Start-Up, Operation, and Maintenance Instructions

MECHANICAL STARTER
1. Check all field wiring connections for tightness, clearance
from moving parts, and correct connection.
2. Check the contactor(s) to ensure 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, such as
relays, for free movement. If the devices do not move
freely, contact the starter manufacturer for replacement
components.
3. 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.
BENSHAW, INC. RediStart MICRO SOLID-STATE
STARTER
This equipment is at line voltage when AC power is connected.
Pressing the STOP button does not remove voltage.
1. Ensure all wiring connections are properly terminated to
the starter.
2. Verify the ground wire to the starter is installed properly
and is sufficient size.
3. Verify the motors are properly grounded to the starter.
4. Verify the proper ac input voltage is brought into the starter
according to the certified drawings.
5. Apply power to the starter
VFD STARTER
1. Turn off unit, tag and lock disconnects and wait 5 minutes.
2. Verify that the DC voltage is zero.
3. Ensure there is adequate clearance around the drive.
4. Verify that the wiring to the terminal strip and power terminals
is correct.
5. Verify that wire size is within the terminal specification
and the wires are secure.
6. Inspect the field supplied branch circuit protection is
properly rated and installed.
7. Verify that the system is properly grounded.
8. Inspect all liquid cooling connections for leaks.
Oil Charge — The oil charge for the 19XR compressor depends
on the compressor Frame size:
Frame 2 compressor — 5 gal (18.9 L)
Frame 3 compressor — 8 gal (30 L)
Frame 4 compressor — 10 gal (37.8 L)
Frame 5 compressor — 18 gal (67.8 L)
The chiller is shipped with oil in the compressor. When the
sump is full, the oil level should be no higher than the middle
of the upper sight glass, and minimum level is the bottom
of the lower sight glass (Fig. 2). If oil is added, it must meet
Carrier’s specification for centrifugal compressor use as described
in the Oil Specification section. Charge the oil through
the oil charging valve located near the bottom of the transmission
housing (Fig. 2). 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 chiller is shut down.
Power Up the Controls and Check the Oil
Heater — Ensure that an oil level is visible in the compressor
before energizing the controls. A circuit breaker in the starter
energizes the oil heater and the control circuit. When first
55
powered, the CVC/ICVC should display the default screen
within a short period of time.
The oil heater is energized by powering the control circuit.
This should be done several hours before start-up to minimize
oil-refrigerant migration. The oil heater is controlled by the
PIC II and is powered through a contactor in the power panel.
Starters contain a separate circuit breaker to power the heater
and the control circuit. This arrangement allows the heater to
energize when the main motor circuit breaker is off for service
work or extended shutdowns. The oil heater relay status (OIL
HEATER RELAY) can be viewed on the COMPRESS table on
the CVC/ICVC. Oil sump temperature can be viewed on the
CVC/ICVC default screen.
SOFTWARE VERSION — The software part number is labeled
on the backside of the CVC/ICVC module. The software
version also appears on the CVC/ICVC configuration screen as
the last two digits of the software part number.
Software Configuration
Do not operate the chiller before the control configurations
have been checked and a Control Test has been
satisfactorily completed. Protection by safety controls cannot
be assumed until all control configurations have been
confirmed.
As the 19XR unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-16, provides a list for configuration values.
Input the Design Set Points — Access the CVC/
ICVC 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 II can control a set point to either the leaving or entering
chilled water. This control method is set in the EQUIP-
MENT SERVICE (TEMP_CTL) table.
Input the Local Occupied Schedule (OCCPC01S) —
Access the schedule OCCPC01S screen on the CVC/ICVC
and set up the occupied time schedule according to the customer’s
requirements. If no schedule is available, the default is factory
set for 24 hours occupied, 7 days per week including
holidays.
For more information about how to set up a time schedule,
see the Controls section, page 10.
The CCN Occupied Schedule (OCCPC03S) should be configured
if a CCN system is being installed or if a secondary
time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be unoccupied.
Input Service Configurations — The following configurations
require the CVC/ICVC screen to be in the SER-
VICE portion of the menu.
password
input time and date
CVC/ICVC configuration
service parameters
equipment configuration
automated control test
PASSWORD — When accessing the SERVICE tables, a password
must be entered. All CVC/ICVC are initially set for a
password of 1-1-1-1.
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. The HOLIDAY TODAY parameter
should only be configured to YES if the present day is a
holiday.