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Figure 62 — Open-Drive — Power Panel
1
2
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Definitions
8
Contents
10
Weekly Maintenance
22
Scheduled Maintenance
22
Troubleshooting Guide
24
List of Tables
27
List of Figures
31
Introduction
36
Abbreviations
38
Machine Identification Label
39
System Components
39
Motor-Compressor
40
Control Center
40
Refrigeration Cycle (
41
Figure 4
41
Summary
44
Details
45
(EX Compressor Shown)
47
Details (See
48
Figure 6
48
Starters
50
Controls
50
Volatile Memory
51
PIC System Components
52
Processor Module (PSIO)
53
Local Interface Device (LID)
54
6-Pack Relay Board
55
8-Input Modules
55
Oil Heater Contactor (1C)
55
Oil Pump Contactor (2C)
55
Oil Auxiliary Relay (4C)
56
Control Transformers (T1-T4)
56
Figure 19, and Figure 20)
58
Alarms and Alerts
59
Menu Structure
61
NEXT PREVIOUS SELECT EXIT
62
Figure 18
63
For Discrete Points
64
Override Operations
65
To Remove an Override
66
Figure 19
67
Figure 20
71
PIC System Functions
74
Deadband
75
Proportional Bands and Gain
75
Demand Limiting
76
Machine Timers
76
Occupancy Schedule
77
Safety Controls
79
Shunt Trip
80
Default Screen Freeze
81
Ramp Loading Control
82
Capacity Override (See
83
Oil Sump Temperature Control
85
Oil Cooler
86
Remote Start/Stop Controls
86
Spare Safety Inputs
87
Spare Alarm Contacts
87
Condenser Pump Control
88
Condenser Freeze Prevention
88
Tower-Fan Relay
89
Water/Brine Reset
91
Surge Prevention Algorithm
93
Surge Protection
95
Lead/Lag Control
96
Machine Communication Wiring
98
Lead/Lag Operation
98
Faulted Chiller Operation
102
Load Balancing
103
Ice Build Control
104
Ice Build Initiation
105
Start-Up/Recycle Operation
106
Termination of Ice Build
107
Service Operation
111
To Log Off
112
Holiday Scheduling (
113
Figure 24
113
NEXT PREVIOUS SELECT EXIT
114
INCREASE DECREASE QUIT ENTER
116
Local Start-Up
118
Shutdown Sequence
120
COMPRESSOR MOTOR LOAD
121
ENTERING CONDENSER WATER
121
LEAVING CHILLED WATER
121
CONTROL
121
Chilled Water Recycle Mode
122
Safety Shutdown
124
Before Initial Start-Up
125
Remove Shipping Packaging
126
Open Oil Circuit Valves
129
Torque All Gasketed Joints
129
Check Machine Tightness
129
Refrigerant Tracer
130
Leak Test Machine
130
Standing Vacuum Test
134
Machine Dehydration
135
Inspect Water Piping
137
Check Relief Devices
138
Inspect Wiring
139
0- 900 500
142
901- 7000 1000
142
7001-14500 2500
142
Check Starter
147
Mechanical-Type Starters
148
Solid-State Starters
149
Oil Charge
150
Software Version
151
Input the Design Set Points
152
Input Service Configurations
153
At low loads (<50%)
159
At high loads (>50%)
159
Check Voltage Supply
160
High Altitude Locations
163
Trimming Refrigerant Charge
165
Initial Start-Up
166
TARGET GUIDE
167
VANE POSITION
167
TARGET GUIDE VANE POSITION
167
If Rotation Is Proper
174
Cooler-Condenser
178
Utility Vessel
178
Pumpout System
178
Operating Instructions
180
To Start the Machine
181
Check the Running System
181
To Stop the Machine
183
After Limited Shutdown
184
Extended Shutdown
184
After Extended Shutdown
184
Cold Weather Operation
185
Manual Guide Vane Operation
185
Refrigeration Log
186
Preparation
187
To Read Refrigerant Pressures
188
(12-ft Vessel Shown)
188
1 2 3 4 5 6 7 8 9 10 11
189
C C CCCCC
190
Compressor Section
191
CC CCCCC
192
C CC CCCC C
193
Condition
194
General Maintenance
195
Adding Refrigerant
196
Removing Refrigerant
196
Refrigerant Leak Testing
197
Leak Rate
197
Figure 35
199
Seal Disassembly (
201
Figure 36
201
Handle carefully
202
Protect seal faces of ring
202
Seal Reassembly (
203
Alignment Methods
205
Preliminary Alignment
207
Near Final Alignment
208
Measurement
211
Adjustment
213
Final Alignment
217
Hot Alignment Check
217
Doweling
220
Changing Oil Filter
224
FA Style Compressors
225
Oil Changes
226
Oil Specification
226
Refrigerant Filter
227
Oil Reclaim Filter
228
Procedure
229
Cleanliness
231
Sleeve Bearings
235
Open-Drive Motor Storage
244
Condenser
247
Check Pressure Transducers
251
Pumpout System Maintenance
251
Figure 47
252
Checking Temperature Sensors
255
Resistance Check
256
Voltage Drop
256
Check Sensor Accuracy
257
Dual Temperature Sensors
257
Checking Pressure Transducers
258
Figure 48
261
Troubleshooting Transducers
262
Transducer Replacement
262
Control Test
264
Control Modules
267
Green LEDs
268
Other Green LED
269
Green LED
269
Notes on Module Operation
270
Options Modules (8-Input)
274
Table 2 — LID Screens
284
Table 4 — Capacity Overrides
302
Table 6 — Recommended Torque
307
B. Timing Out or Timed Out
311
C. In Recycle Shutdown
312
D. Pre-Start Alerts:
313
E. Normal or AUTO.-RESTART
314
F. Start-Up Failures:
315
(Continued)
316
L. Machine Alerts
324
L. Machine Alerts (Continued)
325
(Page 1 of 2)
333
(English)
336
150 1034 2236 1015 1275 579
338
300 2068 3060 1389 1660 754
338
150 1034 – – 1643 746
338
300 2068 – – 2243 1018
338
Compressor End View
353
Machine Front View
354
Motor End View
355
Machine Rear View
359
(Open-Drive Machine Shown)
365
(Status01)
371
Figure 25 — Control Sequence
378
Figure 31 — Refrigeration Log
384
Figure 40 — Alignment Formula
394
To Check Angular Alignment
399
To Check Parallel Alignment
400
Figure 53 — Options Module
410
Size (See Figure 1 Also)
411
Note: See Table 17
414
Open Drive Machine
420
(Remove and use for job file.)
426
MACHINE INFORMATION:
426
INSTRUCTIONS
426
CENTRIFUGAL LIQUID CHILLER
428
CONFIGURATION SETTINGS LOG
428
MACHINE ALIGNMENT REPORT
437
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