Carrier AquaEdge 19XR series - Page 4

4
CONTENTS (cont)
Page
• OPTIONAL THERMAL DISPERSION FLOW
SWITCH CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 84
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 84
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 84
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH
PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 86,87
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 86
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Check Oil Pressure and Compressor Stop . . . . . . 86
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 87
Check Chiller Operating Condition . . . . . . . . . . . . . . 87
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 87
• 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 . . . . . . . . . . . . . . . . . 87,88
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . 87
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Running System . . . . . . . . . . . . . . . . . . . . . 87
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 88
Preparation for Extended Shutdown. . . . . . . . . . . . . 88
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 88
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 88
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 88
Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-93
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Operating the Optional Pumpout Unit . . . . . . . . . . . 90
• TO READ REFRIGERANT PRESSURES
• POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 93-95
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 93
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 93
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Test After Service, Repair, or Major Leak . . . . . . . . 94
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 94
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 94
Trim Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . . . . . 95
Page
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 95
Check the Lubrication System . . . . . . . . . . . . . . . . . . 95
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 95-98
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 95
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Inspect Refrigerant Float System. . . . . . . . . . . . . . . . 96
• ECONOMIZER FLOAT SYSTEM
• ECONOMIZER DAMPER VALVE
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 96
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect the Starting Equipment . . . . . . . . . . . . . . . . . 98
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 98
Optional Pumpout System Maintenance. . . . . . . . . 98
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 98
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 99-178
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Checking Display Messages . . . . . . . . . . . . . . . . . . . . 99
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 99
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . 116
• TRANSDUCER REPLACEMENT
• COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND OPTIONAL WATERSIDE FLOW
DEVICE CALIBRATION
Control Algorithms Checkout Procedure . . . . . . . 117
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 117
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 117
• INPUTS
•OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . 117
• INPUTS
•OUTPUTS
Replacing Defective Processor Modules . . . . . . . 120
• INSTALLATION
Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
• TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
End of Life and Equipment Disposal . . . . . . . . . . . 121
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
APPENDIX A — ICVC PARAMETER INDEX . .179-185