRANSFORMER (T3) CVC/ICVC Operation and Menus. . . . . . . . . . . . . . . . . 15 GENERAL ALARMS AND ALERTS CVC/ICVC MENU ITEMS BASIC CVC/ICVC OPERATIONS (Using the Softkeys) TO VIEW STATUS OVERRIDE OPERATIONS TIME SCHEDULE OPERATION TO VIEW AND CHANGE SET POINTS SERVICE OPERATION PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33 CAPACITY CONTROL FIXED SPEED CAPACITY CONTROL VFD ECW CONTROL OPTION CONTROL POINT DEADBAND DIFFUSER CONTROL PROPORTIONAL BANDS AND GAIN DEMAND LIMITING CHILLER TIMERS OCCUPANCY SCHEDULE Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CONTENTS 2 Page Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 High Discharge Temperature Control . . . . . . . . . . . . 36 Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36 Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 37 Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 37 Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 37 Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 37 Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 38 Evaporator Freeze Protection (ICVC Only). . . . . . . 38 Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 38 Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 38 Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 RESET TYPE 1 RESET TYPE 2 RESET TYPE 3 Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 39 Surge Prevention Algorithm (Fixed Speed Chiller) . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Surge Prevention Algorithm with VFD . . . . . . . . . . . 40 Surge Protection VFD Units . . . . . . . . . . . . . . . . . . . . . 40 Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 40 HEAD PRESSURE REFERENCE OUTPUT Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 COMMON POINT SENSOR INSTALLATION CHILLER COMMUNICATION WIRING LEAD/LAG OPERATION FAULTED CHILLER OPERATION LOAD BALANCING AUTO. RESTART AFTER POWER FAILURE Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ICE BUILD INITIATION START-UP/RECYCLE OPERATION TEMPERATURE CONTROL DURING ICE BUILD TERMINATION OF ICE BUILD RETURN TO NON-ICE BUILD OPERATIONS Attach to Network Device Control . . . . . . . . . . . . . . . 44 ATTACHING TO OTHER CCN MODULES Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 TO ACCESS THE SERVICE SCREENS TO LOG OUT OF NETWORK DEVICE HOLIDAY SCHEDULING START-UP/SHUTDOWN/RECYCLE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47 Local Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47 Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 47 Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64 Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Using the Optional Storage Tank and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48 Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48 Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Tighten All Gasketed Joints and Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 48 Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 48 Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CONTENTS (cont) Page Page Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Check Optional Pumpout Compressor MOTOR COMPRESSOR LUBRICATION SYSTEM CONTROL SYSTEM Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 AUXILIARY EQUIPMENT Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 DESCRIBE CHILLER CYCLES Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REVIEW MAINTENANCE Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54 SAFETY DEVICES AND PROCEDURES Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 CHECK OPERATOR KNOWLEDGE MECHANICAL STARTER REVIEW THE START-UP, OPERATION, AND BENSHAW, INC. RediStart MICRO MAINTENANCE MANUAL SOLID-STATE STARTER VFD STARTER Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Power Up the Controls and Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55 SOFTWARE VERSION Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55 Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55 Input the Local Occupied Schedule (OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55 PASSWORD INPUT TIME AND DATE CHANGE CVC/ICVC CONFIGURATION IF NECESSARY TO CHANGE THE PASSWORD TO CHANGE THE CVC/ICVC DISPLAY FROM ENGLISH TO METRIC UNITS CHANGE LANGUAGE (ICVC ONLY) MODIFY CONTROLLER IDENTIFICATION IF NECESSARY INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY CHANGE THE BENSHAW, INC., RediStart MICRO SOFTWARE CONFIGURATION IF NECESSARY VERIFY VFD CONFIGURATION AND CHANGE PARAMETERS IF NECESSARY VFD CHILLER FIELD SET UP AND VERIFICATION VFD CONTROL VERIFICATION (Non-Running) VFD CONTROL VERIFICATION (Running) CONFIGURE DIFFUSER CONTROL IF NECESSARY MODIFY EQUIPMENT CONFIGURATION IF NECESSARY Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62 COOLER CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION Check Optional Pumpout System Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63 High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63 Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63 CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT CHILLER EQUALIZATION WITH PUMPOUT UNIT TRIMMING REFRIGERANT CHARGE OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67 Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66 To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Check the Running System . . . . . . . . . . . . . . . . . . . . . 66 To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66 Preparation for Extended Shutdown . . . . . . . . . . . . 66 After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67 Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67 Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67 Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Operating the Optional Pumpout Unit . . . . . . . . . . . 67 TO READ REFRIGERANT PRESSURES Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69 TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK 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 GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72 Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71 Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71 Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Test After Service, Repair, or Major Leak . . . . . . . . 71 TESTING WITH REFRIGERANT TRACER TESTING WITHOUT REFRIGERANT TRACER TO PRESSURIZE WITH DRY NITROGEN Repair the Leak, Retest, and Apply Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72 Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72 Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72 WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72 Check the Lubrication System . . . . . . . . . . . . . . . . . . 72 INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65 Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Check Oil Pressure and Compressor Stop . . . . . . 65 To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65 Check Chiller Operating Condition . . . . . . . . . . . . . . 65 Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65 COOLER-CONDENSER OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM MOTOR COMPRESSOR ASSEMBLY SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75 Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73 Check Safety and Operating Controls Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 TO CHANGE THE OIL Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74 3
Page 1: Start-Up, Operation, and Maintenanc
Page 5 and 6: Factory-installed additional compon
Page 7 and 8: Factory-Mounted Starter or Variable
Page 9 and 10: MOTOR COOLING LINE TXV BULB PRESSUR
Page 11 and 12: OPTIONAL METER PACKAGE INTEGRATED S
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.
Page 63 and 64:
Check Optional Pumpout System Contr
Page 65 and 66:
Dry Run to Test Start-Up Sequence F
Page 67 and 68:
Leave the oil charge in the chiller
Page 69 and 70:
LEGEND C — Contactor FU — Fuse,
Page 71 and 72:
2. Evacuate the refrigerant gas fro
Page 73 and 74:
SCHEDULED MAINTENANCE Establish a r
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Water Treatment — Untreated or im
Page 77 and 78:
TRANSDUCER REPLACEMENT — Since th
Page 79 and 80:
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
Page 85 and 86:
TEMPERATURE (F) PIC II VOLTAGE DROP
Page 87 and 88:
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
Page 95 and 96:
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
Page 101 and 102:
101 Fig. 45 — Allen-Bradley Wye-D
Page 103 and 104:
103 LEGEND (cont) ISM — Integrate
Page 105 and 106:
105 LEGEND (cont) ISM — Integrate
Page 107 and 108:
107 LEGEND Denotes Component Termin
Page 109 and 110:
AUX — Auxiliary C — Contactor C
Page 111 and 112:
Fig. 53 — Benshaw, Inc. Solid-Sta
Page 113 and 114:
LEGEND AUX — Auxiliary C — Cont
Page 115 and 116:
1A LEGEND AUX — Auxiliary C — C
Page 117 and 118:
117 Fig. 57 — Typical Variable Fr
Page 119 and 120:
Page 121 and 122:
Page 123 and 124:
Abbreviations and Explanations, 4 A
Page 125 and 126:
MACHINE INFORMATION: DESIGN CONDITI
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19XR, XRV PIC II SETPOINT TABLE CON
Page 129 and 130:
CUT ALONG DOTTED LINE CUT ALONG DOT
Page 131 and 132:
Page 133 and 134:
Page 135 and 136:
Page 137 and 138:
Page 140:
Copyright 2001 Carrier Corporation
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Start-Up, Operation, and Maintenance Instructions

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