Start-Up, Operation, and Maintenance Instructions · PDF fileManufacturer reserves the right...

Click here to load reader

  • date post

    28-Aug-2018
  • Category

    Documents

  • view

    213
  • download

    0

Embed Size (px)

Transcript of Start-Up, Operation, and Maintenance Instructions · PDF fileManufacturer reserves the right...

  • Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.PC 211 Catalog No. 531-982 Printed in U.S.A. Form 19XR-5SS Pg 1 6-01 Replaces: 19XR-4SSBook 2

    Tab 5a

    Start-Up, Operation, and Maintenance InstructionsSAFETY CONSIDERATIONS

    Centrifugal liquid chillers are designed to provide safe andreliable service when operated within design specifica-tions. When operating this equipment, use good judgmentand safety precautions to avoid damage to equipment andproperty or injury to personnel.

    Be sure you understand and follow the procedures andsafety precautions contained in the chiller instructions aswell as those listed in this guide.

    DO NOT VENT refrigerant relief valves within a building. Outletfrom rupture disc or relief valve must be vented outdoors in accor-dance with the latest edition of ANSI/ASHRAE 15 (AmericanNational Standards Institute/American Society of Heating, Refrigera-tion, and Air Conditioning Engineers). The accumulation of refriger-ant in an enclosed space can displace oxygen and cause asphyxiation.PROVIDE adequate ventilation in accordance with ANSI/ASHRAE15, especially for enclosed and low overhead spaces. Inhalation ofhigh concentrations of vapor is harmful and may cause heart irregular-ities, unconsciousness, or death. Misuse can be fatal. Vapor is heavierthan air and reduces the amount of oxygen available for breathing.Product causes eye and skin irritation. Decomposition products arehazardous.DO NOT USE OXYGEN to purge lines or to pressurize a chiller forany purpose. Oxygen gas reacts violently with oil, grease, and othercommon substances.NEVER EXCEED specified test pressures, VERIFY the allowabletest pressure by checking the instruction literature and the design pres-sures on the equipment nameplate.DO NOT USE air for leak testing. Use only refrigerant or drynitrogen.DO NOT VALVE OFF any safety device.BE SURE that all pressure relief devices are properly installed andfunctioning before operating any chiller.

    RISK OF INJURY OR DEATH by electrocution. High voltage ispresent on motor leads even though the motor is not running when asolid-state or inside-delta mechanical starter is used. Open the powersupply disconnect before touching motor leads or terminals.

    DO NOT WELD OR FLAMECUT any refrigerant line or vessel untilall refrigerant (liquid and vapor) has been removed from chiller.Traces of vapor should be displaced with dry air or nitrogen and thework area should be well ventilated. Refrigerant in contact with anopen flame produces toxic gases.DO NOT USE eyebolts or eyebolt holes to rig chiller sections or theentire assembly.DO NOT work on high-voltage equipment unless you are a qualifiedelectrician.DO NOT WORK ON electrical components, including control pan-els, switches, starters, or oil heater until you are sure ALL POWER ISOFF and no residual voltage can leak from capacitors or solid-statecomponents.LOCK OPEN AND TAG electrical circuits during servicing. IFWORK IS INTERRUPTED, confirm that all circuits are deenergizedbefore resuming work.AVOID SPILLING liquid refrigerant on skin or getting it into theeyes. USE SAFETY GOGGLES. Wash any spills from the skin with

    soap and water. If liquid refrigerant enters the eyes, IMMEDIATELYFLUSH EYES with water and consult a physician.NEVER APPLY an open flame or live steam to a refrigerant cylinder.Dangerous over pressure can result. When it is necessary to heatrefrigerant, use only warm (110 F [43 C]) water.DO NOT REUSE disposable (nonreturnable) cylinders or attempt torefill them. It is DANGEROUS AND ILLEGAL. When cylinder isemptied, evacuate remaining gas pressure, loosen the collar andunscrew and discard the valve stem. DO NOT INCINERATE.CHECK THE REFRIGERANT TYPE before adding refrigerant tothe chiller. The introduction of the wrong refrigerant can cause dam-age or malfunction to this chiller.

    Operation of this equipment with refrigerants other than thosecited herein should comply with ANSI/ASHRAE 15 (latest edition).Contact Carrier for further information on use of this chiller with otherrefrigerants.DO NOT ATTEMPT TO REMOVE fittings, covers, etc., whilechiller is under pressure or while chiller is running. Be sure pressure isat 0 psig (0 kPa) before breaking any refrigerant connection.CAREFULLY INSPECT all relief devices, rupture discs, and otherrelief devices AT LEAST ONCE A YEAR. If chiller operates in acorrosive atmosphere, inspect the devices at more frequent intervals.DO NOT ATTEMPT TO REPAIR OR RECONDITION any reliefdevice when corrosion or build-up of foreign material (rust, dirt, scale,etc.) is found within the valve body or mechanism. Replace thedevice.DO NOT install relief devices in series or backwards.USE CARE when working near or in line with a compressed spring.Sudden release of the spring can cause it and objects in its path to actas projectiles.

    DO NOT STEP on refrigerant lines. Broken lines can whip about andrelease refrigerant, causing personal injury.DO NOT climb over a chiller. Use platform, catwalk, or staging. Fol-low safe practices when using ladders.USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift ormove inspection covers or other heavy components. Even if compo-nents are light, use mechanical equipment when there is a risk of slip-ping or losing your balance.BE AWARE that certain automatic start arrangements CANENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open thedisconnect ahead of the starter, tower fans, or pumps.USE only repair or replacement parts that meet the code requirementsof the original equipment.DO NOT VENT OR DRAIN waterboxes containing industrial brines,liquid, gases, or semisolids without the permission of your processcontrol group.DO NOT LOOSEN waterbox cover bolts until the waterbox has beencompletely drained.DOUBLE-CHECK that coupling nut wrenches, dial indicators, orother items have been removed before rotating any shafts.DO NOT LOOSEN a packing gland nut before checking that the nuthas a positive thread engagement.PERIODICALLY INSPECT all valves, fittings, and piping for corro-sion, rust, leaks, or damage.

    PROVIDE A DRAIN connection in the vent line near each pressurerelief device to prevent a build-up of condensate or rain water.

    19XR,XRVHermetic Centrifugal Liquid Chillers

    50/60 HzWith PIC II Controls and HFC-134a

  • 2

    CONTENTS

    PageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Factory-Mounted Starter or Variable

    Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7MOTOR AND LUBRICATING OIL

    COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PRIMARY OIL RECOVERY MODE SECONDARY OIL RECOVERY METHODSTARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10Unit-Mounted Solid-State Starter

    (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Unit-Mounted Wye-Delta Starter

    (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ANALOG SIGNAL DISCRETE SIGNALGeneral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 11 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. . . . . . . . . . . . . . . . . 15 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 OPERATIONPIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33 CAPACITY CONTROL FIXED SPEED CAPACITY CONTROL VFD ECW CONTROL OPTION CONTROL POINT DEADBAND DIFFUSER CONTROL PROPORTIONAL BANDS AND GAIN DEMAND LIMITING CHILLER TIMERS OCCUPANCY SCHEDULESafety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

    PageShunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .