Carrier XRV, EVERGREEN 19XR User Manual

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19XR,XRV

Hermetic Centrifugal Liquid Chillers

50/60 Hz

With PIC II Controls 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 as phyxiation.

PROVIDE adequate ventilation in accordance with ANSI/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 VA LVE O FF an y safe ty de v ice . BE SURE that all pressure relief devices are properly installed and

functioning before operating any chiller. RISK OF INJURY OR DEATH by electrocution. High voltage is

present on motor leads even though the motor is not running when a solid-state or inside-delta mechanical starter is used. Open the power supply disconnect before touching motor leads or terminal

O NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) 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 assembl y.

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

DO NOT WORK 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 solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting i t into the eyes. USE SAFETY GOGG LES. Wash any spills from the s kin 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 ref riger ant cylinde r. 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 DANGER OUS 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 REFRIGERA NT 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 ATTEMPT TO REMOVE 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 op erates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDIT ION 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 device s in series or backward s. 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 t hat meet th e code requi rem ent s 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 complete ly d rai ne d.

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 Ta b 5 a

PC 211 Catalog No. 531-982 Printed in U.S.A. Form 19XR-5SS Pg 1 6-01 Replaces: 19XR-4SS

CONTENTS

Page

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

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

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5

CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7

Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5

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

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

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

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

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Factory-Mounted Starter or Variable

Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7

Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7

REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7

MOTOR AND LUBRICATING OIL

COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8

VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

• PRIMARY OIL RECOVERY MODE

• SECONDARY OIL RECOVERY METHOD

STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10

Unit-Mounted Solid-State Starter

(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Unit-Mounted Wye-Delta Starter

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

Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10

CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

• ANALOG SIGNAL

• DISCRETE SIGNAL

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

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

• CHILLER VISUAL CONTROLLER (CVC)

• INTERNATIONAL CHILLER VISUAL

CONTROLLER (ICVC)

• INTEGRATED STARTER MODULE (ISM)

• CHILLER CONTROL MODULE (CCM)

• OIL HEATER CONTACTOR (1C)

• OIL PUMP CONTACTOR (2C)

• HOT GAS BYPASS CONTACTOR RELAY (3C)

(Optional)

• CONTROL TRANSFORMERS (T1, T2)

• OPTIONAL TRANSFORMER (T3)

CVC/ICVC Operation and Menus. . . . . . . . . . . . . . . . . 15

• GENERAL

• ALARMS AND ALERTS

• CVC/ICVC MENU ITEMS

• BASIC CVC/ICVC OPERATIONS (Using the Softkeys)

• TO VIEW STATUS

• OVERRIDE OPERATIONS

• TIME SCHEDULE OPERATION

• TO VIEW AND CHANGE SET POINTS

• SERVICE OPERATION

PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33

• CAPACITY CONTROL FIXED SPEED

• CAPACITY CONTROL VFD

• ECW CONTROL OPTION

• CONTROL POINT DEADBAND

• DIFFUSER CONTROL

• PROPORTIONAL BANDS AND GAIN

• DEMAND LIMITING

• CHILLER TIMERS

• OCCUPANCY SCHEDULE

Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Page

Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

High Discharge Temperature Control . . . . . . . . . . . . 36

Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36

Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 37

Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 37

Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 37

Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 37

Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 38

Evaporator Freeze Protection (ICVC Only) . . . . . . . 38

Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 38

Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 38

Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

• RESET TYPE 1

• RESET TYPE 2

• RESET TYPE 3

Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 39

Surge Prevention Algorithm

(Fixed Speed Chiller) . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Surge Prevention Algorithm with VFD . . . . . . . . . . . 40

Surge Protection VFD Units . . . . . . . . . . . . . . . . . . . . . 40

Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 40

• HEAD PRESSURE REFERENCE OUTPUT

Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

• COMMON POINT SENSOR INSTALLATION

• CHILLER COMMUNICAT ION WIRING

• LEAD/LAG OPERATION

• FAULTED CHILLER OPERATION

• LOAD BALANCING

• AUTO. RESTART AFTER POWER FAILURE

Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

• 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 . . . . . . . . . . . . . . . 44

• ATTACHING TO OTHER CCN MODULES

Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

• TO ACCESS THE SERVICE SCREENS

• TO LOG OUT OF NETWORK DEVICE

• HOLIDAY SCHEDULING

START-UP/SHUTDOWN/RECYCLE

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47

Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47

Chilled Water Recycle Mode. . . . . . . . . . . . . . . . . . . . . 47

Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64

Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Using the Optional Storage Tank

and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48

Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48

Open Oil Circuit Valves. . . . . . . . . . . . . . . . . . . . . . . . . . 48

Tighten All Gasketed Joints and

Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 48

Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 48

Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

CONTENTS (cont)

Page

Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Check Optional Pumpout Compressor

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54

Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

• MECHANICAL STARTER

• BENSHAW, INC. RediStart MICRO™

SOLID-STATE STARTER

• VFD STARTER

Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Power Up the Controls and

Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55

• SOFTWARE VERSION

Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55

Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55

Input the Local Occupied Schedule

(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55

• PASSWORD

• INPUT TIME AND DATE

• CHANGE CVC/ICVC CONFIGURATION

IF NECESSARY

• TO CHANGE THE PASSWORD

• TO CHANGE THE CVC/ICVC DISPLAY FROM

ENGLISH TO METRIC UNITS

• CHANGE LANGUAGE (ICVC ONLY)

• MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY

• INPUT EQUIPMENT SERVICE PARAMETERS

IF NECESSARY

• CHANGE THE BENSHAW , INC., RediStart

MICRO SOFTWARE CONFIGURATION IF NECESSARY

• VERIFY VFD CONFIGURATION AND CHANGE

PARAMETERS IF NECESSARY

• VFD CHILLER FIELD SET UP AND VERIFICATION

• VFD CONTROL VERIFICATION (Non-Running)

• VFD CONTROL VERIFICATION (Running)

• CONFIGURE DIFFUSER CONTROL IF

NECESSARY

• MODIFY EQUIPMENT CONFIGURATION

IF NECESSARY

Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62

• COOLER CONDENSER PRESSURE TRANSDUCER

AND WATERSIDE FLOW DEVICE CALIBRATION

Check Optional Pumpout System

Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63

High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63

Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63

• CHILLER EQUALIZATION WITHOUT A

PUMPOUT UNIT

• CHILLER EQUALIZATION WITH

PUMPOUT UNIT

• TRIMMING REFRIGERANT CHARGE

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65

Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Check Oil Pressure and Compressor Stop . . . . . . 65

To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65

Check Chiller Operating Condition . . . . . . . . . . . . . . 65

Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65

•COOLER-CONDENSER

• OPTIONAL PUMPOUT STORAGE TANK AND

PUMPOUT SYSTEM

• MOTOR COMPRESSOR ASSEMBLY

Page

• 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

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67

Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66

To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Check the Running System . . . . . . . . . . . . . . . . . . . . . 66

To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66

Preparation for Extended Shutdown . . . . . . . . . . . . 66

After Extended Shutdown. . . . . . . . . . . . . . . . . . . . . . . 67

Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67

Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67

Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Operating the Optional Pumpout Unit . . . . . . . . . . . 67

• TO READ REFRIGERANT PRESSURES

Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69

• TRANSFER REFRIGERANT FROM

PUMPOUT STORAGE TANK TO CHILLER

• TRANSFER REFRIGERANT FROM

CHILLER TO PUMPOUT STORAGE TANK

Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70

• TRANSFER ALL REFRIGERANT TO

CHILLER CONDENSER VESSEL

• TRANSFER ALL REFRIGERANT TO

CHILLER COOLER VESSEL

• RETURN CHILLER TO NORMAL

OPERATING CONDITIONS

GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72

Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71

Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71

Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Test After Service, Repair, or Major Leak . . . . . . . . 71

• TESTING WITH REFRIGERANT TRACER

• TESTING WITHOUT REFRIGERANT TRACER

• TO PRESSURIZE WITH DRY NITROGEN

Repair the Leak, Retest, and Apply

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72

Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72

Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72

WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72

Check the Lubrication System . . . . . . . . . . . . . . . . . . 72

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75

Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73

Check Safety and Operating Controls

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

• TO CHANGE THE OIL

Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74

CONTENTS (cont)

Page

Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74

Compressor Bearing and Gear

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Inspect the Heat Exchanger Tubes

and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

• COOLER AND FLOW DEVICES

• CONDENSER AND FLOW DEVICES

Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75

Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75

Optional Pumpout System Maintenance. . . . . . . . . 75

• OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE

• OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS

Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76

Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76

• RESISTANCE CHECK

• VOLTAGE DROP

• CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76

• UNITS EQUIPPED WITH CVC

• UNITS EQUIPPED WITH ICVC

• TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure . . . . . . . . 77

Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

• RED LED (Labeled as STAT)

• GREEN LED (Labeled as COM)

Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87

Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88

• INPUTS

• OUTPUTS

Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88

• INPUTS

• OUTPUTS

Replacing Defective Processor Modules . . . . . . . . 88

• INSTALLATION

Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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

• SCR REMOVAL/INSTALLATION

Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124

INITIAL START-UP CHECKLIST FOR

19XR, XRV HERMETIC CENTRIFUGAL

LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16

INTRODUCTION

Prior to initial start-up of the 19XR 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 to familiarize those involved in the startup, operation and maintenance of the unit 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 Rules, which are designed to provide reasonable protection against such interfer ence 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:

CCM — Chiller Control Module CCN — Carrier Comfort Network CCW — Counterclockwise CVC — Chiller Visual Controller CW — Clockwise ECDW — Entering Condenser Water ECW — Entering Chilled Water EMS — Energy Management System HGBP — Hot Gas Bypass I/O — Input/Output ICVC — International Chiller Visual Controller ISM — Integrated Starter Module LCD — Liquid Crystal Display LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode OLTA — Overload Trip Amps PIC II — Product Integrated Controls II RLA — Rated Load Amps SCR — Silicon Controlled Rectifier SI — International System of Units TXV — Thermostatic Expansion Valve VFD — Variable Frequency Drive

Words printed in all capital letters or in italics may be viewed on the Chiller Visual Controller/International Chiller Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN, ALARM, etc.).

Words printed in both all capital lette rs and italics can also be viewed on the CVC/ICVC and are parameters (e.g., CON-

TROL MODE, COMPRESSOR START RELAY, ICE BUILD OPTION, etc.) with associated values (e.g., modes, tempera-

tures, percentages, pressures, on, off, etc.).

Words printed in all capital letters and in a box represent softkeys on the CVC/ICVC control panel (e.g., ,

, , , etc.).

EXIT INCREASE QUIT

ENTER

Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed additional components are referred to as accessories.

The chiller software part number of the 19XR unit is located on the back of the CVC/ICVC.

CHILLER FAMILIARIZATION

(Fig. 1 and 2)

Chiller Information Nameplate —

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

System Components —

cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control panel, 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 —

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

Condenser —

temperature/pressure than the cooler and has water flowing

This vessel (also known as the evaporator) is lo-

The condenser operates at a higher

19XR- — High Efficiency Hermetic

Centrifugal Liquid Chiller

19XRV — High Efficiency Hermetic

Cooler Size

10-12 (Frame 1 XR) 15-17 (Frame 1 XR) 20-22 (Frame 2 XR) 30-32 (Frame 3 XR) 35-37 (Frame 3 XR) 40-42 (Frame 4 XR) 45-47 (Frame 4 XR) 50-52 (Frame 5 XR) 5A (Frame 5 XR) 5B (Frame 5 XR) 5C (Frame 5 XR)

Condenser Size

10-12 (Frame 1 XR) 15-17 (Frame 1 XR) 20-22 (Frame 2 XR) 30-32 (Frame 3 XR) 35-37 (Frame 3 XR) 40-42 (Frame 4 XR) 45-47 (Frame 4 XR) 50-52 (Frame 5 XR) 55-57 (Frame 5 XR) 60-62 (Frame 6 XR) 65-67 (Frame 6 XR) 70-72 (Frame 7 XR) 75-77 (Frame 7 XR) 80-82 (Frame 8 XR) 85-87 (Frame 8 XR)

Compressor Code

(First Digit Indicates Compressor Frame Size)*

Centrifugal Liquid Chiller with Variable Frequency Drive Unit-Mounted

*Second digit will be a letter (example 4G3) on units equipped with split ring diffuser.

The components include the

55-57 (Frame 5 XR) 5F (Frame 5 XR) 5G (Frame 5 XR) 5H (Frame 5 XR) 60-62 (Frame 6 XR) 65-67 (Frame 6 XR) 70-72 (Frame 7 XR) 75-77 (Frame 7 XR) 80-82 (Frame 8 XR) 85-87 (Frame 8 XR)

The information

19XRV 52 51 473 DG H 64 –

MODEL NUMBER NOMENCLATURE

through its internal tubes in order to remove heat from the refrigerant.

Motor-Compressor —

This component maintains system temperature and pressure differences and moves th e heatcarrying refrigerant from the cooler to the condenser.

Control Panel —

The control panel is the user interface for controlling the chiller. It regulates the chiller’s capacity as required to maintain proper leaving chille d water temperature . The control panel:

• 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 recy cle under micro pro-

cessor control

• displays status of motor starter

• provides access to other CCN (Carrier Comfort Net-

work) devices and energy management systems

• Languages pre-installed at factory include: English, Chi-

nese, Japa nese, and Kor ean (ICVC onl y).

• International language translator (ILT) is available for

conversion of extended ASCII characters (ICVC only).

Special Order Indicator

– — Standard S — Special Order

Motor Voltage Code

Code Volts-Phase-Hertz

60 — 200-3-60 61 — 230-3-60 62 — 380-3-60 63 — 416-3-60 64 — 460-3-60 65 — 575-3-60 66 — 2400-3-60 67 — 3300-3-60 68 — 4160-3-60 69 — 6900-3-60 50 — 230-3-50 51 — 346-3-50 52 — 400-3-50 53 — 3000-3-50 54 — 3300-3-50 55 — 6300-3-50

Motor Efficiency Code

H — High Efficiency S — Standard Efficiency

Motor Code

BD CD DB EH BE CE DC EJ BF CL DD EK BG CM DE EL BH CN DF EM

CP DG EN CQ DH EP

27 99 Q 59843

Week of Year

Year of Manufacture

SERIAL NUMBER BREAKDOWN

Fig. 1 — 19XR Identification

Unique Number

Place of Manufacture

FRONT VIEW

LEGEND

1 — Guide Vane Actuator 2 — Suction Elbow 3 — Chiller Visual Controller/ International Chiller

Visual Control (CVC/ICVC)

4 — Chiller Identification Nameplate 5 — Cooler, Auto Reset Relief Valves 6 — Cooler Pressure Transducer 7 — Condenser In/Out Temperature Thermistors 8 — Condenser Waterflow Device (ICVC Inputs

available)

9 — Cooler In/Out Temperature Thermistors

10 — Cooler Waterflow Device (ICVC Inputs avail-

able)

11 — Refrigerant Charging Valve 12 — Typical Flange Connection

13 — Oil Drain Charging Valve 14 — Oil Level Sight Glasses 15 — Refrigerant Oil Cooler (Hidden) 16 — Auxiliary Power Panel 17 — Compressor Motor Housing

REAR VIEW

19 20 21 22

LEGEND

18 — Condenser Auto. Reset Relief Valves

19 — Compressor Motor Circuit Breaker 20 — Solid-State Starter Control Display 21 — Unit-Mounted Starter (Optional)

Solid-State Starter Shown

22 — Motor Sight Glass 23 — Cooler Return-End Waterbox Cover 24 — ASME Nameplate (One Hidden) 25 — Typical Waterbox Drain Port 26 — Condenser Return-End Waterbox Cover 27 — Refrigerant Moisture/Flow Indicator 28 — Refrigerant Filter/Drier 29 — Liquid Line Isolation Valve (Optional) 30 — Linear Float Valve Chamber 31 — Vessel Take-Apart Connector 32 — Discharge Isolation Valve (Optional) 33 — Pumpout Valve 34 — Condenser Pressure Transducer

Fig. 2 — Typical 19XR Components

Factory-Mounted Starter or Variable Frequency Drive (Optional) —

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

Storage Vessel (Optional) —

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 nection for the pumpout 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 system is used to transfer refrigerant from vessel to vessel.

The starter allows for the

There are 2 sizes of

/2-in. male flare vapor con-

REFRIGERATION CYCLE

The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening or compressor speed (19XRV only). 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 to use in an air condi tioning circuit or for 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 t he 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 AND LUBRICATING OIL

COOLING CYCLE

The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel (Fig. 3). Refrigerant flow is maintained by the pressure di fferential that 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 the motor cooling and oil cooling systems.

Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles

Flow to the motor cooling system passes through an orifice and into the motor. Once past the orifice, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the b ottom of the motor c asing and is then drai ned back into the cooler through the motor refrigerant drain line . An orifice (in t he motor shell) maintains a higher pressure i n the motor she ll tha n in t he coo ler. The motor is pr otect ed by a temperature sensor imbedded in the stator windings. An increase in motor winding temperature past the motor override set point overrides the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set point, closes the inlet guide vanes. If the temperature rises above the safety limit, the compressor shuts down.

Refrigerant that flows to the oil cooling system is regulated by thermostatic expansion valves (TXVs). The TXV s regulat e flow into the oil/refrigerant plate and frame-type heat exchanger (the oil cooler in Fig. 3). The expansion valve bulbs control oil temperature to the bearings. The refrigerant leaving the oil cooler heat exchanger returns to the chiller cooler.

VFD COOLING CYCLE

The unit-mounted variable frequency drive (VFD) is cooled in a manner similar to the motor and lubricating oil cooling cycle (Fig. 3).

If equipped with a unit-mounted VFD, t he refrigerant line that feeds the motor cooling and oil cooler also feeds the heat exchanger on the unit-mounted VFD. Refrigerant is metered through a thermostatic expansion valve (TXV). To maintain proper operating temperature in the VFD, the TXV bulb is mounted to the heat exchanger to regulate the flow of refrigerant. The refrigerant leaving the heat exchanger returns to the cooler.

LUBRICATION CYCLE

Summary —

up a package located partially in the transmission casing 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).

Details —

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 CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller) default screen. During compressor operation, the oil sump temperature ranges between 125 to 150 F (52 to 66 C).

The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to172 kPad) differential pressure in the system at the pump di scharge. This differential pressure can be read directly from the CVC/ICVC default screen. The oil pump discharges oil to the oil filter assembly. This filter can be closed to permit removal of the filter without draining the entire oil system (see Maintenance sections, pages 71 to 75, for details). The oil is then piped to the oil

The oil pump, oil filter, and oil cooler make

Oil is charged into the lubrication system through

cooler heat exchanger. The oil cooler uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a temperature between 120 and 140 F (49 to 60 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. Part of the oil flows to the thrust bearing, forward pinion bearing, and gear spray. The rest of the oil lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured in the bearing housing as it leaves the thrust and forward journal bearings. The oil then drains into the oil reservoir at the base of the compressor. The PIC II (Product Integrated Control II) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature Control section, page 36). This temperature is read on the CVC/ICVC default screen.

During the chiller start-up, the PIC II energizes the oil pump and provides 45 seconds of pre-lubrication to the bearings after pressure is verified before starting the compressor. During shutdown, the oil pump will run for 60 seconds to postlubricate after the compressor shuts down. The oil pump can also be energized for testing purposes during a 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 II will shut down the compressor.

If the controls are subject to a power failure that lasts more than 3 hours, the oil pump will be energized periodically when the power is restored. This helps to eliminate refrigerant that has migrated to the oil sump during the power failure. The controls energize the pump for 60 seconds every 30 minutes until the chiller is star ted.

Oil Reclaim System —

oil lost from the compressor housing back to the oil reservoir by recovering the oil from 2 areas on the chiller. The guide vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level i n the cooler vessel.

PRIMARY OIL RECOVERY MODE — Oil is normally recovered through the guide vane housing on the chiller. This is possible because oil is normally entrained with refrigerant in the chiller. As the compressor pulls the refrigerant up from the cooler into the guide vane housing to be compressed, the oil normally drops out at this point and falls to the bottom of the guide vane housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is drawn from the housing and is discharged into the oil reservoir.

SECONDARY OIL RECOVERY METHOD — The secondary method of oil recovery is significant under light load conditions, when the refrigerant going up to the compressor suction does not have enough velocity to bring oil along. Under these conditions, oil collects in a greater concentration a t the top level of the refrigerant in the cooler. This oil and refrigerant mixture is skimmed from the side of the cooler and is then drawn up to the guide vane housing. There is a filter in this line. Because the guide vane housing pressure is much lower than the cooler pressure, the refrigerant boils off, leaving t he oil behind to be collected by the primary oil recovery method.

The oil reclaim system returns

MOTOR COOLING LINE

TXV BULB PRESSURE

TRANSDUCER

REAR MOTOR BEARING

ISOLATION VALV E

OIL COOLER

OIL PUMP MOTOR

OIL PUMP

OIL HEATER

SIGHT GLASS

FWD MOTOR BEARING

LABYRINTH GAS LINE

FILTEREDUCTOR

OIL SUPPLY TO FORWARD HIGH SPEED BEARING

ISOLATION VALV E

FILTER

SIGHT GLASS

ISOLATION VALV E

Fig. 4 — Lubrication System

STARTING EQUIPMENT

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

See Carrier Specification Z-415 for specific starter requirements, Z-416 for free-standing VFD requirements and Z-417 for unit-mounted VFD 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.

Three separate circuit breakers are inside the starter. Circuit breaker CB1 is the compress or motor circui t breaker. The disconnect switch on the starter front cover is connected to this breaker. Circuit breaker CB1 supplies pow er 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 II controls, and oil heater.

OIL SKIMMER LINE

solid-state starters. This module controls and monitors all aspects of the starter. See the Controls section on page 10 for additional ISM information. All starter replacement parts are supplied by the starter manufacturer excluding t he ISM (contact Carrier’s Replacement Component Division [RCD]).

Unit-Mounted Solid-State Starter (Optional) —

The 19XR chiller may be equipped with a solid-state, reducedvoltage starter (Fig. 5 and 6). This starter’s primary function is to provide on-off control of the compressor motor. This type of starter reduces the peak starting torque, reduces the m otor inrush current, and decreases mechanical shock. This capability is summed up by the phrase “soft starting.” The solid-state starter is available as a 19XR option (factory supplied and installed). The solid-state starters manufa cturer name is located inside the starter access door.

A solid-state, reduced-voltage starter operates 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 is reduced by silicon controlled rectifiers (SCRs). The voltage and current are then ramped up in a desired period of time. Once full voltage is reached, a bypass contactor is energized to bypass the SCRs.

Circuit breaker CB2 supplies power to the control panel, oil

heater, and portions of the starter controls.

Circuit breaker CB3 supplies power to the oil pump. Both CB2 and CB3 are wired in parallel with CB1 so that power is supplied to them if the CB1 disconnect is open.

All starters must include a Carrier control module called the Integrated Starter Module (ISM), excluding the Benshaw

When voltage is supplied to the solid-state circuitry (CB1 is closed), the heat sinks in the starter a s well as the wires leading to the m otor an d the m otor term in al ar e at l ine vol tage. Do not touch the heat sinks, power wiring, or motor terminals while voltage is present or serious injury will result.

LEGEND

1 — RediStar t MICRO™ Input/Output Card 2 — Fuses 1-4 (Hidden, not depicted) 3 — Circuit Breaker 2 (CB2): Machine Control and Heater Power 4 — Circuit Breaker 3 (CB3): Oil Pump Power 5 — RediStar t MICRO Central Processing Unit Card (CPU) 6 — RediStar t MICRO Power Card (hidden, not depicted) 7 — RediStar t MICRO Bypass Card (hidden, not depicted)

Fig. 5 — Solid-State Starter Box,

Internal View

There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter checkout. The display indicates:

• voltage to the SCRs

• SCR control voltage

• power indication

• proper phasing for rotation

• start circuit energized

• over-temperature

• ground fault

• current unbalance

• run state

• software configurat ion

The starter is further explained in the Check Starter and Troubleshooting Guide sections, pages 54 and 76.

Unit-Mounted Wye-Delta Starter (Optional) —

The 19XR chiller may be equipped with a wye-delta starter mounted on the unit. This starter is used with low-voltage 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. Once the motor is up to speed, the starter automatically connects the phase windings into a delta configuration. Starter control, monitoring, and motor protection is provided by Carrier’s Integrated Starter Module (ISM).

Unit-Mounted VFD (Optional) —

will be equipped with a variable frequency drive motor controller mounted on the unit. See Fig. 7 and 8. This VFD is used with low voltage motors between 380 and 480 VAC. It reduces the starting current inrush by controlling the volta ge and frequency to the compressor motor. Once the motor has accelerated to minimum speed the PIC II modulates the compressor speed and guide vane position to control chilled water temperature. The VFD is further explained in the Controls sect ion and Troubleshooting Guide section, pages 10 and 76.

There is a separate display located on the unit-mounted VFD. Operational parameters and fault codes are displayed relative to the drive. Refer to specific drive literature along with troubleshooting sections. The display is also the interface for entering specific chiller operational parameters. These parameters have been preprogrammed at the factory. An adhesive backed label on the inside of the drive has been provided for verification of the specific job parameters. See Initi al Start-Up Checklist section for details.

The 19XRV uni t

Fig. 6 — Typical Starter External View

(Solid-State Starter Shown)

CONTROLS

Definitions

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.)

DISCRETE SIGNAL — A discrete signal is a 2-position rep- resentation of the value of a monitored source. (Example: A switch produces a discrete signal indicating whether a value is above or below a set point or boundary by generating an on/off, high/low , or open/closed s ignal.)

OPTIONAL METER PACKAGE

INTEGRATED STARTER MODULE (ISM)

OIL PUMP DISCONNECT

Forward

AUTO

RUNNING

SPEED

Reverse

MAN

REMOTE

VOLTS

JOG

RUN

AMPS

PRO-

AUTO

JOB

GRAM

FORWARD

REVERSE

TORQUE

ENTER

PROGRAM

Password

Fig. 7 — Variable Frequency Drive (VFD)

SPEED

VOLTS AMPS

Kw TORQUE

Password

MANUAL RESET

RUNNING

REMOTE

JOG AUTO

FORWARD REVERSE

PROGRAM

AUTO

MAN

PROGRAM

ENTER

DC BUS BAR

MEASUREMENT

POINT

INITIAL DC BUS MEASUREMENT POINT

Forward Reverse

RUN JOB

DANGER

HIGH VOLTAGE

CONTROL AND OIL HEATER DISCONNECT

COMPRESSOR MOTOR DISCONNECT

LINE

LOAD

TXV

Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View

General —

The 19XR hermetic centrifugal liquid chiller contains a microprocessor-based control center t hat monitors and controls all operations of the chiller (see Fig. 9). 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 wat er or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a variable flow pre-whirl assembly that controls the refri geration 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. The microprocessor-based control center protects the chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required.

Forward

AUTO

RUNNING

SPEED

Reverse

MAN

REMOTE

VOLTS

JOG

RUN

AMPS

PROGRAM

AUTO

JOB

FORWARD

REVERSE

TORQUE

ENTER

PROGRAM

Password

VFD MODULE

COOLING LINES

PIC II System Components —

The chiller control system is called the PIC II (Product Integrated Control II). See Table 1. The PIC II controls the operation of the chiller by monitoring all operating conditions. The PIC II 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 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 regulates the hot gas bypass valve, if installed. The PIC II controls provide critical protection for the compressor motor and controls the motor starter.

WATER SENSOR CABLES

COOLER PRESSURE TRANSDUCER CONNECTION

FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE

WATER SENSOR CABLES

CONDENSER PRESSURE CABLE

SCHRADER FITTING (HIDDEN) CONDENSER PRESSURE TRANSDUCER CONNECTION

CONDENSER SERVICE VALV E

TOP VIEW

DISCHARGE ISOLATION VALV E (OPTIONAL)

COMPRESSOR DISCHARGE ELBOW JOINTS

MOTOR WINDING TEMPERATURE CABLE

COMPRESSOR DETAIL

Fig. 9 — 19XR Controls and Sensor Locations

The PIC II can interface with t he Carri er Comfort N etwork (CCN) if desired. It can communicate with other PIC I or PIC II equipped chillers and other CCN devices.

The PIC II consists of 3 modules housed inside 3 major components. The component names and corresponding control voltages are listed below (also see Table 1):

• control panel

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

• power panel

— 230 or 115 v contro l voltage (per job requirement)

— up to 600 v for oil pump power

• starter cabinet

— chiller power wiring (per job requirement)

Table 1 — Major PIC II Components and

Panel Locations*

PIC II COMPONENT PANEL LOCATION

Chiller Visual Controller (CVC/ICVC) and Display

Integrated Starter Module (ISM) Starter Cabinet Chiller Control Module (CCM) Control Panel Oil Heater Contactor (1C) Power Panel Oil Pump Contactor (2C) Power Panel Hot Gas Bypass Relay (3C) (Optional) Power Panel Control Transformers (T1, T2) Power Panel Temperature Sensors See Fig. 9. Pressure Transducers See Fig. 9.

*See Fig. 8-13.

Control Panel

CHILLER VISUAL CONTROLLER (CVC) — The CVC is the “brain” of the PIC II. This module contains all the operating software needed to control the chiller. The CVC is mounted to the control panel (Fig. 12) and is the input ce nter for all local chiller set points, schedules, configurable functions, and options. The CVC has a stop button, an alarm light, four buttons for logic inputs, and a backlight display. The backlight will automatically turn off after 15 minutes of non-use. The functions of the four buttons or “softkeys” are menu driven and are shown on the display directly above the softkeys.

The viewing angle of the CVC can be adjusted for optimum viewing. Remove the 2 bolts connecting the control panel to the brackets attached to the c ooler. Place them in one of t he holes to pivot the control panel forward to backward to change the viewing angle. See Fig. 12. To change the contrast of the display, access the adjustm ent on the back of the CVC. See Fig. 12.

INTERNATIONAL CHILLER VISUAL CONTROLLER (ICVC) — Incorporates all of the functions and operating software of the CVC with the added feature of 4 factory programmed languages:

English (default)

Chinese

Japanese

Korean NOTE: Pressing any one of the four softkey buttons will acti-

vate the backlight display without implementing a softkey function.

INTEGRATED STARTER MODULE (ISM) — This module is located in the starter cabinet. This module initiates commands from the CVC/ICVC for starter functions such as start ing and stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, and the shunt trip. The ISM monitors starter inputs such as line voltage, motor current,

ground fault, remote start contact, spare safety, condenser high pressure, oil pump interlock, starter 1M, and run contacts. The ISM contains logic capable of safety shutdown. It shuts down the chiller if communications with the CVC/ICVC are lost. The ISM can also act as the interface for P IC II to the VFD controller.

CHILLER CONTROL MODULE (CCM) — This module is located in the control panel. The CCM provides t he input and outputs necessary to control the chiller. This module monitors refrigerant pressure, entering and leaving water temperatures, and outputs control for the guide vane actuator, oil heaters, and oil pump. The CCM is the connect ion point for optional demand limit, chilled water reset, remote temperature reset, refrigerant leak sensor and motor kilowatt output.

OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 13) and operates the heater at either 115 or 230 v. It is controlled by the PIC II to maintain oil temperature during chiller shutdown. The XR4 with split ring diffuser has a line voltage oil heater. Refer to the control panel wiring schematic.

OIL PUMP CONTACTOR (2C) — This contactor is located in the power panel. It operates all 200 to 575-v oil pumps. The PIC II 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, controls the opening of the hot gas bypass valve. The PIC II ene rgizes the relay during low load, high lift conditions.

CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the 3 power panel contactor relays, CCM, and CVC/ICVC.

OP TI ONAL TRAN SFOR ME R (T3) — Thi s transformer provides control power to Dataport™/DataLINK™ modules.

Fig. 10 — Control Sensors (Temperature)

Fig. 11 — Control Sensors

(Pressure Transducers, Typical)

Fig. 12 — Control Panel

Fig. 13 — Power Panel

CVC/ICVC Operation and Menus (Fig. 14-20)

GENERAL

• The CVC/ICVC display automatically reverts to the

default screen after 15 minutes if no softkey activity

takes place and if the chiller is not in the pumpdown

mode (Fig. 14).

• If a screen other than the default screen is displayed on

the CVC/ICVC, the name of that screen is in the upper

right corner (Fig. 15).

• The CVC/ICVC may be set to display either English or

SI units. Use the CVC/ICVC configuration screen

(accessed from the Service menu) to change the units.

See the Service Operation section, page 45.

• Local Operation — The PIC II can be placed in local

operating mode by pressing the softkey. The

PIC II then accepts commands from the CVC/ICVC only

and uses the Local Time Schedule to determine chiller

start and stop times.

• CCN Operation — The PIC II can be placed in the CCN

operating mode by pressing the softkey. The PIC

II then accepts modifications from any CCN interface or

module (with the proper authority), as well as from the

CVC/ICVC. The PIC II uses the CCN time schedule to

determine start and stop times. ALARMS AND ALERTS — An alarm shuts down the com-

pressor. An alert does not shut down the compressor, but it notifies the operator that an unusual c ondition has occurred. An alarm (*) or alert (!) is indicated on the ST ATUS screens on the far right field of the CVC/ICVC display screen.

Alarms are indicated when the control center ala rm light (!) flashes. The primary alarm message is displayed on the default screen. An additional, secondary message and troubleshooting information are sent to the ALARM HISTORY table.

When an alarm is detected, the CV C/ICVC default screen will freeze (stop updating) at the time of alarm. The freeze enables the operator to view th e chiller conditions at t he time of alarm. The STATUS tables will show the updated information.

Once all alarms have been cleared (by pressing the softkey), the default CVC/ICVC screen will return to normal operation.

CVC/ICVC MENU ITEMS — To perform any of the operations described below , the PIC II must be powered up and have successfully completed its s elf t est. The self test t akes pla ce automatically, after power-up.

Press the softkey to view the list of menu structures: , , , and

SERVICE

ST ATUS SCHEDULE SETPOINT

• The STATUS menu allows viewing and limited calibra-

tion or modification of control points and sensors, relays

and contacts, and the options board.

• The SCHEDULE menu allows viewing and mod ification

of the local and CCN time schedules and Ice Build time

schedules.

• The SETPOI NT menu allo ws s et poin t adj us tment s , su ch

as the entering chilled water and leaving chilled water set

points.

• The SERVICE menu can be used to view or modify

information on the Alarm History, Control Test, Control

Algorithm Status, Equipment Configuration, ISM Starter

Configuration data, Equipment Service, Time and Date,

Attach to Network Device, Log Out of Network Device,

and CVC/ICVC Configuration screens.

LOCAL

CCN

RESET

For more information on the menu structures, refer to

PRIMARY STATUS

Fig. 17.

SECONDARY STATUS MESSAGE

ALARM LIGHT (ILLUMINATED WHEN POWER ON)

•

STOP BUTTON

•

MESSAGE

BLINKS CONTINUOUSLY ON FOR AN ALARM

BLINKS ONCE TO CONFIRM A STOP

HOLD FOR ONE SECOND TO STOP

COMPRESSOR ON TIME

RUNNING TEMP CONTROL LEAVING CHILLED WATER

CHW IN CHW OUT EVAP REF

55.1 44.1 40.7

CDW IN CDW OUT COND REF

85.0 95.0 98.1

OIL PRESS OIL TEMP AMPS %

21.8 132.9 93

CCN LOCAL RESET MENU

SOFT KEYS

EACH KEY'S FUNCTION IS DEFINED BY THE MENU DESCRIPTION ON MENU LINE ABOVE

DATE TIME

01-01-95 11:48

28.8 HOURS

MENU LINE

Fig. 14 — CVC/ICVC Default Screen

19XR_II

ALARM HISTORY

CONTROL TEST CONTROL ALGORITHM STATUS EQUIPMENT CONFIGURATION ISM (STARTER) CONFIGURATION DATA EQUIPMENT SERVICE TIME AND DATE ATTACH TO NETWORK DEVICE LOG OUT OF DEVICE CVC CONFIGURATION

SERVICE

Fig. 15 — CVC/ICVC Service Screen

Press the softkey that corresponds to the menu structure to

be viewed: , , or

SERVICE menu structures, use the and softkeys to scroll down to the desired item or table. Use the

ST ATUS SCHEDULE SETPOINT

. To view or change parameters within any of these

NEXT PREVIOUS

SELECT softkey to select that item. The softkey choices that then appear depend on the selected table or menu. The softkey choices and their functions are described below.

BASIC CVC/ICVC OPERATIONS (Using the Softkeys) — To perform any of the operations described below, the PIC II must be powered up and have successfully completed its self test.

• Press to leave the selected decision or field with-

QUIT

out saving any changes.

• Press to leave the selected decision or field and

ENTER

save changes.

• Press to scroll the cursor bar down in order to

NEXT highlight a point or to view more points belo w the current screen.

2. Press or to highlight the desired

NEXT PREVIOUS

status table. The list of tables is:

•MAINSTAT — Overall chiller status

•STARTUP — Status r equired to perfor m start-up of

chiller

•COMPRESS — Status of sensors related to the compressor

•HEAT_EX — Status of sensors related to the heat exchangers

•POWER — Status of motor input power

•ISM_STAT — Stat us of motor starter

•CVC_PSWD — Service menu password forcing

access screen

•ICVC_PSWD — Service menu password forcing access screen

• Press to scroll the cursor bar up in order to

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

• Press to view the next screen level (high-

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

• Press to return to the previous screen level.

• Press or to change the high-

EXIT

INCREASE DECREASE

lighted point value.

3. Press to view the desired point status table.

4. On the point status table, press or

SELECT

NEXT PREVIOUS

until the desired point is displayed on the screen.

19XR_II MAINSTAT Control Mode Run Status Start Inhibit Timer Occupied? System Alert/Alarm Chiller Start/Stop Remote Start Contact Temperature Reset Control Point Chilled Water Temp Active Demand Limit Average Line Current

POINT STATUS

OFF

Ready

0.0 Min NO

NORMAL

STOP

Open

0.0 F

44.0 F

44.6 F 100%

0.0%

TO VIEW STATUS (Fig. 16) — The status table shows the actual value of overall chiller status such as CONTROL MODE, RUN STATUS, AUTO CHILLED WATER RESET, and REMOTE RESET SENSOR.

1. On the menu screen, press to view the list of

ST ATUS

point status tables.

Fig. 16 — Example of Status Screen

OVERRIDE OPERATIONS To Override a Value or Status

1. From any point status screen, press or PREVIOUS

2. Press to select the highlighted value. Then:

SELECT

to highlight the desired value.

•

CCN

Start Chiller In CCN Control

Start Chiller in Local Control

DEFAULT SCREEN

LOCAL RESET

(SOFTKEYS)

Clear Alarms

STATUS

List the Status Tables

• MAINSTAT

• STARTUP

• COMPRESS

• HEAT_EX

• POWER

• ISM_STAT

• CVC_PSWD

Select a Status Table

Select a Modification Point

Modify a Discrete Point

START

Modify an Analog Point

INCREASE

Modify Control Options

ENABLE

STOP

OFF

DECREASE

DISABLE

Access Main Menu

SCHEDULE SETPOINT

SELECT

RELEASE

QUIT

EXIT

ENTER

SERVICE

(ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)

Display The Setpoint Table

List the Schedules

• LCW Setpoint

• ECW Setpoint

• Ice Build Setpoint

Select the Setpoint

Modify the Setpoint

INCREASE

• OCCPC01S – LOCAL TIME SCHEDULE

• OCCPC02S – ICE BUILD TIME SCHEDULE

• OCCPC03S – CCN TIME SCHEDULE

Select a Schedule

Select a Time Period/Override

Modify a Schedule Time

INCREASE DECREASE ENTER EXIT

Add/Eliminate a Day

ENABLE DISABLE

SELECT

1 2 3 4 5 6 7 8

Override

SELECT

ENTER EXIT

• Tower Fan High Setpoint

DECREASE

EXIT

•

Base Demand Limit

SELECT

QUIT

(ANALOG VALUES)

(DISCRETE VALUES)

List the Service Tables

EXIT

ENTER

ALARM HISTORY CONTROL TEST CONTROL ALGORITHM STATUS EQUIPMENT CONFIGURATION ISM (STARTER) CONFIG DATA EQUIPMENT SERVICE TIME AND DATE ATTACH TO NETWORK DEVICE LOG OUT OF DEVICE CVC CONFIGURATION ICVC CONFIGURATION

SEE FIGURE 18

Fig. 17 — 19XR Chiller Display Menu Structure (CVC/ICVC)

SELECT

EXIT

SERVICE TABLE

•

ALARM HISTORY

CONTROL TEST

CONTROL ALGORITHM STATUS

List the Control Algorithm Status Tables

• CAPACITY (Capacity Control)

• OVERRIDE (Override Status)

• LL_MAINT (Lead Lag Status)

• ISM_HIST (ISM Alarm History)

• LOADSHED

• WSMDEFME (Water System Manager Control Status)

• OCCDEFCM (Time Schedule Status)

Select a Table

SELECT

Display Alarm History

(The table holds up to 25 alarms and alerts with the most recent alarm at the top of the screen.)

EXIT

SELECT

EXIT

List the Control Tests

Select a Test

• CCM Thermistors

• CCM Pressure Transducers

• Pumps

• Discrete Outputs

• Guide Vane Actuator

• Diffuser Actuator

• Pumpdown/Lockout

• Terminate Lockout

• Guide Vane Calibration

SELECT

EXIT

OCCDEFM (Time Schedule Status)

Data Select Table

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

CONTINUED ON NEXT PAGE

INCREASE DECREASE ENTER EXIT

ICVC CONFIGURATION

SELECT

OCCPC01S (Local Status) OCCPC02S (CCN, ICE BUILD Status) OCCPC03S (CCN Status)

EXIT

Select a Table

Select a Parameter

Modify a Parameter

INCREASE

SELECT (USE ENTER) TO SCROLL DOWN

LID LANGUAGE

ENABLE

• CAPACITY (Capacity Control Algorithm)

• OVERRIDE (Override Status)

• LL_MAINT (LEADLAG Status)

• WSMDEFM2 (Water System Manager Control Status)

Maintenance Table Data

• NET_OPT

• BRODEF

• OCCEFCS

• HOLIDAYS

• CONSUME

• RUNTIME

DISABLE

SELECT

EXIT

SELECT

QUIT

DECREASE

EXIT

ENTER

(ANALOG VALUES)

(DISCRETE VALUES)

Fig. 18 — 19XR Service Menu Structure

SERVICE MENU CONTINUED FROM PREVIOUS PAGE

EQUIPMENT SERVICE

ISM (STARTER) CONFIG DATA

Service Tables:

• OPTIONS

• SETUP1

• SETUP2

• LEADLAG

• RAMP_DEM

• TEMP_CTL

(ENTER A 4-DIGIT PASSWORD)

(VALUES SHOWN AT FACTORY DEFAULT)

Service Tables:

• ISM (STARTER) CONFIG PASSWORD

• ISM_CONF

Select a Service Table

Select a Service Table Parameter

Modify a Service Table Parameter

INCREASE

ENABLE

TIME AND DATE

ATTACH TO NETWORK DEVICE

Select a Device

Modify Device Address

INCREASE

• Use to attach CVC to another CCN network or device

• Attach to "LOCAL" to enter this machine

• To upload new tables

LOG OUT OF DEVICE

DECREASE

DISABLE

List Network Devices

• Local

• Device 1

• Device 2

• Device 3

• Device 4

• Device 5

DECREASE

SELECT

QUIT

• Device 6

• Device 7

• Device 8

• Device 9

SELECT

ENTER

EXIT

ENTER

ATTA CH

EXIT

(ANALOG VALUES)

(DISCRETE VALUES)

Display Time and Date Table:

• To Modify — Current Time — Day of Week

INCREASE

YES

DECREASE

— Current Date — Holiday Today

EXIT

ENTER

(ANALOG VALUE)

(DISCRETE VALUE)

CVC CONFIGURATION

LEGEND

CCN — Carrier Comfort Network CVC — Chiller Visual Controller ICVC — International Chiller Visual Controller ISM — Integrated Starter Module PIC II — Product Integrated Control II

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

Default Screen

CCN

CVC Configuration Table

INCREASE

• To Modify — CVC CCN Address

LOCAL

DECREASE

— English (U.S. IMP.) or S.I. Metric Units — Password

RESET

ENTER

EXIT

• To View — CVC Software Version (last 2 digits of part number

indicate software version)

For Discrete Points — Press or to se- lect the desired state.

ST ART

STOP

OCCPC02S — ICE BUILD Time Schedule OCCPC03S — CCN Time Schedule

For Analog Points — Press or

DECREASE

3. Press to register the new value.

NOTE: When overriding or changing metric values, it is necessary to hold down the softkey 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 pre ss or

2. Press to access the highlighted value.

ENTER

to highlight the desired value.

to select the desired value.

NEXT PREVIOUS

SELECT

INCREASE

3. Press to view the desired time schedule.

4. Press or to highlight the desired

5. Press to access the highlighted period or

6. a. Press or to change the

SELECT

NEXT PREVIOUS

period or override to change.

SELECT

override.

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

3. Pres s to remove the override and return the

Override Indication “SUPVSR,” “SERVC,” or “BEST” flashing next to the point value on the ST ATUS table.

TIME SCHEDULE OPERATION (Fig. 19)

1. On the Menu screen, press .

2. Press or to highlight the desired

RELEASE

point to the PIC II’s automatic control.

— An override value is indicated by

SCHEDULE

NEXT PREVIOUS

schedule. OCCPC01S — LOCAL Time Schedule

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

ENABLE fields. Press to eliminate days from the period.

Fig. 19 — Example of Time Schedule

DISABLE

Operation Screen

7. Press t o register the values and to move hori-

ENTER

zontally (left to right) within a period.

8. Press to leave the period or override.

EXIT

9. Either return to Step 4 to select another period or override, or press again to leave the current time

EXIT

schedule screen and save the changes.

10. The Holiday Designation (HOLIDEF table) may be found in the Service Operation section, page 45. The month, day, and duration for the holiday must be assigned. The Broadcast function in the BRODEF table also must be enabled for holiday periods to function.

TO VIEW AND CHANGE SET POINTS (Fig. 20)

1. To view the SETPOINT table, from the MENU screen press .

SETPOINT

2. There are 5 set points on this screen: BASE DEMAND LIMIT, LCW SETPOINT (leaving chilled water set point), ECW SETPOINT (entering chilled water set point), ICE BUILD SETPOINT, and TOWER FAN HIGH SETPOINT. Only one of the chilled water set points can be active at one time. The set point that is active is determined from the SERVICE menu. See the Service Operation section, page 45. The ice build (ICE BUILD) function is also activated and configured from the SER VICE menu.

3. Press or to highlight the desired

NEXT PREVIOUS

set point entry.

4. Press to modify the highlighted set point.

5. Press or to change the select-

SELECT

INCREASE DECREASE

ed set point value.

6. Press t o save the c hanges and return to the pre-

ENTER

vious screen.

19XR_II

SETPOINT

Base Demand Limit

Control Point LCW Setpoint ECW Setpoint ICE BUILD Setpoint Tower Fan High Setpoint

SETPOINT SELECT

100%

50.0 F

60.0 F

40.0 F

85.0 F

Fig. 20 — Example of Set Point Screen

SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see S ervice Operation section, page 45. For examples of CVC/ICVC display screens, see Table 2.

Table 2 — CVC/ICVC Display Data

IMPORTANT: The following notes apply to all Table 2 examples.

1. Only 12 lines of information appear on the chiller display screen at any one time. Press the or softkey to highlight a point or to view items below or above the current screen. Press the softkey twice to page forward; press the softkey twice to page back.

2. To access the information shown in Examples 10 through 22, enter your 4-digit password after pressing the softkey. If no softkeys are pressed for 15 minutes, the CVC/ICVC automatically logs off (to prevent unrestricted access to PIC II controls) and reverts to the default screen. If this happens, you must re-enter your password to access the tables shown in Examples 10 through 22.

3. Terms in the Description column of these tables are listed as they appear on the chiller display screen.

4. The CVC/ICVC may be configured in English or Metric (SI) units using the CVC/ICVC CONFIGURATION screen. See the Service Operation section, page 45, for instructions on making this change.

5. The items in the Reference Point Name column do not appear on the chiller display screen. They are data or variable names used in CCN or Building Supervisor (BS) software. They are listed in these tables as a convenience to the operator if it is necessary to cross reference CCN/BS documentation or use CCN/BS programs. For more information, see the 19XR CCN literature.

NEXT PREVIOUS

SERVICE

6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized names, those preceded by a dagger can also be changed (that is, written to) by the CCN, BS, and the CVC/ICVC. Capitalized Reference Point Names preceded by two asterisks can be changed only from the CVC/ICVC. Reference Point Names in lower case type can be viewed by CCN or BS only by viewing the whole table.

7. Alarms and Alerts: An asterisk in the far right field of a CVC/ ICVC status screen indicates that the chiller is in an alarm state; an exclamation point in the far right field of the CVC/ICVC screen indicates an alert state. The asterisk (or exclamation point) indicates that the value on that line has exceeded (or is approaching) a limit. For more information on alarms and alerts, see the Alarms and Alerts section, page 15.

LEGEND

CCN — Carrier Comfort Network CHW — Chilled Water CHWR — Chilled Water Return CHWS — Chilled Water Supply CVC — Chiller Visual Controller CT — Current Transformer ECW — Entering Chilled Water HGBP — Hot Gas Bypass ICVC — International Chiller Visual Controller ISM — Integrated Starter Module LCW — Leaving Chilled Water LRA — Locked Rotor Amps mA — Milliamps P — Pressure PIC II — Product Integrated Controls II SS — Solid State T — Temperature VFD — Variable Frequency Drive WSM — Water System Manager

EXAMPLE 1 — CHILLER DISPLAY DEFAULT SCREEN

The following data is displayed in the Default screen.

DESCRIPTION STATUS UNITS

(PRIMARY MESSAGE) (SECONDARY MESSAGE) (DATE AND TIME)

Compressor Ontime 0-500000.0 HOURS C_HRS Entering Chilled Water –40-245 DEG F ECW CHW IN Leaving Chilled Water –40-245 DEG F LCW CHW OUT Evaporator Temperature –40-245 DEG F ERT EVAP REF Entering Condenser Water –40-245 DEG F ECDW CDW IN Leaving Condenser Water –40-245 DEG F LCDW CDW OUT Condenser Temperature –40-245 DEG F CRT COND REF Oil Pressure 0-420 PSI OILPD OILPRESS Oil Sump Temp 40-245 DEG F OILT OIL TEMP Average Line Current 0-999 % AMPS_% AMPS%

NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC/ICVC only.

0-1 CCN 0-1 LOCAL 0-1 RESET

REFERENCE POINT NAME

(ALARM HISTORY)

DISPLAY

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press ( will be highlighted).

3. Press .

*Chiller Start/Stop 0/1 STOP/START CHIL_S_S *Remote Start Contact 0/1 OPEN/CLOSE REMCON

*Control Point 10-120 DEG F LCW_STPT

*Active Demand Limit 40-100 % DEM_LIM

*Service Ontime 0-32767 HOURS S_HRS

NOTES:

1. Reset, Off, Local, CCN

2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout

3. Normal, Alert, Alarm

4. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN

STATUS MAINSTAT

SELECT

Control Mode NOTE 1 NOTE 1 MODE Run Status NOTE 2 NOTE 2 STATUS Start Inhibit Timer 0-15 min T_START Occupied? 0/1 NO/YES OCC System Alert/Alarm 0-2 NOTE 3 SYS_ALM

Temperature Reset –30-30 DEG F T_RESET

Chilled Water Temp –40-245 DEG F CHW_TMP

Average Line Current 0-999 % %_AMPS Motor Percent Kilowatts 0-999 % KW_P Auto Demand Limit Input 4-20 mA AUTODEM Auto Chilled Water Reset 4-20 mA AUTORES Remote Reset Sensor –40-245 DEG F R_RESET Total Compressor Starts 0-99999 c_starts Starts in 12 Hours 0-8 STARTS Compressor Ontime 0-500000.0 HOURS c_hrs

Ice Build Contact 0-1 OPEN/CLOSE ICE_CON Refrigerant Leak Sensor 0-20 mA REF_LEAK

devices.

DESCRIPTION STATUS UNITS POINT

EXAMPLE 3 — STARTUP DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

**Chilled Water Pump 0-1 OFF/ON CHWP

**Condenser Water Pump 0-1 OFF/ON CDP

**Oil Pump Delta P –6.7-200 ^PSI OILPD

**Tower Fan Relay Low 0-1 OFF/ON TFR_LOW **Tower Fan Relay High 0-1 OFF/ON TFR_HIGH

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.

STATUS

STARTUP

SELECT

DESCRIPTION STATUS UNITS POINT

Actual Guide Vane Pos 0-100 % GV_ACT

Chilled Water Flow 0-1 NO/YES CHW_FLOW

Condenser Water Flow 0-1 NO/YES CDW_FLOW Oil Pump Relay 0-1 OFF/ON OILR

Compressor Start Relay 0-1 OFF/ON CMPR Compressor Start Contact 0-1 OPEN/CLOSED CR_AUX Starter Trans Relay 0-1 OFF/ON CMPTRANS Compressor Run Contact 0-1 OPEN/CLOSED RUN_AUX

Starter Fault 0-1 ALARM/NORMAL STR_FLT Spare Safety Input 0-1 ALARM/NORMAL SAFETY Shunt Trip Relay 0-1 OFF/ON TRIPR ISM Fault Status 0-255 STRSTAT

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 4 — COMPRESS DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

**Target Guide Vane Pos 0-100 % GV_TRG

**Oil Pump Delta P –6.7-200 ^PSI OILPD

**Target VFD Speed 0-100 % VFD_OUT **Actual VFD Speed 0-110 % VFD_ACT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

**Chilled Water Delta P –6.7-420 PSI CHW_PD

**Evaporator Pressure –6.7-420 PSI ERP

**Condenser Water Delta P –6.7-420 PSI COND_PD

**Condenser Pressure –6.7-420 PSI CRP

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.

STATUS

COMPRESS

SELECT

Actual Guide Vane Pos 0-100 % GV_ACT Guide Vane Delta 0-100 % GV_DELTA

Oil Sump Temp –40-245 DEG F OILT

Comp Discharge Temp –40-245 DEG F CMPD Comp Thrust Brg Temp –40-245 DEG F MTRB Comp Motor Winding Temp –40-245 DEG F MTRW Spare Temperature 1 –40-245 DEG F SPARE1 Spare Temperature 2 –40-245 DEG F SPARE2 Oil Heater Relay 0/1 OFF/ON OILH Diffuser Actuator 0-100 % DIFF_ACT

Surge Protection Counts 0-5 SPC

Entering Chilled Water –40-245 DEG F ECW Leaving Chilled Water –40-245 DEG F LCW Chilled Water Delta T –6.7-420 ^F CHW_DT Chill Water Pulldown/Min –20-20 ^F CHW_PULL Evaporator Refrig Temp –40-245 DEG F ERT

Evaporator Approach 0-99 ^F EVAP_APP

Entering Condenser Water –40-245 DEG F ECDW Leaving Condenser Water –40-245 DEG F LCDW Condenser Refrig Temp –40-245 DEG F CRT

Condenser Approach 0-99 ^F COND_APP Hot Gas Bypass Relay 0/1 OFF/ON HGBR Surge / HGBP Active? 0/1 NO/YES SHG_ACT Active Delta P 0-200 PSI dp_a Active Delta T 0-200 DEG F dt_a Surge / HGBP Delta T 0-200 DEG F dt_c Head Pressure Reference 0-100 % hpr Evaporator Saturation Temp (ICVC only)

DESCRIPTION STATUS UNITS POINT

EXAMPLE 5 — HEAT_EX DISPLAY SCREEN

STATUS

HEAT_EX

SELECT

DESCRIPTION STATUS UNITS POINT

–40-245 ^F EST

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 6 — POWER DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

**Motor Kilowatt-Hours 0-99999 kWH KWH

NOTES:

1. All variables with CAPITAL LETTER point names are available for CCN read operation.

2. Those shown with (**) shall support write operations for CVC/ICVC only.

STATUS

POWER

SELECT

DESCRIPTION STATUS UNITS POINT

Average Line Current 0-999 % %_AMPS Actual Line Current 0-99999 AMPS AMP_A Average Line Voltage 0-999 % VOLT_P Actual Line Voltage 0-99999 VOLTS VOLT_A Power Factor 0.0-1.0 PF Motor Kilowatts 0-99999 kW KW_A

Demand Kilowatts 0-99999 kWH DEM_KWH Line Current Phase 1 0-99999 AMPS AMPS_1 Line Current Phase 2 0-99999 AMPS AMPS_2 Line Current Phase 3 0-99999 AMPS AMPS_3 Line Voltage Phase 1 0-99999 VOLTS VOLTS_1 Line Voltage Phase 2 0-99999 VOLTS VOLTS_2 Line Voltage Phase 3 0-99999 VOLTS VOLTS_3 Ground Fault Phase 1 0-999 AMPS GF_1 Ground Fault Phase 2 0-999 AMPS GF_2 Ground Fault Phase 3 0-999 AMPS GF_3 Frequency 0-99 Hz FREQ I2T Sum Heat-Phase 1 0-200 % HEAT1SUM I2T Sum Heat-Phase 2 0-200 % HEAT2SUM I2T Sum Heat-Phase 3 0-200 % HEAT3SUM

EXAMPLE 7 — ISM_STAT DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

ISM Fault Status 0-223 ISMFLT Single Cycle Dropout 0-1 NORMAL/ALARM CYCLE_1 Phase Loss 0-1 NORMAL/ALARM PH_LOSS Overvoltage 0-1 NORMAL/ALARM OV_VOLT Undervoltage 0-1 NORMAL/ALARM UN_VOLT Current Imbalance 0-1 NORMAL/ALARM AMP_UNB Voltage Imbalance 0-1 NORMAL/ALARM VOLT_UNB Overload Trip 0-1 NORMAL/ALARM OVERLOAD Locked Rotor Trip 0-1 NORMAL/ALARM LRATRIP Starter LRA Trip 0-1 NORMAL/ALARM SLRATRIP Ground Fault 0-1 NORMAL/ALARM GRND_FLT Phase Reversal 0-1 NORMAL/ALARM PH_REV Frequency Out of Range 0-1 NORMAL/ALARM FREQFLT ISM Power on Reset 0-1 NORMAL/ALARM ISM_POR Phase 1 Fault 0-1 NORMAL/ALARM PHASE_1 Phase 2 Fault 0-1 NORMAL/ALARM PHASE_2 Phase 3 Fault 0-1 NORMAL/ALARM PHASE_3 1CR Start Complete 0-1 FALSE/TRUE START_OK 1M Start/Run Fault 0-1 NORMAL/ALARM 1M_FLT 2M Start/Run Fault 0-1 NORMAL/ALARM 2M_FLT Pressure Trip Contact 0-1 NORMAL/ALARM PRS_RIP Starter Fault 0-1 NORMAL/ALARM STRT_FLT Motor Amps Not Sensed 0-1 NORMAL/ALARM NO_AMPS Starter Acceleration Fault 0-1 NORMAL/ALARM ACCELFLT High Motor Amps 0-1 NORMAL/ALARM HIGHAMPS 1CR Stop Complete 0-1 FALSE/TRUE STOP_OK 1M/2M Stop Fault 0-1 NORMAL/ALARM 1M2MSTOP Motor Amps When Stopped 0-1 NORMAL/ALARM AMPSTOP Hardware Failure 0-1 NORMAL/ALARM HARDWARE

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.

STATUS

ISM_STAT

SELECT

DESCRIPTION STATUS UNITS POINT

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 8 — CVC/ICVC_PSWD DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .or

4. Press .

**Remote Reset Option 0-1 DSABLE/ENABLE RESETOPT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations for the CVC/ICVC only.

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Press .

Base Demand Limit 40-100 % DLM 100 Control Point

Ice Build Setpoint 15-60 DEG F ice_sp 40.0 Tower Fan High Setpoint 55-105 DEG F tf2_sp 75

NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.

STATUS

CVC

SELECT

Disable Service Password 0-1 DSABLE/ENABLE PSWD_DIS

Reset Alarm? 0-1 NO/YES REMRESET CCN Mode? 0-1 NO/YES REM_CCN

ECW Setpoint 15-120 DEG F ecw_sp 60.0 LCW Setpoint 10-120 DEG F lcw_sp 50.0

DESCRIPTION STATUS UNITS POINT

SETPOINT

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

ICVC

EXAMPLE 9 — SETPOINT DISPLAY SCREEN

EXAMPLE 10 — CAPACITY DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Entering Chilled Water –40-245 DEG F ECW Leaving Chilled Water –40-245 DEG F LCW Capacity Control

Target Guide Vane Pos 0-100 % GV_TRG Actual Guide Vane Pos 0-100 % GV_ACT Target VFD Speed 0-100 % VFD_IN Actual VFD Speed 0-100 % VFD_ACT VFD Gain 0.1-1.5 vfd_gain Demand Limit Inhibit 0-100 % DEM_INH Amps/kW Ramp 0-100 % DMD_RAMP VFD Load Factor 0-200 VFD_LF

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screen.

SERVICE

CONTROL ALGORITHM STATUS

SELECT

CAPACITY

SELECT

DESCRIPTION STATUS UNITS POINT

Control Point 10-120 DEG F ctrlpt Control Point Error –99-99 ^F cperr ECW Delta T –99-99 ^F ecwdt ECW Reset –99-99 ^F ecwres LCW Reset –99-99 ^F lcwres Total Error + Resets –99-99 ^F error Guide Vane Delta –2-2 % gvd

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 11 — OVERRIDE DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Comp Motor Winding Temp –40-245 DEG F MTRW Comp Motor Temp Override 150-200 DEG F mt_over Condenser Pressure 0-420 PSI CRP Cond Press Override 90-180 PSI cp_over Evaporator Refrig Temp –40-245 DEG F ERT Evap Ref Override Temp 2-45 DEG F r t_over Comp Discharge Temp –40-245 DEG F CMPD Comp Discharge Alert 125-200 DEG F cd_alert Comp Thrust Brg Temp –40-245 DEG F MTRB Comp Thrust Brg Alert 165-185 DEG F tb_alert Actual Superheat –20-99 ^F SUPRHEAT Superheat Required 6-99 ^F SUPR_REQ Condenser Refrig Temp –40-245 DEG F CRT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight

6. Press .

LeadLag Control

NOTES:

1. DISABLE, LEAD, LAG, STANDBY, INVALID

2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG

3. Reset, Off, Local, CCN

4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout

5. Stop, Start, Retain

6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.

SERVICE

CONTROL ALGORITHM STATUS

SELECT

OVERRIDE

SELECT

DESCRIPTION STATUS UNITS POINT

EXAMPLE 12 — LL_MAINT DISPLAY SCREEN

SERVICE

CONTROL ALGORITHM STATUS

SELECT

LL_MAINT.

SELECT

DESCRIPTION STATUS UNITS POINT

LEADLAG: Configuration NOTE 1 leadlag

Current Mode NOTE 2 llmode Load Balance Option 0/1 DSABLE/ENABLE loadbal LAG START Time 2-60 MIN lagstart LAG STOP Time 2-60 MIN lagstop Prestart Fault Time 2-30 MIN preflt Pulldown: Delta T / Min x.xx ^F pull_dt

LEAD CHILLER in Control 0/1 NO/YES leadctrl LAG CHILLER: Mode NOTE 3 lagmode Run Status NOTE 4 lagstat Start/Stop NOTE 5 lag_s_s

STANDBY CHILLER: Mode NOTE 3 stdmode

Spare Temperature 1 –40-245 DEG F SPARE_1 Spare Temperature 2 –40-245 DEG F SPARE_2

Satisfied? 0/1 NO/YES pull_sat

Recovery Start Request 0/1 NO/YES lag_rec

Run Status NOTE 4 stdstat

Start/Stop NOTE 5 Std_s_s

Recovery Start Request 0/1 NO/YES std_rec

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 13 — ISM_HIST DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

ISM FAULT HISTORY Values At Last Fault: Line Current Phase 1 0-99999 AMPS AMPS_1F Line Current Phase 2 0-99999 AMPS AMPS_2F Line Current Phase 3 0-99999 AMPS AMPS_3F Line Voltage Phase 1 0-99999 VOLTS VOLTS_1F Line Voltage Phase 2 0-99999 VOLTS VOLTS_2F Line Voltage Phase 3 0-99999 VOLTS VOLTS_3F Ground Fault Phase 1 0-999 AMPS GF_1F Ground Fault Phase 2 0-999 AMPS GF_2F Ground Fault Phase 3 0-999 AMPS GF_3F I2T Sum Heat-Phase 1 0-200 % HEAT1SUMF I2T Sum Heat-Phase 2 0-200 % HEAT2SUMF I2T Sum Heat-Phase 3 0-200 % HEAT3SUMF Phase 1 Faulted? 0/1 NO/YES PH1_FLT Phase 2 Faulted? 0/1 NO/YES PH2_FLT Phase 3 Faulted? 0/1 NO/YES PH3_FLT Line Frequency 0-99 Hz FREQ_ F ISM Fault Status 0-9999 ISM_STAT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.

SERVICE

CONTROL ALGORITHM STATUS

SELECT

ISM_HIST

SELECT

DESCRIPTION STATUS UNITS POINT

EXAMPLE 14 — WSMDEFME DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

WSM Active? 0/1 NO/YES WSMSTAT Chilled Water Temp 0.0-99.9 DEG F CHWTEMP

Equipment Status 0/1 OFF/ON CHLRST Commanded State XXXXXXXX TEXT CHLRENA

CHW setpt Reset Value 0.0-25.0 DEG F CHWRVAL Current CHW Set Point 0.0-99.9 DEG F CHWSTPT

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.

SERVICE

CONTROL ALGORITHM STATUS

SELECT

WSMDEFME

SELECT

DESCRIPTION STATUS UNITS POINT

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 15 — NET_OPT DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

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

CCN Occupancy Config: Schedule Number 3-99 occpcxxe 3 Broadcast Option 0-1 DSABLE/ENABLE occbrcst DSABLE

Alarm Configuration Re-Alarm Time 0-1440 MIN 30 Alarm Routing 0-1 10000000

NOTE: No variables are available for CCN read or write operation.

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Enter password (4444 Factory Default).

6. Scroll down to highlight .

7. Press .

Starter Type 0-2 starter 1 (0 = Full, 1 = Red, 2 = SS/VFD) Motor Rated Line Voltage 200-13200 VOLTS v_fs 460 Volt Transformer Ratio:1 1-35 vt_rat 1 Overvoltage Threshold 105-115 % overvolt 115 Undervoltage Threshold 85-95 % undvolt 85 Over/Under Volt Time 1-10 SEC uvuntime 5 Voltage % Imbalance 1-10 % v_unbal 10 Voltage Imbalance Time 1-10 SEC v_time 5 Motor Rated Load Amps 10-5000 AMPS a_fs 200 Motor Locked Rotor Trip 100-60000 AMPS motor_lr 1000 Locked Rotor Start Delay 1-10 cycles lrdelay 5 Starter LRA Rating 100-60000 AMPS start_lr 2000 Motor Current CT Ratio:1 3-1000 ct_turns 100 Current % Imbalance 5-40 % c_unbal 15 Current Imbalance Time 1-10 SEC c_time 5 Grnd Fault CT’s? 0-1 NO/YES gf_phase YES Ground Fault CT Ratio:1 150 gf_ctr 150 Ground Fault Current 1-25 AMPS gf_amps 15 Ground Fault Start Delay 1-20 cycles gf_delay 10 Ground Fault Persistence 1-10 cycles gf_pers 5 Single Cycle Dropout 0/1 DSABLE/ENABLE cycdrop DSABLE Frequency = 60 Hz? (No = 50) 0/1 NO/YES freq YES Line Frequency Faulting 0/1 DSABLE/ENABLE freq_en DSABLE

SERVICE

EQUIPMENT CONFIGURATION

SELECT

NET_OPT

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

EXAMPLE 16 — ISM_CONF DISPLAY SCREEN

SERVICE

ISM (STARTER) CONFIG DATA

SELECT

ISM_CONF

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 17 — OPTIONS DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Auto Restart Option 0/1 DSABLE/ENABLE start DSABLE Remote Contacts Option 0/1 DSABLE/ENABLE r_contact DSABLE Soft Stop Amps Threshold 40-100 % softstop 100

Surge / Hot Gas Bypass

Surge Protection

Ice Build Control

Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE Refrigerant Leak Alarm mA 4-20 mA REF_LEAK 20 Head Pressure Reference

SERVICE

EQUIPMENT SERVICE

SELECT

OPTIONS

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

Surge Limit/HGBP Option 0/1 srg_hgbp 0 Select: Surge=0, HGBP=1 Min. Load Point (T1,P1) Surge/HGBP Delta T1 0.5-20 ^F hgb_dt1 1.5 Surge/HGBP Delta P1 30-170 PSI hgb_dp1 50 Full Load Point (T2,P2) Surge/HGBP Delta T2 0.5-20 ^F hbg_dt2 10 Surge/HGBP Delta P2 50-170 PSI hgb_dp2 85 Surge/HGBP Deadband 0.5-3 ^F hbg_db 1

Surge Delta% Amps 5-20 % surge_a 10 Surge Time Period 7-10 MIN surge_t 8

Ice Build Option 0/1 DSABLE/ENABLE ibopt DSABLE Ice Build Termination 0-2 ibterm 0 0=Temp, 1=Contacts, 2=Both Ice Build Recycle 0/1 DSABLE/ENABLE ibrecyc DSABLE

Delta P at 0% (4mA) 20-60 PSI HPDPO 25 Delta P at 100% (20mA) 20-60 PSI HPDP100 35 Minimum Output 0-100 % HPDPMIN% 0

NOTE: No variables are available for CCN read or write operation.

EXAMPLE 18 — SETUP1 DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Comp Motor Temp Override 150-200 DEG F mt_over 200 Cond Press Override 90-165 PSI cp_over 125 Comp Discharge Alert 125-200 DEG F cd_alert 200 Comp Thrust Brg Alert 165-185 DEG F tb_alert 175

Chilled Medium 0/1 WATER/BRINE medium WATER Chilled Water Deadband .5-2.0 ^F cw _db 1.0 Evap Refrig Trippoint 0.0-40.0 DEG F ert_trip 33 Refrig Override Delta T 2.0-5.0 ^F ref_over 3 Condenser Freeze Point –20 - 35 DEG F cdfreeze 34

Evap Flow Delta P Cutout 0.5 - 50.0 PSI evap_cut 5.0 Cond Flow Delta P Cutout 0.5 - 50.0 PSI cond_cut 5.0 Water Flow Verify Time 0.5-5 MIN wflow_t 5 Oil Pressure Verify Time 15-300 SEC oilpr_t 40 Recycle Control Restart Delta T 2.0-10.0 DEG F rcycr_dt 5 Shutdown Delta T 0.5-4.0 DEG F rcycs_dt 1

SPARE ALERT/ALARM ENABLE Disable=0, Lo=1/3, Hi=2/4

Spare Temp #1 Enable 0-4 sp1_en 0 Spare Temp #1 Limit –40-245 DEG F sp1_lim 245 Spare Temp #2 Enable 0-4 sp2_ en 0 Spare Temp #2 Limit –40-245 DEG F sp2_ lim 245

SERVICE

EQUIPMENT SERVICE

SELECT

SETUP1

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 19 — SETUP2 DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Capacity Control

Guide Vane Travel Limit 30-100 % gv_lim 80

Diffuser Control

VFD Speed Control

VFD Current Limit 0-99999 Amps vfdlim_i 250

SERVICE

EQUIPMENT SERVICE

SELECT

SETUP2

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

Proportional Inc Band 2-10 gv_inc 6.5 Proportional DEC Band 2-10 gv_dec 6.0 Proportional ECW Band 1-3 gw_ecw 2

Diffuser Option 0-1 DSABLE/ENABLE diff_opt DSABLE Guide Vane 25% Load Pt 0-78 % gv_25 25 Diffuser 25% Load Point 0-100 % df_25 0 Guide Vane 50% Load Pt 0-78 % gv_50 50 Diffuser 50% Load Point 0-100 % df_50 0 Guide Vane 75% Load Pt 0-78 % gv_75 75 Diffuser 75% Load Point 0-100 % df_75 0 Diffuser Full Span mA 15-22 mA diff_ma 18

VFD Option 0/1 DSABLE/ENABLE vfd_opt DSABLE VFD Gain 0.1-1.5 vfd_gain 0.75 VFD Increase Step 1-5 % vfd_step 2 VFD Minimum Speed 65-100 % vfd_min 70 VFD Maximum Speed 90-100 % vfd_max 100

NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.

EXAMPLE 20 — LEADLAG DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Lead Lag Control

NOTE: No variables are available for CCN read or write operation.

SERVICE

EQUIPMENT SERVICE

SELECT

LEADLAG

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

LEAD/LAG: Configuration 0-3 leadlag 0

DSABLE=0, Lead=1

LAG=2, STANDBY=3

Load Balance Option 0/1 DSABLE/ENABLE load/bal DSABLE

Common Sensor Option 0/1 DSABLE/ENABLE commsens DSABLE

LAG % Capacity 25-75 % lag_per 50

LAG Address 1-236 lag_add 92

LAG START Timer 2-60 MIN lagstart 10

LAG STOP Timer 2-60 MIN lagstop 10

PRESTART FAULT Timer 2-30 MIN preft 5

STANDBY Chiller Option 0/1 DSABLE/ENABLE stndopt DSABLE

STANDBY % Capacity 25-75 % stnd_per 50

STANDBY Address 1-236 stnd_add 93

Table 2 — CVC/ICVC Display Data (cont)

EXAMPLE 21 — RAMP_DEM DISPLAY SCREEN

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Pulldown Ramp Type: 0/1 ramp_opt 1

Demand Limit + kW Ramp

Demand Watts Interval 5-60 MIN dw_int 15

NOTE: No variables are available for CCN read or write operation.

To access this display from the CVC/ICVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

5. Scroll down to highlight .

6. Press .

Control Point

Temperature Reset

SERVICE

EQUIPMENT SERVICE

SELECT

RAMP_DEM

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

Select: Temp=0, Load=1

Demand Limit Source 0/1 dem_src 0 Select: Amps=0, kW=1 Motor Load Ramp% Min 5-20 kw_ramp 10 Demand Limit Prop Band 3-15 % dem_prop 10 Demand Limit At 20 mA 40-100 % dem_20ma 40 20 mA Demand Limit Opt 0/1 DSABLE/ENABLE dem_sel DSABLE Motor Rated Kilowatts 50-9999 kW motor_kw 145

EXAMPLE 22 — TEMP_CTL DISPLAY SCREEN

SERVICE

EQUIPMENT SERVICE

SELECT

TEMP_CTL

SELECT

DESCRIPTION STATUS UNITS POINT DEFAULT

ECW Control Option 0/1 DSABLE/ENABLE ecw_opt DSABLE Temp Pulldown Deg/Min 2-10 ^F temp_ramp 3

RESET TYPE 1 Degrees Reset At 20 mA –30- 30 ^F deg_20ma 10 RESET TYPE 2 Remote Temp —> No Reset –40-245 DEG F res_rt1 85 Remote Temp —> Full Reset –40-245 DEG F res_rt2 65 Degrees Reset –30-30 ^F deg_rt 10 RESET TYPE 3 CHW Delta T —> No Reset 0-15 ^F restd_1 10 CHW Delta T —> Full Reset 0-15 ^F restd_2 0 Degrees Reset –30-30 ^F deg_chw 5

Select/Enable Reset Type 0-3 res_sel 0

PIC II System Functions

NOTE: W ords not part of paragraph headings and printed in all capital letters can be viewed on the CVC/ICVC (e.g., LOCAL, CCN, RUNNING, ALARM, etc.). Words printed both in all capital letters and italics can also be viewed on the CVC/ICVC and are parameters (CONTROL MODE, TARGET GUIDE VANE POS, etc.) with associated values (e.g., modes, temperatures, pressures, percentages, on, off, enable, disable, etc.). Words printed in all capital letters and in a box represent soft-

keys on the CVC/ICVC (e.g., and ). See T able 2 for examples of the type of information that can appear on the CVC/ICVC screens. Figures 14-20 give an overview of CVC/ICVC operations and menus.

CAPACITY CONTROL FIXED SPEED — The PIC II controls the chiller capacity by modulating the inlet guide vanes in response to chilled water temperature deviation from the CON- TROL POINT. The CONTROL P OINT may be changed by a CCN network device or is determined by the PIC II adding any active chilled water reset to the SET POINT. The PIC II uses the PROPORTIONAL INC (Increase) BAND, PROPOR-

TIONAL DEC (Decrease) BAND, and the PROPORTIONAL ECW (Entering Chilled Water) GAIN to determine how fast or

slow to respond. CONTROL POINT may be viewed or overridden from the MAINSTAT screen.

CAPACITY CONTROL VFD — The PIC II controls the machine capacity by modulating the motor speed and inlet guide vanes in response to chilled water temperature deviation from the CONTROL POINT. The controller will maintain the highest inlet guide vane setting at the lowest speed to maximize efficiency while avoiding surge. The CONTROL POINT may be changed by a CCN network device or is determined by the PIC II add ing any active chille d water reset to the to the SET POINT. CONTROL POINT may be viewed or overridden from the MAINSTAT screen. The PIC II uses the PROPOR-

TIONAL INC (Increase) BAND, PROP DEC (Decrease) BAND, and the PROPORTIONAL ECW (Entering Chilled Water) GAIN to determine how fast or slow it takes the system

to respond. The VFD GAIN allows for additional adjustment of the VFD response. At start-up, the inlet guide vanes (IGV) start in the closed position and the VFD ramps to its minimum speed setting.

The PIC II controller then initia tes th e Capac ity Contr ol algorithm to maintain the chilled water temperature at the CON- TROL POINT. During operation when the CONTROL POIN T is not met, the controller will establish a GUIDE VANE DELT A which will either affect a percentage change to the GUIDE VANES or the VFD TARGET SPEED. Any change that will be made to the IGV position or the VFD SPEED will depend on whether the GUIDE VANE DELTA is positive or negative, and the status of the Surge Control Algorithm. The Surge Control Algorithm determines if the chiller should operate in Normal Mode or Surge Prevention Mode. The logic for how the IGV’s and VFD SPEED wi ll be affected by the GUIDE VANE DEL- TA and the Surge Control Algorithm can be seen below:

GUIDE VANE

DELTA

From +0.2 to +2.0 1st 2nd 2nd 1st From –0.2 to –2.0 2nd 1st 1st —

Normal Control mode occurs when ACTIVE DELTA T > SURGE/HGBP DELTA T.

Surge Prevention Mode occurs when ACTIVE DELTA T

≤ SURGE/HGBP DELT A T.

The T ARGET VFD SPEED, ACTUAL VFD SPEED and the VFD GAIN can be viewed and modifi ed in the CAPACITY

ENTER EXIT

NORMAL

CONTROL

MODE

IGV VFD IGV VFD

SURGE

PREVENTION

MODE

display screen. The TARGET VFD SPEED can be manually overridden by the operator from the COMPRESS scre en. The VFD MINIMUM SPEED, MAXIMUM SPEED, VFD GAIN and INCREASE STEP can be viewed and modified in the SETUP2 display screen. TARGET and ACTUAL VFD SPEED can be viewed in the COMPRESS screen.

ECW CONTROL OPTION — If this option is enabled, the PIC II uses the ENTERING CHILLED WATER temperature to modulate the vanes instead of the LEAVING CHILLED WATER temperature. The ECW CONTROL OPTION may be viewed on the TEMP_CTL screen, which is acces se d from the EQUIPMENT SERVICE screen.

CONTROL POINT DEADBAND — This is the tolerance range on the chilled water/brine temperature control point. If the water temperature goes outside the CHILLED WATER DEADBAND, the PIC II opens or closes the guide vanes until the temperature is within tolerance. The PIC II may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED WATER DEADBAND may be viewed or modified on the SETUP1 screen, which is accessed from the EQUIPMENT SERVICE 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 ) i s th e default setting.

DIFFUSER CONTROL — On 19XR FRAME sizes 4 and 5 compressors equipped with a variable discharge diffuser, the PIC II adjusts the diffuser actuator position (DIFFUSER ACTUATOR on the COMPRESS screen) to correspond to the actual guide vane position (ACTUAL GUIDE VANE POS on the COMPRESS screen).

The diffuser control can be enabled or disabled from the SETUP2 screen. See Table 2, Example 19. In addition, the diffuser and guide vane load points may be viewed and modified from this screen. These points must be correct for the compressor size. The diffuser opening can be incremented from fully open to completely closed. A 0% setting is fully open; a 100% setting is completely closed. To obtain the proper settings for Diffuser Control, contact a Carrier Engineering representative.

PROPOR TIONAL BA NDS AND GAIN — P roportional 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 the CONTROL POINT. The proportional bands and gain may be viewed or modified from the SETUP2 screen, which is accessed from the EQUIPMENT SER VICE table.

The Proportional Band

— There are two response modes, one for temperature response above the control point, the other for the response below the control point.

The temperature response above the control point is called the PROPORTIONAL INC BAND, and it can slow or quicken guide vane response to chilled water/brine temperatures above the DEADBAND. The P ROPORTIONAL INC BAND can be adjusted from a setting of 2 to 10; the default setting is 6.5.

The response below the control point is called the PRO- PORTIONAL DEC BAND, and it can slow or quicken the guide vane response to chilled water temperature below the deadband plus the control point. The PROPORTIONAL DEC BAND can be adjusted on the CVC/ICVC from a setting of 2 to

10. The default setting is 6.0. NOTE: Increasing either of these settings causes the guide

vanes to respond more slowly than they would at a lower setting.

The PROPORTIONAL ECW GAIN can be adjusted on the CVC/ICVC display for values of 1, 2, or 3; the de fault setting is 2. Increase this setting to increase guide vane response to a change in entering chilled water temperature.

DEMAND LIMITING — The PIC II responds to the ACTIVE DEMAND LIMIT set point by limiting the opening of the guide vanes. It compares the ACTIVE DEMAND LIMIT set point to the DEMAND LIMIT SOURCE (either the AVERAGE LINE CURRENT or the MOTOR KW). Depending on how the control is configured. DEMAND LIMIT SOURCE is on the RAMP_DEM screen. The default source is the compressor motor current.

CHILLER TIMERS — The PIC II maintains 2 run time clocks, known as COMPRESSOR ONTIME and SERVICE ONTIME. 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 SER- VICE ONTIME is a reset table timer tha t can be used to indicate the hours since the last service visit or any other event. The time can be changed from the CVC/ICVC 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 an d a stopto-start timer. These timers limit how soon the chiller can be started. START INHIBIT TIMER is displayed on the MAIN- STAT screen. See the Start-Up/Shutdown/Recycle Sequence section, page 46, for more information on this topic.

OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section (page 20), determines when the chiller can run. Each schedule consists of from 1 to 8 occupied or unoccupied time periods, set by the operator. The chiller can be started and run during an occupied time period (when OCCUPIED? is set to YES on the MAINSTAT display screen). It cannot be started or run during an unoccupied time period (when OCCUPIED? is set to NO on th e MAINSTAT display screen). These time periods can be set for each day of the week and for holidays. The day begins with 0000 hours and ends with 2400 hours. The default setting for OCCUPIED? is YES, unless an unoccupied time period is in effect.

These schedules can be set up to follow a building’s occupancy schedule, or the chiller can be set so to run 100% of the time, if the operator wishes. The schedules also can be bypassed by forcing the CHILLER START/STOP parameter on the MAINSTAT screen to START. For more informa tion on forced starts, see Local Start-Up, page 46.

The schedules also can be overridden to keep the chiller in an occupied state for up to 4 hours, on a one time basis. See the Time Schedule Operation section, page 20.

Figure 19 shows a schedule for a typical office building with a 3-hour, off-peak, cool-down period from midnight to 3 a.m., following a weekend shutdown. Holiday periods are in an unoccupied state 24 hours per day. The building operates Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays from 6:00 a.m. to 1:00 p.m. This schedule also incl udes 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.

Whenever the chil le r is in the LOCA L mo de, it us es Occ upancy Schedule 01 (OCCPC01S). When the chiller is in the

ICE BUILD mode, it uses Occupancy Schedule 02 (OCCPC02S). When the chiller is in CCN mode, it uses Occupancy Schedule 03 (OCCPC03S).

The CCN SCHEDULE NUMBER is configured on the NET_OPT display screen, accessed from the EQUIPMENT CONFIGURAT ION table. See Table 2, Example 15. SCHED- ULE NUMBER can be changed to any value from 03 to 99. If this number is changed on the NET_OPT screen, the operator must go to the ATTACH TO NETWORK DEVICE screen to upload the new number into the SCHEDULE screen. See Fig. 18.

Safety Controls —

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 discharge superheat*

• 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

• ground fault

• voltage imbalance

• current imbalance

• excessive motor acceleration time

• excessive starter transition time

• lack of motor current signal

• excessive motor amps

• excessive compressor surge

• temperature and transducer faults

*Superheat is the difference between saturation temperature

and sensible temperature. The high discharge temperature safety measures only sensible temperature.

Starter faults or optional protective devices within the starter can shut down the chiller. The protective devices you have for your application depend on what options were purchased.

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

If the PIC II control initiates a safety shutdown, it displays the reason for the shutdown (the fault) on the CVC/ICVC display screen along with a primary and secondary message, energizes an alarm relay in the starter, and blinks the alarm light on the control panel. The alarm is stored in memory and can be viewed on the ALARM HISTORY and ISM_HIST screens on the CVC/ICVC, along with a message for troubleshooting. If the safety shutdown was also initiated by a fault detected in the motor starter, the conditions at the time of the fault will be stored in ISM_HIST.

To give more precise information or warnings on the chiller’s operating condition, the operator can define alert lim- its 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 76.

The PIC II monitors all safety control

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 165 ± 5 psig (1138 ± 34 kPa), reset at

— CONTROL 165 psig (1138 kPa) Preset

OIL PRESSURE Cutout <15 psid (103 kPad)

LI NE VO LTAG E — HIGH >150% for one second or >115% for ten seconds Preset, based on transformed line voltage

— LOW <85% for ten seconds or ≤80 for 5 seconds or

— SINGLE-CYCLE <50% for one cycle (if enabled) Default is disabled.

COMPRESSOR MOTOR LOAD >110% for 30 seconds Preset

STARTER ACCELERATION TIME (Determined by inrush current)

STARTER TRANSITION If ISM contact open >20 sec. Reduced voltage starters only CONDENSER FREEZE PROTECTION Energizes condenser pump relay if

DISCHARGE SUPERHEAT Minimum value calculated based on

VARIABLE DIFFUSER OPERATION Detects discharge pulses caused by

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

0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds.

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

<33 F (for water chilling) (0.6°C) Preset, configurable chilled medium for water

<EVAP REFRIG TRIPPOINT (set point adjustable from 0 to 40 F [–18 to 4 C]) for brine chilling)

110 ± 7 psig (758 ± 48 kPa)

Alert <18 psid (124 kPad)

<75% for one second

<15% with compressor running Preset >15% with compressor off Preset 150% RLA for 20 sec. For chillers with reduced voltage mechanical >100% RLA for 45 sec. >100% RLA for 10 sec. For chillers with full voltage starters

condenser refrigerant temperature or condenser entering water temperature is below the configured condenser freeze point temperature. Deenergizes when the temperature is 5 F (3 C) above condenser freeze point temperature.

operating conditions and then compared to actual superheat.

incorrect diffuser position.

Ratio = Input Voltage ÷ Voltage Reference

(SETUP1 table) Configure chilled medium for brine (SETUP1

table). Adjust EVAP REFRIG TRIPPOINT for proper cutout

Preset

to ISM. Also monitored at CVC/ICVC and CCM power input.

and solid-state starters

(Configures on ISM_CONF table).

CONDENSER FREEZE POINT configured in SETUP1 table with a default setting of 34 F (1 C).

Calculated minimum required superheat and actual superheat are shown on OVERRIDE screen.

Preset, no calibration needed.

Shunt Trip (Option) —

The function of the shunt trip option on the PIC II is to act as a safety trip. The shunt trip is wired from an output on the ISM to a shunt trip equipped motor circuit breaker. If the PIC II tries to shut down the compressor using a normal shutdown procedure but is unsuccessful for 20 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 also energizes the shunt trip to trip the circuit breaker. Protective devices in the starter can also energize the shunt trip. The shunt trip feature can be tested using the Control Test feature.

Default Screen Freeze —

When the chiller is in an alarm state, the default CVC/ICVC display “freezes,” that is, it stops updating. The first line of the CVC/ICVC default screen displays a primary alarm message; the second line displays a secondary alarm message.

The CVC/ICVC default screen freezes to enable the operator to see the conditions of the chiller at the time o f the alarm . If the value in alarm is one normally displayed on the default screen, it flashes between normal and reverse video. The CVC/ ICVC default screen remains frozen until the condition that

caused the alarm is remedied by the operator. Use CVC/ICVC display and alarm shutdown record sheet (CL-13) to record all values from default screen freeze.

Knowledge of the operating state of the chiller at the time an alarm occurs is useful when troubleshooting. Additional chiller information can be viewed on the status screens and the ISM_HIST screen. Troubleshooting information is recorded in the ALARM HISTORY table, which can be accessed from the SER VICE menu.

To determine what caused the alarm, the operator should read both the primary and secondary default screen messages, as well as the alarm history . The primary message indicates the most recent alarm condition. The secondary message gives more detail on the alarm condition. Since there may be m ore than one alarm condition, another alarm message may appear after the first condition is cleared. Check the ALARM HISTORY screen for additional help in determining the reasons for the alarms. Once all existing alarms are cleared (by pressing the

RESET

softkey), the default CVC/ICVC display returns to

normal operation.

Ramp Loading —

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 CONTROL POINT. This helps reduce electrical demand charges by slowly bringing the chilled water to CONTROL POINT. The total power draw during this period remains almost unchanged.

There are two methods of ramp loading with the PIC II. Ramp loading can be based on chilled water temperature or on motor load. Either method is selected from the RAMP__DEM screen.

1. Temperature ramp loading MIN) limits the degrees per minute rate at which eithe r leaving chilled water or entering chilled water temperature decreases. This rate is configured by the ope rator on the TEMP_CTL screen. 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 l oad is selected as the ramp loading method).

2. Mot or load ramp loading the degrees per minute rate at which the com pressor motor current or compressor motor load increases. The LOAD PULLDOWN rate is configured by the operator on the RAMP_DEM screen in amps or kilowatts. The point name is MOTOR LOAD RAMP%/MIN.

If kilowatts is selected for the DEMAND LIMIT SOURCE, the MOTOR RATED KILOWATTS must be entered (information found on the chiller Requisition form).

The TEMP PULLDOWN DEG/MIN may be viewed or modified on the TEMP_CTL screen which is accessed from the EQUIPMENT SERVICE screen. PULLDOWN RAMP

TYPE, DEMAND LIMIT SOURCE, and MOTOR LOAD RAMP %/MIN may be viewed or modified on the

RAMP_DEM screen.

Capacity Override (Table 4) —

prevent some safety shutdowns caused by exceeding the motor amperage li m it, refrigerant low temperature saf e ty limit, motor high temperature safety limit, and condenser high pressure limit. In all cases there are 2 stages of compressor vane control.

1. The vane s are prevented from opening further, and the status line on the CVC/ICVC indicates the reason for the override.

2. The vanes are cl osed until the condition decreases to below the first step set point. Then the vanes are released to normal capacity control.

Whenever the motor current demand limit set point (ACTIVE DEMAND LIMIT) is reached, it acti vates a capa city override, again, with a 2-step process. Exceeding 110% of the rated load amps for more than 30 seconds will initiate a safet y 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 c ontroller normally will only prevent the guide vanes from opening. If so equipped, the hot gas bypass valve will open instead of holding the vanes. See the Surge Prevention Algorithm section, page 39.

High Discharge Temperature Control —

discharge temperature increases above 160 F (71.1 C), 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 PIC II will bring the chiller into the recycle mode.

Oil Sump Temperature Control —

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

The ramp loading control slows down

(TEMP PULLDOWN DEG/

(LOAD PULLDOWN) limits

Capacity overrides can

If the

The oil sump

As part of the pre-start checks executed by the controls, the oil sump temperature (OIL SUMP TEMP) is compared to the cooler refrigerant temperature (EVAPORATOR REFRIG TEMP). If the difference between t hese 2 te mpera tures 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.

The oil heater relay is energized whene ver the chill er compressor is off and the oil sump temperature i s less than 140 F (60.0 C) or the oil sump temperat ure is le ss t han the cool er r efrigerant temperature plus 53° F (11.7° C). The oil heater is turned off when the oil sump temperature is either

• more than 152 F (66.7 C), or

• more than 142 F (61.1 C) and more than the cooler

refrigerant temperature plus 55° F (12.8° C).

The oil heater is always off during start-up or when the compressor is running.

The oil pump is also energized during the time the oil is being heated (for 60 seconds at the end of every 30 minutes).

Oil Cooler —

sor is running. This is accomplished through a small, plate-type heat exchanger (also called the oil cooler) located behind the oil pump. The heat exchanger uses liquid condenser refrigerant as the cooling liquid. Refrigerant thermostatic expansion valves (TXVs) regulate refrigerant flow to c ontrol the oi l te mperature entering the bearings. The bulbs for the expansion valves are strapped to the oil supply line leaving the heat exchanger, and the valves are set to maintain 110 F (43 C).

NOTE: The TXVs are not adjustable. The oil sump temperature may be at a lower temperature during compressor operations.

Remote Start/Stop Controls —

as a timeclock that uses a set of contacts, m ay 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 (the ST ARTS IN 12 HOURS parameter on the MAINSTAT screen) occur, an excessive starts alarm displays, preventing the chiller from

starting. The operator must press the softkey on the CVC/ICVC to override the starts counter and start the chiller. If the chiller records 12 starts (excluding recycl e starts) in a sliding 12-hour period, it can be restarted only by pressing the

RESET LOCAL CCN This ensures that, if the automatic system is malfunctioning, the chiller will not repeatedly cycle on and off. If the automatic restart after a power failure option (AUTO RESTART OPTION on the OPTIONS screen) is not activated when a power failure occurs, and if the remote contact is closed, the chiller will indicate an alarm because of the loss of voltage.

minal strip J2, terminals 5 and 6 on the ISM. See the certified drawings for further details on contact ratings. The contacts must have 24 vac dry contact rating.

softkey followed by the or softkey.

The contacts for remote start are wired into the starter at ter-

Spare Safety Inputs —

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 a display on the CVC/ICVC. Refer to the certified drawings for safety contact ratings.

Analog temperature sensors may also be added to the module (SPARE TEMP #1 and #2). T he analog temperature sensors may be configured to cause an alert or alarm on the CCN network. The alert will not shut the chiller down. Configuring for alarm state will cause the chiller to shut down.

The oil must be cooled w hen the compres-

A remote device, such

RESET

Normally closed (NC) discrete

Table 4 — Capacity Overrides

OVERRIDE

CAPACITY CONTROL

HIGH CONDENSER

PRESSURE

HIGH MOTOR

TEMPERATURE

LOW REFRIGERANT

TEMPERATURE

(Refrigerant

Override Delta

Temperature)

HIGH COMPRESSOR

MANUAL GUIDE VANE

ACTIVE DEMAND LIMIT

LIFT

(Surge Prevention)

TARGET

MOTOR LOAD —

LOW DISCHARGE

SUPERHEAT

FIRST STAGE SET POINT

View/Modify

on CVC/ICVC

Screen

SETUP1

SETUP1 3° F (1.6° C)

OPTIONS

CAPACITY Automatic 0 to 100% None

MAINSTAT 100% 40 to 100%

OVERRIDE

Default

Val ue

125 psig

(862 kPa)

>200 F

(93.3 C)

Min: T1 — 1.5° F

(0.8° C) P1 — 50 psid (345 kPad)

Max: T2 — 10° F

(5.6° C) P2 — 85 psid (586 kPad)

Calculated Minimum

Superheat for

Conditions

Configurable

Range

90 to 165 psig

(620 to 1138 kPa)

150 to 200 F

(66 to 93 C)

2° to 5° F

(1° to 3° C)

0.5° to 20° F

(0.3° to 8.3° C)

30 to 170 psid

(207 to 1172 kPad)

0.5° to 20° F

(0.3° to 8.3° C)

50 to 170 psid

(348 to 1172 kPad)

None

SECOND STAGE SET

POINT

Val ue Value

>Override

Set Point

+2.4 psid (16.5 kPad)

>Override

Set Point

+10° F (6° C)

≤Trippoint

+ Override

∆T –1° F (0.56° C)

None

≥5% of

Set Point

2° F (1.1° C)

Below Calculated

Minimum Superheat

OVERRIDE

TERMINATION

<Override

Set Point

<Override

Set Point

>Trippoint

+ Override

∆T+2° F (1.2° C)

Within Lift Limits Plus Surge/HGBP Deadband Setting

Release of

Manual Control

2% Lower

Than Set Point

1° F (0.56° C)

Above Calculated

Minimum Superheat

Alarm (Trip) Output Contacts —

One set of alarm contacts is provided in the starter. The contact ratings are provided in the certified drawings. The contacts are located on terminal strip J9, terminals 15 and 16.

Refrigerant Leak Detector —

An input is available on the CCM module [terminal J5-5 (–) and J5-6 (+)] for a refrigerant leak detector. Enabling REFRIGERANT LEAK OPTION (OPTIONS screen) will allow the PIC II controls to go into an alarm state at a user configured level (REFRIGER- ANT LEAK ALARM mA). The input is configured for 4 to 20 mA by setting the DIP switch 1 on SW2 at the ON position, or configured for 1 to 5 vdc by setting switch 1 at the OFF position. The output of the refrigerant l eak detect or is di splayed as REFRIGERANT LEAK SENSOR on the MAINSTAT screen. For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed and 5 vdc input represents 20 mA displayed.

Kilowatt Output —

An output is available on the CCM module [Terminal J8-1 (+) and J8-2 (–)] to represent the power consumption of the chiller . The 4 to 20 mA signal generated by the CCM module can be wired to the building automation or energy management system to monitor the chiller’s energy consumption. A 4 mA signal represents the chiller in an off state and a 20 mA signal represents the chiller operating at its rated peak kilowatt consumption. The rated peak kilowatt consumption is configured by the user in the RAMP_DEM display screen by the setting the MOTOR RATED KILO WATTS from the job data sheet.

Remote Reset of Alarms —

A standard feature of the PIC II controls is the ability to re set a chiller in a shutd own alarm state from a remote location. If the condition which caused the alarm has cleared the chiller can be placed back into a normal CCN operating mode when the REMOTE RESET OPTION (CVC_PSWD/ICVC_PSWD menu) is set to ENABLE. A variety of Carrier Comfort Network software systems including ComfortVIEW™ or Network Service Tool™ can access the PIC I I control s and res et th e dis pla yed alar m.

Third party software from building automation systems (BAS) or energy management systems (EMS) can also access the PIC II controls through a Carrier DataLINK™ module and reset the fault displayed. Both methods would access the CVC_PSWD/ICVC_PSWD screen and force the RESET ALARM? point to YES to reset the fault condition. If the PIC II controls have determined that is safe to start the chiller the CCN MODE? point (CVC_PSWD/ICVC_PSWD screen) can be forced to YES to place the chiller back into normal CCN operating mode. The only exceptions are the following alarms that cannot be reset from a remote location: STATE #100, 205, 217-220, 223, 233, 234, 247, and 250. T o view alarm codes, refer to Troubleshooting Guide, Checking Display Messages, page 76. After the alarm has been reset the PIC II control will increment the Starts in 12 Hours counter by one upon restart. If the limit of 8 starts in a 12-hour period occurs the alarm will be required to be reset at the chiller control panel (CVC/ICVC).

Condenser Pump Control —

The chiller will monitor the condenser pressure (CONDENSER PRESSURE) and may turn on the condenser pump if the condenser pressure becomes too high while the compressor is shut down. The condenser pressure override (COND PRESS OVERRIDE) parame ter is used to determine this pressure point. COND PRESS OVERRIDE is found in the SETUP1 display screen, which is accessed from the EQUI PMEN T SERVICE table. The default value is 125 psig (862 kPa).

If the CONDENSER PRESSURE is greater than or equal to the COND PRESS OVERRIDE, and the entering condenser water temperature (ENTERING CONDENSER WATER) is less than 115 F (46 C), the condenser pump will energize to try to decrease the pressure. The pump will turn off when the condenser pressure is 3.5 psi (24.1 kPa) less than the pressure override or when the condenser refrigerant temperature (CON- DENSER REFRIG TEMP) is within 3° F (1.7° C) of the enter- ing condenser water temperature (E NTERING CONDENSER WATER).

Condenser Freeze Prevention —

rithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. The PIC II controls the pump and, by starting it, helps to prevent the water in the condenser from freezing. The PIC II can perform this function whenever the chiller is not running except when it is either actively in pumpdown or in pumpdown/lockout with the freeze prevention disabled.

When the CONDENSER REFRIG TEMP is less than or

equal to the CONDENSER FREEZE POINT, the CONDENS-

ER WATER PUMP is energized until the CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE POINT plus 5° F (2.7° C) and the ENTERING CONDENSER WATER TEMPERATURE is less than or equal to the CONDENSER FREEZE POINT. An alarm is generated if the chiller

is in PUMPDOWN mode and the pump is energized. An alert is generated if the chiller is not in PUMPDOWN mode and the pump is energized. If the chiller is in RECYCLE SHUTDOWN mode, the mode will transition to a non-recycle shutdown.

Evaporator Freeze Protection (ICVC only) —

refrigerant temperature sensor is in stalled at the bottom of the cooler to provide redundant freeze protection. In place of the cooler and condenser water pressure transducer inputs on the CCM is a 4.3k ohm resister and a jumper lead. When the EVAPORATOR REFRIGERANT TEMPERATURE is less than the EVAP REFRIG TRIPPOINT plus the REFRIG OVERRIDE DELTA T (co nfigurab le from 2 will be displayed and a capacity override will occur. If the EVAPORATOR REFRIG TEMP is equal to or less than the EVAP Refrig TRIPPOINT, Protective Limit ALARM STATE 232 will be displayed and the unit will shut down.

Tower Fan Relay Low and High —

water temperature can cause the chiller to shut dow n when re frigerant temperature is low. The tower fan relays, located in the starter, are controlled by the PIC II to energize and deenergize as the pressure differential between cooler and condenser vessels changes. This prevents low condenser water temperature and maximizes chiller efficiency. The tower fan relay can only accomplish this if the relay has been added t o the cooling tower temperature controller.

The tower fan relay low is turned on whenever the condenser water pump is running, flow is veri fied, and the difference between cooler and condenser pressure is more than 30 psid (207 kPad) for entering condenser water temperature greater than 65 F (18.3 C).

The tower fan relay low is turned off when the condenser pump is off, flow is stopped, or the cooler refrigerant t emperature is less than the override temperature for ENTERING CON- DENSER WATER temperature less than 62 F (16.7 C), or the differential pressure is less than 25 psid (172.4 kPad) for entering condenser water less than 80 F (27 C).

The tower fan relay high is turned on whenever the condenser water pump is running, flow is verified and the difference between cooler and condenser pressure is more than 35 psid (241.3 kPa) for entering condenser water temperature greater than the TOWER FAN HIGH SETPOINT (SETPOINT menu, default 75 F [23.9 C]).

The tower fan relay high is turned off when the condenser pump is off, flow is stopped, or the cooler refrigerant t emperature is less than the override temperature and ENTERING CONDENSER W ATER is less than 70 F (21.1 C), or the difference between cooler and condenser pressure is less than 28 Psid (193 kPa), or ENTERING CONDENSER WATER temperature is less than TOWER FAN HIGH SETPOINT minus 3 F (–16.1 C).

This control algo-

to 5°), state 122

Low condenser

The TOWER FAN RELAY LOW and HIGH parameters are

accessed from the STAR TUP screen.

IMPORTANT: A field-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 wate r tem pe ratu re.

The tower fan relay control is not a substitute for a c ondenser 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 —

may be enabled or disabled and may be viewed or modified on the OPTIONS screen, which is accessed from the EQUIPMENT CONFIGURATION table. If the AUTO. RESTART OPTION is enabled, the chiller will start up automatically after a power failure has occurred (after a single cycle dropout; l ow, high, or loss of voltage; and the power is within ± 15% of normal). The 15- and 5-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 energize for one minute before energizing the cooler pump. AUTO. RESTART will then continue like a normal start-up.

If power to the CVC/ICVC module has been off for more than 3 hours or the timeclock has been set for the first time, start the compressor with the slowest te mperature-based ramp load rate possible in order to minimize oil foaming.

The oil pump is energized occasionally during the time the oil is being brought up to proper temperature in order to eliminate refrigerant that has migrated to the oil sump during the power failure. The pump turns on for 60 seconds a t the end of every 30-minute period until the chiller is started.

Water/Brine Reset —

brine reset are available and can be viewed or m odified on t he TEMP_CTL screen, which is accessed from the EQUIPMENT SERVICE table.

The CVC/ICVC default screen indicates when the chill ed water reset is a ctive. TEMPERATURE RESET on the MAINSTAT screen indicates the amount of reset. The CONTROL

POINT will be determined by adding the TEMPERATURE RESET to the SETPOINT.

To activate a reset type, acce ss the TEMP_CTL s creen and input all configuration information for that reset type. Then, input the reset type number (1, 2, or 3) in the SELECT/ENABLE RESET TYPE input line.

RESET TYPE 1: 4 to 20 mA (1 to 5 vdc) TEMPERATURE RESET — Reset Type 1 is an automatic chilled water temperature reset based on a remote temperature sensor input confi gured for either an externally powered 4 to 20 mA or a 1 to 5 vdc signal. Reset Type 1 permits up to ±30 F (±16 C) of automatic reset to the ch ille d wate r set p oin t.

The auto, chilled water reset is hardwired to terminals J5-3 (–) and J5-4 (+) on the CCM. Switch setting number 2 on SW2 will determine the type of input signal. With the switch set at the ON position the input is configured for an externally powered 4 to 20 mA signal. With the switch in the OFF position the input is configured for an external 1 to 5 vdc signal.

RESET TYPE 2: REMOTE TEMPERATURE RESET — Reset Type 2 is an automatic chilled water temperature reset based on a remote temperature sensor input signal. Reset Type 2 permits ± 30° F (± 16° C) of auto mati c rese t to th e set p oint based on a temperature sensor wired to the CCM module

Three types of chilled water or

This option

(see wiring diagrams or certified drawings). The temperature sensor must be wired to terminal J4-13 and J4-14. To configure Reset Type 2, enter the temperature of the re mote sensor at the point where no temperature reset will occ ur (RE MOTE TEM P –> NO RESET). Next, enter the temperature at which the full amount of reset will occur (REMOTE TEMP –> FULL RESET). Then, enter the maximum amount of reset required to operate the chiller (DEGREES RESET). Reset Type 2 can now be activated.

RESET TYPE 3 — Reset Type 3 is an automati c chilled water temperature reset based on cooler temperature difference. Reset Type 3 adds ± 30° F (± 16° C) based on the temperature difference between the entering and leaving chilled water temperature.

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 (CHW DELTA T –> NO RESET). This chilled wat er temp erature d ifference is usually the full design load temperature difference. Next, enter the difference in chilled water temperature at which the full amount of reset occurs (CHW DELTA T –> FULL RE- SET). Finally, enter the amount of reset (DEGREES RESET). Reset Type 3 can now be activated.

Demand Limit Control Option —

The demand limit control option (20 mA DEMAND LIMIT OPT) is externally controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy management system (EMS). The option is set up on the RAMP_DEM screen. When enabled, 4 mA is the 100% demand set point with an operator-configured minimum demand at a 20 mA set point (DEMAND LIMIT AT 20 mA).

The auto. demand limit is hardwired to terminals J5-1 (–) and J5-2 (+) on the CCM. Switch setting number 1 on SW2 will determine the type of input signal. With the switch set at the ON position the input is configured for an externally powered 4 to 20 mA signal. With the switch in the OFF position the input is configured for an external 1 to 5 vdc signal.

Surge Prevention Algorithm (Fixed Speed Chiller) —

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 at the impeller discharge. The maximum lift a particular impeller whee l can perform varies with the gas flow across the impeller and t he size of th e wh eel .

A surge condition occurs when the lift becomes so high the gas flow across the impeller reverses. This condition can eventually cause chiller damage. The surge prevention algorithm notifies the operator that chiller operating conditions are marginal and to take action to help prevent chiller damage such as lowering entering condenser water temperature.

The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks 2 sets of operator-configured data points, the minimum load points (MIN.

LOAD POINT [T1,P1]) and the full load points (FULL LOAD POINT [T2,P2]). These points have default settings as defined

on the OPTIONS screen or on Table 4.

The surge prevention algorithm function and settings are graphically displayed in Fig. 21 and 22. The two sets of load points on the graph (default settings are shown) describe a line the algorithm uses to determine the maximum lift of the compressor. When the actual differential pressure between the cooler and condenser and the temperature difference bet ween the entering and leaving chilled water are above the line on the graph (as defined by the minimum and full load points), the algorithm goes into a corrective action mode. If the actual values are below the line and outside of the deadband region, the algorithm takes no action. When the point defined by the ACTIVE DELTA P and ACTIVE DELTA T, moves from the region

This is an operator-configurable feature that c an

where the HOT GAS BYP ASS/SURGE PREVENTION is off, the point must pass through the deadband region to the line determined by the configured values before the HOT GAS BYPASS/SURGE PREVENTION will be turned on. As the point moves from the region where the HOT GAS BYPASS/ SURGE PREVENTION is on, the point must pass through the deadband region before the HOT GAS BYPASS/SURGE PREVENTION is turned off. Information on modifying the default set points of the minimum and full load points may be found in the Input Service Configurations section, page 55.

The state of the surge/hot gas bypass algorithm on the

HEAT_EX DISPLAY SCREEN (Surge/HGBP Active?).

Corrective action can be taken by making one of 2 choices. If a hot gas bypass line is present and the hot gas option is selected on the OPTIONS table (SURGE LIMIT/HGBP OPTION is set to 1), the hot gas bypass valve can be energized. If the hot gas bypass option is not selected (SURG E LIMIT/ HGBP OPTION is set to 0), hold the guide vanes. See Table 4,

LEGEND

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

∆P = (Condenser Psi) – (Cooler Psi) ∆T = (ECW) – (LCW)

Fig. 21 — 19XR Hot Gas Bypass/Surge

Prevention with Default English Settings

LEGEND

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

∆P = (Condenser kPa) – (Cooler kPa) ∆T = (ECW) – (LCW)

Fig. 22 — 19XR Hot Gas Bypass/Surge

Prevention with Default Metric Settings

Capacity Overrides. Both of these corrective actions try to reduce the lift experienced by the compressor and help prevent a surge condition.

Surge Prevention Algorithm with VFD —

This is an operator configurable feature that 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 at the impeller discharge. The maximum lift a particular impeller wheel can perform varies with the gas flow through the impeller and the diameter of the impeller.

A surge condition occurs when the lift becomes so high the gas flow across the impeller reverses. This condition can eventually cause chiller damage. W hen enabled, t he Surge Preven tion Algorithm will adjust either the inlet guide vane (IGV) position or compressor speed to maintain the compressor at a safe distance from surge while maintaining machine efficiency. If the surge condition degrades then the algorithm will move aggressively away from surge. This condition can be identified when the SURGE/HGBP ACTIVE? on the HEAT_EX display screen displays a YES.

The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks two sets of operator-configured data points, the lower surge point (MIN.

LOAD POINT [T1,P1]) and the upper surge point (FULL LOAD POINT [T2,P2]). The surge characteristics vary be-

tween different chiller configurations and operating conditions. The surge characteristics are factory set based on the orig inal selection with the values displayed inside the control panel of the chiller. Since operating conditions may af fect the sur ge prevention algorithm, some field adjustments may be necessary.

The surge prevention algorithm function and settings are graphically displayed on Fig. 21 and 22. The two sets of load points on the graph (default settings are shown) describe a line the algorithm uses to determine the maximum lift of the compressor for the particular maximum operating speed. When the actual differential pressure between the cooler a nd condenser and the temperature difference between t he entering a nd leaving chilled water are above the line on the graph (as defined by the minimum and full load points), the algorithm operates in Surge Prevention mode. This is determined when the ACTIVE DELTA T is less than SURGE/HGBP DELTA T minus the deadband.

When in Surge Prevention mode, with a command to increase capacity, the VFD speed will increase until maxi mum VFD speed is reached. At VFD MAXIMUM SPEED, when Capacity still needs to i ncrease, the IGV ’s open. When in Surge Prevention mode, with a command to decrease capacity only the IGVs will close.

Surge Protection VFD Units —

The PIC II monitors surge, which is detected as a fluctuation in compressor motor amperage. Each time the fluctuation exceeds an operatorspecified limit (SURGE DELTA % AMPS), the PIC II registers a surge protection count. If more than 5 surges occur within an operator-specified time (SURGE TIME PERIOD), the PIC II initiates a surge protection shutdown of the chiller.

On VFD units, if a surge count is registered and if ACTUAL VFD SPEED is less than VFD MAXIMUM SPEED then motor speed will be increased by the configured VFD increase step. While the SURGE PROTECTION COUNTS are >0, a speed decrease will not be honored.

The surge limit can be adjusted from the OPTIONS screen (see Table 2). Scroll down to the SURGE DELTA % AMPS

parameter, and use the or softkey

INCREASE

DECREASE

to adjust the percent of surge. The default setting is 10% amps.

The surge time period can also be adjusted from the OPTIONS screen. Scroll to the SURGE TIME PERIOD

parameter, and use the or softkey

INCREASE DECREASE

to adjust the amount of time. The default setting is 8 minutes.

Access the display screen (COMPRESS) to monitor the

surge count (SURGE PROTECTION COUNTS).

Surge Protection (Fixed Speed Chiller) —

The PIC II monitors surge, which is a fluctuation in compressor motor amperage. Each time the fluctuation exceeds an operator-specified limit (SURGE DELTA % AMPS), the PIC II counts the surge. If more than 5 surges occur within an operator-specified time (SURGE TIME PER IOD), the PIC II initiates a surge protection shutdown of the chiller.

The surge limit can be adjusted from the OPTIONS screen.

Scroll down to th e SURGE DELTA % AMPS parameter, and use the or softkey to adjust the

INCREASE DECREASE

percent of surge. The default setting is 10% amps.

The surge time period can also be adjusted from the

OPTIONS screen. Scroll to the SURGE TIME PERIOD parameter, and use the or softkey

INCREASE DECREASE

to adjust the amount of time. The default setting is 8 minutes.

Access the display screen (COMPRESS) to monitor the

surge count (SURGE PROTECTION COUNTS). HEAD PRESSURE REFERENCE OUTPUT (See

Fig. 23) — The PIC II control outputs a 4 to 20 mA signal for the configurable Delta P (condenser pressure minus evaporator pressure) reference curve shown in Fig. 23. An output is available on the ISM module [T erminal J8 (+), J8 (–) labeled spare]. For chillers wi th Be nsha w I nc. so lid- stat e st art ers te rmina l st rip labeled J8 ( +), J8 (–) located ne xt to the RediS tart MICRO™ input/output card is provided. The Delta P at 100% (chiller at maximum load condition default at 35 psi), DELTA P AT 0% (chiller at minimum load condition default at 25 psi) and MIN- IMUM OUTPUT points are configurable in the EQUIPMENT SERVICE-OPTIONS table. When configuring this output ensure that minimum requirements for oil pressure and proper condenser FLASC orifice performance are maint ained. The 4 to 20 mA output can be used as a reference to control a tower bypass valve, tower speed control, or condenser pump speed control.

Lead/Lag Control —

The lead/lag control system automatically starts and stops a lag or second chiller in a 2-chiller water system. A third chiller can be adde d to the lead/lag sys tem 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. Refer to Fig. 17 and 18 for menu, table, and screen selection information.

DE LTA P AT 100%

MINIMUM

DELTA P

DE LTA P

AT 0 %

0 mA 2 mA

REFERENCE OUTPUT

4 mA (0%)

4 T0 20 mA OUTPUT

20 mA

(100%)

Fig. 23 — Head Pressure Reference Output

NOTE: The lead/lag function can be configured on the LEADLAG screen, which is accessed from the SERVICE menu and EQUIPMENT SERVICE table. See Table 2, Example 20. Lead/lag status during chiller operation can be viewed on the LL_MAINT display screen, which is accessed from the SERVICE menu and CONTROL AL GORITHM STATU S table. See Tabl e 2, Example 12.

Lead/Lag System Requirements:

• all chillers in the system must have s oftware capable of performing the lead/lag function

• water pumps MUST be energized from the PIC II controls

• water flows should be constant

• the CCN time schedules for all chillers must be identical

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 (Spare Temp #1 and #2) can be added to the CCM module, if desired. Spare Temp #1 and #2 are wired to plug J4 terminals 25-26 and 27-28 (J4 lower, respectively).

NOTE: If the common point sensor option is chosen on a chilled water system, each chiller should have its own common point sensor installed. Each chiller uses its own common point sensor for control when that chiller is designated as the lead chiller. The PIC II cannot read the value of common point sensors installed on the other chillers in the chilled water system.

If leaving chilled water control (ECW CONTROL OPTION

is set to 0 [DSABLE] TEMP_CTL screen) and a common point sensor is desired (COMMON SENSOR OPTION in LEADLAG screen selected as 1) then the sensor is wired in Spare Temp #1 posit ion on the CCM.

If the entering chilled water control option (ECW CON-

TROL OPTION) is enabled (configured in TEMP_CTL screen) and a common point sensor is desired (COMMON SENSOR OPTION in LEADLAG screen selected as 1) then the sensor is wired in Spare Temp #2 position on the CCM.

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 thi s sens or is n ot inst alled, t he ret urn ch illed w ater 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 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, Carrier Comfort Network Interface section for information on chiller communication wiring.

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

Lead/Lag Chiller Configuration and Operation

• A chiller is designated the lead chiller when its LEADLAG: CONFIGURATION value on the LEADLAG screen is set to “1.”

• A chiller is designated the lag chiller when its

LEADLAG: CONFIGURATION value is set to “2.”

• A chiller is designated as a standby chiller when its LEADLAG: CONFIGURATION value is set to “3.”

• A value of “0” disables the lead/lag designation of a

chiller. To configure the LAG ADDRESS val ue on the LEADLAG

screen, always enter the address of the other chiller on the system. For example, if you are configuring chiller A, enter the address for chiller B as the lag address. If you are configuring chiller B, enter the address for chiller A as the lag address. This makes it easi er to r otat e th e le ad an d lag chil ler s.

If the address assignments in the LAG ADDRESS and

STANDBY ADDRESS parameters conflict, the lead/lag function is disabled and an alert (!) message displays. For example, if the LAG ADDRESS matches the lead chiller’s address, the lead/lag will be disabled and an al ert (!) message displayed. The lead/lag maintenance screen (LL_MAINT) displays the message ‘INVALID CONFIG’ in the LEADLAG: CONFIGU- RATION and CURRENT MODE fields.

The lead chiller responds to normal start/stop controls such

as the occupancy schedule, a forced start or stop, and remote start contact inputs. After completing start-up and ramp loading, the PIC II evaluates the need for additional capacity. If additional capacity is needed, the PIC II 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, the chiller at the STANDBY ADDRESS (if configured) is requested to start. After the second chiller is started and is running, the lead chiller monitors conditions and evaluates whether the c apacity has been 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, the lag a nd standby chillers are also stopped. If the configured lead chiller stops for an alarm condition, the configured lag chiller takes the lead chiller’s place as the lead chiller, and the standby chiller serve s as the lag chiller.

If the configured lead chiller does not complete the start-up

before the PRESTART FAULT TIMER (a user-configured value) elapses, then the lag chill er starts and the lead chiller shuts down. The lead chiller then monitors the start request from the acting lead chiller. The PRESTART FAULT TIMER is initiated at the ti me of a start re quest. T he PRESTART FAULT TIMER provides a timeout if there is a prestart alert condition that prevents the chiller from starting in a timely manner. The PRESTART FAULT TIMER parameter is on the LEADLAG screen, which is acce ssed from the EQUIPMENT SERVICE table of the SERVICE menu.

If the lag chiller does not achieve start-up before the PRE-

START FAULT TIMER elapses, the lag ch iller stops, and the standby chiller is requested to start, if configured and ready.

Standby Chiller Configuration and Operation

— A chille r is designated as a standby chiller when its LEADLAG: CONFIG- URATION value on the LEADLAG screen is set to “3.” The standby chiller can operate as a replacement for the lag chiller only if one of the other two chillers is in an alarm (*) condition (as shown on the CVC/ICVC panel). If both lead and lag chillers are in an alarm (*) condition, the standby chiller defaults 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 load ing m ust be co mple te.

2. Lea d chilled water temperature must be greater than the CONTROL POINT temperature (see the MAINSTAT screen) plus 1/2 the CHILLED WATER DEADBAND temperature (see the SETUP1 screen).

NOTE: The chilled water temperature sensor may be th e 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 LIMIT (see the MAINST AT screen) value must be greater than 95% of full load amps.

4. Lead chiller temperature pulldown rate (TEMP PULL- DOWN DEG/MIN on the TEMP_CTL screen) of the chilled wat er tem per atu re is less t han 0 .5° F (0.27° C) per minute.

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

6. The configur ed LAG START TIMER entry has elapsed. The LAG ST ART TIMER starts when the lead chiller ramp loading is comp leted. The LAG START TIMER entry is on the LEADLAG screen, which is accessed from the EQUIPMENT SERVICE table of the SERVICE menu.

When all the above requirements have been met, the lag chiller is commanded to a STAR TUP mode (SUPVSR flashing next to the point value on the STATUS table). The PIC II 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 condi-

tions must be met in order for the lag chiller to be stopped.

1. Lead chiller compressor motor average line current or load value (MOTOR PERCENT KILOWATTS on the MAINSTAT screen) is les s than the lead chiller percent capacity.

NOTE: Lead chil ler perce nt capaci ty = 1 15 – LAG % CA- PAC I T Y. The LAG % CAPACITY parameter is on the LEADLAG screen, which is accessed from the EQ UIPMENT SER VICE table on the SERVICE menu.

2. The lead chiller chilled water temperature is less than the CONTROL POINT temperature (see the MAINSTAT screen) plus

/2 the CHILLED WA TER DEADBAND tem-

perature (see the SETUP1 screen).

3. The configured LAG STOP TIMER entry has elapsed. The LAG STOP TIMER starts when the lead chiller chilled water temperature is less than the chilled water CONTROL POINT plus 1/2 of the CHILLED WATER DEADBAND and the lead chiller compressor motor load (MOTOR PERCENT KILOWATT or AVERAGE LINE CURRENT on the MAINSTAT screen) is less than the lead chiller percent capacity.

NOTE: Lead chiller percent capacity = 115 – LAG % CAPAC- ITY. The LAG % CAPACITY parameter is on the L EADLAG screen, which is acce ssed from the EQUIPMENT SERVICE table on the SERV ICE menu.

FAULTED CHILLER OPERATION — If the lead chiller shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the lag chiller becom es the ac ting lea d chille r and star ts and stop s the standby chiller, if necessary.

If the lag chiller goes into alarm when the lead chiller is also in alarm, 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 CVC/ICVC panel), press the softkey to cle ar the

RESET alarm. The chiller is placed in CCN mode. The lead chiller communicates and monitors the RUN STATUS of the lag and standby chillers. If both the lag and standby chillers are running, the lead chiller does not attempt to start and does 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 waits for a start request from the oper ating chiller. When the configured lead chiller starts, it assumes its role as lead chiller.

If the lag chiller is the only chiller running when the lead chiller assumes its role as a lead chiller then the lag chiller will perform a RECOVERY START REQUEST (LL_MAINT screen). The lead chiller will start up when the following conditions are met.

1. Lag chiller ramp loading must be complete.

2. Lag CHILLED WATER TEMP (MAINSTAT screen) is greater than CONTROL POINT plus

/2 the CHILLED

WATER DEADBAND temperature.

3. Lag chiller ACTIVE DEMAND LIMIT value must be greater than 95% of full load amps.

4. Lag chiller temperature pulldown rate (TEMP PULL- DOWN DEG/MIN) of the chilled water temperature is less than 0.5 F (0.27 C) per minute.

5. The standby chiller is not running as a lag chiller.

6. The configured LAG START TIMER has elapsed. The LAG START TIMER is started when ramp loading is completed.

LOAD BALANCING — When the LOAD BALANCE OPTION (see LEADLAG scre en) is enabled, the lead chiller sets the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s compressor motor load value MOTOR PERCENT KILOW ATTS or AVERAGE LINE CURR ENT on the MAINST AT screen). This value has limits of 40% to 100%. When the lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL POINT must be modified to a value of 3° F (1.67° C) less than the lead chiller’s CONTR OL POINT value. If th e LOAD BAL- ANCE OPTION is disabled, the ACTIVE DEMAND LIMIT and the CONTROL 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 la g chiller has a 45-second delay. The standby chiller has a 90-second delay. The delay time is added after the chiller water flow is verified. The PIC II ensures the guide vanes are closed. After the guide vane position is confirmed, the delay for lag and standby chillers 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 LOCA L mode and is intended to stagger the compressor motor starts. Preventing the motors from starting simultaneously helps reduce the inrush demands on the building power system.

Ice Build Control —

matically sets the CONTROL POINT of the chiller to a temperature that allows ice building for thermal storage.

NOTE: For ice build control to operate properly, the PIC II must be in CCN mode.

NOTE: See Fig. 17 and 18 for more information on ice buildrelated menus.

The PIC II can be configured for ice build operation.

• From the SERVICE menu, access the EQUIPMENT SERVICE table. From there, select the OPTIONS screen to enable or disable the ICE BUILD OPTION. See Table 2, Example 17.

• The ICE BUILD SETPOINT can be configured from the SETPOINT display, which is accessed from the PIC II main menu. See Table 2, Example 9.

• The ice build schedule can be viewed or modified from the SCHEDULE table. From this table, select the ice build schedule (OCCPC02S) screen. See Fig. 19 and the section on Time Schedule Operation, page 20, for more information on modifying chiller schedules.

The ice build time schedule defines the period(s) during

which ice build is active if the ice build option is enabled. If the ice build time schedule overlaps other schedules, the ice build time schedule takes priority. During the ice build period, the CONTROL POINT is set to the ICE BUILD SETPOINT for temperature control. The ICE BUILD RECYCLE and ICE BUILD TERMINATION parameters, accessed from the OPTIONS screen, allow the c hiller opera tor to rec ycle or terminate the ice build cycle. The ic e build cycle can be configured to terminate if:

• the ENTERING CHILLED WATER temperature is less than the ICE BUILD SETPOINT. In this case, the opera- tor sets the ICE BUILD TERMINATION parameter to 0 on the OPTIONS screen.

• the REMOTE CONTACT inputs from an ice level indicator are opened. In this case, the operator sets the ICE BUILD TERMINATION parameter to 1 on the OPTIONS screen.

• the chilled water temperature is less than the ice build set point and the remote contact inputs from an ice level indicator are open. In this case, the operator sets the ICE BUILD TERMINATION parameter to 2 on the OPTIONS screen.

• the end of the ice build time schedule has been reached.

ICE BUILD INITIATION — The ice build time schedule (OCCPC02S) is the means for activating the ice build option. The ice build option is enabled if:

• a day of the week and a time period on the ice build time schedule are enabled. The SCHEDULE screen shows an X in the day field and ON/OFF times are designated for the day(s),

• and the ICE BUILD OPTION is enabled. The following events take place (unless overridden by a

higher authority CCN device).

• CHILLER START/ST O P is forced to START.

• The CONTROL POINT is forced to the ICE BUILD SET-

POINT.

• Any force (Auto) is removed from the ACTIVE DEMAND LIMIT.

NOTE: A parameter ’s value can be forc ed, that is, the value can be manually changed at the CVC/ICVC by an operator, changed from another CCN device, or changed by other algorithms in the PIC II control system.

NOTE: The Ice Build steps do not occur if the chiller is configured and operating as a lag or standby chiller for lead/lag operation and is actively being controlled by a lead chiller. The lead chiller communicates the ICE BUILD SET POINT, the desired CHILLER START/STOP state, and the ACTIVE DEMAND

The ice build control option auto-

LIMIT to the lag or standby chiller as required for ice build, if configured to do so.

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

• if ICE BUILD TERMINATION is set to the TEMP option and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SETPOINT;

• if ICE BUILD TERMINATION is set to the CONTACTS option and the remote contacts are open;

• if the ICE BUILD TERMINATION is set to the BOTH (temperature and contacts) option and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SETPOINT and the remote contacts are open.

The ICE BUILD RECYCLE on the OPTIONS screen deter-

mines whether or not the chiller will go into an ice build RECYCLE mode.

• If the ICE BUILD RECYCLE is set to DSABLE (dis- able), the PIC II reverts to normal temperature control when the ice build function terminates.

• If the ICE BUILD RECYCLE is set to ENABLE, the PIC II goes into an ICE BUILD RECYCLE mode and the chilled water pump relay remains energized to keep the chilled water flowing when the ice build function terminates. If the temperature of the ENTERING CHILLED WATER increases above the ICE BUILD SETPOINT plus the RECYCLE RESTART DELTA T value, the compres- sor restarts and controls the chilled water/b rine temperature to the ICE BUILD SETPOINT.

TEMPERATURE CONTROL DURING ICE BUILD — During ice build, the capacity control algorithm shall use the

CONTROL POINT minus 5 F (–2.8 C) for control of the LEAVING CHILLED WATER temperature. (See Table 2, ex-

ample 10, the CAPACITY CONTROL parameter on the CA- P ACITY screen.) The ECW CONTROL OPTION and any temperature reset option shall be ignored, if enabled, during ice build. The AUTO DEMAND LIMIT INPUT shall also be ignored if enabled during ice build.

• ECW CONTROL OPTION and any temperature reset options (configured on TEMP_CTL scree n).

• 20 mA DEMAND LIMIT OPT (configured on RAMP_DEM screen).

TERMINATION OF ICE BUILD — The ice build function terminates under the following conditions:

1. Time Schedule — When the current time on the ice build time schedule (OCCPC02S) is not set as an ice build time period.

2. Entering Chilled Water Temperature — Compressor operation terminates, based on temperature, if the ICE BUILD TERMINATION parameter is set to 0 (TEMP), the ENTERING CHILLED WATER temperature is less than the ICE BUILD SETPOINT, and the ICE BUILD

RECYCLE is set to DSAB LE. If th e ICE BU ILD RECYCLE OPTION is set to ENABLE, a recycle shutdown oc- curs and recycle start-up depends on the LEAVING CHILLED WATER temperature being greater than the water/brine CONTROL POINT plus the RESTART DELT A T temperature.

3. Remot e Contacts/Ice Level Input — Compressor operation terminates when the ICE BUILD TERMINATION parameter is set to 1 (CONTA CTS) and the remote contacts are open and the ICE BUILD RECYCLE is se t to DSABLE (0). In this case, the contacts provide ice level termination control. The contacts are used to stop the ice build function when a time period on the ice build schedule (OCCPC02S) is set for ice build operation. The remote contacts can still be opened and closed to start and

stop the chiller when a specific time period on the ice build schedule is not set for ice build.

4. Entering Chilled Water Temperature and ICE BUILD Contacts — Compressor operation terminates when the ICE BUILD TERMINATION parameter is set to 2 (BOTH) and the conditions described above in items 2 and 3 for entering chilled water temperature and remote contacts have occurred.

NOTE: It is not possible to override the CHILLER START/ STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT variables from CCN devices (with a priority 4 or greater) during the ice build period. However, a CCN device can override these settings during 2-chiller lead/lag operation.

RETURN TO NON-ICE BUILD OPERATIONS — The ice build function forces the chiller to start, even if all other schedules indicate that the chiller should stop. When the ice build function terminates, the chiller returns to normal temperature control and start/stop schedule operation. The CHILLER ST ART/ST OP and CONTROL POINT return to normal operation. If the CHILLER START/STOP or CONTROL POINT has been forced (with a device of less than 4 priority) before the ice build function started, when the ice build function ends, the previous forces (of less than 4 priority) are not automatically restored.

Attach to Network Device Control —

menu includes the ATTACH TO NETWORK DEVICE screen. From this screen, the operator can:

• enter the time schedule number (if changed) for OCCPC03S, as defined in the NET_OPT screen

• attach the CVC/ ICVC to any CCN device, if the chiller has been connected to a CCN network. This may include other PIC-controlled chillers.

• upgrade software Figure 24 shows the ATTACH TO NETWORK DEVICE

screen. The LOCAL parameter is always the CVC/ICVC module address of the chiller on which it is mounted. Whenever the controller identification of the CVC/ICVC changes, the change is reflected automatically in the BUS an d ADDRESS colu mns for the local device. See Fig. 18. Default address for local device is BUS 0 ADDRESS 1.

When the A TTACH TO NETWORK DEVICE screen is ac-

cessed, information can not be read from the CVC/ICVC on any device until one of the devices listed on that screen is attached. The CVC/ICVC 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 e nte red .

To attach any CCN device, highlight it using the

softkey and press the softkey. The message “UP- LOADING TABLES, PLEASE WAIT” displays. The CVC/ ICVC then uploads the highlighted device or module. If the

ATTACH

The Service

SELECT

Fig. 24 — Example of Attach to Network

Device Screen

module address cannot be found, the message “COMMUNI- CATION FAILURE” appears. The CVC/ICVC then reverts back to the ATTACH TO DEVICE screen. Try another device or check the address of the device tha t would not attach. The upload process time for each CCN module is different. In general, the uploading process takes 1 to 2 minutes. Before leaving the ATTACH TO NETWORK DEVICE s creen, select the local device. Otherwise, the CVC/ICVC will be unable to display information on the local chiller.

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

If the module number is not valid, the “COMMUNICA- TION FAILURE” message will show and a new address number must be entered or the wiring checked. If the module is communicating properly, the “UPLOAD IN PROGRESS” message will flash and the new module can now be viewed.

Whenever there is a question regarding which module on the CVC/ICVC is currently being shown, check the device name descriptor on the upper left hand corner of the CVC/ ICVC screen. See Fig. 24.

When the CCN device has been viewed, t he ATTACH TO NETWORK DEVICE table should be used to attach to the PIC that is on the ch iller. Move to the ATTACH TO NETWORK DEVICE table (LOCAL should be highlighted) and press t he

ATTACH ICVC for the 19XR will be uploaded and default screen will display .

NOTE: The CVC/ICVC will not automatica lly reattach to the local module on the chiller. Press the softkey to

attach to the LOCAL device and view the chiller operation.

softkey to upload the LOCAL device. The CVC/

ATTACH

Service Operation —

screens available for the SERVICE function is shown in Fig. 18.

TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered.

1. From the main MENU screen, press the softkey. The softkeys now correspond to the numerals 1, 2, 3, 4.

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

NOTE: The initial factory-set password is 1-1-1-1. If the password is incorrect, an error message is displayed

If this occurs, return to Step 1 and try to access the S ERVICE screens again. If the password is correct, the softkey labels change to:

NOTE: The SERVICE screen password can be changed by entering the CVC/ICVC CONFIGURATION screen under SERVICE menu. The password is located at the bottom of the menu.

The CVC/ICVC screen displays the following list of available SERVICE screens:

• Alarm History

• Control Test

• Control Algorithm Status

• Equipment Configuration

• ISM (Starter) Config Data

• Equipment Service

• Time and Date

• Attach to Network Device

• Log Out of Device

• CVC/ICVC Configuration

See Fig. 18 for additional screens and tables available from

the SERVICE screens listed above. Use the softkey to return to the main MENU screen.

NOTE: To prevent unauthorized persons from accessing the CVC/ICVC service screens, the CVC/ICVC automatically signs off and password-protects itself if a key has not been pressed for 15 minutes. The sequence is as follows. Fifteen minutes after the last key is pressed, the default screen displays, the CVC/ICVC screen light goes out (analogous to a screen saver), and the CVC/ICVC logs out of the passwordprotected SERVICE menu. Other screen and menus, such as the STATUS screen can be accessed w ithout the password by pressing the appropriate softkey.

TO LOG OUT OF NETWORK DEVICE — To access this screen and log out of a network device, from the default CVC/

ICVC screen, press the and softkeys. Enter the password and, from the SERVICE menu, highlight

LOG OUT OF NETWORK DEVICE and press the softkey. The CVC/ICVC default screen will now be displayed.

An overview of the tables and

SERVICE

EXIT

MENU SERVICE

SELECT

HOLIDAY SCHEDULING (Fig. 25) — The time schedules may be configured for special operation during a holiday peri od. 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. 19.)

The broadcast function must be activated for the holidays configured on the HOLIDEF screen to work properly. Access the BRODEF screen from th e EQUIPMENT CONFIGURATION table and select ENABLE to activate function. Note that when the chiller is connected to a CCN Network, only one chiller or CCN device can be configured as the broadcast device. The controller that is configured as t he broadcast er is t he device responsible for transmitting holiday, time, and daylightsavings dates throughout the network.

To access the BRODEF screen, see the SERVICE menu structure, Fig. 18.

T o vi ew or change the holiday periods for up to 18 dif ferent holidays, perform the following operation:

1. At the Menu scre en, press to access the Service menu.

2. If not logged on, follow the instructions for Attach to Network Device or To Log Out. Once logged on, press

3. Once Equipment Configuration is highlighted, press

SELECT

4. Press until HOLIDAYS is highlighted. This is the Holiday Definition table.

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

6. Press to highlight the holiday table that is to be viewed or changed. Each table is one holiday period, starting on a specific date, and lasting up to 99 days.

7. Press 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 or to highlight the month, day, or duration.

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

10. Press or to change the selected value.

11. Press to save the changes.

12. Press to return to the previous menu.

Fig. 25 — Example of Holiday Period Screen

until Equipment Configuration is highlighted.

to access.

SELECT

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENTER EXIT

SERVICE

START-UP/SHUTDOWN/

RECYCLE SEQUENCE (Fig. 26)

Local Start-Up —

initiated by pressing the menu softkey on the default CVC/ICVC screen. Local start-up can proceed when the chiller schedule indicates that the current time and date have been established as a run time and date, and after the internal 15-minute start-to-start and the 1-minute stop-to-start inhibit timers have expired. These timers are represented in the START INHIBIT TIMER and can be viewed on the MAINSTAT screen and DEF AULT screen. The timer must expire before the chiller will start. If the timers have not expired the RUN STATUS parameter on the MAINSTAT screen now reads TIMEOUT.

NOTE: The time schedule is said to be “occupied” if the OCCUPIED ? parameter on the MAINSTAT screen is set to YES. For more information on occupancy schedules, see the sections on Time Schedule Operation (page 20), Occupancy Schedule (page 34), and To Prevent Accidental Start-Up (page 65), and Fig. 19.

If the OCCUPIED ? parameter on the MAINSTAT screen

is set to NO, the ch ille r can b e fo rced t o st art as fo llo ws. Fr om the default CVC/ICVC screen, press the and

ST ATUS

SELECT Press the softkey to override the schedule and start the chiller.

NOTE: The chiller will continue to r u n un t il this forced start i s released, regardless of the programme d schedule. To re lease the forced start, highlight CHILLER START/STOP from the

MAINSTAT screen and press the softkey. This action returns the chiller to the start and stop times established by the schedule.

schedule. From the default screen, press the and

SCHEDULE schedule. Select OVERRIDE, and set the desired override time.

have the REMOTE CONTACTS OPTION on the EQUIP- MENT SERVICE screen set to ENABLE. For these chillers, the REMOTE START CONTACT parameter on the MAIN- STAT screen must be CLOSED. From the CVC/ICVC default

screen, press the and softkeys. Scroll to highlight MAINSTAT and press the softkey. Scroll

down the MAINSTAT screen to highlight REMOTE START CONTACT and press the softkey. Then, press the

CLOSE TACTS INPUT and press the softkey.

pre-start tests to verify that all pre-s tart alerts and safeties are within the limits shown in Table 4. The RUN STATUS parame- ter on the MAINSTAT screen line now reads PRESTART. If a test is not successful, the start-up is de layed or aborted. If the tests are successful, the chilled water/brine pump relay energizes, and the MAINSTAT screen line now reads ST ARTUP.

Thirty seconds later the PIC II monitors the chilled water and condenser water flow devices and waits until the WATER FLOW VERIFY TIME (operator-configured, default 5 minutes) expires to confirm flow. After flow is verified, the chilled water temperature is compared to CONTROL POINT plus CHILLED WATER DEADBAND. If the temperature is less than or equal to this value, the PIC II turns off the condenser pump relay and goes into a RECYCLE mode.

softkeys. Scroll to highlight MAINSTAT. Press the softkey . Scroll to highlight CHILLER ST ART/STOP. ST ART

The chiller may also be started by overriding the time

softkeys. Scroll down and select the current

Another condition for start-up must be met for chillers that

softkey. To end the override, select REMOTE CON-

Once local start-up begins, the PIC II performs a series of

Five seconds later, the condenser pump relay energizes.

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

LOCAL

RELEASE

MENU STATUS

SELECT

RELEASE

NOTE: Units equipped with ICVC are not available with fa ctory installed chilled water or condenser water flow devices (available as an accessory for use with the CCM Control board).

If the water/brine temperature is high enough, the start-up sequence continues and checks the guide vane position. If the guide vanes are more than 4% open, the start-up waits until the PIC II closes the vanes. If the vanes are closed and the oil pump pressure is less than 4 psi (28 kPa), the oil pump relay energizes. The PIC II then waits until the oil pressure (OIL PRESS VERIFY TIME, operator-configured, default of 40 seconds) reaches a maximum of 18 psi (124 kPa). After oil pressure is verified, the PIC II waits 40 seconds, and the compressor start relay (1CR) energizes to start the compr ess or.

Compressor ontime and service ontime timers start, and the compressor STARTS IN 12 HOURS counter and the number of starts over a 12-hour period counter advance by one.

Failure to verify any of the requirements up to this point will result in the PIC II aborting the start and displaying the applicable pre-start mode of failure on the CVC/ICVC 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, advances the starts in 12 hours counter by one, and displays the applicable shutdown status on the CVC/ ICVC display.

A — START INITIATED: Pre-start checks are made; evaporator pump

started.

B — Condenser water pump started (5 seconds after A). C — Water flows verified (30 seconds to 5 minutes maximum after B).

Chilled water temperatures checked against control point. Guide vanes checked for closure. Oil pump started; tower fan control enabled.

D — Oil pressure verified (15 seconds minimum, 300 seconds maximum

after C).

E — Compressor motor starts; compressor ontime and service ontime

start, 15-minute inhibit timer starts (10 seconds after D), total compressor starts advances by one, and the number of star ts over a 12-hour period advances by one.

F — SHUTDOWN INITIATED — Compressor motor stops; compressor

ontime and service ontime stop, and 1-minute inhibit timer star ts.

G — Oil pump and evaporator pumps deenergized (60 seconds 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.

O/A — Restart permitted (both inhibit timers expired: minimum of 15 minutes

after E; minimum of 1 minute after F).

Fig. 26 — Control Sequence

Shutdown Sequence —

any of the following occurs:

• the STOP button is pressed for at least one second (the alarm light blinks once to confirm the stop command)

• a recycle condition is present (see Ch illed Water Recycle Mode section)

• the time schedule has gone into unoccupied mode

• the 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 CVC/ICV C

When a stop signal occurs, the shutdown sequence first

stops the compressor by deactivating the start relay (1CR). A status message of “SHUTDOWN IN PROGRESS, COMPRESSOR DEENERGIZED” is displayed, and the 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 shut down 60 seconds after the compressor stops. The condenser water pump shuts down at the same time if the ENTERING CONDENSER WATER tem- perature is greater than or equal to 115 F (46.1 C) and the

CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE POINT plus 5 F (–15.0 C). The stop-to-start timer

now begins to count down. If the start-to-start timer value is still greater than the val ue of the start-to-stop timer, then this time displays on the CVC/ICVC.

Certain conditions that occur during shutdown can change

this sequence.

• If the AVERAGE LINE CURRENT is greater than 5% after shutdown, or the starter contacts remain energized, the oil pump and chilled water pump remain energized and the alarm is displayed.

• The condenser pump shuts down when the CONDENSER PRESSURE is less than the COND PRESS OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the CONDENSER REFRIG TEMP is l es s t ha n or e qu al to the ENTERING CONDENSER WATER temperature plus

3° F (–1.6° C).

• If the chiller shuts dow n due to low refrigerant tempera-

ture, the chilled water pump continues to run until the LEAVING CHILLED WATER temperature is greater than the CONTROL POINT temperature, plus 5° F (3° C).

Automatic Soft Stop Amps Threshold —

stop amps threshold feature closes the guide vanes of the compressor automatically if a non-recycle, non-alarm stop signal occurs before the compressor motor is deenergized.

If the STOP button is pressed, the guide vanes close to a

preset amperage percent until the guide vane is less than 4% open or 4 minutes have passed. The compressor then shuts off.

If the chiller enters an alarm state or if the compressor enters

a RECYCLE mode, the compressor deenergizes immediately.

T o activate the soft stop amps threshold feature, scroll to the

bottom of OPTIONS screen on the CVC/ICVC. Use the

INCREASE AMPS THRESHOLD parameter to the percent of amps at which the motor will shut down. The default setting is 100% amps (no soft stop). The range is 40 to 100%.

When the soft stop amps threshold feature is being applied, a status message, “SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING” displays on the CVC/ICVC.

The soft stop amps threshold function can be terminated and the compressor motor deenergized immediately by depressing the STOP button twice.

or softkey to set the SOFT STOP

DECREASE

Chiller shutdown begins if

The soft

Chilled Water Recycle Mode —

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

• the chiller is in LCW control, the difference between the

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

SETUP1 table) the LEAVING CHILLED WATER tem- perature is 5° F (2.8° C) below the CONTROL POINT, the CONTROL POINT has not increased in the last 5 minutes and ICE BUILD is not active.

• the 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 SETUP1 table), the ENTERING CHILLED WATER tem- perature is 5° F (2.8° C) below the CONTROL POINT, and the CONTROL POINT has not increased in the last 5 minutes.

• the LEAVING CHILLED WATER temperature is within 3° F (2° C) of the EVAP REFRIG TRIPPOINT.

When the chiller is in RECYCLE mode, the c hilled water

pump relay remains energized so the chilled water temperature can be monitored for increasing load. The recycle cont rol uses RESTART DELTA T to check when the compressor should be restarted. This is an operator-configured function which defaults to 5° F (3° C). This value can be viewed or modified on the SETUP1 table. The compressor will restart when the chiller is:

• in LCW CONTROL and the LEAVING CHILLED WATER temperature is greater than the CONTROL POINT plus the RECYCLE RESTART DELTA T.

• in ECW CONTROL and the ENTERING CHILLED WATER temperature is greater than the CONTROL POINT plus the RECYCLE RESTART DELTA T.

Once these conditions are met, the compressor initiates a

start-up with a normal start-up sequence.

An alert condition may be generated if 5 or more re cycle

start-ups occur in less than 4 hours. Excessive recycling can reduce chiller life; therefore, compresso r recycling due to extremely low loads should be reduced.

To reduce compressor recycling, use the t ime schedule to

shut the chiller down during known low load operation period, 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 SETUP1 table to lengthen the time between restarts.

The chiller should not be operated below design minimum

load without a hot gas bypass installed.

Safety Shutdown —

a manual shutdown with the exception that, during a safety shutdown, the CVC/ICVC displays the reason for the shutdown, the alarm light blinks continuously, and the spare alarm contacts are energized.

After a safety shutdown, the softkey must be

pressed to clear the alarm. If the alarm condition is still present, the alarm light continues to blink. Once the alarm is cleared, the operator must press the or softkeys t o restart the chille r.

A safety shutdown is identical to

CCN LOCAL

The chiller may

RESET

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

• 19XR 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 indi-

cator (Fig. 27)

• 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 Tank and Pumpout System —

tion, page 69 for pumpout system preparation, refrigerant transfer, and chiller evacuation.

Remove Shipping Packaging —

aging material from the control center, power panel, guide vane actuator, motor cooling and oil reclaim solenoids, motor and bearing temperature sensor covers, and the factory-mounted starter.

Open Oil Circuit Valves —

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

Refer to Chillers with Storage Tanks sec-

Remove any pack-

Check to ensure the oil fil-

Tighten All Gasketed Joints and Guide Vane Shaft Packing —

the time the chiller arr ives at the jobsite. Tighten all gas keted joints and the guide vane shaft packing to ensure a leak-t ight chiller.

Check Chiller Tightness —

proper sequence and procedures for leak testing.

The 19XR chillers are shipped with the refrigerant con-

tained in the condenser shell and the oil charge in the compressor. The cooler is shipped with a 15 psig (103 kPa) refrigerant charge. Units may be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogen-holding charge in each vessel.

Gaskets and packing normally relax by

Figure 28 outlines the

To determine if there a re any leaks, the chiller should be charged with refrigerant. Use an electronic leak detector to check all flanges and sold er joints after the chill er 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 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 being transferred. Adjust the springs when the refrigerant is in operating condition and the water circuits are full.

Refrigerant Tracer —

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

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

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

Fig. 27 — Typical Wet-Bulb Type

Vacuum Indicator

Carrier recommends the use of an

Fig. 28 — 19XR Leak Test Procedures

Leak Test Chiller —

erant emissions and the difficulties associated with separating contaminants from the refrigerant, Carrier recommends the following leak test procedure. See Fig. 28 for an outline of the leak test procedure. Refer to Fig. 29 and 30 during pumpout procedures and Tables 5A and 5B for refrigerant pressure/ temperature values.

1. If the pressure readings are normal for the chiller condition:

a. Evacuate the holding charge from the vessels, if

present.

b. Raise the chiller pressure, if necessary, by adding

refrigerant until pressure is at the equivalent saturated pressure for the surrounding temperature. Follow the pumpout procedures in the Transfer Refrigerant from Pumpout Storage Tank to Chiller section, Steps 1a - e, page 69.

Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 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 II. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage.

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

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

a. Prepare to leak test chillers shipped with refriger-

ant (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 that 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 possible, given the fact that small leaks may be

present in the system. This can be accomplished b y

following the dehydration procedure, outlined in

the Chiller Dehydration section, page 53. h. Slowly raise the system pressure to a maximum of

160 psig (1103 kPa) but no less than 35 psig

(241 kPa) for HFC-134a by adding refrigerant.

Proceed with the test for small leaks (Steps 3-9).

3. C heck the chiller carefully with an electronic leak detec tor, halide torch, or soap bubble solution.

4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, t o confirm. Total all leak rat e s f o r the entire chil le r. Leakage at rates greater than 1 lb./year (0.45 kg/year) for the entire chiller must be re pair ed. N ote th e tot a l chil ler lea k rat e on the start-up report.

Due to regulations regarding refrig-

5. If no l eak is found during the initial start-up procedures, complete the transfer of refrigerant gas from the pumpout storage tank to the chiller (see Transfer Refrigerant from Pumpout Storage Tank to Chiller section, page 69). Retest for leaks.

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

tank and perform a standing vacuum test as outlined in the Standing Vacuum Test section, below.

b. If the chiller fails the standing vacuum test, check

for large leaks (Step 2b).

c. If the chiller passes the standing vacuum test,

dehydrate the chiller. Follow the procedure in the Chiller Dehydration section. Charge the chiller with refrigerant (see Transfer Refrigerant from Pumpout Storage Tank to Chiller section, page 69).

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

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

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

Standing Vacuum Test —

standing 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. Atta ch an absolute pre ssure manometer or we t bulb indicator to the c hille r.

2. Evacuate the vessel (see Pumpout and Refrigerant Transfer Procedures section, page 67) to at least 18 in. Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or the pump out 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 (0.17 kPa

24 hours, the chiller is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)

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 Chiller To Normal Operating Conditions section, page 71. 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 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 the leak, retest, and proceed with dehydration.

When performing the

) in

Fig. 29 — Typical Optional Pumpout System Piping Schematic with Storage Tank

Fig. 30 — Typical Optional Pumpout System Piping Schematic without Storage Tank

Table 5A — HFC-134a Pressure —

Temperature (F)

TEMPERATURE,

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

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

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)

Table 5B — HFC-134a Pressure —

Temperature (C)

TEMPERATURE,

–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

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

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

(kPa)

Chiller Dehydration —

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.

Dehydration is recommended if

Fig. 31 — Dehydration Cold Trap

Inside-delta type starters must be disconnected by an isolation switch before placing the machine under a vacuum because one lead of each phase is live with respect to ground even though there is not a complete circuit to run the motor. To be safe, isolate any starter befor e evacuati ng the chiller if you are not sure if there are live leads to the hermetic motor.

Dehydration can be done at room temperatures. Using a cold trap (Fig. 31) 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 to boil off any moisture. If low ambient temperatures are involv ed, contact a qua lified service representative for the dehydration techniques required.

Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm [.002 m or larger is recommended) to the refrigerant charging valve (Fig. 2). Tubing from the pump to the chiller should be as short in length and as large in diameter as possible to provide least resistance to gas flow.

2. Use an absolute pressure manom eter or a wet bulb vac uum 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. If the entire chiller is to be dehydrated, open al l isolation valves (if present).

4. With the chille r ambient temperature a t 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 a 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 and pressure, isolated pockets of mois tu re ca n tu rn in to ice . The s low rat e of evaporation (sublimation) of ice at these low temperatures and 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 re ading continues to change after several attempts, perform a leak test up to the maximum 160 psig (1103 kPa) pressure. Locate and repair the leak, and repeat dehydration.

/s]

Inspect Water Piping —

vided in the certified drawings and the piping instruct ions in the 19XR Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that the 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 the cooler and the condenser.

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

Refer to piping diagrams pro-

Check Optional Pumpout Compressor Water Piping —

pumpout system 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. 29 and 30.

Check Relief Valves —

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.

The 19XR relief valves are set to relieve at the 185 psig (1275 kPa) chiller design pressure.

If the optional pumpout storage tank and/or

Be sure the relief valves have

Inspect Wiring

Do not check the 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 the wiring for conformance to the job wiring diagrams and all applicable electrical codes.

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

3. Compare the ampere rating on the starter nameplate to rating on 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 II refrigeration control. Check the certified drawings.

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

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

7. Ensure all electrical equipment and c ontrols are properl y grounded in accordance with job drawings, certified drawings, and all applicable electrical codes.

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

9. For field-installed starters only

, test the chill er 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.

If the motor starte r is a solid-state starter, the motor lea ds 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 the 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 tes ted.

10. Tighten all wiring connections to t he plugs on the ISM and CCM modules.

11. On chillers with free-standing starters, inspect the pow er 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 i nto the contact ors. Cl ean 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 c ommunication 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 the signal ground pins. See installation manual.

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 –4 F to 140 F (–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

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:

CCN BUS

SIGNAL TYPE

+ Red RED (+)

Ground White WHITE (G)

– Black BLACK (–)

CONDUCTOR

INSULATION

COLOR

CCN TERMINAL

CONNECTION

Check Starter

BE AWARE that certain autom atic start arrangements can engage the starter. Open the disconnect ahead of the start er

in addition to shutting off the chiller or pump.

Use the instruction and service manual supplied by the starter manufacturer to verify the st arte r has been ins talled c orrectly, to set up and calibrate the starter, and for complete troubleshooting information.

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

MECHANICAL STARTER

1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection.

2. Check the contactor(s) to ensure 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, such as relays, for free movement. If the devices do not move freely, contact the starter manufacturer for replacement components.

3. Reapply starter control power (not main chiller power) to check the electrical functions.

Ensure the starter (with relay 1CR closed) goes through a complete and proper start cycle.

BENSHAW, INC. RediStart MICRO™ SOLID-STATE STARTER

This equipment is at line voltage w hen AC power is connected. Pressing the STOP button does not remove voltage.

1. Ensure all wiring connections are properly terminat ed to the starter.

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

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

4. Verify the proper ac input voltage is brought into the starter according to the certified drawings.

5. Apply power to the starter

VFD STARTER

1. Turn off unit, tag and lock disconnects and wait 5 minutes.

2. Verify that the DC voltage is zero.

3. Ensure there is adequate clearance around the drive.

4. Verify tha t the wiri n g to th e term in al str ip a nd p ow er te rminals is co rre ct .

5. Verify that w ire size is withi n the terminal speci fication and the wires are secure.

6. Inspect the field supplied branch circuit protection is properly rated and installed.

7. Verify that the system is properly grounded.

8. Inspect all liquid cooling connections for leaks.

Oil Charge —

pends on the compressor Frame size:

• Frame 2 compressor — 5 gal (18.9 L)

• Frame 3 compressor — 8 gal (30 L)

• Frame 4 compressor — 10 gal (37.8 L)

• Frame 5 compressor — 18 gal (67.8 L)

The chiller is s hipp ed wi th o il i n the com pre ss or. 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. 2). If oil is added, it must meet Carrier’s specification for centrifugal compressor use as described in the Oil Specification section. Charge the oil through the oil charging valve located near the bottom of the transmission housing (Fig. 2). 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.

The oil charge for the 19XR compressor de-

Power Up the Controls and Check the Oil Heater —

sor before energizing the controls. A circuit breaker in the starter energizes the oil heater and th e control circuit. When first

Ensure that an oil leve l is vis ible in th e com pres-

powered, the CVC/ICVC should display the default screen within a short period of time.

The oil heater is energized by powering the c ontrol circuit . This should be done several hours before start-up to minimize oil-refrigerant migration. The oil heater is controlled by the PIC II 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 arrangement al lows the heater to energize when the main motor circuit breaker is off for service work or extended shutdowns. The oil heater relay status (OIL HEATER RELAY) can be viewed on the COMPRESS table on the CVC/ICVC. Oil sump temperature can be viewed on the CVC/ICVC default screen.

SOFTWARE VERSION — The software part number is labeled on the backside of the CVC/ICVC module. The software version also appears on the CVC/ICVC configuration screen as the last two digits of the software part number.

Software 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 the 19XR unit is configured, all configuration settings should be written down. A log, such as the one shown on pages CL-1 to CL-16, provides a list for configuration values.

Input the Design Set Points —

ICVC 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 II can control a set point to either the leaving or entering chilled water. This control method is set in the EQUIPMENT SERVICE (TEMP_CTL) table.

Access the CVC/

Input the Local Occupied Schedule (OCCPC01S) —

Access the schedule OCCPC01S screen on the CVC/ICVC and set up the occupied time schedule according to 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 schedule, see the Controls section, page 10.

The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary time schedule is needed.

NOTE: The default CCN Occupied Schedule OCCPC03S is configured to be unoccupied.

Input Service Configurations —

figurations require the CVC/ICVC screen to be in the SERVICE portion of the menu.

• password

• input time and date

• CVC/ICVC configuration

• service parameters

• equipment configuration

• automated control test

PASSWORD — When accessing the SERVICE tables, a password must be ente red. All CVC/ICVC are initiall y set for a password of 1-1-1-1.

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. The HOLIDAY TODAY parameter should only be configured to YES if the present day is a holiday.

The following con-

NOTE: Because a schedule is integral to the chiller control sequence, the chiller will not start until the time and date have been set.

CHANGE CVC/ICVC CONFIGURATION IF NECESSARY — From the SERVICE table, access the CVC/ICVC CONFIGU-RAT ION screen. From there, view or modify the CVC/ICVC CCN address, change to English or SI units, and change the password. If there is more than one chiller at the jobsite, change the CVC/ICVC 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.

TO CHANGE THE PASSWORD — The password may be changed from the CVC/ICVC CONFIGURATION screen.

1. Pres s the and softkeys. Enter the

MENU SER VICE

current password and highlight CVC/ICVC CONFIGURATION. Press the softkey. Only the last

SELECT 5 entries on the CVC/ICVC CONFIG screen can be changed: BUS #, AD DRESS #, BAUD RATE, US IMP/ METRIC, and P ASSWO RD.

2. Use the softkey to scroll to PASSWORD. The

ENTER

first digit of the password is highlighted on the screen.

3. To change the digit, press the or DECREASE

press the softkey .

softkey. When the desired digit is seen,

ENTER

INCREASE

4. The next digit is highlighted. Change it, and the third and

fourth digits in the same way the first was changed.

5. After the last digit is changed, the CVC/ICVC goes to the

BUS parameter. Press the softkey to leave that

EXIT

screen and return to the SERVICE menu.

Be sure to remember the password. Retain a copy for future reference. Without the password, access to the SERVICE menu will not be possible unless the CVC/ ICVC_PSWD menu on the STATUS screen is accessed by a Carrier representat ive.

TO CHANGE THE CVC/ICVC DISPLAY FROM ENGLISH TO METRIC UNITS — By default, the CVC/ ICVC displays information in English units. To change to metric units, access the CVC/ICVC CONFIGURA TION screen:

1. Pres s the and softkeys. Enter the

MENU SER VICE

password and highlight CVC/ICVC CONFIGURA TION. Press the softkey.

2. Use the softkey to scroll to US IMP/METRIC.

SELECT

ENTER

3. Pres s the softkey that corresponds to the units desired for

display on the CVC/ICVC (e.g., US or METRIC).

CHANGE LANGUAGE (ICVC Only) — By default, the ICVC displays information in English. To change to another Language, access the ICVC CONFIGURA TION screen:

1. Pres s the and softkeys. Enter the

MENU SER VICE

password and highlight ICVC CONFIGURATION. Press the softkey.

SELECT

2. Use the softkey to scroll to LID LANGUAGE.

ENTER

3. Press the INCREASE or DECREASE softkey until the

desired language is displayed. Press to confirm

ENTER

desired language.

MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The CVC/ICVC module address can be changed from the CVC/ICVC CONFIGURATION screen. Change this

address for each chiller if there is more th an one chiller at the jobsite. Write the new address on the CVC/ICVC module for future reference.

INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The EQUIPMENT SERVICE table has six service tables.

Configure SERVICE Tables

— Access the SERVICE tables,

shown in T able 2, to modify or view job site parameters:

PARAMETER TABLE

Starter Type ISM_CONF — Select 0 for full voltage, 1 for

Motor Rated Line Vol t ag e

Volt Transformer Ratio

Motor Rated Load Amps

Motor Locked Rotor Trip

Starter LRA Rating

Motor Current CT Ratio

Ground Fault Current Transformers

Ground Fault CT Ratio

Single Cycle Dropout

Line Frequency ISM_CONF — Enter YES for 60 Hz or NO for 50

Line Frequency Faulting

Surge Limiting or Hot Gas Bypass Option

Minimum Load Points (T1, P1)

Full (Maximum) Load Points (T2, P2)

Chilled Medium SETUP1 — Enter water or brine. Evaporator

Refrigerant Trippoint

Evaporator Flow Delta P Cutout

Condenser Flow Delta P Cutout

Diffuser Option (Compressors with Split Ring Diffusers)

Diffuser Full Span mA Rating (Compressors with Split Ring Diffusers)

Motor Rated Kilowatts

*With variable flow systems this point may be configured to the lower end of

the range.

NOTE: Other parameters: Screens are normally left at the default settings; they may be changed by the operator as required. The time and persistence settings on the ISM_CONF table can be adjusted to increase or decrease the sensitivity to a fault condition. Increasing time or persistence decreases sensitivity. Decreasing time or persistence increases sensitivity to the fault condition.

reduced voltage, or 2 for solid state/variable frequency drive.

ISM_CONF — Motor rated voltage from chiller information nameplate.

ISM_CONF — Enter ratio (reduced to a ratio to

1) of power transformer wired to terminal J3 of ISM. If no transformer is used enter 1.

ISM_CONF — Per chiller identification nameplate data.

ISM_CONF — Per chiller identification nameplate data. Enter locked rotor delta amps (LR AMPS D-).

ISM_CONF — Enter value from nameplate in starter cabinet Allen -Bradley this appears as “max locked rotor current @100% nom. voltage.” Benshaw Starters: value is entered as 9999.

ISM_CONF — Enter ratio (reduced to a ratio to

1) of current transformers wired to terminal J4 of ISM. For Benshaw Inc. RediStart MICRO™ Starters set to 100.

ISM_CONF — Enter 0 if no ground fault CTs are wired to terminal J5 of ISM. Enter 1 if ground fault CTs are used.

ISM_CONF — Enter ratio (reduced to a ratio to

1) of ground fault CT. ISM_CONF — ENABLE if motor protection

required from drop in line voltage within one cycle.

Hz. ISM_CONF — ENABLE if motor

protection required for drop in line frequency.

OPTIONS — Enter 1 if HGBP is installed.

OPTIONS — Per Chiller Requisition (DT1, DP2) if available or per job data — See modify load points section.

OPTIONS — Per Chiller Requisition (DT2, DP2) if available or per job data — See modify load points section. For VFD units refer to table located in control panel.

SETUP1 — Usually 3° F (1.7° C) below design refrigerant temperature.

SETUP1 — Per Chiller Requisition if available or enter 50% of design pressure drop to 0.5 psi (3.4 kPa).*

SETUP2 — ENABLE for 4 and 5 size compressor. See model number nomenclature.

SETUP2 — Enter diffuser actuator full span mA rating for 4 and 5 size compressor. Value is located on label on side of diffuser actuator motor.

RAMP_DEM — Enter value from chiller requisition form (product data submittal) if kilowatt ramp demand is enabled.

CHANGE THE BENSHAW INC., RediStart MICRO™ SOFTWARE CONFIGURA TION IF NECESSAR Y — Ben- shaw starter configurations are checked and modified from the menus in the Benshaw Redistart MICRO Default Display. See Fig. 32 and Table 6 for default display and menu items. To access the menus to perform checks and modifications, the Benshaw starter must be powered up and its self-test must have been successfully completed. The self-test takes place automatically after power-up. Current transformer ratio configurations and hardware switch settings checks are performed in the MENU1 display screen. See Table 7 for menu structure and T able 8 for switch settings.

1. Press the softkey until the desired menu is se-

lected on the display.

2. Press the softkey to access the displayed menu

ENTER

items (Table 6).

3. Use the or arrow keys to scroll between menu

↓ ↑

items until the desired item is reached on the display.

4. Press the softkey to access the value to be

ENTER

changed.

5. Use the or arrow keys to adjust the new displayed value. The key incre ases the value while the key

↑ ↓

decreases the value. Holding the arrow key wil l progressively increase the rate of change. The value will stop changing when either the factory set minimum or maximum value is reached. To make fine adjustments press and releas e t he a rr ow ke y.

6. When the correct value has been selected, press the

ENTER

point, there are two options. The key will return the display to the main d isplay. The or arrow keys

key to store the new configuration. At this

↑ ↓

will move the display to the next menu item. When finished press the key to return to the main display.

T o view other settings and troubleshooting guide consult the Benshaw RediStart MICRO instructional manual included i n the starter.

DISPLAY

RediStart MICRO

SCROLL UP

SCROLL DOWN

STOP I = OA

READY V = 461V

MENU SELECTION

ENTER

MENU ENTRY DATA ENTRY

FAULT

RESET

Fig. 32 — Benshaw RediStart

MICRO Default Display

Table 6 — Benshaw RediStart

MICRO Menu Structure

MENU 1 Starter Setup

Initial Current as % RLA

Max. Cur As% LRA

Ramp Time (sec.)

CT Ratio: 1

MENU 2 Meter Setup

Meter #1 display

Meter #2 display

MENU 3 Event Recorder

Events 1-99 Dry Run

MENU 4 Dry Run Mode

Mode

Table 7 — Benshaw RediStart MICRO Menu Items*

DESCRIPTION RANGE UNITS DEFAULT INITIAL CURRENT 50-300 % 125 MAX. CURR AS % LRA 30-70 % 55 RAMP TIME 5-30 SEC 15 CT RATIO 2640-5760 Enter Value from Table 8.

*These values are not displayed in the ISM_CONFIG table.

Table 8 — Benshaw RediStart MICRO Current Transformer DIP Switch Settings

CURRENT TRANSFORMER CT1-CT3

Starter

Frame Size

(Amps)

200 Amps

300 Amps

480 Amps

600 Amps

740 Amps 601- 740 Amps 3900:1 ON ON

1250 Amps

LEGEND

CT — Current Transformer

Motor

RLA Range

(Amps)

95- 135 Amps 3900:1 OFF OFF 136- 200 Amps 5760:1 OFF OFF 201- 231 Amps 2640:1 ON OFF 232- 300 Amps 3900:1 ON OFF 301- 340 Amps 3900:1 ON OFF 341- 480 Amps 5760:1 ON OFF 481- 580 Amps 2640:1 ON ON 581- 600 Amps 3900:1 ON ON

741- 855 Amps 3900:1 ON ON 856-1250 Amps 5760:1 ON ON

Ratio

MIcro Power Card (BIPCMIPWR-C4)

Overload Switch Settings

SW1-1 SW1-2

VERIFY VFD CONFIGURATION AND CHANGE PARAMETERS IF NECESSARY

IMPORTANT: The VFD controller has been factory configured for use and communications to the Chiller Visual Controller/International Chiller Visual Controller (CVC/ ICVC). Some parameters are specific to the chiller configuration and will need to be verified prior to operation. Speed control and starting the drive have been disabled at the VFD keypad. All command functions must be initiated from the CVC/ICVC.

Using the Keypad view fault history and adjust the program of the VFD microprocessor. It operates in two modes: Monitor mode and Program mode:

Use the and keys to:

• Step through the drive parameter menus and error log

• Increase or decrease a numeric value such as the refer-

• Hold down these keys to increase the scroll speed.

Use the softkey to:

• Display a parameter or a selection value in Program

• Save a value.

• Move through each monitor display item when in Moni-

Monitor Mode (Default Mode) may be monitored on the keypad when in this mode. An LED will be illuminated next to the description of what is displayed on the keypad. Use the softkey to scroll through and monitor the following selections:

• All LEDs on — Speed request from the CVC/ICVC

• Motor Speed

• Output Frequency

• Output Voltage

• Output Current

Program Mode figuration parameters of the VFD microprocessor. Particular parameters, parameter numbers, and error log information can be displayed when in Program mode.

Press the softkey until the PROGRAM LED is illuminated to enter the Program mode.

Use the and keys to move through the menus Press softkey to select the desired menu.

Press and keys to move through following parameters.

*Vector control is not used in this configuration. Press softkey to select a parameter menu screen.

Press and keys to adjust the selected parameter. Press the softkey until the PROGRAM LED

turns off to exit the program.

↑ ↓

when the keypad/display is in Program mode. ence or parameter value.

ENTER

mode.

tor mode.

PROGRAM

↑ ↓

ENTER

↑ ↓

P.nnn — General Parameters U.nnn — Vector Control Parameters* H.nnn — Volts/Hertz Control Parameters R.nnn — RMI Remote Monitor Interface

E.nnn — Error Log (See fault codes)

ENTER

↑ ↓

Changing parameters may adversely affect chiller operation.

— The keypad display is used to monitor,

— Specific drive conditions

ENTER

— This mode displays and modifies the con-

Parameters

PROGRAM

Accessing Password Protected Parameters VFD controller has been preconfigured as the factory, the user will need to be able to access th e parameters to verify the job specific parameters are correct, tune th e controller or corre ct a problem. The two passwords protecting the VFD configuration are Parameter Set Display password and Program Disable password. The Parameter Set Display password res tricts viewing. P.nnn parameters above 007 and all H.nnn and R.nnn screens. The password can be accessed at parameter P.006 and will switch between enabled and disabled each ti me the password 107 is entered. The Program Disable password restricts the changing of the drive parameter set. To enable or disable changes select parameter P.051 and enter the password 26.

NOTE: Some of the parameters can be changed only when the drive is stopped.

It is the operator’s responsibility to distribute access to the passwords. Carrier is not responsible for unauthorized access violations within the operator’s organization. Failure to observe this warning could result in bodily injury.

See the Initial Start-Up Checklist section for VFD Job Specific Configuration table. For job specific parameters see inside of the VFD enclosure door, next to the keypad. Refer to the VFD Configuration table for the entire list of parameters.

Restoring the default parameter P.050 will require all the Carrier default parameters to be restored manually.

VFD CHILLER FIELD SET UP AND VERIFICATION Label Locations

installed properly and match the chiller requisition:

• Surge parameters — Located inside the control panel.

• Chiller identificatio n nameplate — Located on the right

side of the control panel.

• VFD Parameter — Located to the right of the VFD controller keypad on the VFD module.

• VFD Nameplate — Located on the right side of the VFD as viewed from its front.

• Record all nameplate information on the Reliance Configuration sheet.

Drive Protection and Other Incoming Wiring

1. Verify that the branch disconnects or other local disconnects are open and properly tagged out.

2. Verify that the branch circuit protection and AC input wiring to the VFD are in accordance with NEC/CEC (National Electrical Code/California Energy Commission) and all other local codes.

3. Verify that the fuses are per the field wiring diagram.

4. Verify that the incoming source does not exceed 85 kA.

5. Verify the power lugs in the VFD and branch protection are properly secured. Inspect the ground cable and ensure it is properly connected at the branch and to the ground lug in the VFD.

6. Verify the conduit for the power wiring in securely connected to the VFD flanged cover and runs continuously to the branch protection.

7. Verify that the incoming and outgoing wires have been properly connected inside of the reactor enclosure if a separate line reactor has been added to the chiller.

8. Ensure the control and signal wires connected to the chiller controller or the VFD are in separate conduit.

— Verify the following labels have been

— Although the

VFD Cooling System Leak Inspection

1. Check for l eaks on the refrigerant cooling flange connections to the VFD enclosure.

2. Check for leaks on all t ubing internal to the VFD enclosure, the tubing flair connection to the V FD module and the TXV valve.

3. Verify that the VFD refrigerant cooling system TXV valve control bulb is securely inserted into the VFD drive module heat sink.

Power Up Verification

1. Inspect control wiring inside the VFD and veri fy the integrity of the connections between the integrated starter module (ISM) and the VFD module.

2. Close the control power switch in the VFD enclosure.

3. Close the oil pump power switch inside the VFD enclosure.

4. Verify the VFD disconnect switch is in the open position.

5. Close and latch the doors of the VFD enclosure.

6. Apply power to the VFD encl osure. Remove lock outs and close all disconnects.

7. Verify that the CVC/ICVC displ ay powers up and goes to the default screen.

8. Close the VFD disconnect switch.

9. Verify the following actions during the VFD start-up self test:

• The display shows SELF and all LEDs are illuminated for 5 to 6 seconds.

• The display reads a 0 after the diagnosis is complete.

• If Err is displayed a fault has been detected. Perform manual reset by establishing a reset through the small hole under the VFD Keypad. If this does not correct the fault contact your Carrier representative.

• If AR w ith a counting do wn number is di splayed wait for the number to count to 0 and the display should then revert to a 0. If the counter starts over at 30 contact Carrier representative.

Configure VFD Parameters

— The VFD controller must have job specific parameters set as defined by the component nameplates and labels. The parameters come preset by the factory, but must be verified prior to start-up by accessing the PROGRAM MODE of the VFD controller keypad. For information on how to access the VFD keypad see page 58.

Press the softkey to access the parameter

PROGRAM

screen to modify or view the following job specific parameters:.

VFD

PARAMETER

P.004 Maximum

P.006 Password 107 P.028 Speed

H.000 Motor

H.001 Frequency Line Frequency selected. Per

H.002 Motor

H.021 Line

H.022 Over

TITLE SETTING

Speed

Display Scaling

Voltage

Amps

Voltage

Frequency Limit

Line Frequency selected. Per Compressor Nameplate.

60 for 60 Hz selection and 50 for 50 Hz selection

Compressor nameplate voltage.

Compressor Nameplate. Compressor nameplate amps.

VFD nameplate voltage.

69 for 60 Hz selection and 57 for 50 Hz selection.

Configure Chiller Visual Controller Parameter

— The chiller controller must have its job specific parameters set as defined by the job sheet or installed nameplates. Below are the job specific parameters that must be set:

T o access the ISM_CONF screen:

1. Press .

2. Press .

ENTER SERVICE

3. Enter the password 1111.

4. Select ISM (CONFIG STARTER DATA)

5. Scroll dow n and select the ISM_CONF DATA screen to modify or view the ISM parameters:

DESCRIPTION SETTING

STARTER TYPE (2 = SS/VFD)

MOTOR RATED LINE VOLTAGE

MOTOR RATED LOAD AMPS

MOTOR LOCKED ROTOR TRIP

STARTER LRA RATING 600 for VFD

MOTOR CURRENT CT RATIO:1

3 GRND FAULT CT? (1=NO)

FREQUENCY-60HZ (NO=50)

6. Press to the softkey to save changes.

7. Press the softkey to and exit the ISM Configura-

SAVE

EXIT

VFD Nameplate Voltage.

VFD Nameplate Chiller Rated Load Amps

Compressor Nameplate

part #19XVR0414XXX 700 for VFD part #19XVR0500XXX 900 for VFD part #19XVR0643XXX

163 120 (414A)

NO for 50 Hz selection YES for 60 Hz selection

tion Screen.

VFD Enable Configuration

1. Press .

2. Press .

MENU SERVICE

— To access the parameters:

3. Select EQUIPMENT SERVICE.

4. Scroll down and select SETUP2.

5. Verify the following parameters:

VFD OPTION ENABLED VFD CURRENT LIMIT COMPRESSOR NAMEPLATE AMPS

Configure Surge Parameters

1. Press .

2. Press .

MENU SERVICE

3. Select EQ UIPMENT SERVICE and OPTIONS to verify the following:

DESCRIPTION SETTINGS

SURGE/HGBP DELTA T1

SURGE/HGBP DELTA P1

SURGE/HGBP DELTA T2

SURGE/HGBP DELTA P2

Surge parameter label

VFD CONTROL VERFICATION (Non-Running) — In order to verify and, if necessary, tune the speed control signal of the chiller controller to the VFD (ISM terminal J8 1-2 labeled 4-20 mA OUT VFD) and the speed feedback signal from the VFD to the chiller controller (ISM terminal J6 1-2 labeled VFD HZ), follow the steps below.

Set T ARGET VFD SPEED to 0%.

1. Press .

2. Press .

3. Press .

4. Press .

STATUS COMPRESS SELECT

5. Set TARGET VFD SPEED to 0%.

Veri fy that the A CTU AL VFD SPEE D shown on the VFD display is with in 0 to 1 Hz.

1. Pres s the softkey on the VFD keypad until all

ENTER

LEDs on the left side of the keypad are illuminated. NOTE: The value displayed is the frequency at which the

VFD is being commanded to operate.

2. Adjust V FD parameter P. 009 (Input O ffset) if outside the tolerance.

To confirm that the speed signal from the CVC/ICVC corresponds to the value displayed at the VFD:

3. Verify that the actual speed signal feedback to the chiller controller is 0% by accessing the COMPRESS screen.

4. Verify ACTUAL SPEED VFD is 0%-1% on CVC/ICVC.

5. Adjust V FD parameter r.002 (Analog Output Offset) if outside the tolerance.

Set VFD TARGET VFD SPEED to 100%.

1. Press .

2. Press .

3. Press .

4. Press .

MENU STATUS COMPRESS SELECT

5. Set TARGET VFD SPEED to 100%.

Veri fy that the A CTU AL VFD SPEE D shown on the VFD display corresponds to the 50 Hz or 60 Hz setting.

1. C heck the ACTUAL VFD SPEED configuration (50 Hz or 60 Hz) on the ISM_CONF screen.

2. Confirm that the VFD displays the configured line frequency within ± 1 Hz.

3. Adjust parameter P.010 (Input Gain) if outside the tolerance.

4. R elease the TARGET VFD SPEED so that it can operate in automatic mode. (Refer to Override Operations section on page 16.)

VFD CONTROL VERIFICATION (Running) Preparation

1. Disconnect power to the VFD. Verify that the branch disconnects or other local disconnects are open and properly tagged out.

2. Connect a voltmeter and ampmeter t o the line side of the VFD. Locate meters safely away from the power cables.

3. Reconnect power to the VFD.

4. Measure the voltage on the line side of the drive.

5. Verify it is within 10% of the chiller nameplate voltage.

6. Set up the CVC/ICVC temperature controller per the requirements of the job.

7. Start the c hiller and ve rify the rotation of t he compressor just as it starts.

8. Allow the chiller to load up. Verify that the chiller loads up smoothly .

NOTE: One or two surges may be counted during the first minute of operation.

Verify That Actual VFD Speed is 100% (±2%)

1. Set the VFD speed to 100%.

2. Verify that the ACTUAL VFD SPEED is 100% (± 2%).

3. If outside the tolerance, adjust r.003 (Output Analog Gain).

4. Leave running for the next test.

ISM Current Calibration Check

1. With the target VFD speed at 100%, load the chiller so that the CVC/ICVC default display shows 75% to 100% under the display title AMPS %. A higher load is preferred.

2. Measure the incoming current with a separate amp meter.

3. Calculate the line side error ratio using the following equation:

Amp Meter current – Ave. ISM current

Amp Meter current

4. If t he L ine Side E rror Ratio is greater tha n ± 0.02 adjust the CVC/ICVC reading by adjusting the ISM CT ratio.

5. Shut down the chiller.

Change CT Ratio

1. New CT Ratio = Present CT Ratio multiplied by (1+ Line Side Error Ratio).

T o access the ISM_CONF screen:

2. Press .

3. Press .

ENTER SERVICE

4. Enter the password 1111.

5. Select ISM (ST ARTER) CONFIG DA TA.

6. Enter password 4444.

7. Select ISM_CONF .

8. Change present CT ratio to new ratio using calculation above.

9. Press to the softkey to save changes.

10. Press the softkey to exit the ISM_CONF screen.

SAVE

EXIT

11. Repeat ISM Current Calibration Check.

VFD Current Control Calibration Check

1. With the target VFD speed at 100%, load the chiller so that the CVC/ICVC default display shows 75% to 100% under the display title AMPS %. A higher load is preferred.

2. Ac cess the current on the keypad of the VFD. Determine the Load Side Current Ratio, using the equation below. Load Side Current Ratio =

VFD Actual Load Amps

Motor Nameplate Amps

Next, access the VFD Load Factor on the Capacit y Control screen. Calculate the Load Side Error Ratio using the equation below:

Load Side Error Ratio

VFD Load Factor – Load Side Current Ratio

Load Side Current Ratio

3. If the load side error ratio is greater than ± 0.02, adjust the VFD load factor by changing the VFD current l imit on the Setup 2 screen.

a. The new VFD current limit = old VFD current

limit multiplied by (1+ Load Side Error Ratio). b. Recheck the VFD Current Control Calibration. c. Release the Speed Control by accessing the TAR-

GET VFD SPEED control.

Press .

STATUS

Press .

COMPRESS

(Refer to Override Operations section on page 16.)

Protecting the VFD Configuration

1. Select parameter P.051 from the VFD keypad.

2. Press the softkey to access the parameter. A

ENTER

zero will be displayed.

3. Use the arrow key to increment the value to 26. This is

↑

the password number.

4. Pres s the softkey t o save the value. P.051 will

ENTER

by displayed. NOTE: Parameter programming is disabled when the

PASSWORD LED is on and enabled when the PASSWORD LED is off.

5. Select parameter P.006 from the VFD Keypad.

6. Press the softkey to access the parameter.

7. Use the arrow key to increment the valu e to 107. This

ENTER

↑

is the password number to restrict displaying the remaining P, and all of the H and r parameters.

8. Press the softkey to save the value.

Modify Minimum and Maximum Load Points (

ENTER

T1/P1; ∆T2/

∆

P2) If Necessary — These pa irs of chil ler load p oints, loc ated on the OPTIONS screen, determine when to limit guide vane travel or open the hot gas bypass valve when surge prevention is needed. These points should be set based on individual chiller operating conditions.

A label that lists the configuration values of the controls is located on the inside of the unit’s control panel. These values are based upon the original selection of the chiller. Jobsite conditions may require a slight modification to these parameters.

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.

An example of such a configuration is shown below. Refrigerant: HCFC-134a

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 T emperature Calculate Maximum Load

— To calculate the maximum load points, use the design load condition data. If the chiller full load cooler temperature difference is more t han 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) = 37 psig (255 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing T emperature:

98 F (36.7 C) = 120 psig (1827 kPa) saturated

refrigerant pressure (HFC-134a)

Maximum Load ∆T2:

54 – 44 = 10º F (12.2 – 6.7 = 5.5º C)

Maximum Load ∆P2:

120 – 37 = 83 psid (827 – 255 = 572 kPad) To avoid unnecessary surge prevention, add about 10 psid

(70 kPad) to ∆P2 from these con dit ions :

∆T2 = 10º F (5.5º C) ∆P2 = 93 psid (642 kPad)

Calculate Minimum Load

— To calculate the minimum load conditions, estimate the temperature difference the cooler will have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use t he proper saturat ed pressure and temperature for the particular refrigerant used.

Suction Temperature:

43 F (6.1 C) = 38 psig (262 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing T emperature:

70 F (21.1 C) = 71 psig (490 kPa) saturated

refrigerant pressure (HFC-134a) Minimum Load ∆T1 (at 20% Load): 2 F (1.1 C) Minimum Load ∆P1:

71 – 38 = 33 psid (490 – 262 = 228 kPad)

Again, to avoid unnecessary surge prevention, add 20 psid (140 kPad) at ∆P1 from these conditions:

∆T1 = 2 F (1.1 C) ∆P1 = 53 psid (368 kPad)

If surge prevention occurs too soon or too late:

LOAD

At low loads

(<50%)

At high loads

(>50%)

SURGE PREVENTION

OCCURS TOO SOON

Increase P1 by 2 psid (14 kPad)

Increase P2 by 2 psid (14 kPad)

SURGE PREVENTION

OCCURS TOO LATE

Decrease P1 by 2 psid (14 kPad)

Decrease P2 by 2 psid (14 kPad)

The differential pressure (∆P) and temperature (∆T) can be monitored during chiller operation by viewing ACTIVE DELTA P and ACTIVE DELTA T (HEAT_EX screen). Comparing SURGE/HGBP DELTA T to ACTIVE DELT A T will de- termine when the SURGE PREVENTION function will occur. The smaller the difference between the SURGE/HGBP DELTA T and the ACTIVE DELTA T values, the closer to surge prevention.

Units with VFD

— On units with VFD further adjustments can be made if response to surge prevention or protection is not functioning as desired. VFD GAIN and VFD INCREASE STEP can be adjusted to allow for more aggressive c hanges i n speed when surge prevention or protection is active.

CONFIGURE DIFFUSER CONTROL IF NECESSARY — If the compressor is equipped with a variable diffuser, (size 5 compressor) access the SETUP2 screen. Scroll to

DIFFUSER CONTROL and press the softkey.

ENABLE

Compare the diffuser and guide vane values (GUIDE VANE

25% LOAD PT , GUIDE VANE 50% LOAD PT, GUIDE VANE 75% LOAD PT, DIFFUSER 25% LOAD POINT, DIFFUSER 50% LOAD POINT, DIFFUSER 75% LOAD POINT) to the

values located on the label inside the control panel. See Fig. 12.

Compressors with variable diffuser control have actuators tested and stamped with the milliamp (mA) value that results in 100% actuator rotation. This value is configured on the SETUP2 screen. It is labeled DIFFUSER FULL SPAN mA.

MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPM ENT SERVICE table has scr eens to select, view, or modify parameters. Carrier’s certified drawings have the configuration values required for the jobsite. Modify these values only if requested.

SERVICE Screen Modifications

— Change the values on these screens according to specific job data. See the certified drawings for the correct values. Modifications can include:

• chilled water reset

• entering chilled water control (Enable/Disable)

• 4 to 20 mA demand limit

• auto restart option (Enable/Disable)

• remote contact option (Enable/Disable)

Owner-Modified CCN Tables

— The following EQUIPMENT CONFIGURATION screens are described for reference only.

OCCDEFCS — The OCCDEFCS screen contains the Local and CCN time schedules, which can be modified here or on the SCHEDULE screen as described previously.

HOLIDAYS — From the HOLIDAYS screen, the days of the year that holidays are in effect can be configured. See the holiday paragraphs in the Controls section for more details.

BRODEF — The BRODEF screen defines the start and end of daylight savings time. Enter the dates for the start and end of daylight savings if required for your location. BRODEF also activates the Broadcast function which enables the holiday periods that are defined on the CVC/ICVC to take effect.

Other Tables — The CONSUME, NET_OPT, and RUN- TIME screens contain parameters used with a CCN system. See the applicable CCN manual for more information on these screens. These tables can only be defined from a CCN Building Supervisor.

Perform a Control Test —

Check the safety controls status by performing an automated control test. Access the CONTROL TEST table and select a test to be performed function (T able 9).

The Automated Control Test checks all outputs and inputs for function. In order to successfully proceed with the controls test, the compressor should be of f, no alarms sh owing, and volt age should be within ±10% of rating plate value. The compressor can be put in OFF mode by pressing the STOP push- butt on on the CVC/ICVC. Each test asks the operator to confirm the operation is occurring and whether or not to continue. If an error occurs, the operator can try to address the problem as the test is being done or note the problem and proceed to the next test.

NOTE: Enter guide vane calibration to calibrate guide input on CCM (Plug J4 upper terminal 9 and 10).

NOTE: If during the control test the guide vanes do not open, verify the low pressure alarm is not active. (An active low pressure alarm causes 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 control test is finished or the softkey is

EXIT pressed, the test stops, and the CONTROL TEST menu displays. 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 i n the table bel ow.

CCM Temperature Thermistors Check of all thermistors. CCM Pressure Transducers Check of all transducers.

Pump

Discrete outputs

Guide Vane Check of the guide vane operation. Diffuser Actuator* Check of the diffuser actuator.

Pumpdown/Lockout

Terminate Lockout

Guide Vane Calibration Calibrates guide vane input on CCM.

*Diffuser tests function only on size 4 and 5 compressor with diffuser control

enabled.

NOTE: During any of the tests, an out-of-range reading will have an asterisk (*) next to the reading and a message will be displayed if you have diffuser control enabled.

Checks operation of pump outputs; pumps are activated. Also tests associated inputs such as flow or pressure.

Activation of all on/off outputs individually.

Pumpdown prevents the low refrigerant alarm during evacuation so refrigerant can be removed form the unit. Also locks the compressor off and starts the water pumps.

To charge refrigerant and enable the chiller to run after pumpdown lockout.

COOLER CONDENSER PRESSURE TRANSDUCER AND WATERSIDE FLOW DEVICE CALIBRATION (Optional with ICVC inputs available) — Calibration can be checked by comparing the pressure readings from the transducer to an accurate refrigeration gage reading. These readings can be viewed or calibrated from the HEAT_EX screen on the CVC/ICVC. The transducer can be checked and calibrated at 2 pressure points. These calibration points are 0 psig (0 kPa) and between 25 and 250 psig (173 and 1724 kPa). To calibrate these transducers:

1. Shut down the compressor, cooler , and condenser pumps. NOTE: There should be no flow through the heat

exchangers.

2. Di sconnect the transducer in question from its Schrader fitting for cooler or condenser transducer calibration. For oil pressure or flow device calibration keep transducer in place.

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 HEAT_EX screen and view the particular transducer reading (the EVAPORATOR PRESSURE or CONDENSER PRESSURE parameter on the HEAT_EX screen). To calibrate oil pressure or waterside flow device, view the particular reading (CHILLED WATER DELTA P and CONDENSER WATER DELTA P on the HEAT_EX screen and OIL PUMP DELTA P on the COMPRESS screen). 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 set to zero by pressing the

SELECT softkey while the appropriate transducer parameter is highlighted on the CVC/ICVC screen. Then press the

ENTER

softkey. The value will now go to zero. No high end calibration is necessary for OIL PUMP DELTA P or flow devices.

If the transducer value is not within the calibration range, the transducer returns to the original reading. If the pressure 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 (displayed in CONTROL TEST menu in the CCM PRESSURE TRANSDUCERS screen) or measure across the positive (+ red) and negative (– black) leads of the transducer. For example, the condenser transducer voltage input is measured at CCM terminals J2-4 and J2-5. The voltage ratio must be between 0.80 and 0.11 for the software to allow calibration. Rotate the waterside fl ow pressure device from the inlet nozzle to the outlet nozzle and repeat this step. If rotating the waterside flow device does not allow calibration then pressurize the transducer until the r atio is within range . Then attempt calibration again.

4. A high pressure point can also be calibrated betwee n 25 and 250 psig (172.4 and 1723.7 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 appropriate transducer paramet er on t he HEAT_EX screen, highlighting the parameter, pressing

the softkey, and then using the

SELECT INCREASE

or sof tk eys to ad jus t th e valu e to the exact

DECREASE

pressure on the refrigerant gage. Press the soft-

ENTER key to finish the calibration. Pressures at high altitude locations must be compensated for, so the chiller temper ature/pressure relationship is correct.

The PIC II does not allow calibration if the transducer is too far out of calibration. In this case, a new transducer must be installed and recalibrated.

Check Optional Pumpout System Controls and Compressor —

a 3-amp 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 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Ensure the watercooled condenser has been connected. Loosen the compressor holddown bolts to allow free spring travel. Open the c ompressor suction and discharge the service valves. Ensure oil is visible in the compressor sight glass. Add oil if necessary.

See the Pumpout and Refrigerant Transfer Procedures and Optional Pumpout System Maintenance sections, pages 67 and 75, for details on the transfer of refrigerant, oil specifications, etc.

Table 9 — Control Test Menu Functions

Controls include an on/off switch,

High Altitude Locations —

Because the chiller is initially calibrated at sea l evel, it is necessary to recalibrate the pressure transducers if the chiller has been moved to a high altitude location. 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.

TESTS TO BE PERFORMED

1. CCM Thermistors Entering Chilled Water

2. CCM Pressure Transducers

3. Pumps Chilled Water — Confirm pressure

4. Discrete Outputs Oil Heater Relay

5. Guide Vane Actuator Open/Close

6. Diffuser Actuator Open/Close

7. Pumpdown Lockout When using pumpdown/lockout,

8 Terminate Lockout Starts pumps and monitors flows.

Evaporator Refrigerant Temperature (ICVC only) Leaving Chilled Water Entering Condenser Water Leaving Condenser Water Remote Reset Sensor Comp Discharge Temp Oil Sump Temp Comp Motor Winding Temp Space Temperature 1 Space Temperature 2

Evaporator Pressure Condenser Pressure Oil Pump Delta P Condenser Water Delta P Transducer Voltage Ref

Condenser Water — Confirm

Hot Gas Bypass Relay Tower Fan Relay Low Tower Fan Relay High Alarm Relay Shunt Trip Relay

observe freeze up precautions when removing charge:

Instructs operator which valves to close and when.

Starts chilled water and condenser water pumps and confirms flows.

Monitors

Turns pumps off after pumpdown.

Locks out compressor.

Instructs operator which valves to open and when.

Monitors

Terminates compressor lockout.

DEVICES TESTED

Delta P

Evaporator pressure Condenser pressure Evaporator temperature during pumpout procedures

Evaporator pressure Condenser pressure Evaporator temperature during charging process

Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups.

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

CHILLER EQUALIZATION WITHOUT A PUMPOUT UNIT

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

T o equalize the pressure differential on a refrigerant isolated 19XR chiller, use the terminate lockout function of the CONTROL TEST on the SERVICE menu. This helps to turn on pumps and advises the operator on proper procedures.

The following steps describe how to equalize refrigerant pressure in an isolated 19XR chiller without a pumpout unit.

1. Access terminate lockout function on the CONTROL TEST screen.

IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.

3. Slowly open the refrigerant cooling isolation valve. T he chiller cooler and condenser pressures will gradually equalize. This process takes approximately 15 minutes.

4. Onc e the pressures have equalized, the cooler isolation valve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 29 and 30, for the location of the valves.

Whenever turning the discharge isolation valve, be sure to reattach the valve locking device. This prevents the valve from opening or closing during service work or during chiller o per ation.

CHILLER EQUALIZATION WITH PUMPOUT UNIT — The following steps describe how to equalize refrigerant pressure on an isolated 19XR chiller using the pumpout unit.

1. Access the terminate lockout function on the CONTROL TEST screen.

IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.

3. Open valve 4 on the pumpout unit and open valves 1a and 1b on the chiller cooler and condenser, Fig. 29 and 30. Slowly open valve 2 on the pumpout unit to e qualize t he pressure. This process takes approximately 15 minutes.

4. Onc e the pressures have equalized, the discharge isolation valve, cooler isolation valve, optional hot gas bypass isolation valve, and the refrigerant isolation val ve 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 prevents the valve from opening or closing during service work or during chiller operati on .

The full refrigerant charge on the 19XR will vary with chiller components and design conditions, as indicated on the job data specifications. An approximate charge may be determined by adding the condenser charge to the cooler charge as listed in T able 10.

Always operate the condenser and chilled water pumps whenever charging, transferring, or removing refrigerant from the chiller.

Use the CONTROL TEST terminate lockout function to monitor conditions and start the pumps.

If the chiller has been shipped with a holding charge

, the refrigerant is added through the pumpout charging connection (Fig. 29 and 30, valve 1b). First evacuate the nitrogen holding charge from the chiller vessels. Charge the refrigerant as a gas until the system pressure exceeds 35 psig (141 kPa) for HFC-134a. After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all the recomme nded refrigerant charge has been added. The charging valve (Fig. 29 and 30, valve 7) can be used to charge liquid to the cooler if the cooler isolation valve (11) is present and is closed. Do not charge liquid through the linear float to the condenser.

TRIMMING REFRIGERANT CHARGE — The 19XR is shipped with the correct charge for the design duty of the chiller. Trimming the charge can best be accom plished when the design load is available. To trim the charge, check the temperature difference between the leav ing chilled water temperatur e 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 10 lists the 19XR chiller refrigerant charges for each cooler and condenser code. Total refrigerant charge is the sum of the cooler and condenser charge.

Table 10 — Refrigerant (HFC-134a) Charge

COOLER

CODE

10 290 132 10 200 91 11 310 141 11 200 91 12 330 150 12 200 91 15 320 145 15 250 113 16 340 154 16 250 113 17 370 168 17 250 113 20 345 157 20 225 102 21 385 175 21 225 102 22 435 197 22 225 102 30 350 159 30 260 118 31 420 190 31 260 118 32 490 222 32 260 118 35 400 181 35 310 141 36 480 218 36 310 141 37 550 250 37 310 141 40 560 254 40 280 127 41 630 286 41 280 127 42 690 313 42 280 127 45 640 290 45 330 150 46 720 327 46 330 150 47 790 358 47 330 150 50 750 340 50 400 181 51 840 381 51 400 181 52 900 408 52 400 181 55 870 395 55 490 222 56 940 426 56 490 222 57 980 445 57 490 222 60 940 426 60 420 190 61 980 445 61 420 190 62 1020 463 62 420 190 65 1020 463 65 510 231 66 1060 481 66 510 231 67 1090 494 67 510 231 70 1220 553 70 780 354 71 1340 608 71 780 354 72 1440 653 72 780 354 75 1365 619 75 925 420 76 1505 683 76 925 420 77 1625 737 77 925 420 80 1500 680 80 720 327 81 1620 735 81 720 327 82 1730 785 82 720 327 85 1690 766 85 860 390 86 1820 825 86 860 390 87 1940 880 87 860 390

REFRIGERANT

CHARGE

lb kg lb kg

CONDENSER

CODE

REFRIGERANT

CHARGE

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 panel.

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

3. Chille r is charged with refrigerant and all refrigerant and oil valves are in their proper operating positions.

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

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

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

NOTE: If the pumps are not automatic, ensure water is circulating properly.

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

7. Access the CONTROL TEST screen. Scroll down on the TERMINATE LOCKOUT option. Press the SELECT (to enable the chil ler to s tart) and answ er Y ES to r eset u nit to operating mode. The chiller is locked out at the factory in order to prevent accidental start-up.

Before starting the chiller, verify:

Dry Run to Test Start-Up Sequence

For electro-mechanical starters.

1. Disengage the main motor disconnect (CB1) 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. Observe the default screen on the CVC/ICVC: the status message in the upper left-hand corner reads, “Manually Stopped,” Press the or softkey to start. If the chiller controls do not go into a start mode (“Unoc- cupied Mode” is displayed) go to the SCHEDULE screen and override the schedule or change the occupied time. Press the softkey to begin the start-up sequences.

3. View the STARTUP display screen and verify the chilled water and condenser water pumps have energized.

4. Verify the oil pump has started and is pressurizing the lubrication system. After the oil pump has run about 11 seconds, the starter energizes (COMPRESSOR START CONT ACT is closed) and goes through its start-up sequence.

5. Check the main contactor (1M) for proper operation.

6. The PIC II eventually shows an alarm for moto rs amps not sensed. Reset this alarm and continue with the initial start-up.

For Benshaw Inc. solid-state starters:

1. Close the main motor disconnect (CB1). Voltage will be applied to the compressor motor but the SCRs will not fire (compressor motor will not rotate). Enter MENU 4 in the Benshaw RediStart MICRO™ Menu structure at the Benshaw display (see Input Service Configurations, Change The Benshaw RediStart MICRO Software Configuration page 57). Select Dry Run Mode and scroll to YES.

2. Follow steps 2 through 4 for the electro-mechanical starters. When the Ramp Time is set for less than 10 seconds COMPRESSOR RUN CONT ACT will close.

3. The PIC II eventually shows an alarm for moto rs amps not sensed. Reset this alarm and enter MENU 4 in the Benshaw display. Select Dry Run Mode and scro ll to N O. Continue with the initial start-up.

CCN

LOCAL

Check Motor Rotation

1. Engage the oil pump circuit breaker (CB3) located inside the right hand side of the starter panel.

2. Then engage the cont rol power circuit breaker (CB2) located in the same section of the starter cabinet.

3. Finally close the main motor disconnect (CB1) on the front of the starter panel.

4. The ISM mounted in the electro-mechanical starters checks for proper phase rotation as soon as power is applied to the starter and the PIC II controls power up. Solid-state starters have phase protection and do not permit a start if the phase rotation is not correct.

5. An alarm message wi ll appear on the CVC/ICVC if the phase rotation is incorrect. If this occurs reverse any 2 of the 3 incoming power leads to the starter and reapply power. The motor is now ready for a rotation check.

6. Aft er the default screen status message states ‘Ready to Start’ press the softkey. The PIC II control performs start-up checks.

7. When the starter is energized and the motor begins to turn, check for clockwise motor rotation (Fig. 33).

LOCAL

Fig. 33 — Correct Motor Rotation

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

Check Oil Pressure and Compressor Stop

1. W hen the motor is at full spe ed, note the differential oil pressure reading on the CVC/ICVC 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.

To Prevent Accidental Start-Up —

override setting may be entered to prevent accidental start-up during service or whenever necessary. Access the MAINSTAT

screen and using the or softkeys, highlight the CHILLER START/STOP parameter. Override the cur-

rent ST AR T value by pressing the softkey. Press the

softkey followed by the softkey. The word

STOP ENTER SUPVSR! displays on the CVC/ICVC indicating the override is in place.

To restart the chiller the STOP override setting must be re-

moved. Access the MAINSTAT screen and using or

PREVIOUS 3 softkeys that appear represent 3 choices:

• — forces the chiller ON

ST ART

• — forces the chiller OFF

STOP

• — puts the chiller under remote or schedule

RELEASE

control. To return the chiller to normal control, press the

RELEASE ENTER more information, see Local Start-Up, page 46.

The default CVC/ICVC screen message line indicates

which command is in effect.

softkeys highlight CHILLER START/STOP. The

softkey followed by the softkey. For

NEXT PREVIOUS

SELECT

Check Chiller Operating Condition —

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

Instruct the Customer Operator —

erator(s) understand all operating and maintenance procedures. Point out the various chiller parts and explain their function as part of the comple te syst em.

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

A chiller STOP

Check to

Ensure the op-

OPTIONAL PUMPOUT 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 SYS TEM — CCN and LOCAL start, reset, menu, softkey functions, CVC/ICVC operation, occupancy schedule, set points, safety controls, and auxiliary and optional controls.

AUXILIARY EQUIPMENT — 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.

SAFETY DEVICES 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. B ecome familiar with the chiller and related equipment before operating the chiller.

2. Pre pare the system for start-up, start and stop the chill er, 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 Chiller for Start-Up —

described in the Initial Start-Up section, page 64.

Follow the steps

To Start the Chiller

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

2. On the CVC/ICVC default screen, press the or

softkey to st art the system. If the c hiller is in t he

CCN OCCUPIED mode and the start timers have expired, the start sequence will start. Follow the procedure described in the Start-Up/Shutdown/Recycle Sequence section, page 46.

Check the Running System —

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

1. The oil reservoir temperature should be above 120 F (49 C) during shutdown.

2. The bearing oil temperature accessed on the COMPRESS table should be 120 to 165 F (49 to 74 C). If the bearing

After the compres-

LOCAL

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 oil is acceptable as long as the oil pressure and temperature are within limits.

4. The oi l pressure should be between 18 and 30 psid (124 to 207 kPad) differential, as seen on the CVC/ICVC 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 60 and 135 psig (390 to 950 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. T ypical 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 ca pacity 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 and is accessed on the EQUIPMENT SERVICE screen, RAMP_DEM table (Table 2, Example 21).

To Stop the Chiller

1. The oc cupancy schedule starts and stops the chiller aut omatically once the time schedule is configured.

2. By pressing the STOP button for one second, the alarm light blinks once to confirm the button has been pressed. The compressor will then follow the normal shutdown sequence as described in the Shutdown Sequence, StartUp/Shutdown/Recycle Sequence section, page 46. The

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

IMPORT ANT : Do not attempt to stop the chiller by opening an isolating knife switch. High intensity arcing may occur.

Do not restart the chiller until the problem i s diagnosed and corrected.

After Limited Shutdown —

should be necessary. F ollow the regular preliminary checks and starting procedures.

Preparation for Extended Shutdown —

erant should be transferred into the pumpout storage tank (if supplied; see Pumpout and Refrigerant Transfer Procedures) to reduce chiller pressure and the possibility of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant or nitrogen to prevent air from leaking into the chiller.

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

CCN LOCA L

No special preparations

The refrig-

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

After Extended Shutdown —

tem 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 and inspect the Schrader fittings on the waterside flow devices for fouling, if necessary.

Check the cooler pressure on the CVC/ICVC default screen and compare it 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 48.

Recharge the chiller by transferring refrigerant from the pumpout storage tank (if supplied). Follow the Pumpout and Refrigerant Transfer Procedures section, below. 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. Ensure that the oil temperature is above 140 F (60 C) or above the cooler refrigerant temperature plus 50° F (27° C).

Cold Weather Operation —

denser water temperature 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 II controls have a low limit tower fan output that can be used to assist in this control (terminal 11 and 12 on ISM).

Manual Guide Vane Operation —

manually operate the guide vanes in order to check control operation or to control the guide vanes in an emergency. Manual operation is possible by overriding the target guide vane position. Access the COMPRESS screen on the CVC/ICVC and scroll down to highlight TARGET GUIDE VANE POS. To control the position, use the or softkey to adjust to the percentage of guide vane opening that is desired. Zero percent is fully closed; 100% is fully open. To release the guide vanes to automatic control, press the

RELEASE

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

softkey.

Refrigeration Log —

Fig. 34), is a convenient checklist for routine inspection and maintenance and provides a continuous record of chiller performance. It is also an aid when scheduling routine maintenance and diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid levels on a sheet similar to the one in Fig. 34. Automatic recording of PIC II data is possible by using CCN devices such as the Data Collection module and a Building Supervisor. Contact a Carrier representative for more information.

INCREASE

A refrigeration log (as shown in

Ensure the water sys-

When the entering con-

It is possible to

DECREASE

tank is supplied, the refrigerant can be isolated in the storage tank. The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuations.

Always run the chiller cooler and condenser water pumps and always charge or transfer refrigerant as a gas when the chiller pressure is less than 30 psig (207 kPa). Below the se pressures, liquid refrigerant flashes into gas, resulting in extremely low temperatures in the cooler/condenser tubes and possibly causing tube freeze-up.

During transfer of refrigerant into and out of the optional storage tank, carefully monitor the storage tank level gage. Do not fill the tank more than 90% of capacity to allow for refrigerant expansion. Overfilling may result in damage to the tank or personal injury.

Do not mix refrigerants from chillers that use different compressor oils. Compressor damage can result.

Operating the Optional Pumpout Unit

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

2. Ensure that the compressor hold-down bolts have been loosened t o al low fr ee sp rin g trav el .

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

4. Oil should be visible in the pumpout unit 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 75. The pumpout unit control wiring schematic is detailed in Fig. 35.

TO READ REFRIGERANT PRESSURES during pumpout or leak testing:

1. The CVC/ICVC display on the chiller control panel is suitable for determining refrigerant-side pressures and low (soft) vacuum. To assure the desired range and accuracy when measuring evacuation and dehydration, use a quality vacuum indicator or manometer. This can be placed on the Schrader connections on each vessel (Fig.

9) by removing the pressure transducer.

2. To determine pumpout storage tank pressure, a 30 in.

-0-400 psi (-101-0-2769 kPa) gage is attached to the storage tank.

3. Refer to Fig. 29, 30, and 36 for valve locations and numbers.

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES

Preparation —

optional pumpout storage tank, pumpout system, or pumpout compressor. The refrigerant can be pumped for service work to either the chiller compressor vessel or chiller condenser vessel by using the optional pumpout system. If a pumpout storage

The 19XR may come equipped with an

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.

REMARKS

ATO R

OPER-

INITIALS

DATE

(or vane

position)

Amperage

FLA

Level

Oil Motor

Tem p

Press.

TEMP

BEARING

Pressure Temp

(reser-

Press. Temp

voir)

Diff.

Fig. 34 — Refrigeration Log

REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

Plant MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPE

COOLER CONDENSER COMPRESSOR

DATE

Pressure Temp

In Out GPM In Out In Out GPM In Out

Refrigerant Water Refrigerant Water

Press. Temp

TIME

REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts.

LEGEND

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

*Bimetal thermal protector imbedded in motor winding.

Internal Thermostat

—

Compressor Terminal

Contactor Terminal

Overload Terminal

Pumpout Unit Terminal

Fig. 35 — 19XR Pumpout Unit Wiring Schematic

OIL RETURN LINE CONNECTION

CONDENSER WATER CONNECTIONS

REFRIGERANT INLET VALVE

Fig. 36 — Optional Pumpout Unit

Chillers with Storage Tanks —

If the chiller has isolation valves, leave them open for the following procedures. The letter “C” describes a closed valve. See Fig. 17, 18, 29, and 30.

TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK T O CHILLER

1. Equalize refrigerant pressure. a. Use the PIC II terminate lockout function on the

PUMPDOWN LOCKOUT screen, accessed from

the CONTROL TEST table to turn on the water pumps and monitor pressures.

If the chilled water and condenser water pumps are not controlled by the PIC II, these pumps must be started and stopped manually at the appropriate times during the refrigerant transfer procedure.

b. Close pumpout unit valves 2, 4, 5, 8, and 10, and

close chiller charging valve 7; open chiller isolation valve s 11, 12, 13, and 14 (i f present).

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

open chiller valves 1a and 1b.

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

CONDITION

CCCCCC

Follow Steps d and e carefully to prevent damage from freeze-up.

d. Slowly open valve 5 to increase chiller pressure to

68 psig 35 psig (141 kPa) for HFC-134a. Feed refrigerant slowly 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 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION

CC C

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

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

CONDITION

CCC

b. Turn off the chiller water pumps using the CVC/

ICVC (or manually, if necessary).

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 the pumpout condenser water. i. Run the pumpout compressor until the pumpout

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

CONDITION

CCCCCCCCCC

l. Turn off pumpout condenser water.

TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK

1. Equalize refrigerant pressure. a. Valve positions:

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

CONDITION

CCCCC

b. Slowly open valve 5. When the pressures are

equalized, open liquid line valve 7 t o allow liquid refrigerant to drain by gravity into the pumpout

storage tank.

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

CONDITION

CC C

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

valves in the following positions:

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

CONDITION

CC C

b. Run the pumpout compressor for approximately

30 minutes; then close valve 10.

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

CONDITION

CC CC

c. Turn off the pumpout compressor.

3. Remove any remaining refrigerant. a. Turn on the chiller water pumps using the PUMP-

DOWN LOCKOUT screen, accessed from the CONTROL TEST table. Turn on the pumps manually, if they are not controlled by the PIC II.

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

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

CONDITION

CCCC

d. Run the pumpout compressor until the chiller pres-

sure reaches 30 psig (207 kPa) for HFC-134a. Then, shut off the pumpout compressor. Warm condenser water will boil off any entrapped l iquid refrigerant and the chiller pressure will rise.

e. When the pressure rises to 40 psig (276 kPa) for

HFC-134a, t urn on the pum pout compressor u ntil the pressure again reaches 30 psig (207 kPa), and then turn off the pumpout compressor. Repeat this process until the pressure no longer rises. Then, turn on the pumpout compressor and pump until the pressure reaches18 in. Hg. (40 kPa absolute).

f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.

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

CONDITION

CCCCCCCCCC

g. Turn off the pumpout condenser water and con-

tinue to use the PIC II PUMPDOWN LOCKOUT screen functions, which lock out the chiller compressor for operation.

4. Establish a vacuum for service. To conserve refrigerant, operate the pumpout compressor

until the chiller pressure is reduced to 18 i n. Hg vac., re f 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 stored in one chiller vessel or the other without the need for an external storage tank.

1. Push refrigerant into the chiller condenser. a. V alve pos itio ns:

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION

b. Using the PIC II controls, turn off the chiller water

pumps and pumpout condenser water. If the chiller water pumps are not controlled through the PIC II, turn them off manually.

c. Turn on the pumpout compressor to push the liquid

refrigerant out of the chiller cooler vessel.

d. When all liquid refrigerant has been pushed into

the chiller condenser vessel, close chiller is olation valve 11.

e. Access the PUMPDOWN LOCKOUT screen on

the PIC II CONTROL TEST table to turn o n the chiller water pumps. If the chiller water pumps are not controlled by the PIC II, turn them on manually.

f. Turn off the pumpout compressor.

2. Evacuate the refrigerant gas from chiller cooler vessel. a. Close pumpout compressor valves 2 and 5, and

open valves 3 and 4.

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION

b. Turn on the pumpout condenser water. c. Run the pumpout compressor until the chiller

cooler vessel pressure reaches 18 in. Hg vac (40 kPa abs.). Monitor pressures on the CVC/

ICVC and on refrigerant gages. d. Close valve 1a. e. Turn off the pumpout compressor.

f. Close valves 1b, 3, and 4.

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION

CCCCCCCCCCC

g. Turn off the pumpout condenser water. h. Proceed to the PUMPDOWN/LOCKOUT function

accessed from the CONTROL TEST table to turn

off the chiller water pumps and lock out the chiller

compressor. Turn off the chiller water pumps man-

ually if they are not controlled by the PIC II.

TRANSFER ALL REFRIGERANT TO CHILLER COOLER VESSEL

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

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION

b. Turn off the chiller water pumps (either through

the PIC II controls or manually, if necessary) and the pumpout condenser water.

c. Turn on the pumpout compressor to push the

refrigerant out of the chiller condenser.

d. When all liquid refrigerant is out of the chiller con-

denser, close the cooler isolation valve 11.

e. Turn off the pumpout compressor.

CC C CCC

C CCCCCC

CCCCCC

2. Evac uate the refrigerant gas from the chiller condenser vessel.

a. Access the PUMPDOWN LOCKOUT function

accessed from the CVC/ICVC CONTROL TEST table to turn on the chiller water pumps. Turn the chiller water pumps on manually if they are not controlled by the PIC II.

b. Close pumpout uni t 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 the pumpout condenser water. d. Run the pumpout compressor until the chiller

condenser pressure reaches 18 in. Hg vac (40 kPa abs.). Monitor pressure at the CVC/ICVC and at

refrigerant gages. e. Close valve 1b. f. Turn off the pumpout compressor.

g. Close valves 1a, 2, and 5.

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

CONDITION

CCCCCCCCCCC

h. Turn off the pumpout condenser water. i. Proceed to the PUMPDOWN LOCKOUT test

from the CVC/ICVC CONTROL TEST table to

turn off the chiller water pumps and lock out the

chiller compressor. Turn off the chiller water

pumps manually if they are not controlled by the

PIC II.

RETURN CHILLER TO NORMAL OPERATING CONDITIONS

1. Ensure vessel that was opened has been evacuated.

2. Access the TERMINATE LOCKOUT function CVC/ ICVC from the CONTROL TEST table to view vessel pressures and turn on chiller water pumps. If the chiller water pumps are not controlled by the PIC II, turn them on manually.

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

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

CONDITION

C CCCCCCC

4. Slowly open valve 5, gradually increasing pressure in the evacuated vessel to 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 1a 1b 2 3 4 5 8 11 12 13 14

CONDITION

C C CCCCC

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

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

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

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

CONDITION

CCCCCCC

10. Proceed to the TERMINA TE LOCKOUT screen (accessed from the CONTROL TEST table) to turn off the water pumps and enable the chiller compressor for start-up. If the chiller water pumps are not controlled by the PIC II, turn them off manually.

GENERAL MAINTENANCE

Refrigerant Properties —

the 19XR chiller is HFC-134a. At normal atmospheric pressure, HFC-134a will boil at –14 F (–25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air and is noncombustible at atmospheric pressure. Read the Material Safety Data Sheet and th e late st ASH RAE Safet y Guid e for Mech anical Refrigeration to learn more about safe handling of this refrigerant.

HFC-134a will dissolve oil and some nonmetallic 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.

Adding Refrigerant —

scribed in Trim Refrigerant Charge section, page 72.

Always use the compressor pumpdown function in the Control Test table to turn on the cooler 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 30 psig (207 kPa) f or HFC-134a.

Removing Refrigerant —

tem is used, the 19XR refrigerant charge may be transferred to a pumpout storage tank or to the chiller condenser or cooler vessels. Follow the procedures in the Pumpout and Refrigerant Transfer Procedures section when transferring refrigerant from one vessel to another.

Adjusting the Refrigerant Charge —

tion or removal of refrigerant is required to improve chiller performance, follow the procedures given under the Trim Refrigerant Charge section, page 72.

Refrigerant Leak Testing —

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 ultrasonic leak detector. Ensure 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 —

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

In addition, Carrier recommends that leaks totalling less than the above rate but more than a rate of 0.1% of the t otal charge per year should be repaired during annual maintenance or whenever the refrigerant is transferred for other service work.

It is recommended by ASHRAE that chillers

The standard refrigerant for

Follow the procedures de-

If the optional pumpout sys-

If the addi-

Because HFC-134a is

Test After Service, Repair, or Major Leak —

all the refrigerant has been lost or if the chiller has been opened for service, the chiller or the affected ve ssels must be pres sure tested and le ak tested. Refer to the Leak Test Chiller section to perform a leak test.

HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, this refrigerant should not be present with high concentrations of air or oxygen above atmospheric pressures, because the mixture can undergo combustion.

TESTING WITH REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures. Use dry nitrogen to raise the machine pressure to leak testing levels.

TESTING WITHOUT REFRIGERANT TRACER — Another method of leak testing is to pressurize with nitrogen only and to use a soap bubble solution or an ultrasonic leak detector to determine if leaks are present.

TO PRESSURIZE WITH DRY NITROGEN NOTE: Pressurizing with dry nitrogen for leak testing should

not be done if the full refrigerant charge is in the vessel because purging the nitrogen is very difficult.

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 t he 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 press ure r eaches te st level. Do not exceed 140 psig (965 kPa).

5. Close the c harging valve on the chiller. Remove the copper tube if it is 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. Then dehydrate the chiller. Refer to the Standing V acuum Test and Chiller Dehydration section (pages 50 and 53) in the Before Initial Start-Up section.

Checking Guide Vane Linkage —

is off, the guide vanes are closed and the actuator mechanism is in the position shown in Fig. 37. If slack develops i n the drive chain, do the following to eliminate backlash:

1. With the chiller shut down and the actuator fully closed, remove the chain guard and loosen the actuator bra cket hold-down bolts.

2. Loosen guide vane sprocket adjusting bolts.

3. Pry bracket upwards to remove slack, t hen retighten the bracket hold-down bolts.

4. Retighten the guide vane sprocket adjusting bolts. Ensure that the guide vane shaft is rotated fully in the clockwise direction in order close it fully.

Trim Refrigerant Charge —

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

not overcharge.

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

After pressurizing the chiller, test for

When the chiller

If, to obtain optimal chill-

Fig. 37 —Guide Vane Actuator Linkage

To remove any excess refrigerant , follow the procedure in Transfer Refrigerant from Chiller to Pumpout Storage Tank section, Steps 1a and b, page 70.

WEEKLY MAINTENANCE

Check the Lubrication System —

el 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, check the oil reclaim system for proper operation. If additional oil is required, add it through the oil drain charging valve (Fig. 2). A pump is required when adding oil against refrigerant pressure. The oil charge for the 19XR compressor depends on the compressor Frame size:

• Frame 2 compressor — 5 gal (18.9 L)

• Frame 3 compressor — 8 gal (30 L)

• Frame 4 compressor — 10 gal (37.8 L)

• Frame 5 compressor — 18 gal (67.8 L)

The added oil must meet Carrier specifications for the 19XR. Refer to Changing Oil Filter and Oil Changes section on page 73. 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.

An oil heater is controlled by the PIC II to maintain oil temperature (see the Controls section) when the compressor is off. The CVC/ICVC COMPRESS screen displays whether the heater is energized or not. The heater is energized if the OIL HEATER RELAY parameter reads ON. If the PIC II shows that the heater is energized and if the sump is still 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 II does not permit compressor start-up if the oil temperature is too low. The PIC II continues with start-up only after the tem pera tu re i s with in al low ab le li mit s.

Mark the oil lev-

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on your 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 —

VICE ONTIME value on the MAINSTAT screen. This value should be reset to zero by the service person or the operator each time major service work is completed so that the time between service can be viewed and tracked.

Inspect the Control Panel —

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

Ensure power to the control center is off when cleaning and tightening connections inside the control panel.

The CVC/ICVC will dis play a SER-

Maintenance consists of

Check Safety and Operating Controls Monthly —

To ensure chiller protection, the automated Control Test should be performed at least once per month. See Table 3 for safety control settings. See Table 9 for Control Test functions.

Changing Oil Filter —

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

1. Ensure 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 valve s located behind power panel on top of oil pump assembly.

4. Connect an oil charging hose from the oil charging valve (Fig. 2) 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 and sent to a laboratory for proper analysis. Do not contaminate this sample.

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

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

6. Onc e 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 tight en down t he retainer nut. Instal l the filte r 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.

Change the oil filter on a

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 —

lowing Carr ier sp ecif ic at ions :

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

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

The polyolester-based oil (P/N: PP23BZ103) may be

ordered from your local Carrier representative.

Oil Changes —

ter the first year of operation and every five 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, the time between oil changes can be extended.

TO CHANGE THE OIL

1. Transfer the refrigerant into the chiller condenser vessel (for isolatable vessels) or to a pumpout storage tank.

2. Mark the existing oil level.

3. Open the control and oil heater circuit breaker.

4. When the chiller pressure is 5 psig (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Fig. 2). Slowly open the valve against refrigerant pressure.

5. Change t he oil filter at this time. See Cha nging Oil Filter section.

6. Change the refrigerant filter at this time, see the next section, 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 II warm it up to at least 140 F (60 C). Operate the oil pump manually, using the Control T est function, for 2 minutes. F or shutdown conditions, the oil level should be full in the lower sight glass. If the oil level is above move the excess oil. The oil level should now be equal to the amount shown in Step 2.

Refrigerant Filter —

the refrigerant cooling line to the motor, should be changed once a year or more often if filter condition indicates a need for more frequent replacement. Change the filter by closing the filter isolation valves (Fig. 4) and slowly opening the flare fittings with a wrench and back-up wrench to relieve the pressure . A moisture indicator sight glass is located beyond this filter to indicate the volume and moisture in the refrigerant. If the moisture indicator indicates moisture, locate the source of water immediately by performing a thorough leak check.

Oil Reclaim Filter —

strainer on the eductor suction line, a strainer on the di scharge pressure line, and a filter on the cooler scavenging line. Replace the filter once per year or more often if filter condition indicates a need for more frequent replacement. Change the filter by closing the filter isolation valves and slowly opening the flare fitting with a wrench and ba ck-up wrench to relieve the pressure. Change the strainers once every 5 years or whenever refrigerant is evacuated from the cooler.

If oil is added, it must meet the fol-

polyolester-based synthetic

compressor oil formatted for

use with HFC, gear-driven,

hermetic compressors.

Carrier recommends changing the oil af-

/2 full in the upper sight glass, re-

A refrigerant filter/drier, located on

The oil reclaim system has a

Inspect Refrigerant Float System —

Perform this inspection every 5 years or when the condenser is opened for service.

1. Transfer the refrigerant into the cooler vessel or into a pumpout storage tank.

2. Remove the float access cover.

3. Clean the chamber and valve assembly thoroughly. Be sure the valve moves freely. Ensure that all openings are free of obstructions.

4. Examine the cover gasket and replace if necessary.

See Fig. 38 for a view of the float valve design. For linear float valve designs, inspect the orientation of the float slide pin. It must be pointed toward the bubbler tube for proper operation.

Inspect Relief Valves and 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 t he chiller is installed i n a corrosive atmosphere or the relief valves are vented i nto a corrosive atmosphere, inspect the relief valves at more frequent intervals.

Compressor Bearing and Gear Maintenance —

The key to good bearing and gear maintenance is proper lubrication. Use the proper grade of oil, maintained at recommended level, temperature, and pressure. Inspect the lubrication system regularly and thoroughly.

To inspec t the bearings, a complet e compressor teard o w n 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 bea ring 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.

Inspect the Heat Exchanger Tubes and Flow Devices

COOLER AND FLOW DEVICES — 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 needed to fully clean the tubes . Inspect the tubes’ condition to determine the scheduled frequency for future cleaning and to determine whether water treatment in the chilled water/brine circuit i s adequate. Inspect the entering and leaving chilled water temperature sensors and flow devices for signs of corrosion or scale. Replace a sensor or Schrader fitting if corroded or remove any scale if found.

CONDENSER AND FLOW DEVICES — Since this water circuit is usually an open-type 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 wa ter is con ta mina ted . Ins pect t he e nteri n g and leav ing condenser water sensors and flow devices for signs of corrosion or scale. Replace the sensor or Schrader fitting 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 th e design difference is supposed to be, the condenser tubes may be dirty or water flow may be incorrect. Because HFC-134a is a high-pressure refrigerant, air usually does not enter the chiller.

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

LEGEND

1 — Refrigerant Inlet from FLASC Chamber 2 — Linear Float Assembly 3 — Float Screen 4 — Bubble Line 5 — Float Cover 6 — Bubble Line Connection 7 — Refrigerant Outlet to Cooler 8 — Gasket

Fig. 38 — 19XR Float Valve Design

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

Water Leaks —

The refrigerant moisture indicator on the refrigerant motor cooling line (Fig. 2) i ndicates whether there is water leakage during chiller operation. Water leaks should be repaired immediately.

The chiller must be dehydrated after re pair of water leaks. See Chiller Dehydration section, page 53.

Water Treatment —

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 tube 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 —

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

The disconnect on the starter front panel does not deenergize all internal circuits. O pen 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.

Untreated or improperly treated wa-

Before working

OPTI ONAL PUMPOUT C OMPRESSOR OI L CHARGE — Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows:

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

Carrier Part Number . . . . . . . . . . . . . . . . . . . . . . . . PP23BZ103

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.

Oil should be visible in one of the compressor sight glasses during both 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 compressor service valve (Fig. 36).

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. 36). Add oil as required.

6. Repl ace the connection and reopen the compressor service valves.

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS (Fig. 39) — The optional pumpout system high-pressure 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.

Ordering Replacement Chiller Parts —

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.

When

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

Check Pressure Transducers —

pressure transducers should be checked against a pressure gage reading. Check all eight transducers: the 2 oil differential pressure transducers, the condenser pressure transducer, the cooler pressure transducer, and the waterside pressure transducers (consisting of 4 flow devices: 2 cooler, 2 condenser).

Note the evaporator and condenser pressure readings on the HEAT_EX screen on the CVC/ICVC (EVAPORATOR PRES- SURE and CONDENSER PRESSURE). A ttach a n accura te 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 t he Troubleshooting Guide section. Oil differential pressure (OIL PUMP DELTA P on the COMPRESS screen) should be zero whenever the compressor is off.

Optional Pumpout System Maintenance —

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

Once a year, the

For

Fig. 39 — Optional Pumpout System Controls

TROUBLESHOOTING GUIDE

Overview —

erator and technician troubleshoot a 19XR chiller.

• The CVC/ICVC shows the chiller’s actual operating conditions and can be viewed while the unit is running.

• The CVC/ICVC default screen freezes when an alarm occurs. The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS screens continue to show current information. Once all alarms have been cleared (by correcting the problems and pressing the softkey), the CVC/ICVC default screen returns to normal operation.

• The CONTROL ALGORITHM STATUS screens (which include the CAPACITY, OVERRIDE, LL_MAINT, ISM_HIST, LOADSHED, WSMDEFME, and OCCDEFCM screens) display inform ation that helps 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 facilitates the proper operation and test 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 CVC/ICVC shows the temperatures and pressures required during these operations .

• From other SERVICE tables, the operator/technician 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 CVC/ICVC default screen. A more detailed message — along with a diagnostic message — is also stored into the ALARM HISTORY table.

Checking Display Messages —

check when troubleshooting the 19XR is the CVC/ICVC display. If the alarm light is flashing, check the primary and secondary message lines on the CVC/ICVC default screen (Fig. 14). These messages will indicate where the fault is occurring. These messages contain the alarm message with a specified code. This code or state appears with each alarm and alert message. The ALARM HISTORY table on the CVC/ ICVC SERVICE menu also contains an alarm message to further expand on the alarm. For a complete list of possible alarm messages, see Table 11. If the alarm light starts to flash while accessing a menu screen, press the soft key to return to the default screen to read the alarm message. The STATUS screen can also be accessed to determine where an alarm exists.

Checking Temperature Sensors —

sensors are thermistor-type sensors. This means that the resistance of the sensor varies with temperature. All sensors have the same res ist an ce char act er ist ics . If the cont ro ls are o n, det ermine sensor temperature by measuring voltage drop; if the controls are powered off, determine sensor temperature by measuring resistance. Compare the readings to the values listed in T able 12A or 12B.

RESISTANCE CHECK — Turn off the control power and, from the module, disconnect the terminal plug of the sensor in question. With a digital ohmmeter, measure sensor resistance between receptacles as designated by the w iring diagram. T he resistance and corresponding temperature are listed in Table 12A or 12B. Check the resistance of both wires to ground. This resistance should be infinite.

The PIC II has many features to help the op-

RESET

The first area to

EXIT

All temperature

VOLTAGE DROP — The voltage drop across any energized sensor can be measured with a digital voltmeter while the control is energized. Table 12A or 12B 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 on.

Relieve all refrigerant pressure or drain t he water before replacing the temperature sensors.

CHECK SENSOR ACCURACY — Place the sensor in a medium of known temperature and compare that temperature to the measured reading. The thermometer used to determi ne 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. 9 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wi ring 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 — For servicing convenience, there are 2 sensors each on the bearing and motor temperature sensors. If one of the sensors is damaged, the other can be used by simply moving a wire. T he number 2 term inal 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

UNITS EQUIPPED WITH CVC — There are 8 pressure transducers on 19XR chillers. They determine cooler, condenser, oil pressure, and cooler and condenser flow. The cooler and condenser transducers are also used by the PIC II t o determine the refrigerant temperatures. The oil supply pressure transducer value and the oil transmission sump pressure transducer value difference is calculated by the CCM. The CVC module t hen displays the differential pressure. In effect, the CVC reads only one input for oil pressure for a total of 5 pressure inputs: cooler pressure, condenser pressure, oil differential pressure, cooler waterside differential pressure, and condenser waterside differential pressure. See the Check Pressure Transducers section (page 75) under Scheduled Maintenance.

UNITS EQUIPPED WITH ICVC — There are 6 factoryinstalled pressure transducers, with inputs available for both cooler and The ICVC software will display a default reading of 26 psi during start-up and operation. An additional transducer, factory installed in the bottom of the cooler barrel, will read as EVAPORATOR SACTURATION TEMP on the HEAT_EX DISPLAY screen. This provides additional protection against a loss of water flow condition.

These pressure transducers can be calibrated if necessary. It is not usually necessary to calibrate at initial start-up. However, at high altitude locations, it is necessary to calibrate the transducers to ensure the proper refrigerant temperature/ pressure relationship. Each transducer is supplied with 5 vdc power from the CCM. If the power supply fails, a transducer voltage reference alarm occurs. If the transducer reading is suspected of being faulty, check the supply voltage. It should be 5 vdc ±.5 v displayed in CONTROL TEST under CCM Pressure Transducers. If the supply voltage is correct, the transducer should be recalibrated or replaced.

TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring. Do not pull on the trans- ducer 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.

Be sure to use a back-up wrench on the Schrader fitting whenever removing a transducer, since the Schrader fitting may back out with the transducer, causing a large leak a nd possible injury to personnel.

Control Algorithms Checkout Procedure —

One of the tables on the CVC/ICVC SERVICE menu is CONTROL ALGORITHM STATUS. The maintenance screens may be viewed from the CONTROL ALGORITHM STATUS table to see how a particular control algorithm is operating.

These maintenance screens are very useful in helping to determine how the control temperature is calculated and guide vane positioned and for observing the reactions from load changes, control point overrides, hot gas bypass, surge prevention, etc. The tables are:

Control Test —

The Control T est feature can check all the thermistor temperature sensors, pressure transducers, pumps and their associated flow devices, 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, as well as other useful troubleshooting issues. During pumpdown operations, the pumps are energized to prevent freeze-up and the vessel pressures and temperatures are displayed. The Pumpdown/Lockout feature prevents compressor start-up when there is no refrigerant i n the chiller or if the vessels are isolated. The Terminate Lockout feature ends the Pumpdown/Lockout after the pumpdown procedure is reversed and refrigerant is added.

LEGEND TO TABLES 11A-11J

CCM — Chiller Control Module CVC — Chiller Visual Controller CHW — Chilled Water

ICVC —

ISM — Integrated Starter Module PIC II — Product Integrated Controls II VFD — Variable Frequency Drive

International Chiller Visual Control

CAPACITY Capacity

OVERRIDE Override

HEAT_EX Surge/

LL_MAINT LEAD/LAG

OCCDEFCM Time

WSMDEFME Water

Control

Status

HGBP Status

Status

Schedules Status

System Manager Status

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

Details of all chilled water control override values.

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

Indicates LEAD/LAG operation status.

The Local and CCN occupied schedules are displayed here to help the operator quickly determine whether the schedule is in the “occupied” mode or not.

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

A. MANUAL STOP

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides

PRIMARY MESSAGE

MANUALLY STOPPED — PRESS CCN OR LOCAL TO START PIC II in OFF mode, press CCN or LOCAL softkey to start unit. TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL Enter the CONTROL TEST table and select TERMINATE LOCKOUT to

SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Chiller unloading before shutdown due to soft/stop feature. SHUTDOWN IN PROGRESS COMPRESSOR DEENERGIZED Chiller compressor is being commanded to stop. Water pumps are

ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.

SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

unlock compressor.

deenergized within one minute.

B. READY TO START

PRIMARY MESSAGE READY TO START IN XX MIN UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chillers will start only when

READY TO START IN XX MIN REMOTE CONTACTS OPEN Remote contacts are open. Close contacts to start. READY TO START IN XX MIN STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release

READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down. Unit ready to start. READY TO START IN XX MIN REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready to start. Remote contact enabled

READY TO START IN XX MIN START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start. Release

READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode. READY TO START UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chiller will start when occupied.

READY TO START REMOTE CONTACTS OPEN Remote contacts have stopped the chiller. Close contacts to start. READY TO START STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release

READY TO START OCCUPIED MODE Chiller timers complete, unit start will commence. READY TO START REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready for start. READY TO START START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT has been manually forced to start.

STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller to stop.

SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

occupied.

point to start.

and closed.

value to start under normal control.

Make sure the time and date are correct. Change values in TIME AND DATE screen.

point to start.

Chiller will start regardless of time schedule or remote contact status.

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE RECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently

RECYCLE RESTART PENDING REMOTE CONTACT CLOSED Unit in recycle mode, chilled water temperature is not sufficiently

RECYCLE RESTART PENDING START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start, chilled

RECYCLE RESTART PENDING ICE BUILD MODE Chiller in ICE BUILD mode. Chilled fluid temperature is satisfied for

SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

above set point to start.

water temperature is not sufficiently above set point to start.

ICE BUILD conditions.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.

STATE

100 PRESTART

101 PRESTART

102 PRESTART

103 PRESTART

104 PRESTART

105 PRESTART

106 PRESTART

107 PRESTART

108 PRESTART

109 PRESTART

*[LIMIT] is shown on the CVC/ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.

[VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

PRIMARY

MESSAGE

ALERT

SECON DARY

MESSAGE

STARTS LIMIT EXCEEDED

HIGH BEARING TEMPERATURE

HIGH MOTOR TEMPERATURE

HIGH DISCHARGE TEMP

LOW REFRIGERANT TEMP

LOW OIL TEMPERATURE

HIGH CONDENSER PRESSURE

LOW LINE VOLTAGE

HIGH LINE VOLTAGE

GUIDE VANE CALIBRATION

ALARM MESSAGE

PRIMARY CAUSE

100->Excessive compressor starts (8 in 12 hours)

101->Comp Thrust Bearing Temp [VALUE] exceeded limit of [LIMIT]*.

102->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*.

103->Comp Discharge Temp [VALUE] exceeded limit of [LIMIT]*.

104->Evaporator Refrig Temp [VALUE] exceeded limit of [LIMIT]*.

105->Oil Sump Temp [VALUE] exceeded limit of [LIMIT]*.

106->Condenser Pressure [VALUE] exceeded limit of [LIMIT]*.

107->Average Line Voltage [VALUE] exceeded limit of [LIMIT]*.

108->Average Line Voltage [VALUE] exceeded limit of [LIMIT]*.

109->Actual Guide Vane Pos Calibration Required Before Start-Up

ADDITIONAL CAUSE/REMEDY

Depress the RESET softkey if additional start is required. Reassess start-up requirements.

Check oil heater for proper operation. Check for low oil level, partially closed coil supply valves, clogged oil filters, etc. Check the sensor wiring and accuracy. Check configurable range in SETUP1 screen.

Check motor sensors for wiring and accuracy. Check motor cooling line for proper operation, or restrictions. Check for excessive starts within a short time span. Check configurable range in SETUP1 screen.

Allow discharge sensor to cool. Check for sensor wiring and accuracy. Check for excessive starts. Check configurable range in SETUP1 screen.

Check transducer wiring and accuracy. Check for low chilled fluid supply temperatures. Check refrigerant charge.

Check oil heater contactor/relay and power. Check oil level and oil pump operation.

Check transducer wiring and accuracy. Check for high condenser water temperatures.

Check voltage supply. Check voltage transformers. Consult power utility if voltage is low.

Check voltage supply. Check power transformers. Consult power utility if voltage is high.

Calibrate guide vane actuator in Control Test.

E. START-UP IN PROGRESS

PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY

STARTUP IN PROGRESS OCCUPIED MODE Chiller is starting. Time schedule is occupied. STARTUP IN PROGRESS REMOTE CONTACT CLOSED Chiller is starting. Remote contacts are enabled and closed. STARTUP IN PROGRESS START COMMAND IN EFFECT Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to

AUTORESTART IN PROGRESS OCCUPIED MODE Chiller is starting after power failure. Time schedule is occupied. AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED Chiller is starting after power failure. Remote contacts are enabled and

AUTORESTART IN PROGRESS START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT

start.

closed.

manually forced to start.

F. NORMAL RUN

PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY RUNNING — RESET ACTIVE 4-20 mA SIGNAL Auto chilled water reset active based on external input. RUNNING — RESET ACTIVE REMOTE TEMP SENSOR Auto chilled water reset active based on external input. RUNNING — RESET ACTIVE CHW TEMP DIFFERENCE Auto chilled water reset active based on cooler ∆T. RUNNING — TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control. RUNNING — TEMP CONTROL ENTERING CHILLED WATER Entering Chilled Water (ECW) control enabled in TEMP_CTL screen RUNNING — TEMP CONTROL TEMPERATURE RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify. RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify. RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT Demand limit set point is less than actual demand. RUNNING — DEMAND LIMITED BY 4-20 mA SIGNAL Demand limit is active based on external auto demand limit option. RUNNING — DEMAND LIMITED BY CCN SIGNAL Demand limit is active based on control limit signal from CCN. RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE Demand limit is active based on LOADSHED screen set-up. RUNNING — TEMP CONTROL HOT GAS BYPASS Hot gas bypass option is energized. See stall prevention in the control

RUNNING — DEMAND LIMITED BY LOCAL SIGNAL Active demand limit manually overridden on MAINSTAT table. RUNNING —TEMP CONTROL ICE BUILD MODE Chiller is running under Ice Build temperature control.

section.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

G. NORMAL RUN WITH OVERRIDES

STATE

120 RUN CAPACITY

121 RUN CAPACITY

122 RUN CAPACITY

123 RUN CAPACITY

124 RUN CAPACITY

125 RUN CAPACITY

*[LIMIT] is shown on the CVC/ICVC 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 has recorded at the time of the fault condition.

PRIMARY

MESSAGE

LIMITED

SECON DARY

MESSAGE

HIGH CONDENSER PRESSURE

HIGH MOTOR TEMPERATURE

LOW EVAP REFRIG TEMP

HIGH COMPRESSOR LIFT

MANUAL GUIDE VANE TARGET

LOW DISCHARGE SUPERHEAT

ALARM MESSAGE

PRIMARY CAUSE

120->Condenser Pressure [VALUE] exceeded limit of [LIMIT]*.

121->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*.

122->Evaporator Refrig Temp [VALUE] exceeded limit of [LIMIT]*.

123->Surge Prevention Override: Lift Too High For Compressor.

124->Run Capacity Limited: Manual Guide Vane Target.

No messages. Check oil charge.

Check for high condenser water temperatures. Check setting in SETUP1.

Check motor cooling lines. Check for closed valves. Check setting in SETUP1.

Check refrigerant charge. Check for low entering cooler temperatures.

Check for high condenser water temperatures or low suction temperature.

Target guide vane point has been forced in MAINSTAT screen. Release force to continue normal operation.

Check refrigerant charge.

ADDITIONAL

CAUSE/REMEDY

H. OUT-OF-RANGE SENSOR ALARMS

STATE

260 SENSOR

261 SENSOR

262 SENSOR

263 SENSOR

264 SENSOR

265 SENSOR

266 SENSOR

267 SENSOR

268 SENSOR

269 SENSOR

270 SENSOR

271 SENSOR

273 SENSOR

PRIMARY

MESSAGE

FAU LT

SECONDARY

MESSAGE

LEAVING CHILLED WATER

ENTERING CHILLED WATER

CONDENSER PRESSURE

EVAPORATOR PRESSURE

COMPRESSOR BEARING TEMP

COMPRESSOR MOTOR TEMP

COMP DISCHARGE TEMP

OIL SUMP TEMP 267->Sensor Fault:

COMP OIL PRESS DIFF

CHILLED WATER FLOW

COND WATER FLOW

VFD SPEED SENSOR OUT OF RANGE

VFD SPEED OUT OF RANGE

ALARM MESSAGE

PRIMARY CAUSE

260->Sensor Fault: Leaving Chilled Water

261->Sensor Fault: Entering Chilled Water

262->Sensor Fault: Condenser Pressure

263->Sensor Fault: Evaporator Pressure

264->Sensor Fault: Comp Thrust Bearing Temp

265->Sensor Fault: Comp Motor Winding Temp

266->Sensor Fault: Comp Discharge Temp

Oil Sump Temp 268->Sensor Fault:

Oil Pump Delta P 269->Sensor Fault:

Chilled Water Delta P 270->Sensor Fault:

Cond Water Delta P 271->Sensor Fault:

Check Actual VFD Speed Sensor 273->Sensor Fault:

Check Actual VFD Speed Sensor

ADDITIONAL

CAUSE/REMEDY

Check sensor resistance or voltage drop. Check for proper wiring.

Check sensor wiring.

Check sensor resistance or voltage drop. Check for proper wiring.

Check sensor wiring and accuracy.

Check voltage input on terminals J6-1 and J6-2 on the ISM module. Check wiring.

Check VFD feedback 0-5 vac. Calibrate VFD speed reference signal.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

I. CHILLER PROTECT LIMIT FAULTS

STATE

200 PROTECTIVE

201 PROTECTIVE

202 PROTECTIVE

203 FAILURE TO

204 FAILURE TO

205 FAILURE TO

206 PROTECTIVE

207 PROTECTIVE

208 PROTECTIVE

209 PROTECTIVE

210 PROTECTIVE

211 PROTECTIVE

212 PROTECTIVE

213 PROTECTIVE

214 PROTECTIVE

215 PROTECTIVE

216 PROTECTIVE

217 PROTECTIVE

218 PROTECTIVE

219 PROTECTIVE

220 PROTECTIVE

221 PROTECTIVE

222 PROTECTIVE

223 PROTECTIVE

PRIMARY

MESSAGE

LIMIT

START

STOP

LIMIT

SECON DARY

MESSAGE

1M CONTACT FAU LT

2M CONTACT FAU LT

MOTOR AMPS NOT SENSED

EXCESS ACCELERATION TIME

1M/2M CONTACT FAU LT

MOTOR AMPS WHEN STOPPED

STARTER FAU LT

HIGH CONDENSER PRESSURE

EXCESSIVE MOTOR AMPS

LINE PHASE LOSS

LINE VOLTAGE DROPOUT

HIGH LINE VOLTAGE

LOW LINE VOLTAGE

STARTER MODULE RESET

POWER LOSS 214->Power Loss:

LINE CURRENT IMBALANCE

LINE VOLTAGE IMBALANCE

MOTOR OVERLOAD TRIP

MOTOR LOCKED ROTOR TRIP

STARTER LOCK ROTOR TRIP

GROUND FAULT 220->Ground Fault Trip;

PHASE REVERSAL TRIP

LINE FREQUENCY TRIP

STARTER MODULE FA IL UR E

ALARM MESSAGE

PRIMARY CAUSE

200->1M Aux Contact Fault; Check 1M Contactor and Aux

201->2M Aux Contact Fault; Check 2M Contactor and Aux

202->Motor Amps Not Sensed — Average Line Current [VALUE]

203->Motor Acceleration Fault — Average Line Current [VALUE]

204->1M/2M Aux Contact Stop Fault; Check 1M/2M Contactors and Aux

205->Motor Amps When Stopped — Average Line Current [VALUE]

206->Starter Fault Cutout; Check Optional Starter Contacts

207->High Cond Pressure cutout. [VALUE] exceeded limit of [LIMIT]*.

208->Compressor Motor Amps [VALUE] exceeded limit of [LIMIT]*.

209->Line Phase Loss; Check ISM Fault History to Identify Phase

210->Single Cycle Line Voltage Dropout

211->High Average Line Voltage [VALUE]

212->Low Average Line Voltage [VALUE]

213->Starter Module PowerOn Reset When Running

Check voltage supply

215->Line Current Imbalance; Check ISM Fault History to Identify Phase

216->Line Voltage Imbalance; Check ISM Fault History to Identify Phase

217->Motor Overload Trip; Check ISM configurations

218->Motor Locked Rotor Amps exceeded; Check Motor & ISM Config

219->Starter Locked Rotor Amps Rating exceeded

Check Motor and Current Transformers

221->Phase Reversal Trip; Check Power Supply

222->Line Frequency — [VALUE] exceeded limit of [LIMIT]. Check Power Supply.

223->Starter Module Hardware Failure

ADDITIONAL

CAUSE/REMEDY

Check for wiring of current transformers to the ISM. Check main circuit breaker for trip.

Check to be sure that the inlet guide vanes are closed at start-up. Check starter for proper operation. Reduce unit pressure if possible.

For Benshaw Inc. RediStart MICRO™ starters, view fault code at RediStart MICRO display. Press FAULT RESET to clear faults.

Check for high condenser water temperatures, low water flow, fouled tubes. Check for division plate/gasket bypass. Check for noncondensables. Check transducer wiring and accuracy. If [VALUE] is less than Limit then check the 1CR Starting Circuit.

Check motor current for proper calibration. Check inlet guide vane actuator.

Check transformers to ISM. Check power distribution bus. Consult power company.

Check transformers to ISM. Check distribution bus. Consult power company.

Check upstream equipment.

Check ISM configuration.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

I. CHILLER PROTECT LIMIT FAULTS (cont)

STATE

227 PROTECTIVE

228 PROTECTIVE

229 PROTECTIVE

230 PROTECTIVE

231 PROTECTIVE

232 PROTECTIVE

233 PROTECTIVE

234 PROTECTIVE

235 PROTECTIVE

236 PROTECTIVE

237 PROTECTIVE

238 PROTECTIVE

239 PROTECTIVE

240 PROTECTIVE

241 LOSS OF

242 LOSS OF

243 POTENTIAL

244 POTENTIAL

245 PROTECTIVE

PRIMARY

MESSAGE

LIMIT

COMMUNICATION

FREEZE-UP

LIMIT

SECON DARY

MESSAGE

OIL PRESS SENSOR FAULT

LOW OIL PRESSURE

LOW CHILLED WATER FLOW

LOW CONDENSER WATER FLOW

HIGH DISCHARGE TEMP

LOW REFRIGERANT TEMP

HIGH MOTOR TEMPERATURE

HIGH BEARING TEMPERATURE

HIGH CONDENSER PRESSURE

CCN OVERRIDE STOP

SPARE SAFETY DEVICE

EXCESSIVE COMPR SURGE

TRANSDUCER VOLTAGE FAULT

LOW DISCHARGE SUPERHEAT

WITH STARTER MODULE

WITH CCM MODULE

EVAP PRESS/TEMP TOO LOW

COND PRESS/TEMP TOO LOW

VFD SPEED OUT OF RANGE

ALARM MESSAGE

PRIMARY CAUSE

227->Oil Pump Delta P [VALUE] exceeded limit of [LIMIT]*.

228->Oil Pump Delta P [VALUE] exceeded limit of [LIMIT].*

229->Low Chilled Water Flow; Check Delta P Config & Calibration

230->Low Condenser Water Flow; Check Delta P Config & Calibration

231->Comp Discharge Temp [VALUE] exceeded limit of [LIMIT].*

232->Evaporator Refrig Temp [VALUE] exceeded limit of [LIMIT]*.

233->Comp Motor Winding Temp [VALUE] exceeded limit of [LIMIT]*.

234->Comp Thrust Bearing Temp [VALUE] exceeded limit of [LIMIT]*.

235->Condenser Pressure [VALUE] exceeded limit of [LIMIT]*.

236->CCN Override Stop while in LOCAL run mode

237->Spare Safety Device Spare safety input has tripped or factory installed

238->Compressor Surge: Check condenser water temp and flow

239->Transducer Voltage Ref [VALUE] exceeded limit of [LIMIT]*.

240->Check for Oil in Refrigerant or Overcharge of Refrigerant

241->Loss of Communication With Starter.

242->Loss of Communication With CCM.

243->Evaporator Refrig Temp [VALUE] exceeded limit of [LIMIT]*.

244->Condenser Refrig Temp [VALUE] exceeded limit of [LIMIT]*.

245->Actual VFD Speed [VALUE] exceeded limit of [LIMIT]*.

Check transducer wiring and accuracy. Check power supply to pump. Check pump operation. Check transducer calibration.

Check transducer wiring and accuracy. Check power supply to pump. Check pump operation. Check oil level. Check for partially closed service valves. Check oil filters. Check for foaming oil at start-up. Check transducer calibration.

Perform pump control test. Check transducer accuracy and wiring. Check water valves. Check transducer calibration.

Check sensor resistance or voltage drop. Check for proper wiring. Check for proper condenser flow and temperature. Check for proper inlet guide vane and diffuser actuator operation. Check for fouled tubes or noncondensables in the system.

Check for proper refrigerant charge. Check float operation. Check for proper fluid flow and temperature. Check for proper inlet guide vane operation.

Check motor sensors wiring and accuracy. Check motor cooling line for proper operation, or restrictions. 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, clogged oil filters, etc. Check the sensor wiring and accuracy.

Check for high condenser water temperatures, low water flow, fouled tubes. Check for division plate/gasket bypass. Check for noncondensables. Check transducer wiring and accuracy.

CCN has signaled the chiller to stop. Reset and restart when ready. If the signal was sent by the CVC/ICVC, release the stop signal on the STATUS01 table.

jumper is not present. Check condenser flow and temperatures.

Check surge protection configuration.

Check wiring to ISM.

Check wiring to CCM.

Check for proper refrigerant charge. Check float operation. Check for proper fluid flow and temperature. Check for proper inlet guide vane operation.

ADDITIONAL

CAUSE/REMEDY

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

I. CHILLER PROTECT LIMIT FAULTS (cont)

STATE

246

247

248

249

250

251

252

253

*[LIMIT] is shown on the CVC/ICVC 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.

PRIMARY

MESSAGE

PROTECTIVE LIMIT

SECON DARY

MESSAGE

INVALID DIFFUSER CONFIG

DIFFUSER POSITION FAU LT

SPARE TEMPERATURE#1248->Spare Temperature #1

SPARE TEMPERATURE#2249->Spare Temperature #2

REFRIGERANT LEAK SENSOR

ISM CONFIG CONFLICT

GUIDE VANE CALIBRATION

ALARM MESSAGE

PRIMARY CAUSE

246->Diffuser Control Invalid Configuration: Check SETUP2 Entries.

247->Diffuser Position Fault: Check Guide Vane and Diffuser Actuators

[VALUE] exceeded limit of [LIMIT]*.

250->Refrigerant Leak Sensor [VALUE] exceeded Limit of [LIMIT]*.

251->ISM Config Conflict (ISM Uploaded); Verify to Reset Alarm

252->ISM Config Conflict (ISM Downloaded); Verify to Reset Alarm

253->Guide Vane Fault [VALUE]. Check Calibration.

ADDITIONAL

CAUSE/REMEDY

Check diffuser/guide vane schedule.

Check rotating stall transducer wiring and accuracy. Check diffuser schedule. Check for proper operation of diffuser actuator and inlet guide vane actuator. Check diffuser coupling. Check inlet guide vane operation. Check inlet guide vane calibration. Check diffuser/inlet guide vane schedule. Check diffuser mechanical set-up for proper orientation. If not using variable diffuser, check that the option has not been enabled.

The refrigerant leak detector’s output wired to J5-5 and J5-6 on the CCM module has reached the alarm limit. Check leak detector and for leaks.

Confirm valid settings in ISM_CONF screen.

Enter Control Test and execute Guide Vane Calibration. Check guide vane feedback (terminals J4-9 and J4-10) on the CCM module.

J. CHILLER ALERTS

STATE

140

141

142

143

144

145

146

147

148

PRIMARY

MESSAGE

SENSOR ALERT LEAVING COND

SENSOR ALERT ENTERING COND

LOW OIL PRESSURE ALERT

AUTORESTART PENDING

SECON DARY

MESSAGE

WATER TEMP

CHECK OIL FILTER 142->Low Oil Pressure Alert.

LINE PHASE LOSS

LINE VOLTAGE DROP OUT

HIGH LINE VOLTAGE

LOW LINE VOLTAGE

STARTER MODULE RESET

POWER LOSS 148->Control Power-Loss

ALARM MESSAGE

PRIMARY CAUSE

140->Sensor Fault: Check Leaving Cond Water Sensor

141->Sensor Fault: Check Entering Cond Water Sensor

Check Oil Filter.

143->Line Phase Loss Power loss has been detected in any phase.

144->Single Cycle Line Voltage Dropout

145>Line Overvoltage — Average Line Volt [VALUE]

146->Line Undervoltage — Average Line Volt [VALUE]

147->Starter Module PowerOn Reset When Running

When Running

ADDITIONAL

CAUSE/REMEDY

Check sensor resistance or voltage drop. Check for proper wiring.

Check for partially or closed shut-off valves. Check oil filter. Check oil pump and power supply. Check oil level. Check for foaming oil at start-up. Check transducer wiring and accuracy.

Chiller automatically restarting. A drop in line voltage has been detected within

2 voltage cycles. Chiller automatically restarting if Autorestart option is enabled.

Check line power.

ISM has detected a hardware fault and has reset. Chiller automatically restarting.

Check control power.

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

J. CHILLER ALERTS (cont)

Table 11 — CVC/ICVC Primary and Secondary Messages and

STATE

149

150

151

152

153

154

155

156

157

158

159

160

*[LIMIT] is shown on the CVC/ICVC 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.

PRIMARY

MESSAGE

SENSOR ALERT HIGH DISCHARGE

SENSOR ALERT HIGH BEARING

CONDENSER PRESSURE ALERT

RECYCLE ALERT

no message: ALERT only

POTENTIAL FREEZE-UP

OPTION SENSOR FAU LT

SENSOR ALERT SPARE TEMPERATURE#1158->Spare Temperature #1

SENSOR ALERT SPARE TEMPERATURE#2159->Spare Temperature #2

DIFFUSER ALERT

SECON DARY

MESSAGE

TEMP

TEMPERATURE

PUMP RELAY ENERGIZED

EXCESSIVE RECYCLE STARTS

no message; ALERT only

COND PRESS/TEMP TOO LOW

REMOTE RESET SENSOR

AUTO CHILLED WATER RESET

AUTO DEMAND LIMIT INPUT

DIFFUSER POSITION

ALARM MESSAGE

PRIMARY CAUSE

149->Comp Discharge Temp [VALUE] exceeded limit of [LIMIT]*.

150->Comp Thrust Bearing Temp [VALUE] exceeded limit of [LIMIT]*.

151->High Condenser Pressure [VALUE]: Pump Energized to Reduce Pressure.

152->Excessive recycle starts. Chiller load is too low to keep compressor on

153->Lead/Lag Disabled: Duplicate Chiller Address; Check Configuration

154->Condenser freeze up prevention

155->Sensor Fault/Option Disabled: Remote Reset Sensor

156->Sensor Fault/Option Disabled: Auto Chilled Water Reset

157->Sensor Fault/Option Disabled: Auto Demand Limit Input

[VALUE] exceeded limit of [LIMIT].*

160->Diffuser Position Alert; Check Diffuser Configuration.

Check sensor resistance or voltage drop. Check for proper wiring. Check for proper condenser flow and temperature. Check for high lift or low load. Check for proper inlet guide vane and diffuser actuator operation (Size 5 compressor Only). Check for fouled tubes or noncondensables in the refrigerant system.

Check sensor resistance or voltage drop. Check for proper wiring. Check for partially closed service valves. Check oil cooler TXV. Check oil filter. Check oil level.

Check sensor wiring and accuracy. Check condenser flow and fluid temperature. Check for fouled tubes. This alarm is not caused by the High Pressure Switch.

line and there has been more than 5 starts in 4 hours. Increase chiller load, adjust hot gas bypass, increase RECYCLE RESTART DELTA T from SETUP1 Screen.

Illegal chiller address configuration in Lead/ Lag screen. Both chillers require a different address.

The condenser pressure transducer is reading a pressure that could freeze the condenser tubes. Check for condenser refrigerant leaks. Check fluid temperature. Check sensor wiring and accuracy. Place the chiller in PUMPDOWN mode if the vessel is evacuated.

Check sensor resistance or voltage drop. Check for proper wiring.

Check diffuser configuration in SETUP2 screen.

ADDITIONAL

CAUSE/REMEDY

Table 12A — Thermistor Temperature (F) vs. Resistance/Voltage Drop

TEMPERATURE

(F)

–25 4.700 98,010 –24 4.690 94,707 –23 4.680 91,522 –22 4.670 88,449 –21 4.659 85,486 –20 4.648 82,627 –19 4.637 79,871 –18 4.625 77,212 –17 4.613 74,648 –16 4.601 72,175 –15 4.588 69,790 –14 4.576 67,490 –13 4.562 65,272 –12 4.549 63,133 –11 4.535 61,070 –10 4.521 59,081

–9 4.507 57,162 –8 4.492 55,311 –7 4.477 53,526 –6 4.461 51,804 –5 4.446 50,143 –4 4.429 48,541 –3 4.413 46,996 –2 4.396 45,505 –1 4.379 44,066

0 4.361 42,679 1 4.344 41,339 2 4.325 40,047 3 4.307 38,800 4 4.288 37,596 5 4.269 36,435 6 4.249 35,313 7 4.229 34,231 8 4.209 33,185

9 4.188 32,176 10 4.167 31,202 11 4.145 30,260 12 4.123 29,351 13 4.101 28,473 14 4.079 27,624 15 3.056 26,804 16 4.033 26,011 17 4.009 25,245 18 3.985 24,505 19 3.960 23,789 20 3.936 23,096 21 3.911 22,427 22 3.886 21,779 23 3.861 21,153 24 3.835 20,547 25 3.808 19,960 26 3.782 19,393 27 3.755 18,843 28 3.727 18,311 29 3.700 17,796 30 3.672 17,297 31 3.644 16,814 32 3.617 16,346 33 3.588 15,892 34 3.559 15,453 35 3.530 15,027 36 3.501 14,614 37 3.471 14,214 38 3.442 13,826 39 3.412 13,449 40 3.382 13,084 41 3.353 12,730 42 3.322 12,387 43 3.291 12,053 44 3.260 11,730 45 3.229 11,416 46 3.198 11,112 47 3.167 10,816 48 3.135 10,529 49 3.104 10,250 50 3.074 9,979 51 3.042 9,717 52 3.010 9,461 53 2.978 9,213 54 3.946 8,973 55 2.914 8,739 56 2.882 8,511 57 2.850 8,291 58 2.819 8,076 59 2.788 7,868

PIC II VOLTAGE DROP (V)

RESISTANCE

(Ohms)

TEMPERATURE

(F)

60 2.756 7,665 61 2.724 7,468 62 2.692 7,277 63 2.660 7,091 64 2.628 6,911 65 2.596 6,735 66 2.565 6,564 67 2.533 6,399 68 2.503 6,238 69 2.472 6,081 70 2.440 5,929 71 2.409 5,781 72 2.378 5,637 73 2.347 5,497 74 2.317 5,361 75 2.287 5,229 76 2.256 5,101 77 2.227 4,976 78 2.197 4,855 79 2.167 4,737 80 2.137 4,622 81 2.108 4,511 82 2.079 4,403 83 2.050 4,298 84 2.021 4,196 85 1.993 4,096 86 1.965 4,000 87 1.937 3,906 88 1.989 3,814 89 1.881 3,726 90 1.854 3,640 91 1.827 3,556 92 1.800 3,474 93 1.773 3,395 94 1.747 3,318 95 1.721 3,243 96 1.695 3,170 97 1.670 3,099 98 1.644 3,031

99 1.619 2,964 100 1.595 2,898 101 1.570 2,835 102 1.546 2,773 103 1.523 2,713 104 1.499 2,655 105 1.476 2,597 106 1.453 2,542 107 1.430 2,488 108 1.408 2,436 109 1.386 2,385 110 1.364 2,335 111 1.343 2,286 112 1.321 2,239 113 1.300 2,192 114 1.279 2,147 115 1.259 2,103 116 1.239 2,060 117 1.219 2,018 118 1.200 1,977 119 1.180 1,937 120 1.161 1,898 121 1.143 1,860 122 1.124 1,822 123 1.106 1,786 124 1.088 1,750 125 1.070 1,715 126 1.053 1,680 127 1.036 1,647 128 1.019 1,614 129 1.002 1,582 130 0.986 1,550 131 0.969 1,519 132 0.953 1,489 133 0.938 1,459 134 0.922 1,430 135 0.907 1,401 136 0.893 1,373 137 0.878 1,345 138 0.864 1,318 139 0.849 1,291 140 0.835 1,265 141 0.821 1,240 142 0.808 1,214 143 0.795 1,190 144 0.782 1,165

PIC II VOLTAGE DROP (V)

RESISTANCE

(Ohms)

TEMPERATURE

(F)

145 0.769 1,141 146 0.756 1,118 147 0.744 1,095 148 0.731 1,072 149 0.719 1,050 150 0.707 1,029 151 0.696 1,007 152 0.684 986 153 0.673 965 154 0.662 945 155 0.651 925 156 0.640 906 157 0.630 887 158 0.619 868 159 0.609 850 160 0.599 832 161 0.589 815 162 0.579 798 163 0.570 782 164 0.561 765 165 0.551 750 166 0.542 734 167 0.533 719 168 0.524 705 169 0.516 690 170 0.508 677 171 0.499 663 172 0.491 650 173 0.484 638 174 0.476 626 175 0.468 614 176 0.460 602 177 0.453 591 178 0.445 581 179 0.438 570 180 0.431 561 181 0.424 551 182 0.418 542 183 0.411 533 184 0.404 524 185 0.398 516 186 0.392 508 187 0.385 501 188 0.379 494 189 0.373 487 190 0.367 480 191 0.361 473 192 0.356 467 193 0.350 461 194 0.344 456 195 0.339 450 196 0.333 445 197 0.328 439 198 0.323 434 199 0.318 429 200 0.313 424 201 0.308 419 202 0.304 415 203 0.299 410 204 0.294 405 205 0.290 401 206 0.285 396 207 0.281 391 208 0.277 386 209 0.272 382 210 0.268 377 211 0.264 372 212 0.260 367 213 0.256 361 214 0.252 356 215 0.248 350 216 0.245 344 217 0.241 338 218 0.237 332 219 0.234 325 220 0.230 318 221 0.227 311 222 0.224 304 223 0.220 297 224 0.217 289 225 0.214 282

PIC II VOLTAGE DROP (V)

RESISTANCE

(Ohms)

Table 12B — Thermistor Temperature (C) vs. Resistance/Voltage Drop

TEMPERATURE

(C)

–33 4.722 106 880 –32 4.706 100 260 –31 4.688 94 165 –30 4.670 88 480 –29 4.650 83 170 –28 4.630 78 125 –27 4.608 73 580 –26 4.586 69 250 –25 4.562 65 205 –24 4.538 61 420 –23 4.512 57 875 –22 4.486 54 555 –21 4.458 51 450 –20 4.429 48 536 –19 4.399 45 807 –18 4.368 43 247 –17 4.336 40 845 –16 4.303 38 592 –15 4.269 38 476 –14 4.233 34 489 –13 4.196 32 621 –12 4.158 30 866 –11 4.119 29 216 –10 4.079 27 633

–9 4.037 26 202 –8 3.994 24 827 –7 3.951 23 532 –6 3.906 22 313 –5 3.861 21 163 –4 3.814 20 079 –3 3.765 19 058 –2 3.716 18 094 –1 3.667 17 184

0 3.617 16 325 1 3.565 15 515 2 3.512 14 749 3 3.459 14 026 4 3.406 13 342 5 3.353 12 696 6 3.298 12 085 7 3.242 11 506 8 3.185 10 959

9 3.129 10 441 10 3.074 9 949 11 3.016 9 485 12 2.959 9 044 13 2.901 8 627 14 2.844 8 231 15 2.788 7 855 16 2.730 7 499 17 2.672 7 161 18 2.615 6 840 19 2.559 6 536 20 2.503 6 246 21 2.447 5 971 22 2.391 5 710 23 2.335 5 461 24 2.280 5 225 25 2.227 5 000 26 2.173 4 786 27 2.120 4 583 28 2.067 4 389 29 2.015 4 204 30 1.965 4 028 31 1.914 3 861 32 1.865 3 701 33 1.816 3 549 34 1.768 3 404 35 1.721 3 266 36 1.675 3 134 37 1.629 3 008

PIC II

VOLTAGE DROP (V )

RESISTANCE

(Ohms)

TEMPERATURE

(C)

38 1.585 2 888 39 1.542 2 773 40 1.499 2 663 41 1.457 2 559 42 1.417 2 459 43 1.377 2 363 44 1.338 2 272 45 1.300 2 184 46 1.263 2 101 47 1.227 2 021 48 1.192 1 944 49 1.158 1 871 50 1.124 1 801 51 1.091 1 734 52 1.060 1 670 53 1.029 1 609 54 0.999 1 550 55 0.969 1 493 56 0.941 1 439 57 0.913 1 387 58 0.887 1 337 59 0.861 1 290 60 0.835 1 244 61 0.811 1 200 62 0.787 1 158 63 0.764 1 118 64 0.741 1 079 65 0.719 1 041 66 0.698 1 006 67 0.677 971 68 0.657 938 69 0.638 906 70 0.619 876 71 0.601 836 72 0.583 805 73 0.566 775 74 0.549 747 75 0.533 719 76 0.518 693 77 0.503 669 78 0.488 645 79 0.474 623 80 0.460 602 81 0.447 583 82 0.434 564 83 0.422 547 84 0.410 531 85 0.398 516 86 0.387 502 87 0.376 489 88 0.365 477 89 0.355 466 90 0.344 456 91 0.335 446 92 0.325 436 93 0.316 427 94 0.308 419 95 0.299 410 96 0.291 402 97 0.283 393 98 0.275 385

99 0.267 376 100 0.260 367 101 0.253 357 102 0.246 346 103 0.239 335 104 0.233 324 105 0.227 312 106 0.221 299 107 0.215 285

PIC II

VOLTAGE DROP (V)

RESISTANCE

(Ohms)

Control Modules

Turn controller power off before servicing controls. This ensures safety and prevents damage to the controller.

The CVC/ICVC, CCM, and ISM modules perform continuous diagnostic evaluations of the hardware to determine its condition. Proper operation of all modules is indicated by LEDs (light-emitting diodes) located on the circuit board of the CVC/ICVC, CCM, and ISM.

There is one green LED located on the CCM and ISM boards respectively, and one red LED located on the CVC/ ICVC, CCM, and ISM boards respectively.

RED LED (Labeled as STAT) — If the red LED:

• blinks continuously at a 2-second interval, the mo dule is

operating properly

• is lit continuously, there is a problem that requires

replacing the module

• is off continuously, the power should be checked

• blinks 3 times per second, a software error has been dis-

covered and the module must be replaced

If there is no input power, check the fuses and circuit breaker. If the fuse is good, check for a shorted secondary of the transformer or, if power is present to the module, replace the module.

GREED LED (Labeled as COM) — These LEDs indicate the communication status between different parts of the controller and the network modules and should blink continuously .

Notes on Module Operation

1. The chiller operator monitors and modifies configurations in the microprocessor by using the 4 softkeys and the CVC/ICVC. Communications between the CVC/ ICVC and the CCM is accomplished through the SIO (Sensor Input/Output) bus, which is a phone cable. The communication between the CCM and ISM is accomplished through the sensor bus, which is a 3-wire cable.

2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED operation. If the red LED is normal, check the module address switches (SW1) (Fig. 40 and 41). Confirm all switches are in OFF position.

All system operating intelligence resides in the CVC/ ICVC. Some safety shutdown logic resides in the ISM in case commu nica tio ns ar e lo st bet wee n th e ISM and C VC/ ICVC. Outputs are controlled by the CCM and ISM as well.

3. Power is supplied to the modules within the control panel via 24-vac power sources.

The transformers are located within the power panel, with the exception of the ISM, which operates from a 115-vac power source and has its own 24-vac transformer located in the module.

In the power panel, T1 supplies power to the compressor oil heater, oil pump, and optional hot gas bypass, and T2 supplies power to both the CVC/ICVC and CCM.

Power is connected to Plug J1 on each module.

MODULE PART NUMBER SOFTWARE PART NUMBER

CVC/ICVC

J7 SIO J1 POWER/

CCN

J8 SERVICE

CCN INTERFACE CONNECTION

DATALINK OR DATAPORT MODULE (OPTION)

SW1BACK OF CVC

Fig. 40 — Rear of CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller)

Chiller Control Module (CCM) (Fig. 41)

INPUTS — Each input channel has 2 or 3 terminals. Refer t o individual chiller wiring diagrams for the correct terminal numbers for your application.

OUTPUTS — Output is 24 vac. There are 2 terminals per output. Refer to the chiller wiring diagram for your specific application for the correct terminal numbers.

Integrated Starter Module (Fig. 42)

INPUTS — Inputs on strips J3 through J6 are analog inputs and J2 is discrete (on/off) input. The specific application of the chiller determines which terminals are used. Refer to the individual chiller wiring diagram for the correct terminal numbers for your application.

OUTPUTS — Outputs are 115-277 vac and wired to strip J9. There are 2 terminals per output.

Replacing Defective Processor Modules —

The module replacement part number is printed on a small label on the rear of the CVC/ICVC module. The chiller model and serial numbers are printed on the chiller nameplate located on an exterior corner post. The proper software is factoryinstalled by Carrier in the replacement module. When ordering a replacement chiller visual control (CVC/ICVC) module, specify the complete replacement part number, full chiller model number, and chiller serial number. The installer must configure the new module to the original chiller data. Follow the procedures described in the Software Configuration section on page 55.

Electrical shock can cause personal injury. Disconnect all electrical power before servicing.

INSTALLATION

1. Verify the existing CVC/ICVC module is defective by using the procedure described in the Troubleshooting Guide section, page 76, and the Control Modules section, page 87. Do not select the ATTACH TO NETWORK DEVICE table if the CVC/ICVC indicates a communication failure.

2. Data regarding the CVC/ICVC configuration should have been recorded and saved. This data must be reconfigured into the new CV C/I C V C. I f t h is data is not availab le , f o llow the procedures described in the Software Configuration section.

If a CCN Building Supervisor or Service Tool is available, the module configuration should have already be en uploaded into memory. 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 CVC/ICVC module from uploading incorrect run hours into memory.

3. To install this module, record values for the TOTAL

COMPRESSOR STARTS and the COMPRESSOR ONTIME from the MAINSTAT screen on the CVC/

ICVC.

4. Power off the controls.

5. Remove the old CVC/ICVC.

6. Install the new CVC/ICVC module. Turn the control power back on.

7. The CV C/ICVC now automatically attaches to the local network device.

8. Access the M AINSTAT table and highlight the TOTAL COMPRESSOR STARTS parameter. Press the

softkey. Increase or decrease the value to match the starts value recorded in Step 3. Press the softkey

when you reach the correct value. Now, move the highlight bar to the COMPRESSOR ONTIME parameter. Press the softkey. Increase or decrease the run hours value to match the value recorded in Step 2. Press

the softkey when the correct value is reached.

9. Complete the CVC/ICVC installa tion. Followi ng the instructions in the Input Service Configurations section, page 55, input all the proper configurations such as the time, date, etc. Check the pressure transducer calibrations. PSIO installation is now complete.

Solid-State Starters —

taining to the Benshaw, Inc., solid-state starter may be found in the following paragraphs and in the Carrier RediStart MICRO™ Instruction Manual supplied by the starter vendor.

Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables found in the Benshaw manual.

1. M otor terminals or starter output lugs or wire should not be touched without disconnecting the incoming power supply. The silicon control rectifiers (SCRs) although technically turned off still have AC mains potential on the output of the starter.

2. Power is present on all yellow wiring throughout the system even though the main circuit brea ker in the unit is off.

With power of f:

• Inspect for physical damage and signs of arcing, overheating, etc.

• Verify the wiring to the starter is correct.

• Verify all connections in the starter are tight.

• Check the control transformer fuses.

TESTING SILICON CONTROL RECTIFIERS IN THE BENSHAW, INC., SOLID-STATE STARTERS — If an SCR is suspected of being defective, use the following procedure as part of a general troubleshooting guide.

1. Verify power is applied.

2. Verify the state of each SCR light-emitting diode (LED) on the micropower card.

NOTE: All LEDs should be lit. If any red or green side of these LEDs is not lit, the line voltage is not present or one or more SCRs has failed.

3. Check incoming power. If voltage is not present check the incoming line. If voltage is present, proceed to Steps 4 through 11.

NOTE: If after completing Steps 4 - 11 all measurements are within specified limits, the SCRs are functioning normally. If after completing Steps 4 - 11 resistance measurements are outside the specified limits, the motor leads on the starter power lugs T1 through T6 should be removed and the steps repeated. This will identify if abnormal resistance measurements are being influenced by the motor windings.

4. Remove power from the starter unit.

SELECT

ENTER

Troubleshooting information per-

SELECT

ENTER

ANALOG OUT

SIO

SW2

V/I INPUTS

J11

DISCRETE

OUTPUTS

J12

DISCRETE

OUTPUTS

SW1

24 VAC

INTERGRATED STARTER MODULE

ISM 19XR04012201 9925

CEPL13025901 PCB05

CEPP130173-03-04-01

00001328

1CR

DISCONNECT POWER BEFORE SERVICING

HIGH VOLTAGE

COMM THERMISTORS

STAT

TRIP

TRANS

SHUNT

WARNING

INTEGRATED STARTER MODULE

DIFF PRESSURE

Fig. 41 — Chiller Control Module (CCM)

PUMP

EVAP

PUMP COND

FAN

DISCRETE CONTROL CONTACTS

ALARM

TRIP

G + G +

SPARE VFD

4-20 MA OUT

PRESSURE

- G +

C B A

COMM

WARNING

HIGH VOLTAGE

STAT COM

DISCONNECT POWER BEFORE SERVICING

115 VAC

LL1

LL2

J11

CONTACT INPUTS

FUSE

SPAR ICE REM STRT 1M 2M SFTY BLD STRT FLT AUX AUX

+ C + C + C + C + C + C

Fig. 42 — Integrated Starter Module (ISM)

J3-1

LINE VOLTAGES

J3-2 J3-3

LINE CURRENTS

IL1

IL2 IL3

+ - + - + -

GROUND

FAULTS

1/4 2/5

3/6

+ G + G + G + G

VFD

5. Using an ohmmeter, perform the following resistance measureme nts and re cord th e re sul ts:

MEASURE BETWEEN

T1 and T6 3 and 6 T2 and T4 2 and 5 T3 and T5 1 and 4

SCR PAIRS

BEING

CHECKED

RECORDED

VAL UE

5. Using quarter-turn increments, alternating between clamping bolts, apply the appropriate number of whole turns referencing the table in Fig. 43.

Care must be taken to prevent nut rotation while tightening the bolts. If the nut rotates while tightening the bolt, SCR replacement must be started over.

If all measured values are greater t h an 5K ohms, proceed to Step 10. If any values are less than 5K ohms, one or more of the SCRs in that pair is shorted.

6. Remove both SCRs in the pair (See SCR Removal/ Installation).

7. Using an ohmmeter, measure the resistance (anode to cathode) of each SCR to determine which device has failed.

NOTE: Both SCRs may be defective, but typically, only one is shorted. If both SCRs provide acceptable resistance measurements, proceed to Step 10.

8. Replace the defective SCR(s).

9. Retest the “pair” for resistance values indicated above.

10. On the right side of the firing card, measure the resistance between the red and white gate/cathode leads for each SCR (1 through 6). A measurement between 5 and 50 ohms is normal. Abnormally high values may indicate a failed gate for that SCR.

If any red or white SCR gate leads are removed from the firing card or an SCR, care must be taken to ensure the leads are replaced EXACTLY as they were (white wires to gates, and red wires to cathodes on both the firing card and SCR), or damage to the starter and/or motor may result.

11. Replace the SCRs and retest the pair.

SCR REMOVAL/INSTALLATION — Refer to Fig. 43.

1. Remove the SCR by loosening the clamping bolts on each side of the SCR,

2. After the SCR has been removed and the bus work is loose, apply a thin coat of either silicon ba sed thermal joint compound or a joint compound for aluminum or copper wire connections to the contact surfaces of the replacement SCR. This allows for improved heat dissipation and electrical conductivity.

3. Place the SCR between the roll pins on the heatsink assemblies so the roll pins fit into the sm all holes in each side of the SCR.

NOTE: Ensure the SCR is installed so the cathode side is the side from which the red wire extends. The heatsink is labeled to show the correct orientation.

4. Hand tighten the bolts until the SCR contacts the heatsink.

6. Reconne ct the red (cathode) wire from the SCR and the white (anode-gate) wire to the appropriate location on the firing card (i.e., SCR1 wires to firing card terminal G1-white wire, and K1-red wire).

7. Reconnect all other wiring and bus work.

8. Return starter to normal operation.

NUT

CLAMPING BOLT

ALUMINUM HEATSINK

ROLL PIN

SCR

SCR PART

NUMBER

BISCR

6601218 1030

6601818 1030

8801230 1035

8801830 1035

15001850 2040

15001850 2050

220012100 Consult Benshaw Representative 330018500 Consult Benshaw Representative

CLAMP

SIZE

DIMENSION

(in.)

2.75

(70 mm)

2.75

(70 mm)

2.75

(70 mm)

2.75

(70 mm)

4.00

(102 mm)

4.00

(102 mm)

NO. OF TURNS

LENGTH

(102 mm)

(127 mm)

LOOSEN AND TIGHTEN BOLTS FROM THIS END

BOLT

(in.)

3.0

(76 mm)

3.0

(76 mm)

3.5

(89 mm)

3.0

(89 mm)

4.0

5.0

Fig. 43 — SCR Installation

Physical Data —

Tables 13A-20 and Fig. 44-57 provide additional information on component weights, compressor fits and clearances, physical and electrical data, a nd wiring schematics for t h e ope ra tor’s convenience during troubleshooting.

Table 13A — Heat Exchanger Data (English)

NUMBER OF TUBES

CODE

Cooler Condenser

10 142 180 2,742 2,704 290 200 34 42 11 161 200 2,812 2,772 310 200 37 45 12 180 225 2,883 2,857 330 200 40 49

15 142 180 3,003 2,984 320 250 39 48 16 161 200 3,089 3,068 340 250 43 52 17 180 225 3,176 3,173 370 250 47 57

20 200 218 3,442 3,523 345 225 48 48 21 240 266 3,590 3,690 385 225 55 55 22 282 315 3,746 3,854 435 225 62 63

30 200 218 4,137 3,694 350 260 55 55 31 240 267 4,319 3,899 420 260 64 65 32 280 315 4,511 4,100 490 260 72 74

35 200 218 4,409 4,606 400 310 61 62 36 240 267 4,617 4,840 480 310 70 72 37 280 315 4,835 5,069 550 310 80 83

40 324 370 5,898 6,054 560 280 89 96 41 364 417 6,080 6,259 630 280 97 106 42 400 463 6,244 6,465 690 280 105 114

45 324 370 6,353 6,617 640 330 98 106 46 364 417 6,561 6,851 720 330 108 117 47 400 463 6,748 7,085 790 330 116 127

50 431 509 7,015 7,285 750 400 115 128 51 485 556 7,262 7,490 840 400 126 137 52 519 602 7,417 7,683 900 400 133 136

5A 225 — 6,426 — 500 — 106 — 5B 241 — 6,499 — 520 — 109 — 5C 258 — 6,577 — 550 — 112 —

55 431 509 7,559 7,980 870 490 127 142 56 485 556 7,839 8,214 940 490 139 152 57 519 602 8,016 8,434 980 490 147 162

5F 225 — 6,879 — 550 — 116 — 5G 241 — 6,962 — 570 — 120 — 5H 258 — 7,050 — 600 — 124 —

60 557 648 8,270 8,286 940 420 144 159

61 599 695 8,462 8,483 980 420 153 168

62 633 741 8,617 8,676 1020 420 160 177

65 557 648 8,943 9,204 1020 510 160 176

66 599 695 9,161 9,428 1060 510 169 187

67 633 741 9,338 9,648 1090 510 177 197

70 644 781 12,395 13,139 1220 780 224 209

71 726 870 12,821 13,568 1340 780 243 229

72 790 956 13,153 13,969 1440 780 257 248

75 644 781 13,293 14,211 1365 925 245 234

76 726 870 13,780 14,702 1505 925 266 257

77 790 956 14,159 15,160 1625 925 283 278

80 829 990 16,156 15,746 1500 720 285 264

81 901 1080 16,530 16,176 1620 720 302 284

82 976 1170 16,919 16,606 1730 720 319 304

85 829 990 17,296 17,001 1690 860 313 295

86 901 1080 17,723 17,492 1820 860 331 318

87 976 1170 18,169 17,984 1940 860 351 341

NOTES:

1. Cooler data: based on a cooler with standard wall tubing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic grooves. Weight includes suction elbow, control panel, and distribution piping. Weight does not include compressor.

Dry (Rigging) Weight (lb) Chiller Charge

Cooler

Only

Condenser

Only

2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic grooves. Weight includes the float valve, discharge elbow, and distribution piping. Weight does not include unit-mounted starter, isolation valves, and pumpout unit.

ENGLISH

Refrigerant Weight (lb) Water Volume (gal)

Cooler Condenser Cooler Condenser

Table 13B — Heat Exchanger Data (SI)

NUMBER OF TUBES

CODE

Cooler Condenser

10 142 180 1244 1226 132 91 129 158 11 161 200 1275 1257 141 91 140 170 12 180 225 1307 1296 150 91 152 185

15 142 180 1362 1353 145 113 149 183 16 161 200 1401 1391 154 113 163 198 17 180 225 1440 1439 168 113 178 216

20 200 218 1561 1598 157 102 183 181 21 240 266 1628 1673 175 102 207 210 22 282 315 1699 1748 197 102 234 239

30 200 218 1876 1675 159 118 208 210 31 240 267 1958 1768 190 118 242 246 32 280 315 2046 1859 222 118 271 282

35 200 218 2000 2089 181 141 232 233 36 240 267 2094 2195 218 141 266 273 37 280 315 2193 2300 249 141 301 314

40 324 370 2675 2745 254 127 338 365 41 364 417 2757 2839 286 127 368 400 42 400 463 2832 2932 313 127 396 433

45 324 370 2881 3001 290 150 372 403 46 364 417 2976 3107 327 150 407 442 47 400 463 3060 3213 358 150 438 481

50 431 509 3181 3304 340 181 435 483 51 485 556 3293 3397 381 181 477 518 52 519 602 3364 3484 408 181 502 552

5A 225 — 2915 — 227 — 401 — 5B 241 — 2949 — 236 — 412 — 5C 258 — 2984 — 250 — 424 —

55 431 509 3428 3619 395 222 481 536 56 485 556 3555 3725 426 222 527 575 57 519 602 3635 3825 446 222 557 613

5F 225 — 3121 — 250 — 439 —

5G 241 — 3159 — 259 — 454 —

5H 258 — 3199 — 273 — 464 — 60 557 648 3751 3758 426 190 546 601

61 599 695 3838 3847 444 190 578 636 62 633 741 3908 3935 462 190 604 669

65 557 648 4056 4174 462 231 605 668 66 599 695 4155 4276 481 231 641 707 67 633 741 4235 4376 494 231 671 745

70 644 781 5622 5959 553 354 848 791 71 726 870 5814 6153 608 354 919 867 72 790 956 5965 6335 653 354 974 937

75 644 781 6028 6445 619 420 927 885 76 726 870 6259 6667 683 420 1009 971 77 790 956 6421 6875 737 420 1072 1052

80 829 990 7326 7141 680 327 1080 1000 81 901 1080 7496 7336 735 327 1143 1075 82 976 1170 7673 7531 785 327 1208 1150

85 829 990 7844 7710 766 390 1183 1118 86 901 1080 8037 7933 825 390 1254 1205 87 976 1170 8240 8156 880 390 1329 1291

NOTES:

1. Cooler data: based on a cooler with standard wall tubing, 2-pass, 1034 psig, nozzle-in-head waterbox with victaulic grooves. Weight includes suction elbow, control panel, and distribution piping. Weight does not include compressor.

Dry (Rigging) Weight (kg) Chiller Charge

Cooler

Only

Condenser

Only

Refrigerant Weight (kg) Water Volume (L)

Cooler Condenser Cooler Condenser

2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic grooves. Weight includes the float valve, discharge elbow, and distribution piping. Weight does not include unit-mounted starter, isolation valves, and pumpout unit.

Table 14 — 19XR Additional Data for Marine Waterboxes*

HEAT EXCHANGER

FRAME, PASS

FRAME 2, 1 AND 2 PASS 150 730 84 1034 331 318 FRAME 2, 2 PASS 150 365 42 1034 166 159 FRAME 3, 1 AND 2 PASS 150 730 84 1034 331 317 FRAME 3, 2 PASS 150 365 42 1034 166 159 FRAME 4, 1 AND 3 PASS 150 1060 123 1034 481 465 FRAME 4, 2 PASS 150 530 61 1034 240 231 FRAME 5, 1 AND 3 PASS 150 1240 139 1034 562 526 FRAME 5, 2 PASS 150 620 69 1034 281 263 FRAME 6, 1 AND 3 PASS 150 1500 162 1034 680 612 FRAME 6, 2 PASS 150 750 81 1034 340 306 FRAME 7, 1 AND 3 PASS 150 2010 326 1034 912 1234 FRAME 7, 2 PASS 150 740 163 1034 336 617 FRAME 8, 1 AND 3 PASS 150 1855 406 1034 841 1537 FRAME 8, 2 PASS 150 585 203 1034 265 768 FRAME 2, 1 AND 3 PASS 300 860 84 2068 390 318 FRAME 2, 2 PASS 300 430 42 2068 195 159 FRAME 3, 1 AND 3 PASS 300 860 84 2068 390 317 FRAME 3, 2 PASS 300 430 42 2068 195 159 FRAME 4, 1 AND 3 PASS 300 1210 123 2068 549 465 FRAME 4, 2 PASS 300 600 61 2068 272 231 FRAME 5, 1 AND 3 PASS 300 1380 139 2068 626 526 FRAME 5, 2 PASS 300 690 69 2068 313 263 FRAME 6, 1 AND 3 PASS 300 1650 162 2068 748 612 FRAME 6, 2 PASS 300 825 81 2068 374 306 FRAME 7, 1 AND 3 PASS 300 3100 326 2068 1406 1234 FRAME 7, 2 PASS 300 1830 163 2068 830 617 FRAME 8, 1 AND 3 PASS 300 2745 405 2068 1245 1533 FRAME 8, 2 PASS 300 1475 203 2068 766 768

*Add to heat exchanger data for total weights or volumes. NOTES:

1. Weight adder shown is the same for cooler and condenser of equal frame size.

2. For the total weight of a vessel with a marine waterbox, add these values to the heat exchanger weights (or volumes).

Psig

ENGLISH SI

Rigging Weight

(lb)

Water Volume

(gal)

kPa

Rigging Weight

(kg)

Water Volume

(L)

Table 15 — Compressor Weights

FRAME 2

COMPONENT

SUCTION ELBOW 50 23 54 24 175 79 175 79 400 181 DISCHARGE ELBOW 60 27 46 21 157 71 157 71 325 147 TRANSMISSION* 320 145 730 331 656 298 656 298 1000 454 SUCTION HOUSING 300 136 350 159 446 202 810 367 1200 544 IMPELLER SHROUD 35 16 80 36 126 57 200 91 250 113 COMPRESSOR BASE 1260 571 1050 476 1589 721 2022 917 3695 1676 DIFFUSER 35 16 70 32 130 59 130 59 300 136 OIL PUMP 125 57 150 68 150 68 150 68 185 84 MISCELLANEOUS 100 45 135 61 144 65 200 91 220 100 TOTAL WEIGHT

(Less Motor and Elbows)

*Transmission weight does not include rotor, shaft, and gear.

COMPRESSOR

WEIGHT

lb kg lb kg lb kg lb kg lb kg

2300 1043 2660 1207 3712 1684 4548 2063 6850 3107

FRAME 3

COMPRESSOR

WEIGHT

FRAME 4

COMPRESSOR

WEIGHT (Without

Split Ring Diffuser)

FRAME 4

COMPRESSOR

WEIGHT (With

Split Ring Diffuser)

FRAME 5

COMPRESSOR

WEIGHT

Table 16 — 19XR Motor Weights Standard and High Efficiency Motors

ENGLISH SI

MOTOR

SIZE

BD 1030 1030 240 240 185 467 467 109 109 84 BE 1070 1070 250 250 185 485 485 113 113 84 BF 1120 1120 265 265 185 508 508 120 120 84 BG 1175 1175 290 290 185 533 533 132 132 84 BH 1175 1175 290 290 185 533 533 132 132 84 CD 1286 1358 258 273 274 583 616 117 124 125 CE 1305 1377 265 281 274 592 625 120 127 125 CL 1324 1435 280 296 274 600 651 127 134 125 CM 1347 1455 303 303 274 611 660 137 137 125 CN 1358 1467 316 316 274 616 665 143 143 125 CP 1401 1479 329 316 274 635 671 149 143 125 CQ 1455 1479 329 316 274 660 671 149 152 125 DB 1665 1725 361 391 236 755 782 164 177 107 DC 1681 1737 391 404 236 762 788 177 183 107 DD 1977 2069 536 596 318 897 938 243 248 144 DE 2018 2089 550 550 318 915 948 249 248 144 DF 2100 2139 575 567 318 952 970 261 257 144 DG 2187 2153 599 599 318 992 977 272 272 144 DH 2203 2207 604 604 318 999 1001 274 274 144 DJ 2228 2305 614 614 318 1011 1046 279 279 144 EH 3060 3120 701 751 414 1388 1415 318 341 188 EJ 3105 3250 716 751 414 1408 1474 325 341 188 EK 3180 3250 716 768 414 1442 1474 325 348 188 EL 3180 3370 737 801 414 1442 1529 334 363 188 EM 3270 3370 737 801 414 1483 1529 334 363 188 EN 3270 3520 801 851 414 1483 1597 363 386 188 EP 3340 3520 830 851 414 1515 1597 376 386 188

*Stator weight includes stator and shell.

†Rotor weight includes rotor and shaft. NOTE: When different voltage motors have different weights the largest weight is given.

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)

Stator Weight*

(kg)

Rotor Weight†

(kg)

End Bell

Cover

(kg)

Table 17A — 19XR Waterbox Cover Weights — English (lb)

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig 177 204 320 350 320 350 NIH, 2 Pass Cover, 150 psig 185 218 320 350 320 350 NIH, 3 Pass Cover, 150 psig 180 196 300 340 300 340 NIH/MWB End Cover, 150 psig 136 136 300 300 300 300 NIH, 1 Pass Cover, 300 psig 248 301 411 486 411 486 NIH, 2 Pass Cover, 300 psig 255 324 411 518 411 518 NIH, 3 Pass Cover, 300 psig 253 288 433 468 433 468 NIH/MWB End Cover, 300 psig 175 175 400 400 400 400

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig 148 185 168 229 187 223 NIH, 2 Pass Cover, 150 psig 202 256 224 298 257 330 NIH, 3 Pass Cover, 150 psig 473 489 629 655 817 843 NIH/MWB End Cover, 150 psig 317 317 393 393 503 503 NIH, 1 Pass Cover, 300 psig 593 668 764 839 959 1035 NIH, 2 Pass Cover, 300 psig 594 700 761 878 923 1074 NIH, 3 Pass Cover, 300 psig 621 656 795 838 980 1031 NIH/MWB End Cover, 300 psig 569 569 713 713 913 913

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig 329 441 329 441 NIH, 2 Pass Cover, 150 psig 426 541 426 541 NIH, 3 Pass Cover, 150 psig 1202 1239 1113 1171 NIH/MWB End Cover, 150 psig 789 789 703 703 NIH, 1 Pass Cover, 300 psig 1636 1801 1472 1633 NIH, 2 Pass Cover, 300 psig 1585 1825 1410 1644 NIH, 3 Pass Cover, 300 psig 1660 1741 1496 1613 NIH/MWB End Cover, 300 psig 1451 1451 1440 1440

FRAME 1 FRAME 2 FRAME 3

Standard

Nozzles

Standard

Nozzles

FRAME 7 COOLER FRAME 7 CONDENSER

Standard

Nozzles

Flanged

FRAME 4 FRAME 5 FRAME 6

Flanged

Standard

Nozzles

Standard

Nozzles

Standard

Nozzles

Flanged

Standard

Nozzles

Flanged

HEAT

EXCHANGER

NIH, 1 Pass Cover, 150 psig 417 494 417 494 NIH, 2 Pass Cover, 150 psig 531 685 531 685 NIH, 3 Pass Cover, 150 psig 1568 1626 1438 1497

COOLER/

CONDENSER

LEGEND

NIH — Nozzle-in-Head MWB — Marine Waterbox

NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.

NIH/MWB End Cover, 150 psig 1339 1339 898 898 NIH, 1 Pass Cover, 300 psig 2265 2429 1860 2015 NIH, 2 Pass Cover, 300 psig 2170 2499 1735 2044 NIH, 3 Pass Cover, 300 psig 2273 2436 1883 1995 NIH/MWB End Cover, 300 psig 1923 1923 1635 1635

WATERBOX

DESCRIPTION

FRAME 8 COOLER FRAME 8 CONDENSER

Standard

Nozzles

Flanged

Standard

Nozzles

RIG MACHINE COMPONENTS — Refer to instructions below, Fig. 6-9, and Carrier Certified Prints for machine component disassembly.

Do not attempt to di sconnect flanges w hile the machi ne is IMPORTANT: Only a qualified service technician should perform this operation.

under pressure. Failure to relieve pressure can result in per-

sonal injury or damage to the unit.

Before rigging the compressor, disconnect all wires enter-

ing the power panel.

Flanged

Table 17B — 19XR Waterbox Cover Weights — SI (kg)

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

HEAT

EXCHANGER

COOLER/

CONDENSER

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig 80 93 145 159 145 159 NIH, 2 Pass Cover, 150 psig 84 99 145 159 145 159 NIH, 3 Pass Cover, 150 psig 82 89 136 154 140 154 NIH/MWB End Cover, 150 psig 62 62 136 136 136 136 NIH, 1 Pass Cover, 300 psig 112 137 186 220 186 220 NIH, 2 Pass Cover, 300 psig 116 147 186 235 186 235 NIH, 3 Pass Cover, 300 psig 115 131 196 212 196 212 NIH/MWB End Cover, 300 psig 79 79 181 181 181 181

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig 67 84 76 104 85 101 NIH, 2 Pass Cover, 150 psig 92 116 107 135 117 150 NIH, 3 Pass Cover, 150 psig 214 222 285 297 371 382 NIH/MWB End Cover, 150 psig 144 144 178 178 228 228 NIH, 1 Pass Cover, 300 psig 269 303 347 381 435 470 NIH, 2 Pass Cover, 300 psig 269 317 345 398 419 487 NIH, 3 Pass Cover, 300 psig 282 298 361 380 445 468 NIH/MWB End Cover, 300 psig 258 258 323 323 414 414

WATERBOX

DESCRIPTION

NIH, 1 Pass Cover, 150 psig 149 200 149 200 NIH, 2 Pass Cover, 150 psig 193 245 193 245 NIH, 3 Pass Cover, 150 psig 545 562 505 531 NIH/MWB End Cover, 150 psig 357 358 319 319 NIH, 1 Pass Cover, 300 psig 742 817 668 741 NIH, 2 Pass Cover, 300 psig 719 828 640 746 NIH, 3 Pass Cover, 300 psig 753 790 679 732 NIH/MWB End Cover, 300 psig 658 658 653 653

FRAME 1 FRAME 2 FRAME 3

Standard

Nozzles

Standard

Nozzles

FRAME 7 COOLER FRAME 7 CONDENSER

Standard

Nozzles

Flanged

FRAME 4 FRAME 5 FRAME 6

Flanged

Standard

Nozzles

Standard

Nozzles

Standard

Nozzles

Flanged

Standard

Nozzles

Standard

Nozzles

Flanged

HEAT

EXCHANGER

NIH, 1 Pass Cover, 150 psig 189 224 189 224 NIH, 2 Pass Cover, 150 psig 241 311 241 311 NIH, 3 Pass Cover, 150 psig 711 738 652 679

COOLER/

CONDENSER

LEGEND

NIH — Nozzle-in-Head MWB — Marine Waterbox

NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.

NIH/MWB End Cover, 150 psig 607 607 407 407 NIH, 1 Pass Cover, 300 psig 1027 1102 844 914 NIH, 2 Pass Cover, 300 psig 984 1134 787 927 NIH, 3 Pass Cover, 300 psig 1031 1105 854 905 NIH/MWB End Cover, 300 psig 872 872 742 742

WATERBOX

DESCRIPTION

FRAME 8 COOLER FRAME 8 CONDENSER

Standard

Nozzles

Flanged

Standard

Nozzles

Flanged

Table 18 — 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

Table 19 — Additional Miscellaneous Weights

ITEM Lb Kg CONTROL CABINET 30 14 UNIT-MOUNTED STARTER 500 227 OPTIONAL ISOLATION VALVES 115 52 UNIT MOUNTED VFD 1000 454

VFD — Variable Frequency Drive

LRA

Table 20 — Motor Voltage Code

MOTOR VOLTAGE CODE

Code Volts Frequency

60 200 60 61 230 60 62 380 60 63 416 60 64 460 60 65 575 60 66 2400 60 67 3300 60 68 4160 60 69 6900 60 50 230 50 51 346 50 52 400 50 53 3000 50 54 3300 50 55 6300 50

COMPRESSOR, TRANSMISSION AREA

Compressor Assembly Torques

LOW SPEED SHAFT THRUST DISK

VIEW A

Fig. 44 — Compressor Fits and Clearances

ITEM DESCRIPTION

1* Oil Heater Retaining Nut 20 28 2 Bull Gear Retaining Bolt 80-85 108-115 3 Demister Bolts 15-19 20-26 4 Impeller Retaining Bolt 44-46 60-62 5* Motor Terminals (Low Voltage) 50 68 6* Guide Vane Shaft Seal Nut 25 34 7* Motor Terminals (High Voltage)

— Insulator 2-4 2.7-5.4 — Packing Nut 5 6.8 — Brass Jam Nut 10 13.6

LEGEND

N•m — Newton meters

*Not shown.

NOTES:

1. All clearances for cylindrical surfaces are diametrical.

2. Dimensions are with rotor in thrust position.

3. Dimensions shown are in inches.

4. Impeller spacing should be performed in accordance with most recent Carrier Service Bulletin on impeller spacing.

TORQUE

ft.-lb N•m

VIEW B — HIGH SPEED SHAFT

19XR COMPRESSOR CLEARANCES

ITEM

G —* —* —* —*

*Depends on impeller size, contact your Carrier Service Representative for more information. NOTE: All clearances for cylindrical surfaces are diametrical.

221-299 321-389 421-489 521-599

.0050 .0040

.0115 .0055

.0190 .0040

–.002 –.0005

.0050 .0040

COMPRESSOR CODE

.0050 .0040

.0115 .0080

.022 .012

–.0020 –.0005

.0050 .0040

Fig. 44 — Compressor Fits and Clearances (cont)

.0055 .0043

.0053 .0043

.0100 .0050

.027 .017

–.0029 –.0014

.0048 .0038

.0069 .0059

.0065 .0055

.0010 .0060

.0350 .0250

–.0019 –.0005

.0062 .0052

100

Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter

Carrier XRV, EVERGREEN 19XR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual