Carrier PC211 User Manual
19XL
50/60 Hz
Hermetic Centrifugal Liquid Chillers
®
with HCFC–22 and HFC–134a
Start-Up, Operation, and Maintenance Instructions
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and
without incurring obligations.
PC 211 Catalog No. 531-94512-94 Form 19XL-3SS Replaces: 19XL- 2SS
Copyright
Carrier Corpor ation 1994
©
Safety Considerations
Centrifugal liquid chillers are designed to provide safe and reliable service when
operated within design specifications. When operating this equipment, use good
judgement and safety precautions to avoid damage to equipment and property or injury
to personnel.
Be sure you understand and follow the procedures and safety precautions contained
in the machine instructions as well as those listed in this guide.
DANGER
DO NOT VENT refrigerant relief devices within a building. Outlet from rupture
disc or re lie f v al ve mu st be vent e d ou t doo rs in a c co rd an ce with the la tes t e dit i on
of ANS I/ASHRAE 15 (Ameri can Nat io nal Sta nd ards In st itute /American Society of
Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of
ref rigerant in an enclosed spa ce can dis pl ace ox ygen and cause asphyxiation .
PROVIDE a dequ a te vent il a ti on in a c cordance with ANSI/ASHRAE 1 5 , es peciall y
for enclosed and low overhead spaces. Inhalation of high concentrations of
vapor is harmful and may cause heart irregularities, unconsciousness, or death.
Misuse can be fata l. Va po r is heavi er than air and reduces the amount o f oxygen
available for breathing. Product causes eye and skin irritation. Decomposition
pro ducts are haza rdous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose.
Oxygen gas reacts violently with oil, grease, and other common substances.
NEVER EXCEED specified test pressures. VERIFY the allowable test pressure by
che cking the instruct io n literature and the design press ures on th e equipment
nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.
DO NO T VALVE O FF any safe t y device.
BE SURE that all pressure relief devices are properly installed and functioning
befor e ope r ati ng an y mac hine.
!
DANGER
WARNING
DO NOT WELD OR FLAM E CUT any refri gerant li ne or vessel un t il all refrigerant
(
liquid and vapor
placed with dry air or nitrogen and the work area should be well ventilated.
Refr ig erant in con t act with an open flame pr od uces toxic gases.
DO NOT US E eyebol t s or eyebolt ho les to rig machin e sections or the entire
assemb ly.
DO NOT work on high-voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches,
sta rte r s, or oil heate r until you a r e sur e AL L P OW E R I S OFF and no re si du al v ol t age can le ak f rom ca pacitors or sol id-st at e components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTE D, confi rm t hat all ci rcuit s are deenergized before resuming work.
DO NOT siphon refrigerant .
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE
SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid
refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult
a ph y sician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous
over pressu re can result. Wh en it is ne cessar y t o he at ref rigerant , u se only
warm (110 F [43 C]) water.
!
) has been removed from chiller. Traces of vapor should be dis-
WARNING
WAR NING
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It
is DANGEROUS AND IL LEGAL. W hen cylinder is emptie d, evacuat e remaining
gas pressure, loosen th e collar , an d unscr ew and discard t he valve stem. DO
NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The
introduction of the wrong refrigerant can cause machine damage or malfunction
to this machine. Operation of this equipment with refrigerants other than those
cited herein shou ld comp ly with ANS I/ASHRAE - 15 (latest ed ition). Con t act Carrier for further information on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under
pressure or while machine is running. Be sure pressure is at 0 psig (0 kPa)
before breakin g an y refrigeran t connec t io n.
CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices
AT L E AS T ONCE A YEAR. If machine op erates i n a co rrosive atmo sphere,
in spect th e devices at mor e f requen t in t ervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the
val ve body o r mechani sm. Re pl ace the device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring. Sudden
release of t he spri ng can cause it and o bj ects in its path to act as proj ect iles.
!
WARNING
CAUTION
DO NOT STEP on refrigerant lines. Broken lines can whip about and release
refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe
practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection
cov ers or ot her heavy component s. Even if compon ents ar e li ght, us e mecha ni cal equipment when there is a risk of slipping or losing your balance.
BE AWARE tha t cert ain au t omati c st art arrangem ents CAN ENGAGE THE
STARTER, TOWER FAN, OR PUMPS. Open the disconnect
tower fan, and pumps.
USE only repair or replacement parts that meet the code requirements of the
original equipment.
DO NO T VE N T OR DR A IN wa te rb ox es c on t ai nin g industr ia l brine s, liq uid, gas e s,
or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely
drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items
hav e been removed b ef ore rot at ing any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.
!
CAUTION
ahead of
the st arter,
CAUTION
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust,
leaks , o r damage.
PROV IDE A DRAIN conne ct ion in the vent lin e near each pressure rel ief de vice
to prevent a build-up of condensate or rain water.
!
CAUTION
Contents
List of Tables
List of Figures
Safety Considerations
Introduction
Abbreviations and Explanations
Machine Familiarization
Machine Information Plate
System Components
Cooler
Condenser
Moto r-Co m pr e ss o r
Control Center
Factory-Mounte d Starte r (O ptional)
Storage Vessel (Optional)
Contents
Refrigeration Cycle
Motor/Oil Ref r ige r ati on Co oling Cyc le
Lubrication Cycle
Summary
Details
Oil Reclaim System
During Normal Machine Operation
During Light Load Conditions
Starting Equipment
Unit Mounted Solid-State S tarter (Optional)
Unit Mounted Wye-Delta Starter (Optional)
Controls
Definitions
Analog Signal
Digit al Signal
Volatile Memory
General
PIC System Components
Pr ocessor Modu le (PSIO)
Starter Management Module (SMM)
Local I nter f ace Devi ce (LID)
6-Pack Relay Board
8-Input Modules
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypa ss Contactor Relay (3C) (Optional )
Control Transformers (T1-T4)
Contents
Control and Oil Heater Volt age Sel ecto r (S1)
LID Operation and Menus
General
Alarm and Alerts
Menu Structure
To View Point Sta tus
Override Operations
Time Schedule Operation
To View and C hange Set Point s
Service Operation
PIC System Funct ions
Capacity Control
Enteri ng Chilled Water Control
Deadband
Proportional Bands and Gain
Dema nd Limiting
Machine Timers
Contents
Occupancy Schedule
Safety Controls
Shunt Trip
Contents
Def a u lt Scr een Fr eeze
Motor Cooling Control
Ramp Loading Control
Capacity Ov erride
High Discharge Temperature Cont r ol
Oil Sump Temperature Control
PSIO Softwa r e Vers ions 08 and Lower
PSIO Software Versions 09 and Hi gher
Oil Cooler
Remote Start/ St op Contr ol s
Spare Safety Inputs
Spare Alarm C ont acts
Condenser Pump Control
Condenser Freeze Pr ote ction
Contents
Tower Fan Relay
Auto. Restart After Power Failur e
Water/Br ine Reset
Demand Limit Control, Option (Requires Optional 8- Input Module)
Surge Prevention Algor ithm
Surge Protection
Lead/Lag Control
Common Point Sensor Installation
Machi ne Communication Wiri ng
Lead/Lag Operation
Faulted Chiller Operation
Load Balancing
Auto Restart After Power Failure
Ice Build Control
Ice Build Initiation
Contents
Start-Up/Recycle Operation
Tempe rature Control During Ice Build
Termination of Ice Build
Retu rn to Non-i ce Build Operati ons
Attach to Network De vi ce Control
Changing Refrigerant Types
Attachi ng to Other CC N Modul es
Service Operation
To Log On
To Log Off
Holida y Scheduling
Start-Up/Shutdown/Recycle Sequence
Local Start-Up
Shutdown Sequence
Automatic Soft-S top Am ps Threshold (PSIO Sof tw are Version 09 and
Higher)
Chilled Water Recycle Mode
Safety Shutdown
Before Initial Start-Up
Job Data Required
Equipment Requi r ed
Using the Optional Storage Ta nk and Pumpout System
Remove Shipping Packaging
Open Oil Circuit Valves
Torque All Gasketed Joints
Check Machine Tightness
Ref rigerant T racer
Contents
Leak Test Machine
Standing Vacuum Te st
Contents
Machine Dehydration
Inspect Water Piping
Check Optional Pumpout Compre ssor Water Piping
Check Relief Devices
Inspect Wiring
Carrie r 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
Softwa re Ver sio n
Set Up Machine Control Configurat ion
Input the Design Set P oi n ts
Contents
Input the Local Occupied Schedule (OCCPC01S)
Selecting Refrigerant Type
To Confirm Refrigerant Type
To Chang e Re frigerant Type
Input Service Configurations
Password
Input Time and Date
Change LID Configuration If Necessary
Modify Controller Identificati on If Necessary
Input Equipment Service Par ameters If Necessary
Modify Equipment Configuration If Necessary
Check V oltage Supply
Perform an Automated Control Test
Check Optional Pumpout System Controls and Compressor
High Altitude Loca ti ons
Charg e Refrig er ant into Mach ine
19XL Mach ine E quali z at ion without Pumpout Uni t
19XL Mach ine E quali z at ion with Pumpout Unit
Trimmi ng Refrigerant Charge
Initial Start-Up
Preparation
Manual Operation of th e Guid e Vane s
Dry Run to Test Start-Up Sequence
Check Rotation
If Rotation Is Proper
If the Motor Rotation Is Not Clockwise
Notes o n Solid- State Starter s (Bens haw, Inc.)
Contents
Check Oil Pressure and Compressor Stop
Calibrate Motor Current Demand Setting
To Prevent Accidental Start-Up
Contents
Check Machine Operating Condition
Instruct the Customer Operator
Cool er-Condenser
Option al Stor age Tank and Pumpout System
Motor Compressor Assembly
Motor Compressor Lubrication Sys te m
Control System
Auxiliary Equ ipment
Describe Machine Cycles
Review Maintenance
Safety Devices and Procedures
Check Operator Know ledge
Review the Start-Up, Operation, and Maintenance Manual
Operating Ins tr uc t ion s
Operator Duties
Contents
Prepare the Machine for Start-Up
To Star t th e M achine
Check the Runni ng System
To Stop the Machine
After Limited Shutdow n
Extended Shutdown
After Extende d Shut down
Cold Weather Operation
Manual Guide Vane Operation
Refrigera ti on Log
Pump out and Ref rigerant Transf er Procedures
Pr eparation
Operating the Optional Pumpout Compressor
To Read Re frige ran t Pressur es
Machines with Storage Tanks
Transfer Refri gerant from Storag e Tank to Mach ine
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
Retu rn Refrigeran t to Normal Operating Conditions
Genera l Mai nt e na nc e
Refrigeran t Pro perties
Adding Refri gera n t
Removing Refrigerant
Adjustin g the Refr igeran t Charge
Contents
Ref rigeran t Leak T est in g
Le ak Ra te
Test After Service, Repair, or Major Le ak
Ref rigerant Tracer
To Pres surize w ith Dry Nitr ogen
Repair the Leak, Retest, and Apply S tanding Vacuum Test
Checking Guide Vane Link age
Checki ng the Auxiliary S witch on Gu ide Vane Actua t or
Trim Refrigerant Charge
Weekly Maintenance
Check the Lubrication System
Sched ule d Mai nt e na nc e
Service Ontime
Inspect th e Co ntro l Cen ter
Contents
Check Safety and O perating Controls Monthly
Changing Oil Filter
Oil Specification
Contents
Oil Changes
To Change the Oil
Refrigeran t F ilter
Oil Reclaim Filters
Inspect Refrigerant Float System
Inspect Relief Valves and Piping
Com pr e sso r Be aring and Gear Ma in t en ance
Inspect the Hea t Exchanger Tubes
Cooler
Condenser
Water Leaks
Water Tre atment
Inspect the Starting Equipment
Check Pressure Transducers
Optional Pumpout System Maintenance
Optional Pumpout Compressor Oil Charge
Option al Pu mp out S af ety Control Settings
Ordering Replacement Chiller Parts
Troub le sh ooting Gui de
Overvi ew
Checking the Display Messages
Checking Tem per a t ur e Sen sor s
Resistance Check
Voltage Drop
Check Sensor Ac cura cy
Dual Tempe r ature Sensors
Contents
Checking Pressure Transducers
Transducer Replacement
Control Algori thms Checkout Procedure
Contents
Control Test
Control Modu les
Red LED
Green LE Ds
Notes on Module Operation
Processor Module (PSIO)
Inputs
Outputs
Starter Management Modul e ( SM M)
Inputs
Outputs
Options Modules (8-Input)
Replacing Defective Processor Modules
Installation
Solid-State Starters
Testing Silicon Control Rectifiers in Benshaw, Inc. Solid-State Starters
Contents
Testing Silicon Control Rectifiers (SCRs) in Cutler-Hammer®
Solid-State Starters
Electronic Protection Relay (EPR)
Physical Data
Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller
List of Tables
Table 1 — Major PIC Components and Panel Locations
Table 2 — LID Screens
Example 1 — Status01 Disp lay Scr een
Example 2 — Status02 Disp lay Scr een
Example 3 — Status03 Disp lay Scr een
Example 4 — Setpoint Display Screen
Example 5 — Confi gur ation (Config) Dis p l ay Scr ee n
Example 6 — Le ad/Lag Confi guration Display Screen
Example 7 — Service1 Display Screen
Example 8 — Service2 Display Screen
Example 9 — Service3 Display Screen
Example 10 — Mainten ance (Maint0 1) Display Scr een
Contents
Example 11 — Mainten ance (Maint0 2) Display Scr een
Example 12 — Mainten ance (Maint0 3) Display Scr een
Example 13 — Mainten ance (Maint0 4) Display Scr een
Contents
Table 3 —
Protective Safety Li m it s and Control Settings
Table 4 — Capacity O ver rides
Table 5A — HCFC-22 Pressure — Temperature (F)
Table 5B — HCFC-22 Pressure — Temperature (C)
Table 5C — H FC-134a Pressure
Table 5D — H FC-134a Pressure
Te m p e r a ture (F )
—
Te m p e r a ture (C)
—
Table 6 — Potentiometer Adjustme nt
Table 7 — Amps Corre ction Fa ctors for 19XL Motors
Table 8 — Control Test Menu Functions
Table 9 — Refrigerant (HCFC-22 or HFC-134a) Charges
Table 10 — LID Primar y an d Seconda r y Messages and Custom Alarm/
Alert Messages with Troublesho oting Guides
A. Shutdown with On/Off/Reset-Off
B. Timing Out or Ti m ed Out
C. In Recycle Shutdown
Contents
Table 10 — LID Primary an d Seconda r y Messages and Custom Alarm/
Alert Messages with Troublesho oting Guides (Continued)
D. Pre-Start Alerts
E. Normal or Auto.-Restart
F. Sta r t-Up Failures
G. Compressor Jumpstart and Refrigerant Protection
H. Nor mal Run with Reset, Tempe r ature, or Demand
I. Normal Run Overrides Active (Alerts)
J. Out-Of-R ange Sensor Failures
K. Machine Pr otect Limit Faults
L. Machine Alerts
M. Spare Sensor Alert Messages
N. Other Problems/Malfunctions
Table 11A—Thermi stor Temperature (F) v s Resistance/Volta ge Drop
Table 11B—Thermi stor Temperature (C) vs Re sistance/Voltage Drop
Table 12 — Benshaw, Inc. Solid-State Starter Tr oubl es hooting Guide
Contents
Table 13 — Cutler- Hamme r® S olid-State Starter Troubl eshooting
Guide
Table 14 — Heat Exchanger Data
Table 15 — Additional Data for Marine Waterboxes
Table 16 — Compressor Wei ghts
Table 17 — Compressor/Motor Weights
Table 18 — Waterbox Cove r We ights
Table 19 — Optional Pum pout System Electr ica l D ata
List of Figures
Figure 1 — 19XL Iden tification
Figure 2A— Typi cal 19XL Components — Design I
Figure 2B— Typi ca l 19 XL Components — Design II
Figure 3 — Refrigera nt Moto r Cooling an d Oil Cooling Cycles
Figure 4 — Lubricat i on System
Figure 5 — Cutler-Hammer Soli d -State Starter, Internal Vi ew
Figure 6 — Benshaw, Inc. Solid-State Starter, Internal View
Figure 7 — Typical St arte r Fr ont View (Solid-S ta te Starter Shown)
Figure 8 — 19XL Contr ols and Sensor Locations
Figure 9 — Control Sensors (Temperature)
Contents
Figure 10— Control Senso rs (Pr essure Tr ans ducer, Typical)
Figure 11— Control Panel (Front View), with Options Module
Figure 12— Power Panel with Options
Loading...