Start-Up, Operation, and Maintenance Instructions

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Chiller Control Module (CCM) (Fig. 41) INPUTS — Each input channel has 2 or 3 terminals. Refer to individual chiller wiring diagrams for the correct terminal numbers for your application. OUTPUTS — Output is 24 vac. There are 2 terminals per output. Refer to the chiller wiring diagram for your specific application for the correct terminal numbers. Integrated Starter Module (Fig. 42) INPUTS — Inputs on strips J3 through J6 are analog inputs and J2 is discrete (on/off) input. The specific application of the chiller determines which terminals are used. Refer to the individual chiller wiring diagram for the correct terminal numbers for your application. OUTPUTS — Outputs are 115-277 vac and wired to strip J9. There are 2 terminals per output. Replacing Defective Processor Modules — The module replacement part number is printed on a small label on the rear of the CVC/ICVC module. The chiller model and serial numbers are printed on the chiller nameplate located on an exterior corner post. The proper software is factoryinstalled by Carrier in the replacement module. When ordering a replacement chiller visual control (CVC/ICVC) module, specify the complete replacement part number, full chiller model number, and chiller serial number. The installer must configure the new module to the original chiller data. Follow the procedures described in the Software Configuration section on page 55. Electrical shock can cause personal injury. Disconnect all electrical power before servicing. INSTALLATION 1. Verify the existing CVC/ICVC module is defective by using the procedure described in the Troubleshooting Guide section, page 76, and the Control Modules section, page 87. Do not select the ATTACH TO NETWORK DEVICE table if the CVC/ICVC indicates a communication failure. 2. Data regarding the CVC/ICVC configuration should have been recorded and saved. This data must be reconfigured into the new CVC/ICVC. If this data is not available, follow the procedures described in the Software Configuration section. If a CCN Building Supervisor or Service Tool is available, the module configuration should have already been uploaded into memory. When the new module is installed, the configuration can be downloaded from the computer. Any communication wires from other chillers or CCN modules should be disconnected to prevent the new CVC/ICVC module from uploading incorrect run hours into memory. 3. To install this module, record values for the TOTAL COMPRESSOR STARTS and the COMPRESSOR ONTIME from the MAINSTAT screen on the CVC/ ICVC. 4. Power off the controls. 5. Remove the old CVC/ICVC. 6. Install the new CVC/ICVC module. Turn the control power back on. 88 7. The CVC/ICVC now automatically attaches to the local network device. 8. Access the MAINSTAT table and highlight the TOTAL COMPRESSOR STARTS parameter. Press the SELECT softkey. Increase or decrease the value to match the starts value recorded in Step 3. Press the ENTER softkey when you reach the correct value. Now, move the highlight bar to the COMPRESSOR ONTIME parameter. Press the SELECT softkey. Increase or decrease the run hours value to match the value recorded in Step 2. Press the ENTER softkey when the correct value is reached. 9. Complete the CVC/ICVC installation. Following the instructions in the Input Service Configurations section, page 55, input all the proper configurations such as the time, date, etc. Check the pressure transducer calibrations. PSIO installation is now complete. Solid-State Starters — Troubleshooting information pertaining to the Benshaw, Inc., solid-state starter may be found in the following paragraphs and in the Carrier RediStart MICRO Instruction Manual supplied by the starter vendor. Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables found in the Benshaw manual. 1. Motor terminals or starter output lugs or wire should not be touched without disconnecting the incoming power supply. The silicon control rectifiers (SCRs) although technically turned off still have AC mains potential on the output of the starter. 2. Power is present on all yellow wiring throughout the system even though the main circuit breaker in the unit is off. With power off: Inspect for physical damage and signs of arcing, overheating, etc. Verify the wiring to the starter is correct. Verify all connections in the starter are tight. Check the control transformer fuses. TESTING SILICON CONTROL RECTIFIERS IN THE BENSHAW, INC., SOLID-STATE STARTERS — If an SCR is suspected of being defective, use the following procedure as part of a general troubleshooting guide. 1. Verify power is applied. 2. Verify the state of each SCR light-emitting diode (LED) on the micropower card. NOTE: All LEDs should be lit. If any red or green side of these LEDs is not lit, the line voltage is not present or one or more SCRs has failed. 3. Check incoming power. If voltage is not present check the incoming line. If voltage is present, proceed to Steps 4 through 11. NOTE: If after completing Steps 4 - 11 all measurements are within specified limits, the SCRs are functioning normally. If after completing Steps 4 - 11 resistance measurements are outside the specified limits, the motor leads on the starter power lugs T1 through T6 should be removed and the steps repeated. This will identify if abnormal resistance measurements are being influenced by the motor windings. 4. Remove power from the starter unit.
ANALOG OUT J8 INTERGRATED STARTER MODULE SIO J7 SIO J6 SW2 V/I INPUTS J5 J11 DISCRETE OUTPUTS STAT COMM THERMISTORS J4 J12 DISCRETE OUTPUTS 89 SW1 DIFF PRESSURE J3 INTEGRATED STARTER MODULE J1 24 VAC PRESSURE J2 CONTACT INPUTS 115 VAC LL1 LL2 FUSE 1A SPAR ICE REM STRT 1M 2M SFTY BLD STRT FLT AUX AUX LINE VOLTAGES L1 L2 L3 LINE CURRENTS IL1 IL2 IL3 GROUND FAULTS 1/4 2/5 3/6 VFD HZ 1 1 ISM 19XR04012201 9925 CEPL13025901 PCB05 CEPP130173-03-04-01 00001328 TRANS 1CR J1 WARNING HIGH VOLTAGE DISCONNECT POWER BEFORE SERVICING 1A EVAP PUMP SHUNT TRIP Fig. 41 — Chiller Control Module (CCM) J9 COND PUMP LO FAN DISCRETE CONTROL CONTACTS 1 + C + C + C + C + C + C J2 HI FAN TRIP ALARM J8 J3-1 J3-2 J3-3 1 G + G + 4-20 MA OUT SPARE VFD Fig. 42 — Integrated Starter Module (ISM) R J4 - G + 1 C B A COMM 1 + - + - + - - J7 WARNING HIGH VOLTAGE DISCONNECT POWER BEFORE SERVICING J5 STAT COM 1 + G + G + G 1 + G J6
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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.
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Start Chiller In CCN Control Start
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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:
Page 33 and 34:
PIC II System Functions NOTE: Words
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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 and 82: I. CHILLER PROTECT LIMIT FAULTS STA
Page 83 and 84: I. CHILLER PROTECT LIMIT FAULTS (co
Page 85 and 86: TEMPERATURE (F) PIC II VOLTAGE DROP
Page 87: Control Modules Turn controller pow
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 140:
Copyright 2001 Carrier Corporation
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Start-Up, Operation, and Maintenance Instructions

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