Carrier 19XL User Manual

Start-up, operation, and maintenance instructions, Safety considerations

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Table of contents

Document Outline

Contents
Safety Considerations
Introduction
Abbreviations and Explanations
Machine Familiarization
- Machine Information Plate
- System Components
- Cooler
- Condenser
- Motor-Compressor
- Control Center
- Factory-Mounted Starter (Optional)
- Storage Vessel (Optional)
Refrigeration Cycle
Motor/Oil Refrigeration Cooling Cycle
Lubrication Cycle
- Summary
- Details
- Oil Reclaim System
  - During Normal Machine Operation,
  - During Light Load Conditions,
Starting Equipment
- Unit-Mounted Solid-State Starter (Optional)
- Unit-Mounted Wye-Delta Starter (Optional)
Controls
- Definitions
  - Analog Signal
  - Digital Signal
  - Volatile Memory
- General
- PIC System Components
  - Processor Module (PSIO)
  - Starter Management Module (SMM)
  - Local Interface Device (LID)
  - 6-Pack Relay Board
  - 8-Input Modules
  - Oil Heater Contactor (1C)
  - Oil Pump Contactor (2C)
  - Hot Gas Bypass Contactor Relay (3C) (Optional)
  - Control Transformers (T1-T4)
  - Control and Oil Heater Voltage Selector (S1)
- LID Operation and Menus
  - General
  - Alarms and Alerts
  - Menu Structure
  - To View Point Status
  - Override Operations
  - Time Schedule Operation
  - To View and Change Set Points
  - Service Operation
- PIC System Functions
  - Capacity Control
  - Entering Chilled Water Control
  - Deadband
  - Proportional Bands and Gain
  - Demand Limiting
  - Machine Timers
  - Occupancy Schedule
- Safety Controls
  - Shunt Trip
- Default Screen Freeze
- Motor Cooling Control
- Ramp Loading Control
- Capacity Override
- High Discharge Temperature Control
- Oil Sump Temperature Control
  - PSIO Software Version 08 and Lower
  - PSIO Software Version 09 and Higher
- Oil Cooler
- Remote Start/Stop Controls
- Spare Safety Inputs
  - Spare Alarm Contacts
- Condenser Pump Control
- Condenser Freeze Prevention
- Tower-Fan Relay
- Auto. Restart After Power Failure
- Water/Brine Reset
- Demand Limit Control, Option — (Requires Optional 8-Input Module)
- Surge Prevention Algorithm
- Surge Protection
- Lead/Lag Control
  - Common Point Sensor Installation
  - Machine Communication Wiring
  - Lead/Lag Operation
  - Faulted Chiller Operation
  - Load Balancing
  - Auto. Restart After Power Failure
- Ice Build Control
  - Ice Build Initiation
  - Start-Up/Recycle Operation
  - Temperature Control During Ice Build
  - Termination Of Ice Build
  - Return to Non-ice Build Operations
- Attach to Network Device Control
  - Changing Refrigerant Types
  - Attaching to other CCN Modules
- Service Operation
  - To Log On
  - To Log Off
  - Holiday Scheduling
Start-Up/Shutdown/Recycle Sequence
- Local Start-Up
- Shutdown Sequence
- Automatic Soft Stop Amps Threshold (PSIO Software Version 09 and Higher)
- Chilled Water Recycle Mode
- Safety Shutdown
Before Initial Start-Up
- Job Data Required
- Equipment Required
- Using the Optional Storage Tank and Pumpout System
- Remove Shipping Packaging
- Open Oil Circuit Valves
- Torque All Gasketed Joints
- Check Machine Tightness
- Refrigerant Tracer
- Leak Test Machine
- Standing Vacuum Test
- Machine Dehydration
- Inspect Water Piping
- Check Optional Pumpout Compressor Water Piping
- Check Relief Devices
- Inspect Wiring
- Carrier Comfort Network Interface
- Check Starter
  - Mechanical-Type Starters
  - Benshaw, Inc. Solid-State Starter
  - Cutler-Hammer® Solid-State Starters
- Oil Charge
- Power Up the Controls and Check the Oil Heater
  - Software Version
- Set Up Machine Control Configuration
- Input the Design Set Points
- Input the Local Occupied Schedule (OCCPC01S)
- Selecting Refrigerant Type
  - To Confirm Refrigerant Type
  - To Change Refrigerant Type
- Input Service Configurations
  - Password
  - Input Time and Date
  - Change Lid Configuration If Necessary
  - Modify Controller Identification If Necessary
  - Input Equipment Service Parameters If Necessary
  - Modify Equipment Configuration If Necessary
  - Check Voltage Supply
  - Perform an Automated Controltest
- Check Optional Pumpout System Controls and Compressor
- High Altitude Locations
- Charge Refrigerant into Machine
  - 19XL Machine Equalization without Pumpout Unit
  - 19XL Machine Equalization With Pumpout Unit
  - Trimming Refrigerant Charge
Initial Start-up
- Preparation
- Manual Operation of the Guide Vanes
- Dry Run to Test Start-Up Sequence
- Check Rotation
- Check Oil Pressure and Compressor Stop
- Calibrate Motor Current Demand Setting
- Check Machine Operating Condition
- To Prevent Accidental Start-Up
- Instruct the Customer Operator
Operating Instructions
- Operator Duties
- Prepare the Machine for Start-Up
- To Start the Machine
- Check the Running System
- To Stop the Machine
- After Limited Shutdown
- Extended Shutdown
- After Extended Shutdown
- Cold Weather Operation
- Manual Guide Vane Operation
- Refrigeration Log
Pumpout and Refrigerant Transfer Procedures
- Preparation
- Operating the Optional Pumpout Compressor
  - To Read Refrigerant Pressures
- Machines with Storage Tanks
  - Transfer Refrigerant from Storage Tank to Machine
  - Transfer the Refrigerant from Machine to Storage Tank
- Machines with Isolation Valves
  - Transfer all Refrigerant to Condenser Vessel
  - Transfer all Refrigerant to Cooler/ Compressor Vessel
- Return Refrigerant to Normal Operating Conditions
General Maintenance
- Refrigerant Properties
- Adding Refrigerant
- Removing Refrigerant
- Adjusting the Refrigerant Charge
- Refrigerant Leak Testing
- Leak Rate
- Test After Service, Repair, or Major Leak
  - Refrigerant Tracer
  - To Pressurize With Dry Nitrogen
- Repair the Leak, Retest, and Apply Standing Vacuum Test
- Checking Guide Vane Linkage
  - Checking the Auxiliary Switch on Guide Vane Actuator
- Trim Refrigerant Charge
Weekly Maintenance
- Check the Lubrication System
Scheduled Maintenance
- Service Ontime
- Inspect the Control Center
- Check Safety and Operating Controls Monthly
- Changing Oil Filter
- Oil Specification
- Oil Changes
  - To Change the Oil
- Refrigerant Filter
- Oil Reclaim Filters
- Inspect Refrigerant Float System
- Inspect Relief Valves and Piping
- Compressor Bearing and Gear Maintenance
- Inspect the Heat Exchanger Tubes
  - Cooler
  - Condenser
- Water Leaks
- Water Treatment
- Inspect the Starting Equipment
- Check Pressure Transducers
- Optional Pumpout System Maintenance
  - Optional Pumpout Compressor Oil Charge
  - Optional Pumpout Safety Control Settings
- Ordering Replacement Chiller Parts
Troubleshooting Guide
- Overview
- Checking the Display Messages
- Checking Temperature Sensors
- Checking Pressure Transducers
  - Transducer Replacement
- Control Algorithms Checkout Procedure
- Control Test
- Control Modules
  - Red Led
  - Green LEDs
- Notes on Module Operation
- Processor Module (PSIO)
  - Inputs
  - Outputs
- Starter Management Module (SMM)
  - Inputs
  - Outputs
- Options Modules (8-Input)
- Replacing Defective Processor Modules
  - Installation
- Solid-State Starters
- Physical Data
Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller
List of Tables
List of Figures