Carrier 19XL User Manual

19XL

Hermetic Centrifugal Liquid Chillers

50/60 Hz

With HCFC-22 and HFC-134a

Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design speciﬁcations. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.

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

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance withANSI/ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

NEVER EXCEED speciﬁed test pressures, VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly installed and

functioning before operating any chiller.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant(liquidandvapor)has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with

an open ﬂame produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.

DO NOT work on high-voltage equipment unless you are a qualiﬁed electrician.

DO NOTWORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solidstate components.

LOCK OPENAND T AGelectrical circuits during servicing. IF WORK IS INTERRUPTED, conﬁrm that all circuits are deenergized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH 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 heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to reﬁll them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.

Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further information on use of this chiller with other refrigerants.

DO NOT ATTEMPTTOREMOVE ﬁttings, covers, etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.

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 act as projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fans, or pumps.

USE only repair or replacement parts that meet the code requirements of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, ﬁttings, and piping for corrosion, rust, leaks, or damage.

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

Manufacturer reserves the right to discontinue, or change at any time, speciﬁcations or designs without notice and without incurring obligations.

Book 2 Tab 5a

PC 211 Catalog No. 531-971 Printed in U.S.A. Form 19XL-4SS Pg 1 7-96 Replaces: 19XL-3SS

CONTENTS

Page

SAFETY CONSIDERATIONS ...................1

INTRODUCTION ..............................4

ABBREVIATIONS AND EXPLANATIONS .......4

CHILLER FAMILIARIZATION ..................5

Chiller Information Plate ......................5

System Components .........................5

Cooler .......................................5

Condenser ...................................5

Motor-Compressor ...........................5

Control Center ...............................5

Factory-Mounted Starter (Optional) ............5

Storage Vessel (Optional) .....................5

REFRIGERATION CYCLE .....................5

MOTOR/OIL REFRIGERATION

COOLING CYCLE ...........................5-8

LUBRICATION CYCLE .......................8,9

Summary ....................................8

Details ......................................8

Oil Reclaim System ..........................9

• DURING NORMAL CHILLER OPERATION

• DURING LIGHT LOAD CONDITIONS

STARTING EQUIPMENT ....................10,11

Unit Mounted Solid-State Starter

(Optional) ..................................10

Unit Mounted Wye-Delta Starter

(Optional) ..................................11

CONTROLS ...............................11-39

Deﬁnitions ..................................11

• ANALOG SIGNAL

• DIGITAL SIGNAL

• VOLATILE MEMORY

General .....................................11

PIC System Components ....................11

• PROCESSOR MODULE (PSIO)

• STARTER MANAGEMENT MODULE (SMM)

• LOCAL INTERFACE DEVICE (LID)

• 6-PACK RELAY BOARD

• 8-INPUT MODULES

• OIL HEATER CONTACTOR (1C)

• OIL PUMP CONTACTOR (2C)

• HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional)

• CONTROL TRANSFORMERS (T1-T4)

• CONTROL AND OIL HEATER VOLTAGE SELECTOR (S1)

LID Operation and Menus ...................14

• GENERAL

• ALARMS AND ALERTS

• MENU STRUCTURE

• TO VIEW POINT STATUS

• OVERRIDE OPERATIONS

• TIME SCHEDULE OPERATION

• TO VIEW AND CHANGE SET POINTS

• SERVICE OPERATION

PIC System Functions .......................28

• CAPACITY CONTROL

• ENTERING CHILLED WATER CONTROL

• DEADBAND

• PROPORTIONAL BANDS AND GAIN

• DEMAND LIMITING

• CHILLER TIMERS

• OCCUPANCY SCHEDULE

Safety Controls .............................29

• SHUNT TRIP

Default Screen Freeze .......................29

Page

Motor Cooling Control .......................29

Ramp Loading Control ......................31

Capacity Override ...........................31

High Discharge Temperature Control .........32

Oil Sump Temperature Control ...............32

• PSIO SOFTWARE VERSIONS 08 AND LOWER

• PSIO SOFTWARE VERSIONS 09 AND HIGHER

Oil Cooler ..................................32

Remote Start/Stop Controls ..................32

Spare Safety Inputs .........................32

• SPARE ALARM CONTACTS

Condenser Pump Control ....................32

Condenser Freeze Protection ................32

Tower Fan Relay ............................33

Auto. Restart After Power Failure ............33

Water/Brine Reset ...........................33

• RESET TYPE 1

• RESET TYPE 2

• RESET TYPE 3

Demand Limit Control, Option

(Requires Optional 8-Input Module) ..........33

Surge Prevention Algorithm .................33

Surge Protection ............................34

Lead/Lag Control ...........................34

• COMMON POINT SENSOR INSTALLATION

• CHILLER COMMUNICATION WIRING

• LEAD/LAG OPERATION

• FAULTED CHILLER OPERATION

• LOAD BALANCING

• AUTO. RESTART AFTER POWER FAILURE

Ice Build Control ............................36

• ICE BUILD INITIATION

• START-UP/RECYCLE OPERATION

• TEMPERATURE CONTROL DURING ICE

BUILD

• TERMINATION OF ICE BUILD

• RETURN TO NON-ICE BUILD OPERATIONS

Attach to Network Device Control ............37

• CHANGING REFRIGERANT TYPES

• ATTACHING TO OTHER CCN MODULES

Service Operation ...........................38

• TO LOG ON

• TO LOG OFF

• HOLIDAY SCHEDULING

START-UP/SHUTDOWN/RECYCLE

SEQUENCE ...............................39-41

Local Start-Up ..............................39

Shutdown Sequence ........................40

Automatic Soft-Stop Amps Threshold

(PSIO Software Version 09 and Higher) ......40

Chilled Water Recycle Mode .................40

Safety Shutdown ............................41

BEFORE INITIAL START-UP ................41-54

Job Data Required ..........................41

Equipment Required ........................41

Using the Optional Storage Tank

and Pumpout System .......................41

Remove Shipping Packaging ................41

Open Oil Circuit Valves ......................41

Tighten All Gasketed Joints and

Guide Vane Shaft Packing ..................41

Check Chiller Tightness .....................41

Refrigerant Tracer ...........................41

Leak Test Chiller ............................41

Standing Vacuum Test ......................43

Chiller Dehydration .........................47

Inspect Water Piping ........................47

CONTENTS (cont)

Page

Check Optional Pumpout Compressor

Water Piping ...............................47

Check Relief Devices ........................47

Inspect Wiring ..............................47

Carrier Comfort Network Interface ...........48

Check Starter ...............................48

• MECHANICAL-TYPE STARTERS

• BENSHAW, INC. SOLID-STATE STARTER

Oil Charge ..................................50

Power Up the Controls and

Check the Oil Heater ........................50

• SOFTWARE VERSION

Set Up Chiller Control Conﬁguration .........50

Input the Design Set Points ..................50

Input the Local Occupied Schedule

(OCCPC01S) ...............................50

Selecting Refrigerant Type ...................50

• TO CONFIRM REFRIGERANT TYPE

• TO CHANGE REFRIGERANT TYPE

Input Service Conﬁgurations ................50

• PASSWORD

• INPUT TIME AND DATE

• CHANGE LID CONFIGURATION

IF NECESSARY

• MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY

• INPUT EQUIPMENT SERVICE PARAMETERS

IF NECESSARY

• MODIFY EQUIPMENT CONFIGURATION

IF NECESSARY

• CHECK VOLTAGE SUPPLY

• PERFORM AN AUTOMATED CONTROL TEST

Check Optional Pumpout System

Controls and Compressor ...................52

High Altitude Locations .....................53

Charge Refrigerant Into Chiller ...............53

• 19XL CHILLER EQUALIZATION WITHOUT

PUMPOUT UNIT

• 19XL CHILLER EQUALIZATION WITH

PUMPOUT UNIT

• TRIMMING REFRIGERANT CHARGE

INITIAL START-UP .........................55,56

Preparation .................................55

Manual Operation of the Guide Vanes ........55

Dry Run to Test Start-Up Sequence ..........55

Check Rotation .............................55

• IF ROTATION IS PROPER

• IF THE MOTOR ROTATION IS NOT

CLOCKWISE

• NOTES ON SOLID-STATE STARTERS

(Benshaw, Inc.)

Check Oil Pressure and Compressor Stop ....56

Calibrate Motor Current .....................56

To Prevent Accidental Start-Up ..............56

Check Chiller Operating Condition ...........56

Instruct the Customer Operator ..............56

• COOLER-CONDENSER

• OPTIONAL STORAGE TANK AND

PUMPOUT SYSTEM

• MOTOR COMPRESSOR ASSEMBLY

• MOTOR COMPRESSOR LUBRICATION SYSTEM

• CONTROL SYSTEM

• AUXILIARY EQUIPMENT

• DESCRIBE CHILLER CYCLES

• REVIEW MAINTENANCE

• SAFETY DEVICES AND PROCEDURES

• CHECK OPERATOR KNOWLEDGE

• REVIEW THE START-UP, OPERATION,

AND MAINTENANCE MANUAL

Page

OPERATING INSTRUCTIONS ...............56-58

Operator Duties .............................56

Prepare the Chiller for Start-Up ..............56

To Start the Chiller ..........................56

Check the Running System ..................56

To Stop the Chiller ..........................57

After Limited Shutdown .....................57

Extended Shutdown .........................57

After Extended Shutdown ...................57

Cold Weather Operation .....................57

Manual Guide Vane Operation ...............57

Refrigeration Log ...........................57

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES ................59-61

Preparation .................................59

Operating the Optional Pumpout

Compressor ................................59

• TO READ REFRIGERANT PRESSURES

Chillers with Pumpout Storage Tanks ........59

• TRANSFER REFRIGERANT FROM

STORAGE TANK TO CHILLER

• TRANSFER THE REFRIGERANT FROM

CHILLER TO STORAGE TANK

Chillers with Isolation Valves ................60

• TRANSFER ALL REFRIGERANT TO

CHILLER CONDENSER VESSEL

• TRANSFER ALL REFRIGERANT TO CHILLER

COOLER/COMPRESSOR VESSEL

• RETURN REFRIGERANT TO NORMAL

OPERATING CONDITIONS

GENERAL MAINTENANCE .................61,62

Refrigerant Properties .......................61

Adding Refrigerant ..........................61

Removing Refrigerant .......................61

Adjusting the Refrigerant Charge ............61

Refrigerant Leak Testing ....................61

Leak Rate ..................................61

Test After Service, Repair, or Major Leak .....61

• REFRIGERANT TRACER

• TO PRESSURIZE WITH DRY NITROGEN

Repair the Leak, Retest, and Apply

Standing Vacuum Test ....................62

Checking Guide Vane Linkage ...............62

• CHECKING THE AUXILIARY SWITCH ON

GUIDE VANE ACTUATOR

Trim Refrigerant Charge .....................62

WEEKLY MAINTENANCE ....................62

Check the Lubrication System ...............62

SCHEDULED MAINTENANCE ..............63-65

Service Ontime .............................63

Inspect the Control Center ...................63

Check Safety and Operating Controls

Monthly ..................................63

Changing Oil Filter ..........................63

Oil Speciﬁcation ............................63

Oil Changes ................................63

• TO CHANGE THE OIL

Refrigerant Filter ............................63

Oil Reclaim Filters ..........................63

Inspect Refrigerant Float System ............64

Inspect Relief Valves and Piping .............64

Compressor Bearing and Gear

Maintenance ...............................64

Inspect the Heat Exchanger Tubes ...........64

• COOLER

• CONDENSER

CONTENTS (cont)

Page

Water Leaks ................................64

Water Treatment ............................65

Inspect the Starting Equipment ..............65

Check Pressure Transducers ................65

Optional Pumpout System Maintenance ......65

• OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

• OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS

Ordering Replacement Chiller Parts ..........65

TROUBLESHOOTING GUIDE ...............66-97

Overview ...................................66

Checking the Display Messages .............66

Checking Temperature Sensors ..............66

• RESISTANCE CHECK

• VOLTAGE DROP

• CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers .............66

• TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure .....67

Control Test ................................67

Page

Control Modules ............................78

• RED LED

• GREEN LEDs

Notes on Module Operation ..................78

Processor Module (PSIO) ....................79

• INPUTS

• OUTPUTS

Starter Management Module (SMM) ..........79

• INPUTS

• OUTPUTS

Options Modules (8-Input) ...................79

Replacing Defective Processor Modules ......80

• INSTALLATION

Solid-State Starters .........................81

• TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS

Physical Data ...............................85

INDEX ....................................98,99

INITIAL START-UP CHECKLIST FOR

19XL HERMETIC CENTRIFUGAL

LIQUID CHILLER ...................CL-1-CL-12

INTRODUCTION

Prior to initial start-up of the 19XL unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data. This book is outlined so that you may become familiar with the control system before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation.

This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center.

Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.

This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC (Federal Communication Commission) Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be required to take whatever measures may be required to correct the interference.

Always store and transport replacement or defective boards in anti-static shipping bag.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

CCN — Carrier Comfort Network CCW — Counterclockwise CW — Clockwise ECW — Entering Chilled Water ECDW — Entering Condenser Water EMS — Energy Management System HGBP — Hot Gas Bypass I/O — Input/Output LCD — Liquid Crystal Display LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode LID — Local Interface Device OLTA — Overload Trip Amps PIC — Product Integrated Control PSIO — Processor Sensor Input/Output Module RLA — Rated Load Amps SCR — Silicon Control Rectiﬁer SI — International System of Units SMM — Starter Management Module TXV — Thermostatic Expansion Valve

The 19XL chillers use HCFC-22 and HFC-134a refrigerant. When referencing refrigerant charges in this manual, the HCFC-22 charge will be listed ﬁrst and the HFC-134a value will be shown next to it in brackets [ ].

Words printed in all capital letters and italics represent values that may be viewed on the LID.

The PSIO software version number of your 19XL unit will be located on the front cover.

CHILLER FAMILIARIZATION

(Fig. 1, 2A, and 2B)

Chiller Information Plate —

is located on the right side of the chiller control center panel.

Fig. 1 — 19XL Identiﬁcation

The information plate

System Components — The components include the

cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control center, and motor starter.All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.

Cooler — This vessel (also known as the evaporator) is

located underneath the compressor. The cooler is maintained at lower temperature/pressure so that evaporating refrigerant can remove heat from water ﬂowing through its internal tubes.

Condenser — The condenser operates at a higher

temperature/pressure than the cooler, and has water ﬂowing through its internal tubes in order to remove heat from the refrigerant.

Motor-Compressor— This component maintains sys-

tem temperature/pressure differences and moves the heat carrying refrigerant from the cooler to the condenser.

Control Center — The control center is the user inter-

face for controlling the chiller. It regulates the chiller’s capacity as required to maintain proper leaving chilled water temperature. The control center:

• registers cooler, condenser, and lubricating system pressures

• shows chiller operating condition and alarm shutdown conditions

• records the total chiller operating hours

• sequences chiller start, stop, and recycle under microprocessor control

• provides access to other CCN (Carrier Comfort Network) devices

Factory-Mounted Starter (Optional)— The starter

allows the proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panels.

Storage Vessel (Optional) — There are 2 sizes

of storage vessels available. The vessels have double relief

valves, a magnetically coupled dial-type refrigerant level gage, a one-inch FPT drain valve, and a vapor connection for the pumpout unit. A 30-in.-0-400 psi (–101-0-2750 kPa) gage also is supplied with each unit.

NOTE: If a storage vessel is not used at the jobsite, factoryinstalled isolation valves on the chiller may be used to isolate the chiller charge in either the cooler or condenser. An optional pumpout compressor system is used to transfer refrigerant from vessel to vessel.

⁄2-in. male ﬂare

REFRIGERATION CYCLE

The compressor continuously draws refrigerant vapor from the cooler, at a rate set by the amount of guide vane opening. As the compressor suction reduces the pressure in the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required for boiling is obtained from the water ﬂowing through the cooler tubes. With heat energy removed, the water becomes cold enough for use in an air conditioning circuit or process liquid cooling.

After taking heat from the water, the refrigerant vapor is compressed. Compression adds still more heat energy and the refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) when it is discharged from the compressor into the condenser.

Relatively cool (typically 65 to 90 F [18 to 32 C]) water ﬂowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.

The liquid refrigerant passes through oriﬁces into the FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant ﬂashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid drains into a ﬂoat chamber between the FLASC chamber and cooler. Here a ﬂoat valve forms a liquid seal to keep FLASC chamber vapor from entering the cooler. When liquid refrigerant passes through the valve, some of it ﬂashes to vapor in the reduced pressure on the cooler side. In ﬂashing, it removes heat from the remaining liquid. The refrigerant is now at a temperature and pressure at which the cycle began.

MOTOR/OIL REFRIGERATION

COOLING CYCLE

The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3). Flow of refrigerant is maintained by the pressure differentialthat exists due to compressor operation.After the refrigerant ﬂows past an isolation valve, an in-line ﬁlter, and a sight glass/moisture indicator, the ﬂow is split between motor cooling and oil cooling systems.

Flow to the motor ﬂows through an oriﬁce and into the motor.There is also another oriﬁce and a solenoid valve which will open if additional motor cooling is required. Once past the oriﬁce, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the bottom of the motor casing and then is drained back into the cooler through the motor refrigerant drain line. A back pressure valve or an oriﬁce in this line maintains a higher pressure in the motor shell than in the cooler/oil sump. The motor is protected by a temperature sensor imbedded in the stator windings. Higher motor temperatures (above 125 F [51 C]) energize a solenoid to provide additional motor cooling. A further increase in temperature past the motor override set point will override the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set point, will close the inlet guide vanes. If the temperature rises above the safety limit, the compressor will shut down.

19XL FRONT VIEW

LEGEND

1—Unit-Mounted Starter 2—Refrigerant Filter Drier 3—Rigging Guide Bolt 4—Refrigerant Moisture Indicator 5—Motor Sight Glass 6—Refrigerant Motor Drain 7—Oil Filter Access Cover 8—Refrigerant Oil Cooler

9—Oil Level Sight Glasses 10 — Guide Vane Actuator 11 — Typical Flange Connection 12 — Control Center 13 — ASME Nameplate, Cooler 14 — Take-Apart, Rabbet Fit Connector

(Lower)

15 — Refrigerant Charging Valve 16 — Cooler Refrigerant Isolation Valve 17 — Cooler Pressure Schrader Fittings 18 — Oil Drain/Charging Valve 19 — Power Panel 20 — Retro-Fit, Rig-in-Place Beams 21 — Typical Waterbox Drain Port 22 — Take-Apart, Shell Leveling Feet 23 — Cooler Return-End Waterbox Cover 24 — ASME Nameplate, Condenser 25 — Condenser Return-End Waterbox Cover 26 — Take-Apart, Rabbet Fit Connector

(Upper)

27 — Protective Truck Holddown Lugs 28 — Refrigerant Cooling Isolation Valve

(Hidden)

19XL REAR VIEW

Fig. 2A — Typical 19XL Components — Design I

LEGEND

29 — Pumpdown System Connection 30 — Cooler Relief Valves 31 — Chiller Identiﬁcation Nameplate 32 — Cooler Pressure Transducer 33 — Suction Elbow 34 — Transmission Vent Line 35 — Discharge Pressure Switch and

Discharge Pressure Transducer

36 — Condenser Isolation Valve 37 — Low-Voltage Access Door, Starter 38 — Medium-Voltage Access Door, Starter 39 — Amp/Volt Gages 40 — Refrigerant Supply Sump 41 — Condenser Pressure Transducer 42 — Liquid Seal Float Chamber 43 — ASME Nameplate, Float Chamber 44 — Condenser Relief Valves 45 — Condenser In/Out Temperature Sensors 46 — Cooler In/Out Temperature Sensors

LEGEND

56789

24 23

151617181920

19XL FRONT VIEW

1—Unit-Mounted Starter 2—Refrigerant Filter Drier 3—Rigging Guide Bolt 4—Motor Sight Glass 5—Refrigerant Moisture Indicator 6—Refrigerant Oil Cooler 7—Oil Filter Access Cover 8—Oil Level Sight Glasses

9—Guide VaneActuator 10 — Typical Flange Connection 11 — Control Center 12 — Cooler Pressure Schrader Fitting

(Hidden)

13 — ASME Nameplate, Cooler 14 — Cooler 15 — Take-Apart Rabbet Fit Connector

(Lower)

16 — Refrigerant Charging Valve 17 — Oil Drain/Charging Valve 18 — Power Panel 19 — Cooler Waterbox Cover 20 — Cooler In/Out Temperature Sensors 21 — Condenser In/Out Temperature Sensors 22 — Condenser Waterbox Cover 23 — Take-Apart Rabbet Fit Connector

(Upper)

24 — Refrigerant Cooling Isolation Valve

(Hidden)

2928272625

40 39

36 35 34 333215

25 — Cooler Relief Valve

26 — Chiller Identiﬁcation Plate 27 — Suction Elbow 28 — Transmission Vent Line 29 — Condenser Relief Valves 30 — Low Voltage Access Door, Starter 31 — Medium Voltage Access Door, Starter 32 — Amp/Volt Gages 33 — Condenser Isolation Valve 34 — Linear Float Valve Chamber 35 — Condenser Pressure Transducer 36 — Discharge Pressure Switch and

Discharge Pressure Transducer

37 — Cooler Refrigerant Isolation Valve 38 — Condenser Return End Waterbox Cover 39 — Typical Waterbox Drain Port 40 — Cooler Return End Waterbox Cover 41 — Cooler Pressure Transducer 42 — Pumpdown Valve

LEGEND

19XL REAR VIEW

Fig. 2B — Typical 19XL Components — Design II

Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles

Refrigerant that ﬂows to the oil cooling system is regulated by a thermostatic expansion valve. There is always a minimum ﬂow bypassing the TXV, which ﬂows through an oriﬁce. The TXV valve regulates ﬂow into the oil/ refrigerant plate and frame-type heat exchanger. The bulb for the expansion valve controls oil temperature to the bearings. The refrigerant leaving the heat exchanger then returns to the cooler.

LUBRICATION CYCLE

Summary—

up a package located partially in the transmission casting of the compressor-motor assembly. The oil is pumped into a ﬁlter assembly to remove foreign particles, and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures. After the oil cooler, part of the ﬂow is directed to the gears and the high speed shaft bearings; the remaining ﬂow is directed to the motor shaft bearings. Oil drains into the transmission oil sump to complete the cycle (Fig. 4).

The oil pump, oil ﬁlter, and oil cooler make

Details— Oil is charged into the lubrication system through

a hand valve. Two sight glasses in the oil reservoir permit oil level observation. Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass

when the compressor is shut down. The oil level should be visible in at least one of the 2 sight glasses during operation. Oil sump temperature is displayed on the LID default screen. Oil sump temperature ranges during compressor operation between 100 to 120 F (37 to 49 C) [120 to 140 F (49 to 60 C)].

The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to 172 kPad) differential pressure in the system at the pump discharge.This dif ferentialpressure can be read directly from the Local Interface Device (LID) default screen. The oil pump discharges oil to the oil ﬁlter assembly. This ﬁlter can be valved closed to permit removal of the ﬁlter without draining the entire oil system (see Maintenance sections, pages 61 to 65, for details). The oil is then piped to the oil cooler. This heat exchanger uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a temperature between 100 and 120 F (37 to 49 C).

As the oil leaves the oil cooler, it passes the oil pressure transducer and the thermal bulb for the refrigerant expansion valve on the oil cooler. The oil is then divided, with a portion ﬂowing to the thrust bearing, forward pinion bearing, and gear spray. The balance then lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured as the oil leaves the thrust and forward

Fig. 4 — Lubrication System

journal bearings within the bearing housing. The oil then drains into the oil reservoir at the base of the compressor. The PIC (Product Integrated Control) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature Control section, page 32). This temperature is read on the LID default screen.

During the chiller start-up, the PIC will energize the oil pump and provide 15 seconds of prelubrication to the bearings after pressure is veriﬁed before starting the compressor. During shutdown, the oil pump will run for 60 seconds to post-lubricate after the compressor shuts down. The oil pump can also be energized for testing purposes in the Control Test.

Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to ﬂash. The resulting oil foam cannot be pumped efficiently; therefore, oil pressure falls off and lubrication is poor. If oil pressure falls below 15 psid (103 kPad) differential, the PIC will shut down the compressor.

Oil Reclaim System — The oil reclaim system oper-

ates to return oil back to the oil reservoir by recovering it from 2 areas on the chiller. The primary area of recovery is from the guide vane housing. Oil also is recovered, along with refrigerant, from the cooler.

Any refrigerant that enters the oil reservoir/transmission area is ﬂashed into gas. The demister line at the top of the

casing will vent this refrigerant into the suction of the compressor. Oil entrained in the refrigerant is eliminated by the demister ﬁlter.

DURING NORMAL CHILLER OPERATION, oil is entrained with the refrigerant. As the compressor pulls the refrigerant into the guide vane housing to be compressed, the oil will normally drop out at this point and fall to the bottom of the housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is vacuumed from the housing by the eductor and is discharged into the oil reservoir. Oil and refrigerant are also recovered from the top of the cooler refrigerant level and are discharged into the guide vane housing. The oil will drop to the bottom of the guide vane housing and be recovered by the eductor system.

DURING LIGHT LOAD CONDITIONS, the suction gas into the compressor does not have enough velocity to return oil, which is ﬂoating in the cooler back to the compressor. In addition, the eductor may not have enough power to pull the oil from the guide vane housing back into the oil reservoir due to extremely low pressure at the guide vanes. Two solenoids, located on the oil reclaim piping, are operated so that the eductor can pull oil and refrigerant directly from the cooler and discharge the mixture into the oil reservoir. The oil reclaim solenoids are operated by an auxiliary contact integral to the guide vane actuator. This switchover of the solenoids occurs when the guide vanes are opened beyond 30 degrees from the closed position.

STARTING EQUIPMENT

The 19XL requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxiliary equipment. The starter serves as the main ﬁeld wiring interface for the contractor.

Three types of starters are available from Carrier Corporation: solid-state, wye-delta, and across-the-line starters. See Carrier Speciﬁcation Z-375 for speciﬁc starter requirements. All starters must meet these speciﬁcations in order to properly start and satisfy mechanical safety requirements. Starters may be supplied as separate, free-standing units, or may be mounted directly on the chiller (unit mounted) for low-voltage units only.

Inside the starter are 3 separate circuit breakers. Circuit breaker CB1 is the compressor motor circuit breaker. The disconnect switch on the starter front cover is connected to this breaker. Circuit breaker CB1 supplies power to the compressor motor.

The main circuit breaker (CB1) on the front of the starter disconnects the main motor current only. Power is still energized for the other circuits. Two more circuit breakers inside the starter must be turned off to disconnect power to the oil pump, PIC controls, and oil heater.

Circuit breaker CB2 supplies power to the control center, oil heater, and portions of the starter controls. Circuit breaker CB3 supplies power to oil pump. Both of these circuit breakers are wired in parallel with CB1 so that power is supplied to them if the CB1 disconnect is open.

All starters are shipped with a Carrier control module called the Starter Management Module (SMM). This module controls and monitors all aspects of the starter. See the Controls section on page 11 for additional SMM information. All starter replacement parts are supplied by the starter manufacturer.

LEGEND

1—Field Wiring Terminal Strips (TB2 and TB3) 2—Circuit Breaker 1, 2, 3, 4 3—Overload Unit 4—Solid-State Controller 5—Silicon Controlled Rectiﬁer (SCR) LED (One of 6) 6—Starter Fault and Run LEDs 7—Voltmeter (Optional) 8—Ammeter (Optional)

9—SCR (One of 6) 10 — Voltage LED 11 — Starter Management Module (SMM) 12 — Pilot Relays (PR1 to PR5) 13 — Starter Access Door

Fig. 5 — Benshaw, Inc. Solid-State Starter,

Internal View

Unit-Mounted Solid-State Starter (Optional)

The 19XL may be equipped with a solid-state, reduced-

—

voltage starter (Fig. 5 and 6). This starter provides on-off control of the compressor motor as its primary function. Using this type of starter reduces the peak starting torque, reduces the motor inrush current, and decreases mechanical shock. This is summed up by the phrase ‘‘soft starting.’’

Two varieties of solid-state starters are available as a 19XL option (factory supplied and installed). When a unit-mounted, optional, solid-state starter is purchased with the 19XL, a Benshaw,Inc. solid-state starter will be shipped with the unit. See Fig. 5. The solid-state starter’s manufacturer name will be located inside the starter access door. See Fig. 6.

These starters operate by reducing the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the voltage and the current are reduced at start-up, the starting torque is reduced as well. The object is to reduce the starting voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage and current are then ramped up in a desired period of time. The voltage is reduced through the use of silicon controlled rectiﬁers (SCR). Once full voltage is reached, a bypass contactor is energized to bypass the SCRs.

When voltage is supplied to the solid-state circuitry, the heat sinks within the starter are at line voltage. Do not touch the heat sinks while voltage is present or serious injury will result.

Fig.6—Typical Starter External View

(Solid-State Starter Shown)

There are a number of LEDs (light-emitting diodes) that are useful in troubleshooting and starter check-out on Benshaw, Inc. solid-state starters. These are used to indicate:

• voltage to the SCRs

• SCR control voltage

• power indication

• proper phasing for rotation

• start circuit energized

• overtemperature

• ground fault

• current unbalance

• run state These LEDs are further explained in the Check Starter and

Troubleshooting Guide section, page 66.

Unit-MountedWye-DeltaStarter (Optional) — The

19XLchiller may be equipped with a wye-delta starter mounted on the unit (Fig. 7). This starter is intended for use with lowvoltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye conﬁguration. This occurs during the starting period when the motor is accelerating up to speed. After a time delay, once the motor is up to speed, the starter automatically connects the phase windings into a delta conﬁguration.

123456 7

1011121314

1—Pilot Relays 2—SMM Power Circuit Breaker and Voltage Calibration

Potentiometer

3—Transistor Resistor Fault Protector (TRFP) 4—Transformer (T2) 5—Control Power Circuit Breaker 6—Oil Pump Circuit Breaker 7—Main Circuit Breaker Disconnect 8—Voltmeter (Optional)

9—Ammeter (Optional) 10 — Current Transformers (T1, T2, T3) 11 — Phase Monitor Relay (Optional) 12 — Overload Unit 13 — Starter Management Module 14 — Starter Access Door 15 — Control Transformer Secondary Circuit Breaker 16 — Signal Resistor 17 — Field Wiring Terminal Strip (TB6)

LEGEND

Fig.7—Wye-Delta Starter, Internal View

Deﬁnitions

CONTROLS

ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantiﬁes values between operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature, generating many values.)

DIGIT ALSIGNAL—A digital (discrete) signal is a 2-position representation of the value of a monitored source. (Example: A switch is a digital device because it only indicates whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.)

VOLATILE MEMORY — Volatile memory is memory in- capable of being sustained if power is lost and subsequently restored.

The memory of the PSIO and LID modules are volatile. If the battery in a module is removed or damaged, all programming will be lost.

General — The 19XL hermetic centrifugal liquid chiller

contains a microprocessor-based control center that monitors and controls all operations of the chiller. The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature, and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable ﬂow prewhirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor ﬂow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. Chiller protection is provided by the processor which monitors the digital and analog inputs and executes capacity overrides or safety shutdowns, if required.

PIC System Components — The Product Integrated

Control (PIC) is the control system on the chiller. See

T able1. The PIC controls the operation of the chiller by monitoring all operating conditions. The PIC can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on only when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off, and the hot gas bypass valve, if installed.

The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PICequipped chillers and other CCN devices.

The PIC consists of 3 modules housed inside the 3 major components. The component names and the control voltage contained in each component are listed below (also see Table 1):

• control center — all extra low-voltage wiring (24 v or less)

• power panel — 230 or 115 v control voltage (per job

requirement)

— up to 600 v for oil pump power

• starter cabinet — chiller power wiring (per job

requirement)

Table 1 — Major PIC Components and

Panel Locations*

PIC COMPONENT

Processor Sensor Input/Output Module

(PSIO)

Starter Management Module (SMM) Starter Cabinet Local Interface Device (LID) Control Center 6-Pack Relay Board Control Center 8-Input Modules (Optional) Control Center Oil Heater Contactor (1C) Power Panel Oil Pump Contactor (2C) Power Panel Hot Gas Bypass Relay (3C) (Optional) Power Panel Control Transformers (T1-T4) Power Panel Control and Oil Heater Voltage Selector (S1) Power Panel Temperature Sensors See Fig. 8 Pressure Transducers See Fig. 8

*See Fig. 5, 6, and Fig. 8-12.

PANEL

LOCATION

Control Center

Fig. 8 — 19XL Controls and Sensor Locations

Fig. 9 — Control Sensors

(Temperature)

Fig. 10 — Control Sensors

(Pressure Transducer, Typical)

LEGEND

1—LID 2—PSIO 3—8-Input Module (One of 2 Available) 4—5-Volt Transducer Power Supply 5—6-Pack Relay Board 6—Circuit Breakers (4)

Fig. 11 — Control Center (Front View),

with Options Module

PROCESSOR MODULE (PSIO) — The PSIO is the brain of the PIC (Fig. 11). This module contains all the operating software needed to control the chiller.The 19XLuses 3 pressure transducers and 8 thermistors to sense pressures and temperatures. These are connected to the PSIO module. The PSIO also provides outputs to the guide vane actuator, oil pump, oil heater, hot gas bypass (optional), motor cooling solenoid, and alarm contact. The PSIO communicates with the LID, the SMM, and the optional 8-input modules for user interface and starter management.

ST ARTER MANAGEMENT MODULE (SMM) — This module is located within the starter cabinet. This module initiates PSIO commands for starter functions such as start/ stop of the compressor, start/stop of the condenser and chilled water pumps, start/stop of the tower fan, spare alarm contacts, and the shunt trip. The SMM monitors starter inputs such as ﬂow switches, line voltage, remote start contact, spare safety, condenser high pressure, oil pump interlock, motor current signal, starter 1M and run contacts, and kW transducer input (optional). The SMM contains logic capable of safely shutting down the machine if communications with the PSIO are lost.

LOCALINTERFACEDEVICE (LID) — The LID is mounted to the control center and allows the operator to interface with the PSIO or other CCN devices (Fig. 11). It is the input center for all local chiller set points, schedules, set-up functions, and options. The LID has a STOP button, an alarm light, 4 buttons for logic inputs, and a display. The function of the 4 buttons or ‘‘softkeys’’are menu driven and are shown on the display directly above the key.

6-PACK RELAY BOARD — This device is a cluster of 6 pilot relays located in the control center (Fig. 11). It is energized by the PSIO for the oil pump, oil heater, alarm, optional hot gas bypass relay, and motor cooling solenoid.

8-INPUT MODULES — One optional module is factory installed in the control center panel when ordered (Fig. 11). There can be up to 2 of these modules per chiller with 8 spare inputs each. They are used whenever chilled water reset, demand reset, or reading a spare sensor is required. The sensors or 4 to 20 mA signals are ﬁeld-installed.

The spare temperature sensors must have the same temperature/resistance curve as the other temperature sensors on this unit. These sensors are 5,000 ohm at 75 F (25 C).

OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 12) and operates the heater at either 115 or 230 v. It is controlled by the PIC to maintain oil temperature during chiller shutdown.

OIL PUMP CONTACTOR (2C) — This contactor is located in the power panel (Fig. 12). It operates all 200 to 575-v oil pumps. The PIC energizes the contactor to turn on the oil pump as necessary.

HOT GAS BYPASS CONTACTOR RELAY (3C) (Optional) — This relay, located in the power panel, (Item 5, Fig. 12) controls the opening of the hot gas bypass valve. The PIC energizes the relay during low load, high lift conditions.

CONTROL TRANSFORMERS (T1-T4) — These transformers convert incoming control voltage to either 21 vac power for the PSIO module and options modules, or 24 vac power for 3 power panel contactor relays, 3 control solenoid valves, and the guide vane actuator. They are located in the power panel. See Fig. 12.

CONTROLANDOIL HEATERVOLTAGE SELECTOR (S1) — It is possible to use either 115 v or 230 v incoming control power in the power panel. The switch is set to the voltage used at the jobsite.

LEGEND

1—T2 — 24 vac Power Transformer for Hot Gas Bypass Relay,

Oil Pump Relay, Oil Heater Relay, Motor Cooling Solenoid, Oil Reclaim Solenoid

2—Oil Pressure Switch 3—T4 — 24 vac, Optional 8-Input Module Transformer

Fig. 12 — Power Panel with Options

4—T1 — 24 vac, Control Center Transformer 5—3C Hot Gas Bypass Relay Location 6—Oil Pump Terminal Block 7—Factory Terminal Connections 8—T3 — 24 vac Guide Vane Actuator Transformer

LID Operation and Menus (Fig. 13-19)

GENERAL

• The LID display will automatically revert to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the Pumpdown mode (Fig. 13).

• When not in the default screen, the upper right-hand corner of the LID always displays the name of the screen that you have entered (Fig. 14).

• The LID may be conﬁgured in English or SI units, through the LID conﬁguration screen.

• Local Operation — By pressing the LOCAL PIC is now in the LOCAL operation mode. The control

will accept changes to set points and conﬁgurations from the LID only. The PIC will use the Local Time Schedule to determine chiller start and stop times.

• CCN Operation — By pressing the CCN is now in the CCN operation mode, and the control will

accept modiﬁcations from any CCN interface or module (with the proper authority), as well as the LID. The PIC will use the CCN time schedule to determine start and stop times.

softkey,the

softkey,the PIC

ALARMS AND ALERTS — Alarm (*) and alert (!) status are indicated on the Status tables.An alarm (*) will shut down the compressor.An alert (!) notiﬁes the operator that an unusual condition has occurred. The chiller will continue to operate when an alert is shown.

Alarms are indicated when the control center alarm light (!) ﬂashes. The primary alarm message is viewed on the default screen and an additional, secondary, message and troubleshooting information are sent to the Alarm History table.

When an alarm is detected, the LID default screen will freeze (stop updating) at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of alarm. The Status tables will show the updated information. Once all alarms have been cleared (by pressing the

RESET softkey), the default LID screen will return to nor-

mal operation. MENU STRUCTURE — To perform any of the operations

described below, the PIC must be powered up and have successfully completed its self test. The self test takes place automatically, after power-up.

• Press QUIT

out saving any changes.

to leave the selected decision or ﬁeld with-

Fig. 13 — LID Default Screen

• Press ENTER to leave the selected decision or ﬁeld and

save changes.

• Press NEXT to scroll the cursor bar down in order to

highlight a point or to view more points below the current screen.

• Press PREVIOUS to scroll the cursor bar up in order to

highlight a point or to view points above the current screen.

• Press SELECT to view the next screen level (high-

lighted with the cursor bar), or to override (if allowable) the highlighted point value.

Fig. 14 — LID Service Screen

• Press EXIT to return to the previous screen level.

• Press INCREASE or DECREASE to change the highlighted point value.

TO VIEW POINT STATUS (Fig. 15) — Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC.

1. On the Menu screen, press STATUS

to view the list of

Point Status tables.

4. On the Point Status table press NEXT or PREVIOUS

until desired point is displayed on the screen.

OVERRIDE OPERATIONS To Override a Value or Status

1. On the Point Status table press NEXT or PREVIOUS

to highlight the desired point.

2. Press SELECT to select the highlighted point. Then:

2. Press NEXT or PREVIOUS to highlight the desired status table. The list of tables is:

• Status01 — Status of control points and sensors

• Status02 — Status of relays and contacts

• Status03 — Status of both optional 8-input modules and

sensors

3. Press SELECT to view the Point Status table desired.

For Discrete Points — Press START or STOP to select the desired state.

For Analog Points — Press INCREASE or

DECREASE

to select the desired value.

3. Press ENTER to register new value.

NOTE: When overriding or changing metric values, it is necessary to hold the softkey down for a few seconds in order to see a value change, especially on kilopascal values.

To Remove an Override

1. On the Point Status table press NEXT or PREVIOUS

to highlight the desired point.

Fig. 15 − Example of Point Status Screen

(Status01)

2. Press SELECT to access the highlighted point.

3. Press RELEASE to remove the override and return the point to the PIC’s automatic control.

4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change.

Override Indication— An override value is indicated by ‘ ‘SUPVSR,’’‘‘SERVC,’’or‘‘BEST’’ﬂashing next to the point

value on the Status table. TIME SCHEDULE OPERATION (Fig. 16)

1. On the Menu screen, press SCHEDULE

2. Press NEXT or PREVIOUS to highlight the desired schedule.

PSIO Software Version 08 and lower:

OCCPC01S — LOCAL Time Schedule OCCPC02S — CCN Time Schedule

PSIO Software Version 09 and higher:

OCCPC01S — LOCAL Time Schedule OCCPC02S — ICE BUILD Time Schedule OCCPC03-99S — CCN Time Schedule (Actual

number is deﬁned in Conﬁg table.)

5. Press SELECT to access the highlighted period or override.

a. Press INCREASE

or DECREASE to change the

time values. Override values are in one-hour increments, up to 4 hours.

b. Press ENABLE to select days in the day-of-week

ﬁelds. Press DISABLE

to eliminate days from the

period.

7. Press ENTER to register the values and to move horizontally (left to right) within a period.

3. Press SELECT to access and view the time schedule.

Fig. 16 — Example of Time Schedule

Operation Screen

8. Press EXIT to leave the period or override.

9. Either return to Step 4 to select another period or override, or press EXIT

again to leave the current time

schedule screen and save the changes.

10. Holiday Designation (HOLIDEF table) may be found in the Service Operation section, page 38. You must assign the month, day, and duration for the holiday.The Broadcast function in the Brodefs table also must be enabled for holiday periods to function.

*Only available on PSIO Software Version 09 and higher.

†Available on PSIO Software Versions 07 and 08.

Fig. 17 — 19XL Menu Structure

Fig. 18 — 19XL Service Menu Structure

Fig. 18 — 19XL Service Menu Structure (cont)

*Only available on PSIO Software Version 09 and higher.

†Available on PSIO Software Versions 07 and 08.

TO VIEW AND CHANGE SET POINTS (Fig. 19)

1. To view the Set Point table, at the Menu screen press SETPOINT

2. There are 4 set points on this screen: Base Demand Limit;

LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point (PSIO Software Version 09 and higher only). Only one of the chilled water set points can be active at one time, and the type of set point is activated in the Service menu. ICE BUILD is also activated and conﬁgured in the Service menu.

3. Press NEXT set point entry.

4. Press SELECT to modify the highlighted set point.

5. Press INCREASE or DECREASE to change the selected set point value.

6. Press ENTER to save the changes and return to the previous screen.

or PREVIOUS to highlight the desired

Fig. 19 — Example of Set Point Screen

SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation section, page 38. For examples of LID display screens, see Table 2.

Table 2 — LID Screens

NOTES:

1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen.

2. The LID may be conﬁgured in English or SI units, as required, through the LID conﬁguration screen.

3. Data appearing in the Reference Point Names column is used for CCN operations only.

4. All options associated with ICE BUILD, Lead/Lag, CCN Occupancy Conﬁguration, and Soft Stopping are only available on PSIO Software Version 9 and higher.

EXAMPLE1—STATUS01 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS (STATUS01 will be highlighted).

3. Press SELECT

DESCRIPTION RANGE UNITS

Control Mode Reset, Off, Local, CCN MODE Run Status Occupied ? No/Yes OCC

Alarm State Normal/Alarm ALM *Chiller Start/Stop Stop/Start CHIL S S Base Demand Limit 40-100 % DLM *Active Demand Limit 40-100 % DEM LIM Compressor Motor Load 0-999 % CA L

Current 0-999 % CA P

Amps 0-999 AMPS CA A *Target Guide Vane Pos 0-100 % GV TRG Actual Guide Vane Pos 0-100 % GV ACT Water/Brine: Setpoint 10-120 (–12.2-48.9) DEG F (DEG C) SP * Control Point 10-120 (–12.2-48.9) DEG F (DEG C) LCW STPT Entering Chilled Water –40-245 (–40-118) DEG F (DEG C) ECW Leaving Chilled Water –40-245 (–40-118) DEG F (DEG C) LCW Entering Condenser Water –40-245 (–40-118) DEG F (DEG C) ECDW Leaving Condenser Water –40-245 (–40-118) DEG F (DEG C) LCDW Evaporator Refrig Temp –40-245 (–40-118) DEG F (DEG C) ERT Evaporator Pressure –6.7-420 (–46-2896) PSI (kPa) ERP Condenser Refrig Temp –40-245 (–40-118) DEG F (DEG C) CRT Condenser Pressure –6.7-420 (–46-2896) PSI (kPa) CRP Discharge Temperature –40-245 (–40-118) DEG F (DEG C) CMPD Bearing Temperature –40-245 (–40-118) DEG F (DEG C) MTRB Motor Winding Temp –40-245 (–40-118) DEG F (DEG C) MTRW Oil Sump Temperature –40-245 (–40-118) DEG F (DEG C) OILT Oil Pressure Transducer –6.7-420 (–46-2896) PSI (kPa) OILP Oil Pressure –6.7-420 (–46-2896) PSID (kPad) OILPD Line Voltage: Percent 0-999 % V P

*Remote Contacts Input Off/On REMCON Total Compressor Starts 0-65535 c starts Starts in 12 Hours 0-8 STARTS Compressor Ontime 0-500000.0 HOURS c hrs *Service Ontime 0-32767 HOURS S HRS *Compressor Motor kW 0-9999 kW CKW

NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations for BEST programming language, data transfer, and overriding.

Actual 0-9999 VOLTS V A

Timeout, Recycle, Startup,

Ramping, Running, Demand, Override, Shutdown, Abnormal, Pumpdown

REFERENCE POINT NAME

(ALARM HISTORY)

STATUS

EXAMPLE2—STATUS02 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS02.

4. Press SELECT

Table 2 — LID Screens (cont)

DESCRIPTION

Hot Gas Bypass Relay X OFF/ON HGBR *Chilled Water Pump X OFF/ON CHWP Chilled Water Flow X NO/YES EVFL *Condenser Water Pump X OFF/ON CDP Condenser Water Flow X NO/YES CDFL Compressor Start Relay X OFF/ON CMPR Compressor Start Contact X OPEN/CLOSED 1CR AUX Compressor Run Contact X OPEN/CLOSED RUN AUX Starter Fault Contact X OPEN/CLOSED STR FLT Pressure Trip Contact X OPEN/CLOSED PRS TRIP Single Cycle Dropout X NORMAL/ALARM V1 CYCLE Oil Pump Relay X OFF/ON OILR Oil Heater Relay X OFF/ON OILH Motor Cooling Relay X OFF/ON MTRC *Tower Fan Relay X OFF/ON TFR Compr. Shunt Trip Relay X OFF/ON TRIPR Alarm Relay X NORMAL/ALARM ALM Spare Prot Limit Input X ALARM/NORMAL SPR PL

NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations from the LID only.

To access this display from the LID default screen:

1. Press MENU

2. Press STATUS

3. Scroll down to highlight STATUS03.

4. Press SELECT

OPTIONS BOARD 1 *Demand Limit 4-20 mA 4-20 mA DEM OPT

*Temp Reset 4-20 mA 4-20 mA RES OPT *Common CHWS Sensor –40-245 (–40-118) DEG F (DEG C) CHWS *Common CHWR Sensor –40-245 (–40-118) DEG F (DEG C) CHWR *Remote Reset Sensor –40-245 (–40-118) DEG F (DEG C) R RESET *Temp Sensor — Spare 1 –40-245 (–40-118) DEG F (DEG C) SPARE1 *Temp Sensor — Spare 2 –40-245 (–40-118) DEG F (DEG C) SPARE2 *Temp Sensor — Spare 3 –40-245 (–40-118) DEG F (DEG C) SPARE3

OPTIONS BOARD 2 *4-20 mA — Spare 1 4-20 mA SPARE1 M

*4-20 mA — Spare 2 4-20 mA SPARE2 M *Temp Sensor — Spare 4 –40-245 (–40-118) DEG F (DEG C) SPARE4 *Temp Sensor — Spare 5 –40-245 (–40-118) DEG F (DEG C) SPARE5 *Temp Sensor — Spare 6 –40-245 (–40-118) DEG F (DEG C) SPARE6 *Temp Sensor — Spare 7 –40-245 (–40-118) DEG F (DEG C) SPARE7 *Temp Sensor — Spare 8 –40-245 (–40-118) DEG F (DEG C) SPARE8 *Temp Sensor — Spare 9 –40-245 (–40-118) DEG F (DEG C) SPARE9

NOTE: All values shall be variables available for read operation to a CCN network. Descriptions shown with (*) support write operations for BEST programming language, data transfer, and overriding.

DESCRIPTION RANGE UNITS

POINT TYPE

INPUT OUTPUT

EXAMPLE3—STATUS03 DISPLAY SCREEN

UNITS

REFERENCE POINT NAME

(ALARM HISTORY)

REFERENCE POINT NAME

(ALARM HISTORY)

EXAMPLE 4 — SETPOINT DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SETPOINT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Base Demand Limit 40-100 % DLM 100 LCW Setpoint 20-120 (–6.7-48.9) DEG F (DEG C) lcw sp ECW Setpoint 20-120 (–6.7-48.9) DEG F (DEG C) ecw sp ICE BUILD Setpoint 20- 60 (–6.7-15.6) DEG F (DEG C) ice sp 40.0 ( 4.4)

50.0 (10.0)

60.0 (15.6)

Table 2 — LID Screens (cont)

EXAMPLE 5 — CONFIGURATION (CONFIG) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT

5. Scroll down to highlight CONFIG.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

RESET TYPE 1 Degrees Reset at 20 mA –30-30 (–17-17) DEG F (DEG C) deg 20ma

RESET TYPE 2 Remote Temp (No Reset) –40-245 (–40-118) DEG F (DEG C) res rt1 Remote Temp (Full Reset) –40-245 (–40-118) DEG F (DEG C) res rt2 65 (18) Degrees Reset –30-30 (–17-17) DEG F (DEG C) res rt 10D(6D)

RESET TYPE 3 CHW Delta T (No Reset) 0-15 (0-8) DEG F (DEG C) restd 1 CHW Delta T (Full Reset) 0-15 (0-8) DEG F (DEG C) restd 2 0D(0D) Degrees Reset –30-30 (–17-17) DEG F (DEG C) deg chw 5D(3D)

Select/Enable Reset Type 0-3 res sel ECW CONTROL OPTION DISABLE/ENABLE ecw opt

Demand Limit At 20 mA 40-100 % dem 20ma 40 20 mA Demand Limit Option DISABLE/ENABLE dem sel DISABLE

Auto Restart Option DISABLE/ENABLE astart DISABLE Remote Contacts Option DISABLE/ENABLE r contact Temp Pulldown Deg/Min 2-10 tmp ramp

Load Pulldown %/Min 5-20 kw ramp 10 Select Ramp Type: 0/1 ramp opt 1

Temp=0,Load=1

Loadshed Group Number 0-99 ldsgrp 0 Loadshed Demand Delta 0-60 % ldsdelta 20 Maximum Loadshed Time 0-120 MIN maxldstm 60

CCN Occupancy Conﬁg:

Schedule Number 3-99 occpcxxe 3 Broadcast Option DISABLE/ENABLE occbrcst DISABLE

ICE BUILD Option DISABLE/ENABLE ibopt DISABLE ICE BUILD TERMINATION

0 =Temp, 1 =Contacts, 2 =Both 0-2 ibterm 0

ICE BUILD Recycle Option DISABLE/ENABLE ibrecyc DISABLE

NOTE: D = delta degrees.

10D(6D) 85 (29)

10D(6D)

0 DISABLE

DISABLE 3

EXAMPLE 6 — LEAD/LAG CONFIGURATION DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT CONFIGURATION.

4. Press SELECT

5. Scroll down to highlight Lead/Lag.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

LEAD/LAG SELECT

DISABLE =0, LEAD =1, LAG =2, STANDBY =3

Load Balance Option DISABLE/ENABLE loadbal DISABLE Common Sensor Option DISABLE/ENABLE commsens DISABLE

LAG Percent Capacity 25-75 % lag per LAG Address 1-236 lag add LAG START Timer 2-60 MIN lagstart 10 LAG STOP Timer 2-60 MIN lagstop 10 PRESTART FAULT Timer 0-30 MIN preﬂt 5 STANDBY Chiller Option DISABLE/ENABLE stndopt DISABLE STANDBY Percent Capacity 25-75 % stnd per STANDBY Address 1-236 stnd add

NOTE: The Lead/Lag Conﬁguration table is available on PSIO Software Version 09 and higher.

LEAD/LAG CONFIGURATION SCREEN

0-3 leadlag 0

50 92

50 93

Table 2 — LID Screens (cont)

EXAMPLE 7 — SERVICE1 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE1.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Motor Temp Override 150-200 (66-93) DEG F (DEG C) mt over Cond Press Override Refrig Override Delta T 2-5 (1-3) DEG F (DEG C) ref over 3D (1.6D)

Chilled Medium Water/Brine medium WATER Brine Refrig Trippoint 8-40 (–13.3-4) DEG F (DEG C) br trip

Compr Discharge Alert 125-200 (52-93) DEG F (DEG C) cd alert Bearing Temp Alert 175-185 (79-85) DEG F (DEG C) tb alert 175 (79)

Water Flow Verify Time 0.5-5 MIN wﬂow t Oil Press Verify Time 15-300 SEC oilpr t 15

Water/Brine Deadband 0.5-2.0 (0.3-1.1) DEG F (DEG C) cw db Recycle Restart Delta T 2.0-10.0 (1.1-5.6) DEG F (DEG C) rcyc dt Recycle Shutdown Delta T 0.5-4.0 (0.27-2.2) DDEGF(DDEG C) rcycs dt 1.0 (0.6)

Surge Limit/HGBP Option 0/1 srg hgbp Select: Surge=0, HGBP=1 Surge/HGBP Delta T1 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt1 1.5 (0.8)

Surge/HGBP Delta P1 Min. Load Points (T1/P1)

Surge/HGBP Delta T2 0.5-15 (0.3-8.3) DEG F (DEG C) hgb dt2 Surge/HGBP Delta P2 Full Load Points (T2/P2)

Surge/HGBP Deadband 1-3 (0.6-1.6) DEG F (DEG C) hgb dp Surge Delta Percent Amps 10-50 % surge a

Surge Time Period 1-5 MIN surge t 2 Demand Limit Source 0/1 dem src

Select: Amps=0, Load=1 Amps Correction Factor 1-8 corfact 3 Motor Rated Load Amps 1-9999 AMPS a fs Motor Rated Line Voltage 1-9999 VOLTS v fs Meter Rated Line kW 1-9999 kW kw fs 600

Line Frequency 0/1 HZ freq 0 Select: 0=60 Hz, 1=50 Hz

Compr Starter Type REDUCE/FULL starter REDUCE Condenser Freeze Point –20-35 (–28.9-1.7) DEG F (DEG C) cdfreeze 34 (1) Soft Stop Amps Threshold 40-100 % softstop 100

NOTES:

1. Condenser Freeze Point and Softstop Amps Threshold are only selectable/readable on PSIO Software Versions 09 and higher.

2. Values in [ ] indicate HFC-134a values.

3. D = delta degrees.

150-245 (1034-1689)

[90-200 (620-1379)]

50-170 (345-1172)

[30-170 (207-1172)]

50-170 (345-1172) [30-170 (207-1172)]

PSI (kPa) cp over

PSI (kPA) hgb dp1

PSI (kPa) hgb dp2 170 (1172) [85 (586)]

200 (93) 195 (1345) [125 (862)]

33 (1) 200 (93)

1.0 (0.6) 5 (2.8)

75 (517) [50 (345)]

10 (5.6)

1 (0.6) 25

200 460

Table 2 — LID Screens (cont)

EXAMPLE 8 — SERVICE2 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE2.

6. Press SELECT

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE OPTIONS BOARD 1 20 mA POWER CONFIGURATION

External = 0, Internal = 1 RESET 20 mA Power Source 0,1 res 20 ma DEMAND 20 mA Power Source 0,1 dem 20 ma SPARE ALERT ENABLE

Disable = 0, Low = 1, High = 2 Temp = Alert Threshold

CHWS Temp Enable 0-2 chws en CHWS Temp Alert –40-245 (–40-118) DEG F (DEG C) chws al 245 (118) CHWR Temp Enable 0-2 chwr en 0 CHWR Temp Alert –40-245 (–40-118) DEG F (DEG C) chwr al Reset Temp Enable 0-2 rres en 0 Reset Temp Alert –40-245 (–40-118) DEG F (DEG C) rres al 245 (118) Spare Temp 1 Enable 0-2 spr1 en Spare Temp 1 Alert –40-245 (–40-118) DEG F (DEG C) spr1 al 245 (118) Spare Temp 2 Enable 0-2 spr2 en 0 Spare Temp 2 Alert –40-245 (–40-118) DEG F (DEG C) spr2 al Spare Temp 3 Enable 0-2 spr3 en 0 Spare Temp 3 Alert –40-245 (–40-118) DEG F (DEG C) spr3 al

OPTIONS BOARD 2 20 mA POWER CONFIGURATION

External = 0, Internal = 1 SPARE 1 20 mA Power Source 0,1 sp1 20 ma SPARE 2 20 mA Power Source 0,1 sp2 20 ma 0

SPARE ALERT ENABLE Disable = 0, Low = 1, High = 2 Temp = Alert Threshold

Spare Temp 4 Enable 0-2 spr4 en Spare Temp 4 Alert –40-245 (–40-118) DEG F (DEG C) spr4 al Spare Temp 5 Enable 0-2 spr5 en 0 Spare Temp 5 Alert –40-245 (–40-118) DEG F (DEG C) spr5 al 245 (118) Spare Temp 6 Enable 0-2 spr6 en Spare Temp 6 Alert –40-245 (–40-118) DEG F (DEG C) spr6 al 245 (118) Spare Temp 7 Enable 0-2 spr7 en Spare Temp 7 Alert –40-245 (–40-118) DEG F (DEG C) spr7 al 245 (118) Spare Temp 8 Enable 0-2 spr8 en 0 Spare Temp 8 Alert –40-245 (–0-118) DEG F (DEG C) spr8 al Spare Temp 9 Enable 0-2 spr9 en 0 Spare Temp 9 Alert –40-245 (–40-118) DEG F (DEG C) spr9 al 245 (118)

NOTE: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp Alert’’ threshold for each point listed. If the ‘‘Enable’’is set to 1, a value above the ‘‘Temp Alert’’ threshold shall generate an alert message. If the ‘‘Enable’’ is set to 2, a value below the ‘‘Temp Alert’’ threshold shall generate an alert message. If the ‘‘Enable’’ is set to 0, alert generation is disabled.

0 0

245 (118)

245 (118) 245 (118)

0 245 (118)

0 0

245 (118)

EXAMPLE 9 — SERVICE3 DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight EQUIPMENT SERVICE.

4. Press SELECT

5. Scroll down to highlight SERVICE3.

DESCRIPTION CONFIGURABLE RANGE UNITS REFERENCE POINT NAME DEFAULT VALUE

Proportional Inc Band 2-10 gv inc Proportional Dec Band 2-10 gv de Proportional ECW Gain 1-3 gv ecw Guide Vane Travel Limit 30-100 % gv lim

6.5

6.0

2.0 50

Table 2 — LID Screens (cont)

EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT01.

CAPACITY CONTROL Control Point 10-120 (–12.2-48.9) DEG F (DEG C) ctrlpt Leaving Chilled Water –40-245 (–40-118) DEG F (DEG C) LCW Entering Chilled Water –40-245 (–40-118) DEG F (DEG C) ECW Control Point Error –99-99 (–55-55) DEG F (DEG C) cperr ECW Delta T –99-99 (–55-55) DEG F (DEG C) ecwdt ECW Reset –99-99 (–55-55) DEG F (DEG C) ecwres LCW Reset –99-99 (–55-55) DEG F (DEG C) lcwres Total Error + Resets –99-99 (–55-55) DEG F (DEG C) error Guide Vane Delta –2-2 % gvd Target Guide Vane Pos 0-100 % GV TRG Actual Guide Vane Pos 0-100 % GV ACT Proportional Inc Band 2-10 gv inc Proportional Dec Band 2-10 gv dec Proportional ECW Gain 1-3 gv ecw Water/Brine Deadband 0.5-2 (0.3-1.1) DEG F (DEG C) cwdb

NOTE: Overriding is not supported on this maintenance screen.Active overrides show the associated point in alert (*). Only values with capital letter reference point names are variables available for read operation.

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

EXAMPLE 11 — MAINTENANCE (MAINT02) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT02.

6. Press SELECT

OVERRIDE/ALERT STATUS MOTOR WINDING TEMP –40-245 (–40-118) DEG F (DEG C) MTRW

Override Threshold 150-200 (66-93) DEG F (DEG C) mt over CONDENSER PRESSURE –6.7-420 (–42-2896) PSI (kPa) CRP

Override Threshold 90-245 (621-1689) PSI (kPa) cp over EVAPORATOR REFRIG TEMP –40-245 (–40-118) DEG F (DEG C) ERT

Override Threshold 2-45 (1-7.2) DEG F (DEG C) rt over DISCHARGE TEMPERATURE –40-245 (–40-118) DEG F (DEG C) CMPD

Alert Threshold 125-200 (52-93) DEG F (DEG C) cd alert BEARING TEMPERATURE –40-245 (–40-118) DEG F (DEG C) MTRB

Alert Threshold 175-185 (79-85) DEG F (DEG C) tb alert

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

Table 2 — LID Screens (cont)

EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLAY SCREEN

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT03.

6. Press SELECT

SURGE/HGBP ACTIVE ? NO/YES Active Delta P 0-200 (0-1379) PSI (kPa) dp a Active Delta T 0-200 (0-111) DEG F (DEG C) dt a

Calculated Delta T 0-200 (0-111) DEG F (DEG C) dt c Surge Protection Counts 0-12 spc

NOTE: Override is not supported on this maintenance screen. Only values with capital letter reference point names are variables available for read operation.

To access this display from the LID default screen:

1. Press MENU

2. Press SERVICE

3. Scroll down to highlight CONTROL ALGORITHM STATUS.

4. Press SELECT

5. Scroll down to highlight MAINT04.

6. Press SELECT

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

EXAMPLE 13 — MAINTENANCE (MAINT04 DISPLAY SCREEN

DESCRIPTION RANGE/STATUS UNITS REFERENCE POINT NAME

LEAD/LAG: Conﬁguration DISABLE,LEAD,LAG,STANDBY, INVALID leadlag Load Balance Option DISABLE/ENABLE loadbal

LAG Start Time 0-60 MIN lagstart LAG Stop Time 0-60 MIN lagstop Prestart Fault Time 0-30 MIN preﬂt Pulldown: Delta T/Min 2-10 F/min (1.1-5.5 C/min) D DEG F/min pull dt

LEAD CHILLER in Control No/Yes leadctrl LAG CHILLER: Mode Reset,Off,Local,CCN lagmode

Recovery Start Request No/Yes lag rec STANDBY CHILLER: Mode Reset,Off,Local,CCN stdmode

Recovery Start Request No/Yes std rec

NOTES:

1. Only values with capital letter reference point names are variables available for read operation. Forcing is not supported on this maintenance screen.

2. The MAINT04 screen is available on PSIO Software Version 09 and higher.

3. D = delta degrees.

Current Mode DISABLE,LEAD,LAG,STANDBY, CONFIG llmode

Satisﬁed? No/Yes (D DEG C/min) pull sat

Run Status Timeout,Recycle,Startup,Ramping,Running Start/Stop Stop,Start,Retain lag s s

Run Status Timeout,Recycle,Startup,Ramping,Running Start/Stop Stop,Start,Retain std s s

Demand,Override,Shutdown,Abnormal,Pumpdown

lagstat

stdstat

PIC System Functions

NOTE: Throughout this manual, words printed in capital letters and italics represent values that may be viewed on the LID. See Table 2 for examples of LID screens. Point names are listed in the Description column. An overview of LID operation and menus is given in Fig. 13-19.

CAPACITY CONTROL — The PIC controls the chiller capacity by modulating the inlet guide vanes in response to chilled water temperature changes away from the CON- TROL POINT. The CONTROL POINT may be changed by a CCN network device, or is determined by the PIC adding any active chilled water reset to the ECW (Entering Chilled

Water) SET POINT or LCW SET POINT. The PIC uses the PROPORTIONAL INC (Increase) BAND, PROPORTIONAL DEC (Decrease)BAND, and the PROPORTIONAL ECW GAIN

to determine how fast or slow to respond. CONTROL POINT may be viewed/overridden on the Status table, Status01 selection.

ENTERING CHILLED WATER CONTROL — If this option is enabled, the PIC uses ENTERING CHILLED WATER temperature to modulate the vanes instead of LEAV-

ING CHILLED WATERtemperature. ENTERING CHILLED W ATER control option may be viewed/modiﬁed on the Equip-

ment Conﬁguration table, Conﬁg table. DEADBAND — This is the tolerance on the chilled water/

brine temperature CONTROL POINT. If the water temperature goes outside of the DEADBAND, the PIC opens or closes the guide vanes in response until it is within tolerance. The PIC may be conﬁgured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. DEADBAND may be viewed or modiﬁed on the Equipment Service1 table.

For example, a 1° F (0.6° C) deadband setting controls the water temperature within ±0.5° F (0.3° C) of the control point. This may cause frequent guide vane movement if the chilled water load ﬂuctuates frequently. A value of 1° F (0.6° C) is the default setting.

PROPORTIONALBANDSAND GAIN — Proportional band is the rate at which the guide vane position is corrected in proportion to how far the chilled water/brine temperature is from the control point. Proportional gain determines how quickly the guide vanes react to how quickly the temperature is moving from CONTROL POINT.

The proportional band can be viewed/modiﬁed on the LID. There are two response modes, one for temperature response above the control point, the other for response below the control point.

The ﬁrst type is called PROPORTIONAL INC BAND, and it can slow or quicken vane response to chilled water/ brine temperature above DEADBAND. It can be adjusted from a setting of 2 to 10; the default setting is 6.5. PRO- PORTIONAL DEC BAND can slow or quicken vane response to chilled water temperature below deadband plus control point. It can be adjusted on the LID from a setting of 2 to 10, and the default setting is 6.0. Increasing either of these settings will cause the vanes to respond slower than at a lower setting.

The PROPORTIONAL ECW GAIN can be adjusted at the LID display from a setting of 1.0 to 3.0, with a default setting of

2.0. Increase this setting to increase guide vane response to a change in entering chilled water temperature. The proportional bands and gain may be viewed/modiﬁed on the Equipment Service3 table.

DEMAND LIMITING — The PIC will respond to the ACTIVE DEMAND LIMIT set point by limiting the opening of the guide vanes. It will compare the set point to either COMPRESSOR MOTOR LOAD or COMPRES- SOR MOTOR CURRENT (percentage), depending on how the control is conﬁgured for the DEMAND LIMIT SOURCE which is accessed on the SERVICE1 table. The default setting is current limiting.

CHILLER TIMERS — The PIC maintains 2 runtime clocks, known as COMPRESSOR ONTIME and SERVICE ON- TIME. COMPRESSOR ONTIME indicates the total lifetime compressor run hours. This timer can register up to 500,000 hours before the clock turns back to zero. The SERVICE ONTIME is a resettable timer that can be used to indicate the hours since the last service visit or any other reason. The time can be changed through the LID to whatever value is desired. This timer can register up to 32,767 hours before it rolls over to zero.

The chiller also maintains a start-to-start timer and a stopto-start timer. These timers limit how soon the chiller can be started. See the Start-Up/Shutdown/Recycle Sequence section, page 39, for operational information.

OCCUPANCY SCHEDULE — This schedule determines when the chiller is either occupied or unoccupied.

Each schedule consists of from one to 8 occupied/unoccupied time periods, set by the operator. These time periods can be enabled to be in effect, or not in effect, on each day of the week and for holidays. The day begins with 0000 hours and ends with 2400 hours. The chiller is in OCCUPIED mode unless an unoccupied time period is in effect.

The chiller will shut down when the schedule goes to UNOCCUPIED. These schedules can be set up to follow the building schedule or to be 100% OCCUPIED if the operator wishes. The schedules also can be bypassed by forcing the Start/Stop command on the PIC Status screen to start. The schedules also can be overridden to keep the unit in an OCCUPIED mode for up to 4 hours, on a one-time basis.

Figure 18 shows a schedule for a typical office building time schedule, with a 3-hour, off-peak cool down period from midnight to 3 a.m., following a weekend shutdown. Example: Holiday periods are unoccupied 24 hours per day. The building operates Monday through Friday, 7:00 a.m. to 6:00 p.m., with a Saturday schedule of 6:00 a.m. to 1:00 p.m., and includes the Monday midnight to 3:00 a.m. weekend cool-down schedule.

NOTE: This schedule is for illustration only, and is not intended to be a recommended schedule for chiller operation.

PSIO Software Version 08 and Lower — Whenever the chiller is in the LOCAL mode, the chiller will start when the Occupancy Schedule 01 indicates OCCUPIED. When in the CCN mode, Occupancy Schedule 02 is used.

PSIO Software Version 09 and Higher — The Local Time Schedule is still the Occupancy Schedule 01. The Ice Build Time Schedule is Schedule 02 and the CCN Default Time Schedule is Schedule 03. The CCN schedule number is deﬁned on the Conﬁg table in the Equipment Conﬁguration table on page 23. The schedule number can change to any value from 03 to 99. If this schedule number is changed on the Conﬁg table, the operator must use the Attach to Network Device table to upload the new number into the Schedule screen. See Fig. 17.

Safety Controls — The PIC monitors all safety control

inputs, and if required, shuts down the chiller or limits the guide vanes to protect the chiller from possible damage from any of the following conditions:

• high bearing temperature

• high motor winding temperature

• high discharge temperature

• low oil pressure

• low cooler refrigerant temperature/pressure

• condenser high pressure or low pressure

• inadequate water/brine cooler and condenser ﬂow

• high, low, or loss of voltage

• excessive motor acceleration time

• excessive starter transition time

• lack of motor current signal

• excessive motor amps

• excessive compressor surge

• temperature and transducer faults Starter faults or optional protective devices within the starter

can shut down the chiller. These devices are dependent on what has been purchased as options.

If compressor motor overload occurs, check the motor for grounded or open phases before attempting a restart.

If the controller initiates a safety shutdown, it displays

the fault on the LID display with a primary and a secondary message, and energizes an alarm relay in the starter and blinks the alarm light on the control center. The alarm is stored in memory and can be viewed in the PIC alarm table along with a message for troubleshooting.

To give a better warning as to the operating condition of the chiller, the operator also can deﬁne alert limits on various monitored inputs. Safety contact and alert limits are deﬁned in Table 3.Alarm and alert messages are listed in the Troubleshooting Guide section, page 66.

SHUNTTRIP — The shunt trip function of the PIC is a safety trip. The shunt trip is wired from an output on the SMM to a shunt trip-equipped motor circuit breaker. If the PIC tries to shut down the compressor through normal shutdown procedure but is unsuccessful for 30 seconds, the shunt trip output is energized and causes the circuit breaker to trip off. If ground fault protection has been applied to the starter, the ground fault trip will also energize the shunt trip to trip the circuit breaker.

Default Screen Freeze — Whenever an alarm

occurs, the LID default screen will freeze displaying the condition of the chiller at the time of alarm. Knowledge of the operating state of the chiller at the time an alarm occurs is useful when troubleshooting. Current chiller information can be viewed on the Status tables. Once all existing alarms

are cleared (by pressing the RESET LID will return to normal operation.

softkey), the default

Motor Cooling Control — Motor temperature is

reduced by refrigerant entering the motor shell and evaporating. The refrigerant is regulated by the motor cooling relay. This relay will energize when the compressor is running and motor temperature is above 125 F (51.7 C). The relay will close when motor temperature is below 100 F (37.8 C). Note that there is always a minimum ﬂow of refrigerant when the compressor is operating for motor cooling; the relay only controls additional refrigerant to the motor.

Table 3 — Protective Safety Limits and Control Settings

MONITORED PARAMETER LIMIT APPLICABLE COMMENTS

TEMPERATURE SENSORS OUT OF RANGE

PRESSURE TRANSDUCERS OUT OF RANGE

COMPRESSOR DISCHARGE TEMPERATURE

MOTOR WINDING TEMPERATURE .220 F (104.4 C) Preset, alert setting conﬁgurable BEARING TEMPERATURE .185 F (85 C) Preset, alert setting conﬁgurable

EVAPORATOR REFRIGERANT TEMPERATURE

TRANSDUCER VOLTAGE ,4.5 vdc . 5.5 vdc Preset CONDENSER PRESSURE — SWITCH

— CONTROL

OIL PRESSURE — SWITCH Cutout ,11 psid (76 kPad) ± 1.5 psid (10.3 kPad)

— CONTROL

LINE VOLTAGE — HIGH .110% for one minute

— LOW ,90% for one minute or <85% for 3 seconds — SINGLE-CYCLE ,50% for one cycle

COMPRESSOR MOTOR LOAD

STARTER ACCELERATION TIME (Determined by inrush current going below 100% compressor motor load)

STARTER TRANSITION .75 seconds Reduced voltage starters only

CONDENSER FREEZE PROTECTION

–40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds

0.08 to 0.98 Voltage Ratio

.220 F (104.4 C) Preset, alert setting conﬁgurable

,33 F (for water chilling) (0.6° C) ,Brine Refrigerant Trippoint (set point adjustable

from 0 to 40 F [–18 to 4 C] for brine chilling)

.263 ± 7 psig (1813 ± 48 kPa), reset at 180 ± 10 (1241 ± 69 kPa)

.260 psig (1793 kPa) for HCFC-22; 215 psig (1482 kPa) for HFC-134a

Cut-in .16.5 psid (114 kPad) ± 4 psid (27.5 kPad) Cutout ,15 psid (103 kPad)

Alert ,18 psid (124 kPad)

.110% for 30 seconds Preset ,10% with compressor running Preset .10% with compressor off Preset

.45 seconds .10 seconds

Energizes condenser pump relay if condenser refrigerant temperature or condenser entering water temperature is below the conﬁgured condenser freeze point temperature. Deenergizes when the temperature is5F(3C)above condenser freeze point temperature.

Must be outside range for 2 seconds. Ratio = Input Voltage ÷ Voltage Reference

Preset, conﬁgure chilled medium for water (Service1 table)

Conﬁgure chilled medium for brine (Service1 table). Adjust brine refrigerant trippoint for proper cutout

Preset Preset Preset, no calibration needed Preset

Preset, based on transformed line voltage to 24 vac rated-input to the Starter Management Module. Also monitored at PSIO power input.

For chillers with reduced voltage mechanical and solid-state starters

For chillers with full voltage starters (Conﬁgured on Service1 table)

CONDENSER FREEZE POINT conﬁgured in Service01 table with a default setting of 34 F (1 C).

Flow Switches (Field Supplied)

Operate water pumps with chiller off. Manually reduce water ﬂow and observe switch for proper cutout.Safety shutdown occurs when cutout time exceeds 3 seconds.

CUT-OUT SETTING ADJUSTMENT SCREW

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