Carrier 19XL manual

Start-Up, Operation, and Maintenance Instructions SAFETY CONSIDERA TIONS Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel. Be sure you unde[...]

CONTENTS Page SAFETY CONSIDERA TIONS ...................1 INTRODUCTION ..............................4 ABBREVIA TIONS AND EXPLANA TIONS .......4 CHILLER F AMILIARIZA TION ..................5 Chiller Information Plate ......................5 System Components .........................5 Cooler .......................................5 Condenser ......[...]

CONTENTS (cont) Page Check Optional Pumpout Compressor W ater Piping ...............................4 7 Check Relief Devices ........................4 7 Inspect Wiring ..............................4 7 Carrier Comfort Network Interface ...........4 8 Check Starter ...............................4 8 • MECHANICAL-TYPE ST AR TERS • BENSHA W , INC.[...]

CONTENTS (cont) Page W ater Leaks ................................6 4 W ater T reatment ............................6 5 Inspect the Starting Equipment ..............6 5 Check Pressure T ransducers ................6 5 Optional Pumpout System Maintenance ......6 5 • OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE • OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS[...]

CHILLER F AMILIARIZA TION (Fig. 1, 2A, and 2B) Chiller Information Plate — The information plate is located on the right side of the chiller control center panel. System Components — The components include the cooler and condenser heat exchangers in separate vessels, motor-compressor , lubrication package, control center, and motor starter . Al[...]

19XL FRONT VIEW 19XL REAR VIEW Fig. 2A — T ypical 19XL Components — Design I LEGEND 1— Unit-Mounted Starter 2— Refrigerant Filter Drier 3— Rigging Guide Bolt 4— Refrigerant Moisture Indicator 5— Motor Sight Glass 6— Refrigerant Motor Drain 7— Oil Filter Access Cover 8— Refrigerant Oil Cooler 9— Oil Level Sight Glasses 1 0— G[...]

4 56 7 89 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 19XL FRONT VIEW 31 30 29 28 27 26 25 41 40 39 38 37 36 35 34 33 32 15 42 19XL REAR VIEW Fig. 2B — T ypical 19XL Components — Design II LEGEND 1— Unit-Mounted Starter 2— Refrigerant Filter Drier 3— Rigging Guide Bolt 4— Motor Sight Glass 5— Refrigerant Moisture Indicator 6— Refri[...]

Refrigerant that flows to the oil cooling system is reg- ulated by a thermostatic expansion valve. There is always a minimum flow bypassing the TXV , which flows through an orifice. The TXV valve regulates flow into the oil/ refrigerant plate and frame-type heat exchanger . The bulb for the expansion valve controls oil temperature to the bear-[...]

journal bearings within the bearing housing. The oil then drains into the oil reservoir at the base of the compressor . The PIC (Product Integrated Control) measures the temperature of the oil in the sump and maintains the temperature during shut- down (see Oil Sump T emperature Control section, page 32). This temperature is read on the LID default[...]

ST ARTING EQUIPMENT The 19XL requires a motor starter to operate the centrif- ugal hermetic compressor motor , the oil pump, and various auxiliary equipment. The starter serves as the main field wiring interface for the contractor . Three types of starters are available from Carrier Cor- poration: solid-state, wye-delta, and across-the-line starte[...]

• overtemperature • ground fault • current unbalance • run state These LEDs are further explained in the Check Starter and T roubleshooting Guide section, page 66. Unit-Mounted W ye-Delta Starter (Optional) — The 19XL chiller may be equipped with a wye-delta starter mounted on the unit (Fig. 7). This starter is intended for use with low- [...]

Fig. 8 — 19XL Controls and Sensor Locations Fig. 9 — Control Sensors (T emperature) Fig. 10 — Control Sensors (Pressure T ransducer , T ypical) LEGEND 1— LID 2— PSIO 3— 8-Input Module (One of 2 Available) 4— 5-V olt Transducer Power Supply 5— 6-Pack Relay Board 6— Circuit Breakers (4) Fig. 1 1 — Control Center (Front V iew), wit[...]

PROCESSOR MODULE (PSIO) — The PSIO is the brain of the PIC (Fig. 1 1). This module contains all the operating software needed to control the chiller . The 19XL uses 3 pres- sure transducers and 8 thermistors to sense pressures and tem- peratures. These are connected to the PSIO module. The PSIO also provides outputs to the guide vane actuator , o[...]

LID Operation and Menus (Fig. 13-19) GENERAL • The LID display will automatically revert to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the Pumpdown mode (Fig. 13). • When not in the default screen, the upper right-hand cor- ner of the LID always displays the name of the screen that you ha[...]

• Press EXIT to return to the previous screen level. • Press INCREASE or DECREASE to change the high- lighted point value. TO VIEW POINT ST A TUS (Fig. 15) — Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC. 1. On the Menu screen, press ST A TUS to view the list of [...]

3. Press RELEASE to remove the override and return the point to the PIC’ s automatic control. Override Indication— An override value is indicated by ‘ ‘SUPVSR,’ ’ ‘ ‘SER VC,’ ’ or ‘ ‘BEST’ ’ flashing next to the point value on the Status table. TIME SCHEDULE OPERA TION (Fig. 16) 1. On the Menu screen, press SCHEDULE . 2[...]

*Only available on PSIO Software V ersion 09 and higher . †Available on PSIO Software V ersions 07 and 08. Fig. 17 — 19XL Menu Structure 17[...]

Fig. 18 — 19XL Service Menu Structure 18[...]

*Only available on PSIO Software V ersion 09 and higher . †Available on PSIO Software V ersions 07 and 08. Fig. 18 — 19XL Service Menu Structure (cont) 19[...]

TO VIEW AND CHANGE SET POINTS (Fig. 19) 1. T o view the Set Point table, at the Menu screen press SETPOINT . 2. There are 4 set points on this screen: Base Demand Limit; LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point (PSIO Software V ersion 09 and higher only). Only one of [...]

T able 2 — LID Screens NOTES: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be configured in English or SI units, as required, through the LID configuration screen. 3. Data appearing in the Reference Poin[...]

T able 2 — LID Screens (cont) EXAMPL E2—S T A TUS02 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press ST A TUS . 3. Scroll down to highlight ST A TUS02 . 4. Press SELECT . DESCRIPTION POINT TYPE UNITS REFERENCE POINT NAME (ALARM HISTOR Y) INPUT OUTPUT Hot Gas Bypass Relay X OFF/ON HGBR *Chilled W ater[...]

T able 2 — LID Screens (cont) EXAMPLE 5 — CONFIGURA TION (CONFIG) DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT CONFIGURA TION . 4. Press SELECT . 5. Scroll down to highlight CONFIG . 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE P[...]

T able 2 — LID Screens (cont) EXAMPLE 7 — SERVICE1 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight SERVICE1 . 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEF AUL T [...]

T able 2 — LID Screens (cont) EXAMPLE 8 — SERVICE2 DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight EQUIPMENT SERVICE . 4. Press SELECT . 5. Scroll down to highlight SERVICE2 . 6. Press SELECT . DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEF AUL T [...]

T able 2 — LID Screens (cont) EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight ALGORITHM ST A TUS . 4. Press SELECT . 5. Scroll down to highlight MAINT01 . DESCRIPTION RANGE/ST A TUS UNITS REFERENCE POINT NAME CAP ACITY CONTROL [...]

T able 2 — LID Screens (cont) EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLA Y SCREEN T o access this display from the LID default screen: 1. Press MENU . 2. Press SERVICE . 3. Scroll down to highlight CONTROL ALGORITHM ST A TUS . 4. Press SELECT . 5. Scroll down to highlight MAINT03 . 6. Press SELECT . DESCRIPTION RANGE/ST A TUS UNITS REFERENCE POI[...]

PIC System Functions NOTE: Throughout this manual, words printed in capital let- ters and italics represent values that may be viewed on the LID. See T able 2 for examples of LID screens. Point names are listed in the Description column. An overview of LID operation and menus is given in Fig. 13-19. CAP ACITY CONTROL — The PIC controls the chille[...]

Safety Controls — The PIC monitors all safety control inputs, and if required, shuts down the chiller or limits the guide vanes to protect the chiller from possible damage from any of the following conditions: • high bearing temperature • high motor winding temperature • high discharge temperature • low oil pressure • low cooler refrige[...]

T able 3 — Protective Safety Limits and Control Settings MONITORED P ARAMETER LIMIT APPLICABLE COMMENTS TEMPERA TURE SENSORS OUT OF RANGE –40 to 245 F (–40 to 1 18.3 C) Must be outside range for 2 seconds PRESSURE TRANSDUCERS OUT OF RANGE 0.08 to 0.98 V oltage Ratio Must be outside range for 2 seconds. Ratio = Input V oltage ÷ V oltage Refer[...]

Ramp Loading Control — The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the chiller is started, and the chilled water loop has to be brought down to normal design conditions. This helps reduce electrical demand char ges by sl[...]

High Discharge T emperature Control — If the discharge temperature increases above 160 F (71.1 C) (PSIO Software V ersion 09 and higher) or 180 F (82 C) (PSIO Software V ersion 08 or lower), the guide vanes are propor- tionally opened to increase gas flow through the compressor . If the leaving chilled water temperature is then brought 5° F (2.[...]

T ower Fan Relay — Low condenser water tempera- ture can cause the chiller to shut down on low refrigerant temperature. The tower fan relay , located in the starter , is controlled by the PIC to energize and deener gize as the pres- sure dif ferential between cooler and condenser vessels changes in order to prevent low condenser water temperature[...]

The algorithm first determines if corrective action is nec- essary . This is done by checking 2 sets of operator con- figured data points, which are the MINIMUM and the MAXIMUM Load Points, (T1/P1;T2/P2). These points have default settings for each type of refrigerant, HCFC-22 or HFC-134a, as defined on the Service1 table, or on T able 4. These [...]

Operation Features: • 2 chiller lead/lag • addition of a third chiller for backup • manual rotation of lead chiller • load balancing if configured • staggered restart of the chillers after a power failure • chillers may be piped in parallel or in series chilled water flow COMMON POINT SENSOR INST ALLA TION — Lead/ lag operation does[...]

4. Lead chiller temperature pulldown rate of the CHILLED W A TER temperature is less than 0.5° F (0.27° C) per minute. 5. The lag chiller status indicates it is in CCN mode and is not faulted. If the current lag chiller is in an alarm con- dition, then the standby chiller becomes the active lag chiller , if it is configured and available. 6. The[...]

ST AR T -UP/RECYCLE OPERA TION — If the chiller is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINA- TION value, to avoid starting the compressor unnecessarily: •i f ICE BUILD TERMINATION is set to the temperature only option (zero) and the ENTERING CHILLED W ATER temperature is [...]

A TT ACHING T O OTHER CCN MODULES — If the chiller PSIO has been connected to a CCN Network or other PIC controlled chillers through CCN wiring, the LID can be used to view or change parameters on the other controllers. Other PIC chillers can be viewed and set points changed (if the other unit is in CCN control), if desired from this particular L[...]

6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday pe- riod, starting on a specific date, and lasting up to 99 days. 7. Press SELECT to access the holiday table. The Con- figuration Select table now shows the holiday start month and day , and how many days the holiday period will last. 8. Press[...]

and go into a RECYCLE mode. If the water/brine tempera- ture is high enough, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 3 psid (21 kPad), the oil pump relay will then [...]

Safety Shutdown — A safety shutdown is identical to a manual shutdown with the exception that the LID will dis- play the reason for the shutdown, the alarm light will blink continuously , and the spare alarm contacts will be ener- gized. A safety shutdown requires that the RESET softkey be pressed in order to clear the alarm. If the alarm is stil[...]

Fig. 26 — 19XL Leak T est Procedures 42[...]

procedures in the T ransfer Refrigerant from Storage T ank to Chiller section, Steps 1a-e, page 59. Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 68 psig (469 kPa) for HCFC-22 and 35 psig (241 kPa) for HFC-134a. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is r[...]

T able 5A — HCFC-22 Pressure — T emperature (F) TEMPERA TURE (F) PRESSURE (psi) Absolute Gage −50 1 1.67 6.154* −48 12.34 4.829* −46 13.00 3.445* −44 13.71 2.002* −42 14.45 0.498* −40 15.22 0.526 −38 16.02 1.328 −36 16.86 2.163 −34 17.73 3.032 −32 18.63 3.937 −30 19.57 4.877 −28 20.55 5.853 −26 21.56 6.868 −24 22.62 [...]

T able 5C — HFC-134a Pressure — T emperature (F) TEMPERA TURE (F) PRESSURE (psig) 0 6.50 2 7.52 4 8.60 6 9.66 8 10.79 10 1 1.96 12 13.17 14 14.42 16 15.72 18 17.06 20 18.45 22 19.88 24 21.37 26 22.90 28 24.48 30 26.1 1 32 27.80 34 29.53 36 31.32 38 33.17 40 35.08 42 37.04 44 39.06 46 41.14 48 43.28 50 45.48 52 47.74 54 50.07 56 52.47 58 54.93 T[...]

Fig. 27 — T ypical Optional Pumpout System Piping Schematic with Storage T ank Fig. 28 — T ypical Optional Pumpout System Piping Schematic without Storage T ank 46[...]

Chiller Dehydration — Dehydration is recommended if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure. Do not start or megohm test the compressor motor or oil pump motor, even for a rotation check, if the [...]

6. Be sure that fused disconnects or circuit breakers have been supplied for the oil pump, power panel, and pumpout unit. 7. Check that all electrical equipment and controls are prop- erly grounded in accordance with job drawings, certi- fied drawings, and all applicable electrical codes. 8. Make sure that the customer ’ s contractor has verifi[...]

3. Some dashpot-type magnetic overload relays must be filled with oil on the jobsite. If the starter is equipped with de- vices of this type, remove the fluid cups from these mag- netic overload relays. Add dashpot oil to cups per instructions supplied with the starter . The oil is usually shipped in a small container attached to the starter frame[...]

Oil Charge — The 19XL compressor holds approxi- mately 8 gal. (30 L) of oil. The chiller will be shipped with oil in the compressor . When the sump is full, the oil level should be no higher than the middle of the upper sight glass and minimum level is the bottom of the lower sight glass (Fig. 2A or 2B). If oil is added, it must meet Carrier ’ [...]

MODIFY CONTROLLER IDENTIFICA TION IF NECES- SAR Y — The controller identification screen is used to change the PSIO module address. Change this address for each chiller if there is more than one chiller at the jobsite. W rite the new address on the PSIO module for future reference. Change the LID address if there is more than one chiller on the [...]

T able 6 — Amps Correction Factors for 19XL Motors VOL T/ Hz MOTOR CODE CB CC CD CE CL CM CN CP CQ CR 200/60 4536 32 3222 208/60 5558 42 4222 220/60 3422 23 1111 230/60 5644 35 2222 240/60 5644 38 2222 360/60 4242 22 1111 380/60 7464 45 3222 400/60 7584 45 3234 440/60 3322 11 1134 460/60 5432 22 2256 480/60 7543 33 3378 550/60 4232 12 3222 575/60[...]

Loosen the compressor holddown bolts to allow free spring travel. Open the compressor suction and discharge service valves. Check that oil is visible in the compressor sight glass. Add oil if necessary . See Pumpout and Refrigerant T ransfer Procedures and Optional Pumpout System Maintenance sections, pages 59 and 65, for details on transfer of ref[...]

19XL CHILLER EQUALIZA TION WITH PUMPOUT UNIT — The following procedure describes how to equal- ize refrigerant pressure on an isolated 19XL chiller using the pumpout unit. 1. Access the TERMINA TE LOCKOUT mode in the Con- trol T est. 2. T urn on the chilled water and condenser water pumps to prevent possible freezing. 3. Open valve 4 on the pumpo[...]

INITIAL ST ART -UP Preparation — Before starting the chiller , check that the: 1. Power is on to the main starter , oil pump relay , tower fan starter , oil heater relay , and the chiller control center . 2. Cooling tower water is at proper level, and at or below design entering temperature. 3. Chiller is charged with refrigerant and all refriger[...]

2. Observe that all 6-gate LEDs are lit on the starter SCR control board. 3. The factory setting should bring the motor to full voltage in 15 to 30 seconds. If the setting is not correct, adjust the ramp potentiometer counterclockwise for a shorter time, clockwise for a longer time. (See Fig. 5 for starter com- ponent placement.) Check Oil Pressure[...]

2. The bearing oil temperature accessed on the Status01 table should be 120 to 165 F (49 to 74 C). If the bearing temperature reads more than 180 F (83 C) with the oil pump running, stop the chiller and determine the cause of the high temperature. Do not r estart the chiller until corrected. 3. The oil level should be visible anywhere in one of the[...]

Date REFRIGERA TION LOG CARRIER 19XT HERMETIC CENTRIFUGAL REFRIGERA TION MACHINE Plant CHILLER MODEL NO. CHILLER SERIAL NO. REFRIGERANT TYPE DA TE COOLER CONDENSER COMPRESSOR OPER- AT O R INITIALS REMARKS TIME Refrigerant W ater Refrigerant W ater BEARING TEMP Oil Motor Press. T emp Pressure T emp Press. T emp Pressure T emp Press. Diff. T emp (res[...]

PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES Preparation — The 19XL may come equipped with an optional storage tank or pumpout system, or a pump- out compressor . The refrigerant can be pumped for service work to either the cooler/compressor vessel or the condenser vessel by using the optional pumpout system. If a storage tank is supplied, the ref[...]

2. T ransfer remaining refrigerant. a. Close valve 5 and open valve 4. V A L V E 1 a1 b 2 34 5 67 8 1 01 11 21 31 4 CONDITION CCC b. T urn of f the chiller water pumps through the LID. c. T urn of f the pumpout condenser water , and turn on the pumpout compressor to push liquid out of the storage tank. d. Close liquid line valve 7. e. T urn of f th[...]

TRANSFER ALL REFRIGERANT TO CHILLER COOLER/COMPRESSOR VESSEL 1. Push refrigerant into the chiller cooler vessel. a. V alve positions: V AL VE 1a 1b 2 3 4 5 8 1 1 12 13 14 CONDITION C C C CCC b. T urn of f chiller water pumps and pumpout condenser water . c. T urn on pumpout compressor to push refrigerant out of the condenser . d. When all liquid is[...]

HCFC-22 and HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In gen- eral, neither refrigerant should not be allowed to be pre- sent with high concentrations of air or oxygen above atmospheric pressures, as the mixture can undergo combustion. REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a [...]

SCHEDULED MAINTENANCE Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and water quality . The time intervals listed in this section are of fered as guides to service only . Service Ontime — The LID will display a SERVICE ONTIME value on the Status01 table. This value should be res[...]

Inspect Refrigerant Float System — Perform inspection every 5 years or when the condenser is opened for service. T ransfer the refrigerant into the cooler vessel or into a storage tank. Remove the float access cover . Clean the chamber and valve assembly thoroughly . Be sure that the valve moves freely . Make sure that all openings are free of o[...]

W ater T reatment — Untreated or improperly treated wa- ter may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment specialist should be obtained to develop and monitor a treatment program. Water must be within design flow limits, clean, and treated to ensure proper chiller performance and reduce the pot[...]

TROUBLESHOOTING GUIDE Overview — The PIC has many features to aid the operator and the technician in troubleshooting a 19XL chiller . • By using the LID display , the chiller actual operating con- ditions can be viewed while the unit is running. • When an alarm occurs, the default LID screen will freeze at the time of alarm. The freeze enable[...]

If the transducer value is not within the calibration range, the transducer will return to the original reading. If the LID pressure value is within the allowed range (noted above), check the voltage ratio of the transducer . T o ob- tain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at [...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides A. SHUTDOWN WITH ON/OFF/RESET -OFF PRIMAR Y MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY MANUALL Y STOPPED — PRESS CCN OR LOCAL TO ST ART PIC in OFF mode, press the CCN or local softkey to start unit. TERMINA TE PUMPDOWN MODE T O SELECT[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) C. IN RECYCLE SHUTDOWN PRIMAR Y MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY RECYCLE REST ART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not high enough to start. RECYCLE REST ART PENDING REMOTE CONT A[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) F . ST AR T -UP F AILURES: This is an alarm condition. A manual reset is required to clear . PRIMAR Y MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY F AILURE T O ST ART LOW OIL PRESSURE OILPD [V ALUE] ex[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) G. COMPRESSOR JUMPST ART AND REFRIGERANT PROTECTION PRIMAR Y MESSAGE SECONDAR Y MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY UNAUTHORIZED OPERA TION UNIT SHOULD BE STOPPED CA P Emergency: Compressor running without cont[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) I. NORMAL RUN OVERRIDES ACTIVE (ALERTS) PRIMAR Y MESSAGE SECONDAR Y MESSAGE ALARM MESSAGE/PRIMAR Y CAUSE ADDITIONAL CAUSE/REMEDY RUN CAP ACITY LIMITED HIGH CONDENSER PRESSURE CRP [V ALUE]* exceeded limit of [LIMIT]*. Condenser pressur[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) K. CHILLER PROTECT LIMIT F AUL TS Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise. PRIMAR Y MESSAGE SECONDAR Y MESSAGE ALARM MESSAGE/PRIMAR Y CAUSE ADDITIONAL CAUSE/REMEDY PROTECTIVE LIMIT[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) L. CHILLER ALERTS PRIMAR Y MESSAGE SECONDAR Y MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY RECYCLE ALERT HIGH AMPS A T SHUTDOWN High Amps at Recycle: Check guide vane drive. Check that guide vanes are closing. Check mot[...]

T able 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with T roubleshooting Guides (cont) N. OTHER PROBLEMS/MALFUNCTIONS DESCRIPTION/MALFUNCTION PROBABLE CAUSE/REMEDY Chilled W ater/Brine T emperature T oo High (Machine Running) Chilled water set point set too high. Access set point on LID and verify . Capacity override or[...]

T able 10A — Thermistor T emperature (F) vs Resistance/V oltage Drop TEMPERA TURE VOL T AGE RESIST ANCE (F) DROP (V) (Ohms) −25 4.821 98,010 −24 4.818 94,707 −23 4.814 91,522 −22 4.806 88,449 −21 4.800 85,486 −20 4.793 82,627 −19 4.786 79,871 −18 4.779 77,212 −17 4.772 74,648 −16 4.764 72,175 −15 4.757 69,790 −14 4.749 67,[...]

T able 10B — Thermistor T emperature (C) vs Resistance/V oltage Drop TEMPERA TURE VOL T AGE RESIST ANCE (C) DROP (V) (Ohms) −40 4.896 168 230 −39 4.889 157 440 −38 4.882 147 410 −37 4.874 138 090 −36 4.866 129 410 −35 4.857 121 330 −34 4.848 1 13 810 −33 4.838 106 880 −32 4.828 100 260 −31 4.817 94 165 −30 4.806 88 480 −29[...]

Control Modules Turn controller power of f before servicing controls. This ensures safety and prevents damage to controller. The Processor module (PSIO), 8-input (Options) mod- ules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous di- agnostic evaluations of the hardware to determine its con- dition. [...]

Processor Module (PSIO) (Fig. 41) INPUTS — Each input channel has 3 terminals; only 2 of the terminals are used. Application of chiller determines which terminals are normally used. Always refer to individual unit wiring for terminal numbers. OUTPUTS — Output is 20 vdc. There are 3 terminals per output, only 2 of which are used, depending on th[...]

T erminal block connections are provided on the options modules. All sensor inputs are field wired and installed. Options module number 1 can be factory or field-installed. Options module 2 is shipped separately and must be field installed. For installation, refer to the unit or field wiring diagrams. Be sure to address the module for the prope[...]

Solid-State Starters — Troubleshooting guides and in- formation pertaining to the operation of the solid-state starter may be found in Fig. 44-46 and T able 1 1. Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting table. When the power is of f: • Inspect for physical damage and signs of a[...]

LEGEND SCR — Silicon Control Rectifier *See test procedure described in T esting SCRs in Solid-State Starters section on page 81. Fig. 45 — Solid-State Starter , General Operation T roubleshooting Guide (T ypical) 82[...]

Fig. 46 — Solid-State Starter , Starter Fault (Motor W ill Not Start) T roubleshooting Guide (T ypical) 83[...]

T able 1 1 — Benshaw , Inc. Solid-State Starter T roubleshooting Guide PROBLEM PROBABLE CAUSES AREA OF CORRECTION AK board phase correct not on. 1. L1 and L3 switch phases reversed. 2. Missing phase voltage. 3. Improper line voltage. 1. Switch incoming phases L1 and L3 at top of CD1 or CB1. 2. Check for missing phase voltage. 3. V erify proper li[...]

Physical Data — T ables 12-17 and Fig. 47-51 pro- vide additional information regarding compressor fits and clearances, physical and electrical data, and wiring sche- matics for operator convenience during troubleshooting. T able 12 — Heat Exchanger Data COOLER VESSEL HEA T EXCHANGER CODE NUMBER OF TUBES RIGGING WEIGHTS VESSEL CHARGE Dry Wt. R[...]

T able 14 — W aterbox Cover Weights* ENGLISH (lb) HEA T EXCHANGER W A TERBOX DESCRIPTION FRAME 4, ST ANDARD NOZZLES FRAME 4, FLANGED FRAME 5, ST ANDARD NOZZLES FRAME 5, FLANGED 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig COOLERS NIH, 1 P ASS COVER 284 414 324 491 412 578 452 655 NIH, 2 P ASS COVER 285 41 1 341 523 410 [...]

T able 15 — Compressor/Motor Weights MOTOR SIZE ENGLISH SI Compressor Weight (lb) Stator Weight (lb) Rotor Weight (lb) End Bell Cover (lb) Compressor Weight (kg) Stator Weight (kg) Rotor Weight (kg) End Bell Cover (lb) 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz CB 2660 1 135 1 147 171 233 250 1208 515 520 78 106 1 14 CC 2660 1 143 1 150 197 [...]

NOTES: 1. Dimensions are in inches with rotor in the thrust position. 2. All clearances listed are new chiller tolerances. 3. All radial clearances are diametrical. NOTE: Radial clearances shown are diametrical. Fig. 47 — Compressor Fits and Clearances 88[...]

COMPRESSOR ASSEMBL Y TORQUES ITEM DESCRIPTION TORQUE ft-lb N•m 1* Oil Heater Grommet Nut 10 14 2 Impeller Retaining Bolt 44-46 60-62 3 Bull Gear Retaining Bolt 80-85 108-1 15 4 Motor T erminals (Low V oltage) 50 68 5 Demister Bolts 15-19 20-26 6* Guide V ane Shaft Seal Nut 25 34 7* Motor T erminals (High V oltage) — Insulator 2-4 2.7-5.4 — Pa[...]

LEGEND BRG — Bearing C— Contact CB — Circuit Breaker CLR — Clear COM — Common COMM — Communication Connector EXT — External G.V . — Guide V ane HGBP — Hot Gas Bypass INT — Internal J— Module Connector K— Relay Designation LID — Local Interface Device MA — Milliampere NC — Normally Closed NO — Normally Open PSIO — P[...]

Fig. 48 — Electronic PIC Controls Wiring Schematic (For 19XL with No Backlight or with Fluorescent Backlight) (cont) 91[...]

LEGEND BRG — Bearing C— Contact CB — Circuit Breaker CLR — Clear COM — Common COMM — Communication Connector EXT — External G.V . — Guide V ane HGBP — Hot Gas Bypass INT — Internal J— Module Connector K— Relay Designation LID — Local Interface Device MA — Milliampere NC — Normally Closed NO — Normally Open PSIO — P[...]

Fig. 49 — Electronic PIC Controls Wiring Schematic (For 19XL with Halogen Backlight) (cont) 93[...]

LEGEND 1M — Main Starter Contactor C— Contactor CB — Circuit Board CR — Control Relay COMM — Communications Connector J— Connector N.C. — Normally Closed N.O. — Normally Open OL — Overload OS — 3-Phase Current Power Source PR — Pilot Relay PWR — Power RLA — Rated Load Amps SMM — Starter Management Module TB — T erminal[...]

Fig. 50 — Chiller Power Panel, Starter Assembly , and Motor Wiring Schematic (cont) 95[...]

Fig. 51 — T ypical Wye-Delta Unit Mounted Starter Wiring Schematic LEGEND 1M, 2M — Main Compressor Contactors CB — Circuit Breaker CR — Control Relay CT — Current Transformer DS — Disconnect GF — Ground Fault GFR — Ground Fault Relay H1, H2 — Power Transformer Input T erminal HPS — High-Pressure Switch J— Module Connector L1, [...]

NOTES: 1. Contactors 2M and S are mechanically interlocked. 2. T ransition resistor fault protector (TRFP) is preset to trip if transition contactor (1A) remains energized for longer than one second. 3. When optional phase loss reversal relay (PMR) or phase loss, phase reversal, overvoltage, undervoltage relay (PMRVR) is not provided, terminals 3-1[...]

INDEX Abbreviations and Explanations, 4 Adding Refrigerant, 61 Adjusting the Refrigerant Charge, 61 After Extended Shutdown, 57 After Limited Shutdown, 57 Attach to Network Device Control, 37 Automatic Soft-Stop Amps Threshold, 40 Auto. Restart After Power Failure, 33 Before Initial Start-Up, 41 Calibrate Motor Current, 56 Capacity Override, 31 Car[...]

INDEX (cont) Storage V essel, 5 Summary (Lubrication Cycle), 8 Surge Prevention Algorithm, 33 Surge Protection, 34 System Components, 5 T emperature Sensors (Check), 66 T est After Service, Repair, or Major Leak, 61 T ighten All Gasketed Joints and Guide V ane Shaft Packing, 41 T ower Fan Relay , 33 T rim Refrigerant Charge, 62 T roubleshooting Gui[...]

Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 Ta b 5 a PC 21 1 Catalog No. 531-971 Printed in U.S.A. Form 19XL-4SS Pg 100 7-96 Replaces: 19XL-3SS[...]