Carrier 19XL Manuel d'utilisateur

Start-Up, Operation, and Maintenance InstructionsSAFETY CONSIDERATIONSCentrifugal liquid chillers are designed to providesafe and reliable service whe

STARTING EQUIPMENTThe 19XL requires a motor starter to operate the centrif-ugal hermetic compressor motor, the oil pump, and variousauxiliary equipmen

Copyright 1996 Carrier CorporationManufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and w

• overtemperature• ground fault• current unbalance• run stateThese LEDs are further explained in the Check Starter andTroubleshooting Guide section, p

Fig. 8 — 19XL Controls and Sensor LocationsFig. 9 — Control Sensors(Temperature)Fig. 10 — Control Sensors(Pressure Transducer, Typical)LEGEND1—LID2—PS

PROCESSOR MODULE (PSIO) — The PSIO is the brainof the PIC (Fig. 11). This module contains all the operatingsoftware needed to control the chiller. The

LID Operation and Menus (Fig. 13-19)GENERAL• The LID display will automatically revert to the defaultscreen after 15 minutes if no softkey activity ta

• Press EXIT to return to the previous screen level.• Press INCREASE or DECREASE to change the high-lighted point value.TO VIEW POINT STATUS (Fig. 15)

3. Press RELEASE to remove the override and return thepoint to the PIC’s automatic control.Override Indication— An override value is indicated by‘‘SUP

*Only available on PSIO Software Version 09 and higher.†Available on PSIO Software Versions 07 and 08.Fig. 17 — 19XL Menu Structure17

Fig. 18 — 19XL Service Menu Structure18

*Only available on PSIO Software Version 09 and higher.†Available on PSIO Software Versions 07 and 08.Fig. 18 — 19XL Service Menu Structure (cont)19

CONTENTSPageSAFETY CONSIDERATIONS ...1INTRODUCTION ...4ABBREVIATIONS AND EXPLANATIONS ...4CHILLER FAMIL

TO VIEW AND CHANGE SET POINTS (Fig. 19)1. To view the Set Point table, at the Menu screen pressSETPOINT.2. There are 4 set points on this screen: Base

Table 2 — LID ScreensNOTES:1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or

Table 2 — LID Screens (cont)EXAMPLE2—STATUS02 DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press STATUS.3. Scroll

Table 2 — LID Screens (cont)EXAMPLE 5 — CONFIGURATION (CONFIG) DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press

Table 2 — LID Screens (cont)EXAMPLE 7 — SERVICE1 DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press SERVICE.3. Sc

Table 2 — LID Screens (cont)EXAMPLE 8 — SERVICE2 DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press SERVICE.3. Sc

Table 2 — LID Screens (cont)EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press

Table 2 — LID Screens (cont)EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press

PIC System FunctionsNOTE: Throughout this manual, words printed in capital let-ters and italics represent values that may be viewed on theLID. See Tab

Safety Controls — The PIC monitors all safety controlinputs, and if required, shuts down the chiller or limits theguide vanes to protect the chiller f

CONTENTS (cont)PageCheck Optional Pumpout CompressorWater Piping ...47Check Relief Devices ...47Inspe

Table 3 — Protective Safety Limits and Control SettingsMONITORED PARAMETER LIMIT APPLICABLE COMMENTSTEMPERATURE SENSORSOUT OF RANGE–40 to 245 F (–40 t

Ramp Loading Control — The ramp loading controlslows down the rate at which the compressor loads up. Thiscontrol can prevent the compressor from loadi

High Discharge Temperature Control — If thedischarge temperature increases above 160 F (71.1 C)(PSIO Software Version 09 and higher) or 180 F (82 C) (

Tower Fan Relay — Low condenser water tempera-ture can cause the chiller to shut down on low refrigeranttemperature. The tower fan relay, located in t

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 MI

Operation Features:• 2 chiller lead/lag• addition of a third chiller for backup• manual rotation of lead chiller• load balancing if configured• stagger

4. Lead chiller temperature pulldown rate of the CHILLEDWATER temperature is less than 0.5° F (0.27° C) perminute.5. The lag chiller status indicates

START-UP/RECYCLE OPERATION — If the chiller is notrunning when ice build activates, then the PIC checks thefollowing parameters, based on the ICE BUIL

ATTACHING TO OTHER CCN MODULES — If the chillerPSIO has been connected to a CCN Network or other PICcontrolled chillers through CCN wiring, the LID ca

6. Press NEXT to highlight the holiday table that youwish to view or change. Each table is one holiday pe-riod, starting on a specific date, and lastin

CONTENTS (cont)PageWater Leaks ...64Water Treatment ...65Inspect the Starting Equipment ...

and go into a RECYCLE mode. If the water/brine tempera-ture is high enough, the start-up sequence continues on tocheck the guide vane position. If the

Safety Shutdown — A safety shutdown is identical toa manual shutdown with the exception that the LID will dis-play the reason for the shutdown, the al

Fig. 26 — 19XL Leak Test Procedures42

procedures in the Transfer Refrigerant from StorageTank to Chiller section, Steps 1a-e, page 59.Never charge liquid refrigerant into the chiller ifthe

Table 5A — HCFC-22 Pressure — Temperature (F)TEMPERATURE(F)PRESSURE (psi)Absolute Gage−50 11.67 6.154*−48 12.34 4.829*−46 13.00 3.445*−44 13.71 2.002*

Table 5C — HFC-134a Pressure — Temperature (F)TEMPERATURE(F)PRESSURE(psig)0 6.502 7.524 8.606 9.668 10.7910 11.9612 13.1714 14.4216 15.7218 17.0620 18

Fig. 27 — Typical Optional Pumpout System Piping Schematicwith Storage TankFig. 28 — Typical Optional Pumpout System Piping Schematicwithout Storage T

Chiller Dehydration — Dehydration is recommendedif the chiller has been open for a considerable period of time,if the chiller is known to contain mois

6. Be sure that fused disconnects or circuit breakers havebeen supplied for the oil pump, power panel, andpumpout unit.7. Check that all electrical eq

3. Some dashpot-type magnetic overload relays must be filledwith oil on the jobsite. If the starter is equipped with de-vices of this type, remove the

CHILLER FAMILIARIZATION(Fig. 1, 2A, and 2B)Chiller Information Plate —The information plateis located on the right side of the chiller control centerp

Oil Charge — The 19XL compressor holds approxi-mately 8 gal. (30 L) of oil. The chiller will be shipped withoil in the compressor. When the sump is fu

MODIFY CONTROLLER IDENTIFICATION IF NECES-SARY — The controller identification screen is used to changethe PSIO module address. Change this address for

Table 6 — Amps Correction Factorsfor 19XL MotorsVOLT/HzMOTOR CODECB CC CD CE CL CM CN CP CQ CR200/60 4536323222208/60 5558424222220/60 3422231111230/6

Loosen the compressor holddown bolts to allow free springtravel. Open the compressor suction and discharge servicevalves. Check that oil is visible in

19XL CHILLER EQUALIZATION WITH PUMPOUTUNIT — The following procedure describes how to equal-ize refrigerant pressure on an isolated 19XL chiller using

INITIAL START-UPPreparation —Before starting the chiller, check that the:1. Power is on to the main starter, oil pump relay, tower fanstarter, oil hea

2. Observe that all 6-gate LEDs are lit on the starter SCRcontrol board.3. The factory setting should bring the motor to full voltagein 15 to 30 secon

2. The bearing oil temperature accessed on the Status01 tableshould be 120 to 165 F (49 to 74 C). If the bearingtemperature reads more than 180 F (83

DateREFRIGERATION LOG CARRIER 19XT HERMETIC CENTRIFUGAL REFRIGERATION MACHINEPlantCHILLER MODEL NO. CHILLER SERIAL NO. REFRIGERANT TYPEDATE COOLER CON

PUMPOUT AND REFRIGERANT TRANSFERPROCEDURESPreparation —The 19XL may come equipped withan optional storage tank or pumpout system, or a pump-out compre

19XL FRONT VIEW19XL REAR VIEWFig. 2A — Typical 19XL Components — Design ILEGEND1—Unit-Mounted Starter2—Refrigerant Filter Drier3—Rigging Guide Bolt4—R

2. Transfer remaining refrigerant.a. Close valve 5 and open valve 4.VALVE 1a1b23456781011121314CONDITION CCCb. Turn off the chiller water pumps throug

TRANSFER ALL REFRIGERANT TO CHILLERCOOLER/COMPRESSOR VESSEL1. Push refrigerant into the chiller cooler vessel.a. Valve positions:VALVE 1a 1b 2 3 4 5 8

HCFC-22 and HFC-134a should not be mixed withair or oxygen and pressurized for leak testing. In gen-eral, neither refrigerant should not be allowed to

SCHEDULED MAINTENANCEEstablish a regular maintenance schedule based on theactual chiller requirements such as chiller load, run hours,and water qualit

Inspect Refrigerant Float System — Performinspection every 5 years or when the condenser is openedfor service. Transfer the refrigerant into the coole

Water Treatment — Untreated or improperly treated wa-ter may result in corrosion, scaling, erosion, or algae. Theservices of a qualified water treatmen

TROUBLESHOOTING GUIDEOverview —The PIC has many features to aid theoperator and the technician in troubleshooting a 19XLchiller.• By using the LID dis

If the transducer value is not within the calibration range,the transducer will return to the original reading. Ifthe LID pressure value is within the

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting GuidesA. SHUTDOWN WITH ON/OFF/RESET-OFFPRIMARY MESSAG

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)C. IN RECYCLE SHUTDOWNPRIMARY MESSAGE SE

45678910111213141516171819202122232419XL FRONT VIEW31302928272625414039383736 35 34 3332154219XL REAR VIEWFig. 2B — Typical 19XL Components — Design I

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)F. START-UP FAILURES: This is an alarm c

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)G. COMPRESSOR JUMPSTART AND REFRIGERANT

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)P

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)K. CHILLER PROTECT LIMIT FAULTSExcessive

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)L. CHILLER ALERTSPRIMARY MESSAGE SECONDA

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)N. OTHER PROBLEMS/MALFUNCTIONSDESCRIPTIO

Table 10A — Thermistor Temperature (F) vs Resistance/Voltage DropTEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (Ohms)−25 4.821 98,010−24 4.818 94,707−23

Table 10B — Thermistor Temperature (C) vs Resistance/Voltage DropTEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (Ohms)−40 4.896 168 230−39 4.889 157 440−3

Control ModulesTurn controller power off before servicing controls. Thisensures safety and prevents damage to controller.The Processor module (PSIO),

Processor Module (PSIO) (Fig. 41)INPUTS — Each input channel has 3 terminals; only 2 ofthe terminals are used.Application of chiller determines whicht

Refrigerant that flows to the oil cooling system is reg-ulated by a thermostatic expansion valve. There is alwaysa minimum flow bypassing the TXV, which

Terminal block connections are provided on the optionsmodules. All sensor inputs are field wired and installed.Options module number 1 can be factory o

Solid-State Starters — Troubleshooting guides and in-formation pertaining to the operation of the solid-state startermay be found in Fig. 44-46 and Ta

LEGENDSCR — Silicon Control Rectifier*See test procedure described in Testing SCRs in Solid-State Starters section on page 81.Fig. 45 — Solid-State Sta

Fig. 46 — Solid-State Starter, Starter Fault (Motor Will Not Start)Troubleshooting Guide (Typical)83

Table 11 — Benshaw, Inc. Solid-State Starter Troubleshooting GuidePROBLEM PROBABLE CAUSES AREA OF CORRECTIONAK board phase correct noton.1. L1 and L3

Physical Data — Tables 12-17 and Fig. 47-51 pro-vide additional information regarding compressor fits andclearances, physical and electrical data, and

Table 14 — Waterbox Cover Weights*ENGLISH (lb)HEATEXCHANGERWATERBOXDESCRIPTIONFRAME 4,STANDARDNOZZLESFRAME 4,FLANGEDFRAME 5,STANDARDNOZZLESFRAME 5,FLA

Table 15 — Compressor/Motor WeightsMOTORSIZEENGLISH SICompressorWeight(lb)Stator Weight(lb)Rotor Weight(lb)End BellCover(lb)CompressorWeight(kg)Stator

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 d

COMPRESSOR ASSEMBLY TORQUESITEM DESCRIPTIONTORQUEft-lb N•m1* Oil Heater Grommet Nut 10 142 Impeller Retaining Bolt 44-46 60-623 Bull Gear Retaining Bo

journal bearings within the bearing housing. The oil then drainsinto the oil reservoir at the base of the compressor. The PIC(Product Integrated Contr

LEGENDBRG — BearingC—ContactCB — Circuit BreakerCLR — ClearCOM — CommonCOMM — Communication ConnectorEXT — ExternalG.V. — Guide VaneHGBP — Hot Gas Byp

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

LEGENDBRG — BearingC—ContactCB — Circuit BreakerCLR — ClearCOM — CommonCOMM — Communication ConnectorEXT — ExternalG.V. — Guide VaneHGBP — Hot Gas Byp

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

LEGEND1M — Main Starter ContactorC—ContactorCB — Circuit BoardCR — Control RelayCOMM — Communications ConnectorJ—ConnectorN.C. — Normally ClosedN.O. —

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

Fig. 51 — Typical Wye-Delta Unit Mounted Starter Wiring SchematicLEGEND1M, 2M — Main Compressor ContactorsCB — Circuit BreakerCR — Control RelayCT — C

NOTES:1. Contactors 2M and S are mechanically interlocked.2. Transition resistor fault protector (TRFP) is preset to trip if transition contactor(1A)

INDEXAbbreviations and Explanations, 4Adding Refrigerant, 61Adjusting the Refrigerant Charge, 61After Extended Shutdown, 57After Limited Shutdown, 57A

INDEX (cont)Storage Vessel, 5Summary (Lubrication Cycle), 8Surge Prevention Algorithm, 33Surge Protection, 34System Components, 5Temperature Sensors (