Start-Up, Operation, and Maintenance Instructions
Start-Up, Operation, and Maintenance Instructions
Start-Up, Operation, and Maintenance Instructions
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CONTENTS (cont)<br />
Page<br />
Page<br />
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53<br />
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53<br />
Check Optional Pumpout Compressor<br />
MOTOR COMPRESSOR LUBRICATION<br />
SYSTEM<br />
CONTROL SYSTEM<br />
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 AUXILIARY EQUIPMENT<br />
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 DESCRIBE CHILLER CYCLES<br />
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REVIEW MAINTENANCE<br />
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54 SAFETY DEVICES AND PROCEDURES<br />
Check <strong>Start</strong>er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 CHECK OPERATOR KNOWLEDGE<br />
MECHANICAL STARTER<br />
REVIEW THE START-UP, OPERATION, AND<br />
BENSHAW, INC. Redi<strong>Start</strong> MICRO<br />
MAINTENANCE MANUAL<br />
SOLID-STATE STARTER<br />
VFD STARTER<br />
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55<br />
Power <strong>Up</strong> the Controls <strong>and</strong><br />
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55<br />
SOFTWARE VERSION<br />
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55<br />
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55<br />
Input the Local Occupied Schedule<br />
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55<br />
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55<br />
PASSWORD<br />
INPUT TIME AND DATE<br />
CHANGE CVC/ICVC CONFIGURATION<br />
IF NECESSARY<br />
TO CHANGE THE PASSWORD<br />
TO CHANGE THE CVC/ICVC DISPLAY FROM<br />
ENGLISH TO METRIC UNITS<br />
CHANGE LANGUAGE (ICVC ONLY)<br />
MODIFY CONTROLLER IDENTIFICATION<br />
IF NECESSARY<br />
INPUT EQUIPMENT SERVICE PARAMETERS<br />
IF NECESSARY<br />
CHANGE THE BENSHAW, INC., Redi<strong>Start</strong><br />
MICRO SOFTWARE CONFIGURATION<br />
IF NECESSARY<br />
VERIFY VFD CONFIGURATION AND CHANGE<br />
PARAMETERS IF NECESSARY<br />
VFD CHILLER FIELD SET UP AND VERIFICATION<br />
VFD CONTROL VERIFICATION (Non-Running)<br />
VFD CONTROL VERIFICATION (Running)<br />
CONFIGURE DIFFUSER CONTROL IF<br />
NECESSARY<br />
MODIFY EQUIPMENT CONFIGURATION<br />
IF NECESSARY<br />
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62<br />
COOLER CONDENSER PRESSURE TRANSDUCER<br />
AND WATERSIDE FLOW DEVICE CALIBRATION<br />
Check Optional Pumpout System<br />
Controls <strong>and</strong> Compressor. . . . . . . . . . . . . . . . . . . . . 63<br />
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63<br />
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63<br />
CHILLER EQUALIZATION WITHOUT A<br />
PUMPOUT UNIT<br />
CHILLER EQUALIZATION WITH<br />
PUMPOUT UNIT<br />
TRIMMING REFRIGERANT CHARGE<br />
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67<br />
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66<br />
Prepare the Chiller for <strong>Start</strong>-<strong>Up</strong> . . . . . . . . . . . . . . . . . 66<br />
To <strong>Start</strong> the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66<br />
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66<br />
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66<br />
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66<br />
Preparation for Extended Shutdown . . . . . . . . . . . . 66<br />
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67<br />
Cold Weather <strong>Operation</strong>. . . . . . . . . . . . . . . . . . . . . . . . . 67<br />
Manual Guide Vane <strong>Operation</strong>. . . . . . . . . . . . . . . . . . . 67<br />
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67<br />
PUMPOUT AND REFRIGERANT TRANSFER<br />
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71<br />
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67<br />
Operating the Optional Pumpout Unit . . . . . . . . . . . 67<br />
TO READ REFRIGERANT PRESSURES<br />
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69<br />
TRANSFER REFRIGERANT FROM<br />
PUMPOUT STORAGE TANK TO CHILLER<br />
TRANSFER REFRIGERANT FROM<br />
CHILLER TO PUMPOUT STORAGE TANK<br />
Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70<br />
TRANSFER ALL REFRIGERANT TO<br />
CHILLER CONDENSER VESSEL<br />
TRANSFER ALL REFRIGERANT TO<br />
CHILLER COOLER VESSEL<br />
RETURN CHILLER TO NORMAL<br />
OPERATING CONDITIONS<br />
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72<br />
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71<br />
Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71<br />
Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 71<br />
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71<br />
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71<br />
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71<br />
Test After Service, Repair, or Major Leak . . . . . . . . 71<br />
TESTING WITH REFRIGERANT TRACER<br />
TESTING WITHOUT REFRIGERANT TRACER<br />
TO PRESSURIZE WITH DRY NITROGEN<br />
Repair the Leak, Retest, <strong>and</strong> Apply<br />
St<strong>and</strong>ing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72<br />
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72<br />
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72<br />
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72<br />
Check the Lubrication System . . . . . . . . . . . . . . . . . . 72<br />
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66<br />
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64<br />
Dry Run to Test <strong>Start</strong>-<strong>Up</strong> Sequence . . . . . . . . . . . . . 65<br />
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65<br />
Check Oil Pressure <strong>and</strong> Compressor Stop . . . . . . 65<br />
To Prevent Accidental <strong>Start</strong>-<strong>Up</strong>. . . . . . . . . . . . . . . . . . 65<br />
Check Chiller Operating Condition . . . . . . . . . . . . . . 65<br />
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65<br />
COOLER-CONDENSER<br />
OPTIONAL PUMPOUT STORAGE TANK AND<br />
PUMPOUT SYSTEM<br />
MOTOR COMPRESSOR ASSEMBLY<br />
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75<br />
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Check Safety <strong>and</strong> Operating Controls<br />
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
TO CHANGE THE OIL<br />
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73<br />
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74<br />
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