Start-Up, Operation, and Maintenance Instructions

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I. CHILLER PROTECT LIMIT FAULTS (cont) STATE PRIMARY MESSAGE 227 PROTECTIVE LIMIT 228 PROTECTIVE LIMIT 229 PROTECTIVE LIMIT 230 PROTECTIVE LIMIT 231 PROTECTIVE LIMIT 232 PROTECTIVE LIMIT 233 PROTECTIVE LIMIT 234 PROTECTIVE LIMIT 235 PROTECTIVE LIMIT 236 PROTECTIVE LIMIT 237 PROTECTIVE LIMIT 238 PROTECTIVE LIMIT 239 PROTECTIVE LIMIT 240 PROTECTIVE LIMIT 241 LOSS OF COMMUNICATION 242 LOSS OF COMMUNICATION 243 POTENTIAL FREEZE-UP 244 POTENTIAL FREEZE-UP 245 PROTECTIVE LIMIT Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) SECONDARY MESSAGE OIL PRESS SENSOR FAULT LOW OIL PRESSURE LOW CHILLED WATER FLOW LOW CONDENSER WATER FLOW HIGH DISCHARGE TEMP LOW REFRIGERANT TEMP HIGH MOTOR TEMPERATURE HIGH BEARING TEMPERATURE HIGH CONDENSER PRESSURE CCN OVERRIDE STOP SPARE SAFETY DEVICE EXCESSIVE COMPR SURGE TRANSDUCER VOLTAGE FAULT LOW DISCHARGE SUPERHEAT WITH STARTER MODULE WITH CCM MODULE EVAP PRESS/TEMP TOO LOW COND PRESS/TEMP TOO LOW VFD SPEED OUT OF RANGE ALARM MESSAGE ADDITIONAL PRIMARY CAUSE CAUSE/REMEDY 227->Oil Pump Delta P Check transducer wiring and accuracy. [VALUE] exceeded limit of Check power supply to pump. [LIMIT]*. Check pump operation. Check transducer calibration. 228->Oil Pump Delta P Check transducer wiring and accuracy. [VALUE] exceeded limit of Check power supply to pump. [LIMIT].* Check pump operation. Check oil level. Check for partially closed service valves. Check oil filters. Check for foaming oil at start-up. Check transducer calibration. 229->Low Chilled Water Perform pump control test. Flow; Check Delta P Config Check transducer accuracy and wiring. & Calibration Check water valves. Check transducer calibration. 230->Low Condenser Water Perform pump control test. Flow; Check Delta P Config Check transducer accuracy and wiring. & Calibration Check water valves. Check transducer calibration. 231->Comp Discharge Check sensor resistance or voltage drop. Temp [VALUE] exceeded Check for proper wiring. limit of [LIMIT].* Check for proper condenser flow and temperature. Check for proper inlet guide vane and diffuser actuator operation. Check for fouled tubes or noncondensables in the system. 232->Evaporator Refrig Check for proper refrigerant charge. Temp [VALUE] exceeded Check float operation. limit of [LIMIT]*. Check for proper fluid flow and temperature. Check for proper inlet guide vane operation. 233->Comp Motor Winding Check motor sensors wiring and accuracy. Temp [VALUE] exceeded Check motor cooling line for proper operation, or limit of [LIMIT]*. restrictions. Check for excessive starts within a short time span. 234->Comp Thrust Bearing Check oil heater for proper operation. Temp [VALUE] exceeded Check for low oil level, partially closed oil supply limit of [LIMIT]*. valves, clogged oil filters, etc. Check the sensor wiring and accuracy. 235->Condenser Pressure Check for high condenser water temperatures, low [VALUE] exceeded limit of water flow, fouled tubes. [LIMIT]*. Check for division plate/gasket bypass. Check for noncondensables. Check transducer wiring and accuracy. 236->CCN Override Stop CCN has signaled the chiller to stop. Reset and while in LOCAL run mode restart when ready. If the signal was sent by the CVC/ICVC, release the stop signal on the STATUS01 table. 237->Spare Safety Device Spare safety input has tripped or factory installed jumper is not present. 238->Compressor Surge: Check condenser flow and temperatures. Check condenser water Check surge protection configuration. temp and flow 239->Transducer Voltage Ref [VALUE] exceeded limit of [LIMIT]*. 240->Check for Oil in Refrigerant or Overcharge of Refrigerant 241->Loss of Communica- Check wiring to ISM. tion With Starter. 242->Loss of Communica- Check wiring to CCM. tion With CCM. 243->Evaporator Refrig Check for proper refrigerant charge. Temp [VALUE] exceeded Check float operation. limit of [LIMIT]*. Check for proper fluid flow and temperature. Check for proper inlet guide vane operation. 244->Condenser Refrig Temp [VALUE] exceeded limit of [LIMIT]*. 245->Actual VFD Speed [VALUE] exceeded limit of [LIMIT]*. 82
I. CHILLER PROTECT LIMIT FAULTS (cont) STATE 246 247 248 249 250 251 252 253 PRIMARY MESSAGE PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT PROTECTIVE LIMIT Table 11 — CVC/ICVC Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (cont) *[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped. J. CHILLER ALERTS STATE PRIMARY MESSAGE SECONDARY MESSAGE INVALID DIFFUSER CONFIG DIFFUSER POSITION FAULT SPARE TEMPERATURE #1 SPARE TEMPERATURE #2 REFRIGERANT LEAK SENSOR ISM CONFIG CONFLICT ISM CONFIG CONFLICT GUIDE VANE CALIBRATION 140 SENSOR ALERT LEAVING COND WATER TEMP 141 SENSOR ALERT ENTERING COND WATER TEMP 142 143 144 145 146 147 148 LOW OIL PRESSURE ALERT AUTORESTART PENDING AUTORESTART PENDING AUTORESTART PENDING AUTORESTART PENDING AUTORESTART PENDING AUTORESTART PENDING ALARM MESSAGE PRIMARY CAUSE 246->Diffuser Control Invalid Configuration: Check SETUP2 Entries. 247->Diffuser Position Fault: Check Guide Vane and Diffuser Actuators 248->Spare Temperature #1 [VALUE] exceeded limit of [LIMIT]*. 249->Spare Temperature #2 [VALUE] exceeded limit of [LIMIT]*. 250->Refrigerant Leak Sensor [VALUE] exceeded Limit of [LIMIT]*. 251->ISM Config Conflict (ISM Uploaded); Verify to Reset Alarm 252->ISM Config Conflict (ISM Downloaded); Verify to Reset Alarm 253->Guide Vane Fault [VALUE]. Check Calibration. 83 ADDITIONAL CAUSE/REMEDY Check diffuser/guide vane schedule. Check rotating stall transducer wiring and accuracy. Check diffuser schedule. Check for proper operation of diffuser actuator and inlet guide vane actuator. Check diffuser coupling. Check inlet guide vane operation. Check inlet guide vane calibration. Check diffuser/inlet guide vane schedule. Check diffuser mechanical set-up for proper orientation. If not using variable diffuser, check that the option has not been enabled. The refrigerant leak detector’s output wired to J5-5 and J5-6 on the CCM module has reached the alarm limit. Check leak detector and for leaks. Confirm valid settings in ISM_CONF screen. Confirm valid settings in ISM_CONF screen. Enter Control Test and execute Guide Vane Calibration. Check guide vane feedback (terminals J4-9 and J4-10) on the CCM module. SECONDARY ALARM MESSAGE ADDITIONAL MESSAGE PRIMARY CAUSE CAUSE/REMEDY 140->Sensor Fault: Check sensor resistance or voltage drop. Check Leaving Cond Water Sensor Check for proper wiring. 141->Sensor Fault: Check sensor resistance or voltage drop. Check Entering Cond Water Sensor Check for proper wiring. CHECK OIL FILTER 142->Low Oil Pressure Alert. Check for partially or closed shut-off valves. Check Oil Filter. Check oil filter. Check oil pump and power supply. Check oil level. Check for foaming oil at start-up. Check transducer wiring and accuracy. LINE PHASE 143->Line Phase Loss Power loss has been detected in any phase. LOSS Chiller automatically restarting. LINE VOLTAGE 144->Single Cycle Line A drop in line voltage has been detected within DROP OUT Voltage Dropout 2 voltage cycles. Chiller automatically restarting if Autorestart option is enabled. HIGH LINE 145>Line Overvoltage — Check line power. VOLTAGE Average Line Volt [VALUE] LOW LINE 146->Line Undervoltage — Check line power. VOLTAGE Average Line Volt [VALUE] STARTER MODULE 147->Starter Module Power- ISM has detected a hardware fault and has reset. RESET On Reset When Running Chiller automatically restarting. POWER LOSS 148->Control Power-Loss When Running Check control power.
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 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 25 and 26:
Page 27 and 28:
Page 29 and 30:
Page 31 and 32: 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
Page 75 and 76: Water Treatment — Untreated or im
Page 77 and 78: TRANSDUCER REPLACEMENT — Since th
Page 79 and 80: Table 11 — CVC/ICVC Primary and S
Page 81: I. CHILLER PROTECT LIMIT FAULTS STA
Page 85 and 86: TEMPERATURE (F) PIC II VOLTAGE DROP
Page 87 and 88: Control Modules Turn controller pow
Page 89 and 90: ANALOG OUT J8 INTERGRATED STARTER M
Page 91 and 92: NOTES: 1. Cooler data: based on a c
Page 93 and 94: Table 14 — 19XR Additional Data f
Page 95 and 96: HEAT EXCHANGER COOLER/ CONDENSER HE
Page 97 and 98: Table 18 — Optional Pumpout Syste
Page 99 and 100: 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 123 and 124: Abbreviations and Explanations, 4 A
Page 125 and 126: MACHINE INFORMATION: DESIGN CONDITI
Page 127 and 128: 19XR, XRV PIC II SETPOINT TABLE CON
Page 129 and 130: CUT ALONG DOTTED LINE CUT ALONG DOT
Page 131 and 132: CUT ALONG DOTTED LINE CUT ALONG DOT
Page 133 and 134:
CUT ALONG DOTTED LINE CUT ALONG DOT
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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