Carrier XRV Manuals

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Carrier XRV User Manual (140 pages)

Hermetic Centrifugal Liquid Chillers 50/60 Hz With PIC II Controls and HFC-134a

Brand: Carrier | Category: Chiller | Size: 4.73 MB

Safety Considerations
1
- Table of Contents
  2
- Reset Type
  2
Introduction
4
Abbreviations and Explanations
4
19XR Identification
5
Cooler
5
Chiller Familiarization
5
Chiller Information Nameplate
5
System Components
5
Condenser
5
Motor-Compressor
5
Control Panel
5
Front/Rear View
6
Factory-Mounted Starter or Variable
7
- Frequency Drive (Optional)
  7
Storage Vessel (Optional)
7
Refrigeration Cycle
7
Motor and Lubricating Oil
7
- Cooling Cycle
  7
Vfd Cooling Cycle
8
Lubrication Cycle
8
Summary
8
Details
8
Oil Reclaim System
8
- Primary Oil Recovery Mode
  8
- Secondary Oil Recovery Method
  8
Starting Equipment
9
Unit-Mounted Solid-State Starter
9
- (Optional)
  9
Unit-Mounted Wye-Delta Starter
10
- (Optional)
  10
Unit-Mounted VFD (Optional)
10
Controls
10
Definitions
10
- Analog Signal
  10
- Discrete Signal
  10
Integrated Starter Module (Ism
11
- Optional
  11
- Optional
  12
- Chiller Visual Controller (CVC)
  13
- Components and Panel Locations
  13
- International Chiller Visual
  13
- Controller (ICVC)
  13
- Integrated Starter Module (Ism)
  13
- Chiller Control Module (CCM)
  13
- Oil Heater Contactor (1C)
  13
- Oil Pump Contactor (2C)
  13
- Hot Gas Bypass Contactor Relay (3C)
  13
- Control Transformers (T1, T2)
  13
General
11
PIC II System Components
11
CVC/ICVC Operation and Menus
15
- General
  15
- Alarms and Alerts
  15
- CVC/ICVC Menu Items
  15
- BASIC CVC/ICVC OPERATIONS (Using the Softkeys)
  15
- To View Status
  16
- Override Operations
  16
- Alarms and Alerts
  18
- Time Schedule Operation
  20
- To View and Change Set Points
  21
- Service Operation
  21
  - Service Operation
    22
  - Alarms and Alerts
    22
PIC II System Functions
33
- Capacity Control Fixed Speed
  33
- Capacity Control Vfd
  33
- Ecw Control Option
  33
- Control Point Deadband
  33
- Diffuser Control
  33
- Proportional Bands and Gain
  33
- Demand Limiting
  34
- Chiller Timers
  34
- Occupancy Schedule
  34
Safety Controls
34
Shunt Trip (Option)
35
Default Screen Freeze
35
Ramp Loading
36
Capacity Override
36
High Discharge Temperature Control
36
Oil Sump Temperature Control
36
Oil Cooler
36
Remote Start/Stop Controls
36
Spare Safety Inputs
36
Alarm (Trip) Output Contacts
37
Refrigerant Leak Detector
37
Kilowatt Output
37
Remote Reset of Alarms
37
Condenser Pump Control
37
Condenser Freeze Prevention
38
Evaporator Freeze Protection (ICVC Only)
38
Tower Fan Relay Low and High
38
Auto. Restart after Power Failure
38
Water/Brine Reset
38
Demand Limit Control Option
39
Surge Prevention Algorithm
39
- (Fixed Speed Chiller)
  39
Surge Prevention Algorithm with VFD
40
Surge Protection VFD Units
40
Surge Protection (Fixed Speed Chiller)
40
- Head Pressure Reference Output
  40
Lead/Lag Control
40
- Common Point Sensor Installation
  41
- Chiller Communication Wiring
  41
- Lead/Lag Operation
  41
- Load Balancing
  41
- Faulted Chiller Operation
  42
- Load Balancing
  42
- Auto. Restart after Power Failure
  42
Ice Build Control
43
Attach to Network Device Control
44
- Attaching to Other Ccn Modules
  44
- Controls
  45
Service Operation
45
Start-Up/Shutdown/Recycle
46
- Sequence
  46
Local Start-Up
46
Shutdown Sequence
47
Automatic Soft Stop Amps Threshold
47
Chilled Water Recycle Mode
47
Safety Shutdown
47
Before Initial Start-Up
48
Job Data Required
48
Equipment Required
48
Using the Optional Storage Tank
48
- And Pumpout System
  48
Remove Shipping Packaging
48
Open Oil Circuit Valves
48
Tighten All Gasketed Joints and Guide Vane Shaft Packing
48
Check Chiller Tightness
48
Refrigerant Tracer
48
Leak Test Chiller
50
Standing Vacuum Test
50
- Chiller Dehydration
  53
Inspect Water Piping
53
Check Relief Valves
53
Inspect Wiring
53
- Carrier Comfort Network Interface
  54
- Solid-State Starter
  54
- Check the Oil Heater
  55
- Oil Charge
  55
- Software Configuration
  55
Check Starter
54
- Input Time and Date
  55
- Password
  55
- Change CVC/ICVC Configuration
  56
- Change Language
  56
- To Change Display to Metric Units
  56
- To Change the Password
  56
- If Necessary
  57
- If Necessary
  58
- Parameters if Necessary
  58
- Password
  58
- Verify Vfd Configuration and Change
  58
- Vfd Chiller Field Set up and Verification
  58
- If Necessary
  59
  - Necessary
    59
  - Password
    59
- Password
  60
- VFD CONTROL VERIFICATION (Running
  60
- If Necessary
  61
- Modify Equipment Configuration
  61
- Password
  61
- And Waterside Flow Device Calibration
  62
- Cooler Condenser Pressure Transducer
  62
- Perform a Control Test
  62
- Charge Refrigerant into Chiller
  63
- Chiller Equalization Without a
  63
- Controls and Compressor
  63
- High Altitude Locations
  63
- Pumpout Unit
  63
- Initial Start-Up
  64
- Dry Run to Test Start-Up Sequence
  65
Input the Design Set Points
55
Input Service Configurations
55
Check Motor Rotation
65
Check Oil Pressure and Compressor Stop
65
To Prevent Accidental Start-Up
65
Check Chiller Operating Condition
65
- Instruct the Customer Operator
  65
- Cooler-Condenser
  65
- Operating Instructions
  66
- Initial Start-Up
  66
- Operator Duties
  66
- Prepare the Chiller for Start-Up
  66
To Start the Chiller
66
Check the Running System
66
To Stop the Chiller
66
- After Limited Shutdown
  66
Preparation for Extended Shutdown
66
- After Extended Shutdown
  67
- Cold Weather Operation
  67
- Manual Guide Vane Operation
  67
- Operating the Optional Pumpout Unit
  67
- Procedures
  67
- Pumpout and Refrigerant Transfer Procedures
  67
- Refrigeration Log
  67
- To Read Refrigerant Pressures
  67
- Chillers with Storage Tanks
  69
- Transfer Refrigerant from
  69
- Chiller Condenser Vessel
  70
- Chiller Cooler Vessel
  70
- Chillers with Isolation Valves
  70
- Transfer All Refrigerant to
  70
- Adding Refrigerant
  71
- General Maintenance
  71
- Procedures
  71
Removing Refrigerant
71
- Adjusting the Refrigerant Charge
  71
- Refrigerant Leak Testing
  71
- Leak Rate
  71
Test after Service, Repair, or Major Leak
71
Standing Vacuum Test
72
Checking Guide Vane Linkage
72
Trim Refrigerant Charge
72
Weekly Maintenance
72
Check the Lubrication System
72
- Scheduled Maintenance
  73
- Service Ontime
  73
- Inspect the Control Panel
  73
- Monthly
  73
- Changing Oil Filter
  73
- Oil Specification
  73
- Oil Changes
  73
- Refrigerant Filter
  73
- Oil Reclaim Filter
  73
Inspect Relief Valves and Piping
74
Compressor Bearing and Gear Maintenance
74
Inspect the Heat Exchanger Tubes
74
- And Flow Devices
  74
- Cooler and Flow Devices
  74
- Condenser and Flow Devices
  74
Water Leaks
74
Inspect Refrigerant Float System
74
Water Treatment
75
Inspect the Starting Equipment
75
Check Pressure Transducers
75
Optional Pumpout System Maintenance
75
- Optional Pumpout Compressor Oil Charge
  75
- Optional Pumpout Safety Control Settings
  75
Ordering Replacement Chiller Parts
75
Troubleshooting Guide
76
Overview
76
Checking Display Messages
76
Checking Temperature Sensors
76
- Resistance Check
  76
- Voltage Drop
  76
- Check Sensor Accuracy
  76
- Dual Temperature Sensors
  76
Checking Pressure Transducers
76
- Units Equipped with CVC
  76
- Transducer Replacement
  77
Control Algorithms Checkout Procedure
77
Control Test
77
- Troubleshooting
  78
- Chiller Protect Limit Faults
  81
Control Modules
87
- RED LED (Labeled as STAT)
  87
Notes on Module Operation
87
Chiller Control Module (CCM)
88
Integrated Starter Module
88
Replacing Defective Processor Modules
88
- Installation
  88
Solid-State Starters
88
Physical Data
90
Index
123

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