Carrier 23XL - Page 3

3
CONTENTS (cont)
Page
Power Up the Controls and
Check the Oil Heater
. . . . . . . . . . . . . . . . . . . . . . . . . . 60
• SOFTWARE VERSION
Software Configuration
. . . . . . . . . . . . . . . . . . . . . . . . . 60
Input the Design Set Points
. . . . . . . . . . . . . . . . . . . . . 60
Input the Local Occupied Schedule
(OCCPC01S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input Service Configurations
. . . . . . . . . . . . . . . . . . . . 60
• PASSWORD
• INPUT TIME AND DATE
• CHANGE CVC CONFIGURATION IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE CVC DISPLAY FROM ENGLISH
TO METRIC UNITS
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform A Control Test
. . . . . . . . . . . . . . . . . . . . . . . . . . 63
• COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND WATERSIDE FLOW DEVICE CALI-
BRATION
Check Optional Pumpout System
Controls and Compressor
. . . . . . . . . . . . . . . . . . . . . 63
High Altitude Locations
. . . . . . . . . . . . . . . . . . . . . . . . . 63
Charge Refrigerant Into Chiller
. . . . . . . . . . . . . . . . . . 64
• CHILLER EQUALIZATION WITHOUT
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .65,66
Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Dry Run to Test Start-Up Sequence
. . . . . . . . . . . . . 65
Check Oil Pressure and Compressor Stop
. . . . . . 65
To Prevent Accidental Start-Up
. . . . . . . . . . . . . . . . . . 66
Check Chiller Operating Condition
. . . . . . . . . . . . . . 66
Instruct the Customer Operator
. . . . . . . . . . . . . . . . . 66
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP OPERATION,
AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS
. . . . . . . . . . . . . . . . . 66-68
Operator Duties
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up
. . . . . . . . . . . . . . . . . 66
To Start The Chiller
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Running System
. . . . . . . . . . . . . . . . . . . . . 66
To Stop the Chiller
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
After Limited Shutdown
. . . . . . . . . . . . . . . . . . . . . . . . . 67
Preparation for Extended Shutdown
. . . . . . . . . . . . 67
After Extended Shutdown
. . . . . . . . . . . . . . . . . . . . . . . 67
Cold Weather Operation
. . . . . . . . . . . . . . . . . . . . . . . . . 67
Slide Valve Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Refrigeration Log
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-71
Preparation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Page
Operating the Optional Pumpout Unit
. . . . . . . . . . . 69
• TO READ REFRIGERANT PRESSURES
Chillers with Isolation Valves
. . . . . . . . . . . . . . . . . . . . 70
• TRANSFER ALL REFRIGERANT TO CHILLER
CONDENSER VESSEL
• TRANSFER ALL REFRIGERANT TO CHILLER
COOLER VESSEL
• RETURN CHILLER TO NORMAL OPERATING
CONDITIONS
Chillers With Storage Tanks
. . . . . . . . . . . . . . . . . . . . . 71
• TRANSFER REFRIGERNT FROM PUMPOUT
STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
GENERAL MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . 72
Refrigerant Properties
. . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adding Refrigerant
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removing Refrigerant
. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjusting the Refrigerant Charge
. . . . . . . . . . . . . . . 72
Refrigerant Leak Testing
. . . . . . . . . . . . . . . . . . . . . . . . 72
Refrigerant Leak Rate
. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Test After Service, Repair, or Major Leak
. . . . . . . . 72
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test
. . . . . . . . . . . . . . . . . . . . . . . . 72
Trim Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . . . . . 72
WEEKLY MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . 73
Check the Lubrication System
. . . . . . . . . . . . . . . . . . 73
SCHEDULED MAINTENANCE
. . . . . . . . . . . . . . . . 73-76
Service Ontime
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Panel
. . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil and Oil Filter
. . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oil Separator Coalescer
. . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Filter/Drier
. . . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Strainers (TC Frame 1 and
2 Chillers Only)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspect Refrigerant Float System
. . . . . . . . . . . . . . . 74
Inspect Relief Valves and Piping
. . . . . . . . . . . . . . . . 74
Compressor Bearing Maintenance
. . . . . . . . . . . . . . 75
Compressor Rotor Check
. . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Heat Exchanger Tubes
. . . . . . . . . . . . . . 75
• COOLER
• CONDENSER
Water Leaks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Water Treatment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Starting Equipment
. . . . . . . . . . . . . . . . . 75
Check Pressure Transducers
. . . . . . . . . . . . . . . . . . . . 76
Optional Pumpout System Maintenance
. . . . . . . . . 76
• OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE
• OPTIONAL PUMPOUT SAFETY
CONTROL SETTINGS
Ordering Replacement Chiller Parts
. . . . . . . . . . . . . 76
TROUBLESHOOTING GUIDE
. . . . . . . . . . . . . . . . 76-103
Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the Display Messages
. . . . . . . . . . . . . . . . . 77
Checking Temperature Sensors
. . . . . . . . . . . . . . . . . 77
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS