Carrier 19XL - Page 46

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Fig. 27 — Typical Optional Pumpout System Piping Schematic

with Storage Tank

Fig. 28 — Typical Optional Pumpout System Piping Schematic

without Storage Tank

Main Page

Safety Considerations1
Table of Contents2
Introduction4
Abbreviations and Explanations4
Chiller Familiarization5
Chiller Information Plate5
System Components5
Cooler5
Condenser5
Motor-Compressor5
Control Center5
Factory-Mounted Starter (Optional)5
Storage Vessel (Optional)5
Refrigeration Cycle5
Cooling Cycle8
Lubrication Cycle8
Summary8
Details8
Oil Reclaim System9
- During Normal Chiller Operation9
- During Light Load Conditions9
- During Light Load Conditions Starting Equipment10
Unit Mounted Solid-State Starter10
- (Optional)10
Unit Mounted Wye-Delta Starter11
- (Optional)11
Controls11
Deﬁnitions11
- Analog Signal11
- Digital Signal11
General11
PIC System Components11
- Starter Management Module (Smm)11
- 8-Input Modules11
- 6-Pack Relay Board13
- HOT GAS BYPASS CONTACTOR RELAY (3C) (Op13
- Controland Oil Heater Voltage Selector (S1)13
- Oil Heater Contactor (1C13
- Oil Pump Contactor (2C13
- Control Transformers (T1-T413
LID Operation and Menus14
- General14
- Alarms and Alerts14
- Menu Structure14
- To View Point Status15
- Override Operations15
- Time Schedule Operation16
- To View and Change Set Points20
- Service Operation20
PIC System Functions28
- Capacity Control28
- Entering Chilled Water Control28
- Deadband28
- Proportional Bands and Gain28
- Demand Limiting28
- Chiller Timers28
- Occupancy Schedule28
Safety Controls29
- Shunt Trip29
Default Screen Freeze29
Motor Cooling Control29
Ramp Loading Control31
Capacity Override31
High Discharge Temperature Control32
Oil Sump Temperature Control32
Oil Cooler32
Remote Start/Stop Controls32
Spare Safety Inputs32
- SPARE ALARM CONTACTS Condenser Pump Control32
Condenser Freeze Protection32
Tower Fan Relay33
Auto. Restart after Power Failure33
Water/Brine Reset33
- Reset Type33
Demand Limit Control, Option (Requires Optional 8-Input Module)33
Surge Prevention Algorithm33
Surge Protection34
Lead/Lag Control34
- Common Point Sensor Installation35
- Chiller Communication Wiring35
- Lead/Lag Operation35
- Faulted Chiller Operation36
- Load Balancing36
- Auto. Restart after Power Failure36
Ice Build Control36
- Ice Build Initiation36
- Temperature Control During Ice Build37
- Return to Non-Ice Build Operations37
Attach to Network Device Control37
- Changing Refrigerant Types37
- ATTACHING to OTHER CCN MODULES Service Operation38
- To Log on38
- To Log off38
- Holiday Scheduling38
Controls39
Start-Up/Shutdown/Recycle39
- Sequence39
Local Start-Up39
Shutdown Sequence40
Automatic Soft-Stop Amps Threshold40
- (PSIO Software Version 09 and Higher)40
Chilled Water Recycle Mode40
Safety Shutdown41
Before Initial Start-Up41
Job Data Required41
Equipment Required41
Using the Optional Storage Tank and Pumpout System41
Remove Shipping Packaging41
Open Oil Circuit Valves41
Tighten All Gasketed Joints and Guide Vane Shaft Packing41
Check Chiller Tightness41
Refrigerant Tracer41
Standing Vacuum Test43
Check Relief Devices47
Inspect Wiring47
Chiller Dehydration47
Inspect Water Piping47
- Water Piping47
Carrier Comfort Network Interface48
Check Starter48
- Mechanical-Type Starters48
- Benshaw, Inc. Solid-State Starter49
Oil Charge50
Power up the Controls and Check the Oil Heater50
Set up Chiller Control Conﬁguration50
Input the Design Set Points50
Input the Local Occupied Schedule50
- (Occpc01S)50
Selecting Refrigerant Type50
- TO CHANGE REFRIGERANT TYPE Input Service Conﬁgurations50
- Password50
- Input Time and Date50
- Modify Controller Identification51
- Input Equipment Service Parameters51
- Modify Equipment Configuration52
- Perform an Automated Control Test52
- Controls and Compressor52
High Altitude Locations53
Charge Refrigerant into Chiller53
- 19Xl Chiller Equalization Without Pumpout Unit53
- 19Xl Chiller Equalization with54
- Pumpout Unit54
Initial Start-Up55
Preparation55
Manual Operation of the Guide Vanes55
Dry Run to Test Start-Up Sequence55
Check Rotation55
- If Rotation Is Proper55
- If the Motor Rotation Is Not Clockwise55
- Notes on Solid-State Starters55
Check Oil Pressure and Compressor Stop56
Calibrate Motor Current56
To Prevent Accidental Start-Up56
Check Chiller Operating Condition56
Instruct the Customer Operator56
- Optional Storage Tank and Pumpout System56
- Motor Compressor Lubrication System56
- Control System56
- Review the Start-Up, Operation, and Maintenance Manual56
Operating Instructions56
To Stop the Chiller57
After Limited Shutdown57
Extended Shutdown57
After Extended Shutdown57
Cold Weather Operation57
Manual Guide Vane Operation57
Refrigeration Log57
Pumpout and Refrigerant Transfer Procedures59
Preparation59
Operating the Optional Pumpout59
- Compressor59
Chillers with Pumpout Storage Tanks59
- Transfer Refrigerant from Storage Tank to Chiller59
- Transfer the Refrigerant from60
Chillers with Isolation Valves60
- Transfer All Refrigerant to Chiller Condenser Vessel60
- Transfer All Refrigerant to Chiller Cooler/Compressor Vessel61
- Return Refrigerant to Normal61
General Maintenance61
Refrigerant Properties61
Adding Refrigerant61
Removing Refrigerant61
Adjusting the Refrigerant Charge61
Refrigerant Leak Testing61
Leak Rate61
Test after Service, Repair, or Major Leak61
Repair the Leak, Retest, and Apply62
- Standing Vacuum Test62
Checking Guide Vane Linkage62
Trim Refrigerant Charge62
Weekly Maintenance62
Check the Lubrication System62
Scheduled Maintenance63
Service Ontime63
Inspect the Control Center63
Check Safety and Operating Controls63
- Monthly63
Changing Oil Filter63
Oil Speciﬁcation63
Oil Changes63
- To Change the Oil63
Refrigerant Filter63
Water Leaks64
Inspect Refrigerant Float System64
Inspect Relief Valves and Piping64
Compressor Bearing and Gear64
- Maintenance64
Inspect the Heat Exchanger Tubes64
Water Treatment65
Inspect the Starting Equipment65
Check Pressure Transducers65
Optional Pumpout System Maintenance65
- Optional Pumpout Compressor Oil Charge65
- Optional Pumpout Safety Control65
Ordering Replacement Chiller Parts65
Troubleshooting Guide66
Overview66
Checking the Display Messages66
Checking Temperature Sensors66
- Voltage Drop66
- DUAL TEMPERATURE SENSORS Checking Pressure Transducers66
Control Algorithms Checkout Procedure67
Control Test67
Control Modules78
- Red Led78
- GREEN Leds78
Notes on Module Operation78
Processor Module (PSIO)79
Starter Management Module (SMM)79
Options Modules (8-Input)79
Replacing Defective Processor Modules80
- Installation80
Solid-State Starters81
- Testing Silicon Control Rectifiers81
Physical Data85
Index98

Carrier 19XL - Page 46

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