Carrier 19XL User Manual

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Page 1

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

Page 2

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

Page 3

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

Page 4

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.

Page 5

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.

Page 6

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

Page 7

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

Page 8

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

Page 9

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.

Page 10

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

Page 11

• 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

Page 12

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

Page 13

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

Page 14

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

Page 15

• 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.

Page 16

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.

Page 17

*Only available on PSIO Software Version 09 and higher.

†Available on PSIO Software Versions 07 and 08.

Fig. 17 — 19XL Menu Structure

Page 18

Fig. 18 — 19XL Service Menu Structure

Page 19

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

*Only available on PSIO Software Version 09 and higher.

†Available on PSIO Software Versions 07 and 08.

Page 20

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.

Page 21

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

Page 22

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)

Page 23

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

Page 24

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

Page 25

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

Page 26

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

Page 27

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

Page 28

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.

Page 29

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.

Page 30

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

Page 31

Ramp Loading Control — The ramp loading control

slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the chiller is started, and the chilled water loop has to be brought down to normal design conditions. This helps reduce electrical demand charges by slowly bringing the chilled water to control point. However, the total power draw during this period remains almost unchanged.

There are 2 methods of ramp loading with the PIC. Ramp loading can be based on chilled water temperature or on motor load.

1. Temperature ramp loading limits the rate at which either

leaving chilled water or entering chilled water temperature decreases by an operator-conﬁgured rate. The lowest temperature ramp table will be used the ﬁrst time the chiller is started (at commissioning). The lowest temperature ramp rate will also be used if chiller power has been off for 3 hours or more (even if the motor ramp load is selected).

2. Motor load ramp loading limits the rate at which the

compressor motor current or compressor motor load increases by an operator-conﬁgured rate.

The TEMP (Temperature) PULLDOWN, LOAD PULL DOWN, and SELECT RAMP TYPE may be viewed/modified

on the LID Equipment Conﬁguration table, Conﬁg table (see Table 2). Motor load is the default type.

Capacity Override (Table 4) — Capacity overrides

can prevent some safety shutdowns caused by exceeding motor amperage limit, refrigerant low temperature safety limit, motor high temperature safety limit, and condenser high pressure limit. In all cases there are 2 stages of compressor vane control.

1. The vanes are held from opening further, and the status line on the LID indicates the reason for the override.

2. The vanes are closed until condition decreases below the ﬁrst step set point, and then the vanes are released to normal capacity control.

Whenever the motor current demand limit set point is reached, it activates a capacity override, again with a 2-step process. Exceeding 110% of the rated load amps for more than 30 seconds will initiate a safety shutdown.

The compressor high lift (surge prevention) set point will cause a capacity override as well. When the surge prevention set point is reached, the controller normally will only hold the guide vanes from opening. If so equipped, the hot gas bypass valve will open instead of holding the vanes.

OVERRIDE

CAPACITY CONTROL

HIGH

CONDENSER

PRESSURE

HIGH MOTOR

TEMPERATURE

LOW

REFRIGERANT

TEMPERATURE

(Refrigerant

Override Delta

Temperature)

HIGH

COMPRESSOR

LIFT

(Surge

Prevention)

MANUAL

GUIDE VANE

TARGET

MOTOR LOAD —

ACTIVE

DEMAND LIMIT

Table 4 — Capacity Overrides

FIRST STAGE SET POINT

View/Modify

LID Screen

Equipment

Service1

Equipment

Service1

Equipment

Service1

Minimum:

Equipment

Service1

Control

Algorithm

Maint01

Status01 100% 40 to 100%

Maximum:

Default Value Conﬁgurable Range Value Value

HCFC-22 HFC-134a HCFC-22 HFC-134a

.195 psig (1345 kPa)

.200 F (93.3 C) 150 to 200 F (66 to 93 C)

,3° F (1.6° C)

(Above Trippoint)

HCFC-22 HFC-134a HCFC-22 HFC-134a

T1 — 1.5° F

(0.8° C)

P1 — 75 psid

(517 kPad)

T2 — 10° F

(5.6° C)

P2 — 170 psid

(1172 kPad)

Automatic 0 to 100% None

125 psig

(862 kPa)

Minimum:

T1 — 1.5° F

(0.8° C)

P1 — 50 psid

(345 kPad)

Maximum:

T2 — 10° F

(5.6° C)

P2 — 85 psid

(586 kPad)

150 to 245 psig

(1034 to 1689 kPa)

2° to 5° F

(1° to 3° C)

0.5° to 15° F

(0.3° to 8.3° C)

50 to 170 psid

(345 to 1172 kPad)

0.5° to 15° F

(0.3° to 8.3° C)

50 to 170 psid

(345 to 1172 kPad)

90 to 200 psig

(620 to 1379 kPa)

0.5° to 15° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to 1172 kPad)

0.5° to 15° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to 1172 kPad)

SECOND

STAGE

SET POINT

.Override

Set Point

+ 4 psig

(28 kPa)

.Override

Set Point

+10° F

(6° C)

<Trippoint + Override

DT –1° F (0.56° C)

None

>5% of

Set Point

OVERRIDE

TERMINATION

,Override

Set Point

,Override

Set Point

.Trippoint + Override

DT +2° F

(1.2° C)

Within

Lift Limits

Plus Surge/

HGBP

Deadband

Setting

Release of

Manual Control

2% Lower

Than

Set Point

Page 32

High Discharge Temperature Control — If the

discharge temperature increases above 160 F (71.1 C) (PSIO Software Version 09 and higher) or 180 F (82 C) (PSIO Software Version 08 or lower), the guide vanes are proportionally opened to increase gas ﬂow through the compressor. If the leaving chilled water temperature is then brought 5° F (2.8° C) below the control set point temperature, the controls will bring the chiller into the recycle mode.

OilSump TemperatureControl — The oil sump tem-

perature control is regulated by the PIC which uses the oil heater relay when the chiller is shut down.

As part of the pre-start checks executed by the controls, oil sump temperature is compared against evaporator refrigerant temperature. If the difference between these 2 temperatures is 50 F (27.8 C) or less, the start-up will be delayed until the oil temperature is 50 F (27.8 C) or more. Once this temperature is conﬁrmed, the start-up continues.

PSIO SOFTWAREVERSION 08 AND LOWER — The oil heater relay is energized whenever the chiller compressor is off, and the oil sump temperature is less than 140 F (60 C) or sump temperature is less than the cooler refrigerant temperature plus 60° F (33.3° C). The heater is then turned off when the oil sump temperature is: 1) more than 160 F (71.1 C); or 2) the sump temperature is more than 145 F (62.8 C) and more than the cooler refrigerant temperature plus 65° F (36.1° C). The heater is always off during start-up or when the compressor is running.

PSIO SOFTWARE VERSION 09 AND HIGHER — The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 150 F (65.6 C) or the oil sump temperature is less than the cooler refrigerant temperature plus 70° F (39° C). The oil heater is turned off when the oil sump temperature is either 1) more than 160 F (71.1 C); or 2) the oil sump temperature is more than 155 F (68.3 C) and more than the cooler refrigerant temperature plus 75° F (41.6° C). The oil heater is always off during start-up or when the compressor is running.

When a power failure to the PSIO module has occurred for more than 3 hours (i.e., initial start-up), the oil sump is heated to 100° F (56° C) above the evaporator refrigerant temperature or 190 F (88 C), whichever is lower. Once this temperature is reached, the oil pump will be energized for 1 to 2 minutes or until the oil sump temperature cools to below 145 F (63 C). The normal heating algorithm is now followed once ramp loading has been completed.

After a 3-hour power failure, the oil temperature must rise to the higher oil temperature. The controls will delay the start of the compressor until this temperature is met.

Oil Cooler — The oil must be cooled when the compres-

sor is running. This is accomplished through a small, platetype heat exchanger located behind the oil pump. The heat exchanger uses liquid condenser refrigerant as the cooling liquid.Arefrigerant thermostatic expansion valve (TXV) regulates refrigerant ﬂow to control oil temperature entering the bearings. There is always a ﬂow of refrigerant bypassing the thermostaticTXV .The bulb for the expansion valve is strapped to the oil supply line leaving the heat exchanger and the valve is set to maintain 110 F (43 C).

NOTE: The TXV is not adjustable. Oil sump temperature may be at a lower temperature.

RemoteStart/Stop Controls — A remote device, such

as a time clock which uses a set of contacts, may be used to start and stop the chiller. However, the device should not be programmed to start and stop the chiller in excess of 2 or

3 times every 12 hours. If more than 8 starts in 12 hours occur, then an Excessive Starts alarm is displayed, preventing the chiller from starting. The operator must reset the alarm at the LID in order to override the starts counter and start the chiller. If Automatic Restart After a Power Failure is not activated when a power failure occurs, and the remote contact is closed, the chiller will indicate an alarm because of the loss of voltage.

The contacts for Remote Start are wired into the starter at terminal strip TB5, terminals 8A and 8B. See the certiﬁed drawings for further details on contact ratings. The contacts must be dry (no power).

Spare Safety Inputs — Normally closed (NC) digital

inputs for additional ﬁeld-supplied safeties may be wired to the spare protective limits input channel in place of the factoryinstalled jumper. (Wire multiple inputs in series.) The opening of any contact will result in a safety shutdown and LID display. Refer to the certiﬁed drawings for safety contact ratings.

Analog temperature sensors may also be added to the options modules, if installed. These may be programmed to cause an alert on the CCN network, but will not shut the chiller down.

SPARE ALARM CONTACTS — Two spare sets of alarm contacts are provided within the starter. The contact ratings are provided in the certiﬁed drawings. The contacts are located on terminal strip TB6, terminals 5A and 5B, and terminals 5C and 5D.

Condenser Pump Control — The chiller will moni-

tor the CONDENSER PRESSURE and may turn on this pump if the pressure becomes too high whenever the compressor is shut down. CONDENSER PRESSURE OVERRIDEis used to determine this pressure point. This value is found on the Equipment Service1 LID table and has a default value (Table 4). If the CONDENSER PRESSURE is greater than or equal to the CONDENSER PRESSURE OVERRIDE, and the ENTERING CONDENSER WATER TEMP (Temper- ature) is less than 115 F (46 C), then the condenser pump will energize to try to decrease the pressure. The pump will turn off when the condenser pressure is less than the pressure override less 5 psi (34 kPa), or the CONDENSER

REFRIG (Refrigerant) TEMP is within 3° F (2° C) of the ENTERING CONDENSER WATER temperature.

Condenser Freeze Prevention — This control

algorithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. If the pump is controlled by the PIC, starting the pump will help prevent the water in the condenser from freezing. Condenser freeze prevention can occur whenever the chiller is not running except when it is either actively in pumpdown or in Pumpdown Lockout with the freeze prevention disabled (refer to ControlTest table, Pumpdown/Terminate Lockout tables).

When the CONDENSER REFRIG TEMP is less than or equal to the CONDENSER FREEZE POINT,orthe ENTERING CONDENSER WATER temperature is less than or equal to the CONDENSER FREEZE POINT, then the

CONDENSER WATER PUMP shall be energized until the CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE POINT plus 5° F (2.7° C). An alarm will

be generated if the chiller is in PUMPDOWN mode and the pump is energized. An alert will be generated if the chiller is not in PUMPDOWN mode and the pump is energized. If in recycle shutdown, the mode shall transition to a nonrecycle shutdown.

Page 33

Tower Fan Relay — Low condenser water tempera-

ture can cause the chiller to shut down on low refrigerant temperature. The tower fan relay, located in the starter, is controlled by the PIC to energize and deenergize as the pressure differentialbetween cooler and condenser vessels changes in order to prevent low condenser water temperature and to maximize chiller efficiency. The tower fan relay can only accomplish this if the relay has been added to the cooling tower temperature controller. The TOWER FAN RELAY is turned on whenever the CONDENSER WATER PUMP is running, ﬂow is veriﬁed, and the difference between cooler and condenser pressure is more than 45 psid (310 kPad) [30 psid (207 kPad)] or entering condenser water temperature is greater than 85 F (29 C). The TOWER FAN RELAY is deenergized when the condenser pump is off, ﬂow is lost, the evaporator refrigerant temperature is less than the override temperature, or the differential pressure is less than 40 psid (279 kPad) [28 psid (193 kPad)] and entering condensing water is less than 80 F (27 C).

IMPORTANT:Aﬁeld-supplied water temperature control system for condenser water should be installed. The system should maintain the leaving condenser water temperature at a temperature that is 20° F (11° C) above the leaving chilled water temperature.

The tower-fan relay control is not a substitute for a condenser water temperature control. When used with a Water Temperature Control system, the tower fan relay control can be used to help prevent low condenser water temperatures.

Auto. Restart After Power Failure — This option

may be enabled or disabled, and may be viewed/modiﬁed in the Conﬁg table of Equipment Conﬁguration. If enabled, the chiller will start up automatically after a single cycle dropout, low,high, or loss of voltage has occurred, and the power is within ±10% of normal. The 15- and 3-minute inhibit timers are ignored during this type of start-up.

When power is restored after the power failure, and if the compressor had been running, the oil pump will be energized for one minute prior to the evaporator pump energizing. Auto restart will then continue like a normal start-up.

If power to the PSIO module has been off for more than 3 hours, the oil heat algorithm, discussed in the Oil Sump Temperature Control section on page 32, will take effect before the compressor can start. Refrigerant normally migrates into the oil when the oil heater is left off for extended periods of time. The PIC operates the oil pump for 1 to 2 minutes to ensure that the oil is free of excess refrigerant. Once this algorithm is completed, the RESTART of the chiller will continue.

Water/Brine Reset — Three types of chilled water or

brine reset are available and can be viewed or modiﬁed on the Equipment Conﬁguration table Conﬁg selection.

The LID default screen status message indicates when the chilled water reset is active. The Control Point temperature on the Status01 table indicates the chiller’s current reset temperature.

To activate a reset type, input all conﬁguration information for that reset type in the Conﬁg table. Then input the reset type number in the SELECT/ENABLE RESET TYPE input line.

RESET TYPE 1—Reset Type 1 requires an optional 8-input module. It is an automatic chilled water temperature reset based ona4to20mAinput signal. This type permits up to ± 30° F (± 16° C) of automatic reset to the chilled water or brine temperature set point, based on the input froma4to 20 mA signal. This signal is hardwired into the number one 8-input module.

If the 4-20 mAsignal is externally powered from the 8-input module, the signal is wired to terminals J1-5(+) and J1-6(–). If the signal is to be internally powered by the 8-input module (for example, when using variable resistance), the signal is wired to J1-7(+) and J1-6(–). The PIC must now be conﬁgured on the Service2 table to ensure that the appropriate power source is identiﬁed.

RESET TYPE 2—Reset Type requires an optional 8-input module. It is an automatic chilled water temperature reset based on a remote temperature sensor input. This reset type permits ± 30° F (± 16° C) of automatic reset to the set point based on a temperature sensor wired to the number one 8-input module (see wiring diagrams or certiﬁed drawings). The temperature sensor must be wired to terminal J1-19 and J1-20. To conﬁgure Reset Type 2, enter the temperature of the remote sensor at the point where no temperature reset will occur. Next, enter the temperature at which the full amount of reset will occur. Then, enter the maximum amount of reset required to operate the chiller. Reset Type 2 can now be activated.

RESET TYPE 3—Reset Type 3 is an automatic chilled water temperature reset based on cooler temperature difference. This type of reset will add ± 30° F (± 16° C) based on the temperature differencebetween entering and leaving chilled water temperature. This is the only type of reset available without the need of the number one 8-input module. No wiring is required for this type as it already uses the cooler water sensors. To conﬁgure Reset Type 3, enter the chilled water temperature difference (the difference between entering and leaving chilled water) at which no temperature reset occurs. This chilled water temperature difference is usually the full design load temperature difference. The difference in chilled water temperature at which the full amount of reset will occur is now entered on the next input line. Next, the amount of reset is entered. Reset Type 3 can now be activated.

Demand Limit Control, Option — (Requires Optional 8-Input Module) —

be externally controlled witha4to20mAsignal from an energy management system (EMS). The option is set up on the Conﬁg table. When enabled, the control is set for 100% demand with 4 mAand an operator conﬁgured minimum demand set point at 20 mA.

The Demand Reset input from an energy management system is hardwired into the number one, 8-input module. The signal may be internally powered by the module or externally powered. If the signal is externally powered, the signal is wired to terminals J1-1 (+) and J1-2 (–). If the signal is internally powered, the signal is wired to terminals J1-3 (+) and J1-2 (–). When enabled, the control is set for 100% demand with 4 mA and an operator conﬁgured minimum demand set point at 20 mA.

The demand limit may

Surge Prevention Algorithm — This is an operator

conﬁgurable feature which can determine if lift conditions are too high for the compressor and then take corrective action. Lift is deﬁned as the difference between the pressure at the impeller eye and the impeller discharge. The maximum lift that a particular impeller can perform varies with the gas ﬂow across the impeller and the size of the impeller.

Page 34

The algorithm ﬁrst determines if corrective action is necessary. This is done by checking 2 sets of operator conﬁgured data points, which are the MINIMUM and the MAXIMUM Load Points, (T1/P1;T2/P2). These points have default settings for each type of refrigerant, HCFC-22 or HFC-134a, as deﬁned on the Service1 table, or on Table 4. These settings and the algorithm function are graphically displayed in Fig. 20 and 21. The two sets of load points on this graph (default settings are shown) describe a line which the algorithm uses to determine the maximum lift of the compressor. Whenever the actual differential pressure between the cooler and condenser, and the temperature difference between the entering and leaving chilled water are above the line on the graph (as deﬁned by the MINIMUM and MAXIMUM Load Points) the algorithm will go into a corrective action mode. If the actual values are below the line, the algorithm takes no action. Modiﬁcation of the default set points of the MINIMUM and MAXIMUM load points is described in the Input Service Conﬁguration section on page 50.

Corrective action can be taken by making one of 2 choices. If a hot gas bypass line is present, and the hot gas is conﬁgured on the Service1 table, then the hot gas bypass valve can be energized. If a hot gas bypass if not present, then the action taken is to hold the guide vanes. See Table 4 — Capacity Overrides. Both of these corrective actions will reduce the lift experienced by the compressor and help to prevent a surge condition. Surge is a condition when the lift becomes so high that the gas ﬂow across the impeller reverses. This condition can eventually cause chiller damage. The surge prevention algorithm is intended to notify the operator that chiller operating conditions are marginal, and to take action to help prevent chiller damage such as lowering entering condenser water temperature.

LEGEND

ECW — Entering Chilled Water HGBP — Hot Gas Bypass LCW — Leaving Chilled Water

DP = (Condenser Psi) — (Cooler Psi) DT = (ECW) − (LCW)

Fig. 20 — 19XL Hot Gas Bypass/Surge

Prevention

Surge Protection — Surging of the compressor can be

determined by the PIC through operator conﬁgured settings. Surge will cause amperage ﬂuctuations of the compressor motor. The PIC monitors these amperage swings, and if the swing is greater than the conﬁgurable setting in one second, then one surge count has occurred. The SURGE DELTA PERCENTAMPS setting is displayed and conﬁgured on the Service1 screen. It has a default setting of 25% amps, SURGE PROTECTION COUNTS can be monitored on the Maint03 table.

Asurge protection shutdown of the chiller will occur whenever the surge protection counter reaches 12 counts within an operator speciﬁed time, known as the SURGE TIME PERIOD. The SURGE TIME PERIOD is displayed and conﬁgured on the Service1 screen. It has a default of 2 minutes.

Lead/Lag Control

NOTE: Lead/lag control is only available on chillers with PSIO Software Version 09 or higher.

Lead/lag is a control system process that automatically starts and stops a lag or second chiller in a 2-chiller water system. Refer to Fig. 16 and 17 for menu, table, and screen selection information. On chillers that have PSIO software with Lead/ Lag capability, it is possible to utilize the PIC controls to perform the lead/lag function on 2 chillers. A third chiller can be added to the lead/lag system as a standby chiller to start up in case the lead or lag chiller in the system has shut down during an alarm condition and additional cooling is required.

NOTE: Lead/lag conﬁguration is viewed and edited under Lead/Lag in the Equipment Conﬁguration table (located in the Service menu). Lead/lag status during chiller operation is viewed in the MAINT04 table in the Control Algorithm Status table. See Table 2.

LEGEND

ECW — Entering Chilled Water HGBP — Hot Gas Bypass LCW — Leaving Chilled Water

DP = (Condenser kPa) — (Cooler kPa) DT = (ECW) — (LCW)

Fig. 21 — 19XL with Default Metric Settings

Lead/Lag System Requirements:

• all chillers must have PSIO software capable of performing the lead/lag function

• water pumps MUST be energized from the PIC controls

• water ﬂows should be constant

• CCN Time Schedules for all chillers must be identical

Page 35

Operation Features:

• 2 chiller lead/lag

• addition of a third chiller for backup

• manual rotation of lead chiller

• load balancing if conﬁgured

• staggered restart of the chillers after a power failure

• chillers may be piped in parallel or in series chilled water ﬂow

COMMON POINT SENSOR INSTALLATION — Lead/ lag operation does not require a common chilled water point sensor. Common point sensors can be added to the 8-input option module, if desired. Refer to the certiﬁed drawings for termination of sensor leads.

NOTE: If the common point sensor option is chosen on a chilled water system, both chillers should have their own 8-input option module and common point sensor installed. Each chiller will use its own common point sensor for control, when that chiller is designated as the lead chiller.The PIC cannot read the value of common point sensors installed on other chillers in the chilled water system.

When installing chillers in series, a common point sensor should be used. If a common point sensor is not used, the leaving chilled water sensor of the upstream chiller must be moved into the leaving chilled water pipe of the downstream chiller.

If return chilled water control is required on chillers piped in series, the common point return chilled water sensor should be installed. If this sensor is not installed, the return chilled water sensor of the downstream chiller must be relocated to the return chilled water pipe of the upstream chiller.

To properly control the common supply point temperature sensor when chillers are piped in parallel, the water ﬂow through the shutdown chillers must be isolated so that no water bypass around the operating chiller occurs. The common point sensor option must not be used if water bypass around the operating chiller is occurring.

CHILLER COMMUNICATION WIRING — Refer to the chiller’s Installation Instructions or to the Carrier Comfort Network Interface section on page 48 of this manual for information on chiller communication wiring.

LEAD/LAG OPERATION — The PIC control provides the ability to operate 2 chillers in the LEAD/LAG mode. It also provides the additional ability to start a designated standby chiller when either the lead or lag chiller is faulted and capacity requirements are not met. The lead/lag option operates in CCN mode only. If any other chiller conﬁgured for lead/lag is set to the LOCAL or OFF modes, it will be unavailable for lead/lag operation.

NOTE: Lead/lag conﬁguration is viewed and edited in Lead/ Lag, under the Equipment Conﬁguration table of the Service menu. Lead/lag status during chiller operation is viewed in the MAINT04 table in the Control Algorithm Status table.

Lead/Lag Chiller Conﬁguration and Operation — The conﬁgured lead chiller is identiﬁed when the LEAD/LAG SELECT value for that chiller is conﬁgured to the value of ‘‘1.’’The conﬁgured lag chiller is identiﬁed when the LEAD/ LAG SELECT for that chiller is conﬁgured to the value of ‘‘2.’’The standby chiller is conﬁgured to a value of ‘‘3.’’A value of ‘‘0’’ disables the lead/lag in that chiller.

To conﬁgure the LAG ADDRESS value on the LEAD/ LAG Conﬁguration table, always use the address of the other chiller on the system for this value. Using this address will make it easier to rotate the lead and lag chillers.

If the address assignments placed into the LAG ADDRESS and STANDBYADDRESS values conﬂict, the lead/ lag will be disabled and an alert (!) message will occur. For example, if the LAG ADDRESS matches the lead chiller’s address, the lead/lag will be disabled and an alert (!) message will occur. The lead/lag maintenance screen (MAINT04) will display the message ‘INVALID CONFIG’ in the LEAD/LAG CONFIGURATION and CURRENT MODE ﬁelds.

The lead chiller responds to normal start/stop controls such as occupancy schedule, forced start/stop, and remote start contact inputs. After completing start up and ramp loading, the PIC evaluates the need for additional capacity. If additional capacity is needed, the PIC initiates the start up of the chiller conﬁgured at the LAG ADDRESS. If the lag chiller is faulted (in alarm) or is in the OFF or LOCAL modes, then the chiller at the STANDBY ADDRESS (if conﬁgured) is requested to start. After the second chiller is started and is running, the lead chiller shall monitor conditions and evaluate whether the capacity has reduced enough for the lead chiller to sustain the system alone. If the capacity is reduced enough for the lead chiller to sustain the CONTROL POINT temperatures alone, then the operating lag chiller is stopped.

If the lead chiller is stopped in CCN mode for any reason other than an alarm (*) condition, then the lag and standby chillers are stopped. If the conﬁgured lead chiller stops for and alarm condition, then the conﬁgured lag chiller takes the lead chiller’s place as the lead chiller and the standby chiller serves as the lag chiller.

If the conﬁgured lead chiller does not complete the startup before the PRESTART FAULT TIMER (user conﬁgured value) elapses, then the lag chiller shall be started and the lead chiller will shut down. The lead chiller then monitors the start request from the acting lead chiller to start.The PRE- START FAULT TIMER is initiated at the time of a start request. The PRESTART FAULT TIMER’s function is to provide a timeout in the event that there is a prestart alert condition preventing the chiller from starting in a timely manner. The timer is conﬁgured under Lead/Lag, found in the Equipment Conﬁguration table of the Service menu.

If the lag chiller does not achieve start-up before the PRESTART FAULT TIMER elapses, then the lag chiller shall be stopped and the standby chiller will be requested to start, if conﬁgured and ready.

Standby Chiller Conﬁguration and Operation — The conﬁgured standby chiller is identiﬁed as such by having the LEAD/LAG SELECT conﬁgured to the value of ‘‘3.’’ The standby chiller can only operate as a replacement for the lag chiller if one of the other two chillers is in an alarm (*) condition (as shown on the LID panel). If both lead and lag chillers are in an alarm (*) condition, the standby chiller shall default to operate in CCN mode based on its conﬁgured Occupancy Schedule and remote contacts input.

Lag Chiller Start-Up Requirements — Before the lag chiller can be started, the following conditions must be met:

1. Lead chiller ramp loading must be complete.

2. Lead chiller CHILLED WATERtemperature must be greater

than the CONTROL POINT plus 1/2 the WATER/BRINE DEADBAND.

NOTE: The chilled water temperature sensor may be the leaving chilled water sensor, the return water sensor, the common supply water sensor, or the common return water sensor, depending on which options are conﬁgured and enabled.

3. Lead chiller ACTIVE DEMAND LIMITvalue must be greater

than 95% of full load amps.

Page 36

4. Lead chiller temperature pulldown rate of the CHILLED WATER temperature is less than 0.5° F (0.27° C) per minute.

5. The lag chiller status indicates it is in CCN mode and is not faulted. If the current lag chiller is in an alarm condition, then the standby chiller becomes the active lag chiller, if it is conﬁgured and available.

6. The conﬁgured LAG START TIMER entry has elapsed. The LAG START TIMER shall be started when the lead chiller ramp loading is completed. TheLAG STARTTIMER entry is accessed by selecting Lead/Lag from the Equipment Conﬁguration table of the Service menu.

When all of the above requirements have been met, the lag chiller is forced to a STARTmode. The PIC control then monitors the lag chiller for a successful start. If the lag chiller fails to start, the standby chiller, if conﬁgured, is started.

Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.

1. Lead chiller COMPRESSOR MOTOR LOAD value is less

than the lead chiller percent capacity plus 15%. NOTE: Lead chiller percent capacity = 100 – LAG PER-

CENT CAPACITY

The LAG PERCENT CAPACITY value is conﬁgured on the Lead/Lag Conﬁguration screen.

2. The lead chiller chilled water temperature is less than

the CONTROL POINT plus

⁄2of the WATER/BRINE

DEADBAND.

3. The conﬁgured LAG STOP TIMER entry has elapsed.

The LAG STOP TIMER is started when the CHILLED WATER TEMPERATURE is less than the CHILLED WATER CONTROL POINT plus

⁄2of the WATER/

BRINE DEADBAND and the lead chiller COMPRESSOR

MOTOR LOAD is less than the lead chiller percent

capacity plus 15%. The timer is ignored if the chilled

water temperature reaches 3° F (1.67° C) below theCON-

TROL POINT and the lead chiller COMPRESSOR

MOTOR LOAD value is less than the lead chiller percent

capacity plus 15%.

FAULTED CHILLER OPERATION — If the lead chiller shuts down on an alarm (*) condition, it stops communication to the lag and standby chillers. After 30 seconds, the lag chiller will now become the acting lead chiller and will start and stop the standby chiller, if necessary.

If the lag chiller faults when the lead chiller is also faulted, the standby chiller reverts to a stand-alone CCN mode of operation.

If the lead chiller is in an alarm (*) condition (as shown on the LID panel), the RESET

softkey is pressed to clear

the alarm, and the chiller is placed in the CCN mode, the lead chiller will now communicate and monitor the RUN STATUS of the lag and standby chillers. If both the lag and standby chillers are running, the lead chiller will not attempt to start and will not assume the role of lead chiller until either the lag or standby chiller shuts down. If only one chiller is running, the lead chiller will wait for a start request from the operating chiller.When the conﬁgured lead chiller starts, it assumes its role as lead chiller.

LOAD BALANCING — When the LOAD BALANCE

OPTION is enabled, the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’sCOMPRESSOR MOTOR LOAD value. This value has limits of 40% to 100%. When setting the lag chiller ACTIVE DEMAND LIMIT, the CONTROL POINT will be modi-

ﬁed to a value of 3° F (1.67° C) less than the lead chiller’s CONTROL POINT value. If the LOAD BALANCE OPTION

is disabled, the ACTIVE DEMAND LIMIT and the CON- TROL POINT are forced to the same value as the lead chiller.

AUTO. RESTART AFTER POWER FAILURE — When an auto. restart condition occurs, each chiller may have a delay added to the start-up sequence, depending on its lead/ lag conﬁguration. The lead chiller does not have a delay. The lag chiller has a 45-second delay. The standby chiller has a 90-second delay. The delay time is added after the chiller water ﬂow veriﬁcation. The PIC controls ensure that the guide vanes are closed. After the guide vane position is conﬁrmed, the delay for lag and standby chiller occurs prior to energizing the oil pump. The normal start-up sequence then continues. The auto. restart delay sequence occurs whether the chiller is in CCN or LOCAL mode and is intended to stagger the compressor motors from being energized simultaneously. This will help reduce the inrush demands on the building power system.

Ice Build Control

IMPORTANT:The Ice Build control option is only available on chillers with PSIO Software Version 09 and higher.

Ice build control automatically sets the chilled WATER/ BRINE CONTROL POINT of the chiller to a temperature where an ice building operation for thermal storage can be accomplished.

The PIC can be conﬁgured for ice build operation. Conﬁguration of ice build control is accomplished through entries in the Conﬁg table, Ice Build Setpoint table, and the Ice Build Time Schedule table. Figures 16 and 17 show how to access each entry.

The Ice Build Time Schedule deﬁnes the period during which ice build is active if the ice build option is ENABLED. If the Ice Build Time Schedule overlaps other schedules deﬁning time, then the Ice Build Time Schedule shall take priority. During the ice build period, the WATER/ BRINE CONTROLPOINT is set to the ICE BUILD SET POINT for temperature control. The ICE BUILD RECYCLE OPTION and ICE BUILD TERMINATION entries from a screen in the Conﬁg (conﬁguration) table provide options for chiller recycle and termination of ice build cycle, respectively.Termination of ice build can result from the ENTERING CHILLED WATER/BRINE temperature being less than the ICE BUILD SET POINT, opening of the REMOTE CON- TACT inputs from an ice level indicator, or reaching the end of the Ice Build Time Schedule.

ICE BUILD INITIATION — The Ice Build Time Schedule provides the means for activating ice build. The ice build time table is named OCCPC02S.

If the Ice Build TimeSchedule is OCCUPIED and the ICE BUILD OPTION is ENABLED, then ice build is active and the following events automatically take place (unless overridden by a higher authority CCN device):

1. Force CHILLER START/STOP to START.

2. Force WA TER/BRINECONTROL POINT to the ICE BUILD

SET POINT.

3. Remove any force (Auto) on the ACTIVE DEMAND LIMIT. NOTE: Items 1-3 (shown above) shall not occur if the chiller

is conﬁgured and operating as a lag or standby chiller for lead/lag and is actively controlled by a lead chiller. The lead chiller communicates the ICE BUILD SET POINT, desired CHILLER START/STOPstate, and ACTIVE DEMAND LIMIT to the lag or standby chiller as required for ice build, if conﬁgured to do so.

Page 37

START-UP/RECYCLE OPERATION — If the chiller is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINA- TION value, to avoid starting the compressor unnecessarily:

•ifICE BUILD TERMINATION is set to the temperature only option (zero) and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SET

POINT;

•ifICE BUILD TERMINATION is set to the contacts only option (1) and the remote contacts are open;

• if the ICE BUILD TERMINATION is set to the both temperature and contacts option (2) andENTERING CHILLED

WATERtemperature is less than or equal to theICE BUILD SET POINT and remote contacts are open.

The ICE BUILD RECYCLE OPTION determines whether or not the PIC will go into a RECYCLE mode. If the ICE BUILD RECYCLE OPTION is set to DSABLE (disable) when the ice build terminates, the PIC will revert back to normal temperature control duty. If the ICE BUILD RECYCLE OPTION is set to ENABLE, when ice build terminates, the PIC will go into an ICE BUILD RECYCLE mode and the chilled water pump relay will remain energized to keep the chilled water ﬂowing. If the entering CHILLED WATER/

BRINE TEMPERATUREincreases above the ICE BUILD SET POINT plus the RECYCLE RESTART DELTA T value, the compressor will restart and control the CHILLED WATER/ BRINE TEMPERATURE to the ICE BUILD SET POINT.

TEMPERATURE CONTROL DURING ICE BUILD —During ice build, the capacity control algorithm uses the WATER/BRINECONTROL POINT minus 5 F (2.7 C) to control the LEAVING CHILLED WATER temperature. The ECW OPTION and any temperature reset option are ignored during ice build. The 20 mA DEMAND LIMIT OPTION is also ignored during ice build.

TERMINATION OF ICE BUILD — Ice build termination occurs under the following conditions:

1. Ice Build Time Schedule — When the Ice Build Time

Schedule transitions to UNOCCUPIED, ice build operation shall terminate.

2. ECW TEMPERATURE — Termination of compressor

operation, based on temperature, shall occur if the ICE BUILD TERMINATION is set to the ice build termination temperature option (0) and the ENTERING

CHILLED WATER TEMPERATURE is less than the ICE BUILD SET POINT.IftheICE BUILD RECYCLE

OPTION is set to ENABLE and recycle start-up shall be based on LEAVINGCHILLED

WATER temperature being greater than the WATER/ BRINE CONTROL POINT plus RECYCLE RESTART DELTA T.

3. Remote Contacts/Ice Level Input — Termination of

compressor operation occurs when ICE BUILD TERMI- NATION is set to the contacts only option (1) and the remote contacts are open. In this case, the contacts are provided for ice level termination control. The remote contacts can still be opened and closed to start and stop the chiller when the Ice Build Time Schedule is UNOCCUPIED. The contacts are used to stop the ICE BUILD mode when the Ice Build Time Schedule is OCCUPIED.

4. ECW TEMPERATURE and Remote Contacts — Termi-

nation of compressor operation shall occur when ICE BUILD TERMINATIONis set to both the temperature and contacts (2) option and the previously described conditions for ENTERING CHILLED WATER temperature and remote contacts have occurred.

, a recycle shutdown occurs

NOTE: Overriding the CHILLER START/STOP, WATER/ BRINE CONTROL POINT, and ACTIVE DEMAND LIMIT variables by CCN devices (with a priority less than 4) during the ice build period is not possible. However, overriding can be accomplished with CCN during two chiller lead/ lag.

RETURN TO NON-ICE BUILD OPERATIONS — Upon termination of ice build, the chiller shall return to normal temperature control and start/stop schedule operation. If the CHILLER START/STOP or WATER/BRINE CONTROL POINT has been forced (with a priority less than 4), prior to entering ice build operation, then chiller START/STOP and WATER/BRINE CONTROL POINT forces will be removed.

Attach to Network Device Control — On the Serv-

ice menu, one of the selections is ATTACH TO NETWORK DEVICE. This table serves the following purposes:

• to upload new parameters when switching the controller to HFC-134a refrigerant.

• to upload the Occupancy Schedule Number (if changed) for OCCPC03S software (version 09 and later), as deﬁned in the Service01 table

• to attach the LID to any CCN device, if the chiller has been connected to a CCN Network. This may include other PIC controlled chillers.

• to change to a new PSIO or LID module or upgrade software.

Figure 22 illustrates the ATTACH TO NETWORK DEVICE table. The Local description is always the PSIO module address of the chiller the LID is mounted on. Whenever the controller identiﬁcation of the PSIO is changed, this change is reﬂected on the bus and address for the LOCAL DEVICE of the ATTACH TO DEVICE screen automatically. See Fig. 17.

Whenever the ATTACH TO NETWORK DEVICE table is entered, no information can be read from the LID on any device until you attach one of the devices listed on the display.The LID erases information about the module to which it was attached to make room for information on another device. Therefore, a CCN module must be attached when this screen is entered. To attach a device, highlight it using the

SELECT

message, ‘‘UPLOADING TABLES, PLEASE WAIT’’ displays. The LID then uploads the highlighted device or module. If the module address cannot be found, the message, ‘‘COMMUNICATION FAILURE’’appears. The LID then reverts to the ATTACH TO DEVICE screen. Try another device or check the address of the device that would not attach. The upload process time for each CCN module is different. In general, the uploading process takes 3 to 5 minutes. Before leaving the ATTACH TO NETWORK DEVICE screen, select the LOCAL device. Otherwise, the LID will be unable to display information on the local chiller.

CHANGING REFRIGERANT TYPES — To select refrigerant type, go to the Control Test table. Whenever the refrigerant type is changed, the ATTACH TO NETWORK DEVICE table must be used. After changing the refrigerant type in the Control Testtable, move to theATTACH TO NETWORK DEVICE table. Make sure the highlight bar is

located on the LOCAL selection. Press the ATTACH key. The information in the PSIO module will now be up-

loaded. The default screen will appear. The new refrigerant type change for the controller is complete.

softkey and then press the ATTACH softkey .The

soft-

Page 38

ATTACHINGTO OTHER CCN MODULES — If the chiller PSIO has been connected to a CCN Network or other PIC controlled chillers through CCN wiring, the LID can be used to view or change parameters on the other controllers. Other PIC chillers can be viewed and set points changed (if the other unit is in CCN control), if desired from this particular LID module.

To view the other devices, move to the ATTACH TO

NETWORK DEVICE table. Move the highlight bar to any device number. Press the SELECT softkey to change the bus number and address of the module to be viewed. Press

EXIT softkey to move back to the ATTACH TO NETWORK DEVICE table. If the module number is not valid, the ‘‘COMMUNICATION FAILURE’’ message will show and a new address number should be entered or the wiring checked. If the model is communicating properly, the ‘‘UPLOAD IN PROGRESS’’messagewill ﬂash and the new module can now be viewed.

Whenever there is a question regarding which module on the LID is currently being shown, check the device name descriptor on the upper left hand corner of the LID screen. See Fig. 22.

When the CCN device has been viewed, the ATTACH TO NETWORK DEVICE table should now be used to attach to the PIC that is on the chiller. Move to the ATTACH TO NETWORK DEVICE table and press the

ATTACH

for the 19XL will now be uploaded. NOTE: The LID will not automatically reattach to the PSIO

module on the chiller. Press the ATTACH to LOCAL DEVICE and view the chiller PSIO.

softkey to upload the LOCAL device. The PSIO

softkey to attach

If the password is entered incorrectly,an error message is displayed. If this occurs, return to Step 1 and try logging on again.

NOTE: The initial factory set password is 1-1-1-1. TO LOG OFF — Access the Log Out of Device table of the

Service menu in order to password-protect the Service menu. The LID will automatically sign off and password-protect itself if a key is not pressed for 15 minutes. The LID default screen is then displayed.

HOLIDAY SCHEDULING (Fig. 23) — The time schedules may be conﬁgured for special operation during a holiday period. When modifying a time period, the ‘‘H’’ at the end of the days of the week ﬁeld signiﬁes that the period is applicable to a holiday. (See Fig. 18.)

The Broadcast function must be activated for the holidays conﬁgured in the Holidef tables to work properly. Access the Brodefs table in the Equipment Conﬁguration table and answer ‘‘Yes’’ to the activated function. However, when the chiller is connected to a CCN Network, only one chiller or CCN device can be conﬁgured to be the broadcast device. The controller that is conﬁgured to be the broadcaster is the device responsible for transmitting holiday,time, and daylightsavings dates throughout the network.

To view or change the holiday periods for up to 18 different holidays, perform the following operation:

1. At the Menu screen, press SERVICE ice menu.

to access the Serv-

Fig. 22 — Example of Attach to Network

Device Screen

Service Operation — An overview of the menu-

driven programs available for Service Operation is shown in Fig. 17.

TO LOG ON

1. On the Menu screen, press SERVICE correspond to the numerals 1, 2, 3, 4.

2. Press the four digits of your password, one at a time. An asterisk (*) appears as you enter each digit.

The menu bar (Next-Previous-Select-Exit) is displayed to indicate that you have successfully logged on.

. The keys now

2. If not logged on, follow the instructions for To Log On or To Log Off. Once logged on, press NEXT til Equipment Conﬁguration is highlighted.

3. Once Equipment Conﬁguration is highlighted, press

SELECT

4. Press NEXT until Holidef is highlighted. This is the Holiday Deﬁnition table.

5. Press SELECT to enter the Data Table Select screen. This screen lists 18 holiday tables.

to access.

un-

Page 39

6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday pe-

riod, starting on a speciﬁc date, and lasting up to 99 days.

7. Press SELECT to access the holiday table. The Conﬁguration Select table now shows the holiday start month

and day,and how many days the holiday period will last.

8. Press NEXT or PREVIOUS to highlight the month, day, or duration.

9. Press SELECT to modify the month, day, or duration.

START-UP/SHUTDOWN/RECYCLE

SEQUENCE (Fig. 24)

Local Start-Up —

is initiated by pressing the LOCAL on the default LID screen. Local start-up can proceed when

Time Schedule 01 is in OCCUPIED mode, and after the internal 15-minute start-to-start and the 3-minute stop-to-start inhibit timers have expired (on PSIO software Version 08 and lower or a 1-minute stop-to-start timer on PSIO Software Version 09 and higher).

The chiller start/stop status point on the Status01 table may be overridden to start, regardless of the time schedule, in order to locally start the unit. Also, the remote contacts may be enabled through the LID and closed to initiate a start-up.

Whenever the chiller is in LOCAL control mode, the PIC will wait for Time Schedule 01 to become occupied and the remote contacts to close, if enabled. The PIC will then perform a series of pre-start checks to verify that all pre-start alerts and safeties are within the limits shown in Table 3. The run status line on the LID now reads ‘‘Starting.’’ If the checks are successful, the chilled water/brine pump relay will be energized. Five seconds later, the condenser pump relay is energized. Thirty seconds later the PIC monitors the chilled water and condenser water ﬂow switches, and waits until the WATER FLOW VERIFY TIME (operator conﬁgured, default 5 minutes) to conﬁrm ﬂow.After ﬂow is veriﬁed, the chilled water/brine temperature is compared to CONTROL POINT plus DEADBAND. If the temperature is less than or equal to this value, the PIC will turn off the condenser pump relay

Local start-up (or a manual start-up)

menu softkey which is

10. Press INCREASE or DECREASE to change the selected value.

11. Press ENTER to save the changes.

12. Press EXIT to return to the previous menu.

Fig. 23 — Example of Holiday Period Screen

A—START INITIATED — Prestart checks made; evaporator B—Condenser water pump started (5 seconds after A)

C—Water ﬂows veriﬁed (30 seconds to 5 minutes maximum

D—Oil pressure veriﬁed (30 seconds minimum, 300 seconds E—Compressor motor starts, compressor ontime and serv-

F—SHUTDOWNINITIATED— Compressor motor stops, com-

G—Oil pump and evaporator pumps deenergized (60 seconds

O/A — Restart permitted (both inhibit timers expired) (minimum of

pump started

after B). Chilled water temperatures checked against controlpoint. Guidevanes checkedfor closure.Oil pumpstarted; tower fan control enabled.

maximum after C) ice ontime start, 15-minute inhibit timer starts (10 seconds

after D), total compressor starts advances by one, number of starts over a 12-hour period advances by one

pressor ontime and service ontime stops, 3-minute inhibit timer starts on PSIO Software Version 08 and lower and 1-minute inhibit timer starts for PSIO Software Version 09 and higher.

after F). Condenser pump and tower fan control may continue to operate if condenser pressure is high. Evaporator pump may continue if in RECYCLE mode.

15 minutes after E; [minimum of 3 minutes after F on PSIO Software Version 08 and lower] [minimum of 1 minute after F on PSIO Software Version 09 and higher]

Fig. 24 — Control Sequence

Page 40

and go into a RECYCLE mode. If the water/brine temperature is high enough, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 3 psid (21 kPad), the oil pump relay will then be energized. The PIC then waits until the OIL PRESS (Pressure) VERIFY TIME (operator conﬁgured, default 15 seconds) for oil pressure to reach 18 psid (124 kPad). After oil pressure is veriﬁed, the PIC waits 15 seconds, and then the compressor start relay (1CR) is energized to start the compressor. Compressor ontime and service ontime timers start and the compressor starts counter and the number of starts over a 12-hour period counter are advanced by one.

Failure to verify any of the requirements up to this point will result in the PIC aborting the start and displaying the applicable pre-start mode of failure on the LID default screen. A pre-start failure does not advance the starts in 12 hours counter. Any failure, after the 1CR relay has energized, results in a safety shutdown, energizes the alarm light, and displays the applicable shutdown status on the LID display.

Shutdown Sequence — Shutdown of the chiller can

occur if any of the following events happen:

• the STOP button is pressed for at least one second (the

alarm light will blink once to conﬁrm stop command)

• recycle condition is present (see Chilled WaterRecycle Mode

section)

• time schedule has gone into UNOCCUPIED mode (chiller

protective limit has been reached and chiller is in alarm)

• the start/stop status is overridden to stop from the CCN

network or the LID

When a stop signal occurs, the shutdown sequence ﬁrst stops the compressor by deactivating the start relay. A status message of ‘‘SHUTDOWN IN PROGRESS, COMPRESSOR DEENERGIZED’’isdisplayed. Compressor ontime and service ontime stop. The guide vanes are then brought to the closed position. The oil pump relay and the chilled water/ brine pump relay are shut down 60 seconds after the compressor stops. The condenser water pump will be shut down when the CONDENSER REFRIGERANT TEMP is less than the CONDENSER PRESSURE OVERRIDE minus 5 psi (34 kPa) or is less than or equal to the ENTERING CONDENSER WATER TEMP plus 3° F (2° C). The stopto-start timer will now begin to count down. If the start-tostart timer is still greater than the value of the start-to-stop timer, then this time is now displayed on the LID.

Certain conditions during shutdown will change this sequence:

• if the COMPRESSOR MOTOR LOAD is greater than 10%

after shutdown, or the starter contacts remain energized, the oil pump and chilled water pump remain energized and the alarm is displayed

• if the ENTERING CONDENSER WATER temperature is

greater than 115 F (46 C) at shutdown, the condenser pump will be deenergized after the 1CR compressor start relay

• if the chiller shuts down due to low refrigerant tempera-

ture, the chilled water pump will stay running until the

LEAVING CHILLED WATER is greater than CONTROL POINT, plus 5° F (3° C)

AutomaticSoft StopAmps Threshold (PSIO Software Version 09 and Higher) —

AMPS THRESHOLD closes the guide vanes of the compressor automatically when a non-recycle, non-alarm stop signal occurs before the compressor motor is deenergized.

The SOFT STOP

If the STOP button is pressed, the guide vanes close to a preset amperage percent or until the guide vane is less than 2% open. The compressor will then shut off.

If the chiller enters an alarm state or if the compressor enters a RECYCLE mode, the compressor will be deenergized immediately.

To activate SOFT STOP AMPS THRESHOLD, view the bottom of Service1 table. Set the SOFT STOP AMPS THRESHOLD value to the percentage amps at which the motor will shut down. The default setting is 100% amps (no Soft Stop).

When the SOFT STOP AMPS THRESHOLD is being applied, a status message ‘‘SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING’’ is shown.

ChilledWaterRecycle Mode— The chiller may cycle

off and wait until the load increases to restart again when the compressor is running in a lightly loaded condition. This cycling of the chiller is normal and is known as recycle. A recycle shutdown is initiated when any of the following conditions are true:

• when in LCW control, the difference between the LEAV-

ING CHILLED WATER temperature and ENTERING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T (found in the Service1 table) and the LEAVING CHILLED WATER TEMP is below the CONTROL POINT, and the CONTROL POINT has not

increased in the last 5 minutes.

• when ECW CONTROL OPTION is enabled, the difference

between the ENTERING CHILLED WATER temperature and the LEAVING CHILLED WATER temperature is less than the RECYCLE SHUTDOWN DELTA T (found in the Service1 table) and the ENTERING CHILLED WATER

TEMPERATURE is below the CONTROL POINT, and the CONTROL POINT has not increased in the last 5 minutes.

• when the LEAVINGCHILLED WATERtemperatureis within

3° F (2° C) of the BRINE REFRIG TRIPPOINT

When the chiller is in RECYCLE mode, the chilled water pump relay remains energized so that the chilled water temperature can be monitored for increasing load. The recycle control uses RECYCLE RESTART DELTA T to check when the compressor should be restarted. This is an operatorconﬁgured function which defaults to 5° F (3° C). This value is viewed/modiﬁed on the Service1 table. The compressor will restart when:

• in LCW CONTROL the LEAVINGCHILLED WATERtem-

perature is greater than the CONTROL POINT plus the RECYCLE RESTART DELTA T; or

• in ECW CONTROL, the ENTERING CHILLED WATER

temperature is greater than the CONTROL POINT plus the

RECYCLE RESTART DELTA T

Once these conditions are met, the compressor will initiate a start-up, with a normal start-up sequence.

An alert condition may be generated if 5 or more RECYCLE STARTUPs occur in less than 4 hours. This excessive recycling can reduce chiller life. Compressor recycling due to extremely low loads should be reduced. To reduce compressor recycling, use the time schedule to shut the chiller down during low load operation or increase the chiller load by running the fan systems. If the hot gas bypass is installed, adjust the values to ensure that hot gas is energized during light load conditions. Increase the RECYCLE RESTART DELTA T on the Service1 table to lengthen the time between restarts.

The chiller should not be operated below design minimum load without a hot gas bypass installed on the chiller.

Page 41

Safety Shutdown — A safety shutdown is identical to

a manual shutdown with the exception that the LID will display the reason for the shutdown, the alarm light will blink continuously, and the spare alarm contacts will be ener-

gized. A safety shutdown requires that the RESET be pressed in order to clear the alarm. If the alarm is still

present, the alarm light will continue to blink. Once the alarm is cleared, the operator must press the CCN

LOCAL

Do not reset starter loads or any other starter safety for 30 seconds after the compressor has stopped. Voltage output to the compressor start signal is maintained for 10 seconds to determine starter fault.

softkeys to restart the chiller.

softkey

BEFORE INITIAL START-UP

Job Data Required

• list of applicable design temperatures and pressures (product data submittal)

• chiller certiﬁed prints

• starting equipment details and wiring diagrams

• diagrams and instructions for special controls or options

• 19XL Installation Instructions

• pumpout unit instructions

Equipment Required

• mechanic’s tools (refrigeration)

• digital volt-ohmmeter (DVM)

• clamp-on ammeter

• electronic leak detector

• absolute pressure manometer or wet-bulb vacuum indicator (Fig. 25)

• 500 v insulation tester (megohmmeter) for compressor motors with nameplate voltage of 600 v or less, or a 5000-v insulation tester for compressor motor rated above 600 v

Using the Optional Storage Tankand Pumpout System —

Procedures section, page 59 for: pumpout system preparation, refrigerant transfer, and chiller evacuation.

Refer to Pumpout and Refrigerant Transfer

Remove Shipping Packaging — Remove any

packaging material from the control center, power panel, guide vane actuator, motor cooling and oil reclaim solenoids, motor and bearing temperature sensor covers, and the factorymounted starter.

Open Oil Circuit Valves — Check that the oil ﬁlter

isolation valves (Fig. 4) are open by removing the valve cap and checking the valve stem.

Tighten All Gasketed Joints and Guide Vane Shaft Packing —

by the time the chiller arrives at the jobsite. Tighten all gasketed joints and guide vane shaft packing to ensure a leaktight chiller.

Gaskets and packing normally relax

Check Chiller Tightness — Figure 26 outlines the

proper sequence and procedures for leak testing.

19XL chillers are shipped with the refrigerant contained in the condenser shell and the oil charge shipped in the compressor. The cooler will have a 15 psig (103 kPa) refrigerant charge. Units may be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogenholding charge in each vessel. To determine if there are any leaks, the chiller should be charged with refrigerant. Use an electronic leak detector to check all ﬂanges and solder joints after the chiller is pressurized. If any leaks are detected, follow the leak test procedure.

If the chiller is spring isolated, keep all springs blocked in both directions in order to prevent possible piping stress and damage during the transfer of refrigerant from vessel to vessel during the leak test process, or any time refrigerant is transferred. Adjust the springs when the refrigerant is in operating condition, and when the water circuits are full.

Refrigerant Tracer — Carrier recommends the use of

an environmentally acceptable refrigerant tracer for leak testing with an electronic detector or halide torch.

Ultrasonic leak detectors also can be used if the chiller is under pressure.

Fig. 25 — Typical Wet-Bulb Type

Vacuum Indicator

Do not use air or oxygen as a means of pressurizing the chiller. Some mixtures of HCFC-22 or HFC-134a and air can undergo combustion.

Leak Test Chiller — Due to regulations regarding

refrigerant emissions and the difficultiesassociated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Fig. 26 for an outline of the leak test procedures. Refer to Fig. 27 and 28 during pumpout procedures and Tables 5A, B, C, and D for refrigerant pressure/temperature values.

1. If the pressure readings are normal for chiller

condition: a. Evacuate the holding charge from the vessels, if present. b. Raise the chiller pressure, if necessary, by adding re-

frigerant until pressure is at equivalent saturated pressure for the surrounding temperature. Follow the pumpout

Page 42

Fig. 26 — 19XL Leak Test Procedures

Page 43

procedures in the Transfer Refrigerant from Storage Tank to Chiller section, Steps 1a-e, page 59.

Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 68 psig (469 kPa) for HCFC-22 and 35 psig (241 kPa) for HFC-134a. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN LOCKOUT and TERMINATE LOCKOUT mode on the PIC. Flashing of liquid refrigerant at low pressures can cause tube freezeup and considerable damage.

c. Leak test chiller as outlined in Steps 3-9.

2. If the pressure readings are abnormal for chiller condition:

a. Prepare to leak test chillers shipped with refrigerant

(Step 2h).

b. Check for large leaks by connecting a nitrogen bottle

and raising the pressure to 30 psig (207 kPa). Soap test all joints. If the test pressure holds for 30 minutes,

prepare the test for small leaks (Steps 2g-h). c. Plainly mark any leaks which are found. d. Release the pressure in the system. e. Repair all leaks. f. Retest the joints that were repaired. g. After successfully completing the test for large leaks,

remove as much nitrogen, air, and moisture as pos-

sible, given the fact that small leaks may be present in

the system. This can be accomplished by following

the dehydration procedure, outlined in the Chiller

Dehydration section, page 47. h. Slowly raise the system pressure to a maximum of

210 psig (1448 kPa) but no less than 68 psig (469 kPa)

for HCFC-22, 35 psig (241 kPa) for HFC-134a by add-

ing refrigerant. Proceed with the test for small leaks

(Steps 3-9).

3. Check the chiller carefully with an electronic leak detector, halide torch, or soap bubble solution.

4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to conﬁrm. Total all leak rates for the entire chiller. Leakage at rates greater than 1 lb/year (0.45 kg/year) for the entire chiller must be repaired. Note total chiller leak rate on the start-up report.

5. If no leak is found during initial start-up procedures, complete the transfer of refrigerant gas from the storage tank to the chiller (see Pumpout and Refrigerant Transfer Procedures, Transfer Refrigerant from Storage Tank to Chiller section, Step 1e, page 59). Retest.

6. If no leak is found after a retest: a. Transfer the refrigerant to the storage tank and

perform a standing vacuum test as outlined in the Standing Vacuum Test section, this page.

b. If the chiller fails this test, check for large leaks

(Step 2b).

c. Dehydrate the chiller if it passes the standing vacuum

test. Follow the procedure in the Chiller Dehydration section. Charge chiller with refrigerant (see Pumpout and Refrigerant Transfer Procedures, Transfer Refrigerant from Storage Tank to Chiller section, Steps 1a-e or page 59).

7. If a leak is found, pump the refrigerant back into the storage tank, or if isolation valves are present, pump into the non-leaking vessel (see Pumpout and Refrigerant Transfer procedures section).

8. Transfer the refrigerant until chiller pressure is at 18 in. Hg (40 kPa absolute).

9. Repair the leak and repeat the procedure, beginning from Step 2h to ensure a leaktight repair. (If chiller is opened to the atmosphere for an extended period, evacuate it before repeating leak test.)

StandingVacuumTest— When performing the stand-

ing vacuum test, or chiller dehydration, use a manometer or a wet bulb indicator. Dial gages cannot indicate the small amount of acceptable leakage during a short period of time.

1. Attach an absolute pressure manometer or wet bulb indicator to the chiller.

2. Evacuate the vessel (see Pumpout and Refrigerant Transfer Procedures section, page 59) to at least 18 in. Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or the pumpout unit.

3. Valve off the pump to hold the vacuum and record the manometer or indicator reading.

4. a. If the leakage rate is less than 0.05 in. Hg (.17 kPa) in

24 hours, the chiller is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (.17 kPa) in

24 hours, repressurize the vessel and test for leaks. If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Refrigerant To Normal Operating Conditions section, page 61. If not, use nitrogen and a refrigerant tracer. Raise the vessel pressure in increments until the leak is detected. If refrigerant is used, the maximum gas pressure is approximately 120 psig (827 kPa) for HCFC-22, 70 psig (483 kPa) for HFC-134a at normal ambient temperature. If nitrogen is used, limit the leak test pressure to 230 psig (1585 kPa) maximum.

5. Repair leak, retest, and proceed with dehydration.

Page 44

TEMPERATURE

(F)

−50 11.67 6.154*

−48 12.34 4.829*

−46 13.00 3.445*

−44 13.71 2.002*

−42 14.45 0.498*

−40 15.22 0.526

−38 16.02 1.328

−36 16.86 2.163

−34 17.73 3.032

−32 18.63 3.937

−30 19.57 4.877

−28 20.55 5.853

−26 21.56 6.868

−24 22.62 7.921

−22 23.71 9.015

−20 24.85 10.15

−18 26.02 11.32

−16 27.24 12.54

−14 28.50 13.81

−12 29.81 15.11

−10 31.16 16.47

−8 32.56 17.87

−6 34.01 19.32

−4 35.51 20.81

−2 37.06 22.36 0 38.66 23.96

2 40.31 25.61 4 42.01 27.32 6 43.78 29.08 8 45.59 30.90

10 47.46 32.77 12 49.40 34.70 14 51.39 36.69 16 53.44 38.74 18 55.55 40.86

20 57.73 43.03 22 59.97 45.27 24 62.27 47.58 26 64.64 49.95 28 67.08 52.39

PRESSURE (psi)

Absolute Gage

Table 5A — HCFC-22 Pressure — Temperature (F)

TEMPERATURE

(F)

30 69.59 54.90 32 72.17 57.47 34 74.82 60.12 36 77.54 62.84 38 80.34 65.64

40 83.21 68.51 42 86.15 71.46 44 89.18 74.48 46 92.28 77.58 48 95.46 80.77

50 98.73 84.03 52 102.07 87.38 54 105.50 90.81 56 109.02 94.32 58 112.62 97.93

60 116.31 101.62 62 120.09 105.39 64 123.96 109.26 66 127.92 113.22 68 131.97 117.28

70 136.12 121.43 72 140.37 125.67 74 144.71 130.01 76 149.15 134.45 78 153.69 138.99

80 158.33 143.63 82 163.07 148.37 84 167.92 153.22 86 172.87 158.17 88 177.93 163.23

90 183.09 168.40 92 188.37 173.67 94 193.76 179.06 96 199.26 184.56 98 204.87 190.18

100 210.60 195.91 102 216.45 201.76 104 222.42 207.72 106 228.50 213.81 108 234.71 220.02

PRESSURE (psi)

Absolute Gage

TEMPERATURE

*Inches of mercury below one atmosphere.

(F)

110 241.04 226.35 112 247.50 232.80 114 254.08 239.38 116 260.79 246.10 118 267.63 252.94

120 274.60 259.91 122 281.71 267.01 124 288.95 274.25 126 296.33 281.63 128 303.84 289.14

130 311.50 296.80 132 319.29 304.60 134 327.23 312.54 136 335.32 320.63 138 343.56 328.86

140 351.94 337.25 142 360.48 345.79 144 369.17 354.48 146 378.02 363.32 148 387.03 372.33 150 396.19 381.50 152 405.52 390.83 154 415.02 400.32 156 424.68 409.99 158 434.52 419.82 160 444.53 420.83

PRESSURE (psi)

Absolute Gage

TEMPERATURE

(C)

−18 264 163

−17 274 173

−16 284 183

−15 296 195

−14 307 206

−13 318 217

−12 330 229

−11 342 241

−10 354 253

−9 367 266

−8 380 279

−7 393 292

−6 407 306

−5 421 320

−4 436 335

−3 451 350

−2 466 365

−1 482 381 0 498 397

1 514 413 2 531 430 3 548 447 4 566 465 5 584 483

6 602 501 7 621 520 8 641 540 9 660 559

10 681 580 11 701 600

PRESSURE (kPa)

Absolute Gage

Table 5B — HCFC-22 Pressure — Temperature (C)

TEMPERATURE

(C)

12 723 622 13 744 643 14 766 665 15 789 688

16 812 711 17 836 735 18 860 759 19 885 784 20 910 809

21 936 835 22 962 861 23 989 888 24 1020 919 25 1040 939

26 1070 969 27 1100 1000 28 1130 1030 29 1160 1060 30 1190 1090

31 1220 1120 32 1260 1160 33 1290 1190 34 1320 1220 35 1360 1260

36 1390 1290 37 1420 1320 38 1460 1360 39 1500 1400 40 1530 1430 41 1570 1470

PRESSURE (kPa)

Absolute Gage

TEMPERATURE

(C)

42 1610 1510 43 1650 1550 44 1690 1590 45 1730 1630

46 1770 1670 47 1810 1710 48 1850 1750 49 1900 1800 50 1940 1840

51 1980 1890 52 2030 1930 53 2080 1980 54 2130 2030 55 2170 2070

56 2220 2120 57 2270 2170 58 2320 2220 59 2370 2270 60 2430 2330

61 2480 2380 62 2530 2430 63 2590 2490 64 2640 2540 65 2700 2600

66 2760 2660 67 2820 2720 68 2870 2770 69 2930 2830 70 3000 2900

PRESSURE (kPa)

Absolute Gage

Page 45

TEMPERATURE

(F)

0 6.50 2 7.52 4 8.60 6 9.66 8 10.79

10 11.96 12 13.17 14 14.42 16 15.72 18 17.06

20 18.45 22 19.88 24 21.37 26 22.90 28 24.48

30 26.11 32 27.80 34 29.53 36 31.32 38 33.17

40 35.08 42 37.04 44 39.06 46 41.14 48 43.28

50 45.48 52 47.74 54 50.07 56 52.47 58 54.93

Table 5C — HFC-134a Pressure — Temperature (F)

PRESSURE

(psig)

TEMPERATURE

(F)

60 57.46 62 60.06 64 62.73 66 65.47 68 68.29

70 71.18 72 74.14 74 77.18 76 80.30 78 83.49

80 86.17 82 90.13 84 93.57 86 97.09 88 100.70

90 104.40 92 108.18 94 112.06 96 116.02 98 120.08

100 124.23 102 128.47 104 132.81 106 137.25 108 141.79

110 146.43 112 151.17 114 156.01 116 160.96 118 166.01

PRESSURE

(psig)

TEMPERATURE

(F)

120 171.17 122 176.45 124 181.83 126 187.32 128 192.93

130 198.66 132 204.50 134 210.47 136 216.55 138 222.76 140 229.09

PRESSURE

(psig)

TEMPERATURE

(C)

−18.0 44.8

−16.7 51.9

−15.6 59.3

−14.4 66.6

−13.3 74.4

−12.2 82.5

−11.1 90.8

−10.0 99.4

−8.9 108.0

−7.8 118.0

−6.7 127.0

−5.6 137.0

−4.4 147.0

−3.3 158.0

−2.2 169.0

−1.1 180.0

0.0 192.0

1.1 204.0

2.2 216.0

3.3 229.0

4.4 242.0

5.0 248.0

5.6 255.0

6.1 261.0

6.7 269.0

7.2 276.0

7.8 284.0

8.3 290.0

8.9 298.0

9.4 305.0

Table 5D — HFC-134a Pressure — Temperature (C)

PRESSURE GAGE (kPa)

TEMPERATURE

(C)

10.0 314.0

11.1 329.0

12.2 345.0

13.3 362.0

14.4 379.0

15.6 396.0

16.7 414.0

17.8 433.0

18.9 451.0

20.0 471.0

21.1 491.0

22.2 511.0

23.3 532.0

24.4 554.0

25.6 576.0

26.7 598.0

27.8 621.0

28.9 645.0

30.0 669.0

31.1 694.0

32.2 720.0

33.3 746.0

34.4 773.0

35.6 800.0

36.7 828.0

37.8 857.0

38.9 886.0

40.0 916.0

41.1 946.0

42.2 978.0

PRESSURE

GAGE (kPa)

TEMPERATURE

(C)

43.3 1010.0

44.4 1042.0

45.6 1076.0

46.7 1110.0

47.8 1145.0

48.9 1180.0

50.0 1217.0

51.1 1254.0

52.2 1292.0

53.3 1330.0

54.4 1370.0

55.6 1410.0

56.7 1451.0

57.8 1493.0

58.9 1536.0

60.0 1580.0

PRESSURE

GAGE (kPa)

Page 46

Fig. 27 — Typical Optional Pumpout System Piping Schematic

with Storage Tank

Fig. 28 — Typical Optional Pumpout System Piping Schematic

without Storage Tank

Page 47

Chiller Dehydration — Dehydration is recommended

if the chiller has been open for a considerable period of time, if the chiller is known to contain moisture, or if there has been a complete loss of chiller holding charge or refrigerant pressure.

Do not start or megohm test the compressor motor or oil pump motor, even for a rotation check, if the chiller is under dehydration vacuum. Insulation breakdown and severe damage may result.

InspectWaterPiping — Refer to piping diagrams pro-

vided in the certiﬁed drawings, and the piping instructions in the 19XL Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that ﬂow directions are correct and that all piping speciﬁcations have been met.

Piping systems must be properly vented, with no stress on waterbox nozzles and covers. Water ﬂows through the cooler and condenser must meet job requirements. Measure the pressure drop across cooler and across condenser.

Dehydration is readily accomplished at room temperatures. Use of a cold trap (Fig. 29) may substantially reduce the time required to complete the dehydration. The higher the room temperature, the faster dehydration takes place. At low room temperatures, a very deep vacuum is required for boiling off any moisture. If low ambient temperatures are involved, contact a qualiﬁed service representative for the dehydration techniques required.

Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm

[.002 m charging valve (Fig. 2A or 2B). Tubing from the pump to the chiller should be as short and as large a diameter as possible to provide least resistance to gas ﬂow.

2. Use an absolute pressure manometer or a wet bulb vacuum

indicator to measure the vacuum. Open the shutoff valve to the vacuum indicator only when taking a reading. Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum.

3. Open all isolation valves (if present), if the entire chiller

is to be dehydrated.

4. With the chiller ambient temperature at 60 F (15.6 C) or

higher,operate the vacuum pump until the manometer reads

29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C). Operate the pump an additional 2 hours.

Do not apply greater vacuum than 29.82 in. Hg vac (757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb vacuum indicator. At this temperature/pressure, isolated pockets of moisture can turn into ice. The slow rate of evaporation (sublimination) of ice at these low temperatures/ pressures greatly increases dehydration time.

5. Valve off the vacuum pump, stop the pump, and record

the instrument reading.

6. After a 2-hour wait, take another instrument reading. If

the reading has not changed, dehydration is complete. If the reading indicates vacuum loss, repeat Steps 4 and 5.

7. If the reading continues to change after several attempts,

perform a leak test up to the maximum 230 psig (1585 kPa) pressure. Locate and repair the leak, and repeat dehydration.

/s] or larger is recommended) to the refrigerant

Fig. 29 — Dehydration Cold Trap

Water must be within design limits, clean, and treated to ensure proper chiller performance and reduce the potential of tubing damage due to corrosion, scaling, or erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

CheckOptional Pumpout Compressor Water Piping —

are installed, check to ensure the pumpout condenser water has been piped in. Check for ﬁeld-supplied shutoff valves and controls as speciﬁed in the job data. Check for refrigerant leaks on ﬁeld-installed piping. See Fig. 27 and 28.

If the optional storage tank and/or pumpout system

Check Relief Devices — Be sure that relief devices

have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing.

19XL relief valves are set to relieve at the 300 psig

(2068 kPa) chiller design pressure.

Inspect Wiring

Do not check voltage supply without proper equipment and precautions. Serious injury may result. Follow power company recommendations.

Do not apply any kind of test voltage, even for a rotation check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.

1. Examine wiring for conformance to job wiring diagrams and to all applicable electrical codes.

2. On low-voltage compressors (600 v or less) connect voltmeter across the power wires to the compressor starter and measure the voltage. Compare this reading with the voltage rating on the compressor and starter nameplates.

3. Compare the ampere rating on the starter nameplate with the compressor nameplate. The overload trip amps must be 108% to 120% of the rated load amps.

4. The starter for a centrifugal compressor motor must contain the components and terminals required for PIC refrigeration control. Check certiﬁed drawings.

5. Check the voltage to the following components and compare to the nameplate values: oil pump contact, pumpout compressor starter, and power panel.

Page 48

6. Be sure that fused disconnects or circuit breakers have been supplied for the oil pump, power panel, and pumpout unit.

7. Check that all electrical equipment and controls are properly grounded in accordance with job drawings, certiﬁed drawings, and all applicable electrical codes.

8. Make sure that the customer’s contractor has veriﬁed proper operation of the pumps, cooling tower fans, and associated auxiliary equipment. This includes ensuring that motors are properly lubricated and have proper electrical supply and proper rotation.

9. For ﬁeld-installed starters only, test the chiller compressor motor and its power lead insulation resistance with a 500-v insulation tester such as a megohmmeter. (Use a 5000-v tester for motors rated over 600 v.) Factorymounted starters do not require a megohm test.

a. Open the starter main disconnect switch and follow

lockout/tagout rules.

To attach the CCN communication bus wiring, refer to the certiﬁed drawings and wiring diagrams. The wire is inserted into the CCN communications plug (COMM1) on the PSIO module. This plug also is referred to as J5.

NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/ nylon, vinyl, Teﬂon,or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl or Teﬂon with a minimum operating temperature range of –20 C to 60 C is required. See table below for cables that meet the requirements.

MANUFACTURER CABLE NO.

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

If the motor starter is a solid-state starter, the motor leads must be disconnected from the starter before an insulation test is performed. The voltage generated from the tester can damage the starter solid-state components.

b. With the tester connected to the motor leads, take

10-second and 60-second megohm readings as follows:

6-Lead Motor — Tie all 6 leads together and test between the lead group and ground. Next tie leads in pairs, 1 and 4, 2 and 5, and 3 and 6. Test between each pair while grounding the third pair.

3-Lead Motor — Tie terminals 1, 2, and 3 together and test between the group and ground.

c. Divide the 60-second resistance reading by the

10-second reading. The ratio, or polarization index, must be one or higher. Both the 10- and 60-second readings must be at least 50 megohms.

If the readings on a ﬁeld-installed starter are unsatisfactory, repeat the test at the motor with the power leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads.

NOTE: Unit-mounted starters do not have to be megohm tested.

10. Tighten up all wiring connections to the plugs on the SMM, 8-input, and PSIO modules.

11. Ensure that the voltage selector switch inside the power panel is switched to the incoming voltage rating.

12. On chillers with free-standing starters, inspect the power panel to ensure that the contractor has fed the wires into the bottom of the panel. Wiring into the top of the panel can cause debris to fall into the contactors. Clean and inspect the contactors if this has occurred.

Carrier Comfort Network Interface — The Carrier

Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.

The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it; the negative pins must be wired to the negative pins; the signal ground pins must be wired to signal ground pins.

When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. The following color code is recommended:

SIGNAL

TYPE

+ RED 1

Ground WHITE 2

– BLACK 3

CCN BUS CONDUCTOR

INSULATION COLOR

PSIO MODULE

COMM 1 PLUG (J5)

PIN NO.

Check Starter

BE AWARE that certain automatic start arrangements can engage the starter. Open the disconnect ahead of the starter in addition to shutting offthe chiller or pump.

Use the instruction and service manual supplied by the starter manufacturer to verify that the starter has been installed correctly.

The main disconnect on the starter front panel may not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.

Whenever a starter safety trip device activates, wait at least 30 seconds before resetting the safety. The microprocessor maintains its output to the 1CR relay for 10 seconds to determine the fault mode of failure.

MECHANICAL-TYPE STARTERS

1. Check all ﬁeld wiring connections for tightness, clear-

ance from moving parts, and correct connection.

2. Check the contactor(s) to be sure they move freely. Check

the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time. Check all other electro-mechanical devices, e.g., relays, timers, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components.

Page 49

3. Some dashpot-type magnetic overload relays must be filled with oil on the jobsite. If the starter is equipped with devices of this type, remove the ﬂuid cups from these magnetic overload relays. Add dashpot oil to cups per instructions supplied with the starter. The oil is usually shipped in a small container attached to the starter frame near the relays. Use only dashpot oil supplied with the starter. Do not substitute.

Factory-ﬁlled dashpot overload relays need no oil at start-up and solid-state overload relays do not have oil.

4. Reapply starter control power (not main chiller power)to check electrical functions. When using a reduced-voltage starter (such as a wye-delta type) check the transition timer for proper setting. The factory setting is 30 seconds (± 5 seconds), timed closing. The timer is adjustable in a range between 0 and 60 seconds and settings other than the nominal 30 seconds may be chosen as needed (typically 20 to 30 seconds are used).

When the timer has been set, check that the starter (with relay 1CR closed) goes through a complete and proper start cycle.

BENSHAW, INC. SOLID-STATE STARTER

This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on the equipment.

1. Check that all wiring connections are properly terminated to the starter.

2. Verifythat the ground wire to the starter is installed properly and is of sufficient size.

3. Verifythat the motors are properly grounded to the starter.

4. Check that all of the relays are properly seated in their sockets.

5. Verify that the proper ac input voltage is brought into the starter per the certiﬁed drawings.

6. Verifythe initial factory settings of the starting torque and ramp potentiometers are set per the note on the schematic for the starters.

NOTE: The potentiometers are located at the lower left hand corner on the circuit board mounted in front of the starter power stack (Fig. 30 and 31).

The starting torque potentiometer should be set so that when the PIC calls for the motor to start, the rotor should just start to turn. The nominal dial position for a 60 Hz motor is approximately the 11:30 position. The nominal dial position for a 50 Hz motor is approximately in the 9:30 position because the board is turned on its side, so that the 9:00 o’clock position is located where the 6:00 o’clock position would normally be located. The ramp potentiometer should be set so that the motor is up to full speed in 15 to 20 seconds, the bypass contactors have energized, and the auxiliary LCD is energized.

7. Proceed to apply power to the starter.

8. The Power +15 and Phase Correct LEDs should be on. If not, see the starter Troubleshooting Guide section.

LEGEND

1—Phase Voltage Indicator 2—Starter Fault and Run LEDs (5)

• Overtemp

• Ground Fault

• Current Unbalance (CUB) While Stopped

• Current Unbalance

• Run (Start Initiated)

3—Starting Torque Potentiometer 4—Ramp Up Potentiometer 5—Phase Correct LED 6—Relay On LED 7—Power +15 and Auxiliary (Starter

in RUN State) LEDs (Hidden)

8—SCR Indicator LEDs (Hidden) 9—Reset Button

Fig. 30 — Benshaw, Inc. Solid-State Starter

Power Stack

NOTE: Adjustments:

Starting torque — 0% to 100% rated motor torque. Ramp time to full motor voltage — 0.5 seconds to 60 seconds.

Fig. 31 — Ramp Up and Starting Torque

Potentiometers

Page 50

Oil Charge — The 19XL compressor holds approxi-

mately 8 gal. (30 L) of oil. The chiller will be shipped with oil in the compressor. When the sump is full, the oil level should be no higher than the middle of the upper sight glass and minimum level is the bottom of the lower sight glass (Fig. 2A or 2B). If oil is added, it must meet Carrier’s speciﬁcation for centrifugal compressor usage as described in the Oil Speciﬁcation section on page 63. Charge the oil through the oil charging valve, located near the bottom of the transmission housing (Fig. 2A or Fig. 2B). The oil must be pumped from the oil container through the charging valve due to higher refrigerant pressure. The pumping device must be able to lift from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil should only be charged or removed when the chiller is shut down.

Power Up the Controls and Check the Oil Heater

Ensure that an oil level is visible in the compressor

—

before energizing controls. A circuit breaker in the starter energizes the oil heater and the control circuit. When ﬁrst powered, the LID should display the default screen within a short period of time.

The oil heater is energized by powering the control circuit. This should be done several hours before start-up to minimize oil-refrigerant migration. The oil heater is controlled by the PIC and is powered through a contactor in the power panel. Starters contain a separate circuit breaker to power the heater and the control circuit. This set up allows the heater to energize when the main motor circuit breaker is offfor service work or extended shutdowns. The oil heater relay status can be viewed on the Status02 table on the LID. Oil sump temperature can be viewed on the LID default screen.

When the Time/Date is conﬁgured for the ﬁrst time or if power is lost for more than 3 hours, the oil heat algorithm will take effect before the compressor can start. See the Oil Sump Temperature Control section on page 32 for additional information. The oil pump will then energize for 1 to 2 minutes to bring the oil temperature to normal operating temperature. A LOW OIL TEMPERATURE alert will show on the default LID screen if the operator has the controls set to start.

SOFTWARE VERSION — The software version will always be labeled on the PSIO module, and on the back side of the LID module. On both the Controller ID and LID ID display screens, the software version number will also appear.

Set Up Chiller Control Conﬁguration

Do not operate the chiller before the control conﬁgurations have been checked and a Control Test has been satisfactorily completed. Protection by safety controls cannot be assumed until all control conﬁgurations have been conﬁrmed.

As conﬁguration of the 19XL unit is performed, write down all conﬁguration settings. A log, such as the one shown on pages CL-1 to CL-2, provides a convenient list for conﬁguration values.

Input the Design Set Points — Access the LID set

point screen and view/modify the base demand limit set point, and either the LCW set point or the ECW set point. The PIC can control a set point to either the leaving or entering chilled water.This control method is set in the Equipment Conﬁguration table, Conﬁg table.

Inputthe Local OccupiedSchedule (OCCPC01S)

Access the schedule OCCPC01S screen on the LID

—

and set up the occupied time schedule per the customer’s requirements. If no schedule is available, the default is factory set for 24 hours occupied 7 days per week including holidays.

For more information about how to set up a time sched-

ule, see the Controls section, page 11.

The CCN Occupied Schedule should be conﬁgured if a CCN system is being installed or if a secondary time schedule is needed.

NOTE: The default CCN Occupied Schedule is OCCPC03S for Software Version 09 and above; the default is OCCPC02S for Software Version 08 and below.

SelectingRefrigerant Type— The 19XL control must

be conﬁgured for the refrigerant being used, either HCFC-22 or HFC-134a.

TO CONFIRM REFRIGERANT TYPE — Conﬁrm that the correct refrigerant type is indicated by entering the Controls Test tables on the Service menu, Fig. 17. Select REFRIGERANT TYPE. The screen will display the current refrig-

erant setting. Press EXIT out changes.

TO CHANGE REFRIGERANT TYPE — Enter the Controls Test tables on the Service Menu. See Fig. 17. Select

REFRIGERANT TYPE. The screen will display the current refrigerant setting. Press YES rent setting. Next, move to the ATTACH TO NETWORK

DEVICE screen on the Service menu and the ATTACH TO LOCAL DEVICE to upload the new refrigerant tables.

softkey to leave the screen with-

softkey to change the cur-

InputService Conﬁgurations — The following con-

ﬁgurations require the LID screen to be in the Service portion of the menu.

• password

• input time and date

• LID conﬁguration

• controller identiﬁcation

• service parameters

• equipment conﬁguration

• automated control test PASSWORD — When accessing the Service tables, a pass-

word must be entered. All LIDs are initially set for a password of 1-1-1-1. This password may be changed in the LID conﬁguration screen, if desired.

INPUT TIME AND DATE — Access the Time and Date table on the Service menu. Input the present time of day, date, and day of the week. ‘‘Holiday Today’’should only be conﬁgured to ‘‘Yes’’ if the present day is a holiday.

CHANGE LID CONFIGURATION IF NECESSARY— The LID Conﬁguration screen is used to view or modify the LID CCN address, change to English or SI units, and to change the password. If there is more than one chiller at the jobsite, change the LID address on each chiller so that each chiller has its own address. Note and record the new address. Change the screen to SI units as required, and change the password if desired.

Page 51

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY—The controller identiﬁcation screen is used to change the PSIO module address. Change this address for each chiller if there is more than one chiller at the jobsite. Write the new address on the PSIO module for future reference.

Change the LID address if there is more than one chiller on the jobsite. Access the LID conﬁguration screen to view or modify this address.

INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The Equipment Service table has three service tables: Service1, Service2, and Service3.

Conﬁgure SERVICE1 Table — Access Service1 table to modify/view the following to jobsite parameters:

Chilled Medium Water or Brine? Brine Refrigerant Trippoint Usually 3° F (1.7° C) below

Surge Limiting or Hot Gas

Bypass (HGBP) Option

Minimum Load Points

(T1/P1)

Maximum Load Points

(T2/P2)

Amps Correction Factor See Table 6 Motor Rated Load Amps Per job data Motor Rated Line Voltage Per job data Motor Rated Line kW Per job data

Line Frequency 50 or 60 Hz Compressor Starter Type Reduced voltage or full?

NOTE:Other values are left atthe defaultvalues.These maybe changed bythe operator as required. Service2 and Service3tables canbe modiﬁed by the owner/operator as required.

design refrigerant temperature

Is HGBP installed? Per job data —

See Modify Load Points section

Per job data —

See Modify Load Points section

(if kW meter installed)

Modify Minimum and Maximum Load Points (DT1/P1; D T2/P2) If Necessary —These pairs of chiller load points,

located on the Service1 table, determine when to limit guide vane travel or to open the hot gas bypass valve when surge prevention is needed. These points should be set based on individual chiller operating conditions.

If, after conﬁguring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed by the operator.

Example of conﬁguration: Chiller operating parameters Refrigerant used: HCFC-22

Estimated Minimum Load Conditions:

44 F (6.7 C) LCW

45.5 F (7.5 C) ECW

43 F (6.1 C) Suction Temperature

70 F (21.1 C) Condensing Temperature

Estimated Maximum Load Conditions:

44 F (6.7 C) LCW

54 F (12.2 C) ECW

42 F (5.6 C) Suction Temperature

98 F (36.7 C) Condensing Temperature Calculate Maximum Load — To calculate maximum load

points, use design load condition data. If the chiller full load cooler temperature difference is more than 15° F (8.3 C),

estimate the refrigerant suction and condensing temperatures at this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.

Suction Temperature:

42 F (5.6 C) = 71.5 psig (521 kPa) saturated

refrigerant pressure (HCFC-22)

Condensing Temperature:

98 F (36.7 C) = 190 psig (1310 kPa) saturated

refrigerant pressure (HCFC-22)

Maximum Load DT2:

54 – 44 = 10° F (12.2 – 6.7 = 5.5° C)

Maximum Load DP2:

190 – 71.5 = 118.5 psid (1310 – 521 = 789 kPad) To avoid unnecessary surge prevention, add about 10 psid

(70 kPad) to DP2 from these conditions:

DT2 = 10° F (5.5° C) DP2 = 130 psid (900 kPad)

Calculate Minimum Load — To calculate minimum load conditions, estimate the temperature difference that the cooler will have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated pressure and temperature for the particular refrigerant used.

Suction Temperature:

43 F (6.1 C) = 73 psig (503 kPa) saturated

refrigerant pressure (HCFC-22)

Condensing Temperature:

70 F (21.1 C) = 121 psig (834 kPa) saturated

refrigerant pressure (HCFC-22)

Minimum Load DT1:

45.5 – 44 = 1.5° F (7.5 – 6.7 = 0.8° C)

Minimum Load DP1:

121 – 73 = 45 psid (834 – 503 = 331 kPad) Again, to avoid unnecessary surge prevention, add 10 psid

(70 kPad) at DP1 from these conditions:

DT1 = 1.5 F (0.8 C) DP1 = 60 psid (410 kPad)

If surge prevention occurs too soon or too late:

LOAD At low

loads

(,50%) At high

loads

(.50%)

SURGE PREVENTION SURGE PREVENTION

OCCURS TOO SOON OCCURS TOO LATE

Increase P1 by

10 psid (70 kPad)

Increase P2 by

10 psid (70 kPad)

Decrease P1 by

10 psid (70 kPad)

Decrease P2 by

10 psid (70 kPad)

Modify Amp Correction Factors — To modify the amp correction factor, use the values listed in Table 6. Enter the appropriate amp correction factor in the Service1 table of Equipment Service.

Page 52

Table 6 — Amps Correction Factors

for 19XL Motors

VOLT/

CB CC CD CE CL CM CN CP CQ CR

200/60 4536323222 208/60 5558424222 220/60 3422231111 230/60 5644352222

240/60 5644382222 360/60 4242221111 380/60 7464453222 400/60 7584453234

440/60 3322111134 460/60 5432222256 480/60 7543333378 550/60 4232123222

575/60 4442234333

600/60 8564346544 3300/60 4441233322 2400/60 4433232233

4160/60 4433232233

220/50 3122232111

230/50 4223243211

240/50 5354353322

320/50 2222111133

346/50 4433321234

360/50 5544422288

380/50 5233324222

400/50 6445436433

415/50 8556547544 3000/50 3223231212 3300/50 4333342212

MOTOR CODE

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The Equipment Conﬁguration table has tables to select and view or modify. Carrier’s certiﬁed drawings will have the conﬁguration values required for the jobsite. Modify these tables only if requested.

Conﬁg T ableModiﬁcations — Change the values in this table per job data. See certiﬁed drawings for values. Modiﬁcations include:

• chilled water reset

• entering chilled water control (Enable/Disable)

• 4-20 mA demand limit

• auto. restart option (Enable/Disable)

• remote contact option (Enable/Disable) Owner-Modiﬁed CCN Tables—The following tables are de-

scribed for reference only. Occdef Table Modiﬁcations — The Occdef tables contain

the Local and CCN time schedules, which can be modiﬁed here, or in the Schedule screen as described previously.

Holidef TableModiﬁcations — The Holidef tables conﬁgure the days of the year that holidays are in effect. See the holiday paragraphs in the Controls section for more details.

Brodefs Table Modiﬁcations — The Brodefs table deﬁnes the outside-air temperature sensor and humidity sensor if one is to be installed. It will deﬁne the start and end of daylight savings time. Enter the dates for the start and end of daylight savings if required for the location. Brodefs also will activate the Broadcast function which enables the holiday periods that are deﬁned on the LID.

Other Tables— TheAlarmdef, Cons-def, and Runt-def contain tables for use with a CCN system. See the applicable CCN manual for more information on these tables. These tables can only be deﬁned through a CCN Building Supervisor.

CHECK VOLTAGE SUPPLY — Access the Status 01 screen and read the actual line voltage. This reading should be equal

to the incoming power to the starter. Use a voltmeter to check incoming power at the starter power leads. If the readings are not equal, an adjustment can be made to the 24-v input to the SMM at the potentiometer located in the low-voltage section to equalize the two readings.

PERFORMAN AUTOMATED CONTROL TEST — Check the safety controls status by performing an automated controls test. Access the Control Test table and select the Automated Tests function (Table 8).

The Automated Control Test will check all outputs and inputs for function. It will also set the refrigerant type. The compressor must be in the OFF mode in order to operate the controls test and the 24-v input to the SMM must be in range (per line voltage percent on Status01 table). The OFF mode is caused by pressing the STOP pushbutton on the LID. Each test will ask the operator to conﬁrm that the operation is occurring, and whether or not to continue. If an error occurs, the operator has the choice to try to address the problem as the test is being done, or to note the problem and proceed to the next test.

NOTE: If during the Control Test the guide vanes do not open, check to see that the low pressure alarm is not active. (This will cause the guide vanes to close).

NOTE: The oil pump test will not energize the oil pump if cooler pressure is below –5 psig (–35 kPa).

When the test is ﬁnished, or the EXIT

softkey is pressed,

the test will be stopped and the Control Test menu will be displayed. If a speciﬁc automated test procedure is not completed, access the particular control test to test the function when ready. The Control Test menu is described as follows:

Automated Tests As described above, a complete PSIO Thermistors Check of all PSIO thermistors only.

Options Thermistors Check of all options boards Transducers Check of all transducers.

Guide Vane Actuator Check of the guide vane operation. Pumps Check operation of pump outputs,

Discrete Outputs Activation of all on/off outputs or Pumpdown/Lockout Pumpdown prevents the low refrig-

Terminate Lockout To charge refrigerant and enable

Refrigerant Type* Sets type of refrigerant used:

*Make sure to Attach to Local Device after changing refrigerant type.

Refer to Selecting Refrigerant Type section on page 50.

control test.

thermistors.

either all pumps can be activated, or individual pumps. The test will also test the associated input such as ﬂow or pressure.

individually. erant alarm during evacuation so

refrigerant can be removed from the unit, locks the compressor off, and starts the water pumps.

the chiller to run after pumpdown lockout.

HCFC-22 or HFC-134a.

Check Optional Pumpout System Controls and Compressor—

fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 220 ± 5 psig (1250 ± 34 kPa), and automatically reset at 185 + 0,

−7 psig (1280 +0,–48 kPa) with HCFC-22. HFC-134a units open at 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Check that the water-cooled condenser has been connected.

Controls include an on/offswitch, a 3-amp

Page 53

Loosen the compressor holddown bolts to allow free spring travel. Open the compressor suction and discharge service valves. Check that oil is visible in the compressor sight glass. Add oil if necessary.

See Pumpout and Refrigerant Transfer Procedures and Optional Pumpout System Maintenance sections, pages 59 and 65, for details on transfer of refrigerant, oil speciﬁcations, etc.

HighAltitude Locations — Recalibration of the pres-

sure transducers will be necessary as the chiller was initially calibrated at sea level. Please see the calibration procedure in the Troubleshooting Guide section.

Charge Refrigerant into Chiller

The transfer, addition, or removal of refrigerant in spring isolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions.

The standard 19XL chiller will have the refrigerant already charged in the vessels. The 19XL may be ordered with a nitrogen holding charge of 15 psig (103 kPa). Evacuate the entire chiller, and charge chiller from refrigerant cylinders.

19XL CHILLER EQUALIZATION WITHOUT PUMPOUT UNIT

When equalizing refrigerant pressure on the 19XL chiller after service work or during the initial chiller start-up, do not use the discharge isolation valve to equalize. The motor cooling isolation valve or charging hose (connected between pumpout valves on top of cooler and condenser) is to be used as the equalization valve.

To equalize the pressure differential on a refrigerant isolated 19XL chiller, use the TERMINATE LOCKOUT function of the Control Test in the SERVICE menu. This will help to turn on pumps and advise the proper procedure. The following procedure describes how to equalize refrigerant pressure on an isolated 19XL chiller without a pumpout unit:

1. Access TERMINATE LOCKOUT function on the Con-

trol Test.

2. Turn on the chilled water and condenser water pumps to

ensure against freezing.

3. Slowly open the refrigerant cooling isolation valve.

The chiller cooler and condenser pressures will gradually equalize. This process will take approximately 15 minutes.

4. Once the pressures have equalized, the cooler isolation

valve, the condenser isolation valve, and the hot gas bypass isolation valve may now be opened. Refer to Fig. 27 and 28, valves 11, 12, and 14.

Whenever turning the discharge isolation valve, be sure to reattach the valve locking device. This will prevent the valve from opening or closing during service work or during chiller operation.

Table 7 — Control Test Menu Functions

TESTS TO BE

PERFORMED

1. Automated Tests* Operates the second through

2. PSIO Thermistors Entering chilled water

3. Options Thermistors Common chilled water supply

4. Transducers Evaporator pressure

5. Guide Vane Actuator Open

6. Pumps All pumps or individual pumps may

7. Discrete Outputs All outputs or individual outputs may

8. Pumpdown/Lockout When using pumpdown/lockout,

9. Terminate Lockout Starts pumps and monitors ﬂows

10. Refrigerant Type Sets refrigerant type used:

*During any of the tests that are not automated, an out-of-range read-

ing will have an asterisk (*) next to the reading and a message will be displayed.

seventh tests Leaving chilled water

Entering condenser water Leaving condenser water Discharge temperature Bearing temperature Motor winding temperature Oil sump temperature

sensor Common chilled water return sensor Remote reset sensor Temperature sensor — Spare 1

Condenser pressure Oil pressure differential Oil pump pressure

Close be activated:

be energized:

observe freeze up precautions when removing charge:

Instructs operator as to which valves to close and when

Starts chilled water and condenser water pumps and conﬁrms ﬂows

Monitors — Evaporator pressure

Turns pumps off after pumpdown Locks out compressor

Instructs operator as to which values to open and when

Monitors — Evaporator pressure

Terminates compressor lockout

NOTE: Be sure to ATTACH TO LOCAL DEVICE after changing refrigerant type.

See Attach to Network Device Control section, page 37.

DEVICES TESTED

Spare 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 9

Oil pump — Conﬁrm pressure Chilled water pump — Conﬁrm ﬂow Condenser water pump — Conﬁrm

ﬂow

Hot gas bypass relay Oil heater relay Motor cooling relay Tower fan relay Alarm relay Shunt trip relay

Condenser pressure Evaporator temperature during pumpout procedures

Condenser pressure Evaporator temperature during charging process

HCFC-22 or HFC-134a.

Page 54

19XL CHILLER EQUALIZATION WITH PUMPOUT UNIT — The following procedure describes how to equalize refrigerant pressure on an isolated 19XL chiller using the pumpout unit.

1. Access the TERMINATE LOCKOUT mode in the Control Test.

2. Turn on the chilled water and condenser water pumps to prevent possible freezing.

3. Open valve 4 on the pumpout unit and open valves 1a and 1b on the chiller cooler and condenser, Fig. 27 and

28. Slowly open valve 2 on the pumpout unit to equalize the pressure. This process will take approximately 15 minutes.

4. Once the pressures have equalized, the discharge isolation valve, cooler isolation valve, optional hot gas bypass isolation valve, and the refrigerant isolation valve can be opened. Close valves 1a and 1b, and all pumpout unit valves.

Whenever turning the discharge isolation valve, be sure to reattach the valve locking device. This will prevent the valve from opening or closing during service work or during chiller operation.

The full refrigerant charge on the 19XL will vary with chiller components and design conditions, indicated on the job data speciﬁcations. An approximate charge may be found by adding the condenser charge to the cooler charge listed in Table 8.

Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups. Use the Control Test Terminate Lockout to monitor conditions and start the pumps.

If the chiller has been shipped with a holding charge, the refrigerant will be added through the refrigerant charging valve (Fig. 27 and 28, valve 7) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the

vessels. Charge the refrigerant as a gas until the system pressure exceeds 68 psig (469 kPa); [35 psig (141 kPa)]. After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all of the recommended refrigerant charge has been added.

TRIMMING REFRIGERANT CHARGE — The 19XL is shipped with the correct charge for the design duty of the chiller.Trimming the charge can be best accomplished when design load is available. To trim, check the temperature difference between leaving chilled water temperature and cooler refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the temperature difference to design conditions or minimum differential.

Table 8 — Refrigerant Charges*

19XL TOTAL REFRIGERANT CHARGE

COOLER

SIZE

40 1420 640 1100 499 900 409 41 1490 680 1150 522 950 431 42 1550 700 1250 568 1000 454

43 1600 730 1350 613 1050 477 50 1850 840 1500 681 1100 499 51 1900 860 1600 726 1200 545

52 1980 900 1750 795 1300 590 53 2050 930 1850 840 1350 613 55 — — 1900 863 1550 704

56 — — 2200 999 1650 749 57 — — 2500 1135 1750 795 58 — — 2700 1226 1900 863

*DesignI chillers use HCFC-22. Design II chillers use either HCFC-22

or HFC-134a.

NOTES:

1. The size of the cooler determines refrigerant charge for the entire chiller.

2. Design I chillers have ﬂoat chambers.

3. Design II chillers have linear ﬂoats.

Design I

Chiller

lb kg lb kg lb kg

HCFC-22 HFC-134a

Design II

Chiller

Page 55

INITIAL START-UP

Preparation—

1. Power is on to the main starter, oil pump relay, tower fan starter, oil heater relay, and the chiller control center.

2. Cooling tower water is at proper level, and at or below design entering temperature.

3. Chiller is charged with refrigerant and all refrigerant and oil valves are in their proper operating position.

4. Oil is at the proper level in the reservoir sight glasses.

5. Oil reservoir temperature is above 140 F (60 C) or refrigerant temperature plus 50° F (28° C).

6. Valves in the evaporator and condenser water circuits are open.

NOTE: If pumps are not automatic, make sure water is circulating properly.

7. Solid-state starter checks: The Power +15 and the Phase Correct LEDs must be lit before the starter will energize. If the Power +15 LED is not on, incoming voltage is not present or is incorrect. If the Phase Correct LED is not lit, rotate any 2 incoming phases to correct the phasing.

Do not permit water or brine that is warmer than 110 F (43 C) to ﬂow through the cooler or condenser. Refrigerant overpressure may discharge through the relief devices and result in the loss of refrigerant charge.

8. Press RELEASE to automate the chiller start/stop value on the Status01 table to enable the chiller to start. The

initial factory setting of this value is overridden to stop in order to prevent accidental start-up.

Before starting the chiller, check that the:

Manual Operation of the Guide Vanes — Manual

operation of the guide vanes is helpful to establish a steady motor current for calibration of the motor amps value.

In order to manually operate the guide vanes, it is necessary to override the TARGET GUIDE VANE POSITION value which is accessed on the Status01 table. Manual control is indicated by the word ‘‘SUPVSR!’’ ﬂashing after the target value position. Manual control is also indicated on the default screen on the run status line.

1. Access the Status01 table and look at the target guide vane

position (Fig. 16). If the compressor is off, the value will read zero.

2. Move the highlight bar to the TARGET GUIDE VANE

POSITION line and press the SELECT

3. Press ENTER

will now read a value of zero, and the word ‘‘SUPVSR!’’ will ﬂash.

4. Press the SELECT

RELEASE

MATIC mode. After a few seconds the ‘‘SUPVSR!’’ will disappear.

to override the automatic target. The screen

softkey, and then press

softkey to release the vanes to AUTO-

softkey.

Dry Run to Test Start-Up Sequence

1. Disengage the main motor disconnect on the starter front

panel. This should only disconnect the motor power. Power to the controls, oil pump, and starter control circuit should still be energized.

2. Look at the default screen on the LID: the Status mes-

sage in the upper left-hand corner will read, ‘‘Manually Stopped.’’ Press CCN or Local to start. If the chiller

controls do not go into start mode, go to the Schedule screen and override the schedule or change the oc-

cupied time. Press the LOCAL up sequences.

3. Check that chilled water and condenser water pumps energize.

4. Check that the oil pump starts and pressurizes the lubrication system. After the oil pump has run about 11 seconds, the starter will be energized and go through its start-up sequence.

5. Check the main contactor for proper operation.

6. The PIC will eventually show an alarm for motor amps not sensed. Reset this alarm and continue with the initial start-up.

softkey to begin the start-

Check Rotation

1. Engage the main motor disconnect on the front of the starter panel. The motor is now ready for rotation check.

2. After the default screen Status message states ‘‘Ready for Start’’pressthe LOCAL be made by the control.

3. When the starter is energized and the motor begins to turn. Check for clockwise rotation (Fig. 32).

IF ROTATION IS PROPER, allow the compressor to come up to speed.

IF THE MOTOR ROTATION IS NOT CLOCKWISE (as viewed through the sight glass), reverse any 2 of the 3 incoming power leads to the starter and recheck rotation.

NOTE: Solid-state starters have phase protection and will not allow a start if the phase is not correct. Instead, a Starter Fault message will occur if this happens.

Do not check motor rotation during coastdown. Rotation may have reversed during equalization of vessel pressures.

Fig. 32 — Correct Motor Rotation

NOTES ON SOLID-STATE STARTERS (Benshaw, Inc.)

1. When the compressor is energized to start by the 1CR relay, conﬁrm that the Relay On LED is lit on the starter SCR control board. The compressor motor should start to turn immediately when this light comes on. If not, adjust the start torque potentiometer in a clockwise direction.

softkey; start-up checks will

Page 56

2. Observe that all 6-gate LEDs are lit on the starter SCR control board.

3. The factory setting should bring the motor to full voltage in 15 to 30 seconds. If the setting is not correct, adjust the ramp potentiometer counterclockwise for a shorter time, clockwise for a longer time. (See Fig. 5 for starter component placement.)

Check Oil Pressure and Compressor Stop

1. When the motor is up to full speed, note the differential oil pressure reading on the LID default screen. It should be between 18 and 30 psid (124 to 206 kPad).

2. Press the Stop button and listen for any unusual sounds from the compressor as it coasts to a stop.

Calibrate Motor Current

1. Make sure that the compressor motor rated load amps in the Service1 table has been conﬁgured. Place an ammeter on the line that passes through the motor load current transfer on the motor side of the power factor correction capacitors (if provided).

2. Start the compressor and establish a steady motor current value between 70% and 100% RLA by manually overriding the guide vane target value on the LID and setting the chilled water set point to a low value. Do not exceed 105% of the nameplate RLA.

3. When a steady motor current value in the desired range is met, compare the compressor motor amps value on the Status01 table to the actual amps shown on the ammeter on the starter. Adjust the amps value on the LID to the actual value seen at the starter if there is a difference.

Highlight the amps value then press SELECT Press INCREASE to that indicated on the ammeter. Press ENTER

equal.

4. Make sure that the target guide vane position is released into AUTOMATIC mode.

or DECREASE to bring the value

when

To Prevent Accidental Start-Up — The PIC can be

set up so that start-up of the unit is more difficult than just pressing the LOCAL ice or when necessary. By accessing the Status01 table, and

highlighting the chiller Start/Stop line, the value can be overridden to stop by pressing SELECT

STOP

after the value. When attempting to restart, remember to release the override. The default chiller message line will also state that the Start/Stop has been set to ‘‘Start’’or ‘‘Stop’’ when the value is overridden.

and ENTER softkeys. ‘‘SUPVSR’’ will appear

or CCN softkeys during chiller serv-

and then the

Check Chiller Operating Condition — Check to

be sure that chiller temperatures, pressures, water ﬂows, and oil and refrigerant levels indicate that the system is functioning properly.

Instructthe Customer Operator— Check to be sure

that the operator(s) understand all operating and maintenance procedures. Point out the various chiller parts and explain their function as part of the complete system.

COOLER-CONDENSER — Float chamber, relief devices, refrigerant charging valve, temperature sensor locations, pressure transducer locations, Schrader ﬁttings, waterboxes and tubes, and vents and drains.

OPTIONAL STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices.

MOTOR COMPRESSOR ASSEMBLY — Guide vane actuator, transmission, motor cooling system, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil ﬁlter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.

MOTOR COMPRESSOR LUBRICATION SYSTEM — Oil pump, cooler ﬁlter, oil heater, oil charge and speciﬁcation, operating and shutdown oil level, temperature and pressure, and oil charging connections.

CONTROL SYSTEM — CCN and Local start, reset, menu, softkey functions, LID operation, occupancy schedule, set points, safety controls, and auxiliary and optional controls.

AUXILIARYEQUIPMENT— Starters and disconnects, separate electrical sources, pumps, and cooling tower.

DESCRIBE CHILLER CYCLES — Refrigerant, motor cooling, lubrication, and oil reclaim.

REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importance of maintaining a leak-free chiller.

SAFETYDEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.

CHECK OPERATOR KNOWLEDGE — Start, stop, and shutdown procedures; safety and operating controls; refrigerant and oil charging; and job safety.

REVIEW THE START-UP, OPERATION,AND MAINTENANCE MANUAL

OPERATING INSTRUCTIONS

Operator Duties

1. Become familiar with refrigeration chiller and related equipment before operating the chiller.

2. Prepare the system for start-up, start and stop the chiller, and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any abnormal readings.

4. Inspect the equipment, make routine adjustments, and perform a Control Test. Maintain the proper oil and refrigerant levels.

5. Protect the system from damage during shutdown periods.

6. Maintain the set point, time schedules, and other PIC functions.

Prepare the Chillerfor Start-Up — Follow the steps

described in the Initial Start-Up section, page 55.

To Start the Chiller

1. Start the water pumps, if they are not automatic.

2. On the LID default screen, press the LOCAL

softkey to start the system. If the chiller is in

CCN

the OCCUPIED mode, and the start timers have expired, the start sequence will start. Follow the procedure described in the Start-Up/Shutdown/Recycle section, page 39.

Check the Running System — After the compres-

sor starts, the operator should monitor the LID display and observe the parameters for normal operating conditions:

1. The oil reservoir temperature should be above 140 F (60 C) during shutdown, and above 100 F (38 C) during compressor operation.

Page 57

2. The bearing oil temperature accessed on the Status01 table should be 120 to 165 F (49 to 74 C). If the bearing temperature reads more than 180 F (83 C) with the oil pump running, stop the chiller and determine the cause of the high temperature. Do not restart the chiller until corrected.

3. The oil level should be visible anywhere in one of the two sight glasses. Foaming of the oil is acceptable as long as the oil pressure and temperature are within limits.

4. The oil pressure should be between 18 and 30 psid (124 to 207 kPad), as seen on the LID default screen. Typically the reading will be 18 to 25 psid (124 to 172 kPad) at initial start-up.

5. The moisture indicator sight glass on the refrigerant motor cooling line should indicate refrigerant ﬂow and a dry condition.

6. The condenser pressure and temperature varies with the chiller design conditions. Typically the pressure will range between 100 and 210 psig (690 to 1450 kPa) with a corresponding temperature range of 60 to 105 F (15 to 41 C). The condenser entering water temperature should be controlled below the speciﬁed design entering water temperature to save on compressor kilowatt requirements.

7. Cooler pressure and temperature also will vary with the design conditions. Typical pressure range will be between 60 and 80 psig (410 and 550 kPa), with temperature ranging between 34 and 45 F (1 and 8 C).

8. The compressor may operate at full capacity for a short time after the pulldown ramping has ended, even though the building load is small. The active electrical demand setting can be overridden to limit the compressor IkW, or the pulldown rate can be decreased to avoid a high demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate. It is accessed on the Equipment Conﬁguration, Conﬁg table (Table 2, Example 5).

To Stop the Chiller

1. The occupancy schedule will start and stop the chiller automatically once the time schedule is set up.

2. By pressing the STOP button for one second, the alarm light will blink once to conﬁrm that the button has been pressed, then the compressor will follow the normal shutdown sequence as described in the Controls section. The

chiller will not restart until the CCN or LOCAL softkey is pressed. The chiller is now in the OFF mode.

If the chiller fails to stop, in addition to action that the PIC will initiate, the operator should close the guide vanes by overriding the guide vane target to zero to reduce chiller load; then by opening the main disconnect. Do not attempt to stop the chiller by opening an isolating knife switch. High intensity arcing may occur. Do not re- start the chiller until the problem is diagnosed and corrected.

After Limited Shutdown — No special preparations

should be necessary. Follow the regular preliminary checks and starting procedures.

ExtendedShutdown— The refrigerant should be trans-

ferred into the storage vessel (if supplied; see Pumpout and Refrigerant Transfer Procedures) in order to reduce chiller pressure and possibility of leaks. Maintain a holding charge

of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant to prevent air from leaking into the chiller.

If freezing temperatures are likely to occur in the chiller area, drain the chilled water, condenser water, and the pumpout condenser water circuits to avoid freeze-up. Keep the waterbox drains open.

Leave the oil charge in the chiller with the oil heater and controls energized to maintain the minimum oil reservoir temperature.

After Extended Shutdown — Be sure that the water

system drains are closed. It may be advisable to ﬂush the water circuits to remove any soft rust which may have formed. This is a good time to brush the tubes if necessary.

Check the cooler pressure on the LID default screen, and compare to the original holding charge that was left in the chiller. If (after adjusting for ambient temperature changes) any loss in pressure is indicated, check for refrigerant leaks. See Check Chiller Tightness section, page 41.

Recharge the chiller by transferring refrigerant from the storage tank (if supplied). Follow the Pumpout and Refrigerant Transfer Procedures section, page 59. Observe freeze-up precautions.

Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the compressor oil level appears abnormally high, the oil may have absorbed refrigerant. Make sure that the oil temperature is above 140 F (60 C) or cooler refrigerant temperature plus 50° F (27° C).

Cold Weather Operation — When the entering con-

denser water drops very low, the operator should automatically cycle the cooling tower fans off to keep the temperature up. Piping may also be arranged to bypass the cooling tower. The PIC controls have a low limit tower fan relay (PR3) that can be used to assist in this control.

Manual Guide Vane Operation — Manual opera-

tion of the guide vanes in order to check control operation or control of the guide vanes in an emergency operation is possible by overriding the target guide vane position. Access the Status01 table on the LID and highlight TARGET GUIDE VANE POSITION. To control the position, enter a percentage of guide vane opening that is desired. Zero percent is fully closed, 100% is fully open. To release the guide vanes to AUTOMATIC mode, press the

RELEASE

NOTE: Manual control will increase the guide vanes and override the pulldown rate during start-up. Motor current above the electrical demand setting, capacity overrides, and chilled water below control point will override the manual target and close the guide vanes. For descriptions of capacity overrides and set points, see the Controls section.

softkey.

Refrigeration Log — A refrigeration log, such as

the one shown in Fig. 33, provides a convenient checklist for routine inspection and maintenance and provides a continuous record of chiller performance. It is an aid in scheduling routine maintenance and in diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to that shown. Automatic recording of PIC data is possible through the use of CCN devices such as the Data Collection module and a Building Supervisor. Contact your Carrier representative for more information.

Page 58

Date

REMARKS

ATOR

OPER-

FLA

Oil Motor

BEARING

INITIALS

(or vane

position)

Amperage

Level

Temp

(reservoir)

Diff.

Press.

TEMP

REFRIGERATION LOG CARRIER 19XT HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

CHILLER MODEL NO. CHILLER SERIAL NO. REFRIGERANT TYPE

Refrigerant Water Refrigerant Water

Pressure Temp

Fig. 33 — Refrigeration Log

Press. Temp

Pressure Temp

In Out GPM In Out In Out GPM In Out

Press. Temp

TIME

Plant

DATE COOLER CONDENSER COMPRESSOR

REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water drained from dehydrator. Include amounts.

Page 59

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES

Preparation —

an optional storage tank or pumpout system, or a pumpout compressor. The refrigerant can be pumped for service work to either the cooler/compressor vessel or the condenser vessel by using the optional pumpout system. If a storage tank is supplied, the refrigerant can be isolated in the external storage tank. The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuations.

The 19XL may come equipped with

Operating the Optional Pumpout Compressor

1. Be sure that the suction and the discharge service valves on the optional pumpout compressor are open (backseated) during operation. Rotate the valve stem fully counterclockwise to open. Frontseating the valve closes the refrigerant line and opens the gage port to compressor pressure.

2. Make sure that the compressor holddown bolts have been loosened to allow free spring travel.

3. Open the refrigerant inlet valve on the pumpout compressor.

4. Oil should be visible in the pumpout compressor sight glass under all operating conditions and during shutdown. If oil is low, add oil as described under Optional Pumpout System Maintenance section, page 65. The pumpout unit control wiring schematic is detailed in Fig. 34.

LEGEND

C—Contactor FU — Fuse, 3 Amps HP — High-Pressure Cutout OL — Compressor Overload T’STAT — Internal Thermostat

Compressor Terminal Contactor Terminal

Overload Terminal Pumpout Unit Terminal

*Bimetal thermal protector imbedded in motor winding.

Fig. 34 — 19XL Pumpout Unit

Wiring Schematic

TO READ REFRIGERANT PRESSURES during pumpout or leak testing:

1. The LID display on the chiller control center is suitable for determining refrigerant-side pressures and low (soft) vacuum. For evacuation or dehydration measurement, use a quality vacuum indicator or manometer to ensure the desired range and accuracy. This can be placed on the Schrader connections on each vessel by removing the pressure transducer.

2. To determine storage tank pressure, a 30 in.-0-400 psi (-101-0-2760 kPa) gage is attached to the vessel.

3. Refer to Fig. 27, 28, and 35 for valve locations and numbers.

Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping if springs have not been blocked in both up and down directions.

Chillers with Pumpout Storage Tanks — If the

chiller has isolation valves, leave them open for the following procedures. The letter ‘‘C’’ describes a closed valve. See Fig. 16, 17, 27, and 28.

TRANSFER REFRIGERANT FROM STORAGETANKTO CHILLER

1. Equalize refrigerant pressure. a. Use the Control Test Terminate Lockout to turn on

water pumps and monitor pressures.

b. Close pumpout unit/storage tank valves 2, 4, 5, 8, and

10 and close chiller charging valve 7; open chiller isolation valves 11, 12, 13, and 14 (if present).

c. Open pumpout unit/storage tank valves 3 and 6, open

chiller valves 1a and 1b.

OIL RETURN LINE CONNECTION

CONDENSER WATER CONNECTIONS

VENT VALVE 8

REFRIGERANT INLET VALVE

PUMPOUT STARTER PANEL

Fig. 35 — Optional Pumpout Unit

VALVE 1a1b234 567 81011121314 CONDITION CCCCCC

d. Gradually crack open valve 5 to increase chiller pres-

sure to 68 psig (469 kPa), [35 psig (141 kPa)]. Slowly feed refrigerant to prevent freeze up.

e. Open valve 5 fully after the pressure rises above the

freeze point of the refrigerant. Open liquid line valves 7 and 10 until refrigerant pressure equalizes.

VALVE 1a1b23456781011121314 CONDITION CC C

Page 60

2. Transfer remaining refrigerant. a. Close valve 5 and open valve 4.

VALVE 1a1b23456781011121314 CONDITION CCC

b. Turn off the chiller water pumps through the LID. c. Turn off the pumpout condenser water, and turn on the

pumpout compressor to push liquid out of the storage

tank. d. Close liquid line valve 7. e. Turn off the pumpout compressor. f. Close valves 3 and 4. g. Open valves 2 and 5.

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14 CONDITION CC CC

h. Turn on pumpout condenser water. i. Run the pumpout compressor until the storage tank

pressure reaches 5 psig (34 kPa) (18 in. Hg [40 kPa

absolute] if repairing the tank). j. Turn off the pumpout compressor. k. Close valves 1a, 1b, 2, 5, 6, and 10.

VALVE 1a1b23456781011121314 CONDITION C C CCCCCCCC

l. Turn off pumpout condenser water.

TRANSFER THE REFRIGERANT FROM CHILLER TO STORAGE TANK

1. Equalize refrigerant pressure. a. Valve positions:

VALVE 1a1b234 567 81011121314 CONDITION CCCCCC

b. Slowly open valve 5 and liquid line valves 7 and 10

to allow liquid refrigerant to drain by gravity into the pumpout storage tank.

VALVE 1a1b23456781011121314 CONDITION CC C

2. Transfer the remaining liquid. a. Turn off pumpout condenser water. Place valves in the

following positions:

VALVE 1a1b23 45678101121314 CONDITION CC C

b. Run the pumpout compressor for approximately30 min-

utes; then, close valve 10.

VALVE 1a1b23456781011121314 CONDITION CC CC

c. Turn off the pumpout compressor.

3. Remove any remaining refrigerant. a. Turn on chiller water pumps using the Control Test

Pumpdown. b. Turn on pumpout condenser water. c. Place valves in the following positions:

VALVE 1a1b23456781011121314 CONDITION CCCC

d. Run the pumpout compressor until the chiller pres-

sure reaches 65 psig (448 kPa) [30 psig (207 kPa)],

then shut off the pumpout compressor. Warm condenser water will boil off any entrapped liquid refrigerant and chiller pressure will rise.

e. When the pressure rises to 70 psig (483 kPa) [40 psig

(276 kPa)], turn on the pumpout compressor until the pressure again reaches 65 psig (448 kPa) [30 psig (207 kPa)], and then turn off the compressor. Repeat this process until the pressure no longer rises, then turn on the pumpout compressor and pump out until the pressure reaches 18 in. Hg (40 kPa absolute).

f. Close valves 1a, 1b, 3, 4, 6, and 7.

VALVE 1a1b23456781011121314 CONDITION C C CCCCCCCC

g. Turn off the pumpout condenser water and continue

with the Control Test for Pumpdown, which will lock out the chiller compressor for operation.

4. Establish vacuum for service. a. In order to conserve refrigerant, operate the pump-

out compressor until the chiller pressure is reduced to 18 in. Hg vac, ref 30 in. bar. (40 kPa abs.) following Step 3e.

Chillers with Isolation Valves

TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL — For chillers with isolation valves, refrigerant can be transferred from one chiller vessel to another without the need for an external storage tank and valve 7 stays closed. See Fig. 27, 28, and 35 for valve locations.

1. Push refrigerant into chiller condenser. a. Valve positions:

VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITION CC C CCC

b. Turn off chiller water pumps and pumpout unit con-

denser water.

c. Turn on pumpout compressor to push liquid out of the

cooler/compressor.

d. When all liquid has been pushed into the condenser,

close cooler isolation valve 11.

e. Access the Control Test, Pumpdown table on the LID

display to turn on the chiller water pumps.

f. Turn off the pumpout compressor.

2. Evacuate gas from cooler/compressor vessel. a. Close pumpout valves 2 and 5, and open valves 3

and 4.

VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITION C CCCCCC

b. Turn on pumpout condenser water. c. Run pumpout until the compressor reaches 18 in. Hg

vac (40 kPa abs.). Monitor pressures on the LID and

on refrigerant gages. d. Close valve 1a. e. Turn off pumpout compressor. f. Close valves 1b, 3, and 4.

VALVE 1a1b2345811121314 CONDITION C C CCCCCC C C C

g. Turn off pumpout condenser water. h. Proceed to Pumpdown test on the LID to turn offchiller

water pumps and lock out chiller compressor.

Page 61

TRANSFER ALL REFRIGERANT TO CHILLER COOLER/COMPRESSOR VESSEL

1. Push refrigerant into the chiller cooler vessel. a. Valve positions:

VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITION C CC CCC

b. Turn off chiller water pumps and pumpout condenser

water.

c. Turn on pumpout compressor to push refrigerant out

of the condenser.

d. When all liquid is out of the condenser, close cooler

isolation valve 11.

e. Turn off the pumpout compressor.

2. Evacuate gas from the chiller condenser vessel. a. Access the Control Test Pumpdown table on the LID

display to turn on the chiller water pumps.

b. Close pumpout valves 3 and 4; open valves 2 and 5.

VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITION CC CCCCC

c. Turn on pumpout condenser water. d. Run the pumpout compressor until the chiller com-

pressor reaches 18 in. Hg vac (40 kPa abs.). Monitor

pressure at the LID and refrigerant gages. e. Close valve 1b. f. Turn off pumpout compressor. g. Close valves 1a, 2, and 5.

VALVE 1a1b2345811121314 CONDITION C C CCCCCC C C C

h. Turn off pumpout condenser water. i. Proceed to the Pumpdown test on the LID to turn off

chiller water pumps and lockout chiller compressor.

RETURN REFRIGERANT TO NORMAL OPERATING CONDITIONS

1. Be sure that the chiller vessel that was opened has been evacuated.

2. Access the Control TestTerminateLockout table to view vessel pressures and turn on chiller water pumps.

3. Open valves 1a, 1b, and 3.

VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITION C CCCC C C C

4. Crack open valve 5, gradually increasing pressure in the evacuated vessel to 68 psig (469 kPa) [35 psig (141 kPa)]. Feed refrigerant slowly to prevent tube freeze up.

5. Leak test to ensure vessel integrity.

6. Open valve 5 fully.

VALVE 1a1b2345811121314 CONDITION CCCCCCC

7. Open valve 11 to equalize the liquid refrigerant level between vessels.

8. Close valves 1a, 1b, 3, and 5.

9. Open isolation valves 11, 12, 13, and 14 (if present).

VALVE 1a1b2345811121314 CONDITION C C CCCCC

10. Proceed to Terminate Pumpdown Lockout test to turn off water pumps and enable the chiller compressor for start-up.

GENERAL MAINTENANCE

Refrigerant Properties —

is the standard refrigerant in the 19XL. At normal atmospheric pressure, HCFC-22 will boil at –41 F (–40 C) and HFC-134a will boil at –14 F (–25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerants are practically odorless when mixed with air. Both refrigerants are non-combustible at atmospheric pressure. Read the Material Safety Data Sheet and the latestASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of these refrigerants.

HCFC-22 and HFC-134a will dissolve oil and some non-metallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. When handling this refrigerant, protect the hands and eyes and avoid breathing fumes.

HCFC-22 or HFC-134a

Adding Refrigerant — Follow the procedures de-

scribed in Trimming Refrigerant Charge section, page 54.

Always use the compressor Pumpdown function in the Control Test table to turn on the evaporator pump and lock out the compressor when transferring refrigerant. Liquid refrigerant may ﬂash into a gas and cause possible freeze-up when the chiller pressure is below 65 psig (448 kPa) [30 psig (207 kPa)].

RemovingRefrigerant — If the optional pumpout unit

is used, the 19XL refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels. Follow procedures in the Pumpout and Refrigerant TransferProcedures section when removing refrigerant from the pumpout storage tank to the chiller vessel.

Adjusting the Refrigerant Charge — If the addi-

tion or removal of refrigerant is required for improved chiller performance, follow the procedures given under the Trim Refrigerant Charge section, page 62.

Refrigerant Leak Testing — Because HCFC-22 and

HFC-134a are above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the chiller. Use an electronic, halide leak detector, soap bubble solution, or ultra-sonic leak detector. Be sure that the room is well ventilated and free from concentration of refrigerant to keep false readings to a minimum. Before making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.

Leak Rate — ASHRAE recommends that chillers should

be immediately taken off line and repaired if the refrigerant leakage rate for the entire chiller is more than 10% of the operating refrigerant charge per year.

Additionally,Carrier recommends that leaks totalling less than the above rate but more than a rate of 1 lb (0.5 kg) per year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work.

Test After Service, Repair, or Major Leak — If

all refrigerant has been lost or if the chiller has been opened for service, the chiller or the affected vessels must be pressured and leak tested. Refer to the Leak Test Chiller section to perform a leak test.

Page 62

HCFC-22 and HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, neither refrigerant should not be allowed to be present with high concentrations of air or oxygen above atmospheric pressures, as the mixture can undergo combustion.

REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures.

TO PRESSURIZE WITH DRY NITROGEN — Another method of leak testing is to pressurize with nitrogen only and use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present. This should only be done if all refrigerant has been evacuated from the vessel.

1. Connect a copper tube from the pressure regulator on the cylinder to the refrigerant charging valve. Never apply full cylinder pressure to the pressurizing line. Follow the listed sequence.

2. Open the charging valve fully.

3. Slowly open the cylinder regulating valve.

4. Observe the pressure gage on the chiller and close the regulating valve when the pressure reaches test level. Do not exceed 140 psig (965 kPa).

5. Close the charging valve on the chiller. Remove the copper tube if no longer required.

Repair the Leak, Retest, and Apply Standing Vacuum Test —

leaks with an electronic, halide leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any leaks found, and retest.

After retesting and ﬁnding no leaks, apply a standing vacuum test, and then dehydrate the chiller. Refer to the Standing Vacuum Test and Chiller Dehydration in the Before Initial Start-Up section, pages 43 and 47.

After pressurizing the chiller, test for

Fig. 36 — Guide Vane Actuator Linkage

Refrigerant may be added either through the storage tank or directly into the chiller as described in the Charge Refrigerant into Chiller section.

To remove any excess refrigerant, follow the procedure in Transfer Refrigerant from Chiller to Storage Tank section, Steps 1a and b, page 60.

WEEKLY MAINTENANCE

Checking Guide VaneLinkage — When the chiller

is off, the guide vanes are closed and the actuator mechanism is in the position shown in Fig. 36. If slack develops in the drive chain, backlash can be eliminated as follows:

1. With the machine shut down and the actuator fully closed, remove the chain guard and loosen the actuator bracket holddown bolts.

2. Loosen guide vane sprocket adjusting bolts.

3. Pry bracket upwards to remove slack, then retighten the bracket holddown bolts.

4. Retighten the guide vane sprocket adjusting bolts. Make sure that the guide vane shaft is rotated fully in the clockwise direction in order for it to be fully closed.

CHECKINGTHE AUXILIARYSWITCHON GUIDE VANE ACTUATOR — The auxiliary switch used to activate the oil reclaim system solenoids should move to the OPEN position when the actuator is 70 degrees open. (At this point the guide vanes should be 30 degrees open.)

Trim Refrigerant Charge — If it becomes necessary

to adjust the refrigerant charge to obtain optimum chiller performance, operate the chiller at design load and then add or remove refrigerant slowly until the difference between leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions or becomes a minimum.

Do not overcharge.

Checkthe Lubrication System —

on the reservoir sight glass, and observe the level each week while the chiller is shut down.

If the level goes below the lower sight glass, the oil reclaim system will need to be checked for proper operation. If additional oil is required, add it through the oil drain charging valve (Fig. 2A or Fig. 2B). A pump is required for adding oil against refrigerant pressure. The oil charge is approximately 8 gallons (30 L). The added oil must meet Carrier speciﬁcations for the 19XL. Refer to Changing Oil Filter and Oil Changes sections on page 63. Any additional oil that is added should be logged by noting the amount and date. Any oil that is added due to oil loss that is not related to service will eventually return to the sump. It must be removed when the level is high.

A 1200-watt oil heater is controlled by the PIC to maintain oil temperature (see the Controls section) when the compressor is off. The LID Status02 table displays whether the heater is energized or not. If the PIC shows that the heater is energized, but the sump is not heating up, the power to the oil heater may be off or the oil level may be too low. Check the oil level, the oil heater contactor voltage, and oil heater resistance.

The PIC will not permit compressor start-up if the oil temperature is too low.The control will continue with start-up only after the temperature is within limits.

Mark the oil level

Page 63

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on the actual chiller requirements such as chiller load, run hours, and water quality. The time intervals listed in this section are offered as guides to service only.

Service Ontime — The LID will display a SERVICE

ONTIME value on the Status01 table. This value should be

reset to zero by the service person or the operator each time major service work is completed so that time between service can be viewed.

Inspect the Control Center — Maintenance is lim-

ited to general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up. In the event of chiller control malfunctions, refer to the Troubleshooting Guide section for control checks and adjustments.

Be sure power to the control center is off when cleaning and tightening connections inside the control center.

Check Safety and Operating Controls Monthly

To ensure chiller protection, the Control TestAutomated

—

Test should be done at least once per month. See Table 3 for safety control settings. See Table 7 for Control Test functions.

Changing Oil Filter — Change the oil ﬁlter on a yearly

basis or when the chiller is opened for repairs. The 19XL has an isolatable oil ﬁlter so that the ﬁlter may be changed with the refrigerant remaining in the chiller. Use the following procedure:

1. Make sure that the compressor is off, and the disconnect for the compressor is open.

2. Disconnect the power to the oil pump.

3. Close the oil ﬁlter isolation valves (Fig. 4).

4. Connect an oil charging hose from the oil charging valve (Fig. 4), and place the other end in a clean container suitable for used oil. The oil drained from the ﬁlter housing should be used as an oil sample to be sent to a laboratory for proper analysis.Do not contaminate this sample.

5. Slowly open the charging valve to drain the oil from the housing.

The oil ﬁlter housing is at a high pressure. Relieve this pressure slowly.

6. Once all oil has been drained, place some rags or absorbent material under the oil ﬁlter housing to catch any drips once the ﬁlter is opened. Remove the 4 bolts from the end of the ﬁlter housing and remove the ﬁlter cover.

7. Remove the ﬁlter retainer by unscrewing the retainer nut. The ﬁlter may now be removed and disposed of properly.

8. Replace the old ﬁlter with a new ﬁlter. Install the ﬁlter retainer and tighten down the retainer nut. Install the ﬁlter cover and tighten the 4 bolts.

9. Evacuate the ﬁlter housing by placing a vacuum pump on the charging valve. Follow the normal evacuation procedures. Shut the charging valve when done, and reconnect the valve so that new oil can be pumped into the ﬁlter housing. Fill with the same amount that was removed, then close the charging valve.

10. Remove the hose from the charging valve, open the isolation valves to the ﬁlter housing, and turn on the power to the pump and the motor.

Oil Speciﬁcation — The 19XL compressor holds ap-

proximately 11.7 gal. (44.3 L) of oil. If oil is added, it must meet the following Carrier speciﬁcations:

• Oil type for HCFC-22 Chillers only ...........Alkyl-

ISO Viscosity Grade ..........................86

• Oil Type for units using R-134a ............Inhibited

ISO Viscosity Grade ..........................68

The alkyl-benzene type oil (part number PP23BZ101) or the polyolester-based oil (part number PP23BZ103) may be ordered from your local Carrier representative.

benzene-based synthetic compressor oil

speciﬁcally formatted for use in HCFC-22 gear-driven machines

polyolester-based synthetic compressor

oil formatted for use with HFC, gear-

driven, hermetic compressors.

Oil Changes — Carrier recommends changing the oil

after the ﬁrst year of operation and every 3 years thereafter as a minimum in addition to a yearly oil analysis. However, if a continuous oil monitoring system is functioning and a yearly oil analysis is performed, time between oil changes can be extended.

TO CHANGE THE OIL

1. Transfer the refrigerant into the condenser (for isolatable

vessels) or a storage tank.

2. Mark the existing oil level.

3. Open the control and oil heater circuit breaker.

4. When the chiller pressure is 5 psi (34 kPa) or less, drain

the oil reservoir by opening the oil charging valve (Fig. 2A or Fig. 2B). Slowly open the valve against refrigerant pressure.

5. Change the oil ﬁlter at this time. See Changing Oil Filter

section.

6. Change the refrigerant ﬁlter at this time; see the next sec-

tion, Refrigerant Filter.

7. Charge the chiller with oil. Charge until the oil level is

equal to the oil level marked in Step 2. Turn on the power to the oil heater and let the PIC warm it up to at least 140 F (60 C). Operate the oil pump manually,through the Control Test, for 2 minutes. The oil level should be full in the lower sight glass for shutdown conditions. If the oil level is above remove the excess oil. The oil level should now be equal to the amount shown in Step 2.

⁄2full in the upper sight glass,

Refrigerant Filter — A refrigerant ﬁlter drier, located

on the refrigerant cooling line to the motor (Fig. 2A or 2B), should be changed once a year, or more often if ﬁlter condition indicates a need for more frequent replacement. Change the ﬁlter with the chiller pressure at 0 psig (0 kPa) by transferring the refrigerant to the condenser vessel, (if isolation valves are present), or a storage tank. A moisture indicator sight glass is located beyond this ﬁlter to indicate the volume and moisture in the refrigerant. If the moisture indicator (dry-eye) indicates moisture, locate the source of water immediately by performing a thorough leak check.

Oil Reclaim Filters — The oil reclaim system has a

strainer on the eductor suction line and a ﬁlter on the cooler scavaging line. Replace these ﬁlters once per year, or more often if ﬁlter condition indicates a need for more frequent replacement. Change these ﬁlters by transferring the refrigerant charge to a storage vessel or the condenser.

Page 64

Inspect Refrigerant Float System — Perform

inspection every 5 years or when the condenser is opened for service. Transfer the refrigerant into the cooler vessel or into a storage tank. Remove the ﬂoat access cover. Clean the chamber and valve assembly thoroughly. Be sure that the valve moves freely. Make sure that all openings are free of obstructions. Examine the cover gasket and replace if necessary. See Fig. 37 for views of both ﬂoat valve designs. On the linear ﬂoat valve design, inspect orientation of the ﬂoat slide pin. It must be pointed toward the bubbler tube for proper operation.

Compressor Bearing and Gear Maintenance —

proper lubrication. Use the proper grade of oil, maintained at recommended level, temperature, and pressure. Inspect the lubrication system regularly and thoroughly.

To inspect the bearings, a complete compressor teardown is required. Only a trained service technician should remove and examine the bearings. The cover plate on older compressor bases was used for factory-test purposes, and is not usable for bearing or gear inspection. The bearings and gears should be examined on a scheduled basis for signs of wear. The frequency of examination is determined by the hours of chiller operation, load conditions during operation, and the condition of the oil and the lubrication system. Excessive bearing wear can sometimes be detected through increased vibration or increased bearing temperature. If either symptom appears, contact an experienced and responsible service organization for assistance.

The key to good bearing and gear maintenance is

Inspect the Heat Exchanger Tubes

COOLER — Inspect and clean the cooler tubes at the end of the ﬁrst operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes. Upon inspection, the tube condition will determine the scheduled frequency for cleaning, and will indicate whether water treatment is adequate in the chilled water/brine circuit. Inspect the entering and leaving chilled water temperature sensors for signs of corrosion or scale. Replace the sensor if corroded or remove any scale if found.

Fig. 37 — 19XL Float Valve Designs

InspectRelief Valvesand Piping— The relief valves

on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against damage to the equipment and possible injury to personnel, these devices must be kept in peak operating condition.

As a minimum, the following maintenance is required.

1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt, scale, leakage, etc.

2. If corrosion or foreign material is found, do not attempt to repair or recondition. Replace the valve.

3. If the chiller is installed in a corrosive atmosphere or the relief valves are vented into a corrosive atmosphere, make valve inspections at more frequent intervals.

CONDENSER — Since this water circuit is usually an opentype system, the tubes may be subject to contamination and scale. Clean the condenser tubes with a rotary tube cleaning system at least once per year, and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors for signs of corrosion or scale. Replace the sensor if corroded or remove any scale if found.

Higher than normal condenser pressures, together with the inability to reach full refrigeration load, usually indicate dirty tubes or air in the chiller. If the refrigeration log indicates a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes may be dirty, or water ﬂow may be incorrect. Because HCFC-22 and HFC134-a are high-pressure refrigerants, air usually does not enter the chiller, rather, the refrigerant leaks out.

During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do not use wire brushes.

Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for proper treatment.

Water Leaks — Water is indicated during chiller opera-

tion by the refrigerant moisture indicator (Fig. 2A or 2B) on the refrigerant motor cooling line. Water leaks should be repaired immediately.

Chiller must be dehydrated after repair of water leaks. See Chiller Dehydration section, page 47.

Page 65

WaterTreatment— Untreated or improperly treated wa-

ter may result in corrosion, scaling, erosion, or algae. The services of a qualiﬁed water treatment specialist should be obtained to develop and monitor a treatment program.

Water must be within design ﬂow limits, clean, and treated to ensure proper chiller performance and reduce the potential of tubing damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.

Inspect the Starting Equipment — Before work-

ing on any starter, shut off the chiller, and open all disconnects supplying power to the starter.

Oil should be visible in one of the compressor sight glasses both during operation and at shutdown. Always check the oil level before operating the compressor. Before adding or changing oil, relieve the refrigerant pressure as follows:

1. Attach a pressure gage to the gage port of either com-

pressor service valve (Fig. 35).

2. Close the suction service valve and open the discharge

line to the storage tank or the chiller.

3. Operate the compressor until the crankcase pressure drops

to 2 psig (13 kPa).

4. Stop the compressor and isolate the system by closing

the discharge service valve.

5. Slowly remove the oil return line connection (Fig. 35).

Add oil as required.

6. Replace the connection and reopen the compressor serv-

ice valves.

The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.

Never open isolating knife switches while equipment is operating. Electrical arcing can cause serious injury.

Inspect starter contact surfaces for wear or pitting on mechanical-type starters. Do not sandpaper or ﬁle silverplated contacts. Follow the starter manufacturer’s instructions for contact replacement, lubrication, spare parts ordering, and other maintenance requirements.

Periodically vacuum or blow off accumulated debris on the internal parts with a high-velocity, low-pressure blower.

Power connections on newly installed starters may relax and loosen after a month of operation. Turn power off and retighten. Recheck annually thereafter.

Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.

Check Pressure Transducers — Once a year, the

pressure transducers should be checked against a pressure gage reading. Check all three transducers: oil pressure, condenser pressure, cooler pressure.

Note the evaporator and condenser pressure readings on the Status01 table on the LID. Attach an accurate set of refrigeration gages to the cooler and condenser Schrader ﬁttings. Compare the two readings. If there is a difference in readings, the transducer can be calibrated, as described in the Troubleshooting Guide section.

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS (Fig. 38) — The optional pumpout system high-pressure switch should open at 220 ± 5 psig (1517 ± 34 kPa) and should reset automatically on pressure drop to 190 psig (1310 kPa) for HCFC-22 chillers. For chillers using HFC-134a, the switch opens at 161 psig (1110 kPa) and closes at 130 psig (896 kPa). Check the switch setting by operating the pumpout compressor and slowly throttling the pumpout condenser water.

Fig. 38 — Optional Pumpout System

Controls

Optional Pumpout System Maintenance —

For compressor maintenance details, refer to the 06D, 07D Installation, Start-Up, and Service Instructions.

OPTIONALPUMPOUT COMPRESSOR OILCHARGE — The pumpout compressor uses oil with the same speciﬁcations as the centrifugal compressor oil. For more details on oil selection, see Oil Speciﬁcation section, page 63.

The total oil charge, 4.5 pints (2.6 L), consists of

3.5 pints (2.0 L) for the compressor and one additional pint (0.6 L) for the oil separator.

Ordering Replacement Chiller Parts — When

ordering Carrier speciﬁed parts, the following information must accompany an order:

• chiller model number and serial number

• name, quantity, and part number of the part required

• delivery address and method of shipment.

Page 66

TROUBLESHOOTING GUIDE

Overview —

operator and the technician in troubleshooting a 19XL chiller.

• By using the LID display, the chiller actual operating conditions can be viewed while the unit is running.

• When an alarm occurs, the default LID screen will freeze at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of alarm. The Status tables will still show the current information. Once all alarms have been cleared, the default LID screens will return to normal operation.

• The Control Algorithm Status tables will display various screens of information in order to diagnose problems with chilled water temperature control, chilled water temperature control overrides, hot gas bypass, surge algorithm status, and time schedule operation.

• The Control Test feature allows proper operation and testing of temperature sensors, pressure transducers, the guide vane actuator, oil pump, water pumps, tower control, and other on/off outputs while the compressor is stopped. It also has the ability to lock off the compressor and turn on water pumps for pumpout operation. The display will show the required temperatures and pressures during these operations.

• Other Service menu tables can access conﬁgured items, such as chilled water resets, override set points, etc.

• If an operating fault is detected, an alarm message is generated and displayed on the LID default screen. A more detailed message — along with a diagnostic message — also is stored into the Alarm History table.

The PIC has many features to aid the

Checking the Display Messages — The ﬁrst area

to check when troubleshooting the 19XL is the LID display. If the alarm light is ﬂashing, check the primary and secondary message lines on the LID default screen (Fig. 13). These messages will indicate where the fault is occurring. The Alarm History table on the LID Service menu will also carry an alarm message to further expand on this alarm. For a complete listing of messages, see Table 9. If the alarm light starts to ﬂash while accessing a menu screen, depress

EXIT

to return to the Default screen to read the failure

message. The compressor will not run with an alarm condition existing, unless the alarm type is an unauthorized start or a failure to shut down.

Checking Temperature Sensors — All tempera-

ture sensors are of the thermistor type. This means that the resistance of the sensor varies with temperature. All sensors have the same resistance characteristics. Determine sensor temperature by measuring voltage drop if the controls are powered, or resistance if the controls are powered off. Compare the readings to the values listed in Tables 10A or 10B.

RESISTANCE CHECK — Turn off the control power and disconnect the terminal plug of the sensor in question from the module. Measure sensor resistance between receptacles designated by the wiring diagram with a digital ohmmeter.The resistance and corresponding temperature is listed in Tables 10A or 10B. Check the resistance of both wires to ground. This resistance should be inﬁnite.

VOLTAGE DROP — Using a digital voltmeter, the voltage drop across any energized sensor can be measured while the control is energized. Tables 10A or 10B lists the relationship between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Sensors should also be checked

at the sensor plugs. Check the sensor wire at the sensor for 5 vdc if the control is powered.

Relieve all refrigerant pressure or drain the water prior to replacing the temperature sensors.

CHECK SENSOR ACCURACY — Place the sensor in a medium of a known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5° F (.25° C) graduations. The sensor in question should be accurate to within 2° F (1.2° C).

See Fig. 8 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconnected by unlatching the connector. These connectors allow only one-way connection to the sensor.When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads.

DUAL TEMPERATURE SENSORS — There are 2 sensors each on the bearing and motor temperature sensors for servicing convenience. In case one of the dual sensors is damaged, the other one can be used by moving a wire.

The number 2 terminal in the sensor terminal box is the common line. To use the second sensor, move the wire from the number 1 position to the number 3 position.

Checking Pressure Transducers — There are 3

pressure transducers on the 19XL. These determine cooler, condenser, and oil pressure. The cooler and condenser transducers also are used by the PIC to determine the refrigerant temperatures. All 3 can be calibrated if necessary. It is not usually necessary to calibrate at initial start-up. However, at high altitude locations, calibration of the transducer will be necessary to ensure the proper refrigerant temperature/ pressure relationship. Each transducer is supplied with 5 vdc power from a power supply. If the power supply fails, a transducer voltage reference alarm will occur. If the transducer reading is suspected of being faulty, check the supply voltage. It should be 5 vdc ± .5 v. If the supply voltage is correct, the transducer should be recalibrated or replaced.

IMPORTANT:Whenever the oil pressure or the cooler pressure transducer is calibrated, the other sensor should be calibrated to prevent problems with oil differential pressure readings.

Calibration can be checked by comparing the pressure readings from the transducer against an accurate refrigeration gage. These readings are all viewed or calibrated from the Status01 table on the LID. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 240 and 260 psig (1655 to 1793 kPa). To calibrate these transducers:

1. Shut down the compressor.

2. Disconnect the transducer in question from its Schrader

ﬁtting. NOTE: If the cooler or condenser vessels are at 0 psig

(0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.

3. Access the Status01 table, and view the particular trans-

ducer reading; it should read 0 psi (0 kPa). If the reading is not 0 psi (0 kPa), but within ± 5 psi (35 kPa), the value

may be zeroed by pressing the SELECT the highlight bar is located on the transducer, and then by pressing the ENTER

. The value will now go to zero.

softkey while

Page 67

If the transducer value is not within the calibration range, the transducer will return to the original reading. If the LID pressure value is within the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35. For example, the condenser transducer voltage input is measured at PSIO terminals J7-1 and J7-2. The voltage ratio must be between 0.80 vdc and 0.11 vdc for the software to allow calibration. Pressurize the transducer until the ratio is within range. Then attempt calibration again.

4. A high pressure point can also be calibrated between 240 and 260 psig (1655 and 1793 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). The high pressure point can be calibrated by accessing the transducer on the Status01 screen,

highlighting the transducer, pressing the SELECT softkey, and then increasing or decreasing the value to the exact pressure on the refrigerant gage. Press ENTER to ﬁnish. High altitude locations must compensate the

pressure so that the temperature/pressure relationship is correct.

If the transducer reading returns to the previous value and the pressure is within the allowed range, check the voltage ratio of the transducer. Refer to Step 3 above. The voltage ratio for this high pressure calibration must be between 0.585 and 0.634 vdc to allow calibration. Change the pressure at the transducer until the ratio is within the acceptable range. Then attempt calibrate to the new pressure input.

The PIC will not allow calibration if the transducer is too far out of calibration. A new transducer must be installed and re-calibrated.

TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type ﬁttings, there is no need to remove refrigerant from the vessel. Disconnect the transducer wiring by pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer. Do not pull on the transducer wires. Unscrew the transducer from the Schrader ﬁtting. When installing a new transducer, do not use pipe sealer, which can plug the sensor. Put the plug connector back on the sensor and snap into place. Check for refrigerant leaks.

Make sure to use a backup wrench on the Schrader ﬁtting whenever removing a transducer.

ControlAlgorithms Checkout Procedure — The

Control Algorithm Status table is in the LID Service menu. The ControlAlgorithm Status table contains maintenance tables that may be viewed in order to see how the particular control algorithm is operating. The tables are:

MAINT01 Capacity

MAINT02 Override MAINT03 Surge/

MAINT04 (PSIO Software Version 09 and Higher)

OCCDEFM Time

WSMDEFME Water

Control

Status HGBP

Status LEAD/LAG

Status

Schedules Status

System Manager Status

This table shows all values that are used to calculate the chilled water/brine control point.

Details of all chilled water control override values are viewed here.

The surge and hot gas bypass control algorithm status is viewed from this screen. All values dealing with this control are displayed.

This screen indicates LEAD/LAG operation status.

The Local and CCN occupied schedules are displayed here in a manner that the operator can quickly determine whether the schedule is in the OCCUPIED mode or not.

The water system manager is a CCN module which can turn on the chiller and change the chilled water control point. This screen indicates the status of this system.

These maintenance tables are very useful in determining how the control temperature is calculated, the position of the guide vane, reaction from load changes, control point overrides, hot gas bypass reaction, surge prevention, etc.

Control Test — The Control Test feature can check all

of the thermistor temperature sensors, including those on the Options modules, pressure transducers, pumps and their associated ﬂow switches, the guide vane actuator, and other control outputs, such as hot gas bypass. The tests can help to determine whether a switch is defective, or a pump relay is not operating, among other useful troubleshooting tests. During pumpdown operations, the pumps are energized to prevent freeze-up and the vessel pressures and temperatures are displayed. The lockout feature will prevent start-up of the compressor when no refrigerant is present in the chiller, or if the vessels are isolated. The lockout is then terminated by the operator by using the Terminate Lockout function after the pumpdown procedure is reversed and refrigerant is added.

Page 68

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides

A. SHUTDOWN WITH ON/OFF/RESET-OFF

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED — PRESS CCN OR LOCAL TO START TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING SHUTDOWN IN PROGRESS COMPRESSOR DEENERGIZED

ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.

B. TIMING OUT OR TIMED OUT

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

READY TO START IN XX MIN UNOCCUPIED MODE READY TO START IN XX MIN REMOTE CONTACTS OPEN READY TO START IN XX MIN STOP COMMAND IN EFFECT

READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode. READY TO START UNOCCUPIED MODE

READY TO START REMOTE CONTACTS OPEN READY TO START STOP COMMAND IN EFFECT

READY TO START IN XX MIN REMOTE CONTACTS CLOSED Chiller timer counting down unit. Ready for start. READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down unit. Ready for start. READY TO START REMOTE CONTACTS CLOSED Chiller timers complete, unit start will commence. READY TO START OCCUPIED MODE Chiller timers complete, unit start will commence.

STARTUP INHIBITED LOADSHED IN EFFECT

READY TO START IN XX MIN START COMMAND IN EFFECT

PIC in OFF mode, press the CCN or local softkey to start unit.

Enter the Control Test table and select Terminate Lockout to unlock compressor.

Chiller unloading before shutdown due to Soft Stop feature.

Chiller compressor is being commanded to stop. Water pumps are deenergized within one minute.

Time schedule for PIC is unoccupied. Chillers will start only when occupied.

Remote contacts have stopped chiller. Close contacts to start.

Chiller START/STOP on Status01 manually forced to stop. Release value to start.

Time schedule for PIC is UNOCCUPIED. Chiller will start when occupied. Make sure the time and date have been set on the Service menu.

Remote contacts have stopped chiller. Close contacts to start.

Chiller START/STOP on Status01 manually forced to stop. Release value to start.

CCN loadshed module commanding chiller to stop.

Chiller START/STOP on Status01 has been manually forced to start. Chiller will start regardless of time schedule or remote contact status.

1CR AUX — Compressor Start Contact CA P CCN — Carrier Comfort Network CDFL — Condenser Water Flow CHIL S S CHW — Chilled Water CHWS — Chilled Water Supply CHWR — Chiller Water Return CMPD — Discharge Temperature CRP — Condenser Pressure CRT — Condenser Refrigerant

— Compressor Current

— Chiller Start/Stop

Temperature

LEGEND

ECW — Entering Chilled Water ERT — Evaporator Refrigerant

EVFL — Chilled Water Flow GV TRG LID — Local Interface Device MTRB — Bearing Temperature MTRW — Motor Winding Temperature OILPD — Oil Pressure OILT — Oil Sump Temperature PIC — Product Integrated Control

Temperature

— Target Guide Vane Position

PSIO — Processor Sensor RLA — Rated Load Amps

RUN AUX SPR PL SMM — Starter Management

STR FLT TXV — Thermostatic Expansion

VP V REF — Voltage Reference

Input/Output Module

— Compressor Run Contact — Spare Protective Limit Input

Module

— Starter Fault

Valve

—Line Voltage: Percent

Page 69

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RECYCLE RESTART PENDING OCCUPIED MODE RECYCLE RESTART PENDING REMOTE CONTACT CLOSED

RECYCLE RESTART PENDING START COMMAND IN EFFECT

RECYCLE RESTART PENDING ICE BUILD MODE

D. PRE-STARTALERTS:These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY PRESTART ALERT STARTS LIMIT EXCEEDED

PRESTART ALERT HIGH MOTOR TEMPERATURE

PRESTART ALERT HIGH BEARING TEMPERATURE

PRESTART ALERT HIGH DISCHARGE TEMP

PRESTART ALERT LOW REFRIGERANT TEMP

PRESTART ALERT LOW OIL TEMPERATURE

PRESTART ALERT LOW LINE VOLTAGE

PRESTART ALERT HIGH LINE VOLTAGE

PRESTART ALERT HIGH CONDENSER PRESSURE

*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predeﬁned or selected by the operator as an override or an alert. [VALUE] is

the actual temperature, pressure, voltage, etc., at which the control tripped.

STARTS EXCESSIVE Compressor Starts (8 in 12 hours)

MTRW [VALUE]* exceeded limit of [LIMIT]*. Check motor temperature.

MTRB [VALUE]* exceeded limit of [LIMIT]*. Check thrust bearing temperature.

CMPD [VALUE]* exceeded limit of [LIMIT]*. Check discharge temperature.

ERT [VALUE]* exceeded limit of [LIMIT]*. Check refrigerant temperature.

OILT [VALUE]* exceeded limit of [LIMIT]*. Check oil temperature.

V P [VALUE]* exceeded limit of [LIMIT]*. Check voltage suppy.

V P [VALUE]* exceeded limit of [LIMIT]*. Check voltage supply.

CRP [VALUE]* exceeded limit of [LIMIT]*. Check condenser water and transducer.

Unit in recycle mode, chilled water temperature is not high enough to start.

Chiller START/STOP on Status01 manually forced to start, chilled water temperature is not high enough to start.

Chiller in ICE BUILD mode. Chilled Water/Brine Temperature is satisﬁed for Ice Build Setpoint temperature.

Depress the RESET softkey if additional start is required. Reassess start-up requirements.

Check motor cooling line for proper operation. Check for excessive starts within a short time span.

Check oil heater for proper operation, check for low oil level, partially closed oil supply valves, etc. Check sensor accuracy.

Check sensor accuracy.Allow discharge temperature to cool. Check for excessive starts.

Check transducer accuracy. Check for low chilled water/brine supply temperature.

Check oil heater power, oil heater relay. Check oil level.

Check voltage supply. Check voltage transformers. Consult power utility if voltage is low. Adjust voltage potentiometer in starter for SMM voltage input.

Check for high condenser water temperature. Check transducer accuracy.

E. NORMAL OR AUTO.-RESTART

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

STARTUP IN PROGRESS OCCUPIED MODE Chiller starting. Time schedule is occupied. STARTUP IN PROGRESS REMOTE CONTACT CLOSED Chiller starting. Remote contacts are closed.

STARTUP IN PROGRESS START COMMAND IN EFFECT AUTORESTART IN PROGRESS OCCUPIED MODE Chiller starting. Time schedule is occupied.

AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED Chiller starting. Remote contacts are closed. AUTORESTART IN PROGRESS START COMMAND IN EFFECT

NOTE: See Legend on page 68.

Chiller starting. Chiller START/STOP on Status01 manually forced to start.

Page 70

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

F. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear.

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY FAILURE TO START LOW OIL PRESSURE

FAILURE TO START OIL PRESS SENSOR FAULT

FAILURE TO START

FAILURE TO START STARTER FAULT

FAILURE TO START STARTER OVERLOAD TRIP

FAILURE TO START LINE VOLTAGE DROPOUT

FAILURE TO START

FAILURE TO START FAILURE TO START 1CR AUX CONTACT FAULT

FAILURE TO START MOTOR AMPS NOT SENSED

FAILURE TO START

FAILURE TO START LOW OIL PRESSURE

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is open.

NOTE: See Legend on page 68.

LOW CHILLED WATER FLOW

LOW CONDENSER WATER FLOW

HIGH CONDENSER PRESSURE

EXCESS ACCELERATION TIME

STARTER TRANSITION FAULT

CHECK REFRIGERANT TYPE

OILPD [VALUE] exceeded limit of [LIMIT]*. Check oil pump system.

OILPD [VALUE] exceeded limit of [LIMIT]*. Check oil pressure sensor.

EVFL Evap Flow Fault: Check water pump/ﬂow switch.

CDFL Cond. Flow Fault: Check water pump/ﬂow switch.

STR FLT Starter Fault: Check Starter for Fault Source.

STR FLT Starter Overload Trip: Check amps calibration/reset overload.

V P Single-Cycle Dropout Detected: Check voltage supply.

High Condenser Pressure [OPEN]*: Check switch, oil pressure contact, and water temperature/ﬂow.

High Condenser Pressure [VALUE]*: Check switch, water ﬂow, and transducer.

CA P Excess Acceleration: Check guide vane closure at start-up.

RUN AUX Starter Transition Fault: Check 1CR/1M/Interlock mechanism.

1CR AUX Starter Contact Fault: Check 1CR/1M aux. contacts.

CA P Motor Amps Not Sensed: Check motor load signal.

Current Refrigerant Properties Abnormal — Check Selection of refrigerant type

Low Oil Pressure [LIMIT]*: Check oil pressure switch/pump and 2C aux.

Check for closed oil supply valves. Check oil ﬁlter. Check for low oil temperature. Check transducer accuracy.

Check for excessive refrigerant in oil sump. Run oil pump manually for 5 minutes. Check transducer calibration. Check cooler pressure transducer calibration. Check wiring. Replace transducer if necessary.

Check wiring to ﬂow switch. Check through Control Test for proper switch operation.

A starter protective device has faulted. Check starter for ground fault, voltage trip, temperature trip, etc.

Reset overloads before restart. Check voltage supply. Check transformers

for supply. Check with utility if voltage supply is erratic. Monitor must be installed to conﬁrm consistent, single-cycle dropouts. Check low oil pressure switch.

Check the high-pressure switch. Check for proper condenser pressures and condenser waterﬂow. Check for fouled tubes. Check the 2C aux contact and the oil pressure switch in the power panel. This alarm is not caused by the transducer.

Check water ﬂow in condenser. Check for fouled tubes. Transducer should be checked for accuracy. This alarm is not caused by the high pressure switch.

Check that guide vanes are closed at start-up. Check starter for proper operation. Reduce unit pressure if possible.

Check starter for proper operation. Run contact failed to close.

Check starter for proper operation. Start contact failed to close.

Check for proper motor amps signal to SMM. Check wiring from SMM to current transformer. Check main motor circuit breaker for trip.

Pressures at transducers indicate another refrigerant type in Control Test. Make sure to access the ATTACH TO NETWORK DEVICE table after changing refrigerant type.

The oil pressure differential switch is open when the compressor tried to START. Check the switch for proper operation. Also, check the oil pump interlock (2C aux) in the power panel and the high condenser pressure switch.

Page 71

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARYCAUSE ADDITIONAL CAUSE/REMEDY

Compressor is running with more than

UNAUTHORIZED OPERATION

POTENTIAL FREEZE-UP

FAILURE TO STOP DISCONNECT POWER

LOSS OF COMMUNCIATION

STARTER CONTACT FAULT

POTENTIAL FREEZE UP

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

UNIT SHOULD BE STOPPED

EVAP PRESS/TEMP TOO LOW

WITH STARTER ABNORMAL 1CR OR

RUN AUX

COND PRESS/TEMP TOO LOW

CA P Emergency: Compressor running without control authorization.

ERT Emergency: Freeze-up prevention.

RUN AUX Emergency: DISCONNECT POWER.

Loss of Communication with Starter: Check chiller.

1CR AUX Starter Contact Fault: Check 1CR/1M aux. contacts.

CRT [VALUE] exceeded limit of [LIMIT]* Emergency: Freeze-up

prevention.

10% RLA and control is trying to shut it down. Throw power off to compressor if unable to stop. Determine cause before repowering.

Determine cause. If pumping refrigerant out of chiller, stop operation and go over pumpout procedures.

Starter and run and start contacts are energized while control tried to shut down. Disconnect power to starter.

Check wiring from PSIO to SMM. Check SMM module troubleshooting procedures.

Starter run and start contacts energized while chiller was off. Disconnect power.

The condenser pressure transducer is reading a pressure that could freeze the water in the condenser tubes. Check for condenser refrigerant leaks, bad transducers, or transferred refrigerant. Place the unit in Pumpdown mode to eliminate ALARM if vessel is evacuated.

H. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RUNNING — RESET ACTIVE 4-20MA SIGNAL

Reset program active based upon Conﬁg table setup.RUNNING — RESET ACTIVE REMOTE SENSOR CONTROL RUNNING — RESET ACTIVE CHW TEMP DIFFERENCE RUNNING — TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control. RUNNING — TEMP CONTROL ENTERING CHILLED WATER ECW control activated on Conﬁg table. RUNNING — TEMP CONTROL TEMPERATURE RAMP LOADING Ramp loading in effect. Use Service1 table to modify. RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING Ramp loading in effect. Use Service1 table to modify. RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT Demand limit setpoint is , actual demand. RUNNING — DEMAND LIMITED BY 4-20MA SIGNAL

Demand limit is active based on Conﬁg table setup.RUNNING — DEMAND LIMITED BY CCN SIGNAL RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE

RUNNING — TEMP CONTROL HOT GAS BYPASS RUNNING — DEMAND LIMITED BY LOCAL SIGNAL

RUNNING — TEMP CONTROL ICE BUILD MODE Chiller is running under Ice Build temperature control.

NOTE: See Legend on page 68.

Hot Gas Bypass is energized. See surge prevention

in the control section.

Active demand limit manually overridden or Status01

table.

Page 72

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY RUN CAPACITY

LIMITED

RUN CAPACITY

LIMITED

RUN CAPACITY

LIMITED

RUN CAPACITY

LIMITED

RUN CAPACITY

LIMITED

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped.

HIGH CONDENSER PRESSURE HIGH MOTOR TEMPERATURE LOW EVAP REFRIG TEMP HIGH COMPRESSOR LIFT MANUAL GUIDE VANE TARGET

J. OUT-OF-RANGE SENSOR FAILURES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY SENSOR FAULT LEAVING CHW TEMPERATURE

SENSOR FAULT ENTERING CHW TEMPERATURE SENSOR FAULT CONDENSER PRESSURE SENSOR FAULT EVAPORATOR PRESSURE SENSOR FAULT BEARING TEMPERATURE SENSOR FAULT MOTOR WINDING TEMP SENSOR FAULT DISCHARGE TEMPERATURE SENSOR FAULT OIL SUMP TEMPERATURE SENSOR FAULT OIL PRESSURE TRANSDUCER

NOTE: See Legend on page 68.

CRP [VALUE]* exceeded limit of [LIMIT]*. Condenser pressure override.

MTRW [VALUE]* exceeded limit of [LIMIT]*. Motor temperature override.

ERT [VALUE]* exceeded limit of [LIMIT]*. Check refrigerant charge level.

Surge Prevention Override; lift too high for compressor.

GV TRG Run Capacity Limited: Manual guide vane target.

Sensor Fault: Check leaving CHW sensor.

Sensor Fault: Check entering CHW sensor.

Sensor Fault: Check condenser pressure transducer.

Sensor Fault: Check evaporator pressure transducer.

Sensor Fault: Check bearing temperature sensor.

Sensor Fault: Check motor temperature sensor.

Sensor Fault: Check discharge temperature sensor.

Sensor Fault: Check oil sump temperature sensor.

Sensor Fault: Check oil pressure transducer.

See Capacity Overrides, Table 4. Correct operating condition, modify setpoint, or release override.

See sensor test procedure and check sensors for proper operation and wiring.

Page 73

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

K. CHILLER PROTECT LIMIT FAULTS

Excessive numbers of the same fault can lead to severe chiller damage. Seek service expertise.

PRIMARY MESSAGE SECONDARYMESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

PROTECTIVE LIMIT

PROTECTIVE LIMIT LOW OIL PRESSURE

PROTECTIVE LIMIT NO MOTOR CURRENT

PROTECTIVE LIMIT POWER LOSS PROTECTIVE LIMIT LOW LINE VOLTAGE PROTECTIVE LIMIT HIGH LINE VOLTAGE PROTECTIVE LIMIT PROTECTIVE LIMIT

PROTECTIVE LIMIT

PROTECTIVE LIMIT PROTECTIVE LIMIT

PROTECTIVE LIMIT CCN OVERRIDE STOP

PROTECTIVE LIMIT

PROTECTIVE LIMIT PROTECTIVE LIMIT STARTER FAULT

PROTECTIVE LIMIT

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or alarm

condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is open.

NOTE: See Legend on page 68.

HIGH DISCHARGE TEMP

LOW REFRIGERANT TEMP

HIGH MOTOR TEMPERATURE

HIGH BEARING TEMPERATURE

LOW CHILLED WATER FLOW

LOW CONDENSER WATER FLOW

HIGH CONDENSER PRESSURE

1CR AUX CONTACT FAULT

RUN AUX CONTACT FAULT

SPARE SAFETY DEVICE

EXCESSIVE MOTOR AMPS

EXCESSIVE COMPR SURGE

STARTER OVERLOAD TRIP

TRANSDUCER VOLTAGE FAULT

CMPD [VALUE] exceeded limit of [LIMIT]*. Check discharge temperature.

ERT [VALUE] exceeded limit of [LIMIT]*. Check evap pump and ﬂow switch.

MTRW [VALUE] exceeded limit of [LIMIT]*. Check motor cooling and solenoid.

MTRB [VALUE] exceeded limit of [LIMIT]*. Check oil cooling control.

OILPD [VALUE] exceeded limit of [LIMIT]*. Check oil pump and transducer.

Low Oil Pressure [OPEN]*. Check oil pressure switch/pump and 2C aux.

CA P Loss of Motor Current: Check sensor.

V P Power Loss: Check voltage supply.

V P [VALUE] exceeded limit of [LIMIT]*. Check voltage supply.

EVFL Flow Fault: Check evap pump/ﬂow switch.

CDFL Flow Fault: Check cond pump/ ﬂow switch.

High Cond Pressure [OPEN]*. Check switch, oil pressure contact, and water temp/ﬂow.

High Cond Pressure [VALUE]: Check switch, water ﬂow, and transducer.

1CR AUX Starter Contact Fault: Check 1CR/1M aux contacts.

RUN AUX Starter Contact Fault Check 1CR/1M aux contacts.

CHIL S S CCN Override Stop while in LOCAL run mode.

SRP PL Spare Safety Fault: Check contacts.

CA P [VALUE] exceeded limit of [LIMIT]*. High Amps; Check guide vane drive.

Compressor Surge: Check condenser water temp and ﬂow.

STR FLT Starter Fault: Check starter for fault source.

STR FLT Starter Overload Trip: Check amps calibration/reset overload.

V REF [VALUE] exceeded limit of [LIMIT]*. Check transducer power supply.

Check discharge temperature immediately. Check sensor for accuracy; check for proper condenser ﬂow and temperature; check oil reservoir temperature. Check condenser for fouled tubes or air in chiller. Check for proper guide vane actuator operation.

Check for proper amount of refrigerant charge; check for proper water ﬂow and temperatures. Check for proper guide vane actuator operation.

Check motor temperature immediately. Check sensor for accuracy. Check for proper condenser ﬂow and temperature. Check motor cooling system for restrictions. Check motor cooling solenoid for proper operation. Check refrigerant ﬁlter.

Check for throttled oil supply isolation valves. Valves should be wide open. Check oil cooler thermal expansion valve. Check sensor accuracy. Check journal and thrust bearings. Check refrigerant ﬁlter. Check for excessive oil sump level.

Check power to oil pump and oil level. Check for dirty ﬁlters or oil foaming at start-up. Check for thermal overload cutout. Reduce ramp load rate if foaming noted.

NOTE: This alarm is not related to pressure switch problems.

Check the oil pressure switch for proper operation. Check oil pump for proper pressure. Check for excessive refrigerant in oil system.

Check wiring: Check torque setting on solid-state starter. Check for main circuit breaker trip. Check power supply to PSIO module.

Check 24-vdc input sensor on the SMM; adjust potentiometer if necessary. Check transformers to SMM. Check power to PSIO module. Check distribution bus. Consult power company.

Perform pumps Control Test and verify proper switch operation. Check all water valves and pump operation.

Check the high-pressure switch. Check for proper condenser pressures and condenser waterﬂow. Check for fouled tubes. Check the 2C aux. contact and the oil pressure switch in the power panel. This alarm is not caused by the transducer.

Check water ﬂow in condenser. Check for fouled tubes. Transducer should be checked for accuracy. This alarm is not caused by the high pressure switch.

1CR auxiliary contact opened while chiller was running. Check starter for proper operation.

Run auxiliary contact opened while chiller was running. Check starter for proper operation.

CCN has signaled chiller to stop. Reset and restart when ready. If the signal was sent by the LID, release the Stop signal on STATUS01 table.

Spare safety input has tripped or factory-installed jumper not present.

Check motor current for proper calibration. Check guide vane drive and actuator for proper operation.

Check condenser ﬂow and temperatures. Check conﬁguration of surge protection.

Check starter for possible ground fault, reverse rotation, voltage trip, etc.

Reset overloads and reset alarm. Check motor current calibration or overload calibration (do not ﬁeld-calibrate overloads).

Check transformer power (5 vdc) supply to transducers. Power must be 4.5 to 5.5 vdc.

Page 74

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

with Troubleshooting Guides (cont)

L. CHILLER ALERTS

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

RECYCLE ALERT HIGH AMPS AT SHUTDOWN

SENSOR FAULT ALERT

SENSOR FAULT ALERT LOW OIL PRESSURE

ALERT AUTORESTART PENDING POWER LOSS V P Power Loss: Check voltage supply.

AUTORESTART PENDING LOW LINE VOLTAGE AUTORESTART PENDING HIGH LINE VOLTAGE

SENSOR ALERT HIGH DISCHARGE TEMP

SENSOR ALERT

CONDENSER PRESSURE ALERT

RECYCLE ALERT

*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predeﬁned or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped.

LEAVING COND WATER TEMP

ENTERING COND WATER TEMP

CHECK OIL FILTER Low Oil Pressure Alert: Check oil

HIGH BEARING TEMPERATURE

PUMP RELAY ENERGIZED

EXCESSIVE RECYCLE STARTS

High Amps at Recycle: Check guide vane drive.

Sensor Fault: Check leaving condenser water sensor.

Sensor Fault: Check entering condenser water sensor.

V P [VALUE]* exceeded limit of [LIMIT].* Check voltage supply.

CMPD [VALUE]* exceeded limit of [LIMIT].* Check discharge temperature.

MTRB [VALUE]* exceeded limit of [LIMIT]*. Check thrust bearing temperature.

CRP High Condenser Pressure [LIMIT]*. Pump energized to reduce pressure.

Excessive recycle starts.

Check that guide vanes are closing. Check motor amps correction calibration is correct. Check actuator for proper operation.

Check sensor. See sensor test procedure.

Check oil ﬁlter. Check for improper oil level or temperature.

Check power supply if there are excessive compressor starts occurring.

Discharge temperature exceeded the alert threshold. Check entering condenser water temperature.

Thrust bearing temperature exceeded the alert threshold. Check for closed valves, improper oil level or temperatures.

Check ambient conditions. Check condenser pressure for accuracy.

The chiller load is too small to keep the chiller on line and there have been more than 5 restarts in 4 hours. Increase chiller load, adjust hot gas bypass, increase RECYCLE RESTART DELTA T.

M. SPARE SENSOR ALERT MESSAGES

PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

SPARE SENSOR ALERT COMMON CHWS SENSOR SPARE SENSOR ALERT COMMON CHWR SENSOR SPARE SENSOR ALERT REMOTE RESET SENSOR SPARE SENSOR ALERT TEMP SENSOR — SPARE 1 SPARE SENSOR ALERT TEMP SENSOR — SPARE 2 SPARE SENSOR ALERT TEMP SENSOR — SPARE 3 SPARE SENSOR ALERT TEMP SENSOR — SPARE 4 SPARE SENSOR ALERT TEMP SENSOR — SPARE 5 SPARE SENSOR ALERT TEMP SENSOR — SPARE 6 SPARE SENSOR ALERT TEMP SENSOR — SPARE 7 SPARE SENSOR ALERT TEMP SENSOR — SPARE 8 SPARE SENSOR ALERT TEMP SENSOR — SPARE 9

NOTE: See Legend on page 68.

Sensor Fault: Check common CHWS sensor.

Sensor Fault: Check common CHWR sensor.

Sensor Fault: Check remote reset temperature sensor.

Sensor Fault: Check temperature sensor — Spare 1.

Sensor Fault: Check temperature sensor — Spare 2.

Sensor Fault: Check temperature sensor — Spare 3.

Sensor Fault: Check temperature sensor — Spare 4.

Sensor Fault: Check temperature sensor — Spare 5.

Sensor Fault: Check temperature sensor — Spare 6.

Sensor Fault: Check temperature sensor — Spare 7.

Sensor Fault: Check temperature sensor — Spare 8.

Sensor Fault: Check temperature sensor — Spare 9.

Check alert temperature set points on Equipment Service, SERVICE2 LID table. Check sensor for accuracy if reading is not accurate.

Page 75

Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages

N. OTHER PROBLEMS/MALFUNCTIONS

DESCRIPTION/MALFUNCTION PROBABLE CAUSE/REMEDY

Chilled Water/Brine Temperature Too High (Machine Running)

Chilled Water/Brine Temperature Too Low (Machine Running)

Chilled Water Temperature Fluctuates. Vanes Hunt

Low Oil Sump Temperature While Running (Less than 100 F [38 C])

At Power Up, Default Screen Does Not Appear, ‘‘Tables Loading’’ Message Continually Appears

SMM Communications Failure

High Oil Temperature While Running

Blank LID Screen

‘‘Communications Failure’’ Highlighted Message At Bottom of LID Screen

Controls Test Disabled

Vanes Will Not Open In Control Test

Oil Pump Does Not Run

NOTE: See Legend on page 68.

with Troubleshooting Guides (cont)

Chilled water set point set too high. Access set point on LID and verify. Capacity override or excessive cooling load (chiller at design capacity).

Check LID status messages. Check for outside air inﬁltration into conditioned space.

Condenser temperature too high. Check for proper ﬂow, examine cooling tower operation, check for air or water leaks, check for fouled tubes.

Refrigerant level low. Check for leaks, add refrigerant, and trim charge. Liquid bypass in waterbox. Examine division plates and gaskets for

leaks. Guide vanes fail to open. Use Control Test to check operation. Chilled water control point too high. Access control algorithm status

and check chilled water control operation. Guide vanes fail to open fully. Be sure that the guide vane target is

released. Check guide vane linkage. Check limit switch in actuator. Check that sensor is in the proper terminals.

Chilled water set point set too low. Access set point on LID and verify. Chilled water control point too low. Access control algorithm status and

check chilled water control for proper resets. High discharge temperature keeps guide vanes open. Guide vanes fail to close. Be sure that guide vane target is released.

Check chilled water sensor accuracy. Check guide vane linkage. Check actuator operation.

Deadband too narrow. Conﬁgure LID for a larger deadband. Proportional bands too narrow. Either INC or DEC proportional bands

should be increased. Loose guide vane drive. Adjust chain drive. Defective vane actuator. Check through Control Test. Defective temperature sensor. Check sensor accuracy. Check for proper oil level (not enough oil). Check for proper refrigerant

level (too much refrigerant). Check for proper communications wiring on PSIO module. Check that

the COMM1 communications wires from the LID are terminated to the COMM1 PSIO connection.

Check that PSIO communication plugs are connected correctly. Check SMM communication plug. Check for proper SMM power supply. See Control Modules section on page 78.

Check for proper oil level (too much oil). Check that TXV valve is operating properly.

Increase contrast potentiometer. See Fig. 40. Check red LED on LID for proper operation, (power supply). If LED is blinking, but green LED’s are not, replace LID module, (memory failure)

LID is not properly addressed to the PSIO. Make sure that ‘‘Attach to Network Device,’’ ‘‘Local Device’’ is set to read the PSIO address. Check LED’s on PSIO. Is red LED operating properly? Are green LED’s blinking? See control module troubleshooting section.

Press the ‘‘Stop’’ pushbutton. The PIC must be in the OFF mode for the controls test to operate. Clear all alarms. Check line voltage percent on Status01 screen. The percent must be within 90% to 110%. Check voltage input to SMM, calibrate starter voltage potentiometer for accuracy.

Low pressure alarm is active. Put chiller into pumpdown mode or equalize pressure. Check guide vane actuator wiring.

Check oil pump voltage supply. Cooler vessel pressure under vacuum. Pressurize vessel. Check temperature overload cutout switch.

Page 76

Table 10A — Thermistor Temperature (F) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (Ohms)

−25 4.821 98,010

−24 4.818 94,707

−23 4.814 91,522

−22 4.806 88,449

−21 4.800 85,486

−20 4.793 82,627

−19 4.786 79,871

−18 4.779 77,212

−17 4.772 74,648

−16 4.764 72,175

−15 4.757 69,790

−14 4.749 67,490

−13 4.740 65,272

−12 4.734 63,133

−11 4.724 61,070

−10 4.715 59,081

−9 4.705 57,162

−8 4.696 55,311

−7 4.688 53,526

−6 4.676 51,804

−5 4.666 50,143

−4 4.657 48,541

−3 4.648 46,996

−2 4.636 45,505

−1 4.624 44,066 0 4.613 42,679 1 4.602 41,339 2 4.592 40,047 3 4.579 38,800 4 4.567 37,596 5 4.554 36,435 6 4.540 35,313 7 4.527 34,231 8 4.514 33,185 9 4.501 32,176

10 4.487 31,202 11 4.472 30,260 12 4.457 29,351 13 4.442 28,473 14 4.427 27,624 15 4.413 26,804 16 4.397 26,011 17 4.381 25,245 18 4.366 24,505 19 4.348 23,789 20 4.330 23,096 21 4.313 22,427 22 4.295 21,779 23 4.278 21,153 24 4.258 20,547 25 4.241 19,960 26 4.223 19,393 27 4.202 18,843 28 4.184 18,311 29 4.165 17,796 30 4.145 17,297 31 4.125 16,814 32 4.103 16,346 33 4.082 15,892 34 4.059 15,453 35 4.037 15,027 36 4.017 14,614 37 3.994 14,214 38 3.968 13,826 39 3.948 13,449 40 3.927 13,084 41 3.902 12,730 42 3.878 12,387 43 3.854 12,053 44 3.828 11,730 45 3.805 11,416 46 3.781 11,112 47 3.757 10,816 48 3.729 10,529 49 3.705 10,250 50 3.679 9,979 51 3.653 9,717 52 3.627 9,461 53 3.600 9,213 54 3.575 8,973 55 3.547 8,739 56 3.520 8,511 57 3.493 8,291 58 3.464 8,076

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (Ohms)

59 3.437 7,868 60 3.409 7,665 61 3.382 7,468 62 3.353 7,277 63 3.323 7,091 64 3.295 6,911 65 3.267 6,735 66 3.238 6,564 67 3.210 6,399 68 3.181 6,238 69 3.152 6,081 70 3.123 5,929 71 3.093 5,781 72 3.064 5,637 73 3.034 5,497 74 3.005 5,361 75 2.977 5,229 76 2.947 5,101 77 2.917 4,976 78 2.884 4,855 79 2.857 4,737 80 2.827 4,622 81 2.797 4,511 82 2.766 4,403 83 2.738 4,298 84 2.708 4,196 85 2.679 4,096 86 2.650 4,000 87 2.622 3,906 88 2.593 3,814 89 2.563 3,726 90 2.533 3,640 91 2.505 3,556 92 2.476 3,474 93 2.447 3,395 94 2.417 3,318 95 2.388 3,243 96 2.360 3,170 97 2.332 3,099 98 2.305 3,031

99 2.277 2,964 100 2.251 2,898 101 2.217 2,835 102 2.189 2,773 103 2.162 2,713 104 2.136 2,655 105 2.107 2,597 106 2.080 2,542 107 2.053 2,488 108 2.028 2,436 109 2.001 2,385 110 1.973 2,335 111 1.946 2,286 112 1.919 2,239 113 1.897 2,192 114 1.870 2,147 115 1.846 2,103 116 1.822 2,060 117 1.792 2,018 118 1.771 1,977 119 1.748 1,937 120 1.724 1,898 121 1.702 1,860 122 1.676 1,822 123 1.653 1,786 124 1.630 1,750 125 1.607 1,715 126 1.585 1,680 127 1.562 1,647 128 1.538 1,614 129 1.517 1,582 130 1.496 1,550 131 1.474 1,519 132 1.453 1,489 133 1.431 1,459 134 1.408 1,430 135 1.389 1,401 136 1.369 1,373 137 1.348 1,345 138 1.327 1,318 139 1.308 1,291 140 1.291 1,265 141 1.289 1,240 142 1.269 1,214

TEMPERATURE VOLTAGE RESISTANCE

(F) DROP (V) (Ohms)

143 1.250 1,190 144 1.230 1,165 145 1.211 1,141 146 1.192 1,118 147 1.173 1,095 148 1.155 1,072 149 1.136 1,050 150 1.118 1,029 151 1.100 1,007 152 1.082 986 153 1.064 965 154 1.047 945 155 1.029 925 156 1.012 906 157 0.995 887 158 0.978 868 159 0.962 850 160 0.945 832 161 0.929 815 162 0.914 798 163 0.898 782 164 0.883 765 165 0.868 750 166 0.853 734 167 0.838 719 168 0.824 705 169 0.810 690 170 0.797 677 171 0.783 663 172 0.770 650 173 0.758 638 174 0.745 626 175 0.734 614 176 0.722 602 177 0.710 591 178 0.700 581 179 0.689 570 180 0.678 561 181 0.668 551 182 0.659 542 183 0.649 533 184 0.640 524 185 0.632 516 186 0.623 508 187 0.615 501 188 0.607 494 189 0.600 487 190 0.592 480 191 0.585 473 192 0.579 467 193 0.572 461 194 0.566 456 195 0.560 450 196 0.554 445 197 0.548 439 198 0.542 434 199 0.537 429 200 0.531 424 201 0.526 419 202 0.520 415 203 0.515 410 204 0.510 405 205 0.505 401 206 0.499 396 207 0.494 391 208 0.488 386 209 0.483 382 210 0.477 377 211 0.471 372 212 0.465 367 213 0.459 361 214 0.453 356 215 0.446 350 216 0.439 344 217 0.432 338 218 0.425 332 219 0.417 325 220 0.409 318 221 0.401 311 222 0.393 304 223 0.384 297 224 0.375 289 225 0.366 282

Page 77

Table 10B — Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE

−40 4.896 168 230

−39 4.889 157 440

−38 4.882 147 410

−37 4.874 138 090

−36 4.866 129 410

−35 4.857 121 330

−34 4.848 113 810

−33 4.838 106 880

−32 4.828 100 260

−31 4.817 94 165

−30 4.806 88 480

−29 4.794 83 170

−28 4.782 78 125

−27 4.769 73 580

−26 4.755 69 250

−25 4.740 65 205

−24 4.725 61 420

−23 4.710 57 875

−22 4.693 54 555

−21 4.676 51 450

−20 4.657 48 536

−19 4.639 45 807

−18 4.619 43 247

−17 4.598 40 845

−16 4.577 38 592

−15 4.554 38 476

−14 4.531 34 489

−13 4.507 32 621

−12 4.482 30 866

−11 4.456 29 216

−10 4.428 27 633

−9 4.400 26 202

−8 4.371 24 827

−7 4.341 23 532

−6 4.310 22 313

−5 4.278 21 163

−4 4.245 20 079

−3 4.211 19 058

−2 4.176 18 094

−1 4.140 17 184 0 4.103 16 325 1 4.065 15 515 2 4.026 14 749 3 3.986 14 026 4 3.945 13 342 5 3.903 12 696 6 3.860 12 085 7 3.816 11 506 8 3.771 10 959 9 3.726 10 441

10 3.680 9 949 11 3.633 9 485 12 3.585 9 044 13 3.537 8 627 14 3.487 8 231 15 3.438 7 855 16 3.387 7 499 17 3.337 7 161

TEMPERATURE VOLTAGE RESISTANCE

18 3.285 6 840 19 3.234 6 536 20 3.181 6 246 21 3.129 5 971 22 3.076 5 710 23 3.023 5 461 24 2.970 5 225 25 2.917 5 000 26 2.864 4 786 27 2.810 4 583 28 2.757 4 389 29 2.704 4 204 30 2.651 4 028 31 2.598 3 861 32 2.545 3 701 33 2.493 3 549 34 2.441 3 404 35 2.389 3 266 36 2.337 3 134 37 2.286 3 008 38 2.236 2 888 39 2.186 2 773 40 2.137 2 663 41 2.087 2 559 42 2.039 2 459 43 1.991 2 363 44 1.944 2 272 45 1.898 2 184 46 1.852 2 101 47 1.807 2 021 48 1.763 1 944 49 1.719 1 871 50 1.677 1 801 51 1.635 1 734 52 1.594 1 670 53 1.553 1 609 54 1.513 1 550 55 1.474 1 493 56 1,436 1 439 57 1.399 1 387 58 1.363 1 337 59 1.327 1 290 60 1.291 1 244 61 1.258 1 200 62 1.225 1 158 63 1.192 1 118 64 1.160 1 079 65 1.129 1 041 66 1.099 1 006 67 1.069 971 68 1.040 938 69 1.012 906 70 0.984 876 71 0.949 836 72 0.920 805 73 0.892 775 74 0.865 747 75 0.838 719

TEMPERATURE VOLTAGE RESISTANCE

76 0.813 693 77 0.789 669 78 0.765 645 79 0.743 623 80 0.722 602 81 0.702 583 82 0.683 564 83 0.665 547 84 0.648 531 85 0.632 516 86 0.617 502 87 0.603 489 88 0.590 477 89 0.577 466 90 0.566 456 91 0.555 446 92 0.545 436 93 0.535 427 94 0.525 419 95 0.515 410 96 0.506 402 97 0.496 393 98 0.486 385

99 0.476 376 100 0.466 367 101 0.454 357 102 0.442 346 103 0.429 335 104 0.416 324 105 0.401 312 106 0.386 299 107 0.370 285

Page 78

Control Modules

red LED is normal, check the module address switches (Fig. 39-43). Proper addresses are:

Turn controller power off before servicing controls. This ensures safety and prevents damage to controller.

The Processor module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous diagnostic evaluations of the hardware to determine its condition. See Fig. 39-43. Proper operation of all modules is indicated by LEDs (light-emitting diodes) located on the side of the LID, and on the top horizontal surface of the PSIO, SMM, and 8-input modules.

RED LED — If the LED is blinking continuously at a 2-second rate, it is indicating proper operation. If it is lit continuously it indicates a problem requiring replacement of the module. Off continuously indicates that the power should be checked. If the red LED blinks 3 times per second, a software error has been discovered and the module must be replaced. If there is no input power, check fuses and the circuit breaker. If fuse is good, check for shorted secondary of transformer, or if power is present to the module, replace the module.

GREEN LEDs — There are one or 2 green LEDs on each type of module. These LEDs indicate communication status between differentparts of the controller and the network modules as follows:

LID Module Upper LED — Communication with CCN network, if present;

blinks when communication occurs. Lower LED — Communication with PSIO module; must

blink every 5 to 8 seconds when the LID default screen is displayed.

PSIO Module GreenLED Closest to Communications Connection —Com-

munication with SMM and 8-input module; must blink continuously.

Other Green LED — Communication with LID; must blink every 3 to 5 seconds.

MODULE

SMM (Starter Management Module) 32 8-input Options Module 1 64 8-input Options Module 2 72

ADDRESS

S1 S2

If all modules indicate communications failure, check communications plug on the PSIO module for proper seating. Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, replace the PSIO module.

If only one 8-input module or SMM indicates communication failure, check the communications plug on that module. If a good connection is assured and the condition persists, replace the module.

All system operating intelligence rests in the PSIO module. Some safety shutdown logic resides in the SMM in case communications are lost between the 2 modules. The PSIO monitors conditions using input ports on the PSIO, the SMM, and the 8-input modules. Outputs are controlled by the PSIO and SMM as well.

3. Power is supplied to modules within the control panel via 21-vac power sources.

The transformers are located within the power panel, with the exception of the SMM, which operates from a 24-vac power source and has its own 24-vac transformer located within the starter.

Within the power panel, T1 supplies power to the LID, the PSIO, and the 5-vac power supply for the transducers. The other 21-vac transformer is T4, which supplies power to both 8-input modules (if present). T4 is capable of supplying power to two modules; if additional modules are added, another power supply will be required.

Power is connected to Terminals 1 and 2 of the power input connection on each module.

8-Input Modules and SMM GreenLED — Communication with PSIO module; will blink

continuously.

Notes on Module Operation

1. The chiller operator monitors and modiﬁes conﬁgurations in the microprocessor through the 4 softkeys and the LID. Communication with the LID and the PSIO is accomplished through the CCN bus. The communication between the PSIO, SMM, and both 8-input modules is accomplished through the sensor bus, which is a 3-wire cable.

On sensor bus terminal strips, Terminal 1 of PSIO module is connected to Terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner.See Fig. 39-43. If a Terminal 2 wire is connected to Terminal 1, the system does not work.

2. If a green LED is solid on, check communication wiring. If a green LED is off, check the red LED operation. If the

Fig. 39 — PSIO Module Address Selector Switch

Locations and LED Locations

Page 79

NOTE: Address switches on this module can be at any position. Addresses are only changed through the LID screen or CCN.

Fig. 40 — LID Module (Rear View) and

LED Locations

Starter Management Module (SMM) (Fig. 42)

INPUTS — Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. Application of the chiller determines which terminals are used. Always refer to the individual unit wiring diagram for terminal numbers.

OUTPUTS — Outputs are 24 vdc and wired to strip J1. There are 2 terminals used per output.

Processor Module (PSIO) (Fig. 41)

INPUTS — Each input channel has 3 terminals; only 2 of the terminals are used.Application of chiller determines which terminals are normally used. Always refer to individual unit wiring for terminal numbers.

OUTPUTS — Output is 20 vdc. There are 3 terminals per output, only 2 of which are used, depending on the application. Refer to the unit wiring diagram.

NOTE: SMM address switches should be set as follows:

S1 set at 3; S2 set at 2.

Fig. 42 — Starter Management Module

(SMM)

Options Modules (8-Input) — The options modules

are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, and demand limit inputs. Each option module contains 8 inputs, each input meant for a speciﬁc duty. See the wiring diagram for exact module wire terminations. Inputs for each of the options modules available include the following:

OPTIONS MODULE 1

4 to 20 mA Auto. Demand Reset 4 to 20 mA Auto. Chilled Water Reset Common Chilled Water Supply Temperature Common Chilled Water Return Temperature Remote Temperature Reset Sensor Spare Temperature 1 Spare Temperature 2 Spare Temperature 3

NOTE: Address switches on this module can be at any position. Addresses are only changed through the LID screen or CCN.

Fig. 41 — Processor (PSIO) Module

OPTIONS MODULE 2 4 to 20 mA Spare 1

4 to 20 mA Spare 2 Spare Temperature 4 Spare Temperature 5 Spare Temperature 6 Spare Temperature 7 Spare Temperature 8 Spare Temperature 9

Page 80

Terminal block connections are provided on the options modules. All sensor inputs are ﬁeld wired and installed. Options module number 1 can be factory or ﬁeld-installed. Options module 2 is shipped separately and must be ﬁeld installed. For installation, refer to the unit or ﬁeld wiring diagrams. Be sure to address the module for the proper module number (Fig. 43) and to conﬁgure the chiller for each feature being used.

SWITCH

SETTING

S1 67 S2 42

OPTIONS

MODULE 1

OPTIONS

MODULE 2

Fig. 43 — Options Module

Replacing Defective Processor Modules — The

replacement part number is printed in a small label on front of the PSIO module. The model and serial numbers are printed on the unit nameplate located on an exterior corner post. The proper software is factory-installed by Carrier in the replacement module. When ordering a replacement processor module (PSIO), specify complete replacement part number,full unit model number, and serial number.This new unit requires reconﬁguration to the original chiller data by the installer. Follow the procedures described in the Set Up Chiller Control Conﬁguration section on page 50.

Electrical shock can cause personal injury. Disconnect all electrical power before servicing.

INSTALLATION

1. Verify that the existing PSIO module is defective by using the procedure described in the Troubleshooting Guide section, page 66, and Control Modules section, page 78. Do not select the Attach to Network Device table if the LID displays communication failure.

2. Data regarding the PSIO conﬁguration should have been recorded and saved. This data will have to be reconﬁgured into the LID. If this data is not available, follow the procedures described in the Set Up Chiller Control Conﬁguration section.

If a CCN Building Supervisor or Service Tool is present, the module conﬁguration should have already been uploaded into memory; then, when the new module is installed, the conﬁguration can be downloaded from the computer.

Any communication wires from other chillers or CCN modules should be disconnected to prevent the new PSIO module from uploading incorrect run hours into memory.

3. To install this module, ﬁrst record the TOTAL COM- PRESSOR STARTS and the COMPRESSOR ONTIME from the Status01 table screen on the LID.

4. Power off the controls.

5. Remove the old PSIO. DO NOT install the new PSIO at this time.

6. Turn on the control power. When the LID screen reappears, press the MENU

SERVICE

softkey. Enter the password, if applicable.

softkey, then press the

Move the highlight bar down to the ATTACH TO NETWORK DEVICE line. Press the SELECT Now, press the ATTACH

softkey. The LID will dis-

softkey.

play ‘‘UPLOADING TABLES, PLEASE WAIT’’ and then display ‘‘COMMUNICATIONS FAILURE.’’ Press

the EXIT softkey.

7. Turn the control power off.

8. Install the new PSIO module. Turn the control power back on.

9. The LID will now automatically upload the new PSIO module.

10. Access the Status01 table and move the highlight bar down to the TOTALCOMPRESSOR STARTSline. Press

the SELECT

softkey. Increase the value to indicate

the correct starts value recorded in Step 2. Press the

ENTER

softkey when you reach the correct value. Now, move the highlight bar to the COMPRESSOR ON- TIME line. Press the SELECT

softkey.Increase the run

hours value to the value recorded in Step 2. Press the

ENTER

softkey when the correct value is reached.

11. Complete the PSIO installation. Following the instructions in the Start-up, Operation, and Maintenance manual, input all the proper conﬁgurations such as time, date, etc. Re-calibrate the motor amps and check the pressure transducer calibrations. PSIO installation is now complete.

Page 81

Solid-StateStarters — Troubleshooting guides and in-

formation pertaining to the operation of the solid-state starter may be found in Fig. 44-46 and Table 11.

Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting table.

When the power is off:

• Inspect for physical damage and signs of arcing, overheat-

ing, etc.

• Is the wiring to the starter correct?

• Are all connections in the starter tight?

• Is the current feedback resistor properly adjusted and

installed?

• Is a heater coil installed in each leg of the motor?

• Is the control transformer fuse blown?

• Is the motor connected to the starter? TESTING SILICON CONTROL RECTIFIERS IN

BENSHAW, INC. SOLID-STATE STARTERS — If a silicon control rectiﬁer (SCR) is suspected of being defective, use the following procedure as part of a general troubleshooting guide.

IMPORTANT: Before performing the SCR check below,remove power from the starter and disconnect the motor terminals T1, T2, and T3.

1. Connect ohmmeter across terminals L1 and T1. Resis-

tance reading should be greater than 50,000 ohms.

2. If reading is less than 50,000 ohms, remove connecting

bus heatsink between SCR3 and SCR6 and check anode to cathode of SCR3 and SCR6 separately to determine which device is defective. See Fig. 44. Replace defective device and retest controller.

3. Repeat Steps 1 and 2 across terminals L2 and T2 for SCRs

2 and 5.

4. Repeat Steps 1 and 2 across terminals L3 and T3 for SCRs

1 and 4. If the SCRs tested were not defective but the problem

still persists, refer to the following Steps 5 and 6.

5. Disconnect the SCR1 from the white gate and red cath-

ode wires on the AK control logic card. With an ohmmeter set on Rx1, check between white and red wires.

LEGEND

SCR — Silicon Control Rectiﬁer

Fig. 44 — Typical Benshaw, Inc. Solid-State

Starter (internal View)

Resistance should normally be between 8 and 20 ohms average. Excessively high or low resistance may be indicative of a defective logic card. Replace and retest.

6. Repeat Step 5 for SCR leads 2 through 6. Care should be taken to ensure that the gate and cathode wires are replaced exactly as they were: white wire to gate (G1 through G6); red wire to cathode (K1 through K6).

Damage to the starter may result if wires are reversed.

If the problem is still not resolved, consult the starter manu-

facturer for servicing.

Page 82

LEGEND SCR — Silicon Control Rectiﬁer *See test procedure described in Testing SCRs in Solid-State Starters section on page 81.

Fig. 45 — Solid-State Starter, General Operation Troubleshooting Guide (Typical)

Page 83

Fig. 46 — Solid-State Starter, Starter Fault (Motor Will Not Start)

Troubleshooting Guide (Typical)

Page 84

Table 11 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide

PROBLEM PROBABLE CAUSES AREA OF CORRECTION

AK board phase correct not on.

AK board relay not on. Ribbon cable not properly

AK board power +15 vdc not on.

1L boards LEDs not on. 1. A short exists between line

BC board over-temperature LED (L3) on prior to run command.

BC board LEDs on prior to run command.

BC board LEDs not on after run command but before starter reaches full voltage.

1L board LEDs remain on after starter reaches full voltage.

BC board run LED (L5) not lit. BC board not functioning

AK board power applied, run command given, starter at full voltage, but aux LED not lit.

1L boards LEDs lit. Motor terminal voltage phase

BC board LED L4 and L5 not lit.

BC board LED L3 lit. 1. FU5 and FU6 fuses not

BC board L2 lit. SCR phases not functioning BC board L1 lit. Motor lead grounded. Megger motor to test for motor lead going to ground.

Start command given. Motor does not begin rotation. Turn ‘Starting Torque’ potentiometer RV2 clockwise until motor

Motor does not reach full speed within 25 seconds.

115 vac missing from LL1 and LL2.

SMM not responding. 1. CB4 is not on.

1. L1 and L3 switch phases reversed.

2. Missing phase voltage.

3. Improper line voltage.

seated.

1. Improper line voltage.

2. Transformer malfunction.

and load terminals.

2. An SCR is shorted in the phase assembly.

1. Temperature switch not functioning properly.

2. BC board not functioning properly.

BC board not functioning properly.

1. Phase assembly malfunction.

2. BC board not functioning properly.

Imbalance between phases exists in motor terminal voltages.

properly.

AK board not functioning properly.

imbalance exists. BC board not functioning

properly.

functioning properly.

2. Phase assembly not functioning properly.

3. Fan not functioning properly.

properly.

Ramp up setting is not correct. Turn ‘Ramp’ potentiometer RV1 counterclockwise. Restart motor

1. CB2 is not on.

2. Fuse no. 4 (FU4) blown.

2. Potentiometer RV1 needs adjustment.

1. Switch incoming phases L1 and L3 at top of CD1 or CB1.

2. Check for missing phase voltage.

3. Verify proper line voltage applied against synchronizing transformer voltage.

Check ribbon cable for proper seating. Replace board if necessary.

1. Make sure proper line voltage is present at primary synchronizing transformer.

2. Check synchronizing transformer secondary voltage as follows: On the BC board, measure from TB11-1 to TB11-2 and TB11-1 to TB11-3. Both readings should be within 30 to 36 vac. On the BC board, measure from TB11-1 to TB11-4 and TB11-2 to TB11-4. Both readings should be within 18 to 24 vac. Replace synchronizing transformer if voltages are not within the speciﬁed tolerances.

1. Remove power and check resistance with ohmmeter. Locate and remove stray wire strands if required.

2. Remove power. Use ohmmeter to measure the resistance or each SCR phase assembly from anode to cathode. The reading should be 50,000 ohm or greater. If not, replace phase assembly.

1. Disconnect power and check for continuity between TB11-10 and TB11-11. If no continuity exists, the overtemperature switch is not functioning properly. Replace defective switch if necessary.

2. Make sure BC board is functioning properly. Replace board if necessary.

Board not functioning properly. Replace board, if necessary.

1. Remove power and check SCRs. Ohmmeter reading of each SCR gate to cathode resistance at terminals is 8 to 20 ohm. If not, replace the phase assembly.

2. Replace board, if necessary.

Check for loose SCR gate lead or open SCR gate. Replace phase assembly, if necessary.

Measure 24 vdc at TB11-8 to TB11-4. If voltage is present, replace board. If not present, replace relay 1CR.

Replace board.

Check motor terminal voltages for imbalance between phases. If an imbalance exists, check for loose SCR gate or open SCR gate. Replace phase assembly, if necessary.

Replace board.

1. Check fuses FU5 and FU6. Replace if necessary.

2. Verify that bypass is pulling in by measuring the voltage drop across the contacts. The reading should be 50 mV or less. Replace phase assembly, if necessary.

3. Verify fan operation on each phase for 200 amp units. Replace fan, if necessary.

Measure resistance from anode to cathode for each SCR phase assembly. Replace shorted phase, if necessary.

rotation begins. and verify that motor reaches full speed within 25 seconds.

1. Verify CB2 is on.

2. Check FU4 for continuity. Replace, if necessary.

1. Verify CB4 is on.

2. Adjust potentiometer RV1 for 24 vac at SMM terminals J3-23 and J3-24.

AK — Vendor Board Designation BC — Vendor Board Designation CB — Circuit Breaker CD — Disconnect Switch CR — Control Relay FU — Fuse LED — Light-Emitting Diode

LEGEND

L1, L3 — Terminal Board LL1, LL2 — Control Power Terminals RV1 — Line Voltage Signal Calibration SCR — Silicon Control Rectiﬁer SMM — Starter Management Module TB — Terminal Board

Page 85

Physical Data — Tables 12-17 and Fig. 47-51 pro-

vide additional information regarding compressor ﬁts and

Table 12 — Heat Exchanger Data

RIGGING WEIGHTS VESSEL CHARGE

Dry Wt. Refrigerant

VESSEL

COOLER

HEAT

EXCHANGER

CODE

40 201 5000 2275 5340 2422 1020 463 750 341 550 250 53 201 41 227 5150 2350 5485 2488 1090 494 800 363 600 272 58 220 42 257 5325 2425 5655 2565 1150 522 900 408 650 295 64 242 43 290 5500 2500 5845 2651 1200 544 1000 454 700 318 71 269 50 314 6625 3000 7020 3184 1450 658 1150 522 750 341 79 299 51 355 6850 3100 7255 3291 1500 680 1250 568 850 386 87 329 52 400 7100 3225 7510 3406 1580 717 1400 636 950 431 96 363 53 445 7375 3350 7770 3524 1650 748 1500 681 1000 454 104 394 55 201 — — 8510 3860 — — 1410 640 1060 481 104 395 56 227 — — 8845 4012 — — 1710 776 1160 527 115 438 57 257 — — 9205 4175 — — 2010 913 1260 572 128 486 58 290 — — 9575 4343 — — 2210 1003 1410 640 140 531

NUMBER

OF TUBES

Design I Design II

Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Gal L

COOLER

clearances, physical and electrical data, and wiring schematics for operator convenience during troubleshooting.

Design I Design II HCFC-22 HCFC-22 HFC-134a

Volume

of Water

CONDENSER

VESSEL

CONDENSER

NOTES:

1. Design I chillers are equipped with a ﬂoat box, and chiller weight is based on a 150 psi (1034 kPa) waterbox with 2 pass arrangement.

2. Design II chillers are equipped with a linear ﬂoat, and chiller weight is based on a 300 psi (2068 kPa) waterbox with 1 pass arrangement.

3. Total refrigerant charge is equal to the cooler charge added to the condenser charge.

HEAT

EXCHANGER

CODE

40 218 5050 2100 4855 2202 400 181 350 159 56 212 41 246 5200 2350 5010 2272 400 181 350 159 62 235 42 279 5375 2450 5180 2350 400 181 350 159 68 257 43 315 5575 2525 5370 2436 400 181 350 159 75 284 50 347 7050 3200 6750 3062 400 181 350 159 84 318 51 387 7275 3300 6960 3157 400 181 350 159 92 348 52 432 7500 3400 7200 3266 400 181 350 159 101 382 53 484 7775 3525 7475 3391 400 181 350 159 110 416 55 218 — — 8345 3785 — — 490 222 112 423 56 246 – — 8635 3917 — — 490 222 123 466 57 279 — — 8980 4073 — — 490 222 135 513 58 315 — — 9370 4250 — — 490 222 149 565

NUMBER

OF TUBES

RIGGING WEIGHTS VESSEL CHARGE

Dry Wt. Refrigerant

Design I Design II Design I Design II

Lb Kg Lb Kg Lb Kg Lb Kg Gal L

Table 13 — Additional Data for Marine Waterboxes*

Volume

of Water

ENGLISH SI

HEAT EXCHANGER

FRAME, PASS

FRAME 4, 2 PASS 1115 660 69 51 506 300 261 193 FRAME 4,1&3PASS 2030 1160 138 101 922 527 524 384 FRAME 5, 2 PASS 1220 935 88 64 554 424 331 243 FRAME 5,1&3PASS 2240 1705 175 128 1017 774 663 486

*Add to heat exchanger weights and volumes for total weight or volume.

Rigging Wt

(lb)

Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser

Water Volume

(gal)

Rigging Wt

(kg)

Water Volume

(L)

Page 86

HEAT

EXCHANGER

COOLERS

CONDENSERS

HEAT

EXCHANGER

COOLERS

CONDENSERS

LEGEND

NIH — Nozzle-in-Head MWB — Marine Waterbox CS — Contact Syracuse

DESCRIPTION

NIH, 1 PASS COVER 284 414 324 491 412 578 452 655 NIH, 2 PASS COVER 285 411 341 523 410 573 466 685 NIH, 3 PASS COVER 292 433 309 469 423 602 440 638 NIH, PLAIN END COVER 243 292 243 292 304 426 304 426 MWB COVER CS 621 CS 621 CS 766 CS 766 PLAIN END COVER CS 482 CS 482 CS 471 CS 471 NIH, 1 PASS COVER 306 446 346 523 373 472 413 549 NIH, 2 PASS COVER 288 435 344 547 368 469 428 541 NIH, 3 PASS COVER 319 466 336 502 407 493 419 549 NIH, PLAIN END COVER 226 271 226 271 271 379 271 379 MWB COVER CS 474 CS 474 CS 590 CS 590 PLAIN END COVER CS 359 CS 359 CS 428 CS 428

WATERBOX

DESCRIPTION

NIH, 1 PASS COVER 129 188 147 223 187 262 205 297 NIH, 2 PASS COVER 129 187 155 237 186 260 212 311 NIH, 3 PASS COVER 133 197 140 213 192 273 200 290 NIH, PLAIN END COVER 110 133 110 133 138 193 138 193 MWB COVER CS 282 CS 282 CS 348 CS 348 PLAIN END COVER CS 219 CS 219 CS 214 CS 214 NIH, 1 PASS COVER 139 202 157 237 169 214 188 249 NIH, 2 PASS COVER 131 197 156 248 167 213 194 246 NIH, 3 PASS COVER 145 212 153 228 185 224 190 249 NIH, PLAIN END COVER 103 123 103 123 123 172 123 172 MWB COVER CS 215 CS 215 CS 268 CS 268 PLAIN END COVER CS 163 CS 163 CS 194 CS 194

WATERBOX

Table 14 — Waterbox Cover Weights*

ENGLISH (lb)

FRAME 4,

STANDARD

NOZZLES

150 psig 300 psig 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig

FRAME 4, FLANGED

SI (kg)

FRAME 4,

STANDARD

NOZZLES

1034 kPa 2068 kPa 1034 kPa 2068 kPa 1034 kPa 2068 kPa 1034 kPa 2068 kPa

*These weights are for reference only. To determine frame size, see Fig. 1. NOTE: For Design I chillers, the 150 psig (1034 kPa) standard waterbox cover weights (NIH, 2-pass

cover) have been included in the heat exchanger weights shown in Table 12. Design II chillers are equipped with a linear ﬂoat, and chiller weight is based on a 300 psig (2066 kPa) waterbox with 1-pass arrangement.

FRAME 4, FLANGED

FRAME 5,

STANDARD

NOZZLES

FRAME 5,

STANDARD

NOZZLES

FRAME 5, FLANGED

FRAME 5,

FLANGED

Page 87

Table 15 — Compressor/Motor Weights

ENGLISH SI

MOTOR

SIZE

CB 2660 1135 1147 171 233 250 1208 515 520 78 106 114 CC 2660 1143 1150 197 239 250 1208 518 522 90 109 114 CD 2660 1153 1213 234 252 250 1208 523 551 106 114 114 CE 2660 1162 1227 237 255 250 1208 528 557 108 116 114 CL 2660 1202 1283 246 270 250 1208 546 582 112 123 114 CM 2660 1225 1308 254 275 250 1208 556 594 115 125 114 CN 2660 1276 1341 263 279 250 1208 579 609 119 127 114 CP 2660 1289 1356 266 284 250 1208 585 616 121 129 114 CQ 2660 1306 1363 273 287 250 1208 593 619 124 130 114 CR 2660 1335 1384 282 294 250 1208 606 628 128 133 114

NOTE: For medium voltage motors add 85 lbs (39 kg) to above for 60 Hz motors and 145 lbs (66 kg) for 50 Hz motors. Total compressor/motor weight is the sum of the compressor, stator, rotor, and end bell cover weight. Compressor weight includes suction and discharge elbow weights.

Compressor

Weight

(lb)

Stator Weight

(lb)

60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz

Rotor Weight

(lb)

End Bell

Cover

(lb)

Compressor

Weight

(kg)

Stator Weight

(kg)

Rotor Weight

(kg)

End Bell

Cover

(lb)

Table 16 — Compressor Weights

COMPONENT

SUCTION ELBOW 55 25 DISCHARGE ELBOW 50 23 TRANSMISSION 730 331 SUCTION HOUSING 350 159 IMPELLER SHROUD 80 36 COMPRESSOR BASE 1050 476 DIFFUSER 70 32 OIL PUMP 150 68 MISCELLANEOUS 135 61 TOTAL WEIGHT

(Less Motor)

WEIGHT

Lb Kg

2660 1207

Table 17 — Optional Pumpout System

Electrical Data

MOTOR

CODE

1 19EA47-748 575-3-60 3.8 23.0 4 19EA42-748 200/208-3-60 10.9 63.5 5 19EA44-748 230-3-60 9.5 57.5 6 19EA46-748 400/460-3-50/60 4.7 28.8

LRA — Locked Rotor Amps RLA — Rated Load Amps

CONDENSER

UNIT

LEGEND

VOLTS-PH-Hz

MAX RLA

LRA

Page 88

NOTES:

1. Dimensions are in inches with rotor in the thrust position.

2. All clearances listed are new chiller tolerances.

3. All radial clearances are diametrical.

NOTE: Radial clearances shown are diametrical.

Fig. 47 — Compressor Fits and Clearances

Page 89

COMPRESSOR ASSEMBLY TORQUES

ITEM DESCRIPTION

1* Oil Heater Grommet Nut 10 14

2 Impeller Retaining Bolt 44-46 60-62 3 Bull Gear Retaining Bolt 80-85 108-115 4 Motor Terminals (Low Voltage) 50 68

5 Demister Bolts 15-19 20-26 6* Guide Vane Shaft Seal Nut 25 34 7* Motor Terminals (High Voltage)

LEGEND N•m — Newton Meters *Not shown.

— Insulator 2-4 2.7-5.4 — Packing Nut 5 6.8 — Brass Jam Nut 10 13.6

TORQUE

ft-lb N•m

*‘‘Z’’clearance is determined by a combination of impeller diameter and shroud size. The

table lists ‘‘Z’’ clearances for each compressor code. Figure 1 shows the location (on the chiller information plate) of the compressor code for each chiller.

COMPRESSOR

CODE

203-204 .025 0.635 223-274 .015 0.381 283-307 .025 0.635 321-377 .015 0.381 381-397 .025 0.635 410-469 .015 0.381 470-499 .025 0.635

‘‘Z’’

(in.)

‘‘Z’’

(mm)

COMPRESSOR

CODE

516-517 .015 0.381 518-519 .025 0.635 526-527 .015 0.381 528-529 .025 0.635 536-537 .015 0.381 538-539 .025 0.635

‘‘Z’’ (in.)

(mm)

Fig. 47 — Compressor Fits and Clearances (cont)

‘‘Z’’

COMPRESSOR

CODE

546-547 .015 0.381 548-549 .025 0.635 556-557 .015 0.381 558-559 .025 0.635 566-567 .015 0.381 568-569 .025 0.635

‘‘Z’’

(in.)

‘‘Z’’

(mm)

Page 90

BRG — Bearing C—Contact CB — Circuit Breaker CLR — Clear COM — Common COMM — Communication Connector EXT — External G.V. — Guide Vane HGBP — Hot Gas Bypass INT — Internal J—Module Connector K—Relay Designation LID — Local Interface Device MA — Milliampere NC — Normally Closed

LEGEND

NO — Normally Open PSIO — Processor Sensor Input/

RBPL — Relay Board Plug S—Compressor Motor Start Contactor SMM — Starter Management Module SOL — Solenoid TB — Terminal Board

Output Module

Carrier Factory Wiring Optional (Factory or Field-Installed)

Wiring Thermistor

Fig. 48 — Electronic PIC Controls Wiring Schematic

(For 19XL with No Backlight or with Fluorescent Backlight)

Page 91

(For 19XL with No Backlight or with Fluorescent Backlight) (cont)

Fig. 48 — Electronic PIC Controls Wiring Schematic

Page 92

LEGEND

NO — Normally Open PSIO — Processor Sensor Input/

RBPL — Relay Board Plug S—Compressor Motor Start Contactor SMM — Starter Management Module SOL — Solenoid TB — Terminal Board

Output Module

Carrier Factory Wiring Optional (Factory or Field-Installed)

Wiring Thermistor

Fig. 49 — Electronic PIC Controls Wiring Schematic

(For 19XL with Halogen Backlight)

Page 93

Fig. 49 — Electronic PIC Controls Wiring Schematic

(For 19XL with Halogen Backlight) (cont)

Page 94

1M — Main Starter Contactor C—Contactor CB — Circuit Board CR — Control Relay COMM — Communications Connector J—Connector N.C. — Normally Closed N.O. — Normally Open OL — Overload OS — 3-Phase Current Power Source

*All starters, including across-the-line starters, require 2 separate contacts for the START AUX

DRY contact and RUN AUX DRY contact, as shown above.

LEGEND

PR — Pilot Relay PWR — Power RLA — Rated Load Amps SMM — Starter Management Module TB — Terminal Board X—Variable Number

Starter Cabinet Wiring Field Wiring Carrier Factory Wiring

Fig. 50 — Chiller Power Panel, Starter Assembly,

and Motor Wiring Schematic

Page 95

Fig. 50 — Chiller Power Panel, Starter Assembly,

and Motor Wiring Schematic (cont)

Page 96

PMR — Phase Loss Reversal Relay

PMRVR — Phase Loss, Phase Reversal,

LEGEND

Overvoltage, Undervoltage Relay

POT — Potentiometer

PR — Pilot Relay

S—Compressor Motor Start Contactor

SMM — Starter Management Module

ST — Shunt Trip

T—Motor Terminal

TB — Terminal Board

TR — Transition Resistor

TRFP — Transition Resistor Fault Protector

X—Variable Number

X1, X2 — Power Transformer Output Terminal

Dry Contact

1M, 2M — Main Compressor Contactors

CB — Circuit Breaker

CR — Control Relay

CT — Current Transformer

DS — Disconnect

GF — Ground Fault

GFR — Ground Fault Relay

H1, H2 — Power Transformer Input

Terminal

HPS — High-Pressure Switch

J—Module Connector

L1, L2, L3 — 3-Phase Line Terminals

NC — Normally Closed

OL — Overload

Source to Oil Pump

— 3-Phase Current Power

OS1, OS2,

OS3

Fig. 51 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic

Page 97

NOTE: Optional features are indicated by bold dotted boxes.

Yellow wires remain energized when main disconnect is off.

(1A) remains energized for longer than one second.

1. Contactors 2M and S are mechanically interlocked.

2. Transition resistor fault protector (TRFP) is preset to trip if transition contactor

NOTES:

overvoltage, undervoltage relay (PMRVR)is not provided, terminals 3-13Aand

3-13B are jumpered together.

3. When optional phase loss reversal relay (PMR) or phase loss, phase reversal,

4. When optional ground fault is not provided, terminals 3-13B and 3-13C are

jumpered together.

5. Thisoil pump circuit breaker and terminal board TB7 are provided only onstart-

ers for centrifugal machines.

6. POT to be adjusted to 24 v at rated line voltage.

7. CT4 and CT5 are provided only when the optional watt transducer is provided.

8. These 3 wires to the ammeter switch are connected together only when the

optional 3-phase ammeter is not provided.

is provided. The combination PMRVR has an internal time delay and does not

require PMRTR.

9. PMRTR is provided only if the optional phase loss phase reversal relay (PMR)

the control wires within the starter. Wires entering terminal boards are marked

10. Connections on the above schematic are numbered to match the markings on

Fig. 51 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic (cont)

with the terminal number.

11. Oil pump AUX. contact not supplied on screw machines.

Page 98

Abbreviations and Explanations, 4 Adding Refrigerant, 61 Adjusting the Refrigerant Charge, 61 After Extended Shutdown, 57 After Limited Shutdown, 57 Attach to Network Device Control, 37 Automatic Soft-Stop Amps Threshold, 40 Auto. Restart After Power Failure, 33 Before Initial Start-Up, 41 Calibrate Motor Current, 56 Capacity Override, 31 Carrier Comfort Network Interface, 48 Changing Oil Filter, 63 Charge Refrigerant Into Chiller, 53 Chilled Water Recycle Mode, 40 Chiller Dehydration, 47 Chiller Familiarization, 5 Chiller Information Plate, 5 Chiller Operating Condition (Check), 56 Chiller Tightness (Check), 41 Chillers with Isolation Valves, 60 Chillers with Pumpout Storage Tanks, 59 Cold Weather Operation, 57 Compressor Bearing and Gear Maintenance, 64 Condenser, 5 Condenser Freeze Prevention, 32 Condenser Pump Control, 32 Control Algorithms Checkout Procedure, 67 Control Center, 5, 63 Control Modules, 78 Control Test, 67 Controls, 11 Cooler, 5 Default Screen Freeze, 29 Deﬁnitions (Controls), 11 Demand Limit Control, Option, 33 Design Set Points, (Input), 50 Details (Lubrication Cycle), 8 Display Messages (Check), 66 Dry Run to Test Start-Up Sequence, 55 Equipment Required, 41 Extended Shutdown, 57 Factory-Mounted Starter, 5 General (Controls), 11 General Maintenance, 61 Guide Vane Linkage (Check), 62 Heat Exchanger Tubes (Inspect), 64 High Altitude Locations, 53 High Discharge Temperature Control, 32 Ice Build Control, 36 Initial Start-Up, 55 Instruct the Customer Operator, 56 Introduction, 4 Job Data Required, 41 Lead/Lag Control, 34 Leak Rate, 61 Leak Test Chiller, 41 LID Operation and Menus, 14 Local Occupied Schedule (Input), 50 Local Start-Up, 39 Lubrication Cycle, 8 Lubrication System (Check), 62 Manual Guide Vane Operation, 57 Manual Operation of the Guide Vanes, 55 Motor-Compressor, 5 Motor Cooling Control, 29 Motor/Oil Refrigeration Cooling Cycle, 5 Notes on Module Operation, 78

INDEX

Oil Changes, 63 Oil Charge, 50 Oil Cooler, 32 Oil Pressure and Compressor Stop (Check), 56 Oil Reclaim Filters, 63 Oil Reclaim System, 9 Oil Speciﬁcation, 63 Oil Sump Temperature Control, 32 Open Oil Circuit Valves, 41 Operating Instructions, 56 Operating the Optional Pumpout Compressor, 59 Operator Duties, 56 Optional Pumpout System Maintenance, 65 Options Modules, 79 Ordering Replacement Chiller Parts, 65 Overview (Troubleshooting Guide), 66 Physical Data, 85 PIC System Components, 11 PIC System Functions, 28 Power Up the Controls and Check the Oil Heater, 50 Pumpout Compressor Water Piping (Check), 47 Pumpout System Controls and Compressor (Check), 52 Preparation (Initial Start-Up), 55 Preparation (Pumpout and Refrigerant Transfer

Procedures), 59 Prepare the Chiller for Start-Up, 56 Pressure Transducers (Check), 65, 66 Prevent Accidential Start-Up, 56 Processor Module, 79 Pumpout and Refrigerant Transfer Procedures, 59 Ramp Loading Control, 31 Refrigerant Filter, 63 Refrigerant Float System (Inpsect), 64 Refrigerant Leak Testing, 61 Refrigerant Properties, 61 Refrigerant (Removing), 61 Refrigerant Tracer, 41 Refrigeration Cycle, 5 Refrigeration Log, 57 Relief Devices (Check), 47 Relief Valves and Piping (Inspect), 64 Remote Start/Stop Controls, 32 Repair the Leak, Retest, and Apply Standing

Vacuum Test, 62 Replacing Defective Processor Modules, 80 Rotation (Check), 55 Running System (Check), 56 Safety and Operating Controls (Check Monthly), 63 Safety Considerations, 1 Safety Controls, 29 Safety Shutdown, 41 Scheduled Maintenance, 63 Selecting Refrigerant Type, 50 Service Conﬁguration (Input), 50 Service Ontime, 63 Service Operation, 38 Set Up Chiller Control Conﬁguration, 50 Shipping Packaging (Remove), 41 Shutdown Sequence, 40 Solid-State Starters, 81 Spare Safety Inputs, 32 Standing Vacuum Test, 43 Starter (Check), 48 Starter Management Module, 79 Starting Equipment, 10, 65 Start-Up/Shutdown/Recycle Sequence, 39 Start the Chiller, 56 Stop the Chiller, 57

Page 99

Storage Vessel, 5 Summary (Lubrication Cycle), 8 Surge Prevention Algorithm, 33 Surge Protection, 34 System Components, 5 Temperature Sensors (Check), 66 Test After Service, Repair, or Major Leak, 61 Tighten All Gasketed Joints and Guide Vane Shaft

Packing, 41 Tower Fan Relay, 33 Trim Refrigerant Charge, 62

INDEX (cont)

Troubleshooting Guide, 66 Unit Mounted Solid-State Starter, 10 Unit Mounted Wye-Delta Starter, 11 Using the Optional Storage Tank and Pumpout

System, 41 Water/Brine Reset, 33 Water Leaks, 64 Water Piping (Inspect), 47 Water Treatment, 65 Weekly Maintenance, 62 Wiring (Inspect), 47

Page 100

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 100 7-96 Replaces: 19XL-3SS

Carrier 19XL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual