Inside black box there are two connection points. J1 & J2. Usually these are connected with a jumper. If you remove this jumper the unit will not load above 90%. Please check this and if there is no jumper, install one if you know why it is removed.
In calibrated FLA you should receive approximately 8,25VDC in V1-V2. I usually calibrate the Capacity Control Module (CCM) to start current limit condition at 8,07VDC.
I’ll send you a useful service bulleting if you send me your email address, but I don’t believe that the black box is damaged. Maybe current calibrator needs to be readjusted.
If you have 8,25VDC at your 80% then current calibrator need to be recalibrated.
Last edited by CV_Geardrive; 05-23-2012 at 11:36 AM.
Reason: I put my email in post. Not allowed.
If your talking about the black box in the starter, it is calibrated to the specific chiller it came from. You better make sure it had the same RLA.
Originally Posted by ZeroTolerance
Yes R123, It hasn't been installed yet.
CV GearDrive my e-mail is DPark017@gmail.com
Won't low refrigerant (leak) cause it to also not load to 100%?
Probably, but the most obvious indication of the charge being low enough to cause loading problems will be a period of a fully unload signal from the capacity control module. The frequency of that occurring will be affected by how low the charge is and how much the chiller is trying to load. You will see the red light on the panel light continously and the vane operator drive continously to fully unloaded. It is not like later models with "Adaptive" controls. This has a 2 step freeze stat, where the first step initiates that unload signal. When unloaded, evaporator temp rises, that first step resets, chiller begins loading again to setpoint, and the whole process begins again.
I guess we are not supposed to put our e-mails in our posts, so I need a mod to please remove mine as I cannot edit posts nor can I send PM's like I used to be able to do :/
Why can't I send PM's?
Why can't I edit my posts in certain forums?
Why are my freedoms being taken away lol?
Fouled evaporator tubes can also prevent chiller from reaching 100% RLA and leaving water temperature setpoint. With fouled tubes, The evaporator saturated refrigerant temperature and approach will be in normal range on a CVHE/F. With flows at design, The fouled tubes indicator is best seen with the not so good Delta-T. Through me for a loop the 1st time I ran into this when I had a CVHE with a classic panel that wouldn't load up beyond 75-80% and anything that could have caused it on the capacity control side and vane assembly was all good. I'm just glad in this case I didn't upgrade the chiller to adaptiview to find the evaporator tubes being the culprit.
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Originally Posted by Healey Nut
Don't need no stinking readings, Just replace everything and hope that takes care of the problem. It's all about process of elimination. Unfortunately, Elimination of process seems more and more like the new standard.
It's All Good!!!
All I wanted to know was what symptoms would cause a chiller not to load to its full potential. Don't need help diagnosing it just was curious.
Vanes not closing enough
and Low refrigerant
cause a chiller to not load to 100% but im sure there is more
I'm not sure I'm following you here. Vanes not opening enough would prevent a chiller from loading to 100%.
Originally Posted by ZT
If the chiller was short of refrigerant it is possible for it to run and not load to 100%, but the vanes would be wide open because the controls would be telling the machine it still had to load.
That is true, especially if it is not able to get to setpoint - if leaving chill water temp is high enough above setpoint, even with an increase in the approach, the evap temp may not reach the freeze stat setting. A good point, which I failed to consider....
Originally Posted by KnewYork