Carrier AquaEdge 23XRV Start-Up, Operation And Maintenance Instructions Manual page 4

CONTENTS (cont)
Check Chiller Operating Condition . . . . . . . . . . . . . . 82
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 82
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• COMPRESSOR ASSEMBLY
• 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 . . . . . . . . . . . . . . . . . 83-85
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . 83
To Start The Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Check the Running System . . . . . . . . . . . . . . . . . . . . . 83
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
• FAILURE TO STOP
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 84
Preparation for Extended Shutdown. . . . . . . . . . . . . 84
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 84
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 84
Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-89
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Operating the Optional Pumpout Unit . . . . . . . . . . . 86
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 87
• TRANSFER REFRIGERANT FROM PUMPOUT
STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM CHILLER TO
PUMPOUT STORAGE TANK
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 89,90
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 89
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 89
Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Test After Service, Repair, or Major Leak . . . . . . . . 89
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Refrigerant Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 90
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 90
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 90
Check the Lubrication System . . . . . . . . . . . . . . . . . . 90
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 90-96
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 90
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . 90
• CHANGING OIL
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Oil Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Page
VFD Refrigerant Strainer . . . . . . . . . . . . . . . . . . . . . . . . 91
Vaporizer Refrigerant Return Line Orifice . . . . . . . 91
Compressor Inlet Bearing Oil Orifice . . . . . . . . . . . . 92
Inspect Condenser Refrigerant Float System . . . . 92
Inspect Variable Frequency Drive . . . . . . . . . . . . . . . 94
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 94
Compressor Bearing Maintenance . . . . . . . . . . . . . . 94
Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . 94
Motor Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . 94
• COOLER
• CONDENSER
Water/Brine Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Water/Brine Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Inspect the Control Center . . . . . . . . . . . . . . . . . . . . . . 95
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 95
Optional Pumpout System Maintenance. . . . . . . . . 95
• OPTIONAL PUMPOUT COMPRESSOR
OIL CHARGE
• OPTIONAL PUMPOUT SAFETY
CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 96
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 96-144
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Checking Display Messages . . . . . . . . . . . . . . . . . . . . 97
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 97
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL MOTOR TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . . 97
• COOLER CONDENSER PRESSURE TRANSDUCER
AND OPTIONAL WATER SIDE PRESSURE TRANS-
DUCER CALIBRATION
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 98
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 119
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 119
Replacing Defective ICVC Modules . . . . . . . . . . . . . 120
• INSTALLATION
Gateway Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . 121
• DRIVE STATUS INDICATOR
• MS STATUS INDICATOR
• NET A STATUS INDICATOR
• NET B STATUS INDICATOR
• PD4 EXV BOARD (P COMPRESSOR ONLY)
• PD4 AUX BOARD (P COMPRESSOR ONLY)
• EXV TROUBLESHOOTING
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
APPENDIX A - ICVC PARAMETER INDEX . . 145-152
APPENDIX B - MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 153-156
APPENDIX C - BACNET COMMUNICATION
OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157-163
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
INITIAL START-UP CHECKLIST FOR 23XRV
VARIABLE SPEED SCREW CHILLER
WITH GREENSPEED
INTELLIGENCE . . . . . . . . . . . . . . . . . . . . . . .CL-1 to CL-10
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