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19XR,XRV
Hermetic Centrifugal Liquid Chillers
50/60 Hz
With PIC II Controls and HFC-134a
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY
reliable service when operated within design specifica- FLUSH EYES with water and consult a physician.
tions. When operating this equipment, use good judgment
NEVER APPLY an open flame or live steam to a refrige
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CONTENTS Page Page Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5 Capacity Override . . . . . . .
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CONTENTS (cont) Page Page Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 MOTOR COMPRESSOR LUBRICATION Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 SYSTEM Check Optional Pumpout Compressor CONTROL SYSTEM Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 AUXILIARY EQUIPMENT Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 DESCRIBE CHILLER CYCLES Inspect Wir
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CONTENTS (cont) Page Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74 This unit uses a microprocessor control system. Do not Compressor Bearing and Gear short or jumper between terminations on circuit boards or Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 modules; control or board failure may result. Inspect the Heat Exchanger Tubes Be aware of electrostatic discharge (static electricity) when and Flow Devices . . . . . . . . . . . . . .
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Factory-installed additional components are referred to as through its internal tubes in order to remove heat from the options in this manual; factory-supplied but field-installed ad- refrigerant. ditional components are referred to as accessories. Motor-Compressor — This component maintains sys- The chiller software part number of the 19XR unit is located tem temperature and pressure differences and moves the heat- on the back of the CVC/ICVC. carrying refrigerant from the cooler to the condens
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FRONT VIEW 1 2 3 4 5 LEGEND 17 6 1 — Guide Vane Actuator 2 — Suction Elbow 3 — Chiller Visual Controller/ International Chiller Visual Control (CVC/ICVC) 4 — Chiller Identification Nameplate 5 — Cooler, Auto Reset Relief Valves 16 6 — Cooler Pressure Transducer 7 — Condenser In/Out Temperature Thermistors 8 — Condenser Waterflow Device (ICVC Inputs available) 9 — Cooler In/Out Temperature Thermistors 7 10 — Cooler Waterflow Device (ICVC Inputs avail- able) 11
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refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) Factory-Mounted Starter or Variable Fre- when it is discharged from the compressor into the condenser. quency Drive (Optional) — The starter allows for the proper start and disconnect of electrical energy for the com- Relatively cool (typically 65 to 90 F [18 to 32 C]) water pressor-motor, oil pump, oil heater, and control panel. flowing into the condenser tubes removes heat from the refrig- erant and the vapor condenses to liquid. S
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Flow to the motor cooling system passes through an orifice cooler heat exchanger. The oil cooler uses refrigerant from the and into the motor. Once past the orifice, the refrigerant is condenser as the coolant. The refrigerant cools the oil to a tem- directed over the motor by a spray nozzle. The refrigerant perature between 120 and 140 F (49 to 60 C). collects in the bottom of the motor casing and is then drained As the oil leaves the oil cooler, it passes the oil pressure back into the cooler
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REAR MOTOR FWD MOTOR OIL SUPPLY TO BEARING BEARING FORWARD HIGH SPEED BEARING LABYRINTH GAS LINE MOTOR COOLING LINE ISOLATION VALVE OIL FILTER TXV BULB PRESSURE ISOLATION PUMP TRANSDUCER VALVE OIL SIGHT OIL HEATER GLASS OIL PUMP EDUCTOR FILTER COOLER MOTOR ISOLATION SIGHT GLASS VALVE OIL SKIMMER LINE Fig. 4 — Lubrication System solid-state starters. This module controls and monitors all as- STARTING EQUIPMENT pects of the starter. See the Controls section on page 10 for ad- The 19XR requires a m
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There is a display on the front of the Benshaw, Inc., solid- state starters that is useful for troubleshooting and starter checkout. The display indicates: voltage to the SCRs SCR control voltage 7 power indication proper phasing for rotation start circuit energized 1 over-temperature ground fault 2 current unbalance run state software configuration 3 The starter is further explained in the Check Starter and Troubleshooting Guide sections, pages 54 and 76. 4 6 Unit-Mounted Wy
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Forward AUTO SPEED RUNNING Reverse MAN VOLTS REMOTE JOG RUN AMPS PROGRAM AUTO Hz JOB Kw FORWARD TORQUE REVERSE ENTER PROGRAM AUTO Forward Password SPEED RUNNING MAN Reverse VOLTS REMOTE AMPS JOG RUN Hz AUTO GRAM PRO- JOB Kw FORWARD TORQUE REVERSE ENTER Password PROGRAM OPTIONAL METER PACKAGE MANUAL RESET Fig. 7 — Variable Frequency Drive (VFD) DC BUS BAR + MEASUREMENT - POINT INTEGRATED STARTER MODULE (ISM) INITIAL DC BUS MEASUREMENT POINT + DANGER - OIL PUMP HIGH VOLTAGE DISCONNECT Forward AUTO
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FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE WATER SENSOR WATER CABLES SENSOR CABLES COOLER PRESSURE TRANSDUCER CONNECTION CONDENSER CONDENSER SCHRADER DISCHARGE COMPRESSOR MOTOR WINDING SERVICE PRESSURE FITTING (HIDDEN) ISOLATION DISCHARGE TEMPERATURE VALVE CABLE CONDENSER VALVE ELBOW JOINTS CABLE PRESSURE (OPTIONAL) TRANSDUCER CONNECTION TOP VIEW COMPRESSOR DETAIL Fig. 9 — 19XR Controls and Sensor Locations 12
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The PIC II can interface with the Carrier Comfort Network ground fault, remote start contact, spare safety, condenser high (CCN) if desired. It can communicate with other PIC I or PIC pressure, oil pump interlock, starter 1M, and run contacts. The II equipped chillers and other CCN devices. ISM contains logic capable of safety shutdown. It shuts down the chiller if communications with the CVC/ICVC are lost. The PIC II consists of 3 modules housed inside 3 major The ISM can also act as the interf
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Fig. 12 — Control Panel Fig. 13 — Power Panel 14
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For more information on the menu structures, refer to CVC/ICVC Operation and Menus (Fig. 14-20) PRIMARY STATUS COMPRESSOR DATE TIME MESSAGE ON TIME Fig. 17. GENERAL SECONDARY STATUS The CVC/ICVC display automatically reverts to the RUNNING TEMP CONTROL 01-01-95 11:48 MESSAGE LEAVING CHILLED WATER 28.8 HOURS default screen after 15 minutes if no softkey activity CHW IN CHW OUT EVAP REF ALARM LIGHT takes place and if the chiller is not in the pumpdown 55.1 44.1 40.7 (ILLUMINATED CDW IN CDW OUT C
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Press to leave the selected decision or field with- QUIT 2. Press or to highlight the desired NEXT PREVIOUS out saving any changes. status table. The list of tables is: MAINSTAT — Overall chiller status STARTUP — Status required to perform start-up of chiller COMPRESS — Status of sensors related to the compressor Press to leave the selected decision or field and HEAT_EX — Status of sensors related to the heat ENTER save changes. exchangers POWER — Status of motor input power ISM_ST
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DEFAULT SCREEN LOCAL RESET MENU (SOFTKEYS) CCN Start Chiller In CCN Control Start Chiller in Local Control Clear Alarms Access Main Menu STATUS SCHEDULE SETPOINT SERVICE (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT) 1 1 1 1 List the Status Tables List the Service Tables Display The Setpoint Table • MAINSTAT • STARTUP List the Schedules • COMPRESS • Base Demand Limit • HEAT_EX • LCW Setpoint • POWER • ECW Setpoint • ISM_STAT • Ice Build Setpoint • CVC_PSWD
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SERVICE TABLE SELECT NEXT PREVIOUS EXIT ALARM HISTORY Display Alarm History (The table holds up to 25 alarms and alerts with the most recent alarm at the top of the screen.) CONTROL TEST List the Control Tests CCM Thermistors CCM Pressure Transducers CONTROL ALGORITHM STATUS Pumps Discrete Outputs Guide Vane Actuator List the Control Algorithm Status Tables Diffuser Actuator CAPACITY (Capacity Control) Pumpdown/Lockout OVERRIDE (Override Status) Terminate Lockout LL_M
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SERVICE MENU CONTINUED FROM PREVIOUS PAGE ISM (STARTER) CONFIG DATA EQUIPMENT SERVICE (ENTER A 4-DIGIT PASSWORD) 4 4 4 4 (VALUES SHOWN AT FACTORY DEFAULT) Service Tables: OPTIONS Service Tables: SETUP1 ISM (STARTER) CONFIG PASSWORD SETUP2 • ISM_CONF • LEADLAG • RAMP_DEM • TEMP_CTL Select a Service Table NEXT PREVIOUS SELECT EXIT Select a Service Table Parameter PREVIOUS SELECT EXIT NEXT Modify a Service Table Parameter INCREASE ENTER DECREASE QUIT (ANALOG VALUES) ENABLE DISABLE QUIT ENTE
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For Discrete Points — Press or to se- OCCPC02S — ICE BUILD Time Schedule START STOP lect the desired state. OCCPC03S — CCN Time Schedule For Analog Points — Press or INCREASE 3. Press to view the desired time schedule. SELECT to select the desired value. DECREASE 4. Press or to highlight the desired NEXT PREVIOUS 3. Press to register the new value. ENTER period or override to change. NOTE: When overriding or changing metric values, it is nec- 5. Press to access the highlighted period o
