SAFETY CONSIDERATIONS
INTRODUCTION
ABBREVIATIONS AND EXPLANATIONS
CHILLER FAMILIARIZATION
Chiller Information Nameplate
System Components
Cooler
Condenser
Motor-Compressor
Control Panel
Factory-Mounted Starter or Variable Frequency Drive (Optional)
Storage Vessel (Optional)
REFRIGERATION CYCLE
MOTOR AND LUBRICATING OIL COOLING CYCLE
VFD COOLING CYCLE
LUBRICATION CYCLE
Summary
Details.
Oil Reclaim System
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT
Unit-Mounted Solid-State Starter (Optional)
Unit-Mounted Wye-Delta Starter (Optional)
Unit-Mounted VFD (Optional)
CONTROLS.
Definitions
• ANALOG SIGNAL
• DISCRETE SIGNAL
General
PIC II System Components
• CHILLER VISUAL CONTROLLER (CVC)
• INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC)
• INTEGRATED STARTER MODULE (ISM)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)
• CONTROL TRANSFORMERS (T1, T2)
• OPTIONAL TRANSFORMER (T3)
CVC/ICVC Operation and Menus
• GENERAL
• ALARMS AND ALERTS
• CVC/ICVC MENU ITEMS
• BASIC CVC/ICVC OPERATIONS (Using the Softkeys)
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC II System Functions
• CAPACITY CONTROL FIXED SPEED
• CAPACITY CONTROL VFD
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• DIFFUSER CONTROL
• PROPORTIONAL BANDS AND GAIN
• DEMAND LIMITING
• CHILLER TIMERS
• OCCUPANCY SCHEDULE
Safety Controls
Shunt Trip (Option)
Default Screen Freeze
Ramp Loading
Capacity Override
High Discharge Temperature Control
Oil Sump Temperature Control
Oil Cooler
Remote Start/Stop Controls
Spare Safety Inputs
Alarm (Trip) Output Contacts
Refrigerant Leak Detector
Kilowatt Output
Remote Reset of Alarms
Condenser Pump Control
Condenser Freeze Prevention
Evaporator Freeze Protection (ICVC Only)
Tower Fan Relay Low and High
Auto. Restart After Power Failure
Water/Brine Reset
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option
Surge Prevention Algorithm (Fixed Speed Chiller)
Surge Prevention Algorithm with VFD
Surge Protection VFD Units
Surge Protection (Fixed Speed Chiller)
• HEAD PRESSURE REFERENCE OUTPUT
Lead/Lag Control
• COMMON POINT SENSOR INSTALLATION
• CHILLER 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
• ATTACHING TO OTHER CCN MODULES
Service Operation
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE SEQUENCE
Local Start-Up
Shutdown Sequence
Automatic Soft Stop Amps Threshold
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
Tighten All Gasketed Joints and Guide Vane Shaft Packing
Check Chiller Tightness
Refrigerant Tracer
Leak Test Chiller
Standing Vacuum Test
Chiller Dehydration
Inspect Water Piping
Check Optional Pumpout Compressor Water Piping
Check Relief Valves
Inspect Wiring.
Carrier Comfort Network Interface Check Starter
• MECHANICAL STARTER
• BENSHAW, INC. RediStart MICRO™
SOLID-STATE STARTER
• VFD STARTER
Oil Charge
Power Up the Controls and Check the Oil Heater
• SOFTWARE VERSION
Software Configuration
Input the Design Set Points
Input the Local Occupied Schedule (OCCPC01S)
Input Service Configurations
• PASSWORD
• INPUT TIME AND DATE
• CHANGE CVC/ICVC CONFIGURATION IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE CVC/ICVC DISPLAY FROM ENGLISH TO METRIC UNITS
• CHANGE LANGUAGE (ICVC ONLY)
• MODIFY CONTROLLER IDENTIFICATION IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY
• CHANGE THE BENSHAW, INC., RediStart MICRO SOFTWARE CONFIGURATION IF NECESSARY
• VERIFY VFD CONFIGURATION AND CHANGE PARAMETERS IF NECESSARY
• VFD CHILLER FIELD SET UP AND VERIFICATION
• VFD CONTROL VERIFICATION (Non-Running)
• VFD CONTROL VERIFICATION (Running)
• CONFIGURE DIFFUSER CONTROL IF NECESSARY
• MODIFY EQUIPMENT CONFIGURATION IF NECESSARY
Perform a Control Test
• COOLER CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System Controls and Compressor
High Altitude Locations
Charge Refrigerant Into Chiller
• CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT
• CHILLER EQUALIZATION WITH PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP.
Preparation
Dry Run to Test Start-Up Sequence
Check Motor Rotation
Check Oil Pressure and Compressor Stop
To Prevent Accidental Start-Up
Check Chiller Operating Condition
Instruct the Customer Operator
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS
Operator Duties
Prepare the Chiller for Start-Up
To Start the Chiller
Check the Running System
To Stop the Chiller
After Limited Shutdown
Preparation for Extended Shutdown
After Extended Shutdown
Cold Weather Operation
Manual Guide Vane Operation
Refrigeration Log
PUMPOUT AND REFRIGERANT TRANSFER PROCEDURES
Preparation
Operating the Optional Pumpout Unit
• TO READ REFRIGERANT PRESSURES
Chillers with Storage Tanks
• TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK
Chillers with Isolation Valves
• TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL
• TRANSFER ALL REFRIGERANT TO CHILLER COOLER VESSEL
• RETURN CHILLER 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
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply Standing Vacuum Test
Checking Guide Vane Linkage
Trim Refrigerant Charge.
WEEKLY MAINTENANCE
Check the Lubrication System
SCHEDULED MAINTENANCE
Service Ontime.
Inspect the Control Panel
Check Safety and Operating Controls Monthly
Changing Oil Filter
Oil Specification
Oil Changes.
• TO CHANGE THE OIL
Refrigerant Filter
Oil Reclaim Filter
Inspect Refrigerant Float System Inspect Relief Valves and Piping
Compressor Bearing and Gear Maintenance
Inspect the Heat Exchanger Tubes and Flow Devices
• COOLER AND FLOW DEVICES
• CONDENSER AND FLOW DEVICES
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 Display Messages.
Checking Temperature Sensors
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers
• UNITS EQUIPPED WITH CVC
• UNITS EQUIPPED WITH ICVC
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure
Control Test
Control Modules
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation
Chiller Control Module (CCM)
• INPUTS
• OUTPUTS
Integrated Starter Module
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules
• INSTALLATION
Solid-State Starters.
• TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
Physical Data
INDEX
INITIAL START-UP CHECKLIST FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
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