Mechanical Starter; Benshaw, Inc. Redistart Micro Solid-State Starter; Oil Charge - Carrier 19XR Start-Up, Operation And Maintenance Instructions Manual

MECHANICAL STARTER

1. Check all field wiring connections for tightness, clear-
ance from moving parts, and correct connection.
2. Check the contactor(s) to ensure they move freely. Check
the mechanical interlock between contactors to ensure that
1S and 2M contactors cannot be closed at the same time.
Check all other electro-mechanical devices, such as
relays, for free movement. If the devices do not move
freely, contact the starter manufacturer for replacement
components.
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 the dashpot oil to the cups
according to the instructions supplied with the starter. The
oil is usually shipped in a small container attached to the
starter frame near the relays. Use only the dashpot oil sup-
plied with the starter. Do not substitute.
Solid-state overload relays do not have oil.
4. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through
a complete and proper start cycle.
BENSHAW, INC. REDISTART MICRO SOLID-STATE
STARTER
This equipment is at line voltage when AC power is
connected. Pressing the STOP button does not remove
voltage.
1. Ensure all wiring connections are properly terminated to
the starter.
2. Verify the ground wire to the starter is installed properly
and is sufficient size.
3. Verify the motors are properly grounded to the starter.
4. Ensure all of the relays are properly seated in their
sockets.
5. Verify the proper ac input voltage is brought into the starter
according to the certified drawings.
6. Apply power to the starter.
Oil Charge —
The oil charge for the 19XR compressor
depends on the compressor Frame size:
• Frame 2 compressor — 5 gal (18.9 L)
• Frame 3 compressor — 8 gal (30 L)
• Frame 4 compressor — 10 gal (37.8 L)
• Frame 5 compressor — 18 gal (67.8 L)
The chiller is 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. 2). If oil is added, it
must meet Carrier's specification for centrifugal compressor
use as described in the Oil Specification section. Charge the
oil through the oil charging valve located near the bottom of
the transmission housing (Fig. 2). The oil must be pumped
from the oil container through the charging valve due to higher
refrigerant pressure. The pumping device must be able to lift
from 0 to 200 psig (0 to 1380 kPa) or above unit pressure.
Oil should only be charged or removed when the chiller is
shut down.
Power Up the Controls and Check the Oil Heater
—
Ensure that an oil level is visible in the compressor be-
fore energizing the controls. A circuit breaker in the starter
energizes the oil heater and the control circuit. When first
powered, the CVC should display the default screen within
a short period of time.
The oil heater is energized by powering the control cir-
cuit. This should be done several hours before start-up to
minimize oil-refrigerant migration. The oil heater is con-
trolled by the PIC II and is powered through a contactor in
the power panel. Starters contain a separate circuit breaker
to power the heater and the control circuit. This arrangement
allows the heater to energize when the main motor circuit
breaker is off for service work or extended shutdowns. The
oil heater relay status (OIL HEATER RELAY) can be viewed
on the COMPRESS table on the CVC. Oil sump tempera-
ture can be viewed on the CVC default screen.
SOFTWARE VERSION — The software part number is la-
beled on the backside of the CVC module. The software ver-
sion also appears on the CVC configuration screen as the
last two digits of the software part number.
Software Configuration
Do not operate the chiller before the control configu-
rations have been checked and a Control Test has been
satisfactorily completed. Protection by safety controls
cannot be assumed until all control configurations have
been confirmed.
As the 19XR unit is configured, all configuration settings
should be written down. A log, such as the one shown on
pages CL-1 to CL-12, provides a convenient list for con-
figuration values.
Input the Design Set Points —
point screen and view/modify the base demand limit set point,
and either the LCW set point or the ECW set point. The
PIC II can control a set point to either the leaving or entering
chilled water. This control method is set in the EQUIP-
MENT SERVICE (TEMP_CTL) table.
Input the Local Occupied Schedule (OCCPC01S)
—
Access the schedule OCCPC01S screen on the CVC and
set up the occupied time schedule according to the custom-
er's requirements. If no schedule is available, the default is
factory set for 24 hours occupied, 7 days per week including
holidays.
For more information about how to set up a time sched-
ule, see the Controls section, page 10.
The CCN Occupied Schedule (OCCPC03-99S) should be
configured if a CCN system is being installed or if a sec-
ondary time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be unoccupied.
Input Service Configurations —
figurations require the CVC screen to be in the SERVICE
portion of the menu.
• password
• input time and date
• CVC configuration
• service parameters
• equipment configuration
• automated control test
PASSWORD — When accessing the SERVICE tables, a pass-
word must be entered. All CVC are initially set for a pass-
word of 1-1-1-1.
53
Access the CVC set
The following con-