19xrt hermetic centrifugal liquid chillers

Start-Up, Operation, and Maintenance InstructionsSAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safeand reliable service when operated within design speci-fications. When operating this equipment, use good judg-ment and safety precautions to avoid damage to equip-ment and property or injury to personnel.Be sure you understand and follow the procedures and

safety precautions contained in the chiller instructionsas well as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outletfrom rupture disc or relief valve must be vented outdoors in ac-cordance with the latest edition of ANSI/ASHRAE 15 (AmericanNational Standards Institute/American Society of Heating, Refrig-eration, and Air Conditioning Engineers). The accumulation of re-frigerant in an enclosed space can displace oxygen and causeasphyxiation.PROVIDE adequate ventilation in accordance with ANSI/ASHRAE15, especially for enclosed and low overhead spaces. Inhalation ofhigh concentrations of vapor is harmful and may cause heart ir-regularities, unconsciousness, or death. Misuse can be fatal. Vaporis heavier than air and reduces the amount of oxygen available forbreathing. Product causes eye and skin irritation. Decompositionproducts are hazardous.DO NOT USE OXYGEN to purge lines or to pressurize a chillerfor any purpose. Oxygen gas reacts violently with oil, grease, andother common substances.NEVER EXCEED specified test pressures, VERIFY the allowabletest pressure by checking the instruction literature and the designpressures on the equipment nameplate.DO NOT USE air for leak testing. Use only refrigerant or drynitrogen.DO NOT VALVE OFF any safety device.BE SURE that all pressure relief devices are properly installed andfunctioning before operating any chiller.

DO NOT WELD OR FLAMECUT any refrigerant line or vesseluntil all refrigerant(liquid and vapor)has been removed from chiller.Traces of vapor should be displaced with dry air or nitrogen andthe work area should be well ventilated.Refrigerant in contact withan open flame produces toxic gases.DO NOT USE eyebolts or eyebolt holes to rig chiller sections orthe entire assembly.DO NOT work on high-voltage equipment unless you are a quali-fied electrician.DO NOTWORKON electrical components, including control pan-els, switches, starters, or oil heater until you are sure ALL POWERIS OFF and no residual voltage can leak from capacitors or solid-state components.LOCKOPENANDTAGelectrical circuits during servicing. IFWORKIS INTERRUPTED, confirm that all circuits are deenergized be-fore resuming work.AVOID SPILLING liquid refrigerant on skin or getting it into theeyes. USE SAFETY GOGGLES. Wash any spills from the skinwith soap and water. If liquid refrigerant enters the eyes, IMME-DIATELY FLUSH EYES with water and consult a physician.NEVER APPLY an open flame or live steam to a refrigerant

cylinder. Dangerous over pressure can result. When it is necessaryto heat refrigerant, use only warm (110 F [43 C]) water.DO NOT REUSE disposable (nonreturnable) cylinders orattempt to refill them. It is DANGEROUS AND ILLEGAL. Whencylinder is emptied, evacuate remaining gas pressure, loosenthe collar and unscrew and discard the valve stem. DO NOTINCINERATE.CHECK THE REFRIGERANT TYPE before adding refrigerant tothe chiller. The introduction of the wrong refrigerant can cause dam-age or malfunction to this chiller.Operation of this equipment with refrigerants other than those

cited herein should comply with ANSI/ASHRAE 15 (latest edi-tion). Contact Carrier for further information on use of this chillerwith other refrigerants.DONOTATTEMPTTOREMOVE fittings, covers, etc., while chilleris under pressure or while chiller is running. Be sure pressure is at0 psig (0 kPa) before breaking any refrigerant connection.CAREFULLY INSPECT all relief devices, rupture discs, and otherrelief devices AT LEAST ONCE A YEAR. If chiller operates in acorrosive atmosphere, inspect the devices at more frequentintervals.DO NOT ATTEMPT TO REPAIR OR RECONDITION any reliefdevice when corrosion or build-up of foreign material (rust, dirt,scale, etc.) is found within the valve body or mechanism. Replacethe device.DO NOT install relief devices in series or backwards.USE CAREwhen working near or in line with a compressed spring.Sudden release of the spring can cause it and objects in its path toact as projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip aboutand 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 ormove inspection covers or other heavy components. Even if com-ponents are light, use mechanical equipment when there is a risk ofslipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN EN-GAGE THE STARTER, TOWER FAN, OR PUMPS. Open the dis-connectahead ofthe starter, tower fans, or pumps.

USE only repair or replacement parts that meet the code require-ments of the original equipment.

DONOTVENTORDRAINwaterboxes containing industrial brines,liquid, gases, or semisolids without the permission of your processcontrol group.

DO NOT LOOSEN waterbox cover bolts until the waterbox hasbeen completely drained.DOUBLE-CHECK that coupling nut wrenches, dial indicators, orother items have been removed before rotating any shafts.

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

PERIODICALLY INSPECT all valves, fittings, and piping for cor-rosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pres-sure relief device to prevent a build-up of condensate or rainwater.

19XRTHermetic Centrifugal Liquid Chillers

50/60 Hzwith PIC II Controls and HFC-134a

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.Book 2Tab 5a

PC 211 Catalog No. 531-977 Printed in U.S.A. Form 19XRT-2SS Pg 1 11-98 Replaces: New

CONTENTSPage

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . 5-7Chiller Information Plate . . . . . . . . . . . . . . . . . . . . . . 5System Components . . . . . . . . . . . . . . . . . . . . . . . . . 5Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Factory-Mounted Starter (Optional) . . . . . . . . . . . . 7Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . 7REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . 7MOTOR AND LUBRICATING OILCOOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 7

LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . 7-9Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . 9• PRIMARY OIL RECOVERY MODE• SECONDARY OIL RECOVERY MODESTARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . .10,11Unit-Mounted Solid-State Starter (Optional) . . . 10Unit-Mounted Wye-Delta Starter (Optional) . . . . 11CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11• ANALOG SIGNAL• DISCRETE SIGNALGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PIC II System Components . . . . . . . . . . . . . . . . . . 11• CHILLER VISUAL CONTROLLER (CVC)• 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)CVC Operation and Menus . . . . . . . . . . . . . . . . . . 15• GENERAL• ALARMS AND ALERTS• CVC MENU ITEMS• BASIC CVC OPERATIONS (Using the Softkeys)• TO VIEW STATUS• OVERRIDE OPERATIONS• TIME SCHEDULE OPERATION• TO VIEW AND CHANGE SET POINTS• SERVICE OPERATIONPIC II System Functions . . . . . . . . . . . . . . . . . . . . . 33• CAPACITY CONTROL• ECW CONTROL OPTION• CONTROL POINT DEADBAND• PROPORTIONAL BANDS AND GAIN• CHILLER TIMERS• OCCUPANCY SCHEDULESafety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 36Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . 36Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Page

Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . 36High Discharge Temperature Control . . . . . . . . . 36Oil Sump Temperature Control . . . . . . . . . . . . . . . 36Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . 37Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 37Spare Safety Alarm Contacts . . . . . . . . . . . . . . . . 37Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . 37Condenser Pump Control . . . . . . . . . . . . . . . . . . . . 37Condenser Freeze Prevention . . . . . . . . . . . . . . . . 38Tower-Fan Relay Low and High . . . . . . . . . . . . . . 38Auto. Restart After Power Failure . . . . . . . . . . . . 38Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 38• RESET TYPE 1• RESET TYPE 2• RESET TYPE 3Demand Limit Control Option . . . . . . . . . . . . . . . . 39Surge Prevention Algorithm . . . . . . . . . . . . . . . . . 39Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 40• COMMON POINT SENSOR INSTALLATION• CHILLER COMMUNICATION WIRING• LEAD/LAG OPERATION• FAULTED CHILLER OPERATION• LOAD BALANCING• AUTO. RESTART AFTER POWER FAILUREIce Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42• ICE BUILD INITIATION• START-UP/RECYCLE OPERATION• TEMPERATURE CONTROL DURING ICE BUILD• TERMINATION OF ICE BUILD• RETURN TO NON-ICE BUILD OPERATIONSAttach to Network Device Control . . . . . . . . . . . . 43• ATTACHING TO OTHER CCN MODULESService Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 44• TO ACCESS THE SERVICE SCREENS• TO LOG OUT OF NETWORK DEVICE• HOLIDAY SCHEDULINGSTART-UP/SHUTDOWN/RECYCLESEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45,46

Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . 46Automatic Soft Stop Amps Threshold . . . . . . . . 46Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . 46Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46BEFORE INITIAL START-UP . . . . . . . . . . . . . . . .47-59Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . 47Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . 47Using the Optional Storage Tankand Pumpout System . . . . . . . . . . . . . . . . . . . . . 47

Remove Shipping Packaging . . . . . . . . . . . . . . . . 47Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . 47Tighten All Gasketed Joints and

Guide Vane Shaft Packing . . . . . . . . . . . . . . . . 47Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . 47Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . 49Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . 52Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . 52Check Optional Pumpout CompressorWater Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . 52Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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CONTENTS (cont)Page

Carrier Comfort Network Interface . . . . . . . . . . . 53Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53• MECHANICAL STARTER• BENSHAW, INC. REDISTART MICROSOLID-STATE STARTER

Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Power Up the Controls andCheck the Oil Heater . . . . . . . . . . . . . . . . . . . . . . 54

• SOFTWARE VERSIONSoftware Configuration . . . . . . . . . . . . . . . . . . . . . . 54Input the Design Set Points . . . . . . . . . . . . . . . . . . 54Input the Local Occupied Schedule(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Input Service Configurations . . . . . . . . . . . . . . . . 54• PASSWORD• INPUT TIME AND DATE• CHANGE CVC CONFIGURATION IF NECESSARY• TO CHANGE THE PASSWORD• TO CHANGE THE CVC DISPLAY FROM ENGLISHTO METRIC UNITS

• MODIFY CONTROLLER IDENTIFICATIONIF NECESSARY

• INPUT EQUIPMENT SERVICE PARAMETERS IFNECESSARY

• MODIFY EQUIPMENT CONFIGURATIONIF NECESSARY

Perform A Control Test . . . . . . . . . . . . . . . . . . . . . . 57• COOLER AND CONDENSER PRESSURETRANSDUCER AND WATERSIDE FLOWDEVICE CALIBRATION

Check Optional Pumpout SystemControls and Compressor . . . . . . . . . . . . . . . . . 57

High Altitude Locations . . . . . . . . . . . . . . . . . . . . . 57Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . 58• CHILLER EQUALIZATION WITHOUTPUMPOUT UNIT

• CHILLER EQUALIZATION WITHPUMPOUT UNIT

• TRIMMING REFRIGERANT CHARGEINITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . .59,60Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Dry Run to Test Start-Up Sequence . . . . . . . . . . 59Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . 59• IF THE MOTOR ROTATION IS CLOCKWISE• IF THE MOTOR ROTATION IS NOT CLOCKWISECheck Oil Pressure and Compressor Stop . . . . 60To Prevent Accidental Start-Up . . . . . . . . . . . . . . 60Check Chiller Operating Condition . . . . . . . . . . . 60Instruct the Customer Operator . . . . . . . . . . . . . . 60• COOLER-CONDENSER• OPTIONAL STORAGE TANK ANDPUMPOUT SYSTEM

• MOTOR COMPRESSOR ASSEMBLY• MOTOR COMPRESSOR LUBRICATION SYSTEM• CONTROL SYSTEM• AUXILIARY EQUIPMENT• DESCRIBE CHILLER CYCLES• REVIEW MAINTENANCE• SAFETY DEVICES AND PROCEDURES• CHECK OPERATOR KNOWLEDGE• REVIEW THE START-UP, OPERATION,AND MAINTENANCE MANUAL

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . .60-62Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Prepare the Chiller for Start-Up . . . . . . . . . . . . . . 60To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 60Check the Running System . . . . . . . . . . . . . . . . . . 60To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 61After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . 61

PagePreparation for Extended Shutdown . . . . . . . . . . 61After Extended Shutdown . . . . . . . . . . . . . . . . . . . 61Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . 61Manual Guide Vane Operation . . . . . . . . . . . . . . . 61Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 61PUMPOUT AND REFRIGERANT TRANSFERPROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . .63-65

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Operating the Optional PumpoutUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

• TO READ REFRIGERANT PRESSURESChillers with Storage Tanks . . . . . . . . . . . . . . . . . . 64• TRANSFER REFRIGERANT FROM PUMPOUTSTORAGE TANK TO CHILLER

• TRANSFER THE REFRIGERANT FROMCHILLER TO PUMPOUT STORAGE TANK

Chillers with Isolation Valves . . . . . . . . . . . . . . . . 65• TRANSFER ALL REFRIGERANT TO CHILLERCONDENSER VESSEL

• TRANSFER ALL REFRIGERANT TO CHILLERCOOLER VESSEL

• RETURN REFRIGERANT TO NORMALOPERATING CONDITIONS

GENERAL MAINTENANCE . . . . . . . . . . . . . . . . .66,67Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . 66Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 66Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 66Adjusting the Refrigerant Charge . . . . . . . . . . . . 66Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . 66Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Test After Service, Repair, or Major Leak . . . . . 66• REFRIGERANT TRACER• TO PRESSURIZE WITH DRY NITROGENRepair the Leak, Retest, and ApplyStanding Vacuum Test . . . . . . . . . . . . . . . . . . . . 66

Checking Guide Vane Linkage . . . . . . . . . . . . . . . 66Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . 66WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . 67Check the Lubrication System . . . . . . . . . . . . . . . 67SCHEDULED MAINTENANCE . . . . . . . . . . . . . .67-71Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . 67Check Safety and Operating ControlsMonthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 67Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68• TO CHANGE THE OILRefrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Inspect Refrigerant Float System . . . . . . . . . . . . 68Inspect Relief Valves and Piping . . . . . . . . . . . . . 68Turbine Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Turbine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 68Compressor Bearing and Gear Maintenance . . 68Inspect the Heat Exchanger Tubes and FlowDevices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

• COOLER AND FLOW DEVICES• CONDENSER AND FLOW DEVICESWater Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Inspect the Starting Equipment . . . . . . . . . . . . . . 70Check Pressure Transducers . . . . . . . . . . . . . . . . 70Optional Pumpout System Maintenance . . . . . . 70• OPTIONAL PUMPOUT COMPRESSOR OILCHARGE

• OPTIONAL PUMPOUT SAFETY CONTROLSETTINGS

3

CONTENTS (cont)Page

Ordering Replacement Chiller Parts . . . . . . . . . . 71TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . .71-97Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Checking the Display Messages . . . . . . . . . . . . . 71Checking Temperature Sensors . . . . . . . . . . . . . . 71• RESISTANCE CHECK• VOLTAGE DROP• CHECK SENSOR ACCURACY• DUAL TEMPERATURE SENSORSChecking Pressure Transducers . . . . . . . . . . . . . 72• TRANSDUCER REPLACEMENTControl Algorithms Checkout Procedure . . . . . 72Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82• RED LED (Labeled as STAT)• GREEN LED (Labeled as COM)Notes on Module Operation . . . . . . . . . . . . . . . . . . 82

PageChiller Control Module (CCM) . . . . . . . . . . . . . . . . 83• INPUTS• OUTPUTSIntegrated Starter Module (ISM) . . . . . . . . . . . . . . 83• INPUTS• OUTPUTSReplacing Defective Processor Modules . . . . . . 83• INSTALLATIONSolid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . 83• TESTING SILICON CONTROL RECTIFIERS INBENSHAW, INC., SOLID-STATE STARTERS

• SCR REMOVAL/INSTALLATIONPhysical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98INITIAL START-UP CHECKLIST FOR19XRT HERMETIC CENTRIFUGALLIQUID CHILLER . . . . . . . . . . . . . . . . .CL-1 to CL-12

INTRODUCTIONPrior to initial start-up of the 19XRT chiller, those in-

volved in the start-up, operation, and maintenance should bethoroughly familiar with these instructions and other nec-essary job data. This book is outlined to familiarize thoseinvolved in the start-up, operation and maintenance of theunit with the control system before performing start-up pro-cedures. Procedures in this manual are arranged in the se-quence required for proper chiller start-up and operation.

This unit uses a microprocessor control system. Do notshort or jumper between terminations on circuit boardsor modules. Control or board failure may result.Be aware of electrostatic discharge (static electricity)

when handling or making contact with circuit boards ormodule connections. Always touch a chassis (grounded)part to dissipate body electrostatic charge before work-ing inside control center.Useextremecarewhenhandling tools near circuit boards

and when connecting or disconnecting terminal plugs.Circuit boards can be damaged easily. Always hold boardsby the edges, and avoid touching components andconnections.This equipment uses, and can radiate, radio fre-

quency energy. If not installed and used in accordancewith the instruction manual, it may interfere with radiocommunications. This equipment has been tested andfound to comply with the limits for a Class A comput-ing device pursuant to Subpart J of Part 15 of FCCRules,which are designed to provide reasonable protection againstsuch interference when operated in a commercial envi-ronment. Operation of this equipment in a residentialarea is likely to cause interference, in which case theuser, at his own expense, will be required to takewhatever measures may be required to correct theinterference.Always store and transport replacement or defective

boards in an anti-static shipping bag.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:CCM — Chiller Control ModuleCCN — Carrier Comfort NetworkCVC — Chiller Visual ControlCCW — CounterclockwiseCW — ClockwiseECDW — Entering Condenser WaterECW — Entering Chilled WaterEMS — Energy Management SystemHGBP — Hot Gas BypassI/O — Input/OutputISM — Integrated Starter ModuleLCD — Liquid Crystal DisplayLCDW — Leaving Condenser WaterLCW — Leaving Chilled WaterLED — Light-Emitting DiodeOLTA — Overload Trip AmpsPIC II — Product Integrated Control IIRLA — Rated Load AmpsSCR — Silicon Controlled RectifierSI — International System of UnitsTXV — Thermostatic Expansion Valve

Words printed in all capital letters or in italicsmay be viewedon the Chiller Visual Control (CVC) (e.g., LOCAL, CCN,ALARM, etc.).Words printed inbothall capital letters and italics can also

be viewed on the CVC and are parameters (e.g.,CONTROLMODE, COMPRESSOR START RELAY, ICE BUILDOPTION,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 control panel (e.g., ENTER,

EXIT , INCREASE , QUIT , etc.).Factory-installed additional components are referred to as

options in this manual; factory-supplied but field-installedadditional components are referred to as accessories.The chiller software part number of the 19XRT unit is lo-

cated on the back of the CVC.

4

CHILLER FAMILIARIZATION(Fig. 1 and 2)

Chiller Information Plate— The information plate islocated on the right side of the chiller control panel.

System Components — The components include thecooler and condenser heat exchangers in separate vessels,motor-compressor, turbine, lubrication package, control panel,and motor starter. All connections from pressure vessels haveexternal threads to enable each component to be pressuretested with a threaded pipe cap during factory assembly.

Cooler — This vessel (also known as the evaporator) islocated underneath the compressor. The cooler is main-tained at lower temperature/pressure so evaporating refrig-erant can remove heat from water flowing through its inter-nal tubes.

Condenser — The condenser operates at a highertemperature/pressure than the cooler and has water flowingthrough its internal tubes in order to remove heat from therefrigerant.

Motor-Compressor— This component maintains sys-tem temperature and pressure differences andmoves the heat-carrying refrigerant from the cooler to the condenser.

Turbine— The turbine serves 2 purposes. First, it acts asthe expansion device to separate condenser pressure fromcooler pressure. Second, using the pressure differential be-tween the cooler and condenser, the turbine converts thepressure drop to energy and uses this energy to supplementthe compressor motor, thereby reducing the requiredhorsepower.

Control Panel — The control panel is the user interfacefor controlling the chiller. It regulates the chiller’s capacityas required to maintain proper leaving chilled water tem-perature. The control panel:• registers cooler, condenser, and lubricating systempressures

• shows chiller operating condition and alarm shutdownconditions

• records the total chiller operating hours• sequences chiller start, stop, and recycle under micro-processor control

• displays status of motor starter• provides access to other CCN (Carrier Comfort Network)devices

Fig. 1 — 19XRT Identification

5

321 1514

2122 1720 18

13124 5 6 1110987

19

16

1716

LEGEND

1 — Turbine Housing2 — Power Panel3 — Motor Housing4 — Oil Level Sight Glasses5 — Guide Vane Actuator6 — Demistor Vent Line7 — Suction Elbow8 — Chiller Visual Control (CVC)9 — Condenser Pumpout Connection (Hidden)10 — Condenser Relief Valves11 — Relief Transfer Valve12 — Condenser Pressure Transducer (Hidden)13 — Cooler Relief Valve14 — Cooler Pressure Transducer (Hidden)15 — Cooler Pumpout Connection16 — Cooler/Condenser Waterflow Device

17 — Condenser In/Out TemperatureThermistors

18 — Cooler In/Out Temperature Thermistors19 — Chiller Identification Nameplate

Location20 — Float Chamber21 — Refrigerant Charging Valve22 — Oil Drain Charging Valve

2930

2423 2625

28

27

31

LEGEND

23 — Take-Apart, Connector (Upper)24 — Waterbox Vent Connection (Typical)25 — Cooler Liquid Return Line26 — Oil Filter Access Cover27 — Refrigerant Oil Cooler28 — Take-Apart, Rabbet-Fit Connector

(Lower)29 — Cooler Return-End Waterbox Cover30 — Waterbox Drain Port (Typical)31 — Condenser Return-End Waterbox Cover

1

23

5 6 7

891011

12

4 LEGEND

1 — Turbine Suction2 — Nozzle (Typical, 1 of 6 Shown)3 — Nozzle Block4 — High Efficiency Motor5 — Transmission6 — Compressor Base7 — Guide Vane Actuator8 — Oil Filter Housing9 — Turbine Wheel10 — Turbine Housing11 — Turbine Discharge12 — Turbine Sight Glass

TURBINE COMPONENTS

Fig. 2 — Typical 19XRT Components

RIGHT END VIEW

LEFT END VIEW

6

Factory-Mounted Starter (Optional)— The starterallows for the proper start and disconnect of electrical en-ergy for the compressor-motor, oil pump, oil heater, and con-trol panel.

Storage Vessel (Optional) — There are 2 sizes ofstorage vessels available. The vessels have double relief valves,a magnetically-coupled dial-type refrigerant level gage, aone-inch FPT drain valve, and a1⁄2-in. male flare vaporconnection for the pumpout unit.NOTE: If a storage vessel is not used at the jobsite, factory-installed isolation valves on the chiller may be used to iso-late the chiller charge in either the cooler or condenser.An optional pumpout system is used to transfer refrigerantfrom vessel to vessel.

REFRIGERATION CYCLEThe compressor continuously draws refrigerant vapor from

the cooler, at a rate set by the amount of guide vane opening(Fig. 3). As the compressor suction reduces the pressure inthe cooler, the remaining refrigerant boils at a fairly low tem-perature (typically 38 to 42 F [3 to 6 C]). The energy re-quired for boiling is obtained from the water flowing throughthe cooler tubes. With heat energy removed, the water be-comes cold enough for use in an air conditioning circuit orprocess liquid cooling.After taking heat from the water, the refrigerant vapor is

compressed. Compression adds still more heat energy andthe refrigerant is quite warm (typically 98 to 102 F[37 to 40 C]) when it is discharged from the compressor intothe condenser.Relatively cool (typically 65 to 90 F [18 to 32 C]) water

flowing through the condenser tubes removes heat from therefrigerant, and the vapor condenses to a liquid. Further re-moval of heat from the refrigerant occurs in the lower cham-ber of the condenser, which is called the sensible subcooler.At this point, the liquid refrigerant is subcooled by contactwith the coolest (entering water) condenser tubes.After leaving the sensible subcooler section of the con-

denser, the liquid refrigerant enters the float valve chamber.The main float valve maintains a liquid level in the sub-cooler to prevent hot gas bypass from the condenser to thecooler at part load conditions. A second valve in the floatvalve chamber opens at part load conditions when the liquidlevel increases in the condenser to bypass liquid from thefloat chamber directly to the cooler inlet. The liquid refrig-erant from the main float valve then flows into the turbinehousing chamber on the compressor. The liquid refrigerantpasses through the turbine nozzles and impacts the turbineblades where energy is reclaimed as the refrigerant expandsthrough the turbine to the lower cooler pressure. The turbinewheel is attached to the motor shaft which allows the turbineto supplement and reduce motor power requirements. At thispoint the refrigerant flashes to a mixture of gas and liquidwhich removes heat from the remaining liquid. This mixtureflows back to the cooler where it is now at the same tem-perature and pressure at which the cycle began.

MOTOR AND LUBRICATING OILCOOLING CYCLE

The motor and the lubricating oil are cooled by liquid re-frigerant taken from the bottom of the condenser vessel(Fig. 3). Refrigerant flow is maintained by the pressure

differential that exists due to compressor operation. After therefrigerant flows past an isolation valve, an in-linefilter, and a sight glass/moisture indicator, the flow is splitbetween the motor cooling and oil cooling systems.Flow to the motor cooling system passes through an ori-

fice and into the motor. Once past the orifice, the refrigerantis directed over the motor by a spray nozzle. The refrigerantcollects in the bottom of the motor casing and is then drainedback into the cooler through the motor refrigerant drain line.The refrigerant outlet from the motor casing is sized to actas an orifice to maintain a higher pressure in the motor shellthan in the cooler/oil sump. The motor is protected by a tem-perature sensor imbedded in the stator windings. An in-crease in motor winding temperature past the motor overrideset point overrides the temperature capacity control to hold,and if the motor temperature rises 10° F (5.5° C) above thisset point, closes the inlet guide vanes. If the temperature risesabove the safety limit, the compressor shuts down.Refrigerant that flows to the oil cooling system is regu-

lated by thermostatic expansion valves (TXVs). The TXVsregulate flow into the oil/refrigerant plate and frame-type heatexchanger (the oil cooler in Fig. 3). The expansion valvebulbs control oil temperature to the bearings. The refrigerantleaving the oil cooler heat exchanger then returns to the chillercooler.

LUBRICATION CYCLE

Summary— The oil pump, oil filter, and oil cooler makeup a package located partially in the transmission casting ofthe compressor-motor-turbine assembly. The oil is pumpedinto a filter assembly to remove foreign particles and is thenforced into an oil cooler heat exchanger where the oil is cooledto proper operational temperatures. After the oil cooler, partof the flow is directed to the gears and the high speed shaftbearings; the remaining flow is directed to the motor shaftbearings. Oil drains into the transmission oil sump to com-plete the cycle (Fig. 4).

Details— Oil is charged into the lubrication system througha hand valve. Two sight glasses in the oil reservoir permit oillevel observation. Normal oil level is between the middle ofthe upper sight glass and the top of the lower sight glasswhen the compressor is shut down. The oil level should bevisible in at least one of the 2 sight glasses during operation.Oil sump temperature is displayed on the CVC (ChillerVisual Control) default screen. During compressor opera-tion, the oil sump temperature ranges between 125 to 150 F(52 to 66 C).

The oil pump suction is fed from the oil reservoir. Anoil pressure relief valve maintains 18 to 25 psid (124 to172 kPad) differential pressure in the system at the pumpdischarge. This differential pressure can be read directly fromthe CVC default screen. The oil pump discharges oil to theoil filter assembly. This filter can be closed to permitremoval of the filter without draining the entire oil system(see Maintenance sections, pages 66-71, for details). The oilis then piped to the oil cooler heat exchanger. The oil cooleruses refrigerant from the condenser as the coolant. The re-frigerant cools the oil to a temperature between 120 and140 F (49 to 60 C).

7

LEGEND

1—

Condenser

Tubes

2—

Filter/Drier

3—

MoistureIndicator

4—

RefrigerantCoolingIsolationValves

5—

MainCondenser

LiquidDrainLine

6—

FloatChamberVent

7—

Subcooler

8—

Discharge

IsolationValve

(Optional)

9—

HighCondenser

LevelD

rain

10—

Condenser

SideRefrigerant

ChargingValve

11—

Stator

12—

Transm

ission

13—

Diffuser

14—

Impeller

15—

InletGuide

Vanes

16—

CoolerDistributionPipe

17—

RefrigerantCoolingDrainLines

18—

OilPum

p19

—OilFilter

20—

Rotor

21—

OilCooler

22—

OrificedFitting

23—

ThermalExpansion

Valve

for

OilCooling

24—

CoolerRefrigerantSupplyLine

25—

TurbineSuctionLine

Strainer

26—

CoolerSuctionLine

27—

CoolerRefrigerantCharging

Valve

28—

TurbineBypassLine

Isolation

Valve

29—

TurbineBypassLine

30—

PilotDrainLine

FromTurbine

Bypass

31—

FloatChamber

32—

TurbineFloatValve

33—

TurbineBypassFloatValve

34—

TurbineSuctionIsolationValve

(Optional)

35—

Motor

BackPressureOrifice

Fig.3—

Refrigerant,Motor

Cooling,andOilCoolingCycles

8

As the oil leaves the oil cooler, it passes the oil pressuretransducer and the thermal bulb for the refrigerant expan-sion valve on the oil cooler. The oil is then divided. Part ofthe oil flows to the thrust bearing, forward pinion bearing,and gear spray. The rest of the oil lubricates the motor shaftbearings and the rear pinion bearing. The oil temperature ismeasured in the bearing housing as it leaves the thrust andforward journal bearings. The oil then drains into the oil res-ervoir at the base of the compressor. The PIC II (ProductIntegrated Control II) measures the temperature of the oil inthe sump and maintains the temperature during shutdown(see Oil Sump Temperature Control section, page 36). Thistemperature is read on the CVC default screen.During the chiller start-up, the PIC II energizes the oil pump

and provides 45 seconds of prelubrication to the bearingsafter pressure is verified before starting the compressor.During shutdown, the oil pump will run for 60 seconds topost-lubricate after the compressor shuts down. The oil pumpcan also be energized for testing purposes during a ControlTest.Ramp loading can slow the rate of guide vane opening to

minimize oil foaming at start-up. If the guide vanes openquickly, the sudden drop in suction pressure can cause anyrefrigerant in the oil to flash. The resulting oil foam can-not be pumped efficiently; therefore, oil pressure falls offand lubrication is poor. If oil pressure falls below 15 psid(103 kPad) differential, the PIC II will shut down thecompressor.If the controls are subject to a power failure that lasts more

than 3 hours, the oil pumpwill be energized periodically whenthe power is restored. This helps to eliminate refrigerant thathas migrated to the oil sump during the power failure. Thecontrols energize the pump for 60 seconds every 30 minutesuntil the chiller is started.

Oil Reclaim System — The oil reclaim system re-turns oil lost from the compressor housing back to the oilreservoir by recovering the oil from 2 areas on the chiller.The guide vane housing is the primary area of recovery. Oilis also recovered by skimming it from the operating refrig-erant level in the cooler vessel.

PRIMARY OIL RECOVERY MODE — Oil is normallyrecovered through the guide vane housing on the chiller. Thisis possible because oil is normally entrained with refrigerantin the chiller. As the compressor pulls the refrigerant up fromthe cooler into the guide vane housing to be compressed, theoil normally drops out at this point and falls to the bottomof the guide vane housing where it accumulates. Using dis-charge gas pressure to power an eductor, the oil is drawnfrom the housing and is discharged into the oil reservoir.

SECONDARYOIL RECOVERYMODE— The secondarymethod of oil recovery is significant under light load con-ditions, when the refrigerant going up to the compressor suc-tion does not have enough velocity in which to bring oil along.Under these conditions, oil collects in a greater concentra-tion at the top level of the refrigerant in the cooler. This oiland refrigerant mixture is skimmed from the side of the coolerand is then drawn up to the guide vane housing. There is afilter in this line. Because the guide vane housing pressureis much lower than the cooler pressure, the refrigerant boilsoff, leaving the oil behind to be collected by the primary oilrecovery method.

JOURNALBEARINGS

REAR PINIONBEARING

SIGHTGLASSES

STRAINER

CHECKVALVE

ISOLATIONVALVE

SIGHTGLASS

FILTER

ISOLATIONVALVE

COOLEROILRECLAIMLINE

STRAINEREDUCTOR

OILCHARGEVALVE

THERMALEXPANSIONVALVE BULB

OIL SUPPLYPRESSURETRANSDUCER

ISOLATIONVALVE

OILCOOLER

OIL PUMPAND MOTOR

OIL PRESSURERELIEF VALVE

OILSUPPLYLINE

FILTERISOLATIONVALVE

FILTEROIL DRAIN

THRUST

THRUST

Fig. 4 — Lubrication System

9

STARTING EQUIPMENTThe 19XRT requires a motor starter to operate the cen-

trifugal hermetic compressor motor, the oil pump, and vari-ous auxiliary equipment. The starter is the main field wiringinterface for the contractor.See Carrier Specification Z-415 for specific starter re-

quirements. All starters must meet these specifications inorder to properly start and satisfy mechanical safety require-ments. Starters may be supplied as separate, free-standingunits or may bemounted directly on the chiller (unit mounted)for low-voltage units only.Three separate circuit breakers are inside the starter. Cir-

cuit breaker CB1 is the compressor motor circuit breaker.The disconnect switch on the starter front cover is connectedto this breaker. Circuit breaker CB1 supplies power to thecompressor motor.

The main circuit breaker (CB1) on the front of the starterdisconnects the main motor current only. Power is stillenergized for the other circuits. Two more circuit break-ers inside the starter must be turned off to disconnectpower to the oil pump, PIC II controls, and oil heater.

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 poweris supplied to them if the CB1 disconnect is open.All starters must include a Carrier control module called

the Integrated Starter Module (ISM), excluding theBenshaw solid-state starters. This module controls and moni-tors all aspects of the starter. See the Controls section onpage 11 for additional ISM information. All starter replace-ment parts are supplied by the starter manufacturer exclud-ing the ISM (contact Carrier’s Replacement ComponentDivision [RCD]).

Unit-Mounted Solid-State Starter (Optional)— The 19XRT chiller may be equipped with a solid-state,reduced-voltage starter (Fig. 5 and 6). This starter’s primaryfunction is to provide on-off control of the compressor mo-tor. This type of starter reduces the peak starting torque,reduces the motor inrush current, and decreases mechanicalshock. This capability is summed up by the phrase ‘‘soft start-ing.’’ The solid-state starter is available as a 19XRT option(factory supplied and installed). The solid-state starters manu-facturer name is located inside the starter access door.A solid-state, reduced-voltage starter operates by reduc-

ing the starting voltage. The starting torque of a motor at fullvoltage is typically 125% to 175% of the running torque.When the voltage and the current are reduced at start-up, thestarting torque is reduced as well. The object is to reduce thestarting voltage to just the voltage necessary to develop thetorque required to get the motor moving. The voltage is re-duced by silicon controlled rectifiers (SCRs). The voltageand current are then ramped up in a desired period of time.Once full voltage is reached, a bypass contactor is energizedto bypass the SCRs.

When voltage is supplied to the solid-state circuitry, theheat sinks in the starter as well as the wires leading tothe motor and the motor terminal are at line voltage.Do not touch the heat sinks, power wiring, or motorterminals while voltage is present or serious injury willresult.

There is a display on the front of the Benshaw, Inc., solid-state starters that is useful for troubleshooting and starter check-out. 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 configurationThe starter is further explained in the Check Starter and

Troubleshooting Guide sections, pages 53 and 71.

5

1

2

3

4

6

LEGEND

1 — Ready-Start Micro Input/Output Card2 — Circuit Breaker 2 (CB2):

Machine Control and Heater Power3 — Circuit Breaker 3 (CB3): Oil Pump Power4 — Ready-Start Micro Central Processing Unit Card (CPU)5 — Restart Micro Power Card (hidden, not depicted)6 — Restart Micro Bypass Card (hidden, not depicted)

Fig. 5 — Solid-State Starter Box,Internal View

10

Unit-Mounted Wye-Delta Starter (Optional)— The 19XRT chiller may be equipped with a wye-deltastarter mounted on the unit. This starter is intended for usewith low-voltage motors (under 600 v). It reduces the start-ing current inrush by connecting each phase of the motorwindings into a wye configuration. This occurs during thestarting period when the motor is accelerating up to speed.Once the motor is up to speed, the starter automatically con-nects the phase windings into a delta configuration. Startercontrol, monitoring, and motor protection is provided byCarrier’s Integrated Starter Module (ISM).

CONTROLS

DefinitionsANALOG SIGNAL — An analog signalvaries in propor-tion to the monitored source. It quantifies values betweenoperating limits. (Example: A temperature sensor is an ana-log device because its resistance changes in proportion tothe temperature, generating many values.)

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

General— The 19XRT hermetic centrifugal liquid chillercontains a microprocessor-based control center that moni-tors and controls all operations of the chiller (see Fig. 7).The microprocessor control system matches the coolingcapacity of the chiller to the cooling load while providingstate-of-the-art chiller protection. The system controls cool-ing load within the set point plus the deadband by sensingthe leaving chilled water or brine temperature and regula-ting the inlet guide vane via a mechanically-linked actuatormotor. The guide vane is a variable flow pre-whirl assem-bly that controls the refrigeration effect in the cooler byregulating the amount of refrigerant vapor flow into the com-pressor. An increase in guide vane opening increases capac-ity. Adecrease in guide vane opening decreases capacity. Themicroprocessor-based control center protects the chiller bymonitoring the digital and analog inputs and executingcapacity overrides or safety shutdowns, if required.

PIC II System Components — The chiller controlsystem is called PIC II (Product Integrated Control II).See Table 1. The PIC II controls the operation of the chillerby monitoring all operating conditions. The PIC II can di-agnose a problem and let the operator know what the prob-lem is and what to check. It promptly positions the guidevanes to maintain leaving chilled water temperature. It caninterface with auxiliary equipment such as pumps and cool-ing tower fans to turn them on when required. It continuallychecks all safeties to prevent any unsafe operating condi-tion. It also regulates the oil heater while the compressor isoff and regulates the hot gas bypass valve, if installed. ThePIC II controls provide critical protection for the compres-sor motor and controls the motor starter.The PIC II can interface with the Carrier Comfort Net-

work (CCN) if desired. It can communicate with otherPIC 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 con-trol 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 control voltage (per job requirement)— up to 600 v for oil pump power

• starter cabinet— chiller power wiring (per job requirement)

Table 1 — Major PIC II Components andPanel Locations*

PIC II COMPONENT PANELLOCATION

Chiller Visual Controller (CVC) and Display Control PanelIntegrated Starter Module (ISM) Starter CabinetChiller Control Module (CCM) Control PanelOil Heater Contactor (1C) Power PanelOil Pump Contactor (2C) Power PanelHot Gas Bypass Relay (3C) (Optional) Power PanelControl Transformers (T1, T2) Power PanelTemperature Sensors See Fig. 7.Pressure Transducers See Fig. 7.

*See Fig. 5 and Fig. 7-11.

CHILLER VISUALCONTROLLER (CVC)— The CVC isthe ‘‘brain’’ of the PIC II. This module contains all the op-erating software needed to control the chiller. The CVC ismounted to the control panel (Fig. 10) and is the input centerfor all local chiller set points, schedules, configurablefunctions, and options. The CVC has a stop button, an alarmlight, four buttons for logic inputs, and a backlight display.The backlight will automatically turn off after 15 minutes ofnon-use. The functions of the four buttons or ‘‘softkeys’’ aremenu driven and are shown on the display directly abovethe softkeys.The viewing angle of the CVC can be adjusted for opti-

mum viewing. Remove the 2 bolts connecting the controlpanel to the brackets attached to the cooler. Place them inone of the holes to pivot the control panel forward to back-ward to change the viewing angle. See Fig. 10. To changethe contrast of the display, access the adjustment on the backof the CVC. See Fig. 10.

Fig. 6 — Typical Starter External View(Solid-State Starter Shown)

11

LEGEND

1 — Condenser Temperature Sensor Connection2 — Condenser Pressure Transducer Connection

TOP VIEW

COMPRESSOR AREA

Fig. 7 — 19XRT Control and Sensor Locations

12

INTEGRATED STARTER MODULE (ISM) — This mod-ule is located in the starter cabinet. This module initiates com-mands from the CVC for starter functions such as startingand stopping the compressor, condenser, chilled water pumps,tower fan, spare alarm contacts, and the shunt trip. The ISMmonitors starter inputs such as line voltage, motor current,ground fault, remote start contact, spare safety, condenserhigh pressure, oil pump interlock, starter 1M, and run con-tacts. The ISM contains logic capable of safety shutdown. Itshuts down the chiller if communications with the CVCare lost.

CHILLER CONTROL MODULE (CCM) — This moduleis located in the control panel. The CCM provides the inputand outputs necessary to control the chiller. Thismodulemoni-tors refrigerant pressure, entering and leaving water tem-peratures, and outputs control for the guide vane actuator,oil heaters, and oil pump. The CCM is the connection pointfor optional demand limit, chilled water reset, remote tem-perature reset, and refrigerant leak sensor.

OIL HEATER CONTACTOR (1C) — This contactor is lo-cated in the power panel (Fig. 11) and operates the heater ateither 115 or 230 v. It is controlled by the PIC II to maintainoil temperature during chiller shutdown.

OIL PUMPCONTACTOR (2C) — This contactor is locatedin the power panel. It operates all 200 to 575-v oil pumps.The PIC II energizes the contactor to turn on the oil pumpas necessary.

HOT GAS BYPASS CONTACTOR RELAY (3C) (Op-tional) — This relay, located in the power panel, controls theopening of the hot gas bypass valve. The PIC II energizesthe relay during low load, high lift conditions.

CONTROL TRANSFORMERS (T1, T2) — These trans-formers convert incoming control voltage to 24 vac powerfor the 3 power panel contactor relays, CCM, and CVC.

Fig. 8 — Control Sensors (Temperature)

Fig. 9 — Control Sensors(Pressure Transducers, Typical)

13

Fig. 10 — Control Panel

Fig. 11 — Power Panel

14

CVC Operation and Menus (Fig. 12-18)

GENERAL• The CVC display automatically reverts to the default screenafter 15 minutes if no softkey activity takes place and ifthe chiller is not in the pumpdown mode (Fig. 12).

• If a screen other than the default screen is displayed on theCVC, the name of that screen is in the upper right corner(Fig. 13).

• The CVC may be set to display either English or SI units.Use the CVC configuration screen (accessed from the Serv-ice menu) to change the units. See the Service Operationsection, page 44.

• Local Operation — The PIC II can be placed in localoperating mode by pressing the LOCALsoftkey. ThePIC II then accepts commands from the CVC only anduses the Local Time Schedule to determine chiller startand stop times.

• CCN Operation — The PIC II can be placed in the CCNoperating mode by pressing the CCNsoftkey. ThePIC II then accepts modifications from any CCN interfaceor module (with the proper authority), as well as from theCVC. The PIC II uses the CCN time schedule to deter-mine start and stop times.

ALARMSANDALERTS—An alarm shuts down the com-pressor. An alert does not shut down the compressor, but itnotifies the operator that an unusual condition has occurred.An alarm (*) or alert (!) is indicated on the STATUS screenson the far right field of the CVC display screen.Alarms are indicated when the control center alarm light

(!) flashes. The primary alarm message is displayed on thedefault screen. An additional, secondary message andtroubleshooting information are sent to the ALARM HIS-TORY table.When an alarm is detected, the CVC default screen will

freeze (stop updating) at the time of alarm. The freeze en-ables the operator to view the chiller conditions at the timeof alarm. The STATUS tables will show the updated infor-mation. Once all alarms have been cleared (by pressing theRESET softkey), the default CVC screen will return to nor-mal operation.

CVC MENU ITEMS — To perform any of the operationsdescribed below, the PIC II must be powered up and havesuccessfully completed its self test. The self test takes placeautomatically, after power-up.

Press the MENUsoftkey to view the list of menu struc-

tures: STATUS, SCHEDULE , SETPOINT , and

SERVICE .• The STATUS menu allows viewing and limited calibra-tion or modification of control points and sensors, relaysand contacts, and the options board.

• The SCHEDULE menu allows viewing and modificationof the local and CCN time schedules and Ice Build timeschedules.

• The SETPOINT menu allows set point adjustments, suchas the entering chilled water and leaving chilled water setpoints.

• The SERVICE menu can be used to view or modifyinformation on the Alarm History, Control Test, ControlAlgorithm Status, Equipment Configuration, ISM StarterConfiguration data, Equipment Service, Time and Date, At-tach to Network Device, Log Out of Network Device, andCVC Configuration screens.

For more information on the menu structures, refer toFig. 15.Press the softkey that corresponds to the menu structure

to be viewed : STATUS, SCHEDULE , SETPOINT , or

SERVICE . To view or change parameters within any ofthesemenu structures, use the NEXTand PREVIOUSsoft-keys to scroll down to the desired item or table. Use the

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

BASIC CVCOPERATIONS (Using the Softkeys)—To per-form any of the operations described below, the PIC II mustbe powered up and have successfully completed its self test.

RUNNING TEMP CONTROLLEAVING CHILLED WATER

01-01-95 11:4828.8 HOURS

CHW IN CHW OUT EVAP REF

CDW IN CDW OUT COND REF

OIL PRESS OIL TEMP AMPS %

CCN LOCAL RESET MENU

55.1 44.1 40.7

85.0 95.0 98.1

21.8 132.9 93

PRIMARY STATUSMESSAGE

COMPRESSORONTIME

DATE TIME

SOFT KEYSMENULINE

EACH KEY'S FUNCTION ISDEFINED BY THE MENU DESCRIPTIONON MENU LINE ABOVE

ALARM LIGHT(ILLUMINATEDWHEN POWER ON)

STOP BUTTON• HOLD FOR ONE

SECOND TO STOP

••

BLINKS CONTINUOUSLYON FOR AN ALARMBLINKS ONCE TOCONFIRM A STOP

SECONDARYSTATUSMESSAGE

Fig. 12 — CVC Default Screen

CONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONISM (STARTER) CONFIGURATION DATAEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICECVC CONFIGURATION

ALARM HISTORY

19XRT_II SERVICE

Fig. 13 — CVC Service Screen

15

• Press QUIT to leave the selected decision or field with-out saving any changes.

• Press ENTERto leave the selected decision or field andsave changes.

• Press NEXT to scroll the cursor bar down in order tohighlight a point or to view more points below the currentscreen.

• Press PREVIOUSto scroll the cursor bar up in order tohighlight a point or to view points above the current screen.

• Press SELECTto view the next screen level (high-lighted with the cursor bar), or to override (if allowable)the highlighted point value.

• Press EXIT to return to the previous screen level.

• Press INCREASEor DECREASE to change the high-lighted point value.

TO VIEW STATUS (Fig. 14) — The status table shows theactual value of overall chiller status such asCONTROLMODE,RUNSTATUS,AUTOCHILLEDWATER, RESET, and RE-MOTE RESET SENSOR.

1. On the menu screen, press STATUSto view the list ofpoint status tables.

2. Press NEXTor PREVIOUS to highlight the desired

status table. The list of tables is:• MAINSTAT — Overall chiller status• STARTUP—Status required to perform startup of chiller• COMPRESS — Status of sensors related to thecompressor

• HEAT_EX — Status of sensors related to the heatexchangers

• POWER — Status of motor input power• ISM_STAT — Status of motor starter• CVC_PSWD — Service menu password forcing ac-cess screen

3. Press SELECTto view the desired point status table.

4. On the point status table, press NEXTor

PREVIOUS until the desired point is displayed on thescreen.

OVERRIDE OPERATIONSTo Override a Value or Status

1. From any point status screen, press NEXTorPREVIOUS to highlight the desired value.

19XRT_II MAINSTAT POINT STATUSControl ModeRun StatusStart Inhibit TimerOccupied?System Alert/AlarmChiller Start/StopRemote Start ContactTemperature ResetControl PointChilled Water TempActive Demand LimitAverage Line Current

OFFReady

0.0 MinNO

NORMALSTOPOpen0.0 F

44.0 F44.6 F100%0.0%

Fig. 14 — Example of Status Screen

16

CCN LOCAL RESET MENU

DEFAULT SCREEN

Start Chiller In CCN Control

Start Chiller in Local Control

Clear Alarms

STATUS SCHEDULE SETPOINT SERVICE

(SOFTKEYS)

Access Main Menu

List theStatus Tables

Display The Setpoint Table

List the Service Tables

• OCCPC01S – LOCAL TIME SCHEDULE• OCCPC02S – ICE BUILD TIME SCHEDULE• OCCPC03S – CCN TIME SCHEDULE

List the Schedules

NEXT PREVIOUS SELECT EXIT

ALARM HISTORYCONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONISM (STARTER) CONFIG DATAEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICECVC CONFIGURATION

SEE FIGURE 16

Base Demand Limit • LCW Setpoint • ECW Setpoint • Ice Build Setpoint • Tower Fan High Setpoint

EXITSELECTPREVIOUSNEXTSelect a Schedule

12345678

Override

ENABLE DISABLE

EXITSELECTPREVIOUSNEXTSelect a Time Period/Override

Modify a Schedule Time

ENTER EXIT

INCREASE DECREASE ENTER EXIT (ANALOG VALUES)

(DISCRETE VALUES)Add/Eliminate a Day

1

Select a Status TableNEXT PREVIOUS SELECT EXIT

STARTON

STOPOFF

RELEASE ENTER

EXITNEXT PREVIOUS SELECT

ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERRELEASE

Select a Modification Point

Modify a Discrete Point

Modify an Analog Point

Modify Control Options

• MAINSTAT• STARTUP• COMPRESS• HEAT_EX• POWER• ISM_STAT• CVC_PSWD

Modify the SetpointDECREASEINCREASE QUIT ENTER

NEXT PREVIOUS SELECT EXITSelect the Setpoint

•

(ENTER A 4-DIGIT PASSWORD)1 1 1

Fig. 15 — 19XRT CVC Menu Structure

17


SERVICE TABLE

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

• CCM Thermistors• CCM Pressure Transducers• Pumps• Discrete Outputs• Guide Vane Actuator• Diffuser Actuator• Pumpdown/Lockout• Terminate Lockout• Guide Vane Calibration

CONTINUEDON NEXT PAGE

CONTROL ALGORITHM STATUS

CONTROL TEST

ALARM HISTORY

List the Control Tests

NEXT PREVIOUS SELECT EXITSelect a Test

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)

NEXT PREVIOUS SELECT EXITSelect a Table

• NET_OPT• BRODEF• OCCEFCS• HOLIDAYS• CONSUME• RUNTIME

(ANALOG VALUES)

(DISCRETE VALUES)

Select a ParameterNEXT PREVIOUS SELECT EXIT

Modify a Parameter


DECREASEINCREASE ENTERQUIT

NEXT PREVIOUS SELECT EXITSelect a Table

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

• CAPACITY (Capacity Control Algorithm)• OVERRIDE (Override Status)• LL_MAINT (LEADLAG Status)• WSMDEFM2 (Water System Manager Control Status)

Maintenance Table Data

NEXT PREVIOUS SELECT EXITData Select Table

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

OCCDEFM (Time Schedule Status)

Fig. 16 — 19XRT Service Menu Structure

18


SERVICE MENU CONTINUEDFROM PREVIOUS PAGE

Select a Service Table

Select a Service Table ParameterNEXT PREVIOUS SELECT EXIT

Modify a Service Table Parameter(ANALOG VALUES)

(DISCRETE VALUES)

TIME AND DATE

Display Time and Date Table:• To Modify — Current Time — Day of Week

— Current Date — Holiday TodayATTACH TO NETWORK DEVICEDECREASEINCREASE


DECREASEINCREASE ENTERQUIT

Select a DeviceATTACHNEXT PREVIOUS SELECT

Modify Device AddressEXITINCREASE DECREASE ENTER

• Use to attach CVC to another CCN network or device• Attach to "LOCAL" to enter this machine• To upload new tables

Default ScreenMENURESETCCN LOCAL

LOG OUT OF DEVICE

List Network Devices• Local• Device 1• Device 2• Device 3• Device 4 •• Device 5

• Device 6• Device 7• Device 8• Device 9

Service Tables:• OPTIONS• SETUP1• SETUP2• LEADLAG• RAMP_DEM• TEMP_CTL

EQUIPMENT SERVICE

ISM (STARTER CONFIG DATA)

Service Tables:• ISM (STARTER) CONFIG PASSWORD• ISM_CONF

(ENTER A 4-DIGIT PASSWORD)4 4 4 4

CVC CONFIGURATION

EXITINCREASE DECREASE ENTERCVC Configuration Table

• To Modify — CVC CCN Address— English (US IMP) or S.I. Metric Units— Password

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

indicate software version)

Attach To Any Device

(ANALOG VALUES)ENTER EXIT

ENTER EXITNOYES (DISCRETE VALUES)

LEGEND

CCN — Carrier Comfort NetworkCVC — Chiller Visual ControlIMP — ImperialISM — Integrated Starter ModulePIC II — Product Integrated Control II

Fig. 16 — 19XRT Service Menu Structure (cont)

19

3. Press SELECTto select the highlighted value. Then:

For Discrete Points —Press YES or NO to se-lect the desired state.

YES NO ENTER EXIT

For Analog Points — Press INCREASE or

DECREASE to select the desired value.

4. Press ENTERto register the new value.

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

To Remove an Override

1. On the point status table press NEXTor

PREVIOUS to highlight the desired value.

2. Press SELECTto access the highlighted value.

3. Press RELEASEto remove the override and return thepoint to the PIC II’s automatic control.

Override Indication — An override value is indicated by‘‘SUPVSR,’’ ‘‘SERVC,’’or ‘‘BEST’’flashing next to the pointvalue on the STATUS table.

TIME SCHEDULE OPERATION (Fig. 17)

1. On the Menu screen, press SCHEDULE.

2. Press NEXT or PREVIOUS to highlight the de-sired schedule.

OCCPC01S — LOCAL Time ScheduleOCCPC02S — ICE BUILD Time ScheduleOCCPC03S — CCN Time Schedule

3. Press SELECTto view the desired time schedule.

4. Press NEXT or PREVIOUS to highlight the de-sired period or override to change.

5. Press SELECTto access the highlighted period oroverride.

6. a. Press INCREASEor DECREASE to change the

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

Fig. 17 — Example of Time ScheduleOperation Screen

20

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

fields. Press DISABLEto eliminate days from theperiod.

7. Press ENTERto register the values and to move

horizontally (left to right) within a period.

8. Press EXIT to leave the period or override.

9. Either return to Step 4 to select another period or

override, or press EXITagain to leave the current time

schedule screen and save the changes.

10. TheHolidayDesignation (HOLIDEF table)may be foundin the Service Operation section, page 44. The month,day, and duration for the holiday must be assigned. TheBroadcast function in the BRODEF table also must beenabled for holiday periods to function.

TO VIEW AND CHANGE SET POINTS (Fig. 18)1. To view the SETPOINT table, from the MENU screen

press SETPOINT.

2. There are 5 set points on this screen: BASE DEMANDLIMIT, LCWSETPOINT (leaving chilled water set point),ECW SETPOINT (entering chilled water set point), ICEBUILD SETPOINT, and TOWER FAN HIGH SET-POINT. Only one of the chilled water set points can beactive at one time. The set point that is active is deter-mined from the SERVICE menu. See the Service Opera-tion section, page 44. The ice build (ICE BUILD) func-tion is also activated and configured from the SERVICEmenu.

3. Press NEXTor PREVIOUS to highlight the desiredset point entry.

4. Press SELECTto modify the highlighted set point.

5. Press INCREASEor DECREASE to change the se-lected set point value.

6. Press ENTERto save the changes and return to theprevious screen.

SERVICE OPERATION — To view the menu-driven pro-grams available for Service Operation, see Service Opera-tion section, page 44. For examples of CVC display screens,see Table 2.

19XR_II SETPOINT SELECTSETPOINT

Base Demand LimitControl PointLCW SetpointECW SetpointICE BUILD SetpointTower Fan High Setpoint

100%

50.0 F60.0 F40.0 F85.0 F

Fig. 18 — Example of Set Point Screen

21

Table 2 — CVC Display Data

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

1. Only 12 lines of information appear on the CVC screen at any onetime. Press the NEXT or PREVIOUS softkey to highlight a

point or to view items below or above the current screen. Press

the NEXT softkey twice to page forward; press the

PREVIOUS softkey twice to page back.

2. To access the information shown in Examples 9 through 21, enter

your 4-digit password after pressing the SERVICE softkey. If

no softkeys are pressed for 15 minutes, the CVC automaticallylogs off (to prevent unrestricted access to PIC II controls) and re-verts to the default screen. If this happens, you must reenter yourpassword to access the tables shown in Examples 9 through 21.

3. Terms in the Description column of these tables are listed as theyappear on the CVC screen.

4. The CVC may be configured in English or Metric (SI) units usingthe CVC CONFIGURATION screen. See the Service Operationsection, page 44, for instructions on making this change.

5. The items in the Reference Point Name column do not appear onthe CVC screen. They are data or variable names used in CCN orBuilding Supervisor (BS) software. They are listed in these tablesas a convenience to the operator if it is necessary to cross ref-erenceCCN/BS documentation or useCCN/BS programs. Formoreinformation, see the 19XRT CCN literature.

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

7. Alarms and Alerts: An asterisk in the far right field of a CVC statusscreen indicates that the chiller is in an alarm state; an exclama-tion point in the far right field of the CVC screen indicates an alertstate. The asterisk (or exclamation point) indicates that the valueon that line has exceeded (or is approaching) a limit. For moreinformation on alarms and alerts, see the Alarms and Alertssection, page 15.

LEGEND

12T — Motor OverloadCCN — Carrier Comfort NetworkCHW — Chilled WaterCR — Control RelayCT — Current TransformerCVC — Chiller Visual ControlECW — Entering Chilled WaterHGBP — Hot Gas BypassISM — Integrated Starter ModuleLCW — Leaving Chilled WaterLRA — Locked Rotor AmpsmA — MilliampsP — PressureSS — Solid StateT — TemperatureVFD — Variable Frequency DriveWSM — Water System Manager

EXAMPLE 1 — CVC DEFAULT SCREENThe following data is displayed in the CVC Default screen.

DESCRIPTION RANGE UNITS REFERENCE POINT NAME(ALARM HISTORY) DISPLAY

(PRIMARY MESSAGE)(SECONDARY MESSAGE)(DATE AND TIME)Compressor Ontime 0-500000.0 HOURS C HRSEntering Chilled Water −40-245 DEG F ECW CHW INLeaving Chilled Water −40-245 DEG F LCW CHW OUTEvaporator Temperature −40-245 DEG F ERT EVAP REFEntering Condenser Water −40-245 DEG F ECDW CDW INLeaving Condenser Water −40-245 DEG F LCDW CDW OUTCondenser Temperature −40-245 DEG F CRT COND REFOil Pressure 0-420 PSI OILPD OILPRESSOil Sump Temp −40-245 DEG F OILT OIL TEMPAverage Line Current 0-999 % AMPS % AMPS %

0-1 CCN0-1 LOCAL0-1 RESET

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

22

Table 2 — CVC Display Data (cont)

EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN

To access this display from the CVC default screen:1. Press MENU .

2. Press STATUS ( MAINSTAT will be highlighted).

3. Press SELECT .

DESCRIPTION STATUS UNITS POINTControl Mode NOTE 1 NOTE 1 CMODERun Status NOTE 2 NOTE 2 RUNSTATStart Inhibit Timer 0-15 min T STARTOccupied ? 0/1 NO/YES OCCSystem Alert/Alarm 0-2 NOTE 3 SYS ALM*Chiller Start/Stop 0/1 STOP/START CHIL S S*Remote Start Contact 0/1 OFF/ON REMCONTemperature Reset −30-30 DEG F T RESET*Control Point 10-120 DEG F LCW STPTChilled Water Temp −40-245 DEG F CHW TMP*Active Demand Limit 40-100 % DEM LIMAverage Line Current 0-999 % AMPS %Motor Percent Kilowatts 0-999 % KW PAuto Demand Limit Input 4-20 mA AUTODEMAuto Chilled Water Reset 4-20 mA AUTORESRemote Reset Sensor −40-245 DEG F R RESETTotal Compressor Starts 0-99999 C STARTSStarts in 12 Hours 0-8 STARTSCompressor Ontime 0-500000.0 HOURS C HRS*Service Ontime 0-32767 HOURS S HRSIce Build Contact 0-1 OPEN/CLOSE ICE CONRefrigerant Leak Sensor 0-20 mA REF LEAK

NOTES:1. Reset, Off, Local, CCN2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout3. Normal, Alert, Alarm4. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN

devices.

EXAMPLE 3 — STARTUP DISPLAY SCREEN


2. Press STATUS .

3. Scroll down to highlight STARTUP .

4. Press SELECT .

DESCRIPTION STATUS UNITS POINTActual Guide Vane Pos 0-100 % GV POS

**Chilled Water Pump 0-1 OFF/ON CHWPChilled Water Flow 0-1 NO/YES CHW FLOW

**Condenser Water Pump 0-1 OFF/ON CDPCondenser Water Flow 0-1 NO/YES CDW FLOWOil Pump Relay 0-1 OFF/ON OILR

**Oil Pump Delta P −6.7-200 ^PSI OILPDCompressor Start Relay 0-1 OFF/ON CMPRCompressor Start Contact 0-1 OPEN/CLOSED 1M AUXStarter Trans Relay 0-1 OFF/ON TRANSCompressor Run Contact 0-1 OPEN/CLOSED 2M AUX

**Tower Fan Relay Low 0-1 OFF/ON TFR LOW**Tower Fan Relay High 0-1 OFF/ON TFR HIGHStarter Fault 0-1 ALARM/NORMAL STARTFLTSpare Safety Input 0-1 ALARM/NORMAL SAFETYShunt Trip Relay 0-1 OFF/ON TRIPRStarter Fault Status 0-255 ISMFLT

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

23


EXAMPLE 4 — COMPRESS DISPLAY SCREEN


2. Press STATUS .

3. Scroll down to highlight COMPRESS .

4. Press SELECT .

DESCRIPTION STATUS UNITS POINTActual Guide Vane Pos 0-100 % GV POSGuide Vane Delta 0-100 % GV DELTA

**Target Guide Vane Pos 0-100 % GV TRGOil Sump Temp −40-245 DEG F OILT

**Oil Pump Delta P −6.7-200 PSI OILPDComp Discharge Temp −40-245 DEG F CMPDComp Thrust Brg Temp −40-245 DEG F MTRBComp Motor Winding Temp −40-245 DEG F MTRWSpare Temperature 1 −40-245 DEG F SPARE T1Spare Temperature 2 −40-245 DEG F SPARE T2Oil Heater Relay 0/1 OFF/ON OILHEATDiffuser Actuator 0-100 % DIFF ACT

**Target VFD Speed 0-110 % VFD OUT**Actual VFD Speed 0-100 % VFD ACTSurge Protection Counts 0-5 SPC


EXAMPLE 5 — HEAT EX DISPLAY SCREEN


2. Press STATUS .

3. Scroll down to highlight HEAT EX .

4. Press SELECT .

DESCRIPTION STATUS UNITS POINT**Chilled Water Delta P −6.7-420 PSI CHWPDEntering Chilled Water −40-245 DEG F ECWLeaving Chilled Water −40-245 DEG F LCWChilled Water Delta T −6.7-420 ^ F CHW DTChill Water Pulldown/Min −20-20 ^ F CHW PULLEvaporator Refrig Temp −40-245 DEG F ERT

**Evaporator Pressure −6.7-420 PSI ERPEvaporator Approach 0-99 ^ F EVAP APP

**Condenser Water Delta P −6.7-420 PSI CDWPDEntering Condenser Water −40-245 DEG F ECDWLeaving Condenser Water −40-245 DEG F LCDWCondenser Refrig Temp −40-245 DEG F CRT

**Condenser Pressure −6.7-420 PSI CRPCondenser Approach 0-99 ^ F COND APPHot Gas Bypass Relay 0/1 OFF/ON HGBYPASSSurge/HGBP Active ? 0/1 NO/YES SHG ACTActive Delta P 0-200 PSI DP AActive Delta T 0-200 DEG F DT ASurge/HGBP Delta T 0-200 DEG F DT C


24


EXAMPLE 6 — POWER DISPLAY SCREEN


2. Press STATUS .

3. Scroll down to highlight POWER .

4. Press SELECT .

DESCRIPTION STATUS UNITS POINTAverage Line Current 0-999 % AMPS %Actual Line Current 0-99999 AMPS AMP AAverage Line Voltage 0-999 % VOLT PActual Line Voltage 0-99999 VOLTS VOLT APower Factor 0.0-1.0 POW FACTMotor Kilowatts 0-99999 kW KWMotor Kilowatt-Hours 0-99999 kWH KWHDemand Kilowatts 0-99999 kWH DEM KWLine Current Phase 1 0-99999 AMPS AMPS 1Line Current Phase 2 0-99999 AMPS AMPS 2Line Current Phase 3 0-99999 AMPS AMPS 3Line Voltage Phase 1 0-99999 VOLTS VOLT 1Line Voltage Phase 2 0-99999 VOLTS VOLT 2Line Voltage Phase 3 0-99999 VOLTS VOLT 3Ground Fault Phase 1 0-999 AMPS GF 1Ground Fault Phase 2 0-999 AMPS GF 2Ground Fault Phase 3 0-999 AMPS GF 3Frequency 0-99 Hz FREQ12T Sum Heat-Phase 1 0-200 % SUM1HEAT12T Sum Heat-Phase 2 0-200 % SUM2HEAT12T Sum Heat-Phase 3 0-200 % SUM3HEAT

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

EXAMPLE 7 — ISM STAT SCREEN


2. Press STATUS .

3. Scroll down to highlight ISM STAT .

4. Press SELECT .

DESCRIPTION STATUS UNITS POINTISM Fault Status 0-223 ISMFLTSingle Cycle Dropout 0-1 NORMAL/ALARM CYCLE 1Phase Loss 0-1 NORMAL/ALARM PH LOSSOvervoltage 0-1 NORMAL/ALARM OV VOLTUndervoltage 0-1 NORMAL/ALARM UN VOLTCurrent Imbalance 0-1 NORMAL/ALARM AMP UNBVoltage Imbalance 0-1 NORMAL/ALARM VOLT UNBOverload Trip 0-1 NORMAL/ALARM OVERLOADLocked Rotor Trip 0-1 NORMAL/ALARM LRATRIPStarter LRA Trip 0-1 NORMAL/ALARM SLRATRIPGround Fault 0-1 NORMAL/ALARM GRND FLTPhase Reversal 0-1 NORMAL/ALARM PH REVFrequency Out of Range 0-1 NORMAL/ALARM FREQFLTISM Power on Reset 0-1 NORMAL/ALARM ISM PORPhase 1 Fault 0-1 NORMAL/ALARM PHASE 1Phase 2 Fault 0-1 NORMAL/ALARM PHASE 2Phase 3 Fault 0-1 NORMAL/ALARM PHASE 3ICR Start Complete 0-1 FALSE/TRUE START OK1M Start/Run Fault 0-1 NORMAL/ALARM 1M FLT2M Start/Run Fault 0-1 NORMAL/ALARM 2M FLTPressure Trip Contact 0-1 NORMAL/ALARM PRS TRIPStarter Fault 0-1 NORMAL/ALARM STRT FLTMotor Amps Not Sensed 0-1 NORMAL/ALARM NO AMPSStarter Acceleration Fault 0-1 NORMAL/ALARM ACCELFLTHigh Motor Amps 0-1 NORMAL/ALARM HIGHAMPS1CR Stop Complete 0-1 FALSET/TRUE STOP OK1M/2M Stop Fault 0-1 NORMAL/ALARM 1M2MSTOPMotor Amps When Stopped 0-1 NORMAL/ALARM AMPSTOPHardware Failure 0-1 NORMAL/ALARM HARDWARE

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

25


EXAMPLE 8 — SETPOINT DISPLAY SCREEN


2. Press SETPOINT (Base Demand Limit will be highlighted).

3. Press SELECT .

DESCRIPTION STATUS UNITS POINT DEFAULTBase Demand LimitControl Point 40-100 % DLM 100LCW Set Point 10-120 DEG F lcw sp 50.0

ECW Set Point 15-120 DEG F ecw sp 60.0Ice Build Set Point 15-60 DEG F ice sp 40.0Tower Fan High Set Point 55-105 DEG F TFH SP 75

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

EXAMPLE 9 — CAPACITY DISPLAY SCREEN


2. Press SERVICE .

3. Scroll down to highlight CONTROL ALGORITHM STATUS .

4. Press SELECT .

5. Scroll down to highlight CAPACITY .

DESCRIPTION STATUS UNITS POINTEntering Chilled Water −40-245 DEG F ECWLeaving Chilled Water −40-245 DEG F LCWCapacity ControlControl Point 10-120 DEG F ctrlptControl Point Error −99-99 DEG F cperrECW Delta T −99-99 DEG F ecwdtECW Reset −99-99 DEG F ecwresLCW Reset −99-99 DEG F lcwresTotal Error + Resets −99-99 DEG F errorGuide Vane Delta −2-2 % gvd

Target Guide Vane Pos 0-100 % GV TRGActual Guide Vane Pos 0-100 % GV POSTarget VFD Speed 0-100 % VFD OUTActual VFD Speed 0-100 % VFD ACTVFD Gain 0.1-1.5 VFD CTRLDemand Inhibit Active 0-1 NO/YES DEM INHAmps/kW Ramp 0-100 % DMDLIM

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

26


EXAMPLE 10 — OVERRIDE DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight OVERRIDE .

DESCRIPTION STATUS UNITS POINTComp Motor Winding Temp −40-245 DEG F MTRWComp Motor Temp Override 150-200 DEG F MT OVERCondenser Pressure 0-420 PSI CRPCond Press Override 90-180 PSI CP OVEREvaporator Refrig Temp −40-245 DEG F ERTEvap Ref Override Temp 2-45 DEG F ERT OVERComp Discharge Temp −40-245 DEG F CMPDComp Discharge Alert 125-200 DEG F CD ALEERTComp Thrust Brg Temp −40-245 DEG F MTRBComp Thrust Brg Alert 165-185 DEG F TB ALERTActual Superheat −20-99 ^ F SUPRHEATSuperheat Required 6-99 ^ F SUPR REQCondenser 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 maintenancescreens.

EXAMPLE 11 — LL MAINT DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight LL MAINT. .

DESCRIPTION STATUS UNITS POINTLead Lag ControlLEAD/LAG: NOTE 1 leadlagConfiguration Current Mode NOTE 2 llmodeLoad Balance Option 0/1 DSABLE/ENABLE loadbalLAG START TIME 2-60 MIN lagstartLAG STOP TIME 2-60 MIN lagstopPRESTART FAULT Time 2-30 MIN prefltPulldown: Delta T/Min x.xx ^ DEG pull dtSatisfied? 0/1 NO/YES pull sat

LEAD CHILLER in Control 0/1 NO/YES leadctrlLAG CHILLER: Mode NOTE 3 lagmodeRun Status NOTE 4 lagstatStart/Stop NOTE 5 lag s sRecovery Start Request 0/1 NO/YES lag rec

STANDBY CHILLER: Mode NOTE 3 stdmodeRun Status NOTE 4 stdstatStart/Stop NOTE 5 Std s sRecovery Start Request 0/1 NO/YES std rec

Spare Temperature 1 −40-245 DEG F SPARE T1Spare Temperature 2 −40-245 DEG F SPARE T2

NOTES:1. DISABLE, LEAD, LAG, STANDBY, INVALID2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG3. Reset, Off, Local, CCN4. Timeout, Ready, Recycle, Prestart, Startup Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout5. Stop, Start, Retain6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.

27


EXAMPLE 12 — ISM HIST DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight ISM HIST .

DESCRIPTION STATUS UNITS POINTISM FAULT HISTORYValues At Last Fault:Line Current Phase 1 0-99999 AMPS AMPS H1Line Current Phase 2 0-99999 AMPS AMPS H2Line Current Phase 3 0-99999 AMPS AMPS H3Line Voltage Phase 1 0-99999 VOLTS VOLTS H1Line Voltage Phase 2 0-99999 VOLTS VOLTS H2Line Voltage Phase 3 0-99999 VOLTS VOLTS H3Ground Fault Phase 1 0-999 AMPS GRFT H31Ground Fault Phase 2 0-999 AMPS GRFT H23Ground Fault Phase 3 0-999 AMPS GRFT H12I2T Sum Heat-Phase 1 0-200 % SUM1HT HI2T Sum Heat-Phase 2 0-200 % SUM2HT HI2T Sum Heat-Phase 3 0-200 % SUM3HT HPhase 1 Faulted? 0/1 NO/YES PHASE H1Phase 2 Faulted? 0/1 NO/YES PHASE H2Phase 3 Faulted? 0/1 NO/YES PHASE H3Line Frequency 0-99 Hz FREQ HISM Fault Status 0-9999 ISMFLT H


EXAMPLE 13 — WSMDEFME DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight WSMDEFME .

DESCRIPTION STATUS UNITS POINTWSM Active? 0/1 NO/YES WSMSTATChilled Water Temp 0.0-99.9 DEG F CHWTEMPEquipment Status 0/1 OFF/ON CHLRSTCommanded State XXXXXXXX TEXT CHLRENACHW setpt Reset Value 0.0-25.0 DEG F CHWRVALCurrent CHW Set Point 0.0-99.9 DEG F CHWSTPT


28


EXAMPLE 14 — NET OPT DISPLAY SCREEN


2. Press SERVICE .

3. Scroll down to highlight EQUIPMENT CONFIGURATION .

4. Press SELECT .

5. Scroll down to highlight NET OPT .

DESCRIPTION STATUS UNITS POINT DEFAULTLoadshed FunctionGroup Number 0-99 LDSGRPN 0Demand Limit Decrease 0-60 % LDSDLTA 20Maximum Loadshed Time 0-120 MIN MAXSHED 60

CCN Occupancy Config:Schedule Number 3-99 OCC NUM 3Broadcast Option 0-1 DSABLE/ENABLE OCCBRST DSABLE

Alarm ConfigurationRe-alarm Time 0-1440 MIN RETIME 30Alarm Routing 0-1 ROUTING 10000000

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

EXAMPLE 15 — ISM CONF DISPLAY SCREEN


2. Press SERVICE .

3. Scroll down to highlight ISM (STARTER) CONFIG DATA .

4. Press SELECT .

5. Scroll down to highlight ISM CONF .

DESCRIPTION STATUS UNITS POINT DEFAULTStarter Type 0-2 starter 1(0 = Full , 1 = Red, 2 = SS/VFD)Motor Rated Line Voltage 200-13200 VOLTS v fs 460Volt Transformer Ratio:1 1-33 vt rat 1Overvoltage Threshold 105-115 % overvolt 115Undervoltage Threshold 85-95 % undvolt 85Over/Under Volt Time 1-10 SEC uvuntime 5Voltage % Imbalance 1-10 % v unbal 10Voltage Imbalance Time 1-10 SEC v time 5Motor Rated Load Amps 10-5000 AMPS a fs 200Motor Locked Rotor Trip 100-60000 AMPS motor lr 1000Locked Rotor Start Delay 1-10 cycles lrdelay 5Starter LRA Rating 100-60000 AMPS start lr 2000Motor Current CT Ratio:1 3-1000 ct turns 100Current % Imbalance 5-40 % c unbal 15Current Imbalance Time 1-10 SEC c time 53 Grnd Fault CT’s? (1 = No) 0-1 NO/YES gf phase YESGround Fault CT Ratio:1 150 gf ctr 150Ground Fault Current 1-25 AMPS gf amps 15Ground Fault Start Delay 1-20 cycles gf delay 10Ground Fault Persistence 1-10 cycles gf pers 5Single Cycle Dropout 0/1 DSABLE/ENABLE cycdrop DSABLEFrequency = 60 Hz? (No = 50) 0/1 NO/YES freq YESLine Frequency Faulting 0/1 DSABLE/ENABLE freq en DSABLE


29


EXAMPLE 16 — OPTIONS DISPLAY SCREEN


2. Press SERVICE .

3. Scroll down to highlight EQUIPMENT SERVICE .

4. Press SELECT .

5. Scroll down to highlight OPTIONS .

DESCRIPTION STATUS UNITS POINT DEFAULTAuto Restart Option 0/1 DSABLE/ENABLE ASTART DSABLERemote Contacts Option 0/1 DSABLE/ENABLE MODES DSABLESoft Stop Amps Threshold 40-100 % STRTSTOP 100Surge/Hot Gas BypassSurge Limit/HGBP Option 0/1 srg hgbp 0Select: Surge = 0, HGBP = 1Min. Load Point (T1/P1)Surge/HGBP Delta T1 0.5-20 ^ F hgb dt1 1.5Surge/HGBP Delta P1 30-170 PSI hgb dp1 50Full Load Point (T2/P2)Surge/HGBP Delta T2 0.5-20 ^ F hgb dt2 10Surge/HGBP Delta P2 50-170 PSI hgb dp2 85Surge/HGBP Deadband 0.5-3 ^ F hgb db 1

Surge ProtectionSurge Delta % Amps 5-20 % surge a 10Surge Time Period 7-10 MIN surge t 8

Ice Build ControlIce Build Option 0/1 DSABLE/ENABLE ibopt DSABLEIce Build Termination 0-2 ibterm 00 = Temp, 1 = Contacts , 2 = BothIce Build Recycle 0/1 DSABLE/ENABLE ibrecyc DSABLE

Refrigerant Leak Option 0/1 DSABLE/ENABLE LEAK EN DSABLERefrigerant Leak Alarm mA 4-20 mA LEAK MA 20


EXAMPLE 17 — SETUP1 DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight SETUP1 .

DESCRIPTION STATUS UNITS POINT DEFAULTComp Motor Temp Override 150-200 DEG F MT OVER 200Cond Press Override 90-165 PSI CP OVER 125Comp Discharge Alert 125-200 DEG F C ALERT 200Comp Thrust Brg Alert 165-185 DEG F TB ALERT 175Chilled Medium 0/1 WATER/BRINE MEDIUM WATERChilled Water Deadband .5-2.0 ^F CS DB 1.0Evap Refrig Trippoint 0.0-40.0 DEG F ERT TRIP 33Refrig Override Delta T 2.0-5.0 ^F REF OVER 3Condenser Freeze Point −20 - 35 DEG F CDFREEZE 34Evap Flow Delta P Cutout 0.5 - 50.0 PSI EVAP CUT 5.0Cond Flow Delta P Cutout 0.5 - 50.0 PSI COND CUT 5.0Water Flow Verify Time 0.5-5 MIN WFLOW T 5Oil Press Verify Time 15-300 SEC OILPR T 40Recycle ControlRecycle Restart Delta T 2.0-10.0 DEG F RCYCR DT 5Recycle Shutdown Delta 0.5-4.0 DEG F RCYCS DT 1

SPARE ALERT/ALARM ENABLEDisable=0, Lo=1/3,Hi=2/4Spare Temp #1 Enable 0.4 sp1 en 0Spare Temp #1 Limit −40-245 DEG F sp1 lim 245Spare Temp #2 Enable 0-4 sp2 en 0Spare Temp #2 Limit -40-245 DEG F sp2 lim 245

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

30


EXAMPLE 18 — SETUP2 DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight SETUP2 .

DESCRIPTION STATUS UNITS POINT DEFAULTCapacity ControlProportional Inc Band 2-10 gv inc 6.5Proportional DEC Band 2-10 gv dec 6.0Proportional ECW Gain 1-3 gv ecw 2.0

Guide Vane Travel Limit 30-100 % gv ctrl 80Diffuser ControlDiffuser Option 0-1 DSABLE/ENABLE diff opt DSABLEGuide Vane 25% Load Pt 0-78 % gv 25 25Diffuser 25% Load 0-100 % df 25 0Guide Vane 50% Load Pt 0-78 % gv 50 50Diffuser 50% Load Pt 0-100 % df 50 0Guide Vane 75% Load Pt 0-78 % gv 75 75Diffuser 75% Load Pt 0-100 % df 75 0Diffuser Full Span mA 15-22 mA diff ma 18

VFD Speed ControlVFD Option 0/1 DSABLE/ENABLE vfd opt DSABLEVFD Gain 0.1-1.5 vfd gain 0.75VFD Increase Step 1-5 % vfd step 2VFD Minimum Speed 65-100 % vfd min 70VFD Maximum speed 90-100 % vfd max 100

NOTE: No variables are available for CCN read operation; forcing shall be supported on service screens.

EXAMPLE 19 − LEADLAG DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight LEADLAG .

DESCRIPTION STATUS UNITS POINT DEFAULTLead Lag ControlLEAD/LAG Configuration 0-3 leadlag 0DSABLE=0, LEAD=1,LAG=2, STANDBY=3

Load Balance Option 0/1 DSABLE/ENABLE load/bal DSABLECommon Sensor Option 0/1 DSABLE/ENABLE commsens DSABLELAG Percent Capacity 25-75 % lag per 50LAG Address 1-236 lag add 92LAG START Timer 2-60 MIN lagstart 10LAG STOP Timer 2-60 MIN lagstop 10PRESTART FAULT Timer 2-30 MIN preflt 5STANDBY Chiller Option 0/1 DSABLE/ENABLE stnd opt DSABLESTANDBY Percent Capacity 25-57 % stnd per 50STANDBY Address 1-236 stnd add 93


31


EXAMPLE 20 — RAMP_DEM DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight RAMP_DEM .

DESCRIPTION STATUS UNITS POINT DEFAULTPulldown Ramp Type: 0/1 RAMPSLCT 1Select: Temp=0, Load=1

Demand Limit + kW RampDemand Limit Source 0/1 dem src 0Select: Amps=0, kW=1Motor Load Ramp %/Min 5-20 kw ramp 10Demand Limit Prop Band 3-15 % dem app 10Demand Limit At 20 mA 40-100 % dem 20ma 4020 mA Demand Limit Opt 0/1 DSABLE/ENABLE dem sel DSABLEMotor Rated Kilowatts 50-9999 kW motor kw 145

Demand Watts Interval 5-60 MIN dw int 15


EXAMPLE 21 — TEMP_CTL DISPLAY SCREEN


2. Press SERVICE .


4. Press SELECT .

5. Scroll down to highlight TEMP_CTL .

DESCRIPTION STATUS UNITS POINT DEFAULTControl PointECW Control Option 0/1 DSABLE/ENABLE ecw opt DSABLETemp Pulldown Deg/Min 2-10 ^F tmp ramp 3

Temperature ResetRESET TYPE 1Degrees REset At 20 mA −30- 30 ^F deg 20ma 10RESET TYPE 2Remote Temp (No Reset) −40-245 DEG F res rt1 85Remote Temp (Full Reset) −40-245 DEG F res rt2 65Degrees Reset −30-30 ^F deg rt 10RESET TYPE 3CHW Delta T (No Reset) 0-15 ^F restd 1 10CHW Delta T (Full Reset) 0-15 ^F restd 2 0Degrees Reset −30-30 ^F deg chw 5Select/Enable Reset Type 0-3 res sel 0

32

PIC II System FunctionsNOTE: Words not part of paragraph headings and printedin all capital letters can be viewed on the CVC (e.g., LO-CAL, CCN, RUNNING, ALARM, etc.). Words printed inboth in all capital letters and italics can also be viewed onthe CVC and are parameters (CONTROL MODE, TARGETGUIDE VANEPOS,etc.) with associated values (e.g., modes,temperatures, pressures, percentages, on, off, enable, dis-able, etc.). Words printed in all capital letters and in a boxrepresent softkeys on the CVC (e.g., ENTERand EXIT ).See Table 2 for examples of the type of information that canappear on the CVC screens. Figures 12-18 give an overviewof CVC operations and menus.

CAPACITY CONTROL — The PIC II controls the chillercapacity by modulating the inlet guide vanes in response tochilled water temperature changes away from theCON-TROL POINT. TheCONTROL POINTmay be changed bya CCN network device or is determined by the PIC II addingany active chilled water reset to theSET POINT. The PIC IIuses thePROPORTIONAL INC (Increase) BAND, PRO-PORTIONAL DEC (Decrease) BAND,and thePROPOR-TIONAL ECW (Entering Chilled Water) GAINto determinehow fast or slow to respond.CONTROLPOINTmay be viewedor overridden from the MAINSTAT screen.

ECW CONTROL OPTION — If this option is enabled, thePIC II uses theENTERING CHILLED WATERtemperatureto modulate the vanes instead of theLEAVING CHILLEDWATERtemperature. TheECWCONTROLOPTIONmay beviewed on the TEMP_CTL screen, which is accessed fromthe EQUIPMENT SERVICE screen.

CONTROL POINT DEADBAND — This is the tolerancerange on the chilled water/brine temperature control point.If the water temperature goes outside theCHILLEDWATERDEADBAND,the PIC II opens or closes the guide vanes un-til the temperature is within tolerance. The PIC II may beconfiguredwith a 0.5 to 2 F (0.3 to 1.1 C) deadband.CHILLEDWATER DEADBANDmay be viewed or modified on theSETUP1 screen, which is accessed from the EQUIPMENTSERVICE table.For example, a 1° F (0.6° C) deadband setting controls

the water temperature within ±0.5° F (0.3° C) of the controlpoint. This may cause frequent guide vane movement if thechilled water load fluctuates frequently. A value of 1° F(0.6° C) is the default setting.

PROPORTIONALBANDSANDGAIN—Proportional bandis the rate at which the guide vane position is corrected inproportion to how far the chilled water/brine temperature isfrom the control point. Proportional gain determines howquickly the guide vanes react to how quickly the tempera-ture is moving from theCONTROL POINT.The propor-tional bands and gain may be viewed or modified from theSETUP2 screen, which is accessed from the EQUIPMENTSERVICE table.The Proportional Band — There are two response modes,one for temperature response above the control point, theother for the response below the control point.The temperature response above the control point is called

thePROPORTIONAL INC BAND,and it can slow or quickenguide vane response to chilled water/brine temperatures above

theDEADBAND. ThePROPORTIONAL INC BANDcan beadjusted from a setting of 2 to 10; the default setting is 6.5.The response below the control point is called the

PROPORTIONAL DEC BAND, and it can slow or quickenthe guide vane response to chilled water temperature belowthe deadband plus the control point. ThePROPORTIONALDEC BANDcan be adjusted on the CVC from a setting of2 to 10. The default setting is 6.0.

NOTE: Increasing either of these settings causes the guidevanes to respond more slowly than they would at a lowersetting.ThePROPORTIONAL ECW GAINcan be adjusted on theCVC display for values of 1, 2, or 3; the default setting is 2.Increase this setting to increase guide vane response to a changein entering chilled water temperature.DEMAND LIMITING — The PIC II responds to theACTIVE DEMAND LIMITset point by limiting the openingof the guide vanes. It compares theACTIVEDEMAND LIMITset point to theDEMAND LIMIT SOURCE(either theAVERAGE LINE CURRENTor theMOTOR KW).Depend-ing on how the control is configured.DEMAND LIMITSOURCEis on the RAMP_DEM screen. The default sourceis the compressor motor current.

CHILLERTIMERS—ThePIC II maintains 2 runtime clocks,known asCOMPRESSOR ONTIMEandSERVICE ON-TIME. COMPRESSOR ONTIMEindicates the total life-time compressor run hours. This timer can register up to500,000 hours before the clock turns back to zero. TheSERVICE ONTIMEis a reset table timer that can be used toindicate the hours since the last service visit or any otherevent. The time can be changed from the CVC to whatevervalue is desired. This timer can register up to 32,767 hoursbefore it rolls over to zero.The chiller also maintains a start-to-start timer and a stop-

to-start timer. These timers limit how soon the chiller can bestarted. START INHIBIT TIMER is displayed on theMAINSTAT screen. See the Start-Up/Shutdown/Recycle Se-quence section, page 45, for more information on this topic.

OCCUPANCY SCHEDULE — The chiller schedule, de-scribed in the Time Schedule Operation section (page 20),determines when the chiller can run. Each schedule consistsof from 1 to 8 occupied or unoccupied time periods, set bythe operator. The chiller can be started and run during anoccupied time period (whenOCCUPIED ?is set to YES onthe MAINSTAT display screen). It cannot be started or runduring an unoccupied time period (whenOCCUPIED ? isset to NO on the MAINSTAT display screen). These timeperiods 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 forOCCUPIED ?is YES, unless an un-occupied time period is in effect.These schedules can be set up to follow a building’s oc-

cupancy schedule, or the chiller can be set so to run 100%of the time, if the operator wishes. The schedules also can bebypassed by forcing theCHILLER START/STOPparameteron the MAINSTAT screen to START. For more informationon forced starts, see Local Start-Up, page 45.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.

33

Figure 17 shows a schedule for a typical office buildingwith a 3-hour, off-peak, cool-down period from midnightto 3 a.m., following a weekend shutdown. Holiday periodsare in an unoccupied state 24 hours per day. The buildingoperates Monday through Friday, 7:00 a.m. to 6:00 p.m., andSaturdays from 6:00 a.m. to 1:00 p.m. This schedule alsoincludes the Monday midnight to 3:00 a.m. weekend cool-down schedule.

NOTE: This schedule is for illustration only and is not in-tended to be a recommended schedule for chiller operation.Whenever the chiller is in the LOCAL mode, it uses

Occupancy Schedule 01 (OCCPC01S). When the chiller isin the ICE BUILD mode, it uses Occupancy Schedule 02(OCCPC02S). When the chiller is in CCN mode, it usesOccupancy Schedule 03 (OCCPC03S).The CCNSCHEDULE NUMBERis configured on the

NET_OPT display screen, accessed from the EQUIPMENTCONFIGURATION table. See Table 2, Example 14.SCHEDULE NUMBERcan be changed to any value from03 to 99. If this number is changed on the NET_OPT screen,the operator must go to the ATTACH TO NETWORK DE-VICE screen to upload the new number into the SCHED-ULE screen. See Fig. 16.

Safety Controls — The PIC II monitors all safety con-trol inputs and, if required, shuts down the chiller or limitsthe guide vanes to protect the chiller from possible damagefrom 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 temperatureand sensible temperature. The high discharge temperaturesafety measures only sensible temperature.

Starter faults or optional protective devices within the startercan shut down the chiller. The protective devices youhave for your application depend on what options werepurchased.

If compressor motor overload occurs, check the motorfor grounded or open phases before attempting arestart.

If the PIC II control initiates a safety shutdown, it dis-plays the reason for the shutdown (the fault) on the CVCdisplay screen along with a primary and secondary message,energizes an alarm relay in the starter, and blinks the alarmlight on the control panel. The alarm is stored in memoryand can be viewed on the ALARM HISTORY andISM_HIST screens on the CVC, along with a message fortroubleshooting. If the safety shutdown was also initiated bya fault detected in the motor starter, the conditions at thetime of the fault will be stored in ISM_HIST.To give more precise information or warnings on the chill-

er’s operating condition, the operator can define alert limitson various monitored inputs. Safety contact and alert limitsare defined in Table 3. Alarm and alert messages are listedin the Troubleshooting Guide section, page 71.

34

Table 3 — Protective Safety Limits and Control Settings

MONITORED PARAMETER LIMIT APPLICABLE COMMENTSTEMPERATURE SENSOR OUT OFRANGE

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

PRESSURE TRANSDUCERS OUT OFRANGE

0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds.Ratio = Input Voltage ÷ Voltage Reference

COMPRESSOR DISCHARGETEMPERATURE

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

MOTOR WINDING TEMPERATURE .220 F (104.4 C) Preset, alert setting configurableBEARING TEMPERATURE .185 F (85 C) Preset, alert setting configurableEVAPORATOR REFRIGERANTTEMPERATURE

,33 F (for water chilling) (0.6° C) Preset, configure chilled medium for water(SETUP1 table)

,EVAP REFRIG TRIPPOINT (set pointadjustable from 0 to 40 F [–18 to 4 C] forbrine chilling)

Configure chilled medium for brine (SETUP1table). Adjust EVAP REFRIG TRIPPOINT forproper cutout

TRANSDUCER VOLTAGE ,4.5 vdc,. 5.5 vdc PresetCONDENSER PRESSURE — SWITCH .165 ± 5 psig (1138 ± 34 kPa), reset at

110 ± 7 psig (758 ± 48 kPa)Preset

— CONTROL 165 psig (1138 kPa) PresetOIL PRESSURE Cutout ,15 psid (103 kPad)

Alert ,18 psid (124 kPad)Preset

LINE VOLTAGE — HIGH >150% for 1 second or >115% for 10 seconds Preset, based on transformed line voltage toISM. Also monitored at CVC and CCM powerinput.

— LOW <85% for 10 seconds or <80% for 5 secondsor <75% for 1 second

— SINGLE-CYCLE ,50% for one cycleCOMPRESSOR MOTOR LOAD .110% for 30 seconds Preset

,15% with compressor running Preset.15% with compressor off Preset

STARTER ACCELERATION TIME(Determined by inrush currentgoing below 100% compressormotor load)

.45 seconds For chillers with reduced voltage mechanicaland solid-state starters

.10 seconds For chillers with full voltage starters(Configured on ISM_CONFIG table)

STARTER TRANSITION .75 seconds Reduced voltage starters onlyCONDENSER FREEZE PROTECTION Energizes condenser pump relay if condenser

refrigerant temperature or entering watertemperature is below the configured con-denser freeze point temperature. Deenergizeswhen the temperature is 5 F (3 C) abovecondenser freeze point temperature.

CONDENSER FREEZE POINT configured inSETUP1 table with a default setting of34 F (1 C).

DISCHARGE SUPERHEAT Minimum value calculated based onoperating conditions and then comparedto actual superheat.

Calculated minimum required superheat andactual superheat are shown on OVERRIDEscreen.

VARIABLE DIFFUSER OPERATION Detects discharge pulses caused by incorrectdiffuser position.

Preset, no calibration needed.

35

Shunt Trip (Option) — The function of the shunt tripoption on the PIC II is to act as a safety trip. The shunt tripis wired from an output on the ISM to a shunt trip equippedmotor circuit breaker. If the PIC II tries to shut down thecompressor using a normal shutdown procedure but is un-successful for 30 seconds, the shunt trip output is energizedand causes the circuit breaker to trip off. If ground fault pro-tection has been applied to the starter, the ground fault tripalso energizes the shunt trip to trip the circuit breaker. Pro-tective devices in the starter can also energize the shunt trip.The shunt trip feature can be tested using the Control Testfeature.

Default Screen Freeze — When the chiller is in analarm state, the default CVC display ‘‘freezes,’’ that is, itstops updating. The first line of the CVC default screen dis-plays a primary alarm message; the second line displays asecondary alarm message.The CVC default screen freezes to enable the operator to

see the conditions of the chillerat the time of the alarm.Ifthe value in alarm is one normally displayed on the defaultscreen, it flashes between normal and reverse video. The CVCdefault screen remains frozen until the condition that causedthe alarm is remedied by the operator.

Knowledge of the operating state of the chiller at the timean alarm occurs is useful when troubleshooting. Additionalchiller information can be viewed on the status screens andthe ISM_HIST screen. Troubleshooting information is re-corded in the ALARM HISTORY table, which can be ac-cessed from the SERVICE menu.To determine what caused the alarm, the operator should

read both the primary and secondary default screen mes-sages, as well as the alarm history. The primary messageindicates themost recent alarm condition. The secondarymes-sage gives more detail on the alarm condition. Since theremay be more than one alarm condition, another alarm mes-sage may appear after the first condition is cleared. Checkthe ALARM HISTORY screen for additional help in deter-mining the reasons for the alarms. Once all existing alarmsare cleared (by pressing the RESETsoftkey), the defaultCVC display returns to normal operation.

Ramp Loading— The ramp loading control slows downthe rate at which the compressor loads up. This control canprevent the compressor from loading up during the short pe-riod of time when the chiller is started and the chilled waterloop has to be brought down toCONTROLPOINT.This helpsreduce electrical demand charges by slowly bringing the chilledwater toCONTROL POINT.The total power draw duringthis period remains almost unchanged.There are two methods of ramp loading with the PIC II.

Ramp loading can be based on chilled water temperature oron motor load. Either method is selected from theRAMP__DEM screen.1. Temperature ramp loading(TEMP PULLDOWN DEG/

MIN) limits the degrees per minute rate at which eitherleaving chilled water or entering chilled water tempera-ture decreases. This rate is configured by the operator onthe TEMP_CTL screen. The lowest temperature ramp ratewill also be used if chiller power has been off for 3 hoursor more (even if the motor ramp load is selected as theramp loading method.

2. Motor load ramp loading(LOAD PULLDOWN)limits thedegrees per minute rate at which the compressor motorcurrent or compressor motor load increases. TheLOADPULLDOWN rate is configured by the operator on theRAMP_DEM screen in amps or kilowatts.

If kilowatts is selected for theDEMAND LIMIT SOURCE,theMOTOR RATED KILOWATTSmust be entered (infor-mation found on the chiller Requisition form).TheTEMPPULLDOWNDEG/MINmaybe viewedormodi-

fied on the TEMP_CTL screen which is accessed from theEQUIPMENTSERVICE screen.PULLDOWNRAMPTYPE,DEMAND LIMIT SOURCE,and MOTOR LOAD RAMP%/MINmaybe viewedormodified on theRAMP_DEMscreen.

Capacity Override (Table 4) — Capacity overridescan prevent some safety shutdowns caused by exceeding themotor amperage limit, refrigerant low temperature safety limit,motor high temperature safety limit, and condenser high pres-sure limit. In all cases there are 2 stages of compressor vanecontrol.1. The vanes are prevented from opening further, and

the status line on the CVC indicates the reason for theoverride.

2. The vanes are closed until the condition decreases to be-low the first step set point. Then the vanes are released tonormal capacity control.Whenever the motor current demand limit set point

(ACTIVE DEMAND LIMIT) is reached, it activates a capac-ity override, again, with a 2-step process. Exceeding 110%of the rated load amps for more than 30 seconds will initiatea safety shutdown.The compressor high lift (surge prevention) set point will

cause a capacity override as well. When the surge preven-tion set point is reached, the controller normally will onlyprevent the guide vanes from opening. If so equipped, thehot gas bypass valve will open instead of holding the vanes.See the Surge Prevention Algorithm section, page 39.

HighDischarge Temperature Control— If the dis-charge temperature increases above 160 F (71.1 C), the guidevanes are proportionally opened to increase gas flow throughthe compressor. If the leaving chilled water temperature isthen brought 5° F (2.8° C) below the control set point tem-perature, the PIC II will bring the chiller into the recyclemode.

Oil SumpTemperatureControl— The oil sump tem-perature control is regulated by the PIC II, which uses theoil heater relay when the chiller is shut down.As part of the pre-start checks executed by the controls,

the oil sump temperature (OIL SUMP TEMP) is comparedto the cooler refrigerant temperature (EVAPORATORREFRIG TEMP). If the difference between these 2 tempera-tures is 50 F (27.8 C) or less, the start-up will be delayeduntil the oil temperature is 50 F (27.8 C) or more. Once thistemperature is confirmed, the start-up continues.The oil heater relay is energized whenever the chiller com-

pressor is off and the oil sump temperature is less than140 F (60.0 C) or the oil sump temperature is less thanthe cooler refrigerant temperature plus 53° F (11.7° C). Theoil heater is turned off when the oil sump temperature iseither• more than 152 F (66.7 C), or• more than 142 F (61.1 C) and more than the coolerrefrigerant temperature plus 55° F (12.8° C).

The oil heater is always off during start-up or when thecompressor is running.The oil pump is also energized during the time the oil

is being heated (for 60 seconds at the end of every30 minutes).

36

Table 4 — Capacity Overrides

OVERRIDECAPACITY CONTROL

FIRST STAGE SET POINT SECOND STAGESET POINT

OVERRIDETERMINATION

View/Modifyon CVC Screen

DefaultValue

ConfigurableRange Value Value

HIGH CONDENSERPRESSURE SETUP1 125 psig

(862 kPa)90 to 165 psig

(620 to 1138 kPa)

.OverrideSet Point

+ 2.4 psid (16.5 kPad)

,OverrideSet Point

HIGH MOTORTEMPERATURE SETUP1 .200 F

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

.OverrideSet Point

+10° F (6° C)

,OverrideSet Point

LOW REFRIGERANTTEMPERATURE(Refrigerant

Override DeltaTemperature)

SETUP1 3° F (1.6° C) 2° to 5° F(1° to 3° C)

<Trippoint+ Override

DT –1° F (0.56° C)

.Trippoint+ Override

DT +2° F (1.2° C)

HIGH COMPRESSORLIFT

(Surge Prevention)OPTIONS

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)

0.5° to 15° F(0.3° to 8.3° C)30 to 170 psid

(207 to1172 kPad)0.5° to 15° F(0.3° to 8.3° C)50 to 170 psid

(348 to 1172 kPad)

NoneWithin Lift LimitsPlus Surge/HGBPDeadband Setting

MANUAL GUIDE VANETARGET CAPACITY Automatic 0 to 100% None Release of

Manual ControlMOTOR LOAD —

ACTIVE DEMAND LIMIT MAINSTAT 100% 40 to 100% >5% ofSet Point

2% LowerThan Set Point

LOW DISCHARGESUPERHEAT OVERRIDE

Calculated MinimumSuperheat

for ConditionsNone

2° F (1.1° C)Below Calculated

Minimum Superheat

1° F (0.56° C)Above CalculatedMinimum Superheat

Oil Cooler — The oil must be cooled when the com-pressor is running. This is accomplished through a small,plate-type heat exchanger (also called the oil cooler) locatedbehind the oil pump. The heat exchanger uses liquid con-denser refrigerant as the cooling liquid. Refrigerant thermo-static expansion valves (TXVs) regulate refrigerant flow tocontrol the oil temperature entering the bearings. The bulbsfor the expansion valves are strapped to the oil supply lineleaving the heat exchanger, and the valves are set to main-tain 110 F (43 C).NOTE: The TXVs are not adjustable. The oil sump temper-ature may be at a lower temperature during compressoroperations.

RemoteStart/StopControls— Aremote device, suchas a timeclock that uses a set of contacts, may be used tostart and stop the chiller. However, the device should not beprogrammed to start and stop the chiller in excess of 2 or3 times every 12 hours. If more than 8 starts in 12 hours (theSTARTS IN 12 HOURSparameter on the MAINSTAT screen)occur, an excessive starts alarm displays, preventing the chillerfrom starting. The operator must press the RESETsoftkeyon the CVC to override the starts counter and start the chiller.If the chiller records 12 starts (excluding recycle starts) in asliding 12-hour period, it can be restarted only by pressingthe RESET softkey followed by the LOCALor CCNsoftkey. This ensures that, if the automatic system is mal-functioning, the chiller will not repeatedly cycle on and off.If the automatic restart after a power failure option (AUTORESTART OPTIONon the OPTIONS screen) is not acti-vated when a power failure occurs, and if the remote contactis closed, the chiller will indicate an alarm because of theloss of voltage.The contacts for remote start are wired into the starter at

terminal strip J2, terminals 5 and 6 on the ISM. See the cer-tified drawings for further details on contact ratings. The con-tacts must have 24 vac rating.

Spare Safety Inputs — Normally closed (NC) dis-crete inputs for additional field-supplied safetiesmay be wiredto the spare protective limits input channel in place of the

factory-installed jumper. (Wire multiple inputs in series.) Theopening of any contact will result in a safety shutdown anda display on the CVC. Refer to the certified drawings forsafety contact ratings.Analog temperature sensors may also be added to the mod-

ule (SPARE TEMP #1 and #2). The analog temperature sen-sors may be configured to cause an alert or alarm on the CCNnetwork. The alert will not shut the chiller down. Config-uring for alarm state will cause the chiller to shut down.

Spare Safety Alarm Contacts — One set of alarmcontacts is provided in the starter. The contact ratings areprovided in the certified drawings. The contacts are locatedon terminal strip JP, terminals 15 and 16.

Refrigerant Leak Detector — An input is availableon the CCM module [terminal 15-5 (−) and J5-6 (+)] for arefrigerant leak detector. EnablingREFRIGERANT LEAKOPTION(OPTIONS screen) will allow the PIC II controlsto go into an alarm state at a user configured level(REFRIGERANT LEAK ALARM mA).The input is config-ured for 4 to 20 mA by setting the DIP switch 1 on SW2 atthe ON position, or configured for 0 to 5 vdc by setting switch1 at the OFF position. The output of the refrigerant leak de-tector is displayed asREFRIGERANT LEAK SENSORon theMAINSTAT screen. For a 0 to 5 vdcinput, 0 vdc input rep-resents 4 mA displayed and 5 vdc input represents 20 mAdisplayed.

Condenser Pump Control — The chiller will moni-tor the condenser pressure (CONDENSER PRESSURE) andmay turn on the condenser pump if the condenser pressurebecomes too high while the compressor is shut down. Thecondenser pressure override (COND PRESS OVERRIDE)parameter is used to determine this pressure point.CONDPRESS OVERRIDEis found in the SETUP1 display screen,which is accessed from the EQUIPMENT SERVICE table.The default value is 125 psig (862 kPa).If the CONDENSER PRESSUREis greater than or equal

to theCOND PRESS OVERRIDE,and the entering con-denser water temperature (ENTERING CONDENSERWATER)is less than 115 F (46 C), the condenser pump will

37

energize to try to decrease the pressure. The pump willturn off when the condenser pressure is 3.5 psi (24.1 kPa)less than the pressure override or when the condenser re-frigerant temperature (CONDENSERREFRIGTEMP)is within3° F (1.7° C) of the entering condenser water temperature(ENTERING CONDENSER WATER).

Condenser Freeze Prevention — This controlalgorithm helps prevent condenser tube freeze-up by ener-gizing the condenser pump relay. The PIC II controls thepump and, by starting it, helps to prevent the water in thecondenser from freezing. The PIC II can perform this func-tion whenever the chiller is not runningexceptwhen it iseither actively in pumpdown or in pumpdown/lockout withthe freeze prevention disabled.When theCONDENSER REFRIG TEMPis less than

or equal to theCONDENSER FREEZE POINT, theCONDENSER WATER PUMPis energized until theCONDENSER REFRIG TEMPis greater than theCON-DENSER FREEZE POINTplus 5° F (2.7° C) and theENTERING CONDENSER WATER TEMPERATUREis lessthan or equal to theCONDENSERFREEZEPOINT.An alarmis generated if the chiller is in PUMPDOWN mode and thepump is energized. An alert is generated if the chiller is notin PUMPDOWN mode and the pump is energized. If thechiller is in RECYCLE SHUTDOWN mode, the mode willtransition to a non-recycle shutdown.

Tower Fan Relay Low and High — Low condenserwater temperature can cause the chiller to shut down whenrefrigerant temperature is low. The tower fan relays, locatedin the starter, are controlled by the PIC II to energize anddeenergize as the pressure differential between cooler andcondenser vessels changes. This prevents low condenser wa-ter temperature and maximizes chiller efficiency. The towerfan relay can only accomplish this if the relay has been addedto the cooling tower temperature controller.The tower fan relay low is turned on whenever the con-

denser water pump is running, flow is verified, and the dif-ference between cooler and condenser pressure is more than30 psid (207 kPad) for entering condenser water tempera-ture 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 tem-perature is less than the override temperature forENTER-ING CONDENSER WATERtemperature less than 62 F(16.7 C), or the differential pressure is less than 25 psid(172.4 kPad) for entering condenser water less than80 F (27 C).The tower fan relay high is turned on whenever the con-

denser water pump is running, flow is verified and the dif-ference between cooler and condenser pressure is more than35 psid (241.3 kPa) for entering condenser water tempera-ture greater than theTOWER FAN HIGH SETPOINT(SET-POINT 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 tem-perature is less than the override temperature andENTER-ING CONDENSERWATERis less than 70 F (21.1 C), or thedifference between cooler and condenser pressure is less than28 Psid (193 kPa), orENTERINGCONDENSERWATERtem-perature is less thanTOWER FAN HIGH SETPOINTminus3 F (−16.1 C).TheTOWER FAN RELAY LOWandHIGH parameter is

accessed from the STARTUP screen.

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

The tower fan relay control is not a substitute for acondenser water temperature control. When used witha water temperature control system, the tower fan relaycontrol can be used to help prevent low condenserwater temperatures.

Auto. Restart After Power Failure — This optionmay be enabled or disabled and may be viewed or modifiedon the OPTIONS screen, which is accessed from the EQUIP-MENT CONFIGURATION table. If theAUTO. RESTARToption is enabled, the chiller will start up automatically aftera power failure has occurred (after a single cycle dropout;low, high, or loss of voltage; and the power is within ± 10%of normal). The 15- and 3-minute inhibit timers are ignoredduring 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 forone minute before energizing the cooler pump.AUTO.RESTARTwill then continue like a normal start-up.If power to the CVC module has been off for more than

3 hours or the timeclock has been set for the first time, startthe compressor with the slowest temperature-based ramp loadrate 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 toeliminate refrigerant that has migrated to the oil sump dur-ing the power failure. The pump turns on for 60 seconds atthe end of every 30-minute period until the chiller is started.

Water/Brine Reset — Three types of chilled water orbrine reset are available and can be viewed or modified onthe TEMP_CTL screen, which is accessed from the EQUIP-MENT SERVICE table.The CVC default screen indicates when the chilled water

reset is active.TEMPERATURE RESETon the MAINSTATscreen indicates the amount of reset. The CONTROLPOINTwill be determined by adding theTEMPERATURE RESETto the SETPOINT.To activate a reset type, access the TEMP_CTL screen 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 (0 to 5 vdc)TEMPERATURERESET— Reset Type 1 is an automatic chilled water tem-perature reset based on a remote temperature sensor inputconfigured for either an externally powered 4 to 20 mA or a0 to 5 vdc signal. Reset Type 1 permits up to ±30 F (±16 C)of automatic reset to the chilled water set point.The auto, chilled water reset is hardwired to terminals

J5-3 (−) and J5-4 (+) on the CCM. Switch setting number 2on SW2 will determine the type of input signal. With theswitch set at the ON position the input is configured for anexternally powered 4 to 20 mAsignal. With the switch in theOFF position the input is configured for an external0 to 5 vdc signal.RESETTYPE 2: REMOTETEMPERATURERESET—Re-set Type 2 is an automatic chilled water temperature resetbased on a remote temperature sensor input signal. Reset Type2 permits ± 30° F (± 16° C) of automatic reset to the setpoint based on a temperature sensor wired to the CCMmod-ule (see wiring diagrams or certified drawings). The tem-perature sensor must be wired to terminal J4-13 and J4-14.To configure Reset Type 2, enter the temperature of

the remote sensor at the point where no temperature resetwill occur (REMOTE TEMP [NO RESET]). Next, enter thetemperature at which the full amount of reset will occur

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(REMOTE TEMP [FULL RESET]). Then, enter the maxi-mum 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 automatic chilled wa-ter temperature reset based on cooler temperature differ-ence. Reset Type 3 adds ± 30° F (± 16° C) based on thetemperature difference between the entering and leaving chilledwater temperature.To configure Reset Type 3, enter the chilled water tem-

perature difference (the difference between entering andleaving chilled water) at which no temperature reset occurs(CHW DELTA T [NO RESET]). This chilled water temper-ature difference is usually the full design load temper-ature difference. Next, enter the difference in chilled watertemperature at which the full amount of reset occurs (CHWDELTA T [FULL RESET]). Finally, enter the amount of re-set (DEGREES RESET). Reset Type 3 can now be activated.

Demand Limit Control Option— The demand limitcontrol option (20 mA DEMAND LIMIT OPT) is externallycontrolled by a 4 to 20 mA or 0 to 5 vdcsignal from anenergy management system (EMS). The option is set up onthe RAMP_DEM screen. When enabled, 4 mA is the 100%demand set point with an operator-configured minimum de-mand at a 20 mA set point (DEMAND LIMIT AT 20 mA).The auto. demand limit is hardwired to terminals J5-5 (−)

and J5-6 (+) on the CCM. Switch setting number 1 on SW2will determine the type of input signal. With the switch setat the ON position the input is configured for an externallypowered 4 to 20 mA signal. With the switch in the OFFposition the input is configured for an external 0 to 5 vdcsignal.

Surge Prevention Algorithm— This is an operator-configurable feature that can determine if lift conditions aretoo high for the compressor and then take corrective action.Lift is defined as the difference between the pressure at theimpeller eye and at the impeller discharge. The maximumlift a particular impeller wheel can perform varies with thegas flow across the impeller and the size of the wheel.A surge condition occurs when the lift becomes so

high the gas flow across the impeller reverses. This condi-tion can eventually cause chiller damage. The surge preven-tion algorithm notifies the operator that chiller operatingconditions are marginal and to take action to help preventchiller damage such as lowering entering condenser watertemperature.

The surge prevention algorithm first determines if cor-rective action is necessary. The algorithm checks 2 sets ofoperator-configured data points, theminimum load points (MIN.LOAD POINT [T1/P1]) and the full load points (FULLLOAD POINT [T2/P2]). These points have default settingsas defined on the OPTIONS screen or on Table 4.

The surge prevention algorithm function and settings aregraphically displayed in Fig. 19 and 20. The two sets of loadpoints on the graph (default settings are shown) describe aline the algorithm uses to determine the maximum lift of thecompressor. When the actual differential pressure betweenthe cooler and condenser and the temperature difference be-tween the entering and leaving chilled water are above theline on the graph (as defined by the minimum and full loadpoints), the algorithm goes into a corrective action mode. Ifthe actual values are below the line and outside of the dead-band region, the algorithm takes no action. When the pointdefined by theACTIVE DELTA PandACTIVE DELTA T,moves from the region where the HOT GAS BYPASS/SURGE PREVENTION is off, the point must pass throughthe deadband region to the line determined by the config-ured valves before the HOT GAS BYPASS/SURGEPREVENTION will be turned on. As the point moves fromthe region where the HOT GAS BYPASS/SURGE

PREVENTION is on, the point must pass through the dead-band region before the HOT GAS BYPASS/SURGE PRE-VENTION is turned off. Information on modifying the de-fault set points of the minimum and full load points may befound in the Input Service Configurations section, page 54.Corrective action can be taken by making one of 2 choices.

If a hot gas bypass line is present and the hot gas optionis selected on the OPTIONS table (SURGE LIMIT/HGBPOPTION is set to 1), the hot gas bypass valve can be ener-gized. If the hot gas bypass option is not selected (SURGELIMIT/HGBP OPTIONis set to 0), hold the guide vanes.See Table 4, Capacity Overrides. Both of these correctiveactions try to reduce the lift experienced by the compressorand help prevent a surge condition.

LEGEND

ECW — Entering Chilled WaterHGBP — Hot Gas BypassLCW — Leaving Chilled WaterDP = (Condenser Psi) − (Cooler Psi)DT = (ECW) − (LCW)

Fig. 19 — 19XRT Hot Gas Bypass/SurgePrevention with Default English Settings

LEGEND

ECW — Entering Chilled WaterHGBP — Hot Gas BypassLCW — Leaving Chilled WaterDP = (Condenser kPa) − (Cooler kPa)DT = (ECW) − (LCW)

Fig. 20 — 19XRT Hot Gas Bypass/SurgePrevention with Default Metric Settings

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Surge Protection— The PIC II monitors surge, whichis a fluctuation in compressor motor amperage. Each timethe fluctuation exceeds an operator-specified limit (SURGEDELTA % AMPS), the PIC II counts the surge. If more than5 surges occur within an operator-specified time (SURGETIME PERIOD), the PIC II initiates a surge protection shut-down of the chiller.The surge limit can be adjusted from the OPTIONS screen.

Scroll down to theSURGE DELTA % AMPSparameter, anduse the INCREASEor DECREASEsoftkey to adjust thepercent of surge. The default setting is 10% amps.The surge time period can also be adjusted from the

OPTIONS screen. Scroll to theSURGE TIME PERIODparameter, and use the INCREASEor DECREASEsoft-key to adjust the amount of time. The default setting is8 minutes.

Access the display screen (COMPRESS) to monitor thesurge count (SURGE PROTECTION COUNTS).

Lead/Lag Control — The lead/lag control systemautomatically starts and stops a lag or second chiller in a2-chiller water system. A third chiller can be added to thelead/lag system as a standby chiller to start up in casethe lead or lag chiller in the system has shut down duringan alarm condition and additional cooling is required.Refer to Fig. 15 and 16 for menu, table, and screen selectioninformation.NOTE: The lead/lag function can be configured on the LEAD-LAG screen, which is accessed from the SERVICE menuand EQUIPMENT SERVICE table. See Table 2,Example 19. Lead/lag status during chiller operation can beviewed on the LL_MAINT display screen, which is ac-cessed from the SERVICE menu and CONTROL ALGO-RITHM STATUS table. See Table 2, Example 11.

Lead/Lag System Requirements:• all chillers in the system must have software capable ofperforming 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 waterflow

COMMON POINT SENSOR INSTALLATION — Lead/lag operation does not require a common chilled water pointsensor. Common point sensors (Spare Temp #1 and #2) canbe added to the CCMmodule, 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 achilled water system, each chiller should have its own com-mon point sensor installed. Each chiller uses its own com-mon point sensor for control when that chiller is designatedas the lead chiller. The PIC II cannot read the value of com-mon point sensors installed on the other chillers in the chilledwater system.If leaving chilled water control (ECW CONTROL OP-

TION is set to 0 [DSABLE], TEMP_CTL screen) and a com-mon point sensor is desired (COMMON SENSOR OPTIONin LEADLAG screen selected as 1) then the sensor is wiredin Spare Temp #1 position on the CCM.

If the entering chilled water control option (ECW CON-TROLOPTION) is enabled (configured in TEMP_CTLscreen)and a common point sensor is desired (COMMON SENSOROPTIONin LEADLAG screen selected as 1) then the sensoris 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, theleaving chilled water sensor of the upstream chiller must bemoved into the leaving chilled water pipe of the downstreamchiller.If return chilled water control is required on chillers piped

in series, the common point return chilled water sensor shouldbe installed. If this sensor is not installed, the return chilledwater sensor of the downstream chiller must be relocated tothe return chilled water pipe of the upstream chiller.To properly control the common supply point temperature

sensorwhen chillers are piped in parallel, thewater flow throughthe shutdown chillers must be isolated so no water bypassaround the operating chiller occurs. The common point sen-sor option must not be used if water bypass around theoperating chiller is occurring.

CHILLER COMMUNICATION WIRING — Refer to thechiller’s Installation Instructions, Carrier Comfort NetworkInterface section for information on chiller communicationwiring.LEAD/LAG OPERATION — The PIC II not only has theability to operate 2 chillers in lead/lag, but it can also starta designated standby chiller when either the lead or lag chilleris faulted and capacity requirements are not met. The lead/lag option only operates when the chillers are in CCNmode.If any other chiller configured for lead/lag is set to theLOCAL or OFF modes, it will be unavailable for lead/lagoperation.Lead/Lag Chiller Configuration and Operation• A chiller is designated the lead chiller when itsLEAD/LAG CONFIGURATIONvalue on the LEADLAG screenis set to ‘‘1.’’

• A chiller is designated the lag chiller when itsLEAD/LAGCONFIGURATIONvalue is set to ‘‘2.’’

• A chiller is designated as a standby chiller when itsLEAD/LAG CONFIGURATIONvalue is set to ‘‘3.’’

• Avalue of ‘‘0’’ disables the lead/lag designation of a chiller.

To configure theLAG ADDRESSvalue on the LEAD-LAG screen, always enter the address of the other chiller onthe system. For example, if you are configuring chiller A,enter the address for chiller B as the lag address. If you areconfiguring chiller B, enter the address for chiller A as thelag address. This makes it easier to rotate the lead and lagchillers.If the address assignments in theLAG ADDRESSand

STANDBY ADDRESSparameters conflict, the lead/lag func-tion is disabled and an alert (!) message displays. Forexample, if theLAG ADDRESSmatches the lead chiller’saddress, the lead/lag will be disabled and an alert (!)message displayed. The lead/lag maintenance screen(LL_MAINT) displays the message ‘INVALID CONFIG’ intheLEAD/LAG: CONFIGURATIONandCURRENTMODEfields.The lead chiller responds to normal start/stop controls such

as the occupancy schedule, a forced start or stop, and remotestart contact inputs. After completing start-up and ramp load-ing, the PIC II evaluates the need for additional capacity. Ifadditional capacity is needed, the PIC II initiates the start-upof the chiller configured at theLAG ADDRESS. If the lagchiller is faulted (in alarm) or is in the OFF or LOCALmodes,the chiller at theSTANDBY ADDRESS(if configured) isrequested to start. After the second chiller is started and is

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running, the lead chiller monitors conditions and eval-uates whether the capacity has been reduced enough for thelead chiller to sustain the system alone. If the capacity isreduced enough for the lead chiller to sustain theCONTROLPOINT temperatures alone, then the operating lag chiller isstopped.If the lead chiller is stopped in CCN mode for any reason

other than an alarm (*) condition, the lag and standby chill-ers are also stopped. If the configured lead chiller stops foran alarm condition, the configured lag chiller takes the leadchiller’s place as the lead chiller, and the standby chiller servesas the lag chiller.If the configured lead chiller does not complete the start-up

before thePRESTART FAULT TIMER(a user-configuredvalue) elapses, then the lag chiller starts and the lead chillershuts down. The lead chiller then monitors the start requestfrom the acting lead chiller. ThePRESTART FAULT TIMERis initiated at the time of a start request. ThePRESTARTFAULTTIMERprovides a timeout if there is a prestart alert condi-tion that prevents the chiller from starting in a timely man-ner. ThePRESTARTFAULTTIMERparameter is on the LEAD-LAG screen, which is accessed from the EQUIPMENTSERV-ICE table of the SERVICE menu.If the lag chiller does not achieve start-up before the

PRESTART FAULT TIMERelapses, the lag chiller stops, andthe standby chiller is requested to start, if configured andready.Standby Chiller Configuration and Operation —Achiller isdesignated as a standby chiller when itsLEAD/LAGCONFIGURATIONvalue on the LEADLAG screen is set to‘‘3.’’ The standby chiller can operate as a replacement forthe lag chiller only if one of the other two chillers is in analarm (*) condition (as shown on the CVC panel). If bothlead and lag chillers are in an alarm (*) condition, the standbychiller defaults to operate in CCN mode, based on its con-figured occupancy schedule and remote contacts input.Lag Chiller Start-Up Requirements — Before the lag chillercan be started, the following conditions must be met:1. Lead chiller ramp loading must be complete.2. Lead chilled water temperature must be greater than the

CONTROLPOINTtemperature (see theMAINSTATscreen)plus 1/2 theCHILLED WATER DEADBANDtempera-ture (see the SETUP1 screen).NOTE: The chilled water temperature sensor may be theleaving chilled water sensor, the return water sensor, thecommon supply water sensor, or the common return wa-ter sensor, depending on which options are configured andenabled.

3. Lead chiller ACTIVE DEMAND LIMIT (see theMAINSTAT screen) value must be greater than 95% offull load amps.

4. Lead chiller temperature pulldown rate (TEMP PULL-DOWNDEG/MINon theTEMP_CTLscreen) of the chilledwater temperature is less than 0.5° F (0.27° C) per minute.

5. The lag chiller status indicates it is in CCN mode and isnot in an alarm condition. If the current lag chiller is inan alarm condition, the standby chiller becomes the ac-tive lag chiller, if it is configured and available.

6. The configuredLAG START TIMERentry has elapsed.The LAG START TIMERstarts when the lead chillerramp loading is completed. TheLAG START TIMERentry is on the LEADLAG screen, which is accessedfrom the EQUIPMENT SERVICE table of theSERVICE menu.When all the above requirements have been met, the lag

chiller is commanded to a STARTUPmode (SUPVSR flash-ing next to the point value on the STATUS table). ThePIC II control then monitors the lag chiller for a successful

start. If the lag chiller fails to start, the standby chiller, ifconfigured is started.Lag Chiller Shutdown Requirements — The following con-ditions 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 KILOWATTSon the MAIN-STAT screen) is less than the lead chiller percentcapacity.NOTE: Lead chiller percent capacity = 115 –LAG PER-CENT CAPACITY.The LAG PERCENT CAPACITYparameter is on the LEADLAG screen, which is accessedfrom the EQUIPMENT SERVICE table on the SERV-ICE menu.

2. The lead chiller chilled water temperature is less thantheCONTROL POINTtemperature (see the MAINSTATscreen) plus1⁄2 theCHILLED WATER DEADBANDtem-perature (see the SETUP1 screen).

3. The configuredLAG STOP TIMEentry has elapsed. TheLAG STOP TIMERstarts when the lead chiller chilledwater temperature is less than the chilled waterCONTROL POINTplus 1/2 of theCHILLED WATERDEADBANDand the lead chiller compressor motor load(MOTORPERCENTKILOWATTorAVERAGELINECUR-RENTon the MAINSTAT screen) is less than the leadchiller percent capacity.

NOTE: Lead chiller percent capacity = 115 –LAG PER-CENT CAPACITY.TheLAG PERCENT CAPACITYparam-eter is on the LEADLAG screen, which is accessed from theEQUIPMENT SERVICE table on the SERVICE menu.FAULTED CHILLER OPERATION — If the lead chillershuts down because of an alarm (*) condition, it stops com-municating to the lag and standby chillers. After 30 seconds,the lag chiller becomes the acting lead chiller and starts andstops 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 CCNmode of operation.If the lead chiller is in an alarm (*) condition (as shown

on the CVC panel), press the RESETsoftkey to clear thealarm. The chiller is placed in CCN mode. The lead chillercommunicates and monitors the RUN STATUS of the lagand standby chillers. If both the lag and standby chillers arerunning, the lead chiller does not attempt to start and doesnot assume the role of lead chiller until either the lag or standbychiller shuts down. If only one chiller is running, the leadchiller waits for a start request from the operating chiller.When the configured lead chiller starts, it assumes its role aslead chiller.If the lag chiller is the only chiller running when the lead

chiller assumes its role as a lead chiller then the lag chillerwill perform aRECOVERY START REQUEST(LL_MAINTscreen). The lead chiller will start up when the followingconditions are met.1. Lag chiller ramp loading must be complete.2. LagCHILLED WATER TEMP(MAINSTAT screen) is

greater thanCONTROL POINTplus 1/2 theCHILLEDWATER DEADBANDtemperature.

3. Lag chillerACTIVEDEMANDLIMITvaluemust begreaterthan 95% of full load amps.

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

5. The standby chiller is not running as a lag chiller.6. The configuredLAGSTARTTIMERhas elapsed. TheLAG

START TIMER is started when ramp loading iscompleted.

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LOAD BALANCING — When the LOAD BALANCEOPTION(see LEADLAG screen) is enabled, the lead chillersets theACTIVE DEMAND LIMITin the lag chiller to thelead chiller’s compressor motor load valueMOTOR PER-CENT KILOWATTSor AVERAGE LINE CURRENTon theMAINSTAT screen). This value has limits of 40% to 100%.When the lag chillerACTIVE DEMAND LIMITis set, theCONTROL POINTmust be modified to a value of 3° F(1.67° C) less than the lead chiller’sCONTROLPOINTvalue.If the LOAD BALANCE OPTIONis disabled, theACTIVEDEMAND LIMIT and theCONTROL POINTare forced tothe same value as the lead chiller.AUTO. RESTARTAFTER POWER FAILURE—When anauto. restart condition occurs, each chiller may have a delayadded to the start-up sequence, depending on its lead/lagconfiguration. The lead chiller does not have a delay. Thelag chiller has a 45-second delay. The standby chiller has a90-second delay. The delay time is added after the chillerwater flow is verified. The PIC II ensures the guide vanesare closed. After the guide vane position is confirmed, thedelay for lag and standby chillers occurs prior to energizingthe oil pump. The normal start-up sequence then continues.The auto. restart delay sequence occurs whether the chilleris in CCN or LOCAL mode and is intended to stagger thecompressor motor starts. Preventing the motors from start-ing simultaneously helps reduce the inrush demands on thebuilding power system.

Ice Build Control — The ice build control optionautomatically sets theCONTROL POINTof the chiller to atemperature that allows ice building for thermal storage.NOTE: For ice build control to operate properly, the PIC IImust be in CCN mode.NOTE: See Fig. 15 and 16 for more information on ice build-related menus.The PIC II can be configured for ice build operation.

• From the SERVICEmenu, access the EQUIPMENTSERV-ICE table. From there, select the OPTIONS screen to en-able or disable the ICE BUILD OPTION. SeeTable 2, Example 16.

• The ICE BUILD SETPOINTcan be configured from theSETPOINT display, which is accessed from the PIC II mainmenu. See Table 2, Example 8.

• The ice build schedule can be viewed or modified fromthe SCHEDULE table. From this table, select the ice buildschedule (OCCPC02S) screen. See Fig. 17 and the sectionon Time Schedule Operation, page 20, for more informa-tion on modifying chiller schedules.

The ice build time schedule defines the period(s) duringwhich ice build is active if the ice build option isenabled. If the ice build time schedule overlaps other sched-ules, the ice build time schedule takes priority. During theice build period, theCONTROL POINTis set to theICEBUILD SETPOINTfor temperature control. TheICE BUILDRECYCLEandICE BUILD TERMINATIONparameters, ac-cessed from the OPTIONS screen, allow the chiller operatorto recycle or terminate the ice build cycle. The ice build cyclecan be configured to terminate if:• theENTERINGCHILLEDWATERtemperature is less thanthe ICE BUILD SETPOINT. In this case, the operator setsthe ICE BUILD TERMINATIONparameter to 0 on theOPTIONS screen.

• the REMOTE CONTACT inputs from an ice level indi-cator are opened. In this case, the operator sets theICEBUILD TERMINATIONparameter to 1 on the OPTIONSscreen.

• the chilled water temperature is less than the ice build setpoint and the remote contact inputs from an ice level in-dicator are open. In this case, the operator sets theICE

BUILD TERMINATIONparameter to 2 on the OPTIONSscreen.

• 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 buildoption. The ice build option is enabled if:• a day of the week and a time period on the ice build timeschedule are enabled. The SCHEDULE screen shows anX in the day field and ON/OFF times are designated forthe day(s),

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

higher authority CCN device).1. CHILLER START/STOPis forced to START.2. The CONTROL POINTis forced to theICE BUILD

SETPOINT.3. Any force (Auto) is removed from theACTIVE

DEMAND LIMIT.

NOTE: A parameter’s value can be forced, that is, the valuecan bemanually changed at the CVC by an operator, changedfrom another CCN device, or changed by other algorithmsin the PIC II control system.

NOTE: Items 1-3 (shown above) do not occur if the chilleris configured and operating as a lag or standby chiller forlead/lag operation and is actively being controlled by a leadchiller. The lead chiller communicates theICE BUILD SETPOINT, the desiredCHILLER START/STOPstate, and theACTIVE DEMAND LIMITto the lag or standby chiller asrequired for ice build, if configured to do so.

START-UP/RECYCLE OPERATION— If the chiller is notrunning when ice build activates, the PIC II checks the fol-lowing conditions, based on theICE BUILD TERMINA-TIONvalue, to avoid starting the compressor unnecessarily:• if ICE BUILD TERMINATIONis set to the TEMP optionand theENTERING CHILLEDWATERtemperature is lessthan or equal to theICE BUILD SETPOINT;

• if ICE BUILD TERMINATIONis set to theCONTACTSoption and the remote contacts are open;

• if the ICE BUILD TERMINATIONis set to the BOTH (tem-perature and contacts) option and theENTERINGCHILLEDWATERtemperature is less than or equal to theICE BUILDSETPOINT andthe remote contacts are open.

The ICE BUILD RECYCLEon the OPTIONS screen de-termines whether or not the chiller will go into an ice buildRECYCLE mode.• If the ICE BUILD RECYCLEis set to DSABLE (disable),the PIC II reverts to normal temperature control when theice build function terminates.

• If the ICE BUILD RECYCLEis set to ENABLE, thePIC II goes into anICE BUILD RECYCLEmode and thechilled water pump relay remains energized to keep thechilled water flowing when the ice build function termi-nates. If the temperature of theENTERING CHILLEDWATERincreases above theICE BUILD SETPOINTplustheRECYCLE RESTART DELTA Tvalue, the compressorrestarts and controls the chilled water/brine temperature tothe ICE BUILD SETPOINT.

TEMPERATURECONTROLDURING ICEBUILD—Dur-ing ice build, the capacity control algorithm shall use theCONTROL POINTminus 5 F (−2.8 C) for control of theLEAVING CHILLED WATERtemperature. See Table 2, ex-ample 9, theCAPACITY CONTROLparameter on the CA-PACITY screen.) TheECW CONTROL OPTIONand any

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temperature reset option shall be ignored, if enabled, duringice build. TheAUTO DEMAND LIMIT INPUTshall also beignored if enabled during ice build.• ECW CONTROL OPTIONand any temperature resetoptions (configured on TEMP_CTL screen).

• 20 mA DEMAND LIMIT OPT (configured onRAMP_DEM screen).

TERMINATION OF ICE BUILD — The ice build functionterminates under the following conditions:1. Time Schedule —When the current time on the ice build

time schedule (OCCPC02S) isnotset as an ice build timeperiod.

2. Entering Chilled Water Temperature — Compressoroperation terminates, based on temperature, if theICEBUILD TERMINATIONparameter is set to 0 (TEMP),theENTERINGCHILLEDWATERtemperature is less thanthe ICE BUILD SETPOINT, and the ICE BUILDRECYCLE is set to DSABLE. If theICE BUILD RE-CYCLE OPTIONis set to ENABLE, a recycle shutdownoccurs and recycle start-up depends on theLEAVINGCHILLED WATERtemperature being greater than theWATER/BRINE CONTROL POINTplus theRECYCLERESTART DELTA Ttemperature.

3. Remote Contacts/Ice Level Input — Compressor opera-tion terminates when theICE BUILD TERMINATIONparameter is set to 1 [CONTACTS] and the remote con-tacts are open and theICE BUILD RECYCLEis set toDSABLE (0). In this case, the contacts provide ice leveltermination control. The contacts are used to stop theice build function when a time period on the ice buildschedule (OCCPC02S)is set for ice build operation. Theremote contacts can still be opened and closed to startand stop the chiller when a specific time period on the icebuild schedule isnot set for ice build.

4. Entering ChilledWater Temperature and ICE BUILDCon-tacts — Compressor operation terminates when theICEBUILD TERMINATIONparameter is set to 2 (BOTH)and the conditions described above in items 2 and 3 forentering chilled water temperature and remote contactshave occurred.

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

RETURN TO NON-ICE BUILD OPERATIONS— The icebuild function forces the chiller to start, even if all other sched-ules indicate that the chiller should stop. When the ice buildfunction terminates, the chiller returns to normal tempera-ture control and start/stop schedule operation. TheCHILLERSTART/STOPandCONTROL POINTreturn to normal op-eration. If theCHILLER START/STOPorCONTROLPOINThas been forced (with a device of less than 4 priority) beforethe ice build function started, when the ice build functionends, the previous forces (of less than 4 priority) are not au-tomatically restored.

Attach to Network Device Control — The Servicemenu includes theATTACHTONETWORKDEVICE 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 to any CCN device, if the chiller has beenconnected to a CCN network. This may include other PIC-controlled chillers.

• upgrade software

Figure 21 shows the ATTACH TO NETWORK DEVICEscreen. TheLOCAL parameter is always the CVC module

address of the chiller on which it is mounted. Whenever thecontroller identification of the CVC changes, the change isreflected automatically in the BUS and ADDRESS columnsfor the local device. See Fig. 16. Default address for localdevice is BUS 0 ADDRESS 1.

When the ATTACH TO NETWORK DEVICE screen isaccessed, information can not be read from the CVC on anydevice until one of the devices listed on that screen isattached. The CVC erases information about the module towhich it was attached to make room for information onanother device. Therefore, a CCN module must be attachedwhen this screen is entered.To attach any CCN device, highlight it using the

SELECT softkey and press the ATTACHsoftkey. Themes-sage ‘‘UPLOADING TABLES, PLEASE WAIT’’ displays.The CVC then uploads the highlighted device or module. Ifthe module address cannot be found, the message ‘‘COM-MUNICATION FAILURE’’ appears. The CVC then revertsback to the ATTACH TO DEVICE screen. Try another de-vice or check the address of the device that would not at-tach. The upload process time for each CCN module is dif-ferent. In general, the uploading process takes 1 to 2 minutes.Before leaving theATTACHTONETWORKDEVICE screen,select the local device. Otherwise, the CVC will be unableto display information on the local chiller.

ATTACHINGTOOTHERCCNMODULES— If the chillerCVC has been connected to a CCN Network or other PICcontrolled chillers through CCNwiring, the CVC can be usedto view or change parameters on the other controllers. OtherPIC II chillers can be viewed and set points changed (if theother unit is in CCN control), if desired, from this particularCVC module.If the module number is not valid, the ‘‘COMMUNICA-

TIONFAILURE’’messagewill show and a new address num-ber must be entered or the wiring checked. If the module iscommunicating 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 is currently being shown, check the device namedescriptor on the upper left hand corner of the CVC screen.See Fig. 21.When the CCN device has been viewed, theATTACH TO

NETWORK DEVICE table should be used to attach to thePIC that is on the chiller. Move to the ATTACH TO NET-WORK DEVICE table (LOCAL should be highlighted) andpress the ATTACHsoftkey to upload the LOCAL device.The CVC for the 19XR will be uploaded and default screenwill display.

NOTE: The CVC will not automatically reattach to the localmodule on the chiller. Press the ATTACHsoftkey to attachto the LOCAL device and view the chiller operation.

Fig. 21 — Example of Attach to NetworkDevice Screen

43

Service Operation — An overview of the tables andscreens available for the SERVICE function is shown inFig. 16.TO ACCESS THE SERVICE SCREENS — When theSERVICE screens are accessed, a password must beentered.1. From the main MENU screen, press the SERVICEsoft-

key. The softkeys now correspond to the numerals 1, 2,3, 4.

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

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

If this occurs, return to Step 1 and try to access the SERV-ICE screens again. If the password is correct, the softkeylabels change to:

NOTE: The SERVICE screen password can be changedby entering the CVC CONFIGURATION screen underSERVICE menu. The password is located at the bottomof the menu.The CVC screen displays the following list of availableSERVICE 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 ConfigurationSee Fig. 16 for additional screens and tables available from

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

NOTE: To prevent unauthorized persons from accessing theCVC service screens, the CVC automatically signs off andpassword-protects itself if a key has not been pressed for15 minutes. The sequence is as follows. Fifteen minutesafter the last key is pressed, the default screen displays, theCVC screen light goes out (analogous to a screen saver),and the CVC logs out of the password-protected SERVICEmenu. Other screen and menus, such as the STATUS screencan be accessed without the password by pressing the ap-propriate softkey.

TO LOG OUT OF NETWORK DEVICE — To access thisscreen and log out of a network device, from the default CVCscreen, press the MENUand SERVICE softkeys. Enterthe password and, from the SERVICE menu, highlight LOGOUT OF NETWORK DEVICE and press the SELECTsoftkey. The CVC default screen will now be displayed.

HOLIDAY SCHEDULING (Fig. 22) — The time schedulesmay be configured for special operation during a holidayperiod. When modifying a time period, the ‘‘H’’ at the endof the days of the week field signifies that the period isapplicable to a holiday. (See Fig. 17.)The broadcast function must be activated for the holidays

configured on the HOLIDEF screen to work properly.Access the BRODEF screen from the EQUIPMENT CON-FIGURATION table and select ENABLE to activate func-tion. Note that when the chiller is connected to a CCNNetwork, only one chiller or CCN device can be configuredas the broadcast device. The controller that is configuredas the broadcaster is the device responsible for transmittingholiday, time, and daylight-savings dates throughout thenetwork.To access the BRODEF screen, see the SERVICE menu

structure, Fig. 16.To view or change the holiday periods for up to 18 dif-

ferent holidays, perform the following operation:

1. At theMenu screen, press SERVICEto access the Serv-ice menu.

2. If not logged on, follow the instructions for ATTACHTO NETWORK DEVICE or To Log Out. Once loggedon, press NEXT until Equipment Configuration ishighlighted.

3. Once Equipment Configuration is highlighted, pressSELECT to access.

4. Press NEXTuntil HOLIDAYS is highlighted. This isthe Holiday Definition table.

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

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

7. Press SELECTto access the holiday table. The Con-figuration Select table now shows the holiday start monthand day, and howmany days the holiday period will last.

8. Press NEXT or PREVIOUS to highlight themonth, day, or duration.

9. Press SELECT to modify the month, day, orduration.

10. Press INCREASEor DECREASE to change theselected value.

11. Press ENTERto save the changes.

12. Press EXITto return to the previous menu.

T

Fig. 22 — Example of Holiday Period Screen

44

START-UP/SHUTDOWN/RECYCLESEQUENCE (Fig. 23)

Local Start-Up — Local start-up (or a manual start-up)is initiated by pressing the LOCALmenu softkey on thedefault CVC screen. Local start-up can proceed when thechiller schedule indicates that the current time and date havebeen established as a run time and date, and after the inter-nal 15-minute start-to-start and the 1-minute stop-to-startinhibit timers have expired. These timers are represented intheSTART INHIBIT TIMERand can be viewed on theMAIN-STAT screen and DEFAULT screen. The timer must expirebefore the chiller will start. If the timers have not expiredtheRUN STATUSparameter on the MAINSTAT screen nowreads TIMEOUT.

NOTE: The time schedule is said to be ‘‘occupied’’ if theOCCUPIED ?parameter on the MAINSTAT screen is set toYES. For more information on occupancy schedules, see thesections on Time Schedule Operation (page 20), OccupancySchedule (page 33), and To Prevent Accidental Start-Up(page 60), and Fig. 17.If theOCCUPIED ?parameter on the MAINSTAT screen

is set to NO, the chiller can be forced to start as follows.From the default CVC screen, press the MENUandSTATUS softkeys. Scroll to highlight MAINSTAT. Press

the SELECTsoftkey. Scroll to highlightCHILLER START/STOP. Press the STARTsoftkey to override the scheduleand start the chiller.NOTE: The chiller will continue to run until this forced startis released, regardless of the programmed schedule. Torelease the forced start, highlightCHILLERSTART/STOPfromthe MAINSTAT screen and press the RELEASEsoftkey.This action returns the chiller to the start and stop timesestablished by the schedule.The chiller may also be started by overriding the time sched-

ule. From the default screen, press the MENUandSCHEDULE softkeys. Scroll down and select the currentschedule. Select OVERRIDE, and set the desired overridetime.Another condition for start-up must be met for chillers that

have theREMOTE CONTACTS OPTIONon the EQUIP-MENT SERVICE screen set to ENABLE. For these chillers,theREMOTE CONTACTS INPUTparameter on the MAIN-STAT screenmust beCLOSED. From theCVCdefault screen,press the MENUand STATUS softkeys. Scroll to high-

light MAINSTAT and press the SELECTsoftkey. Scrolldown the STATUS01 screen to highlightREMOTE CON-TACTS INPUTand press the SELECTsoftkey. Then, pressthe CLOSE softkey. To end the override, selectREMOTECONTACTS INPUTand press the RELEASEsoftkey.Once local start-up begins, the PIC II performs a series of

pre-start tests to verify that all pre-start alerts and safetiesare within the limits shown in Table 3. TheRUN STATUSparameter on the MAINSTAT screen line now readsPRESTART. 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 linenow reads STARTUP.Five seconds later, the condenser pump relay energizes.

Thirty seconds later the PIC II monitors the chilled waterand condenser water flow devices and waits until the

WATER FLOW VERIFY TIME(operator-configured, default5 minutes) expires to confirm flow. After flow is verified, thechilled water temperature is compared toCONTROL POINTplus 1/2CHILLEDWATER DEADBAND.If the temperatureis less than or equal to this value, the PIC II turns off thecondenser pump relay and goes into a RECYCLE mode.If the water/brine temperature is high enough, the start-up

sequence continues and checks the guide vane position. Ifthe guide vanes are more than 4% open, the start-up waitsuntil the PIC II closes the vanes. If the vanes are closed andthe oil pump pressure is less than 4 psi (28 kPa), the oilpump relay energizes. The PIC II then waits until the oil pres-sure (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 waits40 seconds, and the compressor start relay (1CR) energizesto start the compressor.Compressor ontime and service ontime timers start, and

the compressor starts in 12 hours counter and the number ofstarts 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 theapplicable pre-start mode of failure on the CVC default screen.A pre-start failure does not advance the starts in 12 hourscounter. Any failure after the 1CR relay has energizedresults in a safety shutdown, advances the starts in the12 hours counter by one, and displays the applicable shut-down status on the CVC display.

A — START INITIATED — Prestart checks made; evaporatorpump 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 con-trol point. Guide vanes checked for closure. Oil pump started;tower fan control enabled.

D — Oil pressure verified (15 seconds minimum, 300 secondsmaximum after C).

E — Compressor motor starts, compressor ontime and serviceontime start, 15-minute inhibit timer starts (10 secondsafter D), total compressor starts advances by one, and thenumber of starts over a 12-hour period advances by one.

F — SHUTDOWN INITIATED—Compressor motor stops, com-pressor ontime and service ontime stops, and 1-minuteinhibit timer starts.

G — Oil pump and evaporator pumps deenergized (60 secondsafter F). Condenser pump and tower fan control may con-tinue to operate if condenser pressure is high. Evaporatorpump may continue if in RECYCLE mode.

O/A — Restart permitted (both inhibit timers expired: minimum of15 minutes after E; minimum of 1 minute after F).

Fig. 23 — Control Sequence

45

Shutdown Sequence — Chiller shutdown begins ifany of the following occurs:• the STOP button is pressed for at least one second (thealarm light blinks once to confirm the stop command)

• a recycle condition is present (see Chilled Water RecycleMode section)

• the time schedule has gone into unoccupied mode• the chiller protective limit has been reached and chiller isin alarm

• the start/stop status is overridden to stop from the CCNnetwork or the CVCWhen a stop signal occurs, the shutdown sequence first

stops the compressor by deactivating the start relay (1CR).A status message of ‘‘SHUTDOWN IN PROGRESS, COM-PRESSOR DEENERGIZED’’ is displayed, and the com-pressor ontime and service ontime stop. The guide vanes arethen brought to the closed position. The oil pump relay andthe chilled water/brine pump relay shut down 60 secondsafter the compressor stops. The condenser water pump shutsdown at the same time if theENTERING CONDENSERWATER temperature is greater than or equal to 115 F(46.1 C) and theCONDENSER REFRIG TEMPis greaterthan theCONDENSER FREEZE POINTplus 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 value of the start-to-stop timer, then this time displays on the CVC.Certain conditions that occur during shutdown can change

this sequence.• If theAVERAGE LINE CURRENTis greater than 15% af-ter shutdown, or the starter contacts remain energized, theoil pump and chilled water pump remain energized andthe alarm is displayed.

• The condenser pump shuts down when theCONDENSERPRESSUREis less than theCONDENSER PRESSUREOVERRIDEthreshold minus 3.5 psi (24.1 kPa) and theCONDENSER REFRIG TEMPis less than or equal to theENTERING CONDENSER WATERtemperature plus3° F (−1.6° C).

• If the chiller shuts down due to low refrigerant tempera-ture, the chilled water pump continues to run until theLEAV-ING CHILLED WATERtemperature is greater than theCONTROL POINTtemperature, plus 5° F (3° C).

Automatic Soft StopAmps Threshold— The softstop amps threshold feature closes the guide vanes of thecompressor automatically if a non-recycle, non-alarm stopsignal 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 than4% open or 4 minutes have passed. The compressor thenshuts off.If the chiller enters an alarm state or if the compres-

sor enters a RECYCLE mode, the compressor deenergizesimmediately.To activate the soft stop amps threshold feature, scroll to

the bottom of OPTIONS screen on the CVC. Use theINCREASE or DECREASE softkey to set theSOFTSTOPAMPS THRESHOLDparameter to the percent of ampsat which the motor will shut down. The default setting is100% 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.The soft stop amps threshold function can be terminated

and the compressor motor deenergized immediately by de-pressing the STOP button twice.

ChilledWater RecycleMode— The chiller may cycleoff and wait until the load increases to restart whenthe compressor is running in a lightly loaded condition. Thiscycling is normal and is known as9recycle.9 A recycle shut-down is initiated when any of the following conditionsare true:• the chiller is in LCW control, the difference between theLEAVING CHILLED WATERtemperature andENTER-ING CHILLED WATER temperature is less than theRECYCLE SHUTDOWN DELTA T(found in theSETUP1 table)andtheLEAVING CHILLEDWATERtem-perature is below theCONTROL POINT, −5 F (−15.0 C)theCONTROL POINThas not increased in the last 5 min-utes and ICE BUILD is not active.

• theECW CONTROL OPTIONis enabled, the differencebetween theENTERING CHILLED WATERtemperatureand theLEAVING CHILLED WATERtemperature is lessthan theRECYCLE SHUTDOWN DELTA T(found in theSETUP1 table),and the ENTERING CHILLED WATERtemperature is below theCONTROL POINT−5 F(−15.0 C)andtheCONTROL POINThas not increased inthe last 5 minutes.

• the LEAVING CHILLED WATERtemperature is within3° F (2° C) of theEVAP REFRIG TRIPPOINT.When the chiller is in RECYCLE mode, the chilled water

pump relay remains energized so the chilled water temper-ature can be monitored for increasing load. The recyclecontrol usesRECYCLE RESTART DELTA Tto check whenthe compressor should be restarted. This is an operator-configured function which defaults to 5° F (3° C). This valuecan be viewed or modified on the SETUP1 table. The com-pressor will restart when the chiller is:• in LCW CONTROL and the LEAVING CHILLEDWATERtemperature is greater than theCONTROL POINTplus theRECYCLE RESTART DELTA T.

• in ECW CONTROLand the ENTERING CHILLEDWATERtemperature is greater than theCONTROL POINTplus theRECYCLE RESTART DELTA T.

Once these conditions are met, the compressor initiates astart-up with a normal start-up sequence.An alert condition may be generated if 5 or more recycle

start-ups occur in less than 4 hours. Excessive recycling canreduce chiller life; therefore, compressor recycling due toextremely low loads should be reduced.

To reduce compressor recycling, use the time schedule toshut the chiller down during known low load operationperiod, or increase the chiller load by running the fan sys-tems. If the hot gas bypass is installed, adjust the values toensure that hot gas is energized during light load condi-tions. Increase theRECYCLE RESTART DELTA Ton theSETUP1 table to lengthen the time between restarts.The chiller should not be operated below design mini-

mum load without a hot gas bypass installed.

Safety Shutdown — A safety shutdown is identical toa manual shutdown with the exception that, during a safetyshutdown, the CVC displays the reason for the shutdown,the alarm light blinks continuously, and the spare alarm con-tacts are energized.After a safety shutdown, the RESETsoftkey 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 CCNor LOCAL softkeys torestart the chiller.

46

BEFORE INITIAL START-UP

Job Data Required• list of applicable design temperatures and pressures (prod-uct data submittal)

• chiller certified prints• starting equipment details and wiring diagrams• diagrams and instructions for special controls or options• 19XRT 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 indica-tor (Fig. 24)

• 500-v insulation tester (megohmmeter) for compressormotors with nameplate voltage of 600 v or less, or a5000-v insulation tester for compressor motor rated above600 v

Using the Optional Storage Tank and PumpoutSystem — Refer to Chillers with Storage Tanks section,page 64 for pumpout system preparation, refrigerant trans-fer, and chiller evacuation.

Remove Shipping Packaging— Remove any pack-aging material from the control center, power panel, guidevane actuator, motor cooling and oil reclaim solenoids,motor and bearing temperature sensor covers, and the factory-mounted starter.

Open Oil Circuit Valves — Check to ensure the oilfilter isolation valves (Fig. 4) are open by removing the valvecap and checking the valve stem.

Tighten All Gasketed Joints and Guide VaneShaft Packing — Gaskets and packing normally relaxby the time the chiller arrives at the jobsite. Tighten all gas-keted joints and the guide vane shaft packing to ensure aleak-tight chiller.

Check Chiller Tightness — Figure 25 outlines theproper sequence and procedures for leak testing.19XRT chillers are shipped with the refrigerant contained

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

To determine if there are any leaks, the chiller shouldbe charged with refrigerant. Use an electronic leak detectorto check all flanges and solder joints after the chiller ispressurized. If any leaks are detected, follow the leak testprocedure.If the chiller is spring isolated, keep all springs blocked in

both directions to prevent possible piping stress and dam-age during the transfer of refrigerant from vessel to vesselduring the leak test process, or any time refrigerant is beingtransferred. Adjust the springs when the refrigerant is inoperating condition and the water circuits are full.

Refrigerant Tracer — Carrier recommends the use ofan environmentally acceptable refrigerant tracer for leak test-ing with an electronic detector or halide torch.Ultrasonic leak detectors can also be used if the chiller is

under pressure.

Do not use air or oxygen as a means of pressurizingthe chiller. Mixtures of HFC-134a and air can undergocombustion.

Fig. 24 — Typical Wet-Bulb TypeVacuum Indicator

47

Fig.25

—19XRTLeak

TestProcedures

48

Leak Test Chiller — Due to regulations regarding re-frigerant emissions and the difficulties associated with sepa-rating contaminants from the refrigerant, Carrier recommendsthe following leak test procedure. See Fig. 25 for an outlineof the leak test procedure. Refer to Fig. 26 and 27 duringpumpout procedures and Tables 5A and 5B for refrigerantpressure/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 saturatedpressure for the surrounding temperature. Follow thepumpout procedures in the Transfer Refrigerant fromPumpout Storage Tank to Chiller section, Steps 1a - e,page 64.

Never charge liquid refrigerant into the chiller ifthe pressure in the chiller is less than 35 psig(241 kPa) for HFC-134a. Charge as a gas only, withthe cooler and condenser pumps running, until thispressure is reached, using PUMPDOWN LOCK-OUT and TERMINATE LOCKOUT mode onthe PIC II. Flashing of liquid refrigerant at lowpressures can cause tube freeze-up and consider-able damage.

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

2. If the pressure readings are abnormal for the chillercondition:a. Prepare to leak test chillers shipped with refrigerant

(Step 2h).b. Check for large leaks by connecting a nitrogen bottle

and raising the pressure to 30 psig (207 kPa). Soaptest 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 pos-sible, given the fact that small leaks may be present inthe system. This can be accomplished by followingthe dehydration procedure, outlined in the ChillerDehydration section, page 52.

h. Slowly raise the system pressure to a maximum of160 psig (1103 kPa) but no less than 35 psig (241 kPa)for HFC-134a by adding refrigerant. Proceed with thetest for small leaks (Steps 3-9).

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

4. Leak Determination — If an electronic leak detector in-dicates a leak, use a soap bubble solution, if possible, toconfirm. Total all leak rates for the entire chiller. Leakageat rates greater than 1 lb/year (0.45 kg/year) for the entirechiller must be repaired. Note the total chiller leak rateon the start-up report.

5. If no leak is found during the initial start-up procedures,complete the transfer of refrigerant gas from thepumpout storage tank to the chiller (see Transfer Refrig-erant from Pumpout Storage Tank to Chiller section,page 64). 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 theStanding Vacuum Test section, below.

b. If the chiller fails the standing vacuum test, check forlarge leaks (Step 2b).

c. If the chiller passes the standing vacuum test, dehy-drate the chiller. Follow the procedure in the ChillerDehydration section. Charge the chiller with refriger-ant (see Transfer Refrigerant from Pumpout StorageTank to Chiller section, page 64).

7. If a leak is found after a retest, pump the refrigerant backinto the pumpout storage tank or, if isolation valves arepresent, pump the refrigerant into the non-leaking ves-sel (see Pumpout and Refrigerant Transfer proceduressection).

8. Transfer the refrigerant until the chiller pressure is at18 in. Hg (40 kPa absolute).

9. Repair the leak and repeat the procedure, beginning fromStep 2h, to ensure a leak-tight repair. (If the chiller is openedto the atmosphere for an extended period, evacuate it be-fore repeating the leak test.)

Standing VacuumTest— When performing the stand-ing vacuum test or chiller dehydration, use a manometer ora wet bulb indicator. Dial gages cannot indicate the smallamount of acceptable leakage during a short period of time.1. Attach an absolute pressure manometer or wet bulb in-

dicator to the chiller.2. Evacuate the vessel (see Pumpout and Refrigerant

Transfer Procedures section, page 63) to at least 18 in.Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump orthe pumpout unit.

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

4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)in 24 hours, the chiller is sufficiently tight.

b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)in 24 hours, repressurize the vessel and test for leaks.If refrigerant is available in the other vessel, pres-surize by following Steps 2-10 of Return Chiller ToNormal Operating Conditions section, page 65. If not,use nitrogen and a refrigerant tracer. Raise the vesselpressure in increments until the leak is detected. Ifrefrigerant is used, the maximum gas pressure isapproximately 70 psig (483 kPa) for HFC-134a at nor-mal ambient temperature. If nitrogen is used, limit theleak test pressure to 230 psig (1585 kPa) maximum.

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

49

Fig. 26 — Optional Pumpout Unit Piping Schematic with Storage Tank

Fig. 27 — Optional Pumpout Unit Piping Schematic

50

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

TEMPERATURE, F PRESSURE (psig)0 6.502 7.524 8.606 9.668 10.7910 11.9612 13.1714 14.4216 15.7218 17.0620 18.4522 19.8824 21.3726 22.9028 24.4830 26.1132 27.8034 29.5336 31.3238 33.1740 35.0842 37.0444 39.0646 41.1448 43.2850 45.4852 47.7454 50.0756 52.4758 54.9360 57.4662 60.0664 62.7366 65.4768 68.2970 71.1872 74.1474 77.1876 80.3078 83.4980 86.1782 90.1384 93.5786 97.0988 100.7090 104.4092 108.1894 112.0696 116.0298 120.08100 124.23102 128.47104 132.81106 137.25108 141.79110 146.43112 151.17114 156.01116 160.96118 166.01120 171.17122 176.45124 181.83126 187.32128 192.93130 198.66132 204.50134 210.47136 216.55138 222.76140 229.09

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

TEMPERATURE, C PRESSURE GAGE (kPa)-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 99.4-8.9 108.0-7.8 118.0-6.7 127.0-5.6 137.0-4.4 147.0-3.3 158.0-2.2 169.0-1.1 180.00.0 192.01.1 204.02.2 216.03.3 229.04.4 242.05.0 248.05.6 255.06.1 261.06.7 269.07.2 276.07.8 284.08.3 290.08.9 298.09.4 305.010.0 314.011.1 329.012.2 345.013.3 362.014.4 379.015.6 396.016.7 414.017.8 433.018.9 451.020.0 471.021.1 491.022.2 511.023.3 532.024.4 554.025.6 576.026.7 598.027.8 621.028.9 645.030.0 669.031.1 694.032.2 720.033.3 746.034.4 773.035.6 800.036.7 828.037.8 857.038.9 886.040.0 916.041.1 946.042.2 978.043.3 1010.044.4 1042.045.6 1076.046.7 1110.047.8 1145.048.9 1180.050.0 1217.051.1 1254.052.2 1292.053.3 1330.054.4 1370.055.6 1410.056.7 1451.057.8 1493.058.9 1536.060.0 1580.0

51

Chiller Dehydration — Dehydration is recommendedif the chiller has been open for a considerable period of time,if the chiller is known to contain moisture, or if there hasbeen a complete loss of chiller holding charge or refrigerantpressure.

Do not start or megohm-test the compressor motor oroil pump motor, even for a rotation check, if the chilleris under dehydration vacuum. Insulation breakdown andsevere damage may result.

Inside-delta type starters must be disconnected by an iso-lation switch before placing themachine under a vacuumbecause one lead of each phase is live with respect toground even though there is not a complete circuit torun themotor. To be safe, isolate any starter before evacu-ating the chiller if you are not sure if there are live leadsto the hermetic motor.

Dehydration can be done at room temperatures. Using acold trap (Fig. 28) may substantially reduce the time re-quired to complete the dehydration. The higher the room tem-perature, the faster dehydration takes place. At low roomtemperatures, a very deep vacuum is required to boil off anymoisture. If low ambient temperatures are involved, contacta qualified service representative for the dehydration tech-niques required.Perform dehydration as follows:

1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]or larger is recommended) to the refrigerant charging valve(Fig. 2). Tubing from the pump to the chiller should beas short in length and as large in diameter as possible toprovide least resistance to gas flow.

2. Use an absolute pressuremanometer or a wet bulb vacuumindicator to measure the vacuum. Open the shutoff valveto the vacuum indicator only when taking a reading. Leavethe valve open for 3 minutes to allow the indicator vacuumto equalize with the chiller vacuum.

3. If the entire chiller is to be dehydrated, open all isolationvalves (if present).

4. With the chiller ambient temperature at 60 F (15.6 C) orhigher, operate the vacuumpump until themanometer reads29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (–100.61 kPa)or a vacuum indicator reads 35 F (1.7 C). Operate thepump 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 bulbvacuum indicator. At this temperature and pressure, iso-lated pockets of moisture can turn into ice. The slow rateof evaporation (sublimation) of ice at these low tempera-tures and pressures greatly increases dehydration time.

5. Valve off the vacuum pump, stop the pump, and recordthe instrument reading.

6. After a 2-hour wait, take another instrument reading. Ifthe reading has not changed, dehydration is complete. Ifthe reading indicates vacuum loss, repeat Steps 4 and 5.

7. If the reading continues to change after several attempts,perform a leak test up to the maximum 160 psig(1103 kPa) pressure. Locate and repair the leak, and re-peat dehydration.

InspectWater Piping— Refer to piping diagrams pro-vided in the certified drawings and the piping instructionsin the 19XRT Installation Instructions manual. Inspect thepiping to the cooler and condenser. Be sure that the flowdirections are correct and that all piping specifications havebeen met.Piping systems must be properly vented with no stress on

waterbox nozzles and covers.Water flows through the coolerand condenser must meet job requirements. Measure the pres-sure drop across the cooler and the condenser.

Water must be within design limits, clean, and treatedto ensure proper chiller performance and to reduce thepotential of tube damage due to corrosion, scaling, orerosion. Carrier assumes no responsibility for chillerdamage resulting from untreated or improperly treatedwater.

Check Optional Pumpout Compressor WaterPiping — If the optional pumpout storage tank and/orpumpout system are installed, check to ensure thepumpout condenser water has been piped in. Check for field-supplied shutoff valves and controls as specified in the jobdata. Check for refrigerant leaks on field-installed piping.See Fig. 26 and 27.

Check Relief Valves — Be sure the relief valves havebeen piped to the outdoors in compliance with thelatest edition of ANSI/ASHRAE Standard 15 and applicablelocal safety codes. Piping connections must allow for accessto the valve mechanism for periodic inspection and leaktesting.The 19XRT relief valves are set to relieve at the 185 psig

(1275 kPa) chiller design pressure.

Inspect Wiring

Do not check the voltage supply without proper equip-ment and precautions. Serious injury may result. Fol-low power company recommendations.

Do not apply any kind of test voltage, even for a rota-tion 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 wiringdiagrams and all applicable electrical codes.

Fig. 28 — Dehydration Cold Trap

52

2. On low-voltage compressors (600 v or less) connect avoltmeter across the power wires to the compressor starterand measure the voltage. Compare this reading to thevoltage rating on the compressor and starternameplates.

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

4. The starter for a centrifugal compressor motor must con-tain the components and terminals required for PIC IIrefrigeration control. Check the certified drawings.

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

6. Ensure that fused disconnects or circuit breakers havebeen supplied for the oil pump, power panel, andpumpout unit.

7. Ensure all electrical equipment and controls are prop-erly grounded in accordance with job drawings, certi-fied drawings, and all applicable electrical codes.

8. Ensure the customer’s contractor has verified proper op-eration of the pumps, cooling tower fans, and associatedauxiliary equipment. This includes ensuring motors areproperly lubricated and have proper electrical supply andproper rotation.

9. For field-installed starters only, test the chiller compres-sor motor and its power lead insulation resistance witha 500-v insulation tester such as a megohmmeter. (Usea 5000-v tester for motors rated over 600 v.) Factory-mounted starters do not require a megohm test.a. Open the starter main disconnect switch and follow

lockout/tagout rules.

If the motor starter is a solid-state starter, themotor leads must be disconnected from the starterbefore an insulation test is performed. The voltagegenerated from the tester can damage the startersolid-state components.

b. With the tester connected to the motor leads, take10-second and 60-second megohm readings asfollows:6-Lead Motor — Tie all 6 leads together and test be-tween the lead group and ground. Next tie the leadsin pairs: 1 and 4, 2 and 5, and 3 and 6. Test betweeneach pair while grounding the third pair.3-Lead Motor — Tie terminals 1, 2, and 3 togetherand test between the group and ground.

c. Divide the 60-second resistance reading by the10-second reading. The ratio, or polarization index,must be one or higher. Both the 10- and 60-secondreadings must be at least 50 megohms.If the readings on a field-installed starter are unsat-isfactory, repeat the test at the motor with the powerleads disconnected. Satisfactory readings in this sec-ond test indicate the fault is in the power leads.

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

10. Tighten all wiring connections to the plugs on the ISMand CCM modules.

11. On chillers with free-standing starters, inspect the powerpanel to ensure that the contractor has fed the wires intothe bottom of the panel. Wiring into the top of the panelcan cause debris to fall into the contactors. Clean andinspect the contactors if this has occurred.

Carrier Comfort Network Interface— The CarrierComfort Network (CCN) communication bus wiring is sup-plied and installed by the electrical contractor. It consists ofshielded, 3-conductor cable with drain wire.The system elements are connected to the communication

bus in a daisy chain arrangement. The positive pin of eachsystem element communication connector must be wired tothe positive pins of the system element on either side of it.The negative pins must be wired to the negative pins. Thesignal ground pins must be wired to the signal ground pins.See installation manual.NOTE: Conductors and drain wire must be 20 AWG(AmericanWire Gage) minimum stranded, tinned copper. In-dividual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene.An aluminum/polyester100% foil shield and an outer jacket of PVC, PVC/nylon,chrome vinyl, or Teflon with a minimum operating tempera-ture range of −4 F to 140 F (−20 C to 60 C) is required. Seetable below for cables that meet the requirements.

MANUFACTURER CABLE NO.Alpha 2413 or 5463

American A22503Belden 8772

Columbia 02525

When connecting the CCN communication bus to a sys-tem element, a color code system for the entire network isrecommended to simplify installation and checkout. The fol-lowing color code is recommended:

SIGNAL TYPE CCN BUS CONDUCTORINSULATION COLOR

CVC PLUG J1PIN NO.

+ Red 1Ground White 2

− Black 3

Check Starter

BE AWARE that certain automatic start arrangementscan engage the starter.Open the disconnectaheadofthe starter in addition to shutting off the chiller or pump.

Use the instruction and service manual supplied by thestarter manufacturer to verify the starter has been installedcorrectly, to set up and calibrate the starter, and for completetroubleshooting information.

The main disconnect on the starter front panel may notdeenergize all internal circuits. Open all internal and re-mote disconnects before servicing the starter.

53

MECHANICAL STARTER1. Check all field wiring connections for tightness, clear-

ance from moving parts, and correct connection.2. Check the contactor(s) to ensure they move freely. Check

themechanical interlock between contactors to ensure that1S and 2M contactors cannot be closed at the same time.Check all other electro-mechanical devices, such asrelays, for free movement. If the devices do not movefreely, contact the starter manufacturer for replacementcomponents.

3. Some dashpot-typemagnetic overload relaysmust be filledwith oil on the jobsite. If the starter is equipped with de-vices of this type, remove the fluid cups from these mag-netic overload relays. Add the dashpot oil to the cupsaccording to the instructions supplied with the starter. Theoil is usually shipped in a small container attached to thestarter frame near the relays. Use only the dashpot oil sup-plied with the starter. Do not substitute.Solid-state overload relays do not have oil.

4. Reapply starter control power(not main chiller power) tocheck the electrical functions.Ensure the starter (with relay 1CR closed) goes througha complete and proper start cycle.

BENSHAW, INC. REDISTART MICRO SOLID-STATESTARTER

This equipment is at line voltage when AC power isconnected. Pressing the STOP button does not removevoltage.

1. Ensure all wiring connections are properly terminated tothe starter.

2. Verify the ground wire to the starter is installed properlyand is sufficient size.

3. Verify the motors are properly grounded to the starter.4. Ensure all of the relays are properly seated in their

sockets.5. Verify the proper ac input voltage is brought into the starter

according to the certified drawings.6. Apply power to the starter.

Oil Charge— The oil charge for the 19XRT compressorholds approximately 8 gal. (30 L) of oil.The chiller is shipped with oil in the compressor. When

the sump is full, the oil level should be no higher than themiddle of the upper sight glass, and minimum level is thebottom of the lower sight glass (Fig. 2). If oil is added, itmust meet Carrier’s specification for centrifugal compressoruse as described in the Oil Specification section. Charge theoil through the oil charging valve located near the bottom ofthe transmission housing (Fig. 2). The oil must be pumpedfrom the oil container through the charging valve due to higherrefrigerant pressure. The pumping device must be able to liftfrom 0 to 200 psig (0 to 1380 kPa) or above unit pressure.Oil should only be charged or removed when the chiller isshut down.

Power Up the Controls and Check theOil Heater— Ensure that an oil level is visible in the compressor be-fore energizing the controls. A circuit breaker in the starterenergizes the oil heater and the control circuit. When firstpowered, the CVC should display the default screen withina short period of time.

The oil heater is energized by powering the control cir-cuit. This should be done several hours before start-up tominimize oil-refrigerant migration. The oil heater is con-trolled by the PIC II and is powered through a contactor inthe power panel. Starters contain a separate circuit breakerto power the heater and the control circuit. This arrangementallows the heater to energize when the main motor circuitbreaker is off for service work or extended shutdowns. Theoil heater relay status (OIL HEATER RELAY) can be viewedon the COMPRESS table on the CVC. Oil sump tempera-ture can be viewed on the CVC default screen.

SOFTWARE VERSION — The software part number is la-beled on the backside of the CVCmodule. The software ver-sion also appears on the CVC configuration screen as thelast two digits of the software part number.

Software Configuration

Do not operate the chiller before the control configu-rations have been checked and a Control Test has beensatisfactorily completed. Protection by safety controlscannot be assumed until all control configurations havebeen confirmed.

As the 19XRT unit is configured, all configuration set-tings should be written down. A log, such as the one shownon pages CL-1 to CL-12, provides a convenient list for con-figuration values.

Input the Design Set Points — Access the CVC setpoint screen and view/modify the base demand limit set point,and either the LCW set pointor the ECW set point. ThePIC II can control a set point to either the leaving or enteringchilled water. This control method is set in the EQUIP-MENT SERVICE (TEMP_CTL) table.

Input the Local OccupiedSchedule (OCCPC01S)— Access the schedule OCCPC01S screen on the CVC andset up the occupied time schedule according to the custom-er’s requirements. If no schedule is available, the default isfactory set for 24 hours occupied, 7 days per week includingholidays.For more information about how to set up a time sched-

ule, see the Controls section, page 11.The CCNOccupied Schedule (OCCPC03S) should be con-

figured if a CCN system is being installed or if a secondarytime schedule is needed.

NOTE: The default CCN Occupied Schedule OCCPC03S isconfigured to be unoccupied.

Input Service Configurations— The following con-figurations require the CVC screen to be in the SERVICEportion of the menu.• password• input time and date• CVC configuration• service parameters• equipment configuration• automated control test

PASSWORD—When accessing the SERVICE tables, a pass-word must be entered. All CVC are initially set for a pass-word of 1-1-1-1.

54

INPUTTIMEANDDATE—Access the TIMEANDDATEtable on the SERVICE menu. Input the present time of day,date, and day of the week. TheHOLIDAY TODAYparam-eter should only be configured to YES if the present day isa holiday.

NOTE: Because a schedule is integral to the chiller controlsequence, the chiller will not start until the time and datehave been set.

CHANGE CVC CONFIGURATION IF NECESSARY —From the SERVICE table, access the CVC CONFIGU-RATION screen. From there, view or modify the CVC CCNaddress, change to English or SI units, and change the pass-word. If there is more than one chiller at the jobsite, changethe CVC address on each chiller so that each chiller has itsown address. Note and record the new address. Change thescreen to SI units as required, and change the password ifdesired.

TO CHANGE THE PASSWORD — The password may bechanged from the CVC CONFIGURATION screen.

1. Press the MENUand SERVICE softkeys. Enter thecurrent password and highlight CVC CONFIGURA-TION. Press the SELECTsoftkey. Only the last 5 en-tries on the CVC CONFIG screen can be changed:BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC,andPASSWORD.

2. Use the ENTERsoftkey to scroll toPASSWORD. Thefirst digit of the password is highlighted on the screen.

3. To change the digit, press the INCREASEorDECREASEsoftkey.When the desired digit is seen, press

the ENTER softkey.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 goes to theBUS

parameter. Press the EXITsoftkey to leave that screenand return to the SERVICE menu.

Be sure to remember the password. Retain a copyfor future reference. Without the password, accessto the SERVICE menu will not be possible unlessthe CVC_PSWD menu on the STATUS screen isaccessed by a Carrier representative.

TO CHANGE THE CVC DISPLAY FROM ENGLISH TOMETRIC UNITS — By default, the CVC displays informa-tion in English units. To change to metric units, access theCVC CONFIGURATION screen:

1. Press the MENUand SERVICE softkeys. Enter thepassword and highlight CVC CONFIGURATION. Pressthe SELECT softkey.

2. Use the ENTERsoftkey to scroll toUS IMP/METRIC.3. Press the softkey that corresponds to the units desired for

display on the CVC (e.g., US or METRIC).

MODIFY CONTROLLER IDENTIFICATION IF NECES-SARY — The CVC module address can be changed fromthe CVC CONFIGURATION screen. Change this addressfor each chiller if there is more than one chiller at the job-site. Write the new address on the CVC module for futurereference.

INPUT EQUIPMENT SERVICE PARAMETERS IF NEC-ESSARY—The EQUIPMENTSERVICE table has six serv-ice tables.Configure SERVICE Tables —Access the SERVICE tables,depicted on the next page, to modify or view the followingto job site parameters:

PARAMETER TABLEStarter Type ISM_CONF — Select 0 for full voltage,

1 for reduced voltage, or 2 for solid state/variable frequency drive.

Motor Rated LineVoltage

ISM_CONF — Per chiller identificationnameplate data.

Volt TransformerRatio

ISM_CONF — Enter ratio (reduced to aratio to 1) of power transformer wired toterminal J3 of ISM. If no transformer isused enter 1.

Motor Rated LoadAmps

ISM_CONF — Per chiller identificationnameplate data.

Motor Locked RotorTrip

ISM_CONF — Per chiller identificationnameplate data. Enter locked rotor deltaamps (LR AMPS D-).

Starter LRA Rating ISM_CONF — Enter value from name-plate in starter cabinet.

Motor CurrentCT Ratio

ISM_CONF — Enter ratio (reduced to aratio to 1) of current transformers wiredto terminal J4 of ISM.

Ground FaultCurrentTransformers

ISM_CONF — Enter 0 if three groundfault CTs are wired to terminal J5 of ISM.Enter 1 if one ground fault CT is used.

Ground Fault CTRatio

ISM_CONF — Enter ratio (reduced to aratio to 1) of ground fault CT.

Single CycleDropout

ISM_CONF — ENABLE if motor protec-tion required from drop in line voltagewithin one cycle.

Line Frequency ISM_CONF — Enter YES for 60 Hz orNO for 50 Hz.

Line FrequencyFaulting

ISM_CONF — ENABLE if motor protec-tion required for drop in line frequency.

Surge LImiting orHot Gas ByapssOption

OPTIONS — Enter 1 if HGBP isinstalled.

Minimum LoadPoints (T1/P1)

OPTIONS — Per job data — See modifyload points section.

Full (Maximum)Load Points(T2/P2)

OPTIONS — Per job data — See modifyload points section.

Chilled Medium SETUP1 — Enter water or brine.EvaporatorRefrigerantTrippoint

SETUP1 — Usually 3° F (1.7° C) belowdesign refrigerant temperature.

Evaporator FlowDelta P Cutout

SETUP1 — Enter 50% of designpressure drop to 0.5 psi (3.4 kPa).*

Condenser FlowDelta P Cutout

SETUP1 — Enter 50% of designpressure drop to 0.5 psi (3.4 kPa).*

Diffuser Option SETUP2 — ENABLE for 5 sizecompressor only. See model numbernomenclature.

*With variable flow systems this point may be configured to the lowerend of the range.

NOTE: Other parameters on these screens are normally left at thedefault settings; however, they may be changed by the operator asrequired. The time and persistence settings on the ISM_CONF tablecan be adjusted to increase or decrease the sensitivity to a faultcondition. Increasing time or persistence decreases sensitivity. De-creasing time or persistence increases sensitivity to the faultcondition.

55

Modify Minimum and Maximum Load Points (DT1/P1;D T2/P2) If Necessary — These pairs of chiller load points,located on the OPTIONS screen, determine when to limitguide vane travel or open the hot gas bypass valve whensurge prevention is needed. These points should be set basedon individual chiller operating conditions.If after configuring a value for these points, surge preven-

tion is operating too soon or too late for conditions, theseparameters should be changed by the operator.An example of such a configuration is shown below.Refrigerant: HCFC-134aEstimated Minimum Load Conditions:44 F (6.7 C) LCW45.5 F (7.5 C) ECW43 F (6.1 C) Suction Temperature70 F (21.1 C) Condensing Temperature

Estimated Maximum Load Conditions:44 F (6.7 C) LCW54 F (12.2 C) ECW42 F (5.6 C) Suction Temperature98 F (36.7 C) Condensing Temperature

Calculate Maximum Load —To calculate the maximum loadpoints, use the design load condition data. If the chillerfull load cooler temperature difference is more than 15 F(8.3 C), estimate the refrigerant suction and condensing tem-peratures at this difference. Use the proper saturated pres-sure and temperature for the particular refrigerant used.Suction Temperature:42 F (5.6 C) = 37 psig (255 kPa) saturated

refrigerant pressure (HFC-134a)Condensing Temperature:98 F (36.7 C) = 120 psig (1827 kPa) saturated

refrigerant pressure (HFC-134a)Maximum LoadDT2:

54 – 44 = 10° F (12.2 – 6.7 = 5.5° C)Maximum LoadDP2:120 – 37 = 83 psid (827 – 255 = 572 kPad)

To avoid unnecessary surge prevention, add about 10 psid(70 kPad) toDP2 from these conditions:

DT2 = 10° F (5.5° C)DP2 = 93 psid (642 kPad)

Calculate Minimum Load —To calculate the minimum loadconditions, estimate the temperature difference the cooler willhave at 10% load, then estimate what the suction and con-densing temperatures will be at this point. Use the propersaturated pressure and temperature for the particular refrig-erant used.Suction Temperature:43 F (6.1 C) = 38 psig (262 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:70 F (21.1 C) = 71 psig (490 kPa) saturated

refrigerant pressure (HFC-134a)

Minimum LoadDT1 (at 20% Load): 2 F (1.1 C)

Minimum LoadDP1:71 – 38 = 33 psid (490 – 262 = 228 kPad)

Again, to avoid unnecessary surge prevention, add 20 psid(140 kPad) atDP1 from these conditions:

DT1 = 2 F (1.1 C)DP1 = 53 psid (368 kPad)

If surge prevention occurs too soon or too late:

LOAD SURGE PREVENTIONOCCURS TOO SOON

SURGE PREVENTIONOCCURS TOO LATE

At lowloads(,50%)

Increase P1 by 10 psid(70 kPad)

Decrease P1 by 10 psid(70 kPad)

At highloads(.50%)

Increase P2 by 10 psid(70 kPad)

Decrease P2 by 10 psid(70 kPad)

The differential pressure (DP) and temperature (DT) canbe monitored during chiller operation by viewingACTIVEDELTA PandACTIVE DELTA T(HEAT_EX screen). Com-paringSURGE/HGBP DELTA Tto activeDETLA Twill de-termine when the SURGE PREVENTION function will oc-cur. The smaller the difference between theSURGE/HGBPDELTA Tand theACTIVE DELTA Tvalues, the closer tosurge prevention.

MODIFY EQUIPMENT CONFIGURATION IF NECES-SARY— The EQUIPMENT SERVICE table has screens toselect, view, or modify parameters. Carrier’s certified draw-ings have the configuration values required for the jobsite.Modify these values only if requested.SERVICEScreenModifications—Change the values on thesescreens according to specific job data. See the certified draw-ings 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 EQUIP-MENT CONFIGURATION screens are described for refer-ence only.OCCDEFCS—The OCCDEFCS screen contains the Localand CCN time schedules, which can be modified here or onthe SCHEDULE screen as described previously.HOLIDAYS—From the HOLIDAYS screen, the days of theyear that holidays are in effect can be configured. See theholiday paragraphs in the Controls section for moredetails.BRODEF— The BRODEF screen defines the start and endof daylight savings time. Enter the dates for the start and endof daylight savings if required for your location. BRODEFalso activates the Broadcast function which enables the holi-day periods that are defined on the CVC to take effect.

Other Tables— The CONSUME NET_OPT, and RUN-TIME screens contain parameters used with a CCN system.See the applicable CCNmanual for more information on thesescreens. These tables can only be defined from a CCN Build-ing Supervisor.

56

Perform a Control Test — Check the safety controlsstatus by performing an automated control test. Access theCONTROL TEST table and select a test to be performedfunction (Table 6).TheAutomated Control Test checks all outputs and inputs

for function. The compressor must be in the OFF mode tooperate the controls test. The compressor can be put in OFFmode by pressing the STOP push-button on the CVC. Eachtest asks the operator to confirm the operation is occurringand whether or not to continue. If an error occurs, the op-erator can try to address the problem as the test is being doneor note the problem and proceed to the next test.NOTE: Enter guide vane calibration to calibrate guideinput 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 lowpressure alarm causes the guide vanes to close.)NOTE: The oil pump test will not energize the oil pump ifcooler pressure is below –5 psig (–35 kPa).

When the control test is finished or the EXITsoftkey ispressed, the test stops, and the CONTROL TEST menu dis-plays. If a specific automated test procedure is not com-pleted, access the particular control test to test the functionwhen ready. The CONTROLTESTmenu is described in thetable below.

CCM Pressure Thermistors Check of all thermistors.CCM Pressure Transducers Check of all transducers.Pumps Checks operation of pump out-

puts; pumps are activated. Alsotests associated inputs such asflow or pressure.

Discrete Ouputs Activation of all on/off outputsindividually.

Guide Vane Check of the guide vaneoperation.

Pumpdown/Lockout Pumpdown prevents the low re-frigerant alarm during evacuationso refrigerant can be removedform the unit. Also locks thecompressor off and starts thewater pumps.

Terminate Lockout To charge refrigerant and enablethe chiller to run after pumpdownlockout.

Guide Vane Calibration Calibrates guide vane input onCCM.

NOTE: During any of the tests, an out-of-range reading will have anasterisk (*) next to the reading and a message will be displayed.

COOLERCONDENSERPRESSURETRANSDUCERANDWATERSIDE FLOW DEVICE CALIBRATION — Cali-bration can be checked by comparing the pressure readingsfrom the transducer to an accurate refrigeration gage read-ing. These readings can be viewed or calibrated from theHEAT_EX screen on the CVC. The transducer can be checkedand calibrated at 2 pressure points. These calibration pointsare 0 psig (0 kPa) and between 25 and 250 psig (173 and1724 kPa). To calibrate these transducers:1. Shut down the compressor, cooler, and condenser pumps.

NOTE: There should be no flow through the heatexchangers.

2. Disconnect the transducer in question from its Schraderfitting for cooler or condenser transducer calibration. Foroil pressure or flow device calibration keep transducer inplace.NOTE: If the cooler or condenser vessels are at 0 psig(0 kPa) or are open to atmospheric pressure, the trans-ducers can be calibrated for zero without removing thetransducer from the vessel.

3. Access the HEAT_EX screen and view the particulartransducer reading (theEVAPORATOR PRESSUREorCONDENSER PRESSUREparameter on the HEAT_EXscreen). To calibrate oil pressure or waterside flow de-vice, view the particular reading(CHILLEDWATERDELTAPandCONDENSERWATERDELTAPon the HEAT_EXscreen, andOIL PUMP DELTA Pon the COMPRESSscreen). It should read 0 psi (0 kPa). If the reading is not0 psi (0 kPa), but within ± 5 psi (35 kPa), the value maybe set to zero by pressing the SELECTsoftkey whilethe appropriate transducer parameter is highlighted on theCVC screen. Then press the ENTERsoftkey. The valuewill now go to zero. No high end calibration is necessaryfor OIL PUMP DELTA Por flow devices.If the transducer value is not within the calibration range,the transducer returns to the original reading. If the pres-sure is within the allowed range (noted above), check thevoltage ratio of the transducer. To obtain the voltage ra-tio, divide the voltage (dc) input from the transducer bythe supply voltage signal (displayed inCONTROL TESTmenu in the CCM PRESSURE TRANSDUCERS screen)or measure across the positive (+ red) and negative(− black) leads of the transducer. For example, the con-denser transducer voltage input is measured at CCM ter-minals J2-4 and J2-5. The voltage ratio must be between0.80 and 0.11 for the software to allow calibration. Pres-surize the transducer until the ratio is within range. Thenattempt calibration again.

4. A high pressure point can also be calibrated between 25and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-lated 250 psig (1724 kPa) pressure (usually froma nitrogen cylinder). The high pressure point can be cali-brated by accessing the appropriate transducer parameteron theHEAT_EX screen, highlighting the parameter, press-ing the SELECT softkey, and then using the

INCREASE or DECREASE softkeys to adjust thevalue to the exact pressure on the refrigerant gage. Pressthe ENTER softkey to finish the calibration. Pressuresat high altitude locations must be compensated for, so thechiller temperature/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 mustbe installed and re-calibrated.

Check Optional Pumpout System Controls andCompressor— Controls include an on/off switch, a 3-ampfuse, the compressor overloads, an internal thermostat, a com-pressor 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 water-cooled condenser has been connected. Loosen thecompressor holddown bolts to allow free spring travel. Openthe compressor suction and discharge the service valves. En-sure oil is visible in the compressor sight glass. Add oil ifnecessary.See the Pumpout and Refrigerant Transfer Procedures and

Optional Pumpout System Maintenance sections, pages 63and 70, for details on the transfer of refrigerant, oil speci-fications, etc.

HighAltitude Locations— Because the chiller is ini-tially calibrated at sea level, it is necessary to recalibratethe pressure transducers if the chiller has been moved to ahigh altitude location. See the calibration procedure in theTroubleshooting Guide section.

57

Table 6 — Control Test Menu Functions

TESTS TO BEPERFORMED DEVICES TESTED

1. CCM Thermistors Entering Chilled WaterLeaving Chilled WaterEntering Condenser WaterLeaving Condenser WaterRemote Reset SensorComp Discharge TempComp Thrust Bearing TempOil Sump TempComp Motor Winding TempSpare Temperature 1Space Temperature 2

2. CCM PressureTransducers

Evaporator PressureCondenser PressureOil Pump Delta PSpare Pressure Delta PCondenser Water Delta PTransducer Voltage Ref

3. Pumps Oil Pump — Confirm pressureChilled Water — Confirm Delta PCondenser Water — Confirm

Delta P4. Discrete Outputs Oil Heater Relay

Hot Gas Bypass RelayTower Fan Relay LowTower Fan Relay HighAlarm RelayShunt Trip Relay

5. Guide Vane Actuator Open/Close6. Pumpdown/Lockout When using pumpdown/lockout,

observe freeze up precautions whenremoving charge:Instructs operator which valves toclose and when.Starts chilled water and condenserwater pumps and confirms flows.MonitorsEvaporator pressureCondenser pressureEvaporator temperature duringpumpout procedures

Turns pumps off after pumpdown.Locks out compressor.

7. Terminate Lockout Starts pumps and monitors flows.Instructs operator which valves toopen and when.MonitorsEvaporator pressureCondenser pressureEvaporator temperature duringcharging process

Terminates compressor lockout.8. Guide Valve Calibration Calibrates guide vane input on CCM

Charge Refrigerant into Chiller

The transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external pip-ing if springs have not been blocked in both up and downdirections.

Always operate the condenser and chilled water pumpsduring charging operations to prevent freeze-ups.

The standard 19XRT chiller is shipped with the refriger-ant already charged in the vessels. However, the 19XRTmaybe ordered with a nitrogen holding charge of 15 psig(103 kPa). Evacuate the nitrogen from the entire chiller, andcharge the chiller from refrigerant cylinders.

CHILLER EQUALIZATION WITHOUT A PUMPOUTUNIT

When equalizing refrigerant pressure on the 19XR chillerafter 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 charginghose (connected between the pumpout valves on top ofthe cooler and condenser) should be used as the equal-ization valve.

To equalize the pressure differential on a refrigerant iso-lated 19XRT chiller, use the terminate lockout function ofthe CONTROL TEST on the SERVICE menu. This helps toturn on pumps and advises the operator on properprocedures.The following steps describe how to equalize refrigerant

pressure in an isolated 19XRT chiller without a pumpout unit.1. Access terminate lockout function on theCONTROLTEST

screen.

IMPORTANT: Turn on the chilled water and con-denser water pumps to prevent freezing.

2.

3. Slowly open the refrigerant cooling isolation valve. Thechiller cooler and condenser pressures will gradually equal-ize. This process takes approximately 15 minutes.

4. Once the pressures have equalized, the cooler isolationvalve, the condenser isolation valve, and the hot gas iso-lation valve may now be opened. Refer to Fig. 26 and 27,for the location of the valves.

Whenever turning the discharge isolation valve, besure to reattach the valve locking device. This pre-vents the valve from opening or closing during serv-ice work or during chiller operation.

CHILLER EQUALIZATION WITH PUMPOUT UNIT —The following steps describe how to equalize refrigerant pres-sure on an isolated 19XRT chiller using the pumpout unit.1. Access the terminate lockout function on the CONTROL

TEST screen.

IMPORTANT: Turn on the chilled water and con-denser water pumps to prevent possible freezing.

2.

3. Open valve 4 on the pumpout unit and open valves 1aand 1b on the chiller cooler and condenser, Fig. 26 and27. Slowly open valve 2 on the pumpout unit to equalizethe pressure. This process takes approximately15 minutes.

4. Once the pressures have equalized, the discharge isola-tion valve, cooler isolation valve, optional hot gas bypassisolation valve, and the refrigerant isolation valve can beopened. Close valves 1a and 1b, and all pumpout unitvalves.

58

Whenever turning the discharge isolation valve, besure to reattach the valve locking device. This pre-vents the valve from opening or closing during serv-ice work or during chiller operation.

The full refrigerant charge on the 19XRT will vary withchiller components and design conditions, as indicated onthe job data specifications. An approximate charge may bedetermined by adding the condenser charge to the cooler chargeas listed in Table 7.

Table 7 — Refrigerant (HFC-134a) Charge

COOLERCODE

REFRIGERANTCHARGE CONDENSER

CODE

REFRIGERANTCHARGE

lb kg lb kg60 1230 558 60 1580 71761 1480 671 61 1580 71762 1720 780 62 1580 71763 1970 894 63 1580 717

Always operate the condenser and chilled water pumpswhenever charging, transferring, or removing refrig-rant from the chiller.

Use the CONTROL TEST terminate lockout function tomonitor conditions and start the pumps.If the chiller has been shipped with a holding charge, the

refrigerant is added through the refrigerant charging valve(Fig. 26 and 27, valve 7) or to the pumpout charging con-nection. First evacuate the nitrogen holding charge from thechiller vessels. Charge the refrigerant as a gas until the sys-tem pressure exceeds 35 psig (141 kPa) for HFC-134a. Afterthe chiller is beyond this pressure the refrigerant should becharged as a liquid until all the recommended refrigerant chargehas been added.TRIMMING REFRIGERANT CHARGE — The 19XRT isshipped with the correct charge for the design duty of thechiller. Trimming the charge can best be accomplished whenthe design load is available. To trim the charge, check thetemperature difference between the leaving chilled water tem-perature and cooler refrigerant temperature at full loaddesign conditions. If necessary, add or remove refrigerant tobring the temperature difference to design conditions or mini-mum differential.Table 7 lists the 19XRT chiller refrigerant charges for each

cooler and condenser code. Total refrigerant charge is thesum of the cooler and condenser charge.

INITIAL START-UP

Preparation — Before starting the chiller, verify: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. Chiller 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 re-

frigerant 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 iscirculating properly.

Do not permit water or brine that is warmer than110 F (43 C) to flow through the cooler or con-denser.Refrigerant overpressuremaydischarge throughthe relief valves and result in the loss of refrigerantcharge.

7. Access the CONTROL TEST screen. Scroll down on theTERMINATE LOCKOUToption. Press the SELECT (toenable the chiller to start) and answer YES to restart unitto operating mode. The chiller is locked out at the factoryin order to prevent accidental start-up.

Dry Run to Test Start-Up Sequence1. Disengage the main motor disconnect on the starter front

panel. This should only disconnect themotor power. Powerto the controls, oil pump, and starter control circuit shouldstill be energized.

2. Observe the default screen on the CVC: the Status mes-sage in the upper left-hand corner reads, ‘‘ManuallyStopped.’’ Press the CCNor LOCAL softkey to start.If the chiller controls do not go into a start mode, go tothe Schedule screen and override the schedule or changethe occupied time. Press the LOCALsoftkey to beginthe start-up sequences.

3. Verify the chilled water and condenser water pumpshave energized.

4. Verify the oil pump has started and is pressurizing thelubrication system. After the oil pump has run about11 seconds, the starter energizes and goes through its start-upsequence.

5. Check the main contactor for proper operation.6. The PIC II eventually shows an alarm for motor amps

not sensed. Reset this alarm and continue with the initialstart-up.

Check Motor Rotation1. Engage themainmotor disconnect on the front of the starter

panel. The motor is now ready for a rotation check.2. After the default screen status message states ‘‘Ready

for Start’’ press the LOCALsoftkey. The PIC II controlperforms start-up checks.

3. When the starter is energized and the motor begins to turn,check for clockwise motor rotation (Fig. 29).

Fig. 29 — Correct Motor Rotation

59

IF THE MOTOR ROTATION IS CLOCKWISE, allow thecompressor to come up to speed.IF THE MOTOR ROTATION IS NOT CLOCKWISE(as viewed through the sight glass), reverse any 2 of the 3incoming power leads to the starter and recheck the rotation.NOTE: Solid-state starters have phase protection and do notpermit a start if the phase is not correct. If this happens, afault message appears on the CVC.

Do not check motor rotation during coastdown. Rota-tion may have reversed during equalization of vesselpressures.

Check Oil Pressure and Compressor Stop1. When the motor is at full speed, note the differential oil

pressure reading on the CVC default screen. It should bebetween 18 and 30 psid (124 to 206 kPad).

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

To Prevent Accidental Start-Up — A chiller STOPoverride setting may be entered to prevent accidental start-upduring service or whenever necessary. Access the MAIN-STAT screen and using the NEXTor PREVIOUS soft-keys, highlight theCHILLERSTART/STOPparameter.Overridethe current START value by pressing the SELECTsoftkey.Press the STOPsoftkey followed by the ENTERsoftkey.The word SUPVSR! displays on the CVC indicating the over-ride is in place.To restart the chiller the STOP override setting must be

removed. Access the MAINSTAT screen and usingNEXT or PREVIOUS softkeys highlight CHILLERSTART/STOP. The 3 softkeys that appear represent 3 choices:

• START — forces the chiller ON

• STOP — forces the chiller OFF

• RELEASE — puts the chiller under remote or schedulecontrol.To return the chiller to normal control, press the

RELEASE softkey followed by the ENTERsoftkey. Formore information, see Local Start-Up, page 45.The default LID screen message line indicates which com-

mand is in effect.

Check Chiller Operating Condition — Check tobe sure that chiller temperatures, pressures, water flows, andoil and refrigerant levels indicate the system is functioningproperly.

Instruct the Customer Operator — Ensure theoperator(s) understand all operating and maintenance pro-cedures. Point out the various chiller parts and explain theirfunction as part of the complete system.COOLER-CONDENSER—Float chamber, relief valves, re-frigerant charging valve, temperature sensor locations, pres-sure transducer locations, Schrader fittings, waterboxes andtubes, and vents and drains.OPTIONAL PUMPOUT STORAGE TANK AND PUMP-OUT SYSTEM — Transfer valves and pumpout system,refrigerant charging and pumpdown procedure, and reliefdevices.MOTOR COMPRESSOR ASSEMBLY — Guide vaneactuator, transmission, motor cooling system, oil coolingsystem, temperature and pressure sensors, oil sight glasses,

integral oil pump, isolatable oil filter, extra oil and motortemperature sensors, synthetic oil, and compressorserviceability.MOTORCOMPRESSOR LUBRICATION SYSTEM—Oilpump, cooler filter, oil heater, oil charge and specification,operating and shutdown oil level, temperature and pressure,and oil charging connections.CONTROLSYSTEM—CCNand LOCALstart, reset, menu,softkey functions, CVC operation, occupancy schedule, setpoints, safety controls, and auxiliary and optional controls.AUXILIARYEQUIPMENT—Starters and disconnects, sepa-rate electrical sources, pumps, and cooling tower.DESCRIBECHILLERCYCLES—Refrigerant, motor cool-ing, lubrication, and oil reclaim.REVIEW MAINTENANCE — Scheduled, routine, andextended shutdowns, importance of a log sheet, importanceof water treatment and tube cleaning, and importance of main-taining a leak-free chiller.

SAFETYDEVICESAND PROCEDURES—Electrical dis-connects, relief device inspection, and handling refrigerant.

CHECKOPERATORKNOWLEDGE—Start, stop, and shut-down procedures, safety and operating controls, refrigerantand oil charging, and job safety.

REVIEW THE START-UP, OPERATION, AND MAINTE-NANCE MANUAL.

OPERATING INSTRUCTIONSOperator Duties1. Become familiar with the chiller and related equipment

before operating the chiller.2. Prepare the system for start-up, start and stop the chiller,

and place the system in a shutdown condition.3. Maintain a log of operating conditions and document any

abnormal readings.4. Inspect the equipment, make routine adjustments, and per-

form a Control Test. Maintain the proper oil and refrig-erant levels.

5. Protect the system from damage during shutdownperiods.

6. Maintain the set point, time schedules, and other PICfunctions.

Prepare the Chiller for Start-Up— Follow the stepsdescribed in the Initial Start-Up section, page 59.

To Start the Chiller1. Start the water pumps, if they are not automatic.

2. On the CVC default screen, press the LOCALorCCN softkey to start the system. If the chiller is in theOCCUPIED mode and the start timers have expired, thestart sequence will start. Follow the procedure describedin the Start-Up/Shutdown/Recycle Sequence section,page 45.

Check the Running System — After the compres-sor starts, the operator should monitor the CVC display andobserve the parameters for normal operating conditions:1. The oil reservoir temperature should be above 120 F

(49 C) during shutdown and above 125 F (58 C) duringcompressor operation.

2. The bearing oil temperature accessed on the COM-PRESS table should be 120 to 165 F (49 to 74 C). If thebearing temperature reads more than 180 F (83 C) withthe oil pump running, stop the chiller and determine thecause of the high temperature.Do not restartthe chilleruntil corrected.

60

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

4. The oil pressure should be between 18 and 30 psid(124 to 207 kPad) differential, as seen on the CVC de-fault 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 refrigerantmotor cooling line should indicate refrigerant flow and adry condition.

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

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

8. The compressor may operate at full capacity for a shorttime after the pulldown ramping has ended, even thoughthe building load is small. The active electrical demandsetting can be overridden to limit the compressor IkW, orthe pulldown rate can be decreased to avoid a highdemand charge for the short period of high demandoperation. Pulldown rate can be based on load rate or tem-perature rate. It is accessed on the Equipment SERVICEscreen, RAMP_DEM table (Table 2, Example 20).

To Stop the Chiller1. The occupancy schedule starts and stops the chiller

automatically 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 shutdownsequence as described in the Controls section. The chillerwill not restart until the CCNor LOCAL softkey ispressed. The chiller is now in the OFF control mode.

IMPORTANT: Do not attempt to stop the chiller byopening an isolating knife switch. High intensityarcing may occur.

Do not restart the chilleruntil the problem is diagnosedand corrected.

After Limited Shutdown — No special preparationsshould be necessary. Follow the regular preliminary checksand starting procedures.

Preparation for Extended Shutdown — Therefrigerant should be transferred into the pumpout storagetank (if supplied; see Pumpout and Refrigerant TransferProcedures) to reduce chiller pressure and the possibilityof leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to4.5 kg) of refrigerant or nitrogen to prevent air from leakinginto the chiller.If freezing temperatures are likely to occur in the chiller

area, drain the chilled water, condenser water, and the pump-out condenser water circuits to avoid freeze-up. Keep thewaterbox drains open.

Leave the oil charge in the chiller with the oil heaterand controls energized to maintain the minimum oil reser-voir temperature.

After Extended Shutdown — Ensure the water sys-tem drains are closed. It may be advisable to flush the watercircuits to remove any soft rust which may have formed. Thisis a good time to brush the tubes and inspect the Schraderfittings on the waterside flow devices for fouling, ifnecessary.Check the cooler pressure on the CVC default screen and

compare it to the original holding charge that was left in thechiller. If (after adjusting for ambient temperature changes)any loss in pressure is indicated, check for refrigerant leaks.See Check Chiller Tightness section, page 47.Recharge the chiller by transferring refrigerant from the

pumpout storage tank (if supplied). Follow the Pumpout andRefrigerant Transfer Procedures section, this page. Observefreeze-up precautions.Carefully make all regular preliminary and running sys-

tem checks. Perform a Control Test before start-up. If thecompressor oil level appears abnormally high, the oil mayhave absorbed refrigerant. Ensure that the oil temperature isabove 140 F (60 C) or above the cooler refrigerant tempera-ture plus 50° F (27° C).

Cold Weather Operation — When the entering con-denser water temperature drops very low, the operator shouldautomatically cycle the cooling tower fans off to keep thetemperature up. Piping may also be arranged to bypass thecooling tower. The PIC II controls have a low limit towerfan output that can be used to assist in this control (terminal11 and 12 on ISM).

Manual Guide Vane Operation — It is possible tomanually operate the guide vanes in order to check con-trol operation or to control the guide vanes in an emergency.Manual operation is possible by overriding the target guidevane position. Access the COMPRESS screen on the CVCand scroll down to highlightTARGET GUIDE VANEPOS. To control the position, use the INCREASEorDECREASE softkey to adjust to the percentage of guidevane opening that is desired. Zero percent is fully closed;100% is fully open. To release the guide vanes to automaticcontrol, press the RELEASEsoftkey.

NOTE: Manual control increases the guide vane openingsand overrides the pulldown rate during start-up. Motor cur-rent above the electrical demand setting, capacity overrides,and chilled water temperature below the control point over-ride the manual target and close the guide vanes. Fordescriptions of capacity overrides and set points, see theControls section.

Refrigeration Log — A refrigeration log (as shown inFig. 30), is a convenient checklist for routine inspection andmaintenance and provides a continuous record of chillerperformance. It is also an aid when scheduling routine main-tenance and diagnosing chiller problems.Keep a record of the chiller pressures, temperatures, and

liquid levels on a sheet similar to the one in Fig. 30. Auto-matic recording of PIC II data is possible by using CCNdevices such as the Data Collection module and a Build-ing Supervisor. Contact a Carrier representative for moreinformation.

61

Date

REFRIGERAT

IONLO

GCARRIER19XRHERMETIC

CENTRIFUGALREFRIGERAT

IONMACHINE

Plant

MACHINEMODELNO.

MACHINESERIALNO.

REFRIGERANTTYPE

DAT

ECOOLE

RCONDENSER

COMPRESSOR

OPER-

ATOR

INITIALS

REMARKS

TIME

Refrigerant

Water

Refrigerant

Water

BEARING

TEMP

Oil

Motor

Press.

Temp

Pressure

Temp

Press.

Temp

Pressure

Temp

Press.

Diff.

Temp

(reser-

voir)

Level

FLA

InOut

GPM

InOut

InOut

GPM

InOut

Amperage

(orvane

position)

REMARKS:Indicateshutdowns

onsafetycontrols,repairs

made,oilorrefrigerantaddedor

removed,airexhaustedandwater

drainedfrom

dehydrator.Includeam

ounts.

Fig.30

—RefrigerationLog

62

PUMPOUT AND REFRIGERANTTRANSFER PROCEDURES

Preparation— The 19XRTmay come equipped with anoptional pumpout storage tank, pumpout system, or pump-out compressor. The refrigerant can be pumped for servicework to either the chiller compressor vessel or chiller con-denser vessel by using the optional pumpout system. If apumpout storage tank is supplied, the refrigerant can be iso-lated in the storage tank. The following procedures describehow to transfer refrigerant from vessel to vessel and performchiller evacuations.

Always run the chiller cooler and condenser water pumpsand always charge or transfer refrigerant as a gas whenthe chiller pressure is less than 30 psig (207 kPa). Be-low these 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 theoptional storage tank, carefully monitor the storagetank level gage. Do not fill the tank more than 90% ofcapacity to allow for refrigerant expansion. Overfillingmay result in damage to the tank or personal injury.

Do not mix refrigerants from chillers that use differentcompressor oils. Compressor damage can result.

Operating the Optional Pumpout Unit1. Be sure that the suction and the discharge service valves

on the optional pumpout compressor are open (back-seated) during operation. Rotate the valve stem fullycounterclockwise to open. Frontseating the valve closesthe refrigerant line and opens the gage port to compres-sor pressure.

2. Ensure that the compressor holddown bolts have been loos-ened to allow free spring travel.

3. Open the refrigerant inlet valve on the pumpoutcompressor.

4. Oil should be visible in the pumpout unit compressor sightglass under all operating conditions and during shut-down. If oil is low, add oil as described under OptionalPumpout SystemMaintenance section, page 70. The pump-out unit control wiring schematic is detailed in Fig. 31.

TO READ REFRIGERANT PRESSURES during pumpoutor leak testing:1. The CVC display on the chiller control panel is suitable

for determining refrigerant-side pressures and low (soft)vacuum. To assure the desired range and accuracy whenmeasuring evacuation and dehydration, use a quality vacuumindicator or manometer. This can be placed on the Schraderconnections on each vessel (Fig. 7) by removing the pres-sure transducer.

2. To determine pumpout storage tank pressure, a 30 in.-0-400 psi (-101-0-2769 kPa) gage is attached to the stor-age tank.

3. Refer to Fig. 26, 27, and 32 for valve locations andnumbers.

Transfer, addition, or removal of refrigerant in spring-isolated chillers may place severe stress on external pip-ing if springs have not been blocked in both up and downdirections.

LEGENDC — ContactorFU — Fuse, 3 AmpsHP — High-Pressure CutoutOL — Compressor OverloadT’STAT — Internal Thermostat

Compressor Terminal

Contactor Terminal

Overload Terminal

Pumpout Unit Terminal

*Bimetal thermal protector imbedded in motor winding.

Fig. 31 — 19XRT Pumpout Unit Wiring Schematic

OIL RETURNLINECONNECTION

CONDENSERWATERCONNECTIONS

REFRIGERANTINLET VALVE

Fig. 32 — Optional Pumpout Unit

63

Chillers with Storage Tanks— If the chiller has iso-lation valves, leave them open for the following procedures.The letter ‘‘C’’ describes a closed valve. See Fig. 15, 16, 26,and 27.

TRANSFER REFRIGERANT FROM PUMPOUT STOR-AGE TANK TO CHILLER1. Equalize refrigerant pressure.

a. Use the PIC II terminate lockout function on the PUMP-DOWN LOCKOUT screen, accessed from the CON-TROL TEST table to turn on the water pumps andmonitor pressures.

If the chilled water and condenser water pumps arenot controlled by the PIC II, these pumps must bestarted and stoppedmanually at the appropriate timesduring the refrigerant transfer procedure.

b. Close pumpout unit valves 2, 4, 5, 8, and 10, and closechiller charging valve 7; open chiller isolation valves11, 12, 13, and 14 (if present).

c. Open pumpout unit/storage tank valves 3 and 6, openchiller valves 1a and 1b.

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

Follow steps D and E carefully to prevent damagefrom freeze-up.

d. Slowly open valve 5 to increase chiller pressure to68 psig 35 psig (141 kPa) for HFC-134a. Feed refrig-erant slowly to prevent freeze up.

e. Open valve 5 fully after the pressure rises above thefreeze point of the refrigerant. Open liquid line valves7 and 10 until refrigerant pressure equalizes.

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

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


b. Turn off the chiller water pumps using the CVC (ormanually, if necessary).

c. Turn off the pumpout condenser water, and turn on thepumpout compressor to push liquid out of the storagetank.

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 14CONDITION C C C C

h. Turn on the pumpout condenser water.i. Run the pumpout compressor until the pumpout stor-

age 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 14CONDITION C C C C C C C C C C

l. Turn off pumpout condenser water.TRANSFER REFRIGERANT FROM CHILLER TOPUMPOUT STORAGE TANK

1. Equalize refrigerant pressure.a. Valve positions:

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

b. Slowly open valve 5. When the pressures are equal-ized, open liquid line valve 7 to allow liquid refrig-erant to drain by gravity into the pumpout storage tank.


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

in the following positions:


b. Run the pumpout compressor for approximately 30min-utes; then close valve 10.


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 CON-TROL TEST table. Turn on the pumps manually, ifthey are not controlled by the PIC II.

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


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 condenserwater will boil off any entrapped liquid refrigerant andthe chiller pressure will rise.

e. When the pressure rises to 40 psig (276 kPa) forHFC-134a, turn on the pumpout compressor until thepressure again reaches 30 psig (207 kPa), and thenturn off the pumpout compressor. Repeat this processuntil the pressure no longer rises. Then, turn on thepumpout compressor and pumpuntil 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 14CONDITION C C C C C C C C C C

g. Turn off the pumpout condenser water and continue touse the PIC II PUMPDOWN LOCKOUT screen func-tions, which lock out the chiller compressor foroperation.

4. Establish a vacuum for service.To conserve refrigerant, operate the pumpout compressoruntil the chiller pressure is reduced to 18 in. Hg vac., ref30 in. bar. (40 kPa abs.) following Step 3e.

64

Chillers with Isolation ValvesTRANSFER ALL REFRIGERANT TO CHILLER CON-DENSER VESSEL — For chillers with isolation valves,refrigerant can be stored in one chiller vessel or the otherwithout the need for an external storage tank.1. Push refrigerant into the chiller condenser.

a. Valve positions:

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

b. Using the PIC II controls, turn off the chiller waterpumps and pumpout condenser water. If the chillerwater pumps are not controlled through the PIC II, turnthem off manually.

c. Turn on the pumpout compressor to push the liquidrefrigerant out of the chiller cooler vessel.

d. When all liquid refrigerant has been pushed intothe chiller condenser vessel, close chiller isolationvalve 11.

e. Access the PUMPDOWN LOCKOUT screen on thePIC II CONTROL TEST table to turn on the chillerwater pumps. If the chiller water pumps are not con-trolled 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 openvalves 3 and 4.

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

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 and on refrigerant gages.

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

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

g. Turn off the pumpout condenser water.h. Proceed to the PUMPDOWN/LOCKOUT function

accessed from the CONTROL TEST table to turn offthe chiller water pumps and lock out the chiller com-pressor. Turn off the chiller water pumps manually ifthey are not controlled by the PIC II.

TRANSFERALLREFRIGERANTTOCHILLERCOOLERVESSEL1. Push the refrigerant into the chiller cooler vessel.

a. Valve positions:

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

b. Turn off the chiller water pumps (either throughthe PIC II controls or manually, if necessary) and thepumpout condenser water.

c. Turn on the pumpout compressor to push the refrig-erant 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.

2. Evacuate the refrigerant gas from the chiller condenservessel.

a. Access the PUMPDOWN LOCKOUT function ac-cessed from the CVC CONTROL TEST table to turnon the chiller water pumps. Turn the chiller water pumpson manually if they are not controlled by the PIC II.

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


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

denser pressure reaches 18 in. Hg vac (40 kPa abs.).Monitor pressure at the CVC 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 14CONDITION C C C C C C C C C C C

h. Turn off the pumpout condenser water.i. Proceed to the PUMPDOWN LOCKOUT test fromthe CVC CONTROL TEST table to turn off the chill-er water pumps and lock out the chiller compressor.Turn off the chiller water pumps manually if they arenot controlled by the PIC II.

RETURN CHILLER TO NORMAL OPERATINGCONDITIONS

1. Ensure vessel that was opened has been evacuated.2. Access theTERMINATE LOCKOUT functionCVC from

the CONTROLTEST table to view vessel pressures andturn on chiller water pumps. If the chiller water pumpsare 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 14CONDITION C C C C C C C C

4. Slowly open valve 5, gradually increasing pressure inthe evacuated vessel to 35 psig (141 kPa). Feed refrig-erant slowly to prevent tube freeze up.

5. Leak test to ensure vessel integrity.6. Open valve 5 fully.


7. Open valve 11 to equalize the liquid refrigerant levelbetween the vessels.

8. Close valves 1a, 1b, 3, and 5.9. Open isolation valves 12, 13, and 14 (if present).


10. Proceed to the TERMINATE LOCKOUT screen (ac-cessed from the CONTROL TEST table) to turn off thewater pumps and enable the chiller compressor for start-up. If the chiller water pumps are not controlled by thePIC II, turn them off manually.

65

GENERAL MAINTENANCE

Refrigerant Properties— The standard refrigerant forthe 19XRT chiller is HFC-134a.At normal atmospheric pres-sure, HFC-134a will boil at –14 F (–25 C) and must, there-fore, be kept in pressurized containers or storage tanks. Therefrigerant is practically odorless when mixed with airand is noncombustible at atmospheric pressure. Read theMaterial Safety Data Sheet and the latest ASHRAE SafetyGuide for Mechanical Refrigeration to learn more about safehandling of this refrigerant.

HFC-134a will dissolve oil and some nonmetallic ma-terials, dry the skin, and, in heavy concentrations, maydisplace enough oxygen to cause asphyxiation. Whenhandling this refrigerant, protect the hands and eyes andavoid breathing fumes.

Adding Refrigerant — Follow the procedures de-scribed in Trim Refrigerant Charge section, this page.

Always use the compressor pumpdown function in theControl Test table to turn on the cooler pump and lockout the compressor when transferring refrigerant. Liq-uid refrigerant may flash into a gas and cause possiblefreeze-up when the chiller pressure is below30 psig (207 kPa) for HFC-134a.

Removing Refrigerant— If the optional pumpout sys-tem is used, the 19XRT refrigerant charge may be trans-ferred to a pumpout storage tank or to the chiller condenseror cooler vessels. Follow the procedures in the Pumpout andRefrigerant Transfer Procedures section when transferring re-frigerant from one vessel to another.

Adjusting the Refrigerant Charge — If the addi-tion or removal of refrigerant is required to improve chillerperformance, follow the procedures given under the TrimRefrigerant Charge section, this page.

Refrigerant Leak Testing — Because HFC-134a isabove atmospheric pressure at room temperature, leak test-ing can be performed with refrigerant in the chiller. Use anelectronic halide leak detector, soap bubble solution, or ultra-sonic leak detector. Ensure that the room is well ventilatedand free from concentration of refrigerant to keep false read-ings to a minimum. Before making any necessary repairs toa leak, transfer all refrigerant from the leaking vessel.

Leak Rate — It is recommended by ASHRAE that chill-ers be taken off line immediately and repaired if the refrig-erant leak rate for the entire chiller is more than 10% of theoperating 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 totalcharge per year should be repaired during annual mainte-nance or whenever the refrigerant is transferred for other serv-ice work.

Test After Service, Repair, or Major Leak — Ifall the refrigerant has been lost or if the chiller has been openedfor service, the chiller or the affected vessels must be pres-sure tested and leak tested. Refer to the Leak Test Chillersection to perform a leak test.

HFC-134a should not be mixed with air or oxygen andpressurized for leak testing. In general, this refrigerantshould not be present with high concentrations of air oroxygen above atmospheric pressures, because the mix-ture can undergo combustion.

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

TO PRESSURIZE WITH DRY NITROGEN — Anothermethod of leak testing is to pressurize with nitrogen onlyand to use a soap bubble solution or an ultrasonic leakdetector to determine if leaks are present.

NOTE: Pressurizing with dry nitrogen for leak testing shouldonly be done ifall refrigerant has been evacuated from thevessel.1. Connect a copper tube from the pressure regulator on the

cylinder to the refrigerant charging valve. Never applyfull cylinder pressure to the pressurizing line. Follow thelisted sequence.

2. Open the charging valve fully.3. Slowly open the cylinder regulating valve.4. Observe the pressure gage on the chiller and close the

regulating valve when the pressure reaches test level.Donot exceed140 psig (965 kPa).

5. Close the charging valve on the chiller. Remove the cop-per tube if it is no longer required.

Repair the Leak, Retest, and Apply StandingVacuum Test — After pressurizing the chiller, test forleaks with an electronic halide leak detector, soap bubblesolution, or an ultrasonic leak detector. Bring the chiller backto 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 VacuumTest and Chiller Dehydration section (pages 49 and 52) inthe Before Initial Start-Up section.

Checking Guide Vane Linkage — When thechiller is off, the guide vanes are closed and the actuatormechanism is in the position shown in Fig. 33. If slack de-velops in the drive chain, do the following to eliminatebacklash:1. With the chiller shut down and the actuator fully closed,

remove the chain guard and loosen the actuator bracketholddown bolts.

2. Loosen guide vane sprocket adjusting bolts.3. Pry bracket upwards to remove slack, then retighten the

bracket holddown bolts.4. Retighten the guide vane sprocket adjusting bolts. En-

sure that the guide vane shaft is rotated fully in the clock-wise direction in order close it fully.

TrimRefrigerant Charge — If, to obtain optimal chillerperformance, it becomes necessary to adjust the refrigerantcharge, operate the chiller at design load and then add orremove refrigerant slowly until the difference between theleaving chilled water temperature and the cooler refrigeranttemperature reaches design conditions or becomes a mini-mum.Do not overcharge.Refrigerant may be added either through the storage tank

or directly into the chiller as described in the ChargeRefrigerant into Chiller section.To remove any excess refrigerant, follow the procedure in

Transfer Refrigerant from Chiller to Pumpout Storage Tanksection, Steps 1a and b, page 64.

66

WEEKLY MAINTENANCE

Check the Lubrication System— Mark the oil levelon the reservoir sight glass, and observe the level each weekwhile 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 re-quired, add it through the oil drain charging valve (Fig. 2).A pump is required when adding oil against refrigerant pres-sure. The oil charge for the 19XRT compressor depends onthe 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)

TheaddedoilmustmeetCarrier specifications for the 19XRT.Refer to Changing Oil Filter and Oil Changes section on thispage. Any additional oil that is added should be logged bynoting the amount and date. Any oil that is added due to oilloss that is not related to service will eventually return to thesump. 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 compressoris off. The CVC COMPRESS screen displays whether theheater is energized or not. The heater is energized if theOILHEATER RELAYparameter reads ON. If the PIC II showsthat the heater is energized and if the sump is still not heat-ing up, the power to the oil heater may be off or the oil levelmay be too low. Check the oil level, the oil heater contactorvoltage, 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-uponly after the temperature is within allowable limits.

SCHEDULED MAINTENANCEEstablish 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 sectionare offered as guides to service only.

Service Ontime — The CVC will display aSERVICEONTIMEvalue on the MAINSTAT screen. This value shouldbe reset to zero by the service person or the operator eachtime major service work is completed so that the time be-tween service can be viewed and tracked.

Inspect the Control Panel — Maintenance consistsof general cleaning and tightening of connections. Vacuumthe cabinet to eliminate dust build-up. If the chiller controlmalfunctions, refer to the Troubleshooting Guide section forcontrol checks and adjustments.

Ensure power to the control center is off when cleaningand tightening connections inside the control panel.

Check Safety and Operating Controls Monthly— To ensure chiller protection, the automated Control Testshould be performed at least once per month. See Table 3for safety control settings. See Table 6 for Control Testfunctions.

Changing Oil Filter— Change the oil filter on a yearlybasis or when the chiller is opened for repairs. The 19XRThas an isolatable oil filter so that the filter may be changedwith the refrigerant remaining in the chiller. Use the follow-ing procedure:

1. Ensure the compressor is off and the disconnect for thecompressor is open.

2. Disconnect the power to the oil pump.3. Close the oil filter isolation valves 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 suit-able for used oil. The oil drained from the filter hous-ing should be used as an oil sample and sent to a labo-ratory for proper analysis.Do not contaminate thissample.

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

The oil filter housing is at a high pressure. Relievethis pressure slowly.

6. Once all oil has been drained, place some rags orabsorbent material under the oil filter housing to catchany drips once the filter is opened. Remove the 4 boltsfrom the end of the filter housing and remove the filtercover.

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

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

9. Evacuate the filter housing by placing a vacuum pumpon the charging valve. Follow the normal evacuationprocedures. Shut the charging valve when done andreconnect the valve so that new oil can be pumped intothe filter housing. Fill with the same amount that wasremoved; then close the charging valve.

10. Remove the hose from the charging valve, open the iso-lation valves to the filter housing, and turn on the powerto the pump and the motor.

Fig. 33 — Guide Vane Actuator Linkage

67

Oil Specification — If oil is added, it must meet thefollowing Carrier specifications:Oil Type for units using R-134a. . . . . . . . . . . . . .Inhibited

polyolester-based syntheticcompressor oil formatted foruse with HFC, gear-driven,

hermetic compressors.ISO Viscosity Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

The polyolester-based oil (P/N: PP23BZ103) may beordered from your local Carrier representative.

Oil Changes — Carrier recommends changing the oilafter the first year of operation and every five years there-after as a minimum in addition to a yearly oil analysis. How-ever, if a continuous oil monitoring system is functioningand a yearly oil analysis is performed, the time between oilchanges can be extended.

TO CHANGE THE OIL1. 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 refrigerantpressure.

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

6. Change the refrigerant filter at this time, see the next sec-tion, Refrigerant Filter.

7. Charge the chiller with oil. Charge until the oil level isequal to the oil level marked in Step 2. Turn on the powerto the oil heater and let the PIC II warm it up to at least140 F (60 C). Operate the oil pump manually, using theControl Test function, for 2 minutes. For shutdown con-ditions, the oil level should be full in the lower sight glass.If the oil level is above1⁄2 full in the upper sight glass,remove the excess oil. The oil level should now be equalto the amount shown in Step 2.

Refrigerant Filter — A refrigerant filter/drier, locatedon the refrigerant cooling line to themotor, should be changedonce a year or more often if filter condition indicates a needfor more frequent replacement. Change the filter by closingthe filter isolation valves (Fig. 4) and slowly opening theflare fittings with a wrench and back-up wrench to relievethe pressure. A moisture indicator sight glass is located be-yond this filter to indicate the volume and moisture in therefrigerant. If the moisture indicator indicates moisture,locate the source of water immediately by performing athorough leak check.

Oil ReclaimFilter— The oil reclaim system has a straineron the eductor suction line, a strainer on the discharge pres-sure line, and a filter on the cooler scavenging line. Replacethe filter once per year or more often if filter condition in-dicates a need for more frequent replacement. Change thefilter by closing the filter isolation valves and slowly open-ing the flare fitting with a wrench and back-up wrench torelieve the pressure. Change the strainers once every 5 yearsor whenever refrigerant is evacuated from the cooler.

Inspect Refrigerant Float System — Perform thisinspection every 5 years or when the condenser is openedfor 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 arefree of obstructions.

4. Examine the cover gasket and replace if necessary. Cleanthe pilot drain line strainer.See Fig. 34 for views of the float valve design. For linear

float valve designs, inspect the orientation of the float slidepin. It must be pointed toward the bubbler tube for properoperation.

Inspect Relief Valves andPiping— The relief valveson this chiller protect the system against the potentially dan-gerous effects of overpressure. To ensure against damage tothe equipment and possible injury to personnel, these de-vices 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 thevalve outlet and carefully inspect the valve body andmecha-nism for any evidence of internal corrosion or rust, dirt,scale, leakage, etc.

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

3. If the chiller is installed in a corrosive atmosphere or therelief valves are vented into a corrosive atmosphere, in-spect the relief valves at more frequent intervals.

TurbineStrainer— Astrainer is located at the inlet flangeon the turbine suction. The strainer should be inspected andcleaned every 5 years. The refrigerant must be removed ortransferred to the condenser section before the strainer canbe accessed.

Turbine Maintenance — No special maintenance isrequired for the turbine section. A visual inspection shouldtake place whenever the bearings and other compressor com-ponents are inspected. Check that the nozzle block flow di-viders are clean. See Fig. 35.

Compressor Bearing and Gear Maintenance—The key to good bearing and gear maintenance is properlubrication. Use the proper grade of oil, maintained at rec-ommended level, temperature, and pressure. Inspect thelubrication system regularly and thoroughly.To inspect the bearings, a complete compressor teardown

is required. Only a trained service technician should removeand examine the bearings. The cover plate on older com-pressor bases was used for factory-test purposes and is notusable for bearing or gear inspection. The bearings and gearsshould be examined on a scheduled basis for signs of wear.The frequency of examination is determined by the hours ofchiller operation, load conditions during operation, and thecondition of the oil and the lubrication system. Excessivebearing wear can sometimes be detected through increasedvibration or increased bearing temperature. If either symp-tom appears, contact an experienced and responsible serviceorganization for assistance.

68

INTERNAL SIDE VIEW(FLOAT VALVES REMOVED)

Fig. 34 — 19XRT Float Chamger

*Nozzle locations are consecutively numbered and the number is located next tothe appropriate hole. The flow dividers can be physically different and must not beinterchanged when inspecting or cleaning the nozzle assembly.

Fig. 35 — Nozzle Assembly

69

Inspect the Heat Exchanger Tubes and FlowDevicesCOOLER AND FLOW DEVICES — Inspect and clean thecooler tubes at the end of the first operating season. Becausethese tubes have internal ridges, a rotary-type tube cleaningsystem is needed to fully clean the tubes. Inspect the tubes’condition to determine the scheduled frequency for futurecleaning and to determine whether water treatment in thechilled water/brine circuit is adequate. Inspect the enteringand leaving chilled water temperature sensors and flow de-vices for signs of corrosion or scale. Replace a sensor orSchrader fitting if corroded or remove any scale if found.CONDENSER AND FLOW DEVICES — Since this watercircuit is usually an open-type system, the tubes may be sub-ject to contamination and scale. Clean the condenser tubeswith a rotary tube cleaning system at least once per year andmore often if the water is contaminated. Inspect the enteringand leaving condenser water sensors and flow devices forsigns of corrosion or scale. Replace the sensor or Schraderfitting if corroded or remove any scale if found.Higher than normal condenser pressures, together with the

inability to reach full refrigeration load, usually indicate dirtytubes or air in the chiller. If the refrigeration log indicates arise above normal condenser pressures, check the condenserrefrigerant temperature against the leaving condenser watertemperature. If this reading is more than what the design dif-ference is supposed to be, the condenser tubes may be dirtyor water flowmay 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. Con-tact your Carrier representative to obtain these brushes.Donot use wire brushes.

Hard scale may require chemical treatment for its pre-vention or removal. Consult a water treatment specialistfor proper treatment.

Water Leaks — The refrigerant moisture indicator onthe refrigerant motor cooling line (Fig. 3) indicates whetherthere is water leakage during chiller operation. Water leaksshould be repaired immediately.

The chiller must be dehydrated after repair of water leaks.See Chiller Dehydration section, page 52.

Water Treatment — Untreated or improperly treatedwater may result in corrosion, scaling, erosion, or algae. Theservices of a qualified water treatment specialist should beobtained to develop and monitor a treatment program.

Watermust bewithin design flow limits, clean, and treatedto ensure proper chiller performance and reduce thepotential of tube damage due to corrosion, scaling, ero-sion, and algae. Carrier assumes no responsibility forchiller damage resulting from untreated or improperlytreated water.

Inspect the Starting Equipment — Before work-ing on any starter, shut off the chiller and open all discon-nects supplying power to the starter.

The disconnect on the starter front panel does not de-energize all internal circuits. Open all internal andremote disconnects before servicing the starter.

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

Inspect starter contact surfaces for wear or pittingon mechanical-type starters. Do not sandpaper or filesilverplated contacts. Follow the starter manufacturer’sinstructions for contact replacement, lubrication, spare partsordering, 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 andretighten. Recheck annually thereafter.

Loose power connections can cause voltage spikes, over-heating, malfunctioning, or failures.

Check Pressure Transducers — Once a year, thepressure transducers should be checked against a pressuregage reading. Check all eight transducers: the 2 oil differ-ential pressure transducers, the condenser pressuretransducer, the cooler pressure transducer, and the watersidepressure 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 (EVAPORATOR PRES-SUREandCONDENSER PRESSURE). Attach an accurateset of refrigeration gages to the cooler and condenser Schraderfittings. Compare the two readings. If there is a difference inreadings, the transducer can be calibrated as described in theTroubleshooting Guide section. Oil differential pressure (OILPUMPDELTA Pon the COMPRESS screen) should be zerowhenever the compressor is off.

Optional Pumpout SystemMaintenance— Forpumpout unit compressor maintenance details, refer to the06D, 07D Installation, Start-Up, and Service Instructions.

OPTIONALPUMPOUTCOMPRESSOROILCHARGE—Use oil conforming to Carrier specifications for reciprocat-ing compressor usage. Oil requirements are as follows:ISO Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Carrier Part Number. . . . . . . . . . . . . . . . . . . .PP23BZ103The 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 theoil level before operating the compressor. Before adding orchanging oil, relieve the refrigerant pressure as follows:1. Attach a pressure gage to the gage port of either com-

pressor service valve (Fig. 32).

70

2. Close the suction service valve and open the dischargeline to the storage tank or the chiller.

3. Operate the compressor until the crankcase pressure dropsto 2 psig (13 kPa).

4. Stop the compressor and isolate the system by closingthe discharge service valve.

5. Slowly remove the oil return line connection (Fig. 32).Add oil as required.

6. Replace the connection and reopen the compressor serv-ice valves.

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS(Fig. 36)—The optional pumpout systemhigh-pressure switchopens at 161 psig (1110 kPa) and closes at 130 psig(896 kPa). Check the switch setting by operating the pump-out compressor and slowly throttling the pumpout con-denser water.

Ordering Replacement Chiller Parts — Whenordering Carrier specified parts, the following informationmust accompany an order:• chiller model number and serial number• name, quantity, and part number of the part required• delivery address and method of shipment.

TROUBLESHOOTING GUIDE

Overview — The PIC II has many features to help theoperator and technician troubleshoot a 19XRT chiller.• The CVC shows the chiller’s actual operating conditionsand can be viewed while the unit is running.

• The CVC default screen freezes when an alarm occurs.The freeze enables the operator to view the chiller con-ditions at the time of alarm. The STATUS screens con-tinue to show current information. Once all alarms havebeen cleared (by correcting the problems and pressing theRESET softkey), the CVC default screen returns to nor-mal operation.

• The CONTROL ALGORITHM STATUS screens (whichinclude the CAPACITY, OVERRIDE, LL_MAINT,ISM_HIST, LOADSHED,WSMDEFME, andOCCDEFCMscreens) display information that helps to diagnose prob-lems with chilled water temperature control, chilled watertemperature control overrides, hot gas bypass, surge al-gorithm status, and time schedule operation.

• The Control Test feature facilitates the proper operationand test of temperature sensors, pressure transducers, theguide vane actuator, oil pump, water pumps, tower con-trol, and other on/off outputswhile the compressor is stopped.It also has the ability to lock off the compressor and turnon water pumps for pumpout operation. The CVC showsthe temperatures and pressures required during theseoperations.

• From other SERVICE tables, the operator or techniciancan access configured items, such as chilled water resets,override set points, etc.

• If an operating fault is detected, an alarm message is gen-erated and displayed on the CVC default screen. A moredetailed message — along with a diagnostic message —is also stored into the ALARM HISTORY table.

CheckingDisplayMessages— The first area to checkwhen troubleshooting the 19XRT is the CVC display. If thealarm light is flashing, check the primary and secondary mes-sage lines on the CVC default screen (Fig. 12). These mes-sages will indicate where the fault is occurring. These mes-sages contain the alarm message with a specified code. Thiscode or state appears with each alarm and alert message. TheALARM HISTORY table on the CVC SERVICE menu alsocontains an alarm message to further expand on the alarm.For a complete list of possible alarm messages, see Table 8.If the alarm light starts to flash while accessing amenu screen,press the EXITsoftkey to return to the default screen toread the alarm message. The STATUS screen can also beaccessed to determine where an alarm exists.

Checking Temperature Sensors — All tempera-ture sensors are thermistor-type sensors. This means that theresistance of the sensor varies with temperature. All sensorshave the same resistance characteristics. If the controls areon, determine sensor temperature by measuring voltage drop;if the controls are powered off, determine sensor tempera-ture by measuring resistance. Compare the readings to thevalues listed in Table 9A or 9B.

RESISTANCE CHECK — Turn off the control power and,from the module, disconnect the terminal plug of the sensorin question. With a digital ohmmeter, measure sensor resis-tance between receptacles as designated by the wiring dia-gram. The resistance and corresponding temperature are listedin Table 9A or 9B. Check the resistance of both wires toground. This resistance should be infinite.

VOLTAGE DROP — The voltage drop across any ener-gized sensor can be measured with a digital voltmeter whilethe control is energized. Table 9A or 9B lists the relation-ship between temperature and sensor voltage drop (volts dcmeasured across the energized sensor). Exercise care whenmeasuring voltage to prevent damage to the sensor leads,connector plugs, andmodules. Sensors should also be checkedat the sensor plugs. Check the sensor wire at the sensor for5 vdc if the control is powered on.

Relieve all refrigerant pressure or drain the water be-fore replacing the temperature sensors.

Fig. 36 — Optional Pumpout System Controls

71

CHECK SENSOR ACCURACY — Place the sensor in amedium of known temperature and compare that temper-ature to the measured reading. The thermometer used todetermine the temperature of the medium should be oflaboratory quality with 0.5° F (.25° C) graduations. The sen-sor in question should be accurate to within 2° F (1.2° C).See Fig. 7 for sensor locations. The sensors are immersed

directly in the refrigerant or water circuits. The wiring at eachsensor is easily disconnected by unlatching the connector.These connectors allow only one-way connection to the sen-sor. When installing a new sensor, apply a pipe sealant orthread sealant to the sensor threads.

DUAL TEMPERATURE SENSORS — For servicing con-venience, there are 2 sensors each on the bearing and motortemperature sensors. If one of the sensors is damaged, theother can be used by simply moving a wire. The number 2terminal in the sensor terminal box is the common line. Touse the second sensor, move the wire from the number 1position to the number 3 position.

Checking Pressure Transducers — There are8 pressure transducers on 19XRT chillers. They determinecooler, condenser, oil pressure, and cooler and condenser flow.The cooler and condenser transducers are also used by thePIC II to determine the refrigerant temperatures. The oil sup-ply pressure transducer value and the oil transmission sumppressure transducer value difference is calculated by the CCM.The CCM module then displays the differential pressure. Ineffect, the CCM reads only one input for oil pressure for atotal of 5 pressure inputs: cooler pressure, condenser pres-sure, oil differential pressure, cooler waterside differentialpressure, and condenser waterside differential pressure. SeetheCheck PressureTransducers section (page 70) under Sched-uled Maintenance.These 5 pressure transducers can be calibrated if neces-

sary. It is not usually necessary to calibrate at initial start-up.However, at high altitude locations, it is necessary to cali-brate the transducers to ensure the proper refrigeranttemperature/pressure relationship. Each transducer is sup-plied with 5 vdc power from the CCM. If the power supplyfails, a transducer voltage reference alarm occurs. If the trans-ducer reading is suspected of being faulty, check the supplyvoltage. It should be 5 vdc ± .5 v displayed in CONTROLTEST under CCM Pressure Transducers. If the supplyvoltage is correct, the transducer should be recalibrated orreplaced.

TRANSDUCER REPLACEMENT — Since the trans-ducers are mounted on Schrader-type fittings, there is noneed to remove refrigerant from the vessel when replacingthe transducers. Disconnect the transducer wiring by pullingup on the locking tab while pulling up on the weather-tightconnecting plug from the end of the transducer.Do not pullon the transducer wires.Unscrew the transducer from theSchrader fitting. When installing a new transducer, do notuse pipe sealer (which can plug the sensor). Put the plugconnector back on the sensor and snap into place. Check forrefrigerant leaks.

Be sure to use a back-up wrench on the Schrader fittingwhenever removing a transducer, since the Schrader fit-ting may back out with the transducer, causing a largeleak and possible injury to personnel.

Control Algorithms Checkout Procedure— Oneof the tables on the CVC SERVICE menu is CONTROLALGORITHM STATUS. The maintenance screens maybe viewed from the CONTROL ALGORITHM STATUStable 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 guidevane positioned and for observing the reactions from loadchanges, control point overrides, hot gas bypass, surge pre-vention, etc. The tables are:

CAPACITY CapacityControl

This table shows all valuesused to calculate the chilledwater/brine control point.

OVERRIDE OverrideStatus

Details of all chilled water con-trol override values.

HEAT_EX Surge/HGBPStatus

The surge and hot gas bypasscontrol algorithm status isviewed from this screen. Allvalues dealing with this controlare displayed.

LL_MAINT LEAD/LAGStatus

Indicates LEAD/LAG operationstatus.

OCCDEFCM TimeSchedulesStatus

The Local and CCN occupiedschedules are displayed hereto help the operator quickly de-termine whether the scheduleis in the 9occupied9 mode ornot.

WSMDEFME WaterSystemManagerStatus

The water system manager is aCCN module that can turn onthe chiller and change thechilled water control point. Thisscreen indicates the status ofthis system.

Control Test — The Control Test feature can check allthe thermistor temperature sensors, pressure transducers, pumpsand their associated flow devices, the guide vane actuator,and other control outputs such as hot gas bypass. The testscan help to determine whether a switch is defective or a pumprelay is not operating, as well as other useful troubleshoot-ing issues. During pumpdown operations, the pumps are en-ergized to prevent freeze-up and the vessel pressures andtemperatures are displayed. The Pumpdown/Lockout fea-ture prevents compressor start-up when there is no refrig-erant in the chiller or if the vessels are isolated. The Termi-nate Lockout feature ends the Pumpdown/Lockout after thepumpdown procedure is reversed and refrigerant is added.

LEGEND TO TABLES 8A - 8JCCM — Chiller Control ModuleCCN — Carrier Comfort NetworkCVC — Chiller Visual ControlCHW — Chilled WaterISM — Integrated Starter ModulePIC II — Product Integrated Control IIVFD — Variable Frequency Drive

72

Table 8 — CVC Primary and Secondary Messages andCustom Alarm/Alert Messages with Troubleshooting Guides

A. MANUAL STOP

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDYMANUALLY 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

unlock compressor.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

deenergized within one minute.ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.

B. READY TO START

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDYREADY TO START IN XX MIN UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chillers will start only when

occupied.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

point to start.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

and closed.READY TO START IN XX MIN START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start. Release

value to start under normal control.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.

Make sure the time and date are correct. Change values in TIME ANDDATE screen.

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

point to start.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.

Chiller will start regardless of time schedule or remote contact status.STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller top stop.

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDYRECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently above

set point to start.RECYCLE RESTART PENDING REMOTE CONTACT CLOSED Unit in recycle mode, chilled water temperature is not sufficiently above

set point to start.RECYCLE RESTART PENDING START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start, chilled

water temperature is not sufficiently above set point to start.RECYCLE RESTART PENDING ICE BUILD MODE Chiller in ICE BUILD mode. Chilled fluid temperature is satisfied for ICE

BUILD conditions.

73

Table 8 — CVC Primary and Secondary Messages andCustom Alarm/Alert Messages with Troubleshooting Guides (cont)

D. PRE-STARTALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.

STATE PRIMARYMESSAGE

SECONDARYMESSAGE

ALARM MESSAGEPRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

100 PRESTARTALERT

STARTS LIMITEXCEEDED

100->Excessive compressorstarts (8 in 12 hours)

Depress the RESET softkey if additional start isrequired. Reassess start-up requirements.

101 PRESTARTALERT

HIGH BEARINGTEMPERATURE

101->Comp Thrust BearingTemp [VALUE] exceededlimit of [LIMIT]*.

Check oil heater for proper operation.Check for low oil level, partially closed coil supplyvalves, clogged oil filters, etc.Check the sensor wiring and accuracy.Check configurable range in SETUP1 screen.

102 PRESTARTALERT

HIGH MOTORTEMPERATURE

102->Comp Motor WindingTemp [VALUE] exceededlimit of [LIMIT]*.

Check motor sensors for wiring and accuracy.Check motor cooling line for proper operation, orrestrictions.Check for excessive starts within a short time span.Check configurable range in SETUP1 screen.

103 PRESTARTALERT

HIGH DISCHARGETEMP

103->Comp DischargeTemp [VALUE] exceededlimit of [LIMIT]*.

Allow discharge sensor to cool.Check for sensor wiring and accuracy.Check for excessive starts.Check configurable range in SETUP1 screen.

104 PRESTARTALERT

LOW REFRIGERANTTEMP

104->Evaporator RefrigTemp [VALUE] exceededlimit of [LIMIT]*.

Check transducer wiring and accuracy.Check for low chilled fluid supply temperatures.Check refrigerant charge.

105 PRESTARTALERT

LOW OILTEMPERATURE

105->Oil Sump Temp[VALUE] exceeded limit of[LIMIT]*.

Check oil heater contactor/relay and power.Check oil level and oil pump operation.

106 PRESTARTALERT

HIGH CONDENSERPRESSURE

106->Condenser Pressure[VALUE] exceeded limit of[LIMIT]*.

Check transducer wiring and accuracy.Check for high condenser water temperatures.

107 PRESTARTALERT

LOW LINEVOLTAGE

107->Average Line Voltage[VALUE] exceeded limit of[LIMIT]*.

Check voltage supply. Check voltage transformers.Consult power utility if voltage is low.

108 PRESTARTALERT

HIGH LINEVOLTAGE

108->Average Line Voltage[VALUE] exceeded limit of[LIMIT]*.

Check voltage supply.Check power transformers.Consult power utility if voltage is high.

109 PRESTARTALERT

GUIDE VANECALIBRATION

109->Actual Guide VanePos Calibration RequiredBefore Start-Up

Calibrate guide vane actuator in Control Test.

*[LIMIT] is shown on the CVC 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.

E. START-UP IN PROGRESS

PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDYSTARTUP 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 start.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 closed.AUTORESTART IN PROGRESS START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT

manually forced to start.

74


F. NORMAL RUN

PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDYRUNNING — 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 DT.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 surge prevention in the

control section.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.

G. NORMAL RUN WITH OVERRIDES


SECONDARYMESSAGE

ALARM MESSAGEPRIMARY CAUSE

ADDITIONALCAUSE/REMEDY

120 RUN CAPACITYLIMITED



Check for high condenser water temperatures.Check setting in SETUP1.



121->Comp Motor WindingTemp [VALUE] exceededlimit of [LIMIT]*.

Check motor cooling lines.Check for closed valves.Check setting in SETUP1.


LOW EVAPREFRIG TEMP

122->Evaporator RefrigTemp [VALUE] exceededlimit of [LIMIT]*.

Check refrigerant charge.Check for low entering cooler temperatures.


HIGH COMPRESSORLIFT

123->Surge PreventionOverride: Lift Too High ForCompressor.

Check for high condenser water temperatures or lowsuction temperature.


MANUAL GUIDEVANE TARGET

124->Run Capacity Limited:Manual Guide Vane Target.

Target guide vane point has been forced inMAINSTAT screen. Release force to continue normaloperation.


LOW DISCHARGESUPERHEAT

No messages. Check oil charge.Check refrigerant charge.

*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, oralarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault condition.

H. OUT-OF-RANGE SENSOR ALARMS


SECONDARYMESSAGE



260 SENSORFAULT

LEAVING CHILLEDWATER

260->Sensor Fault:Leaving Chilled Water

Check sensor resistance or voltage drop.Check for proper wiring.

261 SENSORFAULT

ENTERING CHILLEDWATER

261->Sensor Fault:Entering Chilled Water


262 SENSORFAULT

CONDENSERPRESSURE

262->Sensor Fault:Condenser Pressure

Check sensor wiring.

263 SENSORFAULT

EVAPORATORPRESSURE

263->Sensor Fault:Evaporator Pressure

Check sensor wiring.

264 SENSORFAULT

COMPRESSORBEARING TEMP

264->Sensor Fault:Comp Thrust Bearing Temp


265 SENSORFAULT

COMPRESSORMOTOR TEMP

265->Sensor Fault:Comp Motor Winding Temp


266 SENSORFAULT

COMP DISCHARGETEMP

266->Sensor Fault:Comp Discharge Temp


267 SENSORFAULT

OIL SUMP TEMP 267->Sensor Fault:Oil Sump Temp


268 SENSORFAULT

COMP OILPRESS DIFF

268->Sensor Fault:Oil Pump Delta P

Check sensor wiring and accuracy.

269 SENSORFAULT

CHILLED WATERFLOW

269->Sensor Fault:Chilled Water Delta P


270 SENSORFAULT

COND WATERFLOW

270->Sensor Fault:Cond Water Delta P


75


I. CHILLER PROTECT LIMIT FAULTS


SECONDARYMESSAGE



200 PROTECTIVELIMIT

1M CONTACTFAULT

200->1M Aux Contact Fault;Check 1M Contactor andAux

201 PROTECTIVELIMIT

2M CONTACTFAULT

201->2M Aux Contact Fault;Check 2M Contactor andAux

202 PROTECTIVELIMIT

MOTOR AMPSNOT SENSED

202->Motor Amps NotSensed — Average LineCurrent [VALUE]

Check for wiring of current transformers to the ISM.Check main circuit breaker for trip.

203 FAILURE TOSTART

EXCESSACCELERATIONTIME

203->Motor AccelerationFault — Average LineCurrent [VALUE]

Check to be sure that the inlet guide vanes areclosed at start-up.Check starter for proper operation.Reduce unit pressure if possible.

204 FAILURE TOSTOP

1M/2M CONTACTFAULT

208->1M/2M Aux ContactStop Fault; Check 1M/2MContactors and Aux

205 FAILURE TOSTOP

MOTOR AMPSWHEN STOPPED

205->Motor Amps WhenStopped — Average LineCurrent [VALUE]

206 PROTECTIVELIMIT

STARTERFAULT

206->Starter Fault Cutout;Check Optional StarterContacts

207 PROTECTIVELIMIT


207->High Cond Pressurecutout. [VALUE] exceededlimit of [LIMIT]*.

Check for high condenser water temperatures, lowwater flow, fouled tubes.Check for division plate/gasket bypass.Check for noncondensables.Check transducer wiring and accuracy.

208 PROTECTIVELIMIT

EXCESSIVEMOTOR AMPS

208->Compressor MotorAmps [VALUE] exceededlimit of [LIMIT]*.

Check motor current for proper calibration.Check inlet guide vane actuator.

209 PROTECTIVELIMIT

LINE PHASELOSS

209->Line Phase Loss;Check ISM Fault History toIdentify Phase

Check transformers to ISM.Check power distribution bus.Consult power company.

210 PROTECTIVELIMIT

LINE VOLTAGEDROPOUT

210->Single Cycle LineVoltage Dropout

211 PROTECTIVELIMIT

HIGH LINEVOLTAGE

211->High Average LineVoltage [VALUE]

Check transformers to ISM.Check distribution bus.Consult power company.

212 PROTECTIVELIMIT

LOW LINEVOLTAGE

212->Low Average LineVoltage [VALUE]


213 PROTECTIVELIMIT

STARTER MODULERESET

213->Starter ModulePower-On Reset WhenRunning

214 PROTECTIVELIMIT

POWER LOSS 214->Power Loss:Check voltage supply


215 PROTECTIVELIMIT

LINE CURRENTIMBALANCE

215->Line CurrentImbalance; Check ISM FaultHistory to Identify Phase

216 PROTECTIVELIMIT

LINE VOLTAGEIMBALANCE

216->Line VoltageImbalance; Check ISM FaultHistory to Identify Phase

217 PROTECTIVELIMIT

MOTOR OVERLOADTRIP

217->Motor Overload Trip;Check ISM configurations

Check ISM configuration.

218 PROTECTIVELIMIT

MOTOR LOCKEDROTOR TRIP

218->Motor Locked RotorAmps exceeded; CheckMotor & ISM Config


219 PROTECTIVELIMIT

STARTER LOCKROTOR TRIP

219->Starter Locked RotorAmps Rating exceeded


220 PROTECTIVELIMIT

GROUND FAULT 220->Ground Fault Trip;Check Motor and CurrentTransformers

221 PROTECTIVELIMIT

PHASE REVERSALTRIP

221->Phase Reversal Trip;Check Power Supply

222 PROTECTIVELIMIT

LINE FREQUENCYTRIP

222->Line Frequency —[VALUE] exceeded limitof [LIMIT]. Check PowerSupply.

223 PROTECTIVELIMIT

STARTER MODULEFAILURE

223->Starter ModuleHardware Failure

76


I. CHILLER PROTECT LIMIT FAULTS (cont)


SECONDARYMESSAGE



227 PROTECTIVELIMIT

OIL PRESSSENSOR FAULT

227->Oil Pump Delta P[VALUE] exceeded limit of[LIMIT]*.

Check transducer wiring and accuracy.Check power supply to pumpCheck pump operation.Check transducer calibration.

228 PROTECTIVELIMIT

LOW OILPRESSURE

228->Oil Pump Delta P[VALUE] exceeded limit of[LIMIT].*

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.

229 PROTECTIVELIMIT

LOW CHILLEDWATER FLOW

229->Low Chilled Water Flow;Check Delta P Config &Calibration

Perform pump control test.Check transducer accuracy and wiring.Check water valves.Check transducer calibration.

230 PROTECTIVELIMIT

LOW CONDENSERWATER FLOW

230->Low Condenser WaterFlow; Check Delta P Config &Calibration

Perform pump control test.Check transducer accuracy and wiring.Check water valves.Check transducer calibration.

231 PROTECTIVELIMIT

HIGH DISCHARGETEMP

231->Comp Discharge Temp[VALUE] exceeded limit of[LIMIT].*

Check sensor resistance or voltage drop.Check for proper wiring.Check for proper condenser flow andtemperature.Check for proper inlet guide vane and diffuseractuator operation.Check for fouled tubes or noncondensables in thesystem.

232 PROTECTIVELIMIT

LOW REFRIGERANTTEMP

232->Evaporator Refrig Temp[VALUE] exceeded limit of[LIMIT]*.

Check for proper refrigerant charge.Check float operation.Check for proper fluid flow and temperature.Check for proper inlet guide vane operation.

233 PROTECTIVELIMIT


233->Comp Motor WindingTemp [VALUE] exceeded limitof [LIMIT]*.

Check motor sensors wiring and accuracy.Check motor cooling line for proper operation,or restrictions.Check for excessive starts within a short timespan.

234 PROTECTIVELIMIT

HIGH BEARINGTEMPERATURE

234->Comp Thrust BearingTemp [VALUE] exceeded limitof [LIMIT]*.

Check oil heater for proper operation.Check for low oil level, partially closed oil supplyvalves, clogged oil filters, etc.Check the sensor wiring and accuracy.

235 PROTECTIVELIMIT



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.

236 PROTECTIVELIMIT

CCN OVERRIDESTOP

236->CCN Override Stop whilein LOCAL run mode

CCN has signaled the chiller to stop. Reset andrestart when ready. If the signal was sent by theCVC, release the stop signal on the STATUS01table.

237 PROTECTIVELIMIT

SPARE SAFETYDEVICE

237->Spare Safety Device Spare safety input has tripped or factory installedjumper is not present.

238 PROTECTIVELIMIT

EXCESSIVECOMPR SURGE

238->Compressor Surge:Check condenser water tempand flow

Check condenser flow and temperatures.Check surge protection configuration.

239 PROTECTIVELIMIT

TRANSDUCERVOLTAGE FAULT

239->Transducer Voltage Ref[VALUE] exceeded limit of[LIMIT]*.

240 PROTECTIVELIMIT

LOW DISCHARGESUPERHEAT

240->Check for Oil inRefrigerant or Overcharge ofRefrigerant

241 LOSS OFCOMMUNICATION

WITH STARTERMODULE

241->Loss of CommunicationWith Starter.

Check wiring to ISM.

242 LOSS OFCOMMUNICATION

WITH CCMMODULE

242->Loss of CommunicationWith CCM.

Check wiring to CCM.

243 POTENTIALFREEZE-UP

EVAP PRESS/TEMPTOO LOW

243->Evaporator Refrig Temp[VALUE] exceeded limit of[LIMIT]*.

Check for proper refrigerant charge.Check float operation.Check for proper fluid flow and temperature.Check for proper inlet guide vane operation.


COND PRESS/TEMPTOO LOW

244->Condenser Refrig Temp[VALUE] exceeded limit of[LIMIT]*.

245 PROTECTIVELIMIT

VFD SPEEDOUT OF RANGE

245->Actual VFD Speed[VALUE] exceeded limit of[LIMIT]*.

77


I. CHILLER PROTECT LIMIT FAULTS (cont)


SECONDARYMESSAGE



246 PROTECTIVELIMIT

INVALID DIFFUSERCONFIG

246->Diffuser Control InvalidConfiguration:Check SETUP2 Entries.

Check diffuser/inlet guide vane schedule.

247 PROTECTIVELIMIT

DIFFUSER POSITIONFAULT

247->Diffuser Position Fault:Check Guide Vane and DiffuserActuators

Check rotating stall transducer wiring andaccuracy.Check diffuser schedule.Check for proper operation of diffuser actuatorand 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 properorientation.If not using variable diffuser, check that the optionhas not been enabled.

248 PROTECTIVELIMIT

SPARE TEMPERATURE#1

248->Spare Temperature #1[VALUE] exceeded limit of[LIMIT]*.

249 PROTECTIVELIMIT

SPARE TEMPERATURE#2

249->Spare Temperature #2[VALUE] exceeded limit of[LIMIT]*.

*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, oralarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

J. CHILLER ALERTS


SECONDARYMESSAGE



140 SENSOR ALERT LEAVING CONDWATER TEMP

140->Sensor Fault:Check Leaving Cond WaterSensor


141 SENSOR ALERT ENTERING CONDWATER TEMP

141->Sensor Fault:Check Entering Cond WaterSensor


142 LOW OIL PRESSUREALERT

CHECK OILFILTER

142->Low Oil Pressure Alert.Check Oil Filter.

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.

143 AUTORESTARTPENDING

LINE PHASELOSS

143->Line Phase Loss Power loss has been detected in any phase.Chiller automatically restarting.


LINE VOLTAGEDROP OUT

144->Single Cycle LineVoltage Dropout

A drop in line voltage has been detected within2 voltage cycles. Chiller automatically restarting ifrestart is enabled.


HIGH LINEVOLTAGE

145->Line Overvoltage —Average Line Volt [VALUE]

Check line power.


LOW LINEVOLTAGE

146->Line Undervoltage —Average Line Volt [VALUE]

Check line power.


STARTER MODULERESET

147->Starter Module Power-OnReset When Running

ISM has detected a hardware fault and has reset.Chiller automatically restarting.


POWER LOSS 148->Control Power-LossWhen Running

Check control power.

149 SENSOR ALERT HIGH DISCHARGETEMP

149->Comp Discharge Temp[VALUE] exceeded limit of[LIMIT]*.

Check sensor resistance or voltage drop.Check for proper wiring.Check for proper condenser flow andtemperature.Check for high lift or low load.Check for proper inlet guide vane and diffuseractuator operation (XR5 Only).Check for fouled tubes or noncondensables in therefrigerant system.

150 SENSOR ALERT HIGH BEARINGTEMPERATURE

150->Comp Thrust BearingTemp [VALUE] exceeded limitof [LIMIT]*.

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.

78


J. CHILLER ALERTS (cont)


SECONDARYMESSAGE



151 CONDENSER PRESSUREALERT

PUMP RELAYENERGIZED

151->High CondenserPressure [VALUE]: PumpEnergized to ReducePressure.

Check sensor wiring and accuracy.Check condenser flow and fluid temperature.Check for fouled tubes. This alarm is notcaused by the High Pressure Switch.

152 RECYCLEALERT

EXCESSIVE RECYCLESTARTS

152->Excessive recycle starts. Chiller load is too low to keep compressor online and there has been more than 5 starts in4 hours. Increase chiller load, adjust hot gasbypass, increase RECYCLE RESTART DELTAT from SETUP1 Screen.

153 no message:ALERT only

no message;ALERT only

153->Lead/Lag Disabled:Duplicate Chiller Address;Check Configuration

Illegal chiller address configuration in Lead/Lag screen. Both chillers require a differentaddress.


COND PRESS/TEMPTOO LOW

154->Condenser freeze upprevention

The condenser pressure transducer is readinga pressure that could freeze the condensertubes.Check for condenser refrigerant leaks.Check fluid temperature.Check sensor wiring and accuracy.Place the chiller in PUMPDOWN mode if thevessel is evacuated.

155 OPTION SENSORFAULT

REMOTE RESETSENSOR

155->Sensor Fault/OptionDisabled:Remote Reset Sensor



AUTO CHILLEDWATER RESET

156->Sensor Fault/OptionDisabled:Auto Chilled Water Reset



AUTO DEMANDLIMIT INPUT

157->Sensor Fault/OptionDisabled:Auto Demand Limit Input


158 SENSOR ALERT SPARE TEMPERATURE#1

158->Spare Temperature #1[VALUE] exceeded limit of[LIMIT].*


159 SENSOR ALERT SPARE TEMPERATURE#2

159->Spare Temperature #2[VALUE] exceeded limit of[LIMIT].*


*[LIMIT] is shown on the CVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, oralarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

79

Table 9A — Thermistor Temperature (F) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (Ohms)

−25 4.821 98,010−24 4.818 94,707−23 4.814 91,522−22 4.806 88,449−21 4.800 85,486−20 4.793 82,627−19 4.786 79,871−18 4.779 77,212−17 4.772 74,648−16 4.764 72,175−15 4.757 69,790−14 4.749 67,490−13 4.740 65,272−12 4.734 63,133−11 4.724 61,070−10 4.715 59,081−9 4.705 57,162−8 4.696 55,311−7 4.688 53,526−6 4.676 51,804−5 4.666 50,143−4 4.657 48,541−3 4.648 46,996−2 4.636 45,505−1 4.624 44,0660 4.613 42,6791 4.602 41,3392 4.592 40,0473 4.579 38,8004 4.567 37,5965 4.554 36,4356 4.540 35,3137 4.527 34,2318 4.514 33,1859 4.501 32,17610 4.487 31,20211 4.472 30,26012 4.457 29,35113 4.442 28,47314 4.427 27,62415 4.413 26,80416 4.397 26,01117 4.381 25,24518 4.366 24,50519 4.348 23,78920 4.330 23,09621 4.313 22,42722 4.295 21,77923 4.278 21,15324 4.258 20,54725 4.241 19,96026 4.223 19,39327 4.202 18,84328 4.184 18,31129 4.165 17,79630 4.145 17,29731 4.125 16,81432 4.103 16,34633 4.082 15,89234 4.059 15,45335 4.037 15,02736 4.017 14,61437 3.994 14,21438 3.968 13,82639 3.948 13,44940 3.927 13,08441 3.902 12,73042 3.878 12,38743 3.854 12,05344 3.828 11,73045 3.805 11,41646 3.781 11,11247 3.757 10,81648 3.729 10,52949 3.705 10,25050 3.679 9,97951 3.653 9,71752 3.627 9,46153 3.600 9,21354 3.575 8,97355 3.547 8,73956 3.520 8,51157 3.493 8,29158 3.464 8,07659 3.437 7,868


60 3.409 7,66561 3.382 7,46862 3.353 7,27763 3.323 7,09164 3.295 6,91165 3.267 6,73566 3.238 6,56467 3.210 6,39968 3.181 6,23869 3.152 6,08170 3.123 5,92971 3.093 5,78172 3.064 5,63773 3.034 5,49774 3.005 5,36175 2.977 5,22976 2.947 5,10177 2.917 4,97678 2.884 4,85579 2.857 4,73780 2.827 4,62281 2.797 4,51182 2.766 4,40383 2.738 4,29884 2.708 4,19685 2.679 4,09686 2.650 4,00087 2.622 3,90688 2.593 3,81489 2.563 3,72690 2.533 3,64091 2.505 3,55692 2.476 3,47493 2.447 3,39594 2.417 3,31895 2.388 3,24396 2.360 3,17097 2.332 3,09998 2.305 3,03199 2.277 2,964100 2.251 2,898101 2.217 2,835102 2.189 2,773103 2.162 2,713104 2.136 2,655105 2.107 2,597106 2.080 2,542107 2.053 2,488108 2.028 2,436109 2.001 2,385110 1.973 2,335111 1.946 2,286112 1.919 2,239113 1.897 2,192114 1.870 2,147115 1.846 2,103116 1.822 2,060117 1.792 2,018118 1.771 1,977119 1.748 1,937120 1.724 1,898121 1.702 1,860122 1.676 1,822123 1.653 1,786124 1.630 1,750125 1.607 1,715126 1.585 1,680127 1.562 1,647128 1.538 1,614129 1.517 1,582130 1.496 1,550131 1.474 1,519132 1.453 1,489133 1.431 1,459134 1.408 1,430135 1.389 1,401136 1.369 1,373137 1.348 1,345138 1.327 1,318139 1.308 1,291140 1.291 1,265141 1.289 1,240142 1.269 1,214143 1.250 1,190144 1.230 1,165


145 1.211 1,141146 1.192 1,118147 1.173 1,095148 1.155 1,072149 1.136 1,050150 1.118 1,029151 1.100 1,007152 1.082 986153 1.064 965154 1.047 945155 1.029 925156 1.012 906157 0.995 887158 0.978 868159 0.962 850160 0.945 832161 0.929 815162 0.914 798163 0.898 782164 0.883 765165 0.868 750166 0.853 734167 0.838 719168 0.824 705169 0.810 690170 0.797 677171 0.783 663172 0.770 650173 0.758 638174 0.745 626175 0.734 614176 0.722 602177 0.710 591178 0.700 581179 0.689 570180 0.678 561181 0.668 551182 0.659 542183 0.649 533184 0.640 524185 0.632 516186 0.623 508187 0.615 501188 0.607 494189 0.600 487190 0.592 480191 0.585 473192 0.579 467193 0.572 461194 0.566 456195 0.560 450196 0.554 445197 0.548 439198 0.542 434199 0.537 429200 0.531 424201 0.526 419202 0.520 415203 0.515 410204 0.510 405205 0.505 401206 0.499 396207 0.494 391208 0.488 386209 0.483 382210 0.477 377211 0.471 372212 0.465 367213 0.459 361214 0.453 356215 0.446 350216 0.439 344217 0.432 338218 0.425 332219 0.417 325220 0.409 318221 0.401 311222 0.393 304223 0.384 297224 0.375 289225 0.366 282

80

Table 9B — Thermistor Temperature (C) vs Resistance/Voltage Drop

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (Ohms)−40 4.896 168 230−39 4.889 157 440−38 4.882 147 410−37 4.874 138 090−36 4.866 129 410−35 4.857 121 330−34 4.848 113 810−33 4.838 106 880−32 4.828 100 260−31 4.817 94 165−30 4.806 88 480−29 4.794 83 170−28 4.782 78 125−27 4.769 73 580−26 4.755 69 250−25 4.740 65 205−24 4.725 61 420−23 4.710 57 875−22 4.693 54 555−21 4.676 51 450−20 4.657 48 536−19 4.639 45 807−18 4.619 43 247−17 4.598 40 845−16 4.577 38 592−15 4.554 38 476−14 4.531 34 489−13 4.507 32 621−12 4.482 30 866−11 4.456 29 216−10 4.428 27 633−9 4.400 26 202−8 4.371 24 827−7 4.341 23 532−6 4.310 22 313−5 4.278 21 163−4 4.245 20 079−3 4.211 19 058−2 4.176 18 094−1 4.140 17 1840 4.103 16 3251 4.065 15 5152 4.026 14 7493 3.986 14 0264 3.945 13 3425 3.903 12 6966 3.860 12 0857 3.816 11 5068 3.771 10 9599 3.726 10 441

10 3.680 9 94911 3.633 9 48512 3.585 9 04413 3.537 8 62714 3.487 8 23115 3.438 7 85516 3.387 7 49917 3.337 7 16118 3.285 6 84019 3.234 6 53620 3.181 6 24621 3.129 5 97122 3.076 5 71023 3.023 5 46124 2.970 5 22525 2.917 5 00026 2.864 4 78627 2.810 4 58328 2.757 4 38929 2.704 4 20430 2.651 4 02831 2.598 3 86132 2.545 3 70133 2.493 3 54934 2.441 3 40435 2.389 3 26636 2.337 3 13437 2.286 3 00838 2.236 2 88839 2.186 2 77340 2.137 2 66341 2.087 2 55942 2.039 2 45943 1.991 2 36344 1.944 2 272

TEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (Ohms)45 1.898 2 18446 1.852 2 10147 1.807 2 02148 1.763 1 94449 1.719 1 87150 1.677 1 80151 1.635 1 73452 1.594 1 67053 1.553 1 60954 1.513 1 55055 1.474 1 49356 1.436 1 43957 1.399 1 38758 1.363 1 33759 1.327 1 29060 1.291 1 24461 1.258 1 20062 1.225 1 15863 1.192 1 11864 1.160 1 07965 1.129 1 04166 1.099 1 00667 1.069 97168 1.040 93869 1.012 90670 0.984 87671 0.949 83672 0.920 80573 0.892 77574 0.865 74775 0.838 71976 0.813 69377 0.789 66978 0.765 64579 0.743 62380 0.722 60281 0.702 58382 0.683 56483 0.665 54784 0.648 53185 0.632 51686 0.617 50287 0.603 48988 0.590 47789 0.577 46690 0.566 45691 0.555 44692 0.545 43693 0.535 42794 0.525 41995 0.515 41096 0.506 40297 0.496 39398 0.486 38599 0.476 376100 0.466 367101 0.454 357102 0.442 346103 0.429 335104 0.416 324105 0.401 312106 0.386 299107 0.370 285

81

Control Modules

Turn controller power off before servicing controls. Thisensures safety and prevents damage to the controller.

The CVC, CCM, and ISM modules perform continuousdiagnostic evaluations of the hardware to determine its con-dition. Proper operation of all modules is indicated by LEDs(light-emitting diodes) located on the circuit board of the CVC,CCM, and ISM.There is one green LED located on the CCM and ISM

boards respectively, and one red LED located on the CVC,CCM, and ISM boards respectively.RED LED (Labeled as STAT) — If the red LED:• blinks continuously at a 2-second interval, the module isoperating properly

• is lit continuously, there is a problem that requires replac-ing 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 replacedIf there is no input power, check the fuses and circuit breaker.

If the fuse is good, check for a shorted secondary of thetransformer or, if power is present to the module, replace themodule.

GREEN LED (Labeled as COM) — These LEDs indicatethe communication status between different parts of the con-troller and the network modules and should blinkcontinuously.

Notes on Module Operation1. The chiller operator monitors and modifies configura-

tions in the microprocessor by using the 4 softkeys andtheCVC. Communications between theCVCand theCCMis accomplished through the SIO (Sensor Input/Output)bus, which is a phone cable. The communication be-tween the CCM and ISM is accomplished through the sen-sor bus, which is a 3-wire cable.

2. If a green LED is on continuously, check the communi-cation wiring. If a green LED is off, check the red LEDoperation. If the red LED is normal, check the moduleaddress switches (Fig. 37-39).All system operating intelligence resides in the CVC. Somesafety shutdown logic resides in the ISM in case com-munications are lost between the ISM and CVC. Outputsare controlled by the CCM and ISM as well.

3. Power is supplied to the modules within the control panelvia 24-vac power sources.The transformers are located within the power panel, withthe exception of the ISM, which operates from a 115-vacpower source and has its own 24-vac transformer locatedin the module.In the power panel, T1 supplies power to the compressoroil heater, oil pump, and optional hot gas bypass, and T2supplies power to both the CVC and CCM.Power is connected to Plug J1 on each module.

STAT

CONTRAST BACK OF CVC(CHILLER VISUALCONTROLLER)

J8SERVICE

J5KEYPAD

MODULE PART #SOFTWARE PART #

J1POWER/CCN

J7SIO

Fig. 37 — Rear of CVC (Chiller Visual Controller)

82

Chiller Control Module (CCM) (Fig. 38)INPUTS — Each input channel has 2 or 3 terminals. Referto individual chiller wiring diagrams for the correct terminalnumbers for your application.

OUTPUTS — Output is 24 vac. There are 2 terminals peroutput. Refer to the chiller wiring diagram for your specificapplication for the correct terminal numbers.

Integrated Starter Module (ISM) (Fig. 39)INPUTS — Inputs on strips J3-5 and J3 are analog and dis-crete (on/off) inputs. The specific application of the chillerdetermines which terminals are used. Refer to the individualchiller wiring diagram for the correct terminal numbers foryour application.

OUTPUTS—Outputs are 24 vac and wired to strip J9. Thereare 2 terminals per output.

Replacing Defective Processor Modules— Themodule replacement part number is printed on a small labelon the rear of the CVC module. The chiller model andserial numbers are printed on the chiller nameplate locatedon an exterior corner post. The proper software is factory-installed by Carrier in the replacement module. Whenordering a replacement chiller visual control (CVC) module,specify the complete replacement part number, full chillermodel number, and chiller serial number. The installer mustconfigure the new module to the original chiller data. Fol-low the procedures described in the Software Configurationsection on page 54.

Electrical shock can cause personal injury. Disconnectall electrical power before servicing.

INSTALLATION

1. Verify the existing CVC module is defective by usingthe procedure described in the Troubleshooting Guidesection, page 71, and the Control Modules section,page 82. Do not select the ATTACH TO NETWORKDEVICE table if the CVC indicates a communicationfailure.

2. Data regarding the CVC configuration should have beenrecorded and saved. This data must be reconfigured intothe new CVC. If this data is not available, follow theprocedures described in the Software Configurationsection.If a CCN Building Supervisor or Service Tool is avail-able, the module configuration should have already beenuploaded into memory. When the new module is in-stalled, the configuration can be downloaded from thecomputer.Any communication wires from other chillers or CCNmodules should be disconnected to prevent the newCVCmodule from uploading incorrect run hours into memory.

3. To install this module, record values for theTOTALCOM-PRESSOR STARTSand theCOMPRESSOR ONTIMEfrom the MAINSTAT screen on the CVC.

4. Power off the controls.5. Remove the old CVC.6. Install the new CVC module. Turn the control power

back on.7. The CVC now automatically attaches to the local net-

work device.

8. Access the MAINSTAT table and highlight theTOTALCOMPRESSOR STARTSparameter. Press theSELECT softkey. Increase or decrease the value tomatch the starts value recorded in Step 3. Press theENTER softkey when you reach the correct value. Now,move the highlight bar to theCOMPRESSOR ONTIMEparameter. Press the SELECTsoftkey. Increase or de-crease the run hours value to match the value recordedin Step 2. Press the ENTERsoftkey when the correctvalue is reached.

9. Complete the CVC installation. Following the instruc-tions in the Input Service Configurations section,page 53, input all the proper configurations such as thetime, date, etc. Check the pressure transducer calibra-tions. PSIO installation is now complete.

Solid-State Starters — Troubleshooting informationpertaining to the Benshaw, Inc., solid-state starter may befound in the following paragraphs and in the Carrier RE-DISTARTMICRO Instruction Manual supplied by the startervendor.Attempt to solve the problem by using the following pre-

liminary checks before consulting the troubleshooting tablesfound in the Benshaw manual.

1. Motor terminals or starter output lugs or wire shouldnot be touched without disconnecting the incomingpower supply. The silicon control rectifiers (SCRs)although technically turned off still have AC mainspotential on the output of the starter.

2. Power is present on all yellow wiring throughout thesystem even though the main circuit breaker in theunit is off.

With power off:• Inspect for physical damage and signs of arcing, overheat-ing, 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 THEBENSHAW, INC., SOLID-STATE STARTERS— If an SCRis suspected of being defective, use the following pro-cedure 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 sideof these LEDs is not lit, the line voltage is not presentor one or more SCRs has failed.

3. Check incoming power. If voltage is not present checkthe incoming line. If voltage is present, proceed toSteps 4 through 11.NOTE: If after completing Steps 4 - 11 all mea-surements are within specified limits, the SCRs arefunctioning normally. If after completing Steps 4 - 11resistance measurements are outside the specifiedlimits, themotor leads on the starter power lugsT1 throughT6 should be removed and the steps repeated. This willidentify if abnormal resistance measurements are beinginfluenced by the motor windings.

4. Remove power from the starter unit.

83

STAT COMM THERMISTORSJ4

DIFF PRESSUREJ3

PRESSUREJ2

SW2

V/I INPUTSJ5

SIOJ7

ANALOG OUTJ8

J11DISCRETEOUTPUTS

J12DISCRETEOUTPUTS

J124 VAC

SIOJ6

Fig. 38 — Chiller Control Module (CCM)

INTEGRATED STARTER MODULE

J9 J8 J7 COM STAT

J1 FUSE J2 J3-1 J3-2 J3-3 J4 J5 J6

Fig. 39 — Integrated Starter Module (ISM)

84

5. Using an ohmmeter, perform the following resistancemeasurements and record the results:

MEASUREBETWEEN

SCR PAIRSBEING

CHECKED

RECORDEDVALUE

T1 and T6 3 and 6T2 and T4 2 and 5T3 and T5 1 and 4

If all measured values are greater than 5K ohms, pro-ceed 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 tocathode) of each SCR to determine which device hasfailed.NOTE: Both SCRs may be defective, but typically, onlyone is shorted. If both SCRs provide acceptable resis-tance 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 resis-

tance between the red and white gate/cathode leads foreach SCR (1 through 6). Ameasurement between 5 and50 ohms is normal. Abnormally high values may indi-cate a failed gate for that SCR.

If any red or white SCR gate leads are removedfrom the firing card or an SCR, care must be takento ensure the leads are replaced EXACTLY as theywere (white wires to gates, and red wires to cath-odes on both the firing card and SCR), or damageto the starter and/or motor may result.

11. Replace the SCRs and retest the pair.

SCR REMOVAL/INSTALLATION — Refer to Fig. 40.1. 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 based thermal joint com-pound or a joint compound for aluminum or copper wireconnections to the contact surfaces of the replacement SCR.This allows for improved heat dissipation and electricalconductivity.

3. Place the SCR between the roll pins on the heatsink as-semblies so the roll pins fit into the small holes in eachside of the SCR.NOTE: Ensure the SCR is installed so the cathode side isthe side from which the red wire extends. The heatsink islabeled to show the correct orientation.

4. Hand tighten the bolts until the SCR contacts theheatsink.

5. Using quarter-turn increments, alternating between clamp-ing bolts, apply the appropriate number of whole turnsreferencing the table in Fig. 40.

Caremust be taken to prevent nut rotation while tight-ening the bolts. If the nut rotates while tighting thebolt, SCR replacement must be started over.

6. Reconnect the red (cathode) wire from the SCR and thewhite (anode-gate) wire to the appropriate location onthe firing card (i.e., SCR1 wires to firing card terminalG1-white wire, and K1-red wire).

7. Reconnect all other wiring and bus work.8. Return starter to normal operation.

Physical Data — Tables 10-16 and Fig. 41-47 provideadditional information regarding compressor fits and clear-ances, physical and electrical data, and wiring schematicsfor operator convenience during troubleshooting.

LOOSENANDTIGHTENBOLTSFROMTHIS END

CLAMPINGBOLT

NUT

ALUMINUMHEATSINK

ROLL PIN

SCR

A

SCR PARTNUMBERBISCR

CLAMPSIZE

ADIMENSION

(in.)

NO OFTURNS

BOLTLENGTH(in.)

6601218 1030 2.75( 70 mm) 11⁄2 3.0

( 76 mm)

6601818 1030 2.75( 70 mm) 11⁄2 3.0

( 76 mm)

8801230 1035 2.75( 70 mm) 13⁄4 3.5

( 89 mm)

8801830 1035 2.75( 70 mm) 13⁄4 3.0

( 89 mm)

15001850 2040 4.00(102 mm) 23⁄4 4.0

(102 mm)

15001850 2050 4.00(102 mm) 23⁄4 5.0

(127 mm)220012100 Consult Benshaw Representative330018500 Consult Benshaw Representative

Fig. 40 — SCR Installation

85

Table 10 — Heat Exchanger Data

CODE

ENGLISH SIDry (Rigging) Weight

(lb)*Refrigerant

(lb)Water(lb)

Dry (Rigging) Weight(kg)*

Refrigerant(kg)

Water(kg)

Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser Cooler Condenser60 8,997 10,050 1230 1580 800 1023 4080 4558 558 717 363 46461 9,462 10,610 1480 1580 933 1183 4291 4812 671 717 423 53762 9,926 11,156 1720 1580 1065 1339 4502 5059 780 717 483 60763 10,391 11,703 1970 1580 1198 1495 4712 5307 893 717 543 678

*Rigging weights include optional .035-in. (0.889 mm) wall copper tubes, NIH (nozzle-in-head) 2-pass water-boxes with flanges. For specific machine weights, refer to the 19XR/XRT Computer Selection Program.

Table 11 — Compressor Motor Weights* — High Efficiency Motors

XRT3† Compressor, Low and Medium Voltage Motors**

MOTORSIZE

ENGLISH SI

CompressorWeight††

(lb)

Stator Weight |(lb)

Rotor Weight(lb)

CompressorWeight††

(kg)

Stator Weight |(kg)

Rotor Weight(kg)

60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 HzCD 3710 1402 1477 331 355 1682 636 670 150 161CE 3710 1427 1502 334 363 1682 647 681 151 165CL 3710 1452 1552 347 379 1682 659 704 157 172CM 3710 1465 1577 351 387 1682 664 715 159 176CN 3710 1477 1584 355 391 1682 670 718 161 177CP 3710 1527 1602 371 395 1682 693 727 168 179CQ 3710 1577 1602 387 395 1682 715 727 176 179

*Total compressor weight is the sum of the compressor aerodynamic components (compressor weight column), stator, rotor, and end bell coverweights.†Compressor size number is the first digit of the compressor code. See Model Number Nomenclature Fig. 1.**For high voltage motors, add the following: 300 lb (136 kg) to stator, 150 lb (68 kg) to rotor, and 40 lb (18 kg) to end bell.††Compressor aerodynamic component weight only. Does not include motor weight, does include turbine housing.

\Stator weight includes the stator and shell.

Table 12 — Compressor Component Weights

COMPONENTWEIGHT

lb kgSuction Elbow 54 24Discharge Elbow 46 21Suction Housing 350 159Impeller Shroud 79 36Compressor Base 1050 476Oil Pump 150 68Transmission 729 331Turbine Housing 900 408Nozzle Block 100 45Turbine Housing Cover 150 68Miscellaneous 135 61

NOTE: Total compressor weight less motor and rotor is 3850 lb(1746 kg).

Table 13 — Waterbox Cover Weights

HEATEXCHANGER

WATERBOXDESCRIPTION

ENGLISH SIFrame 6, Standard Nozzles Frame 6, Flanged Frame 6, Standard Nozzles Frame 6, Flanged150 psig 300 psig 150 psig 300 psig 1034 kPa 2068 kPa 1034 kPa 2068 kPa

COOLER

NIH, 1 Pass Cover 590 842 630 919 268 382 286 417NIH, 2 Pass Cover 586 832 642 904 266 378 291 410NIH, 3 Pass Cover 610 875 627 947 277 397 284 429NIH, Plain End Cover 479 616 — — 218 280 — —

CONDENSER

NIH, 1 Pass Cover 770 1087 820 1164 350 494 372 528NIH, 2 Pass Cover 806 1104 862 1216 366 501 391 551NIH, 3 Pass Cover 827 1148 844 1184 376 521 383 537NIH, Plain End Cover 687 901 — — 312 409 — —

LEGEND

NIH — Nozzle-In-Head

NOTE: The waterbox cover weights are included in the heat exchanger weights shown in Table 10.

86

Table 14 — Optional Pumpout SystemElectrical Data

MOTORCODE

CONDENSERUNIT VOLTS-PH-Hz MAX

RLA LRA

1 19EA47-748 575-3-60 3.8 23.04 19EA42-748 200/208-3-60 10.9 63.55 19EA44-748 230-3-60 9.5 57.56 19EA46-748 400/460-3-50/60 4.7 28.8

LEGEND

LRA — Locked Rotor AmpsRLA — Rated Load Amps

Table 15 — Additional Miscellaneous Weights

ITEM Lb KgCONTROL CABINET 30 14UNIT-MOUNTED STARTER 500 227OPTIONAL ISOLATION VALVES 115 52FLOAT CHAMBER COVERS 179 each 81 each

Table 16 — Motor Voltage Code

MOTOR VOLTAGE CODECode Volts Frequency60 200 6061 230 6062 380 6063 416 6064 460 6065 575 6066 2400 6067 3300 6068 4160 6069 6900 6050 230 5051 346 5052 400 5053 3000 5054 3300 5055 6300 50

87

COMPRESSOR ASSEMBLY TORQUES

ITEM DESCRIPTIONTORQUE

ft-lb N•m1* Oil Heater Grommet Nut 10 142 Bull Gear Retaining Bolt 80-85 108-1153 Demister Bolts 15-19 20-264 Impeller Retaining Bolt 44-46 60-625† Motor Terminals (Low Voltage) 50 686* Guide Vane Shaft Seal Nut 25 347* Motor Terminals (High Voltage)

— Insulator 2-4 2.7-5.4— Packing Nut 5 6.8— Brass Jam Nut 10 13.6

8† Turbine Retaining Bolt 50-60 75-81

LEGEND

N•m _ Newton Meters

*Not shown.†See the Turbine Area section of this figure (View C).

NOTES:1. All clearances for cylindrical surfaces are diametrical.2. Dimensions are with rotor in the thrust position.3. Low voltage (under 600 v) motor and terminals shown.4. Dimensions are shown in inches.5. Impeller clearance to shroud: allows 0.024 in. forward movement

from thrust position.

COMPRESSOR, TRANSMISSION, MOTOR AREA

VIEW ALOW SPEED SHAFT THRUST DISK

Fig. 41 — Compressor Fits and Clearances

88

VIEW BHIGH SPEED SHAFT

VIEW CTURBINE AREA

Fig. 41 — Compressor Fits and Clearances (cont)

89

Fig. 42 — Electronic PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor)

90

Fig. 42 — Electronic PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor) (cont)LEGEND

AUX — AuxiliaryBRG — BearingC — ContactorCB — Circuit BreakerCCM — Chiller Control ModuleCCN — Carrier Comfort NetworkCOMP’R — CompressorCOND — CondenserCVC — Chiller Visual ControllerDISCH — DischargeENT — EnteringEVAP — Evaporator

EXT — ExternalFR — FrameGV — Guide VaneHGBP — Hot Gas BypassHT EXCHD — Heat ExchangerISM — Integrated Starter ModuleL — Main Supply PowerLVG — LeavingN.O. — Normally OpenPRESS — Pressure

REQM’T — RequirementTB — Terminal Board

Denotes Oil Pump Terminal

Denotes Power Panel Terminal** Denotes Motor Starter Panel Conn

Denotes Component Terminal

Wire Splice

Denotes Conductor Male/FemaleConnectorOption Wiring

91

LEGEND

AUX

—Auxiliary

C—

Contactor

CB

—CircuitBreaker

CCM

—ChillerControlModule

COMM

—Com

munication

COMPR

—Com

pressor

DISCH

—Discharge

FR

—Frame

G—

Ground

GRD

—Ground

GVA

—Guide

VaneActuator

HGBP

—HotGas

Bypass

HTEXCH

—HeatExchanger

ISM

—Integrated

Starter

Module

L—

MainPow

erSupply

N.O.

—NormallyOpen

PRESS

—Pressure

REQMT

—Requirement

T—

Transformer

TB

—TerminalBoard

Fig.43

—Pow

erPanelWiring

Schem

atic

Denotes

OilPum

pTerminal

Denotes

Pow

erPanelTerminal

*Denotes

Mach.ControlPanelConn.

**Denotes

Motor

Starter

PanelConn.

Denotes

Com

ponentTerminal

Wire

Splice

Denotes

Conductor

Male/Fem

aleConnector

OptionWiring

92

NOTE: Power factor correction capacitors (when required) areconnected ahead of all current transformers for proper calibra-tion and sensing by the ISM and IQDP4130.

LEGEND

AUX — AuxiliaryC — ContactorCB — Circuit BreakerCR — Control RelayCT — Current TransformerDS — Disconnect SwitchFU — FuseG — Ground

HPR — High Pressure RelayISM — Integrated Starter ModuleL — Main Supply PowerLL — Control Power SupplyM — ContactorRES — ResistorS — ContactorTB — Terminal Block

CAUTION: Yellow wires remain energized when unit main disconnect is off.Optional features are indicated by bold dashed lines.

Dry Contact

Field Connection

For connection diagram refer to 261143 D4.

Fig. 44 — Cutler-Hammer Wye Delta Unit Mounted Starter Wiring Schematic (Low Voltage)

93

Fig. 45 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)

94

LEGEND

AUX — AuxiliaryBR — Bridge RectifierCB — Circuit BreakerCOMM — CommunicationCOND — CondenserCPU — Central Processing UnitCVC — Chiler Visual ControllerCT — Current TransformerEVAP — EvaporatorFU — Fuse

G — GroundL — Main Supply PowerLL — Control Power SupplyM — ContactorO/L — Overload ResetS — ContactorSCR — Silicone Controller RectifierST — Shunt TripTB — Terminal Block

Wire Node Symbolmay have terminal blockBenshaw suppliedterminal block

Terminal Strip

Power Connection

NOTES:

1LED status with power applied and prior to run command. ‘‘ON’’

‘‘OFF’’

2Transformer T1 primary fuses FU1/FU2 value dependent on system volt-age andmodel, per Chart 1. Transformer connections per transformer name-plate connection diagram.

3MOVsare used on power stack assemblies for system voltages of 200 through460 vac (as shown). Resistor/capacitor networks (DVDTs) are used on powerstack assemblies in place of MOVs for a system voltage of 575 vac (notshown).

4K3 relay shown in deenergized state. K3 contact will close when power isapplied. K3 contact will open on stop command or system fault.

Fig. 45 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)

PC Board Terminals

Twisted Pair

Twisted Shielded Pair

Shield Wire

Field Wiring

95

LEGEND

AUX

—Auxiliary

C—

Contactor

CB

—CircuitBreaker

COMM

—Com

munication

COND

—Condenser

CPT

—ControlPow

erTransformer

CR

—ControlRelay

CT

—CurrentTransformer

DS

—DisconnectSwitch

EVA

P—

Evaporator

FU

—Fuse

G—

Ground

GFCT

—GroundFaultCurrentTransformer

HPR

—Horsepower

ISM

—IntergratedStarter

Module

L—

MainPow

erSupply

LL—

ControlPow

erSupply

M—

Contactor

MTR

—Motor

PRESS

—Pressure

PT

—Pow

erTransformer

ST

—ShuntTrip

STAT

—Status

TB

—TerminalBlock

TRANS

—Transition

VFD

—VariableFrequency

Drive

VL

—Wire

Label

Starter

VendorPow

erWiring

Starter

VendorControlWiring

FieldInstalledPow

erWiring

(suppliedby

others)

FieldInstalledControlWiring

(suppliedby

others)

Option—

Starter

VendorWiring

TwistedPairWiring

byStarter

Vendor

Customer

TerminalConnection

Fig.46

—TypicalA

cross-the-Line

Starter

Wiring

Schem

atic(MediumVoltage)

96

LEGEND

AUX

—Auxiliary

C—

Contactor

CB

—CircuitBreaker

COMM

—Com

munication

COND

—Condenser

CPT

—ControlPow

erTransformer

CR

—ControlRelay

CT

—CurrentTransformer

DS

—DisconnectSwitch

EVA

P—

Evaporator

FU

—Fuse

G—

Ground

GFCT

—GroundFaultCurrentTransformer

HPR

—Horsepower

ISM

—IntergratedStarter

Module

L—

MainPow

erSupply

LL—

ControlPow

erSupply

M—

Contactor

MTR

—Motor

PRESS

—Pressure

PT

—Pow

erTransformer

ST

—ShuntTrip

STAT

—Status

TB

—TerminalBlock

TRANS

—Transition

VFD

—VariableFrequency

Drive

VL

—Wire

Label

Starter

VendorPow

erWiring

Starter

VendorControlWiring

FieldInstalledPow

erWiring

(suppliedby

others)

FieldInstalledControlWiring

(suppliedby

others)

Option—

Starter

VendorWiring

TwistedPairWiring

byStarter

Vendor

Customer

TerminalConnection

Fig.47

—TypicalP

rimaryReactor

Starter

Wiring

Schem

atic(MediumVoltage)

97

INDEXAbbreviations and Explanations, 4After Limited Shutdown, 61Attach to Network Device Control, 43Automatic Soft Stop Amps Threshold, 46Auto. Restart After Power Failure, 38Before Initial Start-Up, 47Carrier Comfort Network Interface, 53Capacity Override, 36Chilled Water Recycle Mode, 46Chiller Control Module (CCM), 83Chiller Dehydration, 52Chiller Familiarization, 5Chiller Information Plate, 5Chiller Operating Condition (Check), 60Chillers with Isolation Valves, 65Chiller Start-Up (Prepare for), 60Chillers with Storage Tanks, 64Chiller Tightness (Check), 47Cold Weather Operation, 61Compressor Bearing and Gear Maintenance, 68Condenser, 5Condenser Freeze Prevention, 38Condenser Pump Control, 37Control Algorithms Checkout Procedure, 72Control Panel, 5Control Panel (Inspect), 67Control Modules, 82Controls, 11Controls (Definitions), 11Controls (General), 11Control Test, 57, 72Cooler, 5CVC Operation and Menus, 15Default Screen Freeze, 36Defective Processor Modules (Replacing), 83Demand Limit Control Option, 39Design Set Points, (Input), 54Display Messages (Checking), 71Dry Run to Test Start-Up Sequence, 59Equipment Required, 47Extended Shutdown, (Preparation for), 61Extended Shutdown (After), 61Factory-Mounted Starter (Optional), 7General Maintenance, 66Guide Vane Linkage (Checking), 66Heat Exchanger Tubes and Flow Devices (Inspect), 70High Altitude Locations, 57High Discharge Temperature Control, 36Ice Build Control, 42Initial Start-Up, 59Initial Start-Up (Preparation), 59Inspect Water Piping, 52Instruct the Customer Operator, 60Integrated Starter Module (ISM), 83Introduction, 4Job Data Required, 47Lead/Lag Control, 40Leak Rate, 66Leak Test Chiller, 49Local Occupied Schedule (Input), 54Local Start-Up, 45Lubrication Cycle, 7Lubrication Cycle (Details), 7Lubrication Cycle (Summary), 7Lubrication System (Check), 67Manual Guide Vane Operation, 61Module Operation (Notes), 82Motor-Compressor, 5Motor and Lubricating Oil Cooling Cycle, 7Motor Rotation (Check), 59Oil Changes, 68Oil Charge, 54Oil Circuit Valves (Open), 47Oil Cooler, 37Oil Filter (Changing), 67Oil Pressure and Compressor Stop (Check), 60Oil Reclaim Filter, 68Oil Reclaim System, 9Oil Specification, 68

Oil Sump Temperature Control, 36Operating Instructions, 60Operating the Optional Pumpout Unit, 63Operator Duties, 60Optional Pumpout Compressor Water Piping (Check), 52Optional Storage Tank and Pumpout System (Using), 47Optional Pumpout System Controls and Compressor (Check), 57Optional Pumpout System Maintenance, 70Ordering Replacement Chiller Parts, 71Overview (Troubleshooting Guide), 71Physical Data, 85PIC II System Components, 11PIC II System Functions, 33Power Up the Controls and Check the Oil Heater, 54Preparation (Pumpout and Refrigerant Transfer Procedures), 63Pressure Transducers (Check), 70, 72Prevent Accidental Start-Up, 60Pumpout and Refrigerant Transfer Procedures, 63Ramp Loading, 36Refrigerant (Adding), 66Refrigerant (Adjusting the Charge), 66Refrigerant Charge (Trim), 66Refrigerant Filter, 68Refrigerant Float System (Inpsect), 68Refrigerant Into Chiller (Charge), 58Refrigerant Leak Testing, 66Refrigerant Leak Detector, 37Refrigerant Properties, 66Refrigerant (Removing), 66Refrigerant Tracer, 47Refrigeration Cycle, 7Refrigeration Log, 61Relief Valves (Check), 52Relief Valves and Piping (Inspect), 68Remote Start/Stop Controls, 37Repair the Leak, Retest, and Apply Standing Vacuum Test, 66Running System (Check), 60Safety and Operating Controls (Check Monthly), 67Safety Considerations, 1Safety Controls, 34Safety Shutdown, 46Scheduled Maintenance, 67Service Configurations (Input), 54Service Ontime, 67Service Operation, 44Shipping Packaging (Remove), 47Shunt Trip (Option), 36Shutdown Sequence, 46Software Configuration, 54Solid-State Starters, 83Spare Safety Alarm Contacts, 37Spare Safety Inputs, 37Standing Vacuum Test, 49Start the Chiller, 60Starter (Check), 53Starting Equipment, 10Starting Equipment (Inspect), 70Start-Up/Shutdown/Recycle Sequence, 45Stop the Chiller, 61Storage Vessel (Optional), 7Surge Prevention Algorithm, 39Surge Protection, 40System Components, 5Temperature Sensors (Checking), 71Test After Service, Repair, or Major Leak, 66Tighten All Gasketed Joints and Guide Vane Shaft Packing, 47Tower Fan Relay Low and High, 38Troubleshooting Guide, 71Turbine, 5Turbine Maintenance, 68Turbine Strainer, 68Unit-Mounted Solid-State Starter (Optional), 10Unit-Mounted Wye-Delta Starter (Optional), 11Water/Brine Reset, 38Water Leaks, 70Water Treatment, 70Weekly Maintenance, 67Wiring (Inspect), 52

98

Copyright 1998 Carrier Corporation


PC 211 Catalog No. 531-977 Printed in U.S.A. Form 19XRT-2SS Pg 100 199 11-98 Replaces: New

INITIAL START-UP CHECKLIST FOR19XRT HERMETIC CENTRIFUGAL LIQUID CHILLER

(Remove and use for job file.)

MACHINE INFORMATION:

NAME JOB NO.

ADDRESS MODEL

CITY STATE ZIP S/N

DESIGN CONDITIONS:

TONS BRINE FLOWRATE

TEMPERATUREIN

TEMPERATUREOUT

PRESSUREDROP PASS SUCTION

TEMPERATURECONDENSERTEMPERATURE

COOLER ******

CONDENSER ******

COMPRESSOR: Volts RLA OLTA

STARTER: Mfg Type S/N

OIL PUMP: Volts RLA OLTA

CONTROL/OIL HEATER: Volts M 115 M 230

REFRIGERANT: Type: Charge

CARRIER OBLIGATIONS: Assemble . . . . . . . . . . . . . . . Yes M No M

Leak Test . . . . . . . . . . . . . . . Yes M No M

Dehydrate . . . . . . . . . . . . . . . Yes M No M

Charging . . . . . . . . . . . . . . . . Yes M No M

Operating Instructions Hrs.

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UPINSTRUCTIONS

JOB DATA REQUIRED:1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Yes M No M2. Machine Assembly, Wiring and Piping Diagrams . . . . . . . . . . . . Yes M No M3. Starting Equipment Details and Wiring Diagrams . . . . . . . . . . . . Yes M No M4. Applicable Design Data (see above) . . . . . . . . . . . . . . . . . . . . . . Yes M No M5. Diagrams and Instructions for Special Controls . . . . . . . . . . . . . Yes M No M

INITIAL MACHINE PRESSURE:

YES NO

Was Machine Tight?

If Not, Were Leaks Corrected?

Was Machine Dehydrated After Repairs?

CHECK OIL LEVEL AND RECORD: ADD OIL: Yes M No M

Amount:

RECORD PRESSURE DROPS: Cooler Condenser

CHARGE REFRIGERANT: Initial Charge Final Charge After Trim

CUTALO

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PC 211 Catalog No. 531-977 Printed in U.S.A. Form 19XRT-2SS Pg CL-1 7-98 Replaces: 19XRT-1SS

INSPECT WIRING AND RECORD ELECTRICAL DATA:

RATINGS:

Motor Voltage Motor(s) Amps Oil Pump Voltage Starter LRA Rating

Line Voltages: Motor Oil Pump Controls/Oil Heater

FIELD-INSTALLED STARTERS ONLY:

Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state starters; disconnectleads to motor and megger the leads.

MEGGER MOTOR‘‘PHASE TO PHASE’’ ‘‘PHASE TO GROUND’’

T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G

10-Second Readings:

60-Second Readings:

Polarization Ratio:

STARTER: Electro-Mechanical M Solid-State M ManufacturerSerial Number

Motor Load Current Transformer Ratio :

Solid-State Overloads Yes M No M

CONTROLS: SAFETY, OPERATING, ETC.

Perform Controls Test (Yes/No)

PIC II CAUTIONCOMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY CON-NECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH CERTIFIEDDRAWINGS).

Yes

RUN MACHINE: Do these safeties shut down machine?Condenser Water Flow Yes M No MChilled Water Flow Yes M No MPump Interlocks Yes M No M

INITIAL START:

Line Up All Valves in Accordance With Instruction Manual: Start Water Pumps and Establish Water Flow

Oil Level OK and Oil Temperature OK Check Oil Pump Rotation-Pressure

Check Compressor Motor Rotation (Motor End Sight Glass) and Record: Clockwise

Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes* M No M

*If yes, determine cause.

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

A: Trim charge and record under Charge Refrigerant section on page 58.B: Complete any remaining control calibration and record under Controls section (pages 11-44).C: Take at least two sets of operational log readings and record.E: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.F: Give operating instructions to owner’s operating personnel. Hours Given: HoursG: Call your Carrier factory representative to report chiller start-up.

SIGNATURES:

CARRIERTECHNICIAN

DATE

CUSTOMERREPRESENTATIVE

DATE

CL-2

19XRT PIC II SETPOINT TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Base Demand Limit 40 to 100 % 100

LCW Setpoint 10 to 120 DEG F 50.0

ECW Setpoint 15 to 120 DEG F 60.0

Ice Build Setpoint 15 to 60 DEG F 40.0

Tower Fan High Setpoint 55 to 105 DEG F 75

CVC Software Version Number:

CVC Controller Identification: BUS: ADDRESS:

CUTALO

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CL-3

19XRT PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S

Day Flag Occupied UnoccupiedM T W T F S S H Time Time

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

NOTE: Default setting is OCCUPIED 24 hours/day.

ICE BUILD 19XRT PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S


Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

NOTE: Default setting is UNOCCUPIED 24 hours/day.

19XRT PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S


Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

NOTE: Default setting is OCCUPIED 24 hours/day.

CL-4

19XRT PIC II ISM_CONF TABLE CONFIGURATION SHEET


Starter Type(0=Full, 1=Red, 2=SS/VFD)

0 to 2 1

Motor Rated Line Voltage 200 to 13200 VOLTS 460

Volt Transformer Ratio: 1 1 to 33 1

Overvoltage Threshold 105 to 115 % 115

Undervoltage Threshold 85 to 95 % 85

Over/Under Volt Time 1 to 10 SEC 5

Voltage % Imbalance 1 to 10 % 10

Voltage Imbalance Time 1 to 10 SEC 5

Motor Rated Load Amps 10 to 5000 AMPS 200

Motor Locked Rotor Trip 100 to 60000 AMPS 1000

Locked Rotor Start Delay 1 to 10 cycles 5

Starter LRA Rating 100 to 60000 AMPS 2000

Motor Current CT Ratio: 1 3 to 1000 100

Current % Imbalance 5 to 40 % 15

Current Imbalance Time 1 to 10 SEC 5

3 Grnd Fault CT’s? (1=No) 0/1 NO/YES YES

Ground Fault CT Ratio: 1 150 150

Ground Fault Current 1 to 25 AMPS 15

Ground Fault Start Delay 1 to 20 cycles 10

Ground Fault Persistence 1 to 10 cycles 5

Single Cycle Dropout 0/1 DSABLE/ENABLE DSABLE

Frequency-60 Hz? (No=50) 0/1 NO/YES YES

Line Frequency Faulting 0/1 DSABLE/ENABLE DSABLE

CUTALO

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CL-5

19XRT PIC II OPTIONS TABLE CONFIGURATION SHEET


Auto Restart Option 0/1 DSABLE/ENABLE DSABLE

Remote Contacts Option 0/1 DSABLE/ENABLE DSABLE

Soft Stop Amps Threshold 40 to 100 % 100

Surge/Hot Gas Bypass

Surge Limit/HGBP OptionSelect: Surge=0, HGBP=1

0/1 0

Min. Load Point (T1/P1)

Surge/HGBP Delta T1 0.5 to 20 ^F 1.5

Surge/HGBP Delta P1 30 to 170 PSI 50

Full Load Point (T2/P2)

Surge/HGBP Delta T2 0.5 to 20 ^F 10

Surge/HGBP Delta P2 50 to 170 PSI 85

Surge/HGBP Deadband 0.5 to 3 ^F 1

Surge Protection

Surge Delta % Amps 5 to 20 % 10

Surge Time Period 7 to 10 MIN 8

Ice Build Control

Ice Build Option 0/1 DSABLE/ENABLE DSABLE

Ice Build Termination0=Temp, 1=Contacts, 2=Both

0 to 2 0

Ice Build Recycle 0/1 DSABLE/ENABLE DSABLE

Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE

Refrigerant Leak Alarm mA 4 to 20 mA 20

CL-6

19XRT PIC II SETUP1 TABLE CONFIGURATION SHEET


Comp Motor Temp Override 150 to 200 DEG F 200

Cond Press Override 90 to 165 PSI 125

Comp Discharge Alert 125 to 200 DEG F 200

Comp Thrust Brg Alert 165 to 185 DEG F 175

Chilled Medium 0/1 WATER/BRINE WATER

Chilled Water Deadband .5 to 2.0 ^F 1.0

Evap Refrig Trippoint 0.0 to 40.0 DEG F 33

Refrig Override Delta T 2.0 to 5.0 ^F 3

Condenser Freeze Point −20 to 35 DEG F 34

Evap Flow Delta P Cutout 0.5 to 50.0 PSI 5.0

Cond Flow Delta P Cutout 0.5 to 50.0 PSI 5.0

Water Flow Verify Time 0.5 to 5 MIN 5

Oil Press Verify Time 15 to 300 SEC 40

Recycle Control

Recycle Restart Delta T 2.0 to 10.0 DEG F 5

Recycle Shutdown Delta 0.5 to 4.0 DEG F 1

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

Spare Temp #1 Enable 0 to 4 0

Spare Temp #1 Limit −40 to 245 DEG F 245

Spare Temp #2 Enable 0 to 4 0

Spare Temp #2 Limit −40 to 245 DEG F 245

CUTALO

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CL-7

19XRT PIC II SETUP2 TABLE CONFIGURATION SHEET

DESCRIPTION STATUS UNITS DEFAULT VALUE

Capacity Control

Proportional Inc Band 2 to 10 6.5

Proportional Dec Band 2 to 10 6.0

Proportional ECW Gain 1 to 3 2.0

Guide Vane Travel Limit 30 to 100 % 80

VFD Speed Control

VFD Option 0/1 DSABLE/ENABLE DSABLE

VFD Gain 0.1 to 1.5 0.75

VFD Increase Step 1 to 5 % 2

VFD Minimum Speed 65 to 100 % 70

VFD Maximum Speed 90 to 100 % 100

CL-8

19XRT PIC II LEADLAG TABLE CONFIGURATION SHEET

DESDRIPTION RANGE UNITS DEFAULT VALUE

Lead Lag Control

LEAD/LAG ConfigurationDSABLE=0, LEAD=1,LAG=2, STANDBY=3

0 to 3 0

Load Balance Option 0/1 DSABLE/ENABLE DSABLE

Common Sensor Option 0/1 DSABLE/ENABLE DSABLE

LAG Percent Capacity 25 to 75 % 50

LAG Address 1 to 236 92

LAG START Timer 2 to 60 MIN 10

LAG STOP Timer 2 to 60 MIN 10

PRESTART FAULT Timer 2 to 30 MIN 5

STANDBY Chiller Option 0/1 DSABLE/ENABLE DSABLE

STANDBY Percent Capacity 25 to 75 % 50

STANDBY Address 1 to 236 93

CUTALO

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CL-9

19XRT PIC II RAMP_DEM TABLE CONFIGURATION SHEET


Pulldown Ramp Type:Select: Temp=0, Load=1

0/1 1

Demand Limit + kW Ramp

Demand Limit SourceSelect: Amps=0, kW=1

0/1 0

Motor Load Ramp % Min 5 to 20 10

Demand Limit Prop Band 3 to 15 % 10

Demand Limit At 20 mA 40 to 100 % 40

20 mA Demand Limit Opt 0/1 DSABLE/ENABLE DSABLE

Motor Rated Kilowatts 50 to 9999 kW 145

Demand Watts Interval 5 to 60 MIN 15

19XRT PIC II TEMP_CTL TABLE CONFIGURAITON SHEET


Control Point

ECW Control Option 0/1 DSABLE/ENABLE DSABLE

Temp Pulldown Deg/Min 2 to 10 ^F 3

Temperature Reset

RESET TYPE 1

Degrees Reset At 20 mA −30 to 30 ^F 10

RESET TYPE 2

Remote Temp (No Reset) −40 to 245 DEG F 85

Remote Temp (Full Reset) −40 to 245 DEG F 65

Degrees Reset −30 to 30 ^F 10

RESET TYPE 3

CHW Delta T (No Reset) 0 to 15 ^F 10

CHW Delta T (Full Reset) 0 to 15 ^F 0

Degrees Reset −30 to 30 ^F 5

Select/Enable Reset Type 0 to 3 0

CL-10

BROADCAST (BRODEF) CONFIGURATION SHEET


Time Broadcast Enable 0/1 DSABLE/ENABLE DSABLE

Daylight Savings

Start Month 1 to 12 4

Start Day of Week 1 to 7 7

Start Week 1 to 5 3

Start Time 00:00 to 24:00 HH:MM 02:00

Start Advance 0 to 360 MIN 60

Stop Month 1 to 12 10

Stop Day of Week 1 to 7 7

Stop Week 1 to 5 3

Stop Time 00:00 to 24:00 02:00

Stop Back 0 to 360 MIN 60

CUTALO

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CL-11

Copyright 1998 Carrier Corporation


PC 211 Catalog No. 531-977 Printed in U.S.A. Form 19XRT-2SS Pg CL-12 199 11-98 Replaces: New

19xrt hermetic centrifugal liquid chillers

Documents