23XL
50/60 Hz
Hermetic Screw Liquid Chillers
With HCFC-22 and HFC-134a
Start-Up, Operation, and Maintenance
Instructions
SAFETY CONSIDERATIONS
Screw liquid chillers are designed to provide safe and reliable service when operated within design specifications. When
operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures and safety
precautions contained in the machine instructions, as well
as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet from
rupture disc or relief valve must be vented outdoors in accordance with
the latest edition of ANSI/ASHRAE 15 (American National Standards
Institute, American Society of Heating, Refrigeration, and Air Conditioning Engineers), latest edition. The accumulation of refrigerant in an
enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,
especially for enclosed and low overhead spaces. Inhalation of high
concentrations of vapor is harmful and may cause heart irregularities,
unconsciousness, or death. Misuse can be fatal. Vapor is heavier than
air and reduces the amount of oxygen available for breathing. Product
causes eye and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for
any purpose. Oxygen gas reacts violently with oil, grease, and other
common substances.
NEVER EXCEED specified test pressures. VERIFY the allowable test
pressure by checking the instruction literature and the design pressures
on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and functioning before operating any machine.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until
all refrigerant (liquid and vapor) has been removed from chiller. Traces
of vapor should be displaced with dry air or nitrogen and the work area
should be well ventilated. Refrigerant in contact with an open flame
produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig machine sections or the
entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified
electrician.
DO NOT WORK ON electrical components, including control centers,
switches, starters, or oil heater (if applicable) until you are sure ALL
POWER IS OFF and no residual voltage can leak from capacitors or
solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK
IS INTERRUPTED, confirm that all circuits are deenergized before
resuming work.
DO NOT syphon refrigerant.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.
USE SAFETY GOGGLES. Wash any spills from the skin with soap
and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH
EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar, and unscrew
and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the
machine. The introduction of the wrong refrigerant can cause damage
or malfunction to this machine.
Operation of this equipment with refrigerants other than those cited
herein should comply with ANSI/ASHRAE 15 (latest edition). Contact
Carrier for further information on use of this machine with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine is running. Be sure pressure
is at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act
as projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move
inspection covers or other heavy components. Even if components are
light, use mechanical equipment when there is a risk of slipping or
losing your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE
THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead
of the starter, tower fan, or pumps. Shut off the machine or pump before servicing equipment.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other
items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut
has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 211
Catalog No. 532-302
Printed U.S.A.
Form 23XL-2SS
Pg 1
12-94
Replaces: 23XL-1SS
Tab 5e
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . 4
23XL MACHINE FAMILIARIZATION . . . . . . . . . . . 4-7
Machine Identification Nameplate . . . . . . . . . . . . . 4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Muffler-Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factory-Mounted Starter (Optional) . . . . . . . . . . . . 7
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . 7
MOTOR COOLING CYCLE . . . . . . . . . . . . . . . . . . . . 7
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 7-11
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• FRAME 1 AND 2 MACHINES
• FRAME 4 MACHINES
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Loss Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Slide Valve Principle . . . . . . . . . . . . . . . . . . . . . . . . 11
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . 11,12
Unit Mounted Solid-State Starter (Optional) . . . 11
Unit Mounted Wye-Delta Starter . . . . . . . . . . . . . . 12
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
Controls Definitions . . . . . . . . . . . . . . . . . . . . . . . . . 13
• ANALOG SIGNAL
• DIGITAL SIGNAL
• VOLATILE MEMORY
General Controls Overview . . . . . . . . . . . . . . . . . . 13
PIC System Components . . . . . . . . . . . . . . . . . . . . 13
• PROCESSOR MODULE (PSIO)
• STARTER MANAGEMENT MODULE (SMM)
• LOCAL INTERFACE DEVICE (LID)
• 6-PACK RELAY BOARD
• 8-INPUT MODULES
• OIL HEATER CONTACTOR (1C)
• HOT GAS BYPASS RELAY (3C) (Optional)
• CONTROL TRANSFORMERS (T1-T4)
• CONTROL AND OIL HEATER VOLTAGE
SELECTOR (S1)
• VI INLET CONTACTOR RELAY (2C) (Optional)
• TEMPERATURE SENSORS
• PRESSURE TRANSDUCERS
LID Operation and Menus . . . . . . . . . . . . . . . . . . . 17
• GENERAL
• ALARMS AND ALERTS
• MENU STRUCTURE
• TO VIEW POINT STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC System Functions . . . . . . . . . . . . . . . . . . . . . . . 22
• CAPACITY CONTROL
• ENTERING CHILLED WATER CONTROL
• DEADBAND
• PROPORTIONAL BANDS AND GAIN
• DEMAND LIMITING
• MACHINE TIMERS
• OCCUPANCY SCHEDULE
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
• SHUNT TRIP
Ramp Loading Control . . . . . . . . . . . . . . . . . . . . . . 29
Page
Capacity Overrides . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil Sump Temperature Control
(Frame 1 and 2 Machines) . . . . . . . . . . . . . . . . . 29
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . 29
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 29
• SPARE ALARM CONTACTS
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . 29
Condenser Freeze Protection . . . . . . . . . . . . . . . . 31
Tower-Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Auto.-Restart After Power Failure . . . . . . . . . . . . 31
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Demand Limit Control, Option (Requires
Optional 8 — Input Module) . . . . . . . . . . . . . . . . 32
Hot Gas Bypass (Optional) Algorithm . . . . . . . . 32
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
• COMMON POINT SENSOR INSTALLATION
• MACHINE COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
• ICE BUILD INITIATION
• START-UP/RECYCLE OPERATION
• TERMINATION OF ICE BUILD
• RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . 35
• CHANGING REFRIGERANT TYPES
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
• TO LOG ON
• TO LOG OFF
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-39
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . 38
Automatic Soft Stop Amps Threshold . . . . . . . . 38
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . 38
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . 39-56
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Field Supplied Equipment Required . . . . . . . . . . 39
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . 39
Remove Shipping Packaging . . . . . . . . . . . . . . . . 39
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . 39
Check Machine Tightness . . . . . . . . . . . . . . . . . . . 39
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Leak Test Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . 48
Machine Dehydration . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . 48
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Carrier Comfort Network Interface . . . . . . . . . . . 49
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
• MECHANICAL-TYPE STARTERS
• BENSHAW, INC. SOLID-STATE STARTERS
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . 50
Set Up Machine Control Configuration . . . . . . . 50
• SOLID-STATE STARTERS (Cutler-Hammer)
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . 52
Input the Design Set Points . . . . . . . . . . . . . . . . . . 52
2
CONTENTS (cont)
Page
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Selecting Refrigerant Type . . . . . . . . . . . . . . . . . . . 53
• TO CONFIRM REFRIGERANT
• TO CHANGE REFRIGERANT TYPE
Input Service Configurations . . . . . . . . . . . . . . . . 53
• PASSWORD
• INPUT TIME AND DATE
• CHANGE LID CONFIGURATION
IF NECESSARY
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
AS NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
AS NECESSARY
• CHECK VOLTAGE SUPPLY
• PERFORM AN AUTOMATED CONTROLS TEST
Check Optional Pumpout System
Controls and Compressor . . . . . . . . . . . . . . . . . 55
Charge Refrigerant Into Machine . . . . . . . . . . . . . 55
• 23XL MACHINE EQUALIZATION WITHOUT PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 56,57
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Dry Run to Test Start-Up Sequence . . . . . . . . . . 56
Check Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• NOTES ON SOLID-STATE STARTERS
Check Oil Pressure and Compressor Stop . . . . 57
Calibrate Motor Current Demand Setting . . . . . 57
To Prevent Accidental Start-Up . . . . . . . . . . . . . . 57
Check Machine Operating Conditions . . . . . . . . 57
Instruct the Operator . . . . . . . . . . . . . . . . . . . . . . . . 57
• COOLER-CONDENSER
• OPTIONAL STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
• MOTOR COMPRESSOR LUBRICATION SYSTEM
• COMPRESSOR LUBRICATION SYSTEM
• OIL SEPARATION SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE MACHINE CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION,
AND MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 58-60
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Prepare the Machine for Start-Up . . . . . . . . . . . . 58
To Start the Machine . . . . . . . . . . . . . . . . . . . . . . . . 58
Check the Running System . . . . . . . . . . . . . . . . . . 58
To Stop the Machine . . . . . . . . . . . . . . . . . . . . . . . . 58
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . 58
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 58
After Extended Shutdown . . . . . . . . . . . . . . . . . . . 58
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . 59
Slide Valve Operation . . . . . . . . . . . . . . . . . . . . . . . 59
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 61-63
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Operating the Optional Pumpout
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• TO READ REFRIGERANT PRESSURES
Page
Machines with Storage Tanks . . . . . . . . . . . . . . . . 61
• TRANSFER REFRIGERANT FROM
STORAGE TANK TO MACHINE
• TRANSFER THE REFRIGERANT FROM
MACHINE TO STORAGE TANK
Machines with Isolation Valves . . . . . . . . . . . . . . 62
• TRANSFER ALL REFRIGERANT TO
COOLER/COMPRESSOR VESSEL
Return Refrigerant to Normal Operating
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . 63,64
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . 63
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 63
Adjusting the Refrigerant Charge . . . . . . . . . . . . 63
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . 63
Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . 64
Test After Service, Repair, or Major Leak . . . . . 64
• REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Refrigerant Leak, Retest, and
Apply Standing Vacuum Test . . . . . . . . . . . . . . 64
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . 64
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . 64
Check the Lubrication System . . . . . . . . . . . . . . . 64
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . 64-68
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspect the Control Center . . . . . . . . . . . . . . . . . . . 64
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . 64
• FRAME 1 AND 2 MACHINES
• FRAME 4 MACHINES
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Oil Separator Coalescer . . . . . . . . . . . . . . . . . . . . . 66
Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . 66
Refrigerant Strainers . . . . . . . . . . . . . . . . . . . . . . . . 66
Inspect Refrigerant Float System . . . . . . . . . . . . 66
Inspect Relief Valves and Piping . . . . . . . . . . . . . 66
Compressor Bearing Maintenance . . . . . . . . . . . 66
Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . 66
Inspect the Heat Exchanger Tubes . . . . . . . . . . . 66
• COOLER
• CONDENSER
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Inspect the Starting Equipment . . . . . . . . . . . . . . 67
Check Pressure Transducers . . . . . . . . . . . . . . . . 67
Optional Pumpout System Maintenance . . . . . . 67
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY
CONTROL SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . 68
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . 68-102
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking the Display Messages . . . . . . . . . . . . . 68
Checking Temperature Sensors . . . . . . . . . . . . . . 68
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . 68
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . 69
3
CONTENTS (cont)
ABBREVIATIONS AND EXPLANATIONS
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
• RED LED
• GREEN LEDs
Notes on Module Operation . . . . . . . . . . . . . . . . . . 80
Processor Module (PSIO) . . . . . . . . . . . . . . . . . . . . 81
• INPUTS
• OUTPUTS
Starter Management Module (SMM) . . . . . . . . . . 81
• INPUTS
• OUTPUTS
Options Modules (8-Input) . . . . . . . . . . . . . . . . . . . 81
Replacing Defective Processor Modules . . . . . . 82
• INSTALLATION
Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . 83
• TESTING SILICON CONTROL RECTIFIERS
IN BENSHAW, INC. SOLID-STATE STARTERS
• TESTING SILICON CONTROL RECTIFIERS (SCRs)
IN CUTLER-HAMMERt SOLID-STATE STARTERS
• ELECTRONIC PROTECTION RELAY (EPR)
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103,104
Frequently used abbreviations in this manual include:
CCN
CHWR
CHWS
ECDW
ECW
HGBP
I/O
LCD
LCDW
LED
LID
LCW
OLTA
PIC
PSIO
RLA
SCR
SI
SMM
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Carrier Comfort Network
Common Chilled Water Return
Common Chilled Water Supply
Entering Condenser Water
Entering Chilled Water
Hot Gas Bypass
Input/Output
Liquid Crystal Display
Leaving Condenser Water
Light-Emitting Diode
Local Interface Device
Leaving Chilled Water
Overload Trip Amps
Product Integrated Control
Processor Sensor Input/Output Module
Rated Load Amps
Silicon Control Rectifier
International System of Units
Starter Management Module
The 23XL machines use HCFC-22 and HFC-134a refrigerant. When referencing refrigerant charges in this manual,
the HCFC-22 charge will be listed first and the HFC-134a
value will be shown next to it in [ ].
Words printed in all capital letters or in italics may be viewed
on the LID.
The front cover of the PSIO shows the software version
it contains.
Factory installed additional components are called options in this manual. Factory supplied, field installed additional components are referred to as accessories.
INTRODUCTION
Everyone involved in the start-up, operation, and maintenance of the 23XL machine should be thoroughly familiar
with these instructions and other necessary job data before
initial start-up. This book is outlined so that you may become familiar with the control system before performing start-up
procedures. Procedures are arranged in the sequence required for proper machine start-up and operation.
23XL MACHINE FAMILIARIZATION
(Fig. 1, 2A, and 2B)
Machine Identification Nameplate — The machine identification nameplate is located on the right side of
the machine control panel center.
System Components — The components include cooler
and condenser, heat exchangers in separate vessels, motorcompressor, lubrication package, control center, and optional motor starter. All connections from pressure vessels
have external threads to enable each component to be pressure tested with a threaded pipe cap during factory
assembly.
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards
or modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity)
when handling or making contact with circuit boards or
module connections. Always touch a chassis (grounded)
part to dissipate body electrostatic charge before working inside control center.
Use extreme care when handling tools near boards
and when connecting or disconnecting terminal plugs.
Circuit boards can easily be damaged. Always hold
boards by edges and avoid touching components and
connections.
This equipment uses and can radiate radio frequency
energy and, if not installed and used in accordance with
the instruction manual may cause interference to radio
communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference when operated in a commercial environment. Operation of this equipment in a residential area
is likely to cause interference, in which case the user, at
his own expense, will be required to take whatever measures may be required to correct the interference.
Always store and transport replacement or defective
boards in anti-static shipping bag.
VI — Volumetric Index
SERIAL NUMBER BREAKDOWN
Fig. 1 — 23XL Identification
4
FRONT VIEW
1
2
3
4
5
6
7
8
9
10
11
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—
—
—
—
—
—
—
—
—
—
Power Panel
Local Interface Display (LID) Control Center
ASME Nameplate, Cooler
Cooler Refrigerant Isolation Valve
ASME Nameplate, Economizer (Hidden)
Service Valve
Take-Apart Rabbet Fit Connector (Lower)
Cooler Temperature Sensor
ASME Nameplate, Condenser
Typical Waterbox Drain Port
Cooler Supply/Return End
Waterbox Cover
12 — Condenser Supply/Return End
Waterbox Cover
13 — Compressor Nameplate (Hidden)
14
15
16
17
18
19
20
21
22
—
—
—
—
—
—
—
—
—
23
24
25
26
—
—
—
—
REAR VIEW
27 —
28 —
Oil Separator
ASME Nameplate, Muffler (Hidden)
ASME Nameplate, Oil Separator
Cooler Relief Valves (Hidden)
Oil Sump Filter Assembly
Oil Charging Valve
Vessel Separation Feet
Float Chamber
Condenser Isolation Valve (Option or
Accessory)
Refrigerant Charging Valve
Condenser
Condenser Relief Valves (Hidden)
Take-Apart Rabbet Fit Connector
(Upper)
Unit Mounted Starter (Option)
Machine Identification Nameplate
Fig. 2A — Typical 23XL Installation (Frame 1 and 2 Machines)
5
FRONT VIEW
1
2
3
4
5
6
7
—
—
—
—
—
—
—
8
9
10
11
12
13
14
15
16
17
—
—
—
—
—
—
—
—
—
—
18
19
20
21
22
23
—
—
—
—
—
—
24
25
26
27
28
29
30
31
—
—
—
—
—
—
—
—
Compressor Nameplate (Hidden)
Power Panel
Local Interface Display (LID) Control Center
ASME Nameplate, Cooler
Cooler
Vessel Separation Feet
Economizer Float Valve Access Cover
(Hidden)
Refrigerant Charging Valve
Economizer
Oil Filter Assembly (Hidden)
ASME Nameplate, Economizer
Typical Waterbox Drain Port
Take-Apart Rabbet Fit Connector
ASME Nameplate, Condenser
Cooler Supply/Return End Waterbox Cover
Condenser Temperature Sensors
Cooler Relief Valve
REAR VIEW
32 —
33 —
Unit Mounted Starter (Option)
ASME Nameplate, Oil Separator
Oil Separator Relief Valves
Oil Separator
Oil Charging Valve
Condenser Isolation Valve (Option or
Accessory)
Service Valve
Cooler Refrigerant Isolation Valve
Condenser Relief Valves and Oil Filter
Float Chamber
Poppet Valve Assembly
Motor Cooling Isolation Valve
Condenser
Condenser Supply/Return End
Waterbox Cover
Cooler Temperature Sensors
Machine Identification Nameplate
Fig. 2B — Typical 23XL Installation (Frame 4 Machine)
6
Relatively cool (typically 65 to 85 F [18 to 29 C]) water
flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the FLASC
(Flash Subcooler) chamber (Fig. 3 and 4). Since the FLASC
chamber is at a lower pressure, part of the liquid refrigerant
flashes to vapor, thereby cooling the remaining liquid. The
FLASC vapor is recondensed on the tubes which are cooled
by entering condenser water. The liquid then passes through
a float valve assembly which forms a liquid seal to keep FLASC
chamber vapor from entering the cooler.
An optional economizer can be installed between the condenser and cooler. In this case, the float valve meters the
refrigerant liquid into the economizer. Pressure in this chamber is intermediate between condenser and cooler pressures.
At this lower pressure, some of the liquid refrigerant flashes
to gas, cooling the remaining liquid. The flash gas, having
absorbed heat, is returned directly to the compressor at a point
after suction cutoff (Fig. 5). Here it is mixed with gas from
the suction cut-off point to produce an increase in the mass
flow of refrigerant transported and compressed without either an increase in suction volume or a change in suction
temperature. Rather than providing the same capacity with
less power, the compressor provides substantially increased
capacity with only a slight increase in power requirements.
The cooled liquid refrigerant in the economizer is metered through an orifice or linear float valve (depending upon
machine design) into the cooler. Because pressure in the cooler
is lower than economizer pressure, some of the liquid flashes
and cools the remainder to evaporator (cooler) temperature.
The cycle is now complete.
Cooler — This vessel (also known as the evaporator) is
located underneath the compressor. The cooler is maintained at low temperature/pressure so that evaporating refrigerant can remove heat from water/brine flowing through
its internal tubes.
Condenser — The condenser operates at a higher
temperature/pressure than the cooler and has water flowing through its internal tubes to remove heat from the
refrigerant.
Motor-Compressor — The motor-compressor maintains system temperature/pressure differences and moves the
heat carrying refrigerant from the cooler to the condenser.
Muffler-Oil Separator — The muffler provides acoustical attenuation.
Refrigerant/oil separation is accomplished by the oil separator. Discharge gas enters near the midsection and leaves
near the top, while the separated oil drains out through the
bottom and flows through a horizontal oil sump/filter
assembly (Frame 1 and 2 machines).
Frame 1 and 2 machines have an oil separator and a muffler assembly. On Frame 4 machines, the muffler is located
inside the oil separator.
Control Center — The control center is the user interface for controlling the machine and regulating the machine’s capacity to maintain the proper chilled water
temperature. The control center:
• registers cooler, condenser, and lubricating system
pressures
• shows machine operating condition and alarm shutdown
conditions
• records the total machine operating hours, starts, and the
number of hours the machine has been currently running
• sequences machine start, stop, and recycle under microprocessor control
• provides access to other Carrier Comfort Network devices
MOTOR COOLING CYCLE
vessels are available. The vessels have double relief valves,
a magnetically coupled dial-type refrigerant level gage,
a 1-in. FPT drain valve, and a 1⁄2-in. male flare vapor
connection for the pumpout unit. A 30-in.-0-400 psi
(-101-0-2750 kPa) gage is also supplied with each unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled optional isolation valves may be used to isolate the
machine charge in either the cooler or condenser. An optional pumpout compressor system is used to transfer refrigerant from vessel to vessel.
The motor is cooled by liquid refrigerant taken from the
bottom of the condenser vessel. The flow of refrigerant is
maintained by the pressure differential that exists due to compressor operation. The refrigerant flows through an isolation
valve, in-line filter/drier, and a sight glass/moisture indicator
(dry-eye), into the motor through the motor spray nozzle.
See Fig. 3 and 4.
The motor spray nozzle is orificed to control refrigerant
flow through the gaps in the rotor and axial vent holes. The
refrigerant collects in the bottom of the motor casing and
then drains into the cooler through the motor cooling drain
line.
The motor is protected by a temperature sensor imbedded
in the stator windings. Motor temperatures above the MOTOR WINDING TEMPERATURE OVERRIDE THRESHOLD (see Capacity Overrides section, page 29) will override the chilled water temperature capacity control to hold.
If the motor temperature rises 10 F (5.5 C) above this threshold, the slide valve will unload. If the motor temperature rises
above the safety limit, the compressor will shut down.
REFRIGERATION CYCLE
LUBRICATION CYCLE
The compressor continuously draws refrigerant vapor from
the cooler. As the compressor suction reduces the pressure
in the cooler, the remaining refrigerant boils at a fairly low
temperature (typically 38 to 42 F [3 to 6 C]). The energy
required for boiling is obtained from the water flowing through
the cooler tubes. With heat energy removed, the water becomes cold enough for use in an air-conditioning circuit or
process liquid cooling.
After taking heat from the water, the refrigerant vapor is
compressed. Compression adds still more energy, and the refrigerant is quite warm (typically 130 to 160 F [54 to
71 C]) when it is discharged from compressor into
condenser.
Summary — The 23XL does not require an oil pump.
Factory-Mounted Starter (Optional Accessory)
— The starter allows for the proper starting and disconnecting of electrical energy for the compressor-motor, oil heater
(Frame 1 and 2 machines), and control center.
Storage Vessel (Optional) — Two sizes of storage
Oil flow is driven by differential pressure between condenser and evaporator. This system pressure difference holds
the potential to push the oil through the oil separator and
filter into the compressor rotors, bearings, and slide valve.
The cycle is referred to as a ‘‘high side’’ oil system. See Fig.
3,4, and 5.
Details — The oil system:
• lubricates the roller bearings which support the male and
female rotors, and the ball bearings of the 23XL
compressor.
7
bulk of the oil to drop from the refrigerant and collect at the
bottom of the oil separator. A mesh screen is provided near
the oil separator outlet to remove any additional oil which
may still be entrained in the refrigerant vapor.
The oil sump (Frame 1 and 2 machines) contains a level
switch, temperature sensor, 500-watt oil heater (Frame 1 and
2 machines), and oil filter. Oil temperature is measured and
displayed on the LID default screen. During shutdown, oil
temperature is maintained by the Product Integrated Control
(PIC). See Oil Sump Temperature Control section on
page 29.
NOTE: Frame 4 machines do not have an oil heater.
Operating oil pressure must be at least 20 psi (138 kPa)
for HCFC-22 [7 psi (48.3 kPa) for HFC-134a] and is
dependent upon system pressure differential (lift). The oil
pressure transducer is located downstream of the filter, so
the value displayed on the LID will be slightly less than the
lift value. Under normal full load conditions, oil pressure is
approximately 120 psi (827 kPa) [76 psi (517 kPa)]. If sufficient system differential pressure is not established or maintained, oil pressure will not be established (or will be lost)
and machine shutdown will result.
The compressor provides a pressure differential, but the
system pressure differential is constrained by the temperatures of the chilled and tower water circuits. Cold tower water, rapid tower water temperature swings, and high return
water temperature are among the factors which could contribute to frequent low oil pressure alarms. To help ensure
that suitable oil pressure is established at start-up, sufficient
tower water control should exist. Increasing the machine ramp
loading rate will allow faster compressor load up. This will
quickly establish the refrigerant and, therefore, oil pressure
differential. Units equipped with poppet valves provide a minimum pressure differential to ensure oil pressure at start-up.
See the Troubleshooting Guide section on page 68 for further information.
Conversely, rapid loading of the compressor could cause
any refrigerant in the oil to flash due to the sudden drop in
suction pressure. If the resulting oil foam is not pumped efficiently, oil pressure drops and poor lubrication results. Therefore, the PIC control follows an internal oil pressure ramp
loading schedule during initial start-up.
If the start-up oil pressure falls below the values specified
in Table 1, the PIC control will shut down the machine.
• positions the slide valve for capacity control. The slide valve
is connected to a piston via a rod. The position of the piston, which rides in a cylinder, is determined by energizing
one of two solenoids which function to supply and equalize oil pressure to and around the piston. This allows the
slide valve to unload and load.
• seals the gap between the male and female rotors. The oil
hydrodynamically seals this space to allow the refrigerant
vapor to be compressed. A specific flow rate of oil is injected into the compressor rotor housing at the point where
the compression process is initiated.
• cools the compressed refrigerant vapor. The oil that is injected into the compressor for sealing also acts as a heat
sink by absorbing a portion of the heat from compression.
Thus, constant and cool compressor discharge gas temperature, relative to an oil-less screw compressor, is
maintained.
Oil is charged into the system through a hand valve located on the bottom of the oil sump (Frame 1 and 2 machines) or separator (Frame 4 machines). Sight glasses on
the oil sump (Frame 1 and 2 machines) and/or oil separator
(Frame 4 machines) permit oil level observation. When the
compressor is shut down, an oil level should be visible in
the oil sump (Frame 1 and 2 machines) or the lower oil
separator sight glass (Frame 4 machines). During operation,
the oil level should rise and be visible in the oil
separator sight glass (Frame 1 and 2 machines) or the upper
oil separator sight glass (Frame 4 machines). Approximately 4.2 gal. (15.9 L) of an oil and refrigerant mixture
accumulates in the sump of Frame 1 and 2 machines.
Approximately 10 gal (38 L) of oil accumulates in the separator and 2 gal. (7.6 L) accumulates on the cooler of
Frame 4 machines.
Oil is driven from the oil separator through an oil filter to
remove foreign particles. The oil filter has a replaceable cartridge. The filter housing is capable of being valved off to
permit removal of the filter (see Maintenance sections, pages
63-68, for details). The oil then travels through a shutdown
solenoid and past a pressure transducer to three separate inlets on the compressor. The oil pressure measured by the transducer is used to determine the oil pressure differential and
pressure drop across the oil filter. The oil pressure differential is equal to the difference between the oil pressure transducer reading and the evaporator pressure transducer reading. It is read directly from the Local Interface Device (LID)
default screen.
Part of the oil flow to the compressor is directed to the
slide valve and is used for capacity control positioning. The
remaining oil flow is divided between the rotors and bearings. A specific quantity is sent to the rotors and injected at
the start of compression to seal the clearances between the
rotors. Another portion is sent to the bearings and used for
lubrication.
Oil leaves the compressor mixed with the compressed discharge refrigerant vapor. The mixture then enters the oil separator, where oil is removed from the refrigerant and collected
at the bottom to complete the cycle.
FRAME 1 AND 2 MACHINES — The oil and refrigerant
vapor mixture enters the oil separator through a nearly tangential nozzle, giving a rotational flow pattern. Oil is thrown
to the sides of the oil separator and runs down the walls to
a chamber in the bottom where it drains to the sump. A baffle
separates this chamber from the vortex flow to prevent reentrainment. Gas flows up through a vortex funnel to a removable coalescing element where the rest of the oil collects.
This oil runs down the element surface to a scavenge line
which is piped to the first closed lobe port.
FRAME 4 MACHINES — The oil and refrigerant vapor mixture is directed against the rear wall of the oil separator as
it enters the side of the oil separator. This action causes the
Table 1 — Oil Pressure Ramp-Up Rate
TIME
(SEC)
40
80
120
MINIMUM START-UP OIL PRESSURE REQUIREMENT
HCFC-22
HFC-134a
psi
kPa
psi
kPa
4
27.6
1.4
9.7
11
75.8
4
27.6
20
137.9
7
48.3
Oil Reclaim System — The oil reclaim system operates to return oil from the cooler back to the compressor.
FRAME 1 AND 2 MACHINES — The oil reclaim system
returns oil back to the compressor using discharge gas pressure to power an ejector. The oil and refrigerant mixture is
vacuumed from the top of the cooler liquid refrigerant level
and discharged into the compressor suction port.
FRAME 4 MACHINES — Frame 4 machines do not require an oil reclaim system.
Oil Loss Prevention — The suction pan is located on
top of the cooler, where oil collects during low-load operation. The cooler is designed so that when oil drains into the
cooler from the compressor during low loads, it will be reentrained with the suction gas flow.
8
9
Fig. 3 — Refrigerant Oil Flow Schematic (Frame 1 and 2 Machines)
LEGEND
HGBP — Hot Gas Bypass
Refrigerant Liquid Flow
Refrigerant Vapor Flow
Oil and Refrigerant Liquid Flow
Oil and Refrigerant Vapor Flow
Oil Flow
10
Fig. 4 — Refrigerant Oil Flow Schematic (Frame 4 Machines)
LEGEND
HGBP — Hot Gas Bypass
Refrigerant Liquid Flow
Refrigerant Vapor Flow
Oil and Refrigerant Vapor Flow
Oil Flow
Fig. 5 — Screw Compressor Principle
Fig. 7 — Slide Valve Position at Full Load
In addition, the PIC Controls minimize oil loss to the cooler
once the rotor inlet temperature sensor detects hot oil draining down the suction pipe.
If the rotor inlet temperature increases 4 F (2.2 C) on Frame
1 and 2 machines or 8 F (4.4 C) on Frame 4 machines above
the leaving chilled water temperature, the slide valve is proportionately moved in the load direction to increase suction
gas velocity. If the leaving chilled water temperature is then
brought 5 F (2.8 C) below the control point temperature, the
PIC will bring the machine into the recycle mode.
STARTING EQUIPMENT
The 23XL requires a motor starter to operate the hermetic
compressor motor and various auxiliary equipment. The starter
serves as the main field wiring interface for the contractor.
Two types of unit mounted starters are available from Carrier Corporation: solid-state and wye-delta. See Carrier Specification Z-375 for specific starter requirements. All starters
must meet these specifications in order to properly start and
satisfy mechanical safety requirements. Starters may also be
supplied as separate, free-standing units.
Inside the power panel are 3 separate circuit breakers. Circuit breaker CB1 is the compressor motor circuit breaker.
The disconnect switch on the starter front cover is connected
to this breaker.
Slide Valve Principle — Oil flow to the slide piston is
controlled by two solenoid valves. Each solenoid is operated
by load and unload signals from the PIC control.
To unload the compressor, the unload solenoid valve is
energized and the load solenoid valve is deenergized. This
conducts high pressure oil to the cylinder, retracting the operator shaft, and modulating the slide valve toward the open
position. See Fig. 6. The slide valve opening vents compressed gas back to the suction port on the compressor, retarding the start of the compression process.
To load the compressor, the unload solenoid valve is deenergized and the load solenoid valve is energized. This bleeds
oil from the cylinder to the suction pressure area within the
compressor housing. Forces resulting from the discharge-tosuction pressure differential are then allowed to push the slide
valve toward the closed (fully loaded) position. See Fig. 7.
When the slide valve is closed, the compressor pumps the
maximum gas flow.
Extension and retraction of the operator shaft position
the slide valve along the bottom of the rotors. The valve position controls the gas flow rate delivered by the
compressor.
The main circuit breaker (CB1) on the front of the starter
disconnects the main motor current only. Power is still
energized for the other circuits. Another circuit breaker
inside the starter must be turned off to disconnect power
to PIC controls and oil heater (Frame 1 and 2
machines).
Circuit breaker CB2 supplies power to the control and oil
heater power (Frame 1 and 2 machines) supply circuit breaker
and portions of the starter controls.
All starters are shipped with a Carrier control module called
the Starter Management Module (SMM). This module controls and monitors all aspects of the starter. See the Controls
section on page 13 for additional SMM information. All starter
replacement parts are supplied by the starter
manufacturer.
Unit Mounted Solid-State Starter (Optional) —
The 23XL may be equipped with a solid-state, reducedvoltage starter (Fig. 5, 8A, 8B, and 9). This starter provides
on-off control of the compressor motor as its primary function. Using this type of starter reduces the peak starting torque,
reduces the motor inrush current, and decreases mechanical
shock. This is summed up by the phrase ‘‘soft starting.’’
Two varieties of solid-state starters are available as 23XL
options (Carrier supplied and installed). When a solid-state
starter is purchased with the 23XL, either a Benshaw, Inc. or
a Cutler-Hammert solid-state starter will be shipped with
the unit. See Fig. 8A and 8B. The manufacturer’s name will
be located inside the starter access door. See Fig. 9.
Fig. 6 — Slide Valve Position at Unload
11
These starters operate by reducing the starting voltage. The
starting torque of a motor at full voltage is typically 125%
to 175% of the running torque. When the voltage and the
current are reduced at start-up, the starting torque is reduced
as well. The objective is to reduce the starting voltage to just
the voltage necessary to develop the torque required to get
the motor moving. The voltage and current are then ramped
up in the desired period of time. The voltage is reduced through
the use of silicon controlled rectifiers (SCR). Once full voltage is reached, a bypass contactor is energized to bypass the
SCRs.
When voltage is supplied to the solid-state circuitry, the
heat sinks within the starter are at line voltage. Do not
touch heat sinks while voltage is present or serious injury will result.
There are a number of LEDs (light-emitting diodes) that
are useful in troubleshooting and starter check-out on
the Benshaw, Inc. solid-state starters. These are used to
indicate:
• voltage to the SCRs
• SCR control voltage
• power indication
• proper phasing for rotation
• start circuit energized
• overtemperature
• ground fault
• current unbalance
• run state
These LEDs (on Benshaw, Inc. solid-state starters) are further explained in the Check Starter and Troubleshooting Guide
sections, pages 49 and 68.
1
2
3
4
5
6
7
8
9
10
11
12
13
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—
—
—
—
—
—
—
—
—
—
1
2
3
4
5
6
7
8
9
—
—
—
—
—
—
—
—
—
10
11
12
13
—
—
—
—
Field Wiring Terminal Strips (TB2 and TB3)
Circuit Breakers 1, 2, 3, 4
Overload Calibration Unit
Solid-State Controller
SCR LED (One of 6)
Starter Fault and Run LEDs
Voltmeter (Optional)
Ammeter (Optional)
Silicon Controlled Rectifier
(SCR) (One of 6)
Voltage LED
Starter Management Module (SMM)
Pilot Relays (PR1 to PR6)
Starter Access Door
Fig. 8B — Benshaw, Inc. Solid-State Starter,
Internal View
Pilot Relays (PR1 to PR5)
Circuit Breaker 4
Silicon Controlled Rectifier (SCR) (One of 6) (Hidden)
Circuit Breaker 3
Solid-State Controller
Circuit Breaker 2
Circuit Breaker 1
Ammeter (Optional)
Voltmeter (Optional)
Overload Calibration Unit
Field Wiring Terminal Strips (TB2 and TB3) (Hidden)
Starter Management Module (SMM)
Starter Access Door
Fig. 9 — Typical Solid-State Starter, Front View
Unit Mounted Wye-Delta Starter (Optional) —
The 23XL machine may be equipped with a wye-delta starter
mounted on the unit. This starter is intended for use with
low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings
into a wye configuration. This occurs during the starting period when the motor is accelerating up to speed. After a time
delay, once the motor is up to speed, the starter automatically connects the phase windings into a delta configuration.
Fig. 8A — Cutler-HammerT Solid-State Starter,
Internal View
12
CONTROLS
Controls Definitions
PIC System Components — The Product Integrated
Control (PIC) is the machine’s control system. The PIC controls the operation of the machine by monitoring all operating conditions. The PIC can also diagnose a problem with
the machine. It promptly positions the slide valve to maintain leaving chilled water temperature. It can interface with
auxiliary equipment such as pumps and cooling tower fans
so that they turn on only when required. The PIC continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater (Frame 1 and 2 machines) (while the compressor is off) and the hot gas bypass
valve, (if installed).
The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PICequipped chillers and other CCN devices.
The PIC system consists of 3 modules housed inside three
major components. The component names and the control
voltage contained in each component include the following
(also see Table 2 and Fig. 11-16):
• control center
— all extra low-voltage wiring (24V or less)
• power panel
— 230 or 115 control voltage (per job requirement)
• starter cabinet
— machine power wiring (per job requirement)
ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantifies values between
operating limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to
the temperature, detecting many values.)
DIGITAL SIGNAL — A digital (discrete) signal is a twoposition representation of the value of a monitored source.
(Example: A switch is a digital device because it only
indicates whether a value is above or below a set point or
boundary by generating an on/off, high/low, or open/closed
signal.)
VOLATILE MEMORY — Volatile memory is memory incapable of being sustained if power is lost and subsequently
restored.
The memory of the PSIO and LID modules are volatile.
If the battery in a module is removed or damaged, all
programming will be lost.
General Controls Overview — The 23XL hermetic
screw liquid chiller contains a microprocessor-based control
center that monitors and controls all operations of the machine. The microprocessor control system matches the cooling capacity of the machine to the cooling load while providing state-of-the-art machine protection. The system controls
cooling capacity within the set point plus the deadband by
sensing the leaving chilled water or brine temperature and
regulating the slide valve via a mechanically linked, hydraulically actuated piston. Movement of the slide valve alters
the point during rotor travel at which compression begins
and reduces the effective length of the compression cavities.
This permits internal gas recirculation and reduces suction
volume. Thus, smooth, stepless capacity regulation is provided without changing suction pressure. Closing of the slide
valve increases capacity. Opening of the slide valve decreases capacity. See Fig. 10. Machine protection is provided by the processor, which monitors the digital and analog inputs and executes capacity overrides or safety shutdowns,
if required.
Table 2 — Major PIC Components and Locations*
PIC COMPONENT
Processor Sensor Input/Output Module
(PSIO)
Starter Management Module (SMM)
Local Interface Device (LID)
6-Pack Relay Board
8-Input Module (Optional)
Oil Heater Contactor (1C)
(Frame 1 and 2 Machines)
VI Contactor Relay (2C) (Optional)
Hot Gas Bypass Relay (3C) (Optional)
Control Transformers (T1-T4)
Control and Oil Heater Voltage
Selector (S1)
Temperature Sensors
Pressure Transducers
LOCATION
Control Center
Starter Cabinet
Control Center
Control Center
Control Center
Power Panel
Power Panel
Power Panel
Power Panel
Power Panel
See Fig. 11,12,
and 13
See Fig. 11,12,
and 14
VI — Volumetric Index
*See Fig. 8A, 8B, 9, 11, 12, 13, 14, 15, and 16.
PROCESSOR SENSOR INPUT/OUTPUT MODULE (PSIO)
— The PSIO is the brain of the PIC. This module contains
all of the operating software needed to control the machine.
The 23XL uses 3 pressure transducers and 8 thermistors to
sense pressures and temperatures. These are connected to the
PSIO module. The PSIO also provides outputs to the: slide
valve assembly; oil heater (Frame 1 and 2 machines); hot
gas bypass (optional); motor cooling solenoid; and space alarm
contact. The PSIO communicates with the LID, the SMM,
and the optional 8-input modules for user interface and starter
management.
STARTER MANAGEMENT MODULE (SMM) — This module is located within the starter cabinet. This module implements PSIO commands for starter functions such as start/
stop of the compressor, start/stop of the condenser and chilled
water pumps, start/stop of the tower fan, spare alarm contacts, and the shunt trip. The SMM monitors starter inputs
such as flow switches, line voltage, remote start contact, spare
safety, compressor high discharge pressure, motor current signal, starter 1M and run contacts, and kW transducer input
(optional). The SMM contains logic to safely shut down the
machine if communications with the PSIO are lost.
Fig. 10 — Slide-Valve Capacity Control
13
*Some 23XL machines will have both an oil temperature sensor and an oil level safety switch (two separate components).
Fig. 11 — 23XL Control and Sensor Locations (Frame 1 and 2 Machines)
14
*Some 23XL machines will have both an oil temperature sensor and an oil level safety switch (two separate components).
Fig. 12 — 23XL Control and Sensor Locations (Frame 4 Machines)
15
Fig. 13 — Control Sensors (Temperature)
Fig. 14 — Control Sensors
(Pressure Transducer, Typical)
LEGEND
4 — 5-Volt Transducer
Power Supply
2 — PSIO
5 — 6-Pack Relay Board
3 — 8-Input Module (Optional) 6 — Circuit Breakers (4)
(one of two available)
1 — LID
Fig. 15 — Control Panel (Front View),
With Options Module
LEGEND
1 — T2 — 24 vac Power Transformer to: HGBP
3
(Optional), oil heater (Frame 1 and 2 Machines),
4
relays, oil level switch, oil solenoid valve,
5
and capacity control solenoids
6
2 — T4 — 21 vac 8-Input Modules Transformer (Optional)
—
—
—
—
T1 — 21 vac Control Center Transformer
Optional HGBP Relay Connection
Factory Terminal Connections
T3 — 24 vac VI Solenoid Transformer (Optional)
NOTE: Oil heater contactor is only applicable to Frame 1 and 2 Machines.
Fig. 16 — Power Panel With Options
16
• Local Operation — By pressing the LOCAL softkey, the
PIC is now in the LOCAL operation mode, and the control
will accept modification to programming from the LID only.
The PIC will use the Local time schedule to determine machine start and stop times.
• CCN Operation — By pressing the CCN softkey, the
PIC is now in the CCN operation mode. The control will
accept modifications from any CCN interface or module
with the proper authority, as well as the LID. The PIC will
use the CCN time schedule to determine start and stop times.
ALARMS AND ALERTS — Alarm (*) and alert (!) status
are indicated on the Status tables. An alarm (*) will shut down
the compressor. An alert (!) notifies the operator that an unusual condition has occurred. The machine will continue to
operate when an alert is shown.
Alarms are indicated when the control center alarm light
(!) flashes on the LID panel. The alarm message is viewed
on the default screen and an additional message and troubleshooting information are sent to the alarm history screen.
When an alarm is detected, the LID default screen will
freeze (stop updating) at the time of alarm. The freeze enables the operator to view the machine conditions at the time
of alarm. The Status tables will show the updated information. Once all alarms have been cleared (by pressing the
RESET softkey), the default LID screen will return to normal operation.
LOCAL INTERFACE DEVICE (LID) — The LID is mounted
in the control center and allows the operator to interface with
the PSIO or other CCN devices. It is the input center for all
local machine set points, schedules, set up functions, and options. The LID has a stop button, an alarm light, 4 buttons
for logic inputs, and a display. The function of the 4 buttons
or ‘‘softkeys’’ are menu driven and are shown on the display
directly above the keys.
6-PACK RELAY BOARD — This device is located in the
control center and a cluster of 6 pilot relays, energized by
the PSIO, for the oil heater (Frame 1 and 2 machines), spare
alarm, optional hot gas bypass relay, and motor cooling
solenoids.
8-INPUT MODULES (Optional) — One optional module is
factory installed in the control center when ordered. There
can be up to 2 of these modules per chiller with 8 spare inputs each. They are used whenever chilled water reset, demand reset, common supply/return sensors, or reading a spare
sensor is required. The sensors or 4 to 20 mA signals are
field installed.
The spare temperature sensors must have the same
temperature/resistance curve as the other temperature sensors on this unit. These sensors are 5,000 ohm at 75 F
(25 C).
OIL HEATER CONTACTOR RELAY (1C) (Frame 1 and 2
Only) — This contactor relay is located in the power panel
and operates the heater at either 115 or 230 v. It is controlled
by the PIC to maintain oil temperature during machine
shutdown.
HOT GAS BYPASS RELAY (3C) (Optional) — This relay
contactor located in the power panel, controls the opening of
the hot gas bypass solenoid valve. The PIC energizes the
relay during low load, low compression ratio conditions.
CONTROL TRANSFORMERS (T1-T4) — These transformers convert incoming control voltage to either 21-vac
supply power for the PSIO module, LID, and options module, or 24-vac power supply for the power panel, control relays, 6-pack relay board, oil solenoid valve, oil level switch,
slide valve solenoids, and VI (optional) actuator solenoids.
CONTROLAND OIL HEATER VOLTAGE SELECTOR (S1)
— It is possible to utilize either 115 v or 230 v
incoming control power in the power panel. The switch is
set to the voltage used at the jobsite.
VARIABLE CONTACTOR RELAY (2C) (Optional) — This
contactor relay is located in the power panel. The PIC energizes the relay to move the slide valve stop to the high VI
position based on system compression ratio.
TEMPERATURE SENSORS — The temperature sensors sense
the temperature of oil, refrigerant, water, and the motor throughout the machine.
PRESSURE TRANSDUCERS — The pressure transducers
sense the pressure of oil and refrigerant throughout the
machine.
Fig. 17 — LID Default Screen
LID Operation and Menus (Fig. 17 - 23)
GENERAL
• The LID display will automatically revert to the default
screen after 15 minutes if no softkey activity takes place
and if the machine is not in the PUMPDOWN mode
(Fig. 17).
• When not showing the default screen, the upper righthand corner of the LID always displays the name of the
screen that you have entered (Fig. 18).
• The LID may be configured in English or SI units through
the LID configuration screen.
Fig. 18 — LID Service Screen
17
MENU STRUCTURE — To perform any of the operations
described below, the PIC must be powered up and have successfully completed its self test.
TO VIEW POINT STATUS (Fig. 19) — Point status is the
actual value of all of the temperatures, pressures, relays, and
actuators sensed and controlled by the PIC.
1. On the Menu screen, press STATUS to view the list of
Point Status tables.
• Press NEXT to scroll the cursor bar down in order to
highlight a point or to view more points below the current
screen.
2. Press NEXT or PREVIOUS to highlight the desired
status table. The list of tables includes:
• Status01 — Status of control points and sensors
• Status02 — Status of relays and contacts
• Status03 — Status of both optional 8-input modules and
sensors
• Press PREVIOUS to scroll the cursor bar up in order to
highlight a point or to view points above the current screen.
3. Press SELECT to view the desired Point Status table.
• Press SELECT to view the next screen level (highlighted with the cursor bar) or to override (if allowable)
the highlighted point value.
4. On the Point Status screen press NEXT or
PREVIOUS until desired point is displayed on the screen.
• Press INCREASE or DECREASE to change the highlighted point value.
• Press ENTER to leave the selected decision or field and
save changes.
• Press QUIT to leave the selected decision or field without saving any changes.
Fig. 19 — Example of Point Status Screen
(Status01)
OVERRIDE OPERATIONS
To Override a Value or Status
1. On the Point Status table press NEXT
PREVIOUS to highlight the desired point.
or
• Press EXIT to return to the previous screen level.
2. Press SELECT to select the highlighted point. Then:
18
19
Fig. 20 — 23XL Menu Structure
20
Fig. 21 — 23XL Service Menu Structure
For Discrete Points — Press START or STOP to select the desired state.
For Analog Points — Press INCREASE
DECREASE to select the desired value.
3. Press SELECT to access and view the time schedule.
4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change.
or
5. Press SELECT to access the highlighted period or
override.
3. Press ENTER to register new value.
NOTE: When overriding or changing metric values, it is necessary to hold the softkey down for a few seconds in order
to see a value change, especially on kilopascal values.
To Remove an Override
1. On the Point Status table press NEXT or
PREVIOUS to highlight the desired point.
6. a. Press INCREASE or DECREASE to change the
time values. Override values are in one-hour increments, up to 4 hours.
b. Press ENABLE to select days in the day-of-week
fields. Press DISABLE to eliminate days from the
period.
2. Press SELECT to access the highlighted point.
7. Press ENTER to register the values and to move
horizontally (left to right) within a period.
3. Press RELEASE to remove the override and return the
point to the PIC’s automatic control.
8. Press EXIT to leave the period or override.
Override Indication — An override value is indicated by
‘‘SUPVSR’’, ‘‘SERVC’’, or ‘‘BEST’’ flashing next to the point
value on the Status table.
TIME SCHEDULE OPERATION (Fig. 22)
1. On the Menu screen, press SCHEDULE .
2. Press NEXT or PREVIOUS to highlight the desired schedule. When using PSIO Software Version 8 or
12, OCCPC01S is the LOCAL Time Schedule and
OCCPC02S is the CCN Time Schedule. When using PSIO
Software Version 13 and higher, OCCPC01S is the LOCAL Time Schedule, OCCPC02S is the Ice Build Time
Schedule, and OCCPC03S is the CCN Time Schedule
(the actual CCN Occupied Schedule number is defined
on the Config table). The schedule number can change
to any value from 03 to 99.
Fig. 22 — Example of Time Schedule
Operation Screen
21
9. Either return to Step 4 to select another period or over
ride or press EXIT again to leave the current time
schedule screen and save the changes.
10. Holiday Designation may be found in the Service Operation section, page 36. You must assign the month, day,
and duration for the holiday. The Broadcast function in
the Brodefs table also must be enabled for holiday periods to function.
TO VIEW AND CHANGE SET POINTS (Fig. 23)
1. To view the Set Point table, at the Menu screen press
SETPOINT .
Fig. 23 — Example of Set Point Screen
PIC System Functions
NOTE: Throughout this manual, words printed in capital letters and italics are values that may be viewed on the LID.
Operating values for HFC-134a refrigerant, when applicable, follow the HCFC-22 value and are enclosed in brackets. See Table 3 for examples of LID screens. Point names
are listed in the Description column. An overview of LID
operation and menus is given in Fig. 17-23.
CAPACITY CONTROL — The PIC controls the machine
capacity by modulating the slide valve in response to chilled
water temperature changes away from the CONTROL POINT.
The CONTROL POINT may be changed by a CCN network
device, or is determined by the PIC adding any active chilled
water reset to the chilled water SETPOINT. The PIC uses the
PROPORTIONAL INC (Increase) BAND, PROPORTIONAL
DEC (Decrease) BAND, and the PROPORTIONAL ECW (Entering Chilled Water) GAIN to determine how fast or slow
to respond. CONTROL POINT may be viewed/overridden
on the Status table Status01 selection.
ENTERING CHILLED WATER CONTROL — If this option is enabled, the PIC uses ENTERING CHILLED WATER
temperature to modulate the slide valve instead of LEAVING CHILLED WATER temperature. ENTERING CHILLED
WATER control option may be viewed/modified on the Equipment Configuration table Config selection.
DEADBAND — This is the tolerance on the chilled water/
brine temperature CONTROL POINT. If the water temperature goes outside of the DEADBAND, the PIC opens or closes
the slide valve in response until it is within tolerance. The
PIC may be configured with a 0.5 to 2° F (0.3 to 1.1° C)
DEADBAND. DEADBAND may be viewed or modified on
the Equipment Service table, Service1 table.
For example, a 1 F (0.6 C) deadband setting controls the
water temperature within ±0.5° F (0.3° C) of the control point.
This may cause frequent slide valve movement if the chilled
water load fluctuates frequently. A setting of 1 F (0.6 C) is
the default setting.
PROPORTIONAL BANDS AND GAIN — Proportional band
is the rate at which the slide valve position is corrected in
proportion to how far the CHILLED WATER/BRINE temperature is from the control point. Proportional gain determines how quickly the slide valve reacts to how quickly the
temperature is moving from CONTROL POINT.
2. There are 4 set points on this table: Base Demand Limit;
LCW Set Point (leaving chilled water set point); ECW
Set Point (entering chilled water set point); and ICE BUILD
Set Point (PSIO Software Version 13 or higher). Only one
of the chilled water set points can be active at any time.
The type of set point and the ICE BUILD CONFIGURATION are activated in the Service menu.
3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
4. Press SELECT to modify the highlighted set point.
5. Press INCREASE or DECREASE to change the selected set point value.
6. Press ENTER to save the changes and return to the
previous screen.
SERVICE OPERATION — To view the menu-driven programs available for Service Operation, see Service Operation section, page 36. For examples of LID display screens,
see Table 3.
22
Each schedule consists of from one to 8 occupied/unoccupied
time periods, set by the operator. These time periods can be
enabled to be in effect (or not in effect) on each day of the
week and for holidays. The day begins with 0000 hours and
ends with 2400 hours. The machine is in OCCUPIED mode
unless an unoccupied time period is in effect.
Figure 22 shows a typical office building time schedule,
with a 3-hour, off-peak cool down period from midnight to
3 a.m., following a weekend shutdown. Example: Holiday
periods are unoccupied 24 hours per day. The building operates Monday through Friday, 7:00 a.m. to 6:00 p.m., with
a Saturday schedule of 6:00 a.m. to 1:00 p.m., and includes
the Monday midnight to 3:00 a.m. weekend cool-down
schedule.
NOTE: This schedule is for illustration only and is not intended to be a recommended schedule for chiller operation.
The proportional band can be viewed/modified on the LID.
There are two response modes, one for temperature response above the control point, the other for response below
the control point.
The first type is called PROPORTIONAL INC BAND and
it can slow or quicken slide valve response to chilled water/
brine temperature above DEADBAND. The PROPORTIONAL INC BAND can be adjusted from a setting of 5 to
10; the default setting is 6.5. PROPORTIONAL DEC BAND
can slow or quicken slide valve response to chilled water
temperature below control point plus deadband. It can be adjusted on the LID from a setting of 5 to 10, and the default
setting is 6.0. Increasing either of these settings will cause
the slide valve to respond slower than a lower setting.
The PROPORTIONAL ECW GAIN can be adjusted at the LID
display for values of 1, 2, or 3, with a default setting of 2.
Increase this setting to increase slide valve response to a change
in entering cooler water temperature. The proportional bands
and gain may be viewed/modified on the Equipment Service
table, Service3 selection.
DEMAND LIMITING — The PIC will respond to the ACTIVE DEMAND LIMIT set point by limiting the closing of
the slide valve. It will compare the set point to either COMPRESSOR MOTOR LOAD or COMPRESSOR MOTOR
CURRENT (percentage), depending on how the control is
configured for the DEMAND LIMIT SOURCE which is accessed on the SERVICE1 table. The default setting is current limiting.
Safety Controls — The PIC monitors all safety control
inputs, and, if required, shuts down the machine, or limits
the slide valve to protect it from possible damage from any
of the following conditions:
• high motor winding temperature
• high discharge temperature
• low discharge superheat temperature (Frame 1 and 2
machines)
• low oil pressure
• high oil filter pressure drop
• low oil level
• low cooler refrigerant temperature
• condenser high pressure
• inadequate water/brine cooler and condenser flow
• high, low, or loss of voltage
• excessive motor acceleration time
• excessive starter transition time
• lack of motor current signal
• excessive motor amps
• motor power supply phase reversal
• temperature sensor and transducer faults
Starter faults or optional protective devices within the starter
can shut down the machine. These devices are dependent on
what has been purchased as options.
MACHINE TIMERS — The PIC maintains 2 runtime clocks,
known as COMPRESSOR ONTIME and SERVICE ONTIME. COMPRESSOR ONTIME indicates the total lifetime
compressor run hours. This timer can register up to 500,000
hours before the clock turns back to zero. The SERVICE ONTIME is a resettable timer that can be used to indicate the
hours since the last service visit or any other reason. The
time can be changed through the LID to whatever value is
desired. This timer can register up to 32,767 hours before it
rolls over to zero.
The chiller also maintains a 15-minute start-to-start timer
and a 1-minute stop-to-start timer (PSIO Software Version
13 and higher). A 3-minute stop-to-start timer is on PSIO
Version 12 and lower. These timers limit how soon the machine can be started. See the Start-Up/Shutdown/Recycle Sequence section on page 37 for operational information.
If compressor motor overload occurs, check the motor
for grounded or open phases before attempting a
restart.
OCCUPANCY SCHEDULE — This schedule determines when
the chiller is either occupied or unoccupied. See Fig. 20
and 21.
PSIO Software Version 12 and Lower — Whenever the chiller
is in the LOCAL mode, the machine will start when Occupancy Schedule 01 indicates occupied. When in CCN mode,
Occupancy Schedule 02 is used. The machine will shut down
when the schedule goes to UNOCCUPIED. The schedule
can be set up to follow the building schedule or to be 100%
OCCUPIED if the operator wishes the machine to start whenever the PIC is in LOCAL mode. The schedule also can be
bypassed by forcing the Start/Stop command on the PIC status screen to start. The schedule also can be overridden to
keep the unit in an OCCUPIED mode for up to 4 hours, on
a one-time basis.
PSIO Software Version 13 and Higher — The Local Time
Schedule is Schedule 01. The Ice Build Time Schedule is
Schedule 02 and the CCN Default Time Schedule is Schedule 03. The CCN schedule number is defined on the Config
table in the Equipment Configuration table on page 25. The
schedule number can change to any value from 03 to 99. If
this schedule number is changed on the Config table, the operator must use the Attach to Network Device table
to upload the new number into the schedule screen. See
Fig. 21.
If the controller initiates a safety shutdown, it displays the
fault on the LID display with a primary and a secondary message. It also energizes an alarm relay in the starter and blinks
the alarm light on the control center. The alarm is stored in
memory and can be viewed in the PIC alarm table along with
a message for troubleshooting.
To give more specific operating condition warning, the operator also can define alert limits on various monitored inputs. Safety contact and alert limits are defined in Table 4.
Alarm and alert messages are listed in the Troubleshooting
Guide section, page 68.
SHUNT TRIP — The shunt trip function of the PIC is a safety
trip. The shunt trip is wired from an output on the SMM to
the motor circuit breaker. If the PIC tries to shutdown the
compressor through normal shutdown procedure but is unsuccessful for 30 seconds, the shunt trip output is energized
and causes the circuit breaker to trip off. If ground fault protection has been applied to the starter, the ground fault trip
will also energize the shunt trip to trip the circuit breaker.
23
Table 3 — LID Screens
3. Data appearing in the ‘‘Reference Points Names’’ column is used
for CCN operations only.
4. All options associated with ICE BUILD, LEAD/LAG, CCN OCCUPANCY CONFIGURATION, and SOFT STOPPING are only available in PSIO Software Version 13 and higher.
5. All values shall be variables available for read operation from
a CCN Network. Descriptions designated (*) shall support write
operations for BEST programming language, data transfer, and
overriding.
IMPORTANT: The following notes apply to all Table 3
examples:
1. Only 12 lines of information will appear on the LID screen at any
given time. Press NEXT or PREVIOUS to highlight a point, or
to view points below or above the current screen.
2. The LID may be configured in English or Metric units, as required,
through the LID configuration screen.
EXAMPLE 1 — STATUS01 DISPLAY SCREEN
To access this display from the LID default screen:
3. Press SELECT .
1. Press MENU .
2. Press STATUS (STATUS01 will be highlighted).
DESCRIPTION
Control Mode
Run Status
Occupied ?
Alarm State
*Chiller Start/Stop
Base Demand Limit
*Active Demand Limit
Compressor Motor Load
Current
Amps
*Manual Slide Valve Count
Actual Slide Valve State
Water/Brine: Setpoint
*
Control Point
Entering Chilled Water
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Evaporator Refrig Temp
*Evaporator Pressure
Condenser Refrig Temp
*Condenser Pressure
Discharge Temperature
Rotor Inlet Temp
Motor Winding Temp
Oil Sump Temperature
*Oil Pressure Transducer
Oil Pressure
Line Voltage: Percent
Actual
*Remote Contacts Input
Total Compressor Starts
Starts in 12 Hours
Compressor Ontime
*Service Ontime
*Compressor Motor kW
RANGE
UNITS
Reset, Off, Local, CCN
Timeout, Recycle, Startup, Ramping, Running, Demand,
Override, Shutdown, Abnormal, Pumpdown
No/Yes
NORMAL/ALARM
STOP/START
40-100
%
40-100
%
0-999
%
0-999
%
0-999
AMPS
−20-20
Increase, Hold, Decrease
20-120 (−6.7-48.9)
DEG F (DEG C)
20-120 (−6.7-48.9)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
6.7-420 (−46-2896)
PSI (kPa)
−40-245 (−40-118)
DEG F (DEG C)
6.7-420 (−46-2896)
PSI (kPa)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
−40-245 (−40-118)
DEG F (DEG C)
6.7-420 (−46-2896)
PSI (kPa)
6.7-420 (−46-2896)
PSID (kPad)
0-999
%
0-9999
VOLTS
OFF/ON
0-65535
0-8
0-500000
HOURS
0-32767
HOURS
0-9999
kW
REFERENCE POINT NAME
MODE
STATUS
OCC
ALM
CHIL S S
DLM
DEM LIM
CA L
CA P
CA A
SV MAN
SV ACT
SP
LCW STPT
ECW
LCW
ECDW
LCDW
ERT
ERP
CRT
CRP
CMPD
RTRIN
MTRW
OILT
OILP
OILPD
V P
V A
REMCON
c starts
STARTS
c hrs
s hrs
CKW A
EXAMPLE 2 — STATUS02 DISPLAY SCREEN
To access this display from the LID default screen:
3. Scroll down to highlight STATUS02.
1. Press MENU .
4. Press SELECT .
2. Press STATUS .
DESCRIPTION
Slide Valve Increase
Slide Valve Decrease
Hot Gas Bypass Relay
*Chilled Water Pump
Chilled Water Flow
*Condenser Water Pump
Condenser Water Flow
Compressor Start Relay
Compressor Start Contact
Compressor Run Contact
Starter Fault Contact
Pressure Trip Contact
Single Cycle Dropout
Variable Inlet Relay
Oil Heater Relay
Oil Safety Sensor
*Tower Fan Relay
Compr Shunt Trip Relay
Alarm Relay
Spare Prot Limit Input
POINT TYPE
Input
Output
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
24
UNITS
OFF/ON
OFF/ON
OFF/ON
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
OPEN/CLOSED
OPEN/CLOSED
OPEN/CLOSED
OPEN/CLOSED
NORMAL/ALARM
OFF/ON
OFF/ON
OPEN/CLOSED
OFF/ON
OFF/ON
NORMAL/ALARM
NORMAL/ALARM
REFERENCE POINT NAME
SV INC
SV DEC
HGBR
CHWP
EVFL
CDP
CDFL
CMPR
1CR AUX
RUN AUX
STR FLT
PRS TRIP
V1 CYCLE
VIR
OILH
OILSS
TFR
TRIPR
ALM
SPR PL
EXAMPLE 3 — STATUS03 DISPLAY SCREEN
3. Scroll down to highlight STATUS03.
To access this display from the LID default screen:
1. Press MENU .
4. Press SELECT .
2. Press STATUS .
DESCRIPTION
RANGE
OPTIONS BOARD 1
*Demand Limit 4-20 mA
*Temp Reset 4-20 mA
*Common CHWS Sensor
*Common CHWR Sensor
*Remote Reset Sensor
*Temp Sensor — Spare 1
*Temp Sensor — Spare 2
*Temp Sensor — Spare 3
OPTIONS BOARD 2
*4-20 mA — Spare 1
*4-20 mA — Spare 2
*Temp Sensor — Spare 4
*Temp Sensor — Spare 5
*Temp Sensor — Spare 6
*Temp Sensor — Spare 7
*Temp Sensor — Spare 8
*Temp Sensor — Spare 9
4-20
4-20
−40-245
−40-245
−40-245
−40-245
−40-245
−40-245
4-20
4-20
−40-245
−40-245
−40-245
−40-245
−40-245
−40-245
REFERENCE POINT NAME
(ALARM HISTORY)
UNITS
(−40-118)
(−40-118)
(−40-118)
(−40-118)
(−40-118)
(−40-118)
MA
MA
DEG
DEG
DEG
DEG
DEG
DEG
(−40-118)
(−40-118)
(−40-118)
(−40-118)
(−40-118)
(−40-118)
MA
MA
DEG
DEG
DEG
DEG
DEG
DEG
F
F
F
F
F
F
F
F
F
F
F
F
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
C)
C)
C)
C)
C)
C)
DEM OPT
RES OPT
CHWS
CHWR
R RESET
SPARE1
SPARE2
SPARE3
C)
C)
C)
C)
C)
C)
SPARE1
SPARE2
SPARE4
SPARE5
SPARE6
SPARE7
SPARE8
SPARE9
M
M
EXAMPLE 4 — SETPOINT DISPLAY SCREEN
To access this display from the LID default screen:
1. Press
MENU
.
2. Press SETPOINT .
DESCRIPTION
Base Demand Limit
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
CONFIGURABLE RANGE
40-100
15-120 (−9.44-48.9)
20-120 (−6.7-15.6)
20-60 (−6.7-15.6)
UNITS
%
DEG F (DEG C)
DEG F (DEG C)
DEG F (DEG C)
REFERENCE POINT NAME
DLM
sp LCW SP
ECW SP
ice SP
DEFAULT VALUE
100
50.0 (10.0)
60.0 (15.6)
40.0 (4.4)
EXAMPLE 5 — CONFIGURATION (CONFIG) DISPLAY SCREEN
To access this display from the LID default screen:
1. Press MENU .
4. Press SELECT .
5. Scroll down to highlight CONFIG.
6. Press SELECT .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION.
DESCRIPTION
RESET TYPE 1
Degrees Reset at 20 mA
RESET TYPE 2
Remote Temp (No Reset)
Remote Temp (Full Reset)
Degrees Reset
RESET TYPE 3
CHW Delta T (No Reset)
CHW Delta T (Full Reset)
Degrees Reset
Select/Enable Reset Type
ECW Control Option
Demand Limit At 20 mA
20mA Demand Limit Option
Auto Restart Option
Remote Contacts Option
Temp Pulldown Deg/Min
Load Pulldown %/Min
Select Ramp Type:
Temp = 0, Load = 1
Loadshed Group Number
Loadshed Demand Delta
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle Option
CONFIGURABLE RANGE
UNITS
REFERENCE POINT NAME
−30-30 (−17-17)
DEG F (DEG C)
deg
−40-245 (−40-118)
−40-245 (−40-118)
−30-30 (−17-17)
DEG F (DEG C)
DEG F (DEG C)
DEG F (DEG C)
res rt1
res rt2
deg rt
85 (29)
65 (18)
10D (6D)
0-15 (0-8)
0-15 (0-8)
−30-30 (−17-17)
0-3
0/1
40-100
0/1
0/1
0/1
2-10
5-20
0/1
DEG F (DEG C)
DEG F (DEG C)
DEG F (DEG C)
restd 1
restd 2
deg chw
res sel
ecw opt
dem 20mA
dem sel
astart
r contact
tmp ramp
kw ramp
ramp opt
10D (6D)
0D (0D)
5D (3D)
0
0
40
0
0
0
3
10
1
DSABLE/ENABLE
%
DS/ENABLE
DS/ENABLE
DS/ENABLE
20mA
DEFAULT VALUE
10D)(6D))
0-99
0-60
0-120
%
MIN
ldsgrp
ldsdelta
maxldstm
0
20
60
3-99
0/1
0/1
0-2
DS/ENABLE
DS/ENABLE
OCCpcxxe
OCCbrcst
ibopt
ibterm
3
0
DISABLE
0
0/1
DS/ENABLE
ibrecyc
DISABLE
NOTE: D = delta degrees
25
Table 3 — LID Screens (cont)
EXAMPLE 6 — LEAD/LAG CONFIGURATION DISPLAY SCREEN
To access this display from the LID default screen:
4. Press SELECT .
1. Press
MENU
5. Scroll down to highlight LEAD/LAG.
.
6. Press SELECT .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION.
LEAD/LAG CONFIGURATION SCREEN
DESCRIPTION
LEAD/LAG SELECT
DISABLE=0, LEAD=1
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG Percent Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
STANDBY Chiller Option
STANDBY Percent Capacity
STANDBY Address
RANGE
0-3
0/1
0/1
25-75
1-236
2-60
2-60
0-30
0/1
25-75
1-236
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
REFERENCE POINT NAME
leadlag
DEFAULT VALUE
0-
loadbal
commsens
lag per
lag add
lagstart
lagstop
preflt
stndopt
stnd per
stnd add
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
NOTE: This screen is only selectable/readable on PSIO Software Version 13 and higher.
EXAMPLE 7 — SERVICE1 DISPLAY SCREEN
To access this display from the LID default screen:
1. Press
MENU
4. Press SELECT .
5. Scroll down to highlight SERVICE1.
6. Press SELECT .
.
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE.
DESCRIPTION
Motor Temp Override
Cond Press Override
Refrig Override Delta T
Chilled Medium
Brine Refrig Trippoint
Compr Discharge Alert
Water Flow Verify Time
Oil Filter Press Alert
Water/Brine Deadband
Recycle Restart Delta T
Hot Gas Bypass Option
HGBP Delta T1
HGBP Delta P1
Min. Load Points (T1/P1)
HGBP Delta T2
HGBP Delta P2
Full Load Points (T2/P2)
HGBP Deadband
Demand Limit Source
Select: Amps=0, Load=1
Amps Correction Factor
Motor Rated Load Amps
Motor Rated Line Voltage
Meter Rated Line kW
Line Frequency
Select: 0=60 Hz, 1=50 Hz
Compr Starter Type
Variable Inlet Option
Economizer Installed
Condenser Freeze Point
Soft Stop Amps Threshold
CONFIGURABLE RANGE
150-200 (66-93)
150-250 (1034-1724)
2-5 (1-3)
WATER/BRINE
8-40 (−13.3-4)
170-200 F (77-93 C)
0.5-5
15-30 (103-207)
0.5-2.0 (0.3-1.1)
2.0-10.0 (1.1-5.6)
0/1
0.5-15 (0.3-5.6)
50-200 (345-1379) [30-170 (207-1172)]
UNITS
DEG F (DEG C)
PSI (kPa)
DEG F (DEG C)
DEG F (DEG C)
DEG F (DEG C)
MIN
PSID (kPad)
DEG F (DEG C)
DEG F (DEG C)
DSABLE/ENABLE
DEG F (DEG C)
REFERENCE POINT NAME
mt over
cp over
ref over
medium
br trip
cd alert
wflow t
oil alrt
cw db
rcyc dt
hgbp
hgb dt1
hgb dp1
0.5-15 (0.3-5.6)
50-200 (345-1379) [30-170 (207-1172)]
DEG F (DEG C)
PSID (kPad)
hgb
hgb
1-3 (0.6- 1.7)
0/1
DEG F (DEG C)
PSID (kPad)
hgb dp
dem src
1 (0.6)
0
1-8
1-9999
1-9999
1-9999
0/1
AMPS
VOLTS
kW
HZ
corfact
a fs
v fs
kw fs
freq
3
200
460
600
0
0/1
0/1
0/1
−20-35 (−28.9-1.7)
40-100
REDUCE/FULL
DSABLE/ENABLE
NO/YES
DEG F (DEG C)
%
starter
vi opt
economiz
cdfreeze
softstop
REDUCE
DSABLE
NO
34 (1.1)
100
NOTES:
1. D = delta degrees.
2. Values in [ ] indicate HFC-134a values.
26
dt2
dp2
DEFAULT VALUE
200 (93)
230 (1586)
3D(1.7D)
WATER
33 (1)
200 (93)
5
30 (207)
1.0 (0.6)
5 (2.8)
0
2.5D (1.4D)
100 (690) [55 (379)]
10D (1D)
200 (1379) [125 (862)]
EXAMPLE 8 — SERVICE2 DISPLAY SCREEN
4. Press SELECT .
To access this display from the LID default screen:
1. Press
MENU
5. Scroll down to highlight SERVICE2.
.
6. Press SELECT .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE.
DESCRIPTION
OPTIONS BOARD 1
20 mA POWER CONFIGURATION
External = 0, Internal = 1
RESET 20 mA Power Source
DEMAND 20 mA Power Source
SPARE ALERT ENABLE
Disable = 0, Low = 1, High = 2
Temp = Alert Threshold
CHWS Temp Enable
CHWS Temp Alert
CHWR Temp Enable
CHWR Temp Alert
Reset Temp Enable
Reset Temp Alert
Spare Temp 1 Enable
Spare Temp 1 Alert
Spare Temp 2 Enable
Spare Temp 2 Alert
Spare Temp 3 Enable
Spare Temp 3 Alert
OPTIONS BOARD 2
20 mA POWER CONFIGURATION
External = 0, Internal = 1
SPARE1 20 mA Power Source
SPARE2 20 mA Power Source
SPARE ALERT ENABLE
Disable = 0, Low = 1, High = 2
Temp = Alert Threshold
Spare Temp 4 Enable
Spare Temp 4 Alert
Spare Temp 5 Enable
Spare Temp 5 Alert
Spare Temp 6 Enable
Spare Temp 6 Alert
Spare Temp 7 Enable
Spare Temp 7 Alert
Spare Temp 8 Enable
Spare Temp 8 Alert
Spare Temp 9 Enable
Spare Temp 9 Alert
CONFIGURABLE RANGE
0/1
0/1
UNITS
DISABLE/ENABLE
DISABLE/ENABLE
0-2
−40-245
0-2
−40-245
0-2
−40-245
0-2
−40-245
0-2
−40-245
0-2
−40-245
DEFAULT VALUE
res 20 mA
dem 20 mA
0
0
en
al
en
al
en
al
en
al
en
al
en
al
0
245
0
245
0
245
0
245
0
245
0
245
20 mA
20 mA
0
0
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
chws
chws
chwr
chwr
rres
rres
spr1
spr1
spr2
spr2
spr3
spr3
DISABLE/ENABLE
DISABLE/ENABLE
sp1
sp2
0/1
0/1
0-2
−40-245
0-2
−40-245
0-2
−40-245
0-2
−40-245
0-2
−40-245
0-2
−40-245
REFERENCE POINT NAME
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
(−40-118)
DEG F (DEG C)
spr4
spr4
spr5
spr5
spr6
spr6
spr7
spr7
spr8
spr8
spr9
spr9
0
245
0
245
0
245
0
245
0
245
0
245
en
al
en
al
en
al
en
al
en
al
en
al
(118)
(118)
(118)
(118)
(118)
(118)
(118)
(118)
(118)
(118)
(118)
(118)
NOTE: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp Alert’’ threshold for each point listed. If the ‘‘Enable’’ is set to 1, a
value above the ‘‘Temp Alert’’ threshold shall generate an alert message. If the ‘‘Enable’’ is set to 2, a value below the ‘‘Temp Alert’’ threshold shall generate an alert
message. If the ‘‘Enable’’ is set to 0, alert generation is disabled.
EXAMPLE 9 — SERVICE3 DISPLAY SCREEN
3. Scroll down to highlight EQUIPMENT SERVICE.
To access this display from the LID default screen:
1. Press
MENU
4. Press SELECT .
.
5. Scroll down to highlight SERVICE3.
2. Press SERVICE .
DESCRIPTION
Proportional Inc Band
Proportional Dec Band
Proportional ECW Gain
CONFIGURABLE RANGE
REFERENCE POINT NAME
5-10
5-10
1-3
gv
gv
gv
inc
de
ecw
DEFAULT VALUE
6.5
6.0
2.0
EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLAY SCREEN
3. Scroll down to highlight CONTROL ALGORITHM STATUS.
To access this display from the LID default screen:
1. Press
MENU
4. Press SELECT .
.
5. Scroll down to highlight MAINT01.
2. Press SERVICE .
DESCRIPTION
CAPACITY CONTROL
Control Point
Leaving Chilled Water
Entering Chilled Water
Control Point Error
ECW Delta T
ECW Reset
LCW Reset
Total Error + Resets
Manual Slide Valve Count
Actual Slide Valve State
Proportional Inc Band
Proportional Dec Band
Proportional ECW Gain
Water/Brine Deadband
CONFIGURABLE RANGE
0-120 (−17.8-48.9)
−40-245 (−40-118)
−40-245 (−40-118)
−99-99 (−55-55)
−99-99 (−55-55)
−99-99 (−55-55)
−99-99 (−55-55)
−99-99 (−55-55)
−20-20
Increase, Hold, Decrease
5-10
5-10
1-3
0.5-2 (0.3-1.1)
UNITS
DEG
DEG
DEG
DEG
DEG
DEG
DEG
DEG
F
F
F
F
F
F
F
F
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
(DEG
REFERENCE POINT NAME
C)
C)
C)
C)
C)
C)
C)
C)
DEG F (DEG C)
ctript
LCW
ECW
cperr
ecwdt
ecwres
lcwres
error
svt
SV
ACT
sv
inc
sv dec
sv ecw
cwdb
DEFAULT VALUE
6.5
6.0
2.0
1.0 (.5)
NOTE: Overriding shall not be supported on this maintenance screen. Active overriding shall show the associated point in alert (!). Only values with capital letter reference
point names shall be variables available for read operation.
27
Table 3 — LID Screens (cont)
EXAMPLE 11 — MAINTENANCE (MAINT02) DISPLAY SCREEN
To access this display from the LID default screen:
4. Press SELECT .
1. Press
MENU
5. Scroll down to highlight MAINT02.
.
6. Press SELECT .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS.
DESCRIPTION
OVERRIDE/ALERT STATUS
MOTOR WINDING TEMP
Override Threshold
CONDENSER PRESSURE
Override Threshold
EVAPORATOR REFRIG TEMP
Override Threshold
DISCHARGE TEMPERATURE
Alert Threshold
OIL FILTER PRESSURE DROP
Alert Threshold
CONFIGURABLE RANGE
−40-245 (−40-118)
150-200 (66-93)
0-420 (0-2896)
150-250 (1034-1724)
−40-245 (−40-118)
2-45 (1-7.2)
−40-245 (−40-118)
170-200 (76.7-93.3)
0-120 (0-827)
15-90 (103-621)
UNITS
REFERENCE POINT NAME
DEG F (DEG
DEG F (DEG
PSI (kPa)
PSI (kPa)
DEG F (DEG
DEG F (DEG
DEG F (DEG
DEG F (DEG
PSID (kPad)
PSID (kPad)
C)
C)
C)
C)
C)
C)
DEFAULT VALUE
MTRW
mt over
CRP
cp over
ERT
rt over
CMPD
cd alert
oil fltr
oil alrt
200 (93)
230 (1586)
35 (1.7)
200 (93.3)
30 (207)
NOTES:
1. Overriding shall not be supported on this maintenance screen. Active overrides shall show the associated point in alert (!). Only values with capital
letter reference point names shall be variables available for read operation.
2. Values in [ ] indicate HFC-134a values.
EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLAY SCREEN
To access this display from the LID default screen:
4. Press SELECT .
5. Scroll down to highlight MAINT03.
1. Press MENU .
6. Press SELECT .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS.
DESCRIPTION
Hot Gas Bypass ACTIVE ?
Active Delta P
Active Delta T
Calculated Delta T
STATUS
NO/YES
0-200 (0-1379)
0-200 (0-111)
0-200 (0-111)
UNITS
REFERENCE POINT NAME
PSI (kPa)
DEG F (DEG C)
DEG F (DEG C)
dp a
dt a
dt c
NOTE: Overriding shall not be supported on this maintenance screen. Active overrides shall show the associated point in alert (*). Only values with
capital letter reference point names shall be variables available for read operation.
EXAMPLE 13 — MAINTENANCE (MAINT04) DISPLAY SCREEN
To access this display from the LID default screen:
4. Press SELECT .
5. Scroll down to highlight MAINT04..
1. Press MENU .
6. Press SELECT .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS.
DESCRIPTION
LEAD/LAG: Configuration
Current Mode
Load Balance Option
LAG Start Time
LAG Stop Time
Prestart Fault Time
Pulldown: Delta T/Min
Satisfied?
LEAD CHILLER in Control
LAG CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
STANDBY CHILLER: Mode
Run Status
Start/Stop
Recovery Start Request
STATUS
UNITS
DISABLE,LEAD,LAG,STANDBY
DISABLE,LEAD,LAG,STANDBY
DISABLE/ENABLE
0-99
MIN
0-99
MIN
0-30
MIN
x.xx
D DEG
0/1
NO/YES
0/1
NO/YES
Reset,Off,Local,CCN
Timeout,Recycle,Startup,Ramping,Running
Demand,Override,Shutdown,Abnormal,Pumpdown
Stop,Start,Retain
No/Yes
Reset,Off,Local,CCN
Timeout,Recycle,Startup, Ramping,Running
Demand,Override,Shutdown,Abnormal,Pumpdown
Stop,Start,Retain
No/Yes
NOTES:
1. Overriding shall not be supported on this maintenance screen.
2. D =delta degrees.
28
REFERENCE POINT NAME
leadlag
llmode
loadbal
lagstart
lagstop
preflt
pull dt
pull sat
leadctrl
lagmode
lagstat
lag s s
lag rec
stdmode
stdstat
std
std
s s
rec
NOTE: Frame 4 units do not use an oil heater.
Ramp Loading Control — The ramp loading control
slows down the rate at which the compressor loads up. This
control can prevent the compressor from loading up during
the short period of time when the machine is started, and the
chilled water loop has to be brought down to normal design
conditions. This helps reduce electrical demand charges by
slowly bringing the chilled water to control point. However,
the total power draw during this period remains almost unchanged.
There are 2 methods of ramp loading with the PIC. Ramp
loading can be based on chilled water temperature or on motor load.
1. Temperature ramp loading limits the rate at which either
leaving chilled water or entering chilled water temperature decreases by an operator-configured rate.
2. Motor load ramp loading limits the rate at which the compressor motor current or compressor motor load increases by an operator-configured rate.
The TEMP (Temperature) PULLDOWN, LOAD PULL
DOWN, and SELECT RAMP TYPE may be viewed/modified
on the LID Equipment Configuration table Config selection
(see Table 3). Motor load is the default type.
All oil filter isolation valves should always be left open,
except when changing the oil or oil filter as defined in
the Changing Oil and Oil Filter section, page 64.
Remote Start/Stop Controls — A remote device, such
as a timeclock, which uses a set of contacts, may be used to
start and stop the machine. However, the device should not
be programmed to start and stop the machine in excess of 2
or 3 times every 12 hours. If more than 8 starts in 12 hours
occur, then an ‘‘Excessive Recycle Starts’’ alert is displayed,
preventing the machine from starting. The operator must reset the alert at the LID in order to override the starts counter
and start the machine. If Automatic Restart After a Power
Failure is not activated when a power failure occurs, and the
remote contact is closed, the machine will indicate an alarm
because of the loss of voltage.
The contacts for Remote Start are wired into the starter at
terminal strip TB5, as well as terminals 8A and 8B. See the
certified drawings for further details on contact ratings. The
contacts must be dry (no power).
Capacity Overrides (Table 5) — These can prevent
some safety shutdowns caused by exceeding motor amperage limit, refrigerant low temperature safety limit, motor high
temperature safety limit, and condenser high pressure limit.
In all cases there are 2 stages of compressor slide valve
control.
1. The slide valve is held from closing further, and the status line on the LID indicates the reason for the override.
2. The slide valve is opened until condition decreases below the first step set point, and then the valve is released
to normal capacity control.
Whenever the motor current demand limit set point is reached,
it activates a capacity override, again with a two-step process. Exceeding 110% of the rated load amps for more than
10 seconds will initiate a safety shutdown.
Spare Safety Inputs — Normally closed digital inputs for additional field-supplied safeties may be wired to
the spare protective limits input channel in place of the factoryinstalled jumper. (Wire multiple inputs in series.) The opening of any contact will result in a safety shutdown and LID
display showing ‘‘SPARE SAFETY DEVICE.’’
Analog temperature sensors may also be added to the options modules, if installed. These may be programmed to cause
an alert on the CCN network, but will not shut the machine
down.
SPARE ALARM CONTACTS — Two spare sets of alarm
contacts and provided within the starter. The contact ratings
are provided in the certified drawings. The contacts are located on terminal strip TB6, as well as terminals 5A, 5B,
5C, and 5D.
Oil Sump Temperature Control (Frame 1 and 2
Machines Only) — The oil sump temperature control
Condenser Pump Control — The machine will monitor the CONDENSER PRESSURE and may turn on this pump
if the pressure becomes too high whenever the compressor
is shut down. CONDENSER PRESSURE OVERRIDE is used
to determine this pressure point. This value is found on the
Equipment Service1 LID table and has a default value
(Table 3). If the CONDENSER PRESSURE is greater than
or equal to the CONDENSER PRESSURE OVERRIDE, and
the ENTERING CONDENSER WATER TEMP (Temperature) is less than 115 F (46 C), then the condenser pump will
energize to try to decrease the pressure. The pump will turn
off when the condenser pressure is less than the pressure override less 5 psi (34 kPa) [3.5 psi (24 kPa)], or the CONDENSER REFRIG (Refrigerant) TEMP is within 3° F (2° C)
of the ENTERING CONDENSER WATER temperature.
is regulated by the PIC using the oil heater relay when the
machine is shut down. The oil heater relay is energized whenever the chiller compressor is off, and the oil sump temperature is less than 140 F (60 C) or sump temperature is less
than the cooler refrigerant temperature plus 60 F
(33 C). The heater is then turned off when the oil sump temperature is:
1. More than 160 F (71 C).
2. The sump temperature is more than 145 F (62.8 C) and
more than the cooler refrigerant temperature plus 65 F
(18.3 C). (The heater is always off during start-up or when
the compressor is running.)
29
Table 4 — Protective Limits and Control Settings
MONITORED PARAMETER
TEMPERATURE SENSORS
OUT OF RANGE
PRESSURE TRANSDUCERS
OUT OF RANGE
COMPRESSOR DISCHARGE
TEMPERATURE
LOW DISCHARGE SUPERHEAT
CONDENSER FREEZE PROTECTION
MOTOR WINDING TEMPERATURE
PHASE REVERSAL
(MOTOR ROTATION)
LIMIT
APPLICABLE COMMENTS
−40 to 245 F (−40 to 118.3 C)
Must be outside range for 3 seconds
0.06 to 0.98 Voltage Ratio
Must be outside range for 3 seconds.
Ratio = Input Voltage ÷ Voltage Reference
.200 F (93 C)
Preset; alert setting configurable
Oil sump temp −condenser refrigerant temp is less
than 20 F (11.1 C). Only applicable to Frame 1 and 2 machines.
Preset monitored 30 minutes after start-up
completion must be outside range for
10 consecutive minutes.
Energizes condenser pump relay if condenser refrigerant
temperature or condenser entering water temperature is below
the configured condenser freeze point temperature. Deenergizes
when the temperature is 5 F (3 C) above condenser freeze point
temperature
.220 F (104.4 C)
,Start-up condenser pressure - 5 psi (34.5 kPa)
,33 F (0.6 C) for water chilling
EVAPORATOR REFRIGERANT
TEMPERATURE
TRANSDUCER VOLTAGE
CONDENSER PRESSURE
OIL PRESSURE:
— Dirty Oil Filter
— Low Oil Pressure
OIL LEVEL
LINE VOLTAGE — HIGH
— LOW
— SINGLE-CYCLE
COMPRESSOR MOTOR LOAD
,1° F below Design Refrigerant Temperature
(set point adjustable from 8 to 40 F [−13 to 4 C]
for brine chilling)
,4.5 vdc, . 5.5 vdc
.260 psig (1793 kPa)
Oil pressure transducer less than condenser pressure — oil filer
pressure alert starting 40 seconds after motor current
. 10% and oil pressure verified
Oil pressure transducer less than condenser pressure —
110 psi (758 kPa) starting 40 seconds after motor current . 10%
and oil pressure verified
,Required oil pressure + 5 psi (34.5 kPa) starting
60 seconds after motor current . 10%
,Required oil pressure starting 120 seconds
after motor current . 10%
Discrete
.110% for one minute
,90% and .85% for one minute or <85% for 3 seconds
,50% for one cycle
.110% for 10-30 seconds
,10% with compressor running
.10% with compressor off
STARTER ACCELERATION TIME
(Determined by inrush current
going below 100% compressor
motor load)
.15 seconds
STARTER TRANSITION
.30 seconds
CONDENSER FREEZE POINT configured in
Service01 table with a default setting of 34 F (1 C).
Preset; alert setting configurable
Preset; must be outside range for 3 seconds
monitored after compressor motor current . 10%
Preset; configure chilled medium for water
(Service1 table)
Configure chilled medium for brine (Service1
screen). Adjust brine refrigerant trippoint for
proper cutout
Preset
Preset; alert setting configurable
Must be outside range for 3 seconds; oil pressure
alert setting configurable from 15 - 30 psi
(103.4 - 206.8 kPa) on Service1 table
Must be outside range for 3 seconds
Ramp-up rate. See Table 1.
Minimum required oil pressure based on system
pressure ratio is between 20 psi (137.9 kPa)
[7 psi (48 kPa)] and 40 psi (275.8 kPa)
Preset; must be outside range for 15 seconds
Preset
Preset
For machines with reduced voltage mechanical
and solid state starters
For machines with full voltage starters
(Configured on Service1 table)
For machines with reduced voltage
starters and solid-state starters
.5 seconds
Flow Switch (Field Supplied)
Operate water pumps with machine off. Manually reduce water flow
and observe switch for proper cutout. Safety shutdown occurs when
cutout time exceeds 3 seconds. Switches are required to be rated
electronically at 24 vdc.
CUT-OUT
SETTING
ADJUSTMENT
SCREW
30
Table 5 — Capacity Overrides
OVERRIDE
CAPACITY
CONTROL
VIEW/MODIFY
ON LID
TABLE
HIGH CONDENSER
PRESSURE
HIGH MOTOR
TEMPERATURE
LOW REFRIGERANT
TEMPERATURE
(REFRIGERANT
OVERRIDE AT
TEMPERATURE)
MANUAL
SLIDE VALVE
TARGET
MOTOR LOAD —
ACTIVE
DEMAND LIMIT
EQUIPMENT SERVICE1
EQUIPMENT SERVICE1
EQUIPMENT SERVICE1
CONTROL
ALGORITHM
MAINT01
STATUS01
FIRST STAGE SETPOINT
Default
Configurable
Value
Range
230 psi (1586 kPa)
150 to 250 psi
(1034 to 1724 kPa)
.200 F
150 to 200 F
(93 C)
(66 to 93 C)
,2 F (1 C)
2 to 5 F
Above Trippoint
(1 to 3 C)
Automatic
−20 to 20
Counts
100%
40 to 100%
SECOND STAGE
SET POINT
>Override Set point
+5 psi (35 kPa)
.Override Set point
+ 10 F (6 C)
,Trippoint +
(Override DT —
1 F [0.56 C])
Manual control
cannot default
active control
>105% of
Set Point
OVERRIDE
TERMINATION
,Override Set Point
,Override Set Point
.Trippiont +
(Override DT + 2 F [1.2 C])
Release of
Manual Control
2% Lower
Than Set Point
NOTE: [ ] indicates HFC-134a values.
Condenser Freeze Prevention — This control al-
tower-fan relay can only accomplish this if the relay has been
added to the cooling tower temperature controller. TheTOWER
FAN RELAY is turned on whenever the CONDENSER WATER PUMP is running, flow is verified, and the difference
between cooler and condenser pressure is more than 50 psi
(433 kPa) or ENTERING CONDENSER WATER is greater
than 85 F (29 C). The TOWER FAN RELAY is deenergized
when the condenser pump is off, flow is lost, the evaporator
refrigerant temperature is less than the override temperature,
or the differential pressure is less than 45 psi (310 kPa) and
ENTERING CONDENSER WATER is less than 80 F (27 C).
gorithm helps prevent condenser tube freeze up by energizing the condenser pump relay. If the pump is controlled by
the PIC, starting the pump will help prevent the water in the
condenser from freezing. Condenser freeze prevention can
occur whenever the machine is not running except when it
is actively in Pumpdown or in Pumpdown Lockout with the
freeze prevention disabled (refer to Control Test table,
Pumpdown/Terminate Lockout screens). See Fig. 21. When
Pumpdown Lockout is initiated, if the CONDENSER
REFRIG TEMP is less than 40 F (4.4 C), then condenser
freeze prevention shall be disabled until termination of pumpdown lockout.
When the CONDENSER REFRIG TEMP is less than or
equal to the CONDENSER FREEZE POINT or the ENTERING CONDENSER WATER temperature is less than or
equal to the CONDENSER FREEZE POINT, then the CONDENSER WATER PUMP shall be energized until the CONDENSER REFRIG TEMP is greater then the CONDENSER
FREEZE POINT plus 5° F (2.7° C). An alarm will be generated if the machine is in PUMPDOWN mode and the pump
is energized. An alert will be generated if the machine is not
in PUMPDOWN mode and the pump is energized.
Either of the above on requirements may independently
result in the CONDENSER WATER PUMP being energized. However, both sets of off requirements must be met
in order for the pump to be deenergized.
IMPORTANT: A field supplied water temperature control system should be installed. The system should maintain the leaving condenser water temperature at a temperature that is 18 F (10 C) above the leaving chilled
water temperature.
The tower fan relay control is not a substitute for a jobsite condenser water temperature control. When used with
a Water Temperature Control system, the tower fan relay control can be used to help prevent low condenser
water temperatures.
Auto. Restart After Power Failure — This option
may be enabled or disabled, and may be viewed/modified on
the Equipment Configuration menu Config table. If enabled,
the chiller will start up automatically after a single cycle dropout, low, high, or loss of voltage has occurred, and the power
is within ±10% of normal. The start inhibit timers are ignored during this type of start-up.
Tower-Fan Relay — The tower fan relay, located in the
starter, is controlled by the PIC to energize and deenergize
as the pressure differential between cooler and condenser vessels changes in order to prevent low condenser water temperature and to maximize machine efficiency. The
31
signal is wired to terminals J1-1(+) and J1-2(−). If the signal
is internally powered, the signal is wired to terminals J13(+) and J1-2(−).
Water/Brine Reset — Three types of chilled water or
brine reset are available and can be viewed or modified on
the Equipment Configuration menu Config table.
The default screen status message indicates when the chilled
water reset is active. The CONTROL POINT, on the
Status01 table, indicates the machine’s reset temperature.
To activate a reset type, input all configuration information for that reset type in the Config table. Then input the
reset type number in the DISABLE/ENABLE input line.
1. Reset Type 1 (Requires optional 8-input module) — Automatic chilled water temperature reset based on a 4 to
20 mA input signal. This type permits up to ±30° F
(±16° C) of automatic reset to the chilled water or brine
temperature set point, based on the input from a 4 to
20 mA signal. This signal is hardwired into the number
one 8-input module.
If the 4 to 20 mA signal is externally powered from the
8-input module, the signal is wired to terminals J1-5(+)
and J1-6(−). If the signal is to be internally powered by
the 8-input module (for example, when using variable resistance), the signal is wired to J1-7(+) and J1-6(−). The
PIC must now be configured on the Service2 table to ensure that the appropriate power source is identified.
2. Reset Type 2 (Requires optional 8-input module) — Automatic chilled water temperature reset based on a
remote temperature sensor input. This type permits
±30° F (±16° C) of automatic reset to the set point based
on a temperature sensor wired to the number one 8-input
module (see wiring diagrams or certified drawings).
The temperature sensor must be wired to terminal J1-19
and J1-20.
To configure Reset Type 2, enter the temperature of the
remote sensor at the point where no temperature reset will
occur. Next, enter the temperature at which the full amount
of reset will occur. Then, enter the maximum amount of
reset required to operate the machine. Reset Type 2 can
now be activated.
3. Reset Type 3 — Automatic chilled water temperature reset based on cooler temperature difference. This type of
reset will add ±30° F (±16° C) based on the temperature
difference between entering and leaving chilled water temperature. This is the only type of reset available without
the need of the number one 8-input module. No wiring is
required for this type as it already uses the cooler water
sensors.
To configure Reset Type 3, enter the chilled water temperature difference (the difference between entering and
leaving chilled water) at which no temperature reset occurs. This chilled water temperature difference is usually
the full design load temperature difference. The difference in chilled water temperature at which the full amount
of reset will occur is now entered on the next input line.
Next, the amount of reset is entered. Reset Type 3 can
now be activated.
Hot Gas Bypass (Optional) Algorithm (See
Fig. 24 and 25) — If a hot gas bypass solenoid valve is
present, and the hot gas bypass option on the SERVICE1
table is enabled, this operator configurable feature can determine if load conditions are too low for the compressor
and then take corrective action.
The algorithm first determines if corrective action is necessary. This is done by checking two sets of operator configured data points, which are the MINIMUM and the
MAXIMUM Load Points, (T1/P1;T2/P2). These points have
default settings for each type of refrigerant, HCFC-22 or HFC134a, as defined on the SERVICE1 table, and on Table 3.
These settings and the algorithm logic are graphically displayed in Fig. 24 and 25. The two sets of load points on this
graph (default settings are shown) describe a line which the
algorithm uses to activate the hot gas bypass. Whenever the
temperature difference between the entering and leaving chilled
water is on the left side of the line on the graph (as defined
by the MINIMUM and MAXIMUM Load Points), the algorithm will then energize the hot gas bypass valve to falsely
load the machine and prevent displacement of oil. If the actual values are on the right side of the line, the algorithm
takes no action.
LEGEND
— Condenser PressureCooler Pressure
DT
— ECW-LCW
ECW
— Entering Chilled
Water Temperature
LCW
— Leaving Chilled
Water Temperature
HGBP — Hot Gas Bypass
DP
DEFAULT VALUES:
POINT
DT1
DP1
DT2
DP2
HCFC-22
2.5
50
10
HFC-134a
2.5
30
10
200
170
Fig. 24 — 23XL Hot Gas Bypass (English)
LEGEND
DP
— Condenser PressureCooler Pressure
DT
— ECW-LCW
ECW
— Entering Chilled
Water Temperature
LCW
— Leaving Chilled
Water Temperature
HGBP — Hot Gas Bypass
Demand Limit Control, Option — (Requires Optional 8-Input Module) — The demand limit may be
DEFAULT VALUES:
externally controlled with a 4 to 20 mA signal from an energy management system (EMS). The option is set up on the
Config table. When enabled, the control is set for 100% demand with 4 mA and an operator configured minimum demand set point at 20 mA.
The Demand Reset input from an energy management system is hardwired into the number one, 8-input module. The
signal may be internally powered by the module or externally powered. If the signal is externally powered, the
POINT
DT1
DP1
DT2
DP2
HCFC-22
HFC-134a
1.4
345
5.6
1379
1.4
207
5.6
1172
Fig. 25 — 23XL Hot Gas Bypass (SI)
32
LEAD/LAG OPERATION — The PIC control provides the
ability to operate 2 chillers in the LEAD/LAG mode. It also
provides the additional ability to start a designated standby
chiller when either the lead or lag chiller is faulted and capacity requirements are not met. The lead/lag option operates in CCN mode only. If any other chiller configured for
lead/lag is set to the LOCAL or OFF modes, it will be unavailable for lead/lag operation.
NOTE: Lead/Lag configuration is viewed and edited in LEAD/
LAG, under the Equipment Configuration table of the Service menu. Lead/lag status during machine operation is viewed
in the MAINT04 table in the Control Algorithm Status
table.
Lead/Lag Chiller Configuration and Operation — The configured lead chiller is identified when the LEAD/LAG
SELECT value for that chiller is configured to the value of
‘‘1.’’ The configured lag chiller is identified when the LEAD/
LAG SELECT for that chiller is configured to the value of
‘‘2.’’ The standby chiller is configured to a value of ‘‘3.’’ A
value of ‘‘0’’ disables the lead/lag in that chiller.
To configure the LAG ADDRESS value on the LEAD/
LAG Configuration table, always use the address of the other
chiller on the system for this value. Using this address will
make it easier to rotate the lead and lag machines.
If the address assignments placed into the LAG
ADDRESS and STANDBY ADDRESS values conflict, the
lead/lag will be disabled and an alert (!) message will
occur. For example, if the LAG ADDRESS matches the lead
machine’s address, the lead/lag will be disabled and
an alert (!) message will occur. The lead/lag maintenance
screen (MAINT04) will display the message ‘INVALID
CONFIG’ in the LEAD/LAG CONFIGURATION and
CURRENT MODE fields.
The lead chiller responds to normal start/stop controls such
as occupancy schedule, forced start/stop, and remote start
contact inputs. After completing start up and ramp loading,
the PIC evaluates the need for additional capacity. If additional capacity is needed, the PIC initiates the start up of the
chiller configured at the LAG ADDRESS. If the lag chiller
is faulted (in alarm) or is in the OFF or LOCAL modes, then
the chiller at the STANDBY ADDRESS (if configured) is
requested to start. After the second chiller is started and is
running, the lead chiller shall monitor conditions and evaluate whether the capacity has reduced enough for the lead
chiller to sustain the system alone. If the capacity is reduced
enough for the lead chiller to sustain the CONTROL POINT
temperatures alone, then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, then the lag and standby
chillers are stopped. If the configured lead chiller stops for
and alarm condition, then the configured lag chiller takes the
lead chiller’s place as the lead chiller and the standby chiller
serves as the lag chiller.
If the configured lead chiller does not complete the start
up before the PRESTART FAULT TIMER (user configured
value) elapses, then the lag chiller shall be started and the
lead chiller will shut down. The lead chiller then monitors
the start request from the acting lead chiller to start. The PRESTART FAULT TIMER is initiated at the time of a start request. The PRESTART FAULT TIMER’s function is to provide a timeout in the event that there is a prestart alert condition
preventing the machine from starting in a timely manner. The
timer is configured under LEAD/LAG, found in the Equipment Configuration table of the Service menu.
If the lag chiller does not achieve start up before the
PRESTART FAULT TIMER elapses, then the lag chiller shall
be stopped and the standby chiller will be requested to start,
if configured and ready.
Lead/Lag Control
IMPORTANT: Lead/lag control is only available on
machines with PSIO Software Version 13 or higher.
Lead/lag is a control system process that automatically starts
and stops a lag or second chiller in a 2 chiller water system.
Refer to Fig. 20 and 21 for menu, table, and screen selection
information. On machines that have PSIO software with Lead/
Lag capability, it is possible to utilize the PIC controls to
perform the lead/lag function on 2 machines. A third machine can be added to the lead/lag system as a standby chiller
to start up in case the lead or lag chiller in the system has
shut down during an alarm condition and additional cooling
is required.
NOTE: Lead/lag configuration is viewed and edited under
the LEAD/LAG in the Equipment Configuration table, located in the Service menu. See Table 3, Example 6. Lead/lag
status during machine operation is viewed in the MAINT04
table in the Control Algorithm Status table. See Table 3, Example 12.
Lead/Lag System Requirements:
• all machines must have PSIO software capable of performing the lead/lag function
• water pumps MUST be energized from the PIC controls
• water flows should be constant
• CCN Time Schedules for all machines must be identical
Operation Features:
• 2 chiller lead/lag
• addition of a third chiller for backup
• manual rotation of lead chiller
• load balancing if configured
• staggered restart of the chillers after a power failure
• chillers may be piped in parallel or in series chilled water
flow
COMMON POINT SENSOR INSTALLATION — Lead/
lag operation does not require a common chilled water point
sensor. Common point sensors can be added to the 8-input
options module, if desired. Refer to the certified drawings
for termination of sensor leads.
NOTE: If the common point sensor option is chosen on a
chilled water system, both machines should have their own
8-input option module and common point sensor installed.
Each machine will use its own common point sensor for control, when that machine is designated as the lead chiller. The
PIC cannot read the value of common point sensors installed
on other machines in the chilled water system.
When installing chillers in series, a common point sensor
should be used. If a common point sensor is not used, the
leaving chilled water sensor of the upstream chiller must be
moved into the leaving chilled water pipe of the downstream
chiller.
If return chilled water control is required on chillers piped
in series, the common point return chilled water sensor should
be installed. If this sensor is not installed, the return chilled
water sensor of the downstream chiller must be relocated to
the return chilled water pipe of the upstream machine.
To properly control the common supply point temperature
sensor when chillers are piped in parallel, the water flow through
the shutdown chillers must be isolated so that no water bypass around the operating chiller occurs. The common point
sensor option must not be used if water bypass around the
operating chiller is occurring.
MACHINE COMMUNICATION WIRING — Refer to the
machine’s Installation Instructions, Carrier Comfort Network Interface section on page 49 for information on machine communication wiring.
33
If the lead chiller is in an alarm (!) condition (as shown on
the LID panel), the RESET softkey is pressed to clear the
alarm, and the chiller is placed in the CCN mode, the lead
chiller will now communicate and monitor the RUN STATUS of the lag and standby chillers. If both the lag and standby
chillers are running, the lead chiller will not attempt to start
and will not assume the role of lead chiller until either the
lag or standby chiller shuts down. If only one chiller is running, the lead chiller will wait for a start request from the
operating chiller. When the configured lead chiller starts, it
assumes its role as lead chiller.
LOAD BALANCING — When the LOAD BALANCE OPTION is enabled, the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s COMPRESSOR MOTOR LOAD value. This value has limits of
40% to 100%. When setting the lag chiller ACTIVE DEMAND LIMIT, the CONTROL POINT shall be modified to
a value of 3° F (1.67° C) less than the lead chiller’s CONTROL POINT value. If the LOAD BALANCE OPTION is
disabled, the ACTIVE DEMAND LIMIT and the CONTROL POINT are forced to the same value as the lead chiller.
AUTORESTART AFTER POWER FAILURE — When an
autorestart condition occurs, each chiller may have a delay
added to the start-up sequence, depending on its lead/lag configuration. The lead chiller does not have a delay. The lag
chiller has a 45-second delay. The standby chiller has a 90second delay. The delay time is added after the chiller water
flow verification. The PIC controls ensure that the slide valves
are closed. After the slide valve position is confirmed, the
delay for lag and standby chiller occurs prior to energizing
the compressor. The normal start-up sequence then continues. The autorestart delay sequence occurs whether the chiller
is in CCN or LOCAL mode and is intended to stagger the
compressor motors from being energized simultaneously. This
will help reduce the inrush demands on the building power
system.
Standby Chiller Configuration and Operation — The configured standby chiller is identified as such by having the
LEAD/LAG SELECT configured to the value of ‘‘3.’’ The
standby chiller can only operate as a replacement for the lag
chiller if one of the other two chillers is in an alarm (!) condition (as shown on the LID panel). If both lead and lag chillers are in an alarm (!) condition, the standby chiller shall
default to operate in CCN mode based on its configured Occupancy Schedule and remote contacts input.
Lag Chiller Start-Up Requirements — Before the lag chiller
can be started, the following conditions must be met:
1. Lead chiller ramp loading must be complete.
2. Lead chiller CHILLED WATER temperature must be greater
than the CONTROL POINT plus 1/2 the WATER/BRINE
DEADBAND.
NOTE: The chilled water temperature sensor may be the leaving chilled water sensor, the return water sensor, the common supply water sensor, or the common return water sensor, depending on which options are configured and
enabled.
3. Lead chiller ACTIVE DEMAND LIMIT value must be
greater than 95% of full load amps.
4. Lead chiller temperature pulldown rate of the CHILLED
WATER temperature is less than 0.5° F (0.27° C) per minute.
5. The lag chiller status indicates it is in CCN mode and is
not faulted. If the current lag chiller is in an alarm condition, then the standby chiller becomes the active lag chiller,
if it is configured and available.
6. The configured LAG START TIMER entry has elapsed.
The LAG START TIMER shall be started when the lead
chiller ramp loading is completed. The LAG STARTTIMER
entry is accessed by selecting LEAD/LAG from the Equipment Configuration table of the Service menu.
When all of the above requirements have been met, the
lag chiller is forced to a START mode. The PIC control then
monitors the lag chiller for a successful start. If the lag chiller
fails to start, the standby chiller, if configured, is started.
Ice Build Control
IMPORTANT: The Ice Build control option is only available on machines with PSIO Software Version 13 and
higher.
Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.
1. Lead chiller COMPRESSOR MOTOR LOAD value is
less than the lead chiller percent capacity.
NOTE: Lead chiller percent capacity = 100 −LAG PERCENT CAPACITY
The LAG PERCENT CAPACITY value is configured on
the Lead/Lag Configuration screen.
2. The lead chiller chilled water temperature is less than the
CONTROL POINT plus 1/2 of the WATER/BRINE DEADBAND.
3. The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER is started when the CHILLED
WATER TEMPERATURE is less than the CHILLED WATER CONTROL POINT plus 1/2 of the WATER/BRINE
DEADBAND and the lead chiller COMPRESSOR MOTOR LOAD is less than the lead chiller percent capacity.
The timer is ignored if the chilled water temperature reaches
3° F (1.67° C) below the CONTROL POINT and the lead
chiller COMPRESSOR MOTOR LOAD value is less than
the lead chiller percent capacity.
Ice build control automatically sets the chilled WATER/
BRINE CONTROL POINT of the machine to a temperature
where an ice building operation for thermal storage can be
accomplished.
NOTE: For ice build control to properly operate, the PIC
controls must be placed in CCN mode. See Fig. 20 and 21.
The PIC can be configured for ice build operation. Configuration of ice build control is accomplished through entries in the Config table, Ice Build Setpoint table, and the Ice
Build Time Schedule table. Figures 20 and 21 show how to
access each entry.
The Ice Build Time Schedule defines the period during
which ice build is activate if the ice build option is ENABLED. If the Ice Build Time Schedule overlaps other schedules defining time, then the Ice Build Time Schedule shall
take priority. During the ice build period, the WATER/
BRINE CONTROL POINT is set to the ICE BUILD SETPOINT for temperature control. The ICE BUILD RECYCLE
OPTION and ICE BUILD TERMINATION entries from a
screen in the Config (configuration) table provide options
for machine recycle and termination of ice build cycle, respectively. Termination of ice build can result from the ENTERING CHILLED WATER/BRINE temperature being less
than the ICE BUILD SETPOINT, opening of the REMOTE
CONTACT inputs from an ice level indicator, or reaching
the end of the Ice Build Time Schedule.
FAULTED CHILLER OPERATION — If the lead chiller
shuts down on an alarm (*) condition, it stops communication to the lag and standby chillers. After 30 seconds, the lag
chiller will now become the acting lead chiller and will start
and stop the standby chiller, if necessary.
If the lag chiller faults when the lead chiller is also faulted,
the standby chiller reverts to a stand-alone CCN mode of
operation.
34
ICE BUILD INITIATION — The Ice Build Time Schedule
provides the means for activating ice build. The ice build
time table is named OCCPC02S.
If the Ice Build Time Schedule is OCCUPIED and the ICE
BUILD OPTION is ENABLED, then ice build is active and
the following events automatically take place (unless overridden by a higher authority CCN device):
1. Force CHILLER START/STOP to START.
2. Force WATER/BRINE CONTROL POINT to the ICE
BUILD SETPOINT.
3. Remove any force (Auto) on the ACTIVE DEMAND
LIMIT.
NOTE: Items 1-3 (shown above) shall not occur if the chiller
is configured and operating as a lag or standby chiller for
lead/lag and is actively controlled by a lead chiller. The lead
chiller communicates the ICE BUILD SETPOINT, desired
CHILLER START/STOP state, and ACTIVE DEMAND
LIMIT to the lag or standby chiller as required for ice build,
if configured to do so.
START-UP/RECYCLE OPERATION — If the machine is
not running when ice build activates, then the PIC checks
the following parameters, based on the ICE BUILD
TERMINATION value, to avoid starting the compressor
unnecessarily:
• if ICE BUILD TERMINATION is set to the TEMPERATURE ONLY OPTION and the ENTERING CHILLED
WATER temperature is less than or equal to the ICE BUILD
SETPOINT;
• if ICE BUILD TERMINATION is set to the CONTACTS
ONLY OPTION and the remote contacts are open;
• if the ICE BUILD TERMINATION is set to the BOTH
(temperature and contacts) option and ENTERING CHILLED
WATER temperature is less than or equal to the ICE BUILD
SETPOINT and remote contacts are open.
The ICE BUILD RECYCLE OPTION determines whether
or not the PIC will go into a RECYCLE mode. If the ICE
BUILD RECYCLE OPTION is set to DSABLE (disable)
when the ice build terminates, the PIC will revert back to
normal temperature control duty. If the ICE BUILD RECYCLE OPTION is set to ENABLE, when ice build terminates, the PIC will go into an ICE BUILD RECYCLE mode
and the chilled water pump relay will remain energized to
keep the chilled water flowing. If the entering CHILLED
WATER/BRINE TEMPERATURE increases above the ICE
BUILD SETPOINT plus the RECYCLE DELTA T value,
the compressor will restart and control the CHILLED WATER/
BRINE TEMPERATURE to the ICE BUILD SETPOINT.
TEMPERATURE CONTROL DURING ICE BUILD
—During ice build, the capacity control algorithm uses the
WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to
control the LEAVING CHILLED WATER temperature. The
ECW OPTION and any temperature reset option are ignored
during ice build. The 20 mA DEMAND LIMIT OPTION is
also ignored during ice build.
TERMINATION OF ICE BUILD — Ice build termination
occurs under the following conditions:
1. Ice Build Time Schedule — When the Ice Build Time
Schedule transitions to UNOCCUPIED, ice build operation shall terminate.
2. ECW TEMPERATURE — Termination of compressor operation, based on temperature, shall occur if the ICE BUILD
TERMINATION is set to the ICE BUILD TERMINATION TEMP option and the ENTERING CHILLED WATER temperature is less than the ICE BUILD SETPOINT.
If the ICE BUILD RECYCLE OPTION is set to ENABLE, a recycle shutdown occurs and recycle start-
up shall be based on LEAVING CHILLED WATER temperature being greater than the WATER/BRINE CONTROL POINT plus RECYCLE DELTA T.
3. Remote Contacts/Ice Level Input- Termination of compressor operation occurs when ICE BUILD TERMINATION is set to CONTACTS ONLY OPTION and the remote contacts are open. In this case, the contacts are provided
for ice level termination control. The remote contacts can
still be opened and closed to start and stop the chiller when
the Ice Build Time Schedule is UNOCCUPIED. The contacts are used to stop the ICE BUILD mode when the Ice
Build Time Schedule is OCCUPIED.
4. ECW TEMPERATURE and Remote Contacts — Termination of compressor operation shall occur when ICE
BUILD TERMINATION is set to BOTH (temperature and
contacts) option and the previously described conditions
for ECW TEMPERATURE and remote contacts have
occurred.
NOTE: Overriding the CHILLER START/STOP, WATER/
BRINE CONTROL POINT, and ACTIVE DEMAND LIMIT
variables by CCN devices (with a priority less than 4)
during the ice build period is not possible. However, overriding can be accomplished with CCN during two chiller
lead/lag.
RETURN TO NON-ICE BUILD OPERATIONS — Upon
termination of ice build, the machine shall return to normal
temperature control and start/stop schedule operation. If the
CHILLER START/STOP or WATER/BRINE CONTROL
POINT has been forced (with a priority less than 4), prior to
entering ice build operation, then chiller START/STOP and
WATER/BRINE CONTROL POINT forces will be
removed.
Attach to Network Device Control — On the Service menu, one of the selections is ATTACH TO NETWORK
DEVICE. This table serves the following purposes:
• to upload new parameters when switching the controller
to HFC-134a refrigerant.
• to upload the Occupancy Schedule Number (if changed)
for OCCPC03S, as defined in the Service01 table
• to attach the LID to any CCN device, if the machine has
been connected to a CCN Network. This may include other
PIC controlled chillers.
• to change to a new PSIO or LID module or upgrade
software.
Figure 26 illustrates the ATTACH TO NETWORK DEVICE table. The Local description is always the PSIO module address of the machine the LID is mounted on. Whenever the controller identification of the PSIO is changed, this
change is reflected on the bus and address for the LOCAL
DEVICE of the ATTACH TO DEVICE screen
automatically.
Whenever the ATTACH TO NETWORK DEVICE table
is entered, the LID erases information on the module to which
it was attached in order to make room for another device.
Therefore, it is then required to attach to a CCN module when
this screen is entered, even if the LID is attached back to the
original module. When the ATTACH softkey is pressed, the
message ‘‘UPLOADING TABLES, PLEASE WAIT’’ flashes.
The LID will then upload the highlighted device or module.
If the module address cannot be found, the message ‘‘COMMUNICATION FAILURE’’ will appear. The LID will then
revert back to the ATTACH TO DEVICE screen. The upload
process time for various CCN modules is different for each
module. In general, the uploading process will take 3 to 5
minutes.
35
CHANGING REFRIGERANT TYPES — To select refrigerant type, go to the Control Test table. Whenever the refrigerant type is changed, the ATTACH TO NETWORK
DEVICE table must be used. After changing the refrigerant
type in the Control Test table, move to the ATTACH TO NETWORK DEVICE table. Make sure the highlight bar is located on the LOCAL selection. Press the ATTACH softkey.
The information in the PSIO module will now be uploaded.
The default screen will appear. The new refrigerant type change
for the controller is complete.
NOTE: Refrigerant type can be changed on Frame 4 machines only.
ATTACHING TO OTHER CCN MODULES — If the machine PSIO has been connected to a CCN Network or other
PIC controlled chillers through CCN wiring, the LID can be
used to view or change parameters on the other controllers.
Other PIC machines can be viewed and set points changed
(if the other unit is in CCN control), if desired from this particular LID module.
To view the other devices, move to the ATTACH TO NETWORK DEVICE table. Move the highlight bar to any device number. Press SELECT softkey to change the bus number and address of the module to be viewed. Press EXIT softkey
to move back to the ATTACH TO NETWORK DEVICE table.
If the module number is not valid, the ‘‘COMMUNICATION FAILURE’’ message will show and a new address number should be entered or the wiring checked. If the model is
communicating properly, the ‘‘UPLOAD IN PROGRESS’’
message will flash and the new module can now be viewed.
Whenever there is a question regarding which module on
the LID is currently being shown, check the device name
descriptor on the upper left hand corner of the LID screen.
See Fig. 26.
When the CCN device has been viewed, the ATTACH TO
NETWORK DEVICE table should now be used to
attach to the PIC that is on the machine. Move to the
ATTACH TO NETWORK DEVICE table and press the
ATTACH softkey to upload the LOCAL device. The PSIO
for the 23XL will now be uploaded.
NOTE: The LID will not automatically re-attach to the PSIO
module on the machine. Press the ATTACH softkey to attach to LOCAL DEVICE and view the machine PSIO.
2. Press the four digits of your password, one at a time. An
asterisk (*) appears as you enter each digit.
The menu bar (Next-Previous-Select-Exit) is displayed
to indicate that you have successfully logged on.
If the password is entered incorrectly, an error message is
displayed. If this occurs, return to Step 1 and try logging
on again.
NOTE: The initial factory set password is 1-1-1-1.
TO LOG OFF — Access the Log Out of Device table of the
Service menu in order to password-protect the Service menu.
The LID will automatically sign off and password-protect
itself if a key is not pressed for 15 minutes. The LID default
screen is then displayed.
HOLIDAY SCHEDULING (Fig. 27) — The time schedules
may be configured for special operation during a holiday period. When modifying a time period, the ‘‘H’’ at the end of
the days of the week field signifies that the period is applicable to a holiday. (See Fig 22.)
The Broadcast function must be activated for the holidays
configured in the Holidef tables to work properly. Access
the Brodefs table in the Equipment Configuration menu and
answer ‘‘Yes’’ to the activated function. However, when the
machine is connected to a CCN Network, only one machine
or CCN device can be configured to be the broadcast device.
The controller that is configured to be the broadcaster is the
device responsible for transmitting holiday, time, and daylightsavings dates throughout the network.
To view or change the holiday periods for up to 18 different holidays, perform the following operation:
1. At the Menu screen, press SERVICE to access the Service menu.
Fig. 26 — Example of Attach to Network
Device Table
2. If not logged on, follow the instructions for To Log On
or To Log Off. Once logged on, press NEXT until Equipment Configuration is highlighted.
Service Operation — An overview of the menudriven programs available for Service Operation is shown in
Fig. 21.
TO LOG ON
1. On the Menu screen, press SERVICE . The keys now
correspond to the numerals 1, 2, 3, 4.
3. Once Equipment Configuration is highlighted, press
SELECT to access.
36
4. Press NEXT until Holidef is highlighted. This is
the Holiday Definition table.
5. Press SELECT to enter the Data Table Select screen.
This screen lists 18 holiday tables.
6. Press NEXT to highlight the holiday table that you
wish to view or change. Each table is one holiday period, starting on a specific date, and lasting up to
99 days.
Fig. 27 — Example of Holiday Period Screen
START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 28)
Local Start-Up — Local start-up (or a manual start-up)
7. Press SELECT to access the holiday table. The Configuration Select table now shows the holiday start month
and day, and how many days the holiday period will last.
is initiated by pressing the LOCAL menu softkey which is
on the LID default screen. Local start-up can proceed when
Time Schedule 01 is in OCCUPIED mode, and after the internal 15-minute start-to-start and the 1-minute stop-to-start
timer on PSIO Software Version 13 and higher have expired. PSIO Software Version 12 and lower has a 3-minute
stop-to-start timer.
The chiller start/stop status point on the Status01 table may
be overridden to start, regardless of the time schedule, in
order to locally start the unit. Also, the remote contacts may
be enabled through the LID and closed to initiate a start-up.
Whenever the chiller is in LOCAL control mode, the PIC
will wait for Time Schedule 01 to become occupied, and the
remote contacts to close, if enabled. The PIC will then perform a series of pre-start checks to verify that all
pre-start alerts and safeties are within the limits shown
in Table 4. The run status line on the LID now reads
‘‘Starting.’’ If the checks are successful, the chilled water/
brine pump relay will be energized. Five seconds later, the
condenser pump relay is energized. One minute later the PIC
monitors the chilled water and condenser flow switches. The
PIC waits up to the WATER FLOW VERIFY TIME (operator
configured, default 5 minutes) to confirm flow. After flow is
verified, the CHILLED WATER/BRINE temperature is compared to CONTROL POINT plus DEADBAND. If the temperature is less than or equal to the CONTROL POINT plus
DEADBAND, the PIC will turn off the condenser pump and
go into the RECYCLE mode. If the water/brine temperature
is high enough, the start-up sequence continues to check the
slide valve decrease timer. If the slide valve has been unloading for at least 3 minutes since the last machine shutdown, then the refrigerant type is verified. The compressor
start relay (1CR) is energized to start the compressor 10 seconds later.
Failure to verify any of the requirements up to this point
will result in the PIC aborting the start and displaying the
applicable pre-start mode of failure on the LID default screen.
A pre-start failure does not advance the starts in 12 hours
counter. Any failure after the 1CR relay has energized results in a safety shutdown, advances the starts in 12 hours
counter by one, and displays the applicable shutdown status
on the LID display.
8. Press NEXT or PREVIOUS to highlight the month,
day, or duration.
9. Press SELECT
duration.
to modify the month, day, or
10. Press INCREASE or DECREASE to change the selected value.
11. Press ENTER to save the changes.
12. Press
EXIT
to return to the previous menu.
37
When a stop signal occurs, the shutdown sequence first
stops the compressor by deactivating the start relay. The slide
valve decrease timer is activated for 3 minutes to open the
slide valve. The condenser water pump relay is shut down
30 seconds after the compressor run contact is open and motor load is less than 10%. The service ontime and compressor ontime timers are deactivated. The 3-minute stopto-start timer will now begin to count down. If the
15-minute start-to-start timer is still greater than 3 minutes,
then this time is now displayed. Last, the chilled water/brine
pump is shut down.
Certain conditions during shutdown will change this
sequence:
• if the COMPRESSOR MOTOR LOAD is greater than 10%
after shutdown, or the starter contacts remain energized,
the chilled water pump and the condenser water pump remain energized and the alarm is displayed
• if the ENTERING CONDENSER WATER temperature is
less than 115 F (46 C) [125 F (52 C)] and the condenser
refrigerant temperature is less than the CONDENSER
FREEZE POINT plus 5° F ( 3° C) at shutdown, the Condenser Pump Control algorithm will determine when the
condenser pump will be deenergized after shutdown
• if the machine shuts down due to low refrigerant temperature, the chilled water pump will stay running until the
LEAVING CHILLED WATER is greater than CONTROL
POINT, plus 5° F (3° C).
Automatic Soft Stop Amps Threshold (PSIO Software Version 13 and Higher) — The SOFT STOP
AMPS THRESHOLD unloads the slide valve of the compressor automatically when a non-recycle, non-alarm stop
signal is emitted before the compressor motor is
deenergized.
If the STOP button is pressed, the slide valve unloads to
a preset amperage percent. Then, the compressor will shut
off.
If the machine enters an Alarm state or if the compressor
enters a RECYCLE mode, the compressor will be deenergized immediately.
To activate SOFT STOP AMPS THRESHOLD, view the
bottom of Service1 screen. Set the Soft Stop Amps Threshold value to the percentage amps that the slide valve will
achieve the motor will be shut down. The default setting is
100% (no Soft Stop).
When the SOFT STOP AMPS THRESHOLD is being applied, a status message ‘‘SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING’’ is shown.
A
— START INITIATED: Pre-start checks are made; evaporator
pump started
B
— Condenser water pump started (5 seconds after A)
C
— Water flows verified (30 seconds to 5 minutes maximum)
D
— Chilled water temperature checked against control point;
tower fan control enabled; slide valve decrease timer checked
to verify slide valve position
E
— Refrigerant type verified (up to 3 minutes after D).
F
— Compressor motor starts; phase reversal conditions monitored; compressor ontime and service ontime start;
15-minute inhibit timer starts (10 seconds after E)
G
— Shutdown initiated: Compressor motor stops; compressor
ontime and service ontime stop; 3-minute inhibit timer starts
on PSIO Software Version 8 and 12 and 1-minute inhibit
timer on PSIO Software Version 13 and higher; slide valve
decrease activated for 1 minute
H
— Evaporator pump deenergized (30 seconds after G); condenser pump and tower fan control may continue to operate if condenser pressure is high; evaporator pump may
continue if in RECYCLE mode
I
— Slide valve decrease timer expires (3 minutes after G)
O/A — Restart permitted (both inhibit timers expired) (minimum of
15 minutes after F; minimum of 1 minute after G)
Chilled Water Recycle Mode — When the compressor is running in a lightly loaded condition, the machine may
cycle off and wait until the load increases before restarting.
This cycling of the chiller is normal and is known as recycle. A recycle shutdown is initiated when any of the following conditions are present:
• when in LCW control, the LEAVING CHILLED WATER
temperature is more than 5° F (3° C) below the control
point, and the CONTROL POINT has not increased in the
last 5 minutes
• when ECW CONTROL OPTION is enabled, the ENTERING CHILLED WATER temperature is more than 5° F (3°
C) below the CONTROL POINT, and the CONTROL POINT
has not increased in the last 10 minutes
• when the LEAVING CHILLED WATER temperature is within
3° F (2° C) of the BRINE REFRIG TRIPPOINT
Fig. 28 — Control Sequence
Shutdown Sequence — Shutdown of the machine can
occur if any of the following events happen:
• the STOP button is pressed for at least one second (the
alarm light will blink once to confirm stop command)
• recycle condition is present (see Chilled Water Recycle Mode
section)
• time schedule has gone into UNOCCUPIED mode (machine protective limit has been reached and machine is in
alarm)
• the start/stop status is overridden to stop from the CCN
network or the LID
38
When the machine is in RECYCLE mode, the chilled water pump relay remains energized so that the chilled water
temperature can be monitored for increasing load. The recycle control uses RECYCLE RESTART DELTA T to check
when the compressor should be restarted. RECYCLE RESTART DELTA T is an operator-configured function which
defaults to 5 F (3 C). This value is viewed/modified on the
Service1 screen. The compressor will restart when:
• in LCW CONTROL the LEAVING CHILLED WATER temperature is greater than the CONTROL POINT plus the RECYCLE RESTART DELTA T; or
• in ECW CONTROL, the ENTERING CHILLED WATER
temperature is greater than the CONTROL POINT plus the
RECYCLE RESTART DELTA T
Once these conditions are met, the compressor shall initiate a start-up, with a normal start-up sequence.
An Alert condition may be generated if 5 or more RECYCLE STARTUPs occur in less than 4 hours. This excessive recycling can reduce machine life. Compressor recycling
due to extremely low loads should be stopped. To stop compressor recycling, use the time schedule to shut the machine
down during low load operation. Increase the machine load
by running the fan systems. If the hot gas bypass is installed,
adjust the values to ensure that hot gas is energized during
light load conditions. Increase the RECYCLE RESTART
DELTA T on the Service1 table. By increasing this value,
the off time of the machine is increased.
The machine should not be operated below design minimum load.
Fig. 29 — Typical Wet-Bulb Type
Vacuum Indicator
Using the Optional Storage Tank and Pumpout
System — Refer to Pumpout and Refrigerant Transfer Procedures section for pumpout system preparation, refrigerant
transfer, and machine evacuation.
Remove Shipping Packaging — Remove any packaging material from the control center, power panel, slide
valve assembly, motor temperature sensor cover, and the factorymounted starter.
Safety Shutdown — A safety shutdown is identical to
a manual shutdown with the exception that the LID will display the reason for the shutdown, the alarm light will blink
continuously, the default screen display will freeze, and the
spare alarm contacts will be energized. A safety shutdown
requires that the RESET softkey be pressed in order to
clear the alarm. Before pressing the RESET softkey, record
the default screen values. If the alarm is still present, the
alarm light will continue to blink. Once the alarm is cleared,
the operator must press the CCN or LOCAL softkey to
restart the machine.
Open Oil Circuit Valves — Check that the oil filter
isolation valves (Fig. 3 and 4) are open by removing the valve
cap and checking the valve stem.
Check Machine Tightness — Figure 30 outlines the
proper sequence and procedures for leak testing.
23XL machines are shipped with a full refrigerant and oil
charge. Units may be ordered with the refrigerant shipped
separately, and a 15 psig (103 kPa) nitrogen-holding charge
in each vessel. To determine if there are any leaks, the machine should be charged with refrigerant. Use an electronic
leak detector to check all flanges and solder joints after the
machine is pressurized. If any leaks are detected, follow the
leak test procedure.
If the machine is spring isolated, keep all springs blocked
in both directions to prevent possible piping stress and damage when refrigerant is transferred from vessel to vessel during the leak test process or any time refrigerant is transferred.
Adjust the springs when the refrigerant is in operating condition, and the water circuits are full.
Do not reset starter loads or any other starter safety for
30 seconds after the compressor has stopped. Voltage
output to the compressor start signal is maintained for
10 seconds to determine starter fault.
BEFORE INITIAL START-UP
Job Data Required
• list of applicable design temperatures and pressures (product data submittal)
• machine certified drawings
• starting equipment details and wiring diagrams
• diagrams and instructions for special controls or options
• 23XL Installation Instructions
• pumpout unit instructions
Refrigerant Tracer — Carrier recommends the use of
an environmentally acceptable refrigerant tracer for leak testing with an electronic detector or halide torch.
Ultrasonic leak detectors also can be used if the machine
is under pressure.
Field Supplied Equipment Required
•
•
•
•
•
mechanic’s tools (refrigeration)
digital volt-ohmmeter (DVM)
clamp-on ammeter
electronic leak detector
absolute pressure manometer or wet-bulb vacuum indicator (Fig. 29)
• 500 v insulation tester (megohmmeter)
Do not use air or oxygen as a means of pressurizing the
machine. Some mixtures of HCFC-22 or HFC-134a and
air can undergo combustion.
39
Leak Test Machine — Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant, Carrier recommends
the following leak test procedures. See Fig. 30 for an outline
of the leak test procedures. Refer to Fig. 24 and 25 during
pumpout procedures. See the Pumpout and Refrigerant Transfer Procedures Section on page 61. Refer to Tables 6A-6D
for temperature/pressure relationships for HCFC-22 and HFC134a refrigerants. See Fig. 31-34.
1. If the pressure readings are normal for machine
condition:
a. Evacuate the holding charge from the vessels, if present.
b. Raise the machine pressure, if necessary, by adding
refrigerant until pressure is at equivalent saturated pressure for the surrounding temperature.
3.
4.
Never charge liquid refrigerant into the machine if
the pressure in the machine is less than 68 psig
(469 kPa) [35 psig (241 kPa)]. Charge as a gas only,
with the cooler and condenser pumps running, until
this pressure is reached, using PUMPDOWN and TERMINATE PUMPDOWN/LOCKOUT mode on the
PIC. Flashing of liquid refrigerant at low pressures
can cause tube freeze-up and considerable
damage.
5.
6.
c. Leak test machine as outlined in Steps 3 - 7.
2. If the pressure readings are abnormal for machine
condition:
a. Prepare to leak test machines shipped with refrigerant.
If machine is shipped with refrigerant, proceed to
Step 2h.
b. Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 30 psig (207 kPa). Soap
test all joints. If the test pressure holds for 30 minutes,
prepare the test for small leaks (Steps 2g - h).
c. Plainly mark any leaks which are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest only those joints that were repaired.
7.
40
g. After successfully completing the test for large leaks,
remove as much nitrogen, air, and moisture as possible, given the fact that small leaks may be present in
the system. This can be accomplished by following
the dehydration procedure, outlined in the Machine Dehydration section, page 48.
h. Slowly raise the system pressure to a maximum of 210
psig (1448 kPa) but no less than 68 psig (469 kPa)
[35 psig (241 kPa)] by adding refrigerant. Proceed with
the test for small leaks (Steps 3 - 7).
Check the machine carefully with an electronic leak detector, halide torch, or soap solution.
Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire machine. Leakage at rates greater than 1 lb/year (0.45 kg/year) for the
entire machine must be repaired. Note total machine leak
rate on the start-up report.
If no leak is found during initial start-up procedures, complete the transfer of refrigerant gas from the storage tank
to the machine. Retest for leaks.
If no leak is found after a retest:
a. Transfer the refrigerant to the storage tank and perform a standing vacuum test as outlined in the Standing Vacuum Test section, page 48.
b. If the machine fails this test, check for large leaks
(Step 2b).
c. Dehydrate the machine if it passes the standing vacuum
test. Follow the procedure in the Machine Dehydration section. Charge machine with refrigerant.
If a leak is found, pump the refrigerant back into the storage tank, or if isolation valves are present, pump into the
vessel that is not leaking.
Transfer the refrigerant until machine pressure is at least
equal to the pressure specified by the EPA under 40CFR
Part 82.
Repair the leak and repeat the procedure, beginning from
Step 2h to ensure a leaktight repair. If machine is opened
to the atmosphere for an extended period, evacuate it before repeating leak test.
41
Fig. 30 — 23XL Leak Test Procedures
Fig. 31 — Typical Optional Pumpout System Piping Schematic with Storage Tank (Frame 1 and 2 Machines)
42
Fig. 32 — Typical Optional Pumpout System Piping Schematic With Storage Tank (Frame 4 Machines)
43
Fig. 33 — Typical Optional Pumpout System Piping Schematic Without Storage Tank
(Frame 1 and 2 Machines)
44
Fig. 34 — Typical Optional Pumpout System Piping Schematic Without Storage Tank
(Frame 4 Machines)
45
Table 6A — HCFC-22 Pressure — Temperature (F)
TEMPERATURE (F)
-50
-48
-46
-44
-42
-40
-38
36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
- 8
- 6
- 4
- 2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
PRESSURE (psi)
Absolute
Gage
11.67
6.154*
12.34
4.829*
13.00
3.445*
13.71
2.002*
14.45
0.498*
15.22
0.526
16.02
1.328
16.86
2.163
17.73
3.032
18.63
3.937
19.57
4.877
20.55
5.853
21.56
6.868
22.62
7.921
23.71
9.015
24.85
10.15
26.02
11.32
27.24
12.54
28.50
13.81
29.81
15.11
31.16
16.47
32.56
17.87
34.01
19.32
35.51
20.81
37.06
22.36
38.66
23.96
40.31
25.61
42.01
27.32
43.78
29.08
45.59
30.90
47.46
32.77
49.40
34.70
51.39
36.69
53.44
38.74
55.55
40.86
57.73
43.03
59.97
45.27
62.27
47.58
64.64
49.95
67.08
52.39
TEMPERATURE (F)
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
PRESSURE (psi)
Absolute
Gage
69.59
54.90
72.17
57.47
74.82
60.12
77.54
62.84
80.34
65.64
83.21
68.51
86.15
71.46
89.18
74.48
92.28
77.58
95.46
80.77
98.73
84.03
102.07
87.38
105.50
90.81
109.02
94.32
112.62
97.93
116.31
101.62
120.09
105.39
123.96
109.26
127.92
113.22
131.97
117.28
136.12
121.43
140.37
125.67
144.71
130.01
149.15
134.45
153.69
138.99
158.33
143.63
163.07
148.37
167.92
153.22
172.87
158.17
177.93
163.23
183.09
168.40
188.37
173.67
193.76
179.06
199.26
184.56
204.87
190.18
210.60
195.91
216.45
201.76
222.42
207.72
228.50
213.81
234.71
220.02
TEMPERATURE (F)
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
PRESSURE (psi)
Absolute
Gage
241.04
226.35
247.50
232.80
254.08
239.38
260.79
246.10
267.63
252.94
274.60
259.91
281.71
267.01
288.95
274.25
296.33
281.63
303.84
289.14
311.50
296.80
319.29
304.60
327.23
312.54
335.32
320.63
343.56
328.86
351.94
337.25
360.48
345.79
369.17
354.48
378.02
363.32
387.03
372.33
396.19
381.50
405.52
390.83
415.02
400.32
424.68
409.99
434.52
419.82
444.53
420.83
*Inches of mercury below one atmosphere.
Table 6B — HCFC-22 Pressure — Temperature (C)
TEMPERATURE (C)
-18
-17
-16
-15
-14
-13
-12
-11
-10
- 9
- 8
- 7
- 6
- 5
- 4
- 3
- 2
- 1
0
1
2
3
4
5
6
7
8
9
10
PRESSURE (kPa)
Absolute
Gage
264
274
284
296
307
318
330
342
354
367
380
393
407
421
436
451
466
482
498
514
531
548
566
584
602
621
641
660
681
163
173
183
195
206
217
229
241
253
266
279
292
306
320
335
350
365
381
397
413
430
447
465
483
501
520
540
559
580
TEMPERATURE (C)
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
46
PRESSURE
Absolute
701
723
744
766
789
812
836
860
885
910
936
962
989
1020
1040
1070
1100
1130
1160
1190
1220
1260
1290
1320
1360
1390
1420
1460
1500
1530
(kPa)
Gage
600
622
643
665
688
711
735
759
784
809
835
861
888
919
939
969
1000
1030
1060
1090
1120
1160
1190
1220
1260
1290
1320
1360
1400
1430
TEMPERATURE (C)
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
PRESSURE
Absolute
1570
1610
1650
1690
1730
1770
1810
1850
1900
1940
1980
2030
2080
2130
2170
2220
2270
2320
2370
2430
2480
2530
2590
2640
2700
2760
2820
2870
2930
3000
(kPa)
Gage
1470
1510
1550
1590
1630
1670
1710
1750
1800
1840
1890
1930
1980
2030
2070
2120
2170
2220
2270
2330
2380
2430
2490
2540
2600
2660
2720
2770
2830
2900
Table 6C — HFC-134a Pressure — Temperature (F)
TEMPERATURE, F
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
Table 6D — HFC-134a Pressure — Temperature (C)
PRESSURE (psig)
6.50
7.52
8.60
9.66
10.79
11.96
13.17
14.42
15.72
17.06
18.45
19.88
21.37
22.90
24.48
26.11
27.80
29.53
31.32
33.17
35.08
37.04
39.06
41.14
43.28
45.48
47.74
50.07
52.47
54.93
57.46
60.06
62.73
65.47
68.29
71.18
74.14
77.18
80.30
83.49
86.17
90.13
93.57
97.09
100.70
104.40
108.18
112.06
116.02
120.08
124.23
128.47
132.81
137.25
141.79
146.43
151.17
156.01
160.96
166.01
171.17
176.45
181.83
187.32
192.93
198.66
204.50
210.47
216.55
222.76
229.09
TEMPERATURE, C
-18.0
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.0
5.6
6.1
6.7
7.2
7.8
8.3
8.9
9.4
10.0
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
47
PRESSURE (kPa)
44.8
51.9
59.3
66.6
74.4
82.5
90.8
99.4
108.0
118.0
127.0
137.0
147.0
158.0
169.0
180.0
192.0
204.0
216.0
229.0
242.0
248.0
255.0
261.0
269.0
276.0
284.0
290.0
298.0
305.0
314.0
329.0
345.0
362.0
379.0
396.0
414.0
433.0
451.0
471.0
491.0
511.0
532.0
554.0
576.0
598.0
621.0
645.0
669.0
694.0
720.0
746.0
773.0
800.0
828.0
857.0
886.0
916.0
946.0
978.0
1010.0
1042.0
1076.0
1110.0
1145.0
1180.0
1217.0
1254.0
1292.0
1330.0
1370.0
1410.0
1451.0
1493.0
1536.0
1580.0
Do not apply greater vacuum than 29.82 in. Hg vac
(.4 kPa absolute) or go below 33 F (.56 C) on the wet
bulb vacuum indicator. At this temperature/pressure, isolated pockets of moisture can turn into ice. The slow rate
of evaporation (sublimination) of ice at these low
temperatures/pressures greatly increases dehydration time.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If
the reading indicates vacuum loss, repeat Steps 4 and 5.
7. If the reading continues to change after several attempts,
perform a leak test up to the maximum 230 psig (1585
kPa) pressure. Locate and repair the leak, and repeat dehydration.
Standing Vacuum Test — When performing the standing vacuum test or machine dehydration, use a manometer
or a wet bulb indicator. Dial gages cannot indicate the small
amount of leakage acceptable during a short period of time.
1. Attach an absolute pressure manometer or wet bulb indicator to the machine.
2. Evacuate the vessel using a vacuum pump or the pumpout unit (see Pumpout and Refrigerant Transfer Procedures section on page 61) to the pressure level specified
by the EPA under 40 CFR Part 82.
3. Valve off the pump to hold the vacuum and record the
manometer or indicator reading.
4. a. If the leakage rate is less than 0.05 in. Hg (.17 kPa) in
24 hours, the machine is sufficiently tight.
b. If the leakage rate exceeds 0.05 in. Hg (.17 kPa) in 24
hours, repressurize the vessel and test for leaks. If refrigerant is available in the other vessel, pressurize by
following Steps 2 - 10 of Return Refrigerant To Normal Operating Conditions section, on page 63. If not,
use nitrogen and a refrigerant tracer. Raise the vessel
pressure in increments until the leak is detected. If
refrigerant is used, the maximum gas pressure is approximately 120 psig (827 kPa) [70 psig (483 kPa)] at
normal ambient temperature. If nitrogen is used,
limit the leak test pressure to 230 psig (1585 kPa)
maximum.
5. Repair leak, retest, and proceed with dehydration.
Fig. 35 — Dehydration Cold Trap
Machine Dehydration — Dehydration is recommended if the machine has been open for a considerable period of time, if the machine is known to contain moisture, or
if there has been a complete loss of machine holding charge
or refrigerant pressure.
Inspect Water Piping — Refer to piping diagrams provided in the certified drawings, and the piping instructions
in the 23XL Installation Instructions manual. Inspect the piping to the cooler and condenser. Be sure that flow directions
are correct and that all piping specifications have been met.
Piping systems must be properly vented, with no stress on
water box nozzles and covers. Water flows through the cooler
and condenser must meet job requirements. Measure the pressure drop across cooler and across condenser.
Do not start or megohm test the compressor motor if the
machine is under dehydration vacuum. Insulation breakdown and severe damage may result.
Dehydration is readily accomplished at room temperatures. Use of a cold trap (Fig. 35) may substantially reduce
the time required to complete the dehydration. The higher
the room temperature, the faster dehydration takes place. At
low room temperatures, a very deep vacuum is required for
boiling off any moisture. If low ambient temperatures are
involved, contact a qualified service representative for the
dehydration techniques required.
Perform dehydration as follows:
1. Connect a high capacity vacuum pump (5 cfm
[.002 m3/s] or larger is recommended) to the refrigerant
charging valve (Fig. 2A and 2B). Tubing from the pump
to the machine should be as short and as large a diameter
as possible to provide least resistance to gas flow.
2. Use an absolute pressure manometer or a wet bulb vacuum
indicator to measure the vacuum. Open the shutoff valve
to the vacuum indicator only when taking a reading. Leave
the valve open for 3 minutes to allow the indicator vacuum
to equalize with the machine vacuum.
3. Open all isolation valves, if present, if the entire machine
is to be dehydrated.
4. With the machine ambient temperature at 60 F (15.6 C)
or higher, operate the vacuum pump until the manometer
reads 29.8 in. Hg (.7 kPa absolute), ref 30 in. bar, or a
vacuum indicator reads 35 F (1.7 C). Operate the pump
an additional 2 hours.
Water must be within design limits, clean, and treated
to ensure proper machine performance and reduce the
potential of tubing damage due to corrosion, scaling, or
erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated
water.
Check Optional Pumpout Compressor Water Piping — If the optional storage tank and/or pumpout system
are installed, check to ensure the pumpout condenser water
has been piped in. Check for field-supplied shutoff valves
and controls as specified in the job data. Check for refrigerant leaks on field-installed piping. Refer to the Pumpout
and Refrigerant Transfer Procedures section on page 61.
Check Relief Devices — Be sure that relief devices
have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable
local safety codes. Piping connections must allow for access
to the valve mechanism for periodic inspection and leak
testing.
48
11. Ensure that the voltage selector switch inside the power
panel is switched to the incoming voltage rating.
12. On machines with free-standing starters, inspect the power
panel to ensure that the contractor has fed the wires into
the bottom of the panel. Wiring into the top of the panel
can cause debris to fall into the contactors. Clean and
inspect the contactors if this has occurred.
Inspect Wiring
Do not apply any kind of test voltage if the machine is
under a dehydration vacuum. Insulation breakdown and
serious damage may result.
Carrier Comfort Network Interface — The Carrier
1. Examine wiring for conformance to job wiring diagrams and to all applicable electrical codes.
2. Connect voltmeter across the power wires to the compressor starter and measure the voltage. Compare this
reading with the voltage rating on the compressor and
starter nameplates.
3. Compare the ampere rating on the starter nameplate with
the compressor nameplate. The overload trip amps must
be 108% to 120% of the rated load amps.
4. The starter for a screw compressor motor must contain
the components and terminals required for PIC refrigeration control. Check certified drawings.
5. Check the voltage to the pumpout compressor starter and
power panel and compare to the nameplate values.
6. Be sure that fused disconnects or circuit breakers have
been supplied for the power panel and pumpout unit.
7. Check that all electrical equipment and controls are properly grounded in accordance with job drawings, certified drawings, and all applicable electrical codes.
8. Make sure that the customer’s contractor has verified
proper operation of the pumps, cooling tower fans, and
associated auxiliary equipment. This includes ensuring
that motors are properly lubricated and have proper electrical supply and proper rotation.
9. For field-installed starters only, test the machine compressor motor and its power lead insulation resistance
with a 500-v insulation tester such as a megohmmeter.
Factory-mounted starters do not require a megohm test.
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication
bus in a daisy chain arrangement. The positive pin of each
system element communication connector must be wired to
the positive pins of the system element on either side of it;
the negative pins must be wired to the negative pins; the signal ground pins must be wired to signal ground pins.
To attach the CCN communication bus wiring, refer to
the certified prints and wiring diagrams. The wire is inserted
into the CCN communications plug (COMM1) on the PSIO
module. This plug also is referred to as J5.
NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon,
vinyl, Teflon, or polyethylene. An aluminum/polyester 100%
foil shield and an outer jacket of PVC, PVC/nylon, chrome
vinyl or Teflon with a minimum operating temperature range
of −20 C to 60 C is required. See table below for cables that
meet the requirements.
MANUFACTURER
Alpha
American
Belden
Columbia
CABLE NO.
2413 or 5463
A22503
8772
02525
When connecting the CCN communication bus to a system element, a color code system for the entire network is
recommended to simplify installation and checkout. The following color code is recommended:
SIGNAL CCN BUS CONDUCTOR
PSIO MODULE
TYPE
INSULATION COLOR COMM 1 PLUG (J5) PIN NO.
+
RED
1
Ground
WHITE
2
BLACK
3
If the motor starter is a solid-state starter, the motor leads must be disconnected from the starter before an insulation test is performed. The voltage
generated from the tester can damage the starter’s
solid-state components.
Check Starter
b. With the tester connected to the motor leads, take 10second and 60-second megohm readings as
follows:
6-Lead Motor — Tie all 6 leads together and test between the lead group and ground. Next tie leads in
pairs, 1 and 4, 2 and 5, and 3 and 6. Test between
each pair while grounding the third pair.
3-Lead Motor — Tie terminals 1, 2, and 3 together
and test between the group and ground.
c. Divide the 60-second resistance reading by the
10-second reading. The ratio, or polarization index,
must be one or higher. Both the 10- and 60-second
readings must be at least 50 megohms.
If the readings on a field-installed starter are unsatisfactory, repeat the test at the motor with the power
leads disconnected. Satisfactory readings in this second test indicate the fault is in the power leads.
NOTE: Unit-mounted starters do not have to be megohm tested.
10. Tighten up all wiring connections to the plugs on the
SMM, 8-input, and PSIO modules.
BE AWARE that certain automatic start arrangements
can engage the starter. Open the disconnect ahead of
the starter in addition to shutting off the machine or pump.
Use the instruction and service manual supplied by the
starter manufacturer to verify that the starter has been installed correctly.
The main disconnect on the starter front panel may not
deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.
When a starter safety trip device activates, wait at least 30
seconds before resetting the safety. The microprocessor maintains its output to the 1CR relay for 10 seconds to determine
the fault mode of failure.
49
when the board is turned on its side so that the 9:00 o’clock
position is located where the 6:00 o’clock position would
normally be located. The ramp potentiometer should be
set that so the motor is up to full speed in 8 to 10 seconds,
the bypass contactors have energized, and the auxiliary
LCD is energized.
7. Proceed to apply power to the starter.
8. The Power +15 and Phase Correct LEDs should be on. If
not, see the Troubleshooting Guide, Solid-State Starter
section.
MECHANICAL-TYPE STARTERS
1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection.
2. Check the contactor(s) to be sure they move freely. Check
the mechanical interlock between contactors to ensure that
1S and 2M contactors cannot be closed at the same time.
Check all other electro-mechanical devices, e.g., relays,
timers, for free movement. If the devices do not move
freely, contact the starter manufacturer for replacement
components.
3. Some dashpot-type magnetic overload relays must be filled
with oil on the job site. If the starter is equipped with
devices of this type, remove the fluid cups from these magnetic overload relays. Add dashpot oil to cups per instructions supplied with the starter. The oil is usually shipped
in a small container attached to the starter frame near the
relays. Use only dashpot oil supplied with the starter. Do
not substitute.
Factory-filled dashpot overload relays need no oil at start-up
and solid-state overload relays do not have oil.
4. Reapply starter control power (not main chiller power) to
check electrical functions. When using a reduced-voltage
starter (such as a wye-delta type) check the transition timer
for proper setting. The factory setting is 5 seconds (±1
second), timed closing. The timer is adjustable in a range
from 0.1 to 30 seconds and settings other than the nominal 5 seconds may be chosen as needed (typically 3 to 30
seconds are used).
When the timer has been set, check that the starter, with
relay 1CR closed, goes through a complete and proper
start cycle.
BENSHAW, INC. SOLID-STATE STARTERS
Oil Charge — If oil is added, it must meet Carrier’s specification for screw compressor usage as described in the Changing Oil and Oil Filter section on page 64. Charge the oil through
the oil charging valve. The oil must be pumped from the oil
container through the charging valve due to higher refrigerant pressure. The pumping device must be able to lift from
0 to 200 psig (0 to 1380 kPa) or above unit pressure. Oil
should only be charged or removed when the machine is
shut down.
All oil filter isolation valves should always be left open,
except when changing the oil, or oil filter as defined in
the Changing Oil and Oil Filter section, page 64.
Power Up the Controls and Check the Oil Heater
NOTE: Frame 1 and 2 machines include an oil heater.
Frame 4 machines do not use an oil heater.
Ensure that an oil level is visible in the oil sump section
before energizing controls. A circuit breaker in the starter
energizes the oil heater and the control circuit. When first
powered, the LID should display the default screen within a
short period of time.
The oil heater is energized by powering the control circuit. This should be done several hours before start-up to
minimize oil-refrigerant migration. The oil heater is controlled by the PIC and is powered through a contactor in the
power panel. Starters contain a separate circuit breaker to
power the heater and the control circuit. This set up allows
the heater to energize when the main motor circuit breaker
is off for service work or extended shutdowns. The oil heater
relay status can be viewed on the Status02 table on the LID.
Oil sump temperature can be viewed on the LID default screen.
Minimum oil sump temperature set point when the compressor is shut down is 140 F (60 C).
NOTE: The PSIO software version will always be labelled
on the PSIO module and on the back of the LID module.
The PSIO software version number will also appear on both
the Controller ID and LID ID display screens.
This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on
the equipment.
1. Check that all wiring connections are properly terminated to the starter.
2. Verify that the ground wire to the starter is installed properly and is of sufficient size.
3. Verify that the motors are properly grounded to the starter.
4. Check that all of the relays are properly seated in their
sockets.
5. Verify that the proper ac input voltage is brought into the
starter per the certified drawings.
6. Verify the initial factory settings of the starting torque and
ramp potentiometers are set per the note on the schematic
for the starters.
NOTE: The potentiometers are located at the lower left
hand corner on the circuit board mounted in front of the
starter power stack (Fig. 36 and 37). The board is turned
on its side so that the 9:00 o’clock position is located where
the 6:00 o’clock position would normally be located.
The starting torque potentiometer should be set so that
when the PIC calls for the motor to start, the rotor should
start to turn. The nominal dial position for a 60 Hz motor
is approximately in the 11:30 position. The dial position
for 50 Hz motors is approximately in the 9:30 position
Set Up Machine Control Configuration
Do not operate the machine before the control configurations have been checked and a control test has been
satisfactorily completed. Protection by safety controls
cannot be assumed until all control configurations have
been confirmed.
As configuration of the 23XL machine is performed, write
down all configuration settings. A log, such as the one shown
on pages CL-1 to CL-12, provides a convenient list for configuration values.
50
CUTLER-HAMMERt SOLID-STATE STARTERS
This equipment is at line voltage when ac power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on
the equipment.
1. Check that all wiring connections are properly terminated to the starter.
2. Verify that the ground wire to the starter is installed properly and is of sufficient size.
3. Verify that the motor is properly grounded to the starter.
4. Check that all of the relays are properly seated in their
sockets.
5. Verify that the proper ac input voltage is brought into the
starter. Refer to the certified drawings.
The order in which the solid-state control module adjustment potentiometers are set is important because of the interdependency of these functions. See Table 7 and Fig. 38.
The settings should be made in the following sequence:
Potentiometer Adjustment
NOTE: All potentiometers are factory set. The following information is provided for reference.
Adjustment potentiometers are nearly linear. To make an
initial setting, determine the percentage of the potentiometer
rotation. Use the following formula to calculate the percent
of rotation. See Fig. 38 and 39.
% of rotation = (desired setting) −(minimum setting)
(maximum setting) −(minimum setting)
Example: Starting current is adjustable between 100% and
400% of motor full load current. The initial setting for 200%
starting current is as follows:
LEGEND
1 — Phase Voltage Indicator
3 — Starting Torque Potentiometer
2 — Starter Fault and Run LEDs (5) 4 — Ramp Up Potentiometer
• Overtemp
5 — Phase Correct LED
• Ground Fault
6 — Relay On LED
• Current Unbalance (CUB)
7 — Power +15 and Auxiliary (Starter
While Stopped
in RUN State) LEDs (Hidden)
• Current Unbalance
8 — SCR Indicator LEDs (Hidden)
• Run (Start Initiated)
9 — Reset Button
Fig. 36 — Typical Benshaw, Inc. Solid-State Starter
Power Stack
1
% of rotation = (200%) − (100%) = ⁄3 of full rotation (33%)
(400%) −(100%)
Do not adjust any potentiometer beyond its stops.
This type of adjustment will result in damage to the
potentiometer.
NOTE: Adjustments:
Starting torque — 0% to 100% rated motor torque.
Ramp time to full motor voltage — 0.5 seconds to
60 seconds.
Fig. 37 — Ramp Up and Starting Torque
Potentiometers
Fig. 38 — Typical Cutler-Hammer Solid-State
Starters
51
Table 7 — Potentiometer Adjustment
DIAL
Starting Current
ADJUSTMENT RANGE
Minimum
Maximum
(CCW)
(CW)
100%
400%
Ramp Time
(Adjustable
Current Ramp)
2
seconds
30
seconds
Current Limit
100%
400%
Pulse Start
0 (Off)
2 seconds
Current Trip
Power Saver
50%
—
400%
—
CCW —
CW
—
FUNCTION
Sets initial starting
current level.
Sets time during which
current ramps from the
initial starting level to the
maximum possible
current limit setting.
Sets maximum
starting current.
Sets duration of 400%
current pulse. Pulse
is used to break
load free.
Sets running current trip.
—
Pulse Start — A pulse start is not used on this machine. It is
set to the OFF position.
Current Trip — A control contact closes when the motor reaches
a factory set value of 175% of full load amps. This signal is
used as an interlock to shut down the machine if the motor
stalls (increasing load).
Changing Adjustments — The settings are interdependent.
If any setting is changed, the other settings should be checked.
Check the settings in the sequence shown above.
Voltage Measurements — Consider the following when checking voltage measurements:
• Before energizing the starter, check the incoming lines for
properly balanced voltages.
• Close the circuit breaker to apply power to the starter. Verify
the 120 vac control voltage.
• Visually check to ensure that all fans are running (if
applicable).
• Verify phase sequence at line terminals. Incorrect phase
sequence will result in a shunt trip of the circuit breaker.
• Verify that the phase rotation of the lines to the motor is
correct.
• If the motor is found to be rotating in the wrong direction,
interchange any two phases to the motor.
• Start the unit.
• When unit reaches full speed, monitor the running current
to ensure that the motor is not overloaded.
FACTORY
SETTING
100%
10 seconds
250%
OFF
175%
OFF
Counterclockwise
Clockwise
High Altitude Locations — Recalibration of the pressure transducers will be necessary since the machine was
initially calibrated at sea level. Please see the calibration procedure in the Troubleshooting Guide section on page 68.
Input the Design Set Points — Access the LID Set
Point menu and view/modify the Base Demand Limit set point
and either the LCW set point, the ECW set point, or Ice Build
set point. The PIC can control a set point to either the leaving or entering chilled water. This control method is set in
the Equipment Configuration menu Config table. See
Fig. 21.
Fig. 39 — Typical Potentiometer Adjustment
Input the Local Occupied Schedule (OCCPC01S)
— Access the schedule OCCPC01S screen on the LID and
Starting Current — The torque required to start a machine
(initial torque) varies from one application to another. Starting current may be adjusted to match the initial motor torque
of the application. The starting current value is adjustable
from 100% to 400% FLA and is factory set at 100%. If quick
acceleration is desired, set the starting current at a higher
level.
Ramp Time (Adjustable Current Ramp) — The motor current is ramped up from the starting current value over a timed
period set by the ramp time potentiometer (adjustable from
2 to 30 seconds at 400% current limit setting). The 23XL is
factory set at 10 seconds. However, based on jobsite conditions, a range of ±5 seconds is acceptable.
Current Limit — This protection limits motor current to a
set value and holds motor torque at a reduced level during
motor start. The current limit is adjustable from 100% to 400%
of the motor full load current value. The current limit is factory set at 250%.
set up the occupied time schedule per the customer’s requirements. If no schedule is available, set it for 24 hours
occupied days per week including holidays. This is also the
default setting of the schedule. For this schedule, modify Period 1 for ON at 0000 and OFF at 2400 and enable the period to be in effect for all days and holidays. For more information about how to set up a time schedule, read the Controls
section, page 13.
The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary
time schedule is required. It normally is input through the
CCN Building Supervisor, but it can also be modified at the
LID.
52
Configure Service1 Table — Access Service1 table to modify/
view the following to jobsite parameters:
Selecting Refrigerant Type — The 23XL control must
be configured for the refrigerant being used, either HCFC-22
or HFC-134a.
TO CONFIRM REFRIGERANT TYPE — Confirm that the
correct refrigerant type is indicated by entering the Service
menu and selecting Control Test. See Fig. 21. Select Refrigerant Type. The screen will display the current refrigerant
setting. Press EXIT softkey to leave the screen without changes.
TO CHANGE REFRIGERANT TYPE — Enter the Service
menu and select Control Test. See Fig. 21. Select Refrigerant Type. The screen will display the current refrigerant setting. Press the YES softkey to change the current setting.
Next, move to the Attach To Network Device menu and select ATTACH TO LOCAL DEVICE to upload the new refrigerant tables.
Chilled Medium
Brine Refrigerant Trip Point
Hot Gas Bypass Option
Minimum Load Points (T1/P1)
Maximum Load Points (T2/P2)
Motor Rated Load Amps
Motor Rated Line Voltage
Motor Rated Line KW
Line Frequency
Compressor Starter Type
Water or Brine
Usually 3° F (1.7° C) below design
refrigerant temperature
Is HGBP installed?
Per job data — See Modify Load
Points section
Per job data — See Modify Load
Points section
Per job data
Per job data
Per job data
50 or 60 Hz (if optional kW
transducer installed)
Reduced voltage or full voltage
NOTE: Other values are left at the default values. These may be changed by
the operator as required. Service2 and Service3 tables can be modified by the
owner/operator, as required.
Input Service Configurations — The following configurations require the LID screen to be in the Service portion of the menu.
• password
• input time and date
• LID configuration
• controller identification
• service parameters
• equipment configuration
• automated controls test
PASSWORD — When accessing the Service screens, a password must be entered. All LIDs are initially set for a password of 1-1-1-1. This password may be changed in the LID
configuration screen, if desired. See Fig. 21.
INPUT TIME AND DATE — Access the Time and Date
menu on the Service menu. Input the present time of day,
date, and day of the week. ‘‘Holiday Today’’ should only be
configured to ‘‘Yes’’ if the present day is considered a onetime holiday. This causes the chiller to start and stop as depicted by the holiday configuration under the appropriate time
schedule screen.
CHANGE LID CONFIGURATION IF NECESSARY — The
LID Configuration on the service menu is used to view or
modify the LID CCN address, change to English or SI units
and to change the password. If there is more than one machine at the jobsite, change the LID address on each machine so that each machine has its own address. Note and
record the new address. Change to SI units, as required, and
change the password, if desired.
MODIFY CONTROLLER IDENTIFICATION, IF NECESSARY — The controller identification screen is used to change
the PSIO module address. Change this address for each machine if there is more than one machine at the jobsite. Write the new address on the PSIO module for future
reference.
Change the LID address if there is more than one machine
on the jobsite. Access the LID configuration screen to view
or modify this address.
INPUT EQUIPMENT SERVICE PARAMETERS AS NECESSARY — The Equipment Service table has three service
tables: Service1, Service2, and Service3.
Modify Minimum and Maximum Load Points (DT1/P1;
D T2/P2) —The pairs of machine load points, located on the
Service1 table, determine when to open the hot gas bypass
solenoid valve. The points should be set based on individual
machine operating conditions.
Close the ball valve, located next to the hot gas solenoid
valve, halfway. The purpose of the ball valve is to act as an
isolation valve and to control the amount of gas flow by adjusting the flow to accommodate different frame sizes and
jobsite conditions.
If, after setting the ball valve for these points, any additional adjustment should be changed by the operator.
Example of configuration: Machine operating parameters
Estimated Minimum Load Conditions:
44 F (6.7 C) LCW
46.5 F (8.1 C) ECW
43 F (6.1 C) Suction Temperature
70 F (21.1 C) Condensing Temperature
Estimated Maximum Load Conditions:
44 F (6.7 C) LCW
54 F (12.2 C) ECW
42 F (5.6 C) Suction Temperature
98 F (36.7 C) Condensing Temperature
Calculate Maximum Load — To calculate maximum load
points, use design load condition data.
Maximum Load DT2:
54 - 44 = 10 F (12.2 - 6.7 = 5.5 C)
Maximum Load DP2:
(Factory Recommended Setting)
200 psi (1379 kPa)[125 psi (862 kPa)]
Calculate Minimum Load — To calculate minimum load conditions, estimate the temperature difference that the cooler
will have at 25% load or lower, then estimate what the suction and condensing temperatures will be at this point.
Suction Temperature:
43 F (6.1 C) = 73 psig (503 kPa) saturated
refrigerant pressure
Condensing Temperature:
70 F (21.1 C) = 121 psig (834 kPa) saturated
refrigerant pressure
53
Minimum Load DT1:
46.5 −44 = 2.5 F (8.1 −6.7 = 1.4 C)
Minimum Load DP1:
121 − 73 = 45 psid (834 - 503 = 331 kPad)
To avoid unnecessary opening of the hot gas bypass valve,
add 5 psi (35 kPa) at DP1 from these conditions:
DT1 = 2.5 F (1.4 C)
DP1 = 50 psid (345 kPad) [30 psid (207 kPad)]
If opening of the hot gas bypass valve occurs too soon or too
late for the present conditions these parameters should be
changed by the operator. Only the minimum load points change
is required.
Energizing the hot gas bypass solenoid valve with the ball
valve fully open and the cold condenser water at a very low
temperature will result in the equalization of evaporator and
condenser pressure. This will result in a ‘‘Low Oil Pressure’’
alarm. See the Lubrication Cycle section on page 7.
MODIFY EQUIPMENT CONFIGURATION AS NECESSARY — The Equipment Configuration table has tables to
select and view or modify. Carrier’s certified drawings will
have the configuration values required for the jobsite. Modify
these tables only if requested.
Config Table Modifications — Change the values in this table
per job data. See certified drawings for values. Modifications include:
• chilled water reset
• entering chilled water control (Enable/Disable)
• 4-20 mA demand limit
• auto restart option (Enable/Disable)
• remote contact option (Enable/Disable)
Owner-Modified CCN Tables — The following tables are described for reference only.
Occdefcs Table Modifications — The Occdefcs tables contain the Local and CCN time schedules, which can be modified here, or in the Schedule menu selection as described
previously.
Holidef Table Modifications — The Holidef tables configure
the days of the year that holidays are in effect. See the holiday paragraphs in the Controls section for more
details.
Brodefs Table Modifications — The Brodefs screen defines
the outside air temperature sensor and humidity sensor (if
installed). It will define the start and end of daylight savings
time. Enter the dates for the start and end of daylight savings
if required for the location. Brodefs also will activate the
Broadcast function which enables the holiday periods that
are defined on the LID.
Other Tables — The Alarmdef, Cons-def, and Runt-def contain tables for use with a CCN system. See the applicable
CCN manual for more information on these tables.
These tables can only be defined through a CCN Building
Supervisor.
CHECK VOLTAGE SUPPLY — Access the Status01 table
and read the actual line voltage. This reading should be equal
to the incoming power to the starter. Use a voltmeter to check
incoming power at the starter power leads. If the readings
are not equal, an adjustment can be made to the 24-v input
to the SMM at a potentiometer located in the low voltage
section to equalize the two readings.
PERFORM AN AUTOMATED CONTROL TEST — Check
the safety controls status by performing an automated control test. Access the Control Test table and select the
Automated Tests function (Table 8).
The automated control test will check all outputs and inputs for function. It will also set the refrigerant type. The
compressor must be in the OFF mode in order to operate the
controls test and the 24-v input to the SMM must be in range
(per line voltage percent on Status01 table). The OFF mode
is caused by pressing the STOP pushbutton on the LID located on the left side of the four softkeys). Each test will ask
the operator to confirm that the operation is occurring, and
whether or not to continue. If an error occurs, the operator
has the choice to try to address the problem as the test is
being run or to note the problem and proceed to the next
test.
When the test is finished, or the EXIT softkey is pressed,
the test will be stopped and the Control Test table will be
displayed. If a specific automated test procedure is not completed, access that particular controls test to test the function
when ready. The Control Test table is described as
follows:
Automated Tests
PSIO Thermistors
Option Module
Thermistors
Transducers
Slide Valve
Pumps
Discrete Outputs
Pumpdown
Terminate Lockout
Refrigerant Type*
As described above, a complete
controls test.
Check of all PSIO
thermistors only.
Check of all option
module thermistors.
Check of all transducers.
Check of the slide valve
operation.
Check operation of pump outputs,
either all pumps can be
activated, or individual pumps
can be activated.
The test will also test
the associated input such as
flow or pressure.
Activation of all on/off
outputs or individual on/off outputs.
Pumpdown prevents the low
refrigerant alarm during
evacuation so refrigerant
can be removed from the unit.
Pumpdown also locks the
compressor off and
starts the water pumps.
Charges refrigerant and enables
the chiller to run after pumpdown
lockout.
Sets type of refrigerant used:
HCFC-22 or HFC-134a.
*Make sure to Attach to Local Device after changing refrigerant type.
Refer to Selecting Refrigerant Type section on page 53.
54
Table 8 — Control Test Table Functions
Charge Refrigerant into Machine
TESTS TO BE PERFORMED
1. Automated Tests*
2. PSIO Thermistors
3.
4.
5.
6.
7.
8.
9.
10.
DEVICES TESTED
Operates the second through seventh tests
Entering chilled water
Leaving chilled water
Entering condenser water
Leaving condenser water
Discharge temperature
Motor winding temperature
Oil sump temperature
Option Module Thermistors Common chilled water supply sensor
Common chilled water return sensor
Remote reset sensor
Temperature sensor — Spare 1
Spare 2
Spare 3
Spare 4
Spare 5
Spare 6
Spare 7
Spare 8
Spare 9
Transducers
Evaporator pressure
Condenser pressure
Oil pressure
Oil pressure differential
Slide Valve Assembly
Load (Close
Unload (Open)
Pumps
Either or both pumps may be
activated:
Chilled water pump — Confirm flow
Condenser water pump — Confirm flow
Discrete Outputs
All outputs or individual outputs may be
energized:
Hot gas bypass relay
Oil heater relay (Frame 1 and 2 Machines)
VI inlet relay
Tower fan relay
Alarm relay
Pumpdown
When using pumpdown lockout,
observe freeze-up precautions when
removing charge:
Instructs operator as to which valves to
close and when
Starts chilled water and condenser
water pumps and confirms flow
Monitors — Evaporator pressure
Condenser pressure
Evaporator temperature
during pumpout
procedures
Turns pumps off after pumpdown
Locks out compressor
Terminate Lockout
Starts pumps and monitors flows
Instructs operator as to which valves to
open and when
Monitors — Evaporator pressure
Condenser pressure
Evaporator temperature
during charging process
Terminates compressor lockout
Refrigerant Type†
Sets the refrigerant type used:
HCFC-22 or HFC-134a
The transfer, addition, or removal of refrigerant in spring
isolated machines may place severe stress on external
piping if springs have not been blocked in both up and
down directions.
The standard 23XL machine will have the refrigerant already charged in the vessels. The 23XL may be ordered with
a nitrogen holding charge of 15 psig (103 kPa). Evacuate the
entire machine, and charge machine from refrigerant
cylinders.
23XL MACHINE EQUALIZATION WITHOUT
PUMPOUT UNIT
When equalizing refrigerant pressure on the 23XL machine after service work or during the initial machine
start-up, do not use the discharge isolation valve to equalize. The motor cooling isolation valve should be used as
the equalization valve.
To equalize the pressure differential on a refrigerant isolated 23XL machine, use the TERMINATE LOCKOUT function of the Control Test from the SERVICE menu. This will
help to turn on pumps and advise the proper procedure. The
following procedure describes how to equalize refrigerant
pressure on an isolated 23XL machine without a pumpout
unit:
1. Access TERMINATE LOCKOUT function on the Controls Test.
2. Turn on the chilled water and condenser water pumps to
ensure against freezing.
3. Slowly open the motor cooling isolation valve 13.
The machine cooler and condenser pressures will gradually equalize. This process will take approximately
15 minutes.
4. Once the pressures have equalized, the condenser isolation valve and cooler isolation valve may be opened. Refer to Fig. 31-34, Valves 11 and 12.
Whenever turning the discharge isolation valve, be sure
to re-attach the valve locking device. This will prevent
the valve from opening or closing during service work
or during machine operation.
*During any of the tests that are not automated, an out-of-range reading will
have an asterisk (*) next to the reading and a message will be displayed.
†Make sure to Attach to Local Device after changing refrigerant type. Refer to
Selecting Refrigerant Type section on page 53. See Fig. 21.
The full refrigerant charge on the 23XL will vary with
machine components and design conditions, indicated on the
job data specifications. An approximate charge may be found
in Table 9.
Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups. Use the
Control Test, Terminate Lockout to monitor conditions and
start the pumps.
If the machine has been shipped with a holding charge,
the refrigerant will be added through the refrigerant charging valve (Fig. 31-34) or to the pumpout charging connection. First evacuate the nitrogen holding charge from the vessels.
Charge the refrigerant as a gas until the system pressure exceeds 68 psig (469 kPa) [35 psig (141 kPa)]. After the machine is beyond this pressure, the refrigerant should be charged
as a liquid until all of the recommended refrigerant charge
has been added.
Check Optional Pumpout System Controls and
Compressor — Controls include an on/off switch, a 3-amp
fuse, the compressor overloads, an internal thermostat,
a compressor contactor, and a refrigerant high pressure
cutout. The high pressure cutout is factory set to open at 220
± 5 psig (1250 ± 34 kPa), and automatically reset at 185
+0,-7 (1280 +0,-48 kPa) with HCFC-22. HFC-134a units open
at 161 psig (1110 kPa) and reset at 130 psig (896 kPa). Check
that the water-cooled condenser has been connected. Loosen
the compressor holddown bolts to allow free spring travel.
Open the compressor suction and discharge service valves.
Check that oil is visible in the compressor sight glass. Add
oil if necessary.
See Pumpout and Refrigerant Transfer Procedures
and Optional Pumpout System Maintenance sections on
pages 61 and 67 for details on transfer of refrigerant, oil specifications, etc.
55
Table 9 — Refrigerant Charges
REFRIGERANT
COOLER SIZE
10,11
20,21
40
41
42
43
ECONOMIZER
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
HCFC-22
lb
600
650
700
750
900
1000
1000
1100
1100
1200
1200
1300
HFC-134a
kg
272
295
318
340
408
454
454
499
499
544
544
590
lb
*
*
*
*
800
850
850
900
900
950
950
1000
kg
*
*
*
*
363
386
386
408
408
431
431
454
*Not available or retrofitable when using HFC-134a.
TRIMMING REFRIGERANT CHARGE — The 23XL is
shipped with the correct charge for the design duty of the
machine. Trimming the charge can be best accomplished when
design load is available. To trim, check the temperature difference between leaving chilled water temperature and cooler
refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the temperature
difference to design conditions or minimum differential. Do
not overcharge.
8. Press RELEASE to automate the chiller start/stop value
on the Status01 table to enable the chiller to start. The
initial factory setting of this value is overridden to stop in
order to prevent accidental start-up.
Dry Run to Test Start-Up Sequence
1. Disengage the main motor disconnect on the starter front
panel. This should only disconnect the motor power. Power
to the controls, and starter control circuit should still be
energized.
2. Look at the default screen on the LID: the Status message in the upper left-hand corner will show that the machine is in the OCCUPIED mode and is ready to
start. If not, go to the Schedule menu and override the
schedule or change the occupied time. Press the
LOCAL softkey to begin the start-up sequences.
3. Check that chilled water and condenser water pumps
energize.
4. After approximately 3 minutes, the starter will be energized and go through its start-up sequence.
5. Check the main contactor for proper operation.
6. The PIC will eventually show an alarm for motor amps
not sensed. Reset this alarm and continue with the initial
start-up.
INITIAL START-UP
Preparation — Before starting the machine, check to ensure that the:
1. Power is on to the main starter, tower fan starter, oil heater
relay (Frame 1 and 2 machines), and the machine control
center.
2. Cooling tower water is at proper level, above 55 F
(12.8 C) but at or below design entering temperature.
3. Machine is charged with refrigerant and all refrigerant
and oil valves are in their proper operating position.
4. Oil is at the proper level in the oil sump sight glass.
5. Oil temperature is above cooler or refrigerant temperature plus 35° F (19° C) on Frame 1 and 2 machines only.
6. Valves in the evaporator and condenser water circuits are
open.
NOTE: If pumps are not automatic, make sure water is
circulating properly.
7. Solid-state starter checks: The Power +15 and the Phase
Correct LEDs must be lit before the starter will energize.
If the Power +15 LED is not on, incoming voltage is not
present or is incorrect. If the Phase Correct LED is not
lit, rotate any 2 incoming phases to correct the phasing.
Check Rotation
1. Engage the main motor disconnect on the front of the starter
panel. The motor is now ready for a rotation check.
2. After the default screen primary Status message states
‘‘READY TO START,’’press the LOCAL softkey. Start-up
checks will be made by the control.
3. When the starter is energized and the motor begins to turn
over, check the default screen Status messages.
If rotation is not proper, the primary Status message states
‘‘FAILURE TO START’’ and ‘‘MOTOR WIRING INCORRECT’’ is displayed for the secondary Status message. Reverse any 2 of the 3 incoming power leads to the starter and
recheck rotation.
Do not permit water or brine that is warmer than 110 F
(43 C) to flow through the cooler or condenser. Refrigerant overpressure may discharge through the relief devices and result in the loss of refrigerant charge.
56
If rotation is proper , allow the compressor to come up to
speed.
NOTE: Starters may have phase protection and will not allow a start if the phase is not correct. Instead, a ‘‘STARTER
FAULT’’ message will occur if this happens.
NOTES ON SOLID-STATE STARTERS
1. When the compressor is energized to start by the 1CR
relay, confirm that the ‘‘Relay On LED’’ is lit on the starter
SCR control board. The compressor motor should start to
turn immediately when this light comes on. If not, adjust
the start torque potentiometer in a clockwise direction.
2. Observe that all 6-gate LEDs are lit on the starter SCR
control board.
3. The factory setting should bring the motor to full
voltage in 3 to 5 seconds on Wye delta starters or 8 to 10
seconds on solid-state starters. If the setting is not correct, adjust the ramp potentiometer counterclockwise for
a shorter time, clockwise for a longer time.
To Prevent Accidental Start-Up — The PIC can be
set up so that start-up of the unit is more difficult than just
pressing the LOCAL or CCN softkeys during machine
service or when necessary. By accessing the Status01
table, and highlighting the chiller Start/Stop line, the value
can be overridden to stop by pressing SELECT and then
the STOP and ENTER softkeys. ‘‘SUPVSR’’ will appear after the value. When attempting to restart, remember
to release the override. The default machine message line
will also state that the Start/Stop has been set to ‘‘Start’’ or
‘‘Stop’’ when the value is overridden.
Check Machine Operating Conditions — Check
to be sure that machine temperatures, pressures, water flows,
and oil and refrigerant levels indicate that the system is functioning properly.
Instruct the Operator — Check to be sure that the operator(s) understands all operating and maintenance procedures. Point out the various machine parts and explain their
function as part of the complete system.
COOLER-CONDENSER — Float valve, relief devices, refrigerant charging valve, temperature sensor locations, pressure transducer locations, Schrader fittings, waterboxes and
tubes, and vents and drains.
OPTIONAL STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant
charging and pumpdown procedure, and relief devices.
MOTOR COMPRESSOR ASSEMBLY — Slide valve
assembly, motor cooling system, temperature and pressure
sensors, motor temperature sensors, and compressor
serviceability.
MOTOR COMPRESSOR LUBRICATION SYSTEM — Oil
heater (Frame 1 and 2 machines), oil charge and specification, synthetic oil, operating and shutdown oil level, temperature and pressure, and oil charging connections.
COMPRESSOR LUBRICATION SYSTEM — Oil sight glass,
operating and shutdown oil level, temperature and pressure
transducers, isolatable oil filter assembly, oil charging and
drain connections, rotor inlet sensors, discharge pressure transducer, and oil charge and specifications.
OIL SEPARATION SYSTEM — Oil sight glasses, sensors,
muffler, and oil level switch (Frame 4 machines only).
CONTROL SYSTEM — CCN and Local start, reset, menu,
softkey functions, LID operation, occupancy schedule, set
points, safety controls, and auxiliary and optional controls.
AUXILIARY EQUIPMENT — Starters and disconnects, separate electrical sources, pumps, and cooling tower.
DESCRIBE MACHINE CYCLES — Refrigerant, motor cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintaining a leak-free machine.
SAFETY DEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.
CHECK OPERATOR KNOWLEDGE — Start, stop, and shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
REVIEW THE START-UP, OPERATION, AND MAINTENANCE MANUAL.
Check Oil Pressure and Compressor Stop
1. Two minutes after start-up, note the oil pressure reading
on the LID default screen. The value is equal to the difference between the oil and evaporator pressure transducer readings. The minimum oil pressure is 20-40 psi
(138-276 kPa) [7-40 psi (48-276 kPa)]. The oil and evaporator pressure transducer readings can be observed on the
Status01 table. A normal full load reading is approximately 120 psi (827 kPa) [78 psi (538 kPa)].
2. Press the STOP softkey and listen for any unusual sounds
from the compressor as it coasts to a stop.
Calibrate Motor Current Demand Setting
NOTE: Entering condenser water temperature must equal design for compressor to meet 100% RLA at designs tons.
1. Make sure that the compressor motor rated load amps in
the Service1 table has been configured. Place an ammeter
on the line that passes through the motor load current transformer on the motor side of the power factor correction
capacitors (if provided).
2. Set the chilled water set point to the desired value.
Highlight the appropriate chilled water set point on
the set point screen then press SELECT . Press
INCREASE or DECREASE to bring the value top
desired value. Press ENTER when equal.
3. Start the compressor and establish a steady motor current
by overriding the Active Demand Limit on the
Status01 table. Highlight this point, then press
SELECT . Press INCREASE or DECREASE to
bring the value between 70% and 100% RLA. Press
ENTER when finished.
4. Compare the compressor motor amps value on the
Status01 table to the actual amps shown on the ammeter
on the starter. Adjust the amps value on the LID to the
actual value seen at the starter if there is a difference. Highlight the amps value then press SELECT . Press
INCREASE or DECREASE to bring the value to that
indicated on the ammeter. Press ENTER when equal.
The adjustments should not be performed in intervals of
more than 10 amps.
5. Gradually increase the Active Demand Limit and repeat
Step 4.
6. When calibration is complete, make sure that the Active
Demand Limit is released to PIC control.
57
7. The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even though
the building load is small. The active electrical demand
setting can be overridden to limit the compressor IKW
(input kilowatt), or the pulldown rate can be decreased to
avoid a high demand charge for the short period of high
demand operation. Pulldown rate can be based on load
rate or temperature rate. It is accessed on the Equipment
Configuration menu Config table (Table 3,
Example 5).
OPERATING INSTRUCTIONS
Operator Duties
1. Become familiar with refrigeration machine and related
equipment before operating the machine.
2. Prepare the system for start-up, start and stop the machine, and place the system in a shutdown condition.
3. Maintain a log of operating conditions and recognize any
abnormal readings.
4. Inspect the equipment, make routine adjustments, and perform a Control Test. Maintain the proper oil and refrigerant levels.
5. Protect the system from damage during shutdown
periods.
6. Maintain set point, time schedules, and other PIC
functions.
To Stop the Machine
1. The occupancy schedule will start and stop the machine
automatically once the time schedule is set up.
2. By pressing the Stop button for one second, the alarm
light will blink once to confirm that the button has been
pressed. Then the compressor will follow the normal shutdown sequence as described in the Controls section
page 13. The machine will not restart until the CCN or
LOCAL softkey is pressed. The machine is now in the
OFF mode.
If the machine fails to stop, in addition to action that the
PIC will initiate, the operator should open the slide valve
to reduce machine load by overriding the slide valve count
to −20. Then, the operator should open the main disconnect.
Prepare the Machine for Start-Up — Follow the
steps described in the Initial Start-Up section on page 56.
To Start the Machine
1. Start the water pumps, if not automatic.
2. On the LID default screen, press the LOCAL or
CCN softkey to start the system. If the machine is in
the OCCUPIED mode, and all machine timers have expired, the start sequence will start. Follow the procedure
described in the Start-Up/Shutdown/Recycle section on
page 37.
Do not attempt to stop the machine by opening an isolating knife switch. High intensity arcing may occur. Do
not restart the machine until the problem is diagnosed
and corrected.
Check the Running System — After the compressor starts, the operator should monitor the LID display and
observe the parameters for normal operating conditions:
1. The oil sump temperature should be 20-40 F (11-20 C)
above the condenser refrigerant temperature. At start-up,
the oil sump temperature will rapidly decrease. It will then
slowly rise to the compressor discharge temperature. After start-up, the minimum oil sump temperature should
be 20 F (11 C) above the condenser refrigerant temperature. The oil sump temperature is dependent upon the compressor discharge refrigerant temperature.
2. When the compressor is running, the oil sump should be
at least 3⁄4 full. The liquid level should be visible in the
separator sight glass.
3. The oil pressure displayed on the LID default screen is
equal to the difference between the oil pressure and evaporator pressure transducer readings. Both readings are shown
on the Status01 table. Typically the reading will be 4 to
20 psi (28 to 138 kPa) [1.4 to 7 psi (9.7 to
48.3 kPa)] at initial start up until oil pressure ramp
up is complete. The full load reading is approximately
120 psi (821 kPa) [78 psi (538 kPa)].
4. The moisture indicator (dry-eye) sight glass on the refrigerant motor cooling line should indicate refrigerant
flow and a dry condition.
5. The condenser pressure and temperature varies with the
machine design conditions. Typically the pressure will range
between 100 and 210 psig (690 to 1450 kPa)
[60 to 135 psig (329 to 780 kPa)] with a corresponding
temperature range of 60 to 105 F (15 to 41 C). The condenser entering water temperature should be controlled
below the specified design entering water temperature to
save on compressor kilowatt requirements but, not be below 55 F (12.8 C).
6. Cooler pressure and temperature also will vary with the
design conditions. Typical pressure range will be between 60 and 80 psig (410 and 550 kPa) [30 to 40 psig
(204 to 260 kPa)] with temperature ranging between
34 and 45 F (1 and 8 C).
After Limited Shutdown — No special preparations
should be necessary. Follow the regular preliminary checks
and starting procedures.
Extended Shutdown — The refrigerant should be transferred into the storage vessel (if supplied; see Pumpout and
Refrigerant Transfer Procedures) in order to reduce machine
pressure and possibility of leaks. Maintain a holding charge
of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant to prevent air
from leaking into the machine.
If freezing temperatures are likely to occur in the machine
area, drain the chilled water, condenser water, and the pumpout condenser water circuits to avoid freeze-up. Keep the
waterbox drains open.
Leave the oil charge in the machine with the oil heater (if
applicable) and controls energized to maintain the minimum
oil sump temperature.
After Extended Shutdown — Be sure that the water
system drains are closed. It may be advisable to flush the
water circuits to remove any soft rust which may have formed.
This is a good time to brush the tubes if necessary.
Check the cooler pressure on the LID default screen, and
compare to the original holding charge that was left in the
machine. If (after adjusting for ambient temperature changes)
any loss in pressure is indicated, check for refrigerant leaks.
See Check Machine Tightness section, page 39.
Recharge the machine by transferring refrigerant from the
storage tank (if supplied). Follow the Pumpout and Refrigerant Transfer Procedures section. Observe freeze-up
precautions.
58
Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the oil
level appears abnormally high, the oil may have absorbed
refrigerant. Frame 4 machines are able to start with an abnormally high oil level. Make sure that the oil temperature
is above refrigerant temperature plus 35° F (19° C) (Frame
1 and 2 machines only).
NOTE: Frame 4 machines do not have an oil heater.
NOTE: The valve can be increased with manual control to
override the pulldown rate during start-up. However, motor
current above the electrical demand setting, capacity overrides, and chilled water below control point will override the
manual count and decrease the slide valve position. For descriptions of capacity overrides and set points, see the Controls section.
Entering a 0 count value will cause the slide valve to maintain a HOLD state. In this condition, the slide valve will respond to maintain the chilled water (DT) temperature when
the override occurs.
Cold Weather Operation — When the entering condenser water drops very low, to a minimum of 55 F (13 C),
the PIC can automatically cycle the cooling tower fans off to
keep the temperature up. Piping may also be arranged to bypass the cooling tower.
Refrigeration Log — A refrigeration log, such as the
one shown in Fig. 40, provides a convenient checklist for
routine inspection and maintenance, and provides a continuous record of machine performance. It is an aid in scheduling routine maintenance and in diagnosing machine
problems.
Keep a record of the machine pressures, temperatures, and
liquid levels on a sheet similar to that shown. Automatic recording of PIC data is possible through the use of CCN devices such as the Data Collection module and a Building Supervisor. Contact your Carrier representative for more
information.
Slide Valve Operation — Manual operation of the slide
valve to check control operation, or to control the valve in
an emergency operation, is possible by overriding the manual
slide valve count. Access the Status01 table on the LID and
highlight MANUAL SLIDE VALVE COUNT. To control slide
valve movement, enter a desired count value. The MANUAL
SLIDE VALVE COUNT has an allowable input range of plus
or minus 20 to provide up to 10 seconds of slide valve movement in the selected direction. If the counts are positive then
the slide valve position will increase to load the compressor
and vice versa. To release the valve to PIC control press the
RELEASE softkey.
59
60
Pressure
Water
COOLER
Temp
Refrigerant
Pressure
Water
CONDENSER
Temp
MACHINE SERIAL NO.
COMPRESSOR
REFRIGERANT TYPE
Oil
Motor
OPERROTOR DISCHARGE
ATOR REMARKS
Filter
FLA
INLET
INITIALS
TEMP
Press. Temp
Press. Temp
Press.
Diff.
Temp
Level
Voltage
TEMP
In Out GPM In Out
In Out GPM In Out
Amperage
Press.
Refrigerant
MACHINE MODEL NO.
Fig. 40 — Refrigeration Log: Carrier 23XL Hermetic Screw Refrigeration Machine
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, operating hours, start counts, and air exhausted. Include amounts.
TIME
DATE
Plant
TRANSFER REFRIGERANT FROM STORAGE TANK TO
MACHINE
NOTE: Valve 14 is only available on Frame 1 and 2 machines. Valves 16 and 17 are only available on Frame 4 machines.
1. Equalize refrigerant pressure.
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
Preparation — The 23XL may come equipped with isolation valves and/or a pumpout system/optional storage tank
for the purpose of servicing the unit. The pumpout system
may come equipped with or without a storage tank. Three
possibilities are available:
1. If isolation valves are supplied, the refrigerant can be pumped
to either the cooler vessel or the condenser vessel by using the optional pumpout system without a storage tank.
2. Whether or not isolation valves are supplied, the refrigerant can be pumped to and isolated in an optional storage tank by using the optional pumpout system.
3. If isolation valves are not supplied, a pumpout system
with a storage tank is needed.
The following procedures are used to describe how to transfer refrigerant from vessel to vessel and perform machine
evacuation.
a. Use the Control Test Terminate Lockout to turn on water pumps and monitor pressures.
b. Close pumpout/storage tank valves 2, 4, 5, and 8, and
close the appropriate machine charging valve 7A and
7B; open appropriate machine isolation valves 11 through
17.
c. Open pumpout/storage tank valves 3 and 6, open machine valves 1a and 1b.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C
C C
C C C
Operating the Optional Pumpout Compressor
1. Be sure that the suction and the discharge service valves
on the optional pumpout compressor are open (backseated) during operation. Rotate the valve stem fully counterclockwise to open. Frontseating the valve closes the
refrigerant line and opens the gage port to compressor
pressure.
2. Make sure that the compressor holddown bolts have been
loosened to allow free spring travel.
3. Open the refrigerant inlet valve on the pumpout
compressor.
4. Oil should be visible in the compressor sight glass under
all operating conditions and during shutdown. If oil is low,
add oil as described under Optional Pumpout
System Maintenance section, page 67. The pumpout unit
control wiring schematic is detailed in Fig. 41.
TO READ REFRIGERANT PRESSURES during pumpout
or leak testing:
1. The LID display on the machine control center is suitable
for determining refrigerant-side pressures and low (soft)
vacuum. For evacuation or dehydration measurement, use
a quality vacuum indicator or manometer to ensure the
desired range and accuracy. This can be placed on the
Schrader connections on each vessel by removing the pressure transducer.
2. To determine storage tank pressure, a 30 in.-0-400 psi (-1010-2760 kPa) gage is attached to the vessel.
3. Refer to Fig. 31-34, and 42 for valve locations and
numbers.
C
Fu
HP
OL
T’stat
—
—
—
—
—
Contactor
Fuse, 3 Amps
High-Pressure Cutout
Compressor Overload
Internal Thermostat
Compressor Terminal
Contactor Terminal
Overload Terminal
Pumpout Unit Terminal
*Bimetal thermal protector imbedded in motor winding.
Fig. 41 — 23XL Pumpout Unit Wiring Schematic
Transfer, addition, or removal of refrigerant in springisolated machines may place severe stress on external
piping if springs have not been blocked in both up and
down directions.
Machines with Storage Tanks — If the machine has
isolation valves, leave them open for the following procedures. The letter ‘‘C’’ describes a closed valve. Valves 9 and
10 on the storage tank are always closed.
Fig. 42 — Optional Pumpout System
61
b. Turn on pumpout condenser water.
c. Place valves in the following positions:
d. Gradually crack open valve 5 to increase machine pressure to 68 psig (469 kPa) [35 psig (141 kPa)]. Slowly
feed refrigerant to prevent freeze up.
e. Open valve 5 fully after reaching 68 psig (469 kPa)
[35 psig (141 kPa)]. Open liquid line valves 7a and 7b
until refrigerant pressure equalizes.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C
C
C C C
d. Run the pumpout compressor until the machine pressure reaches 65 psig (448 kPa), [30 psig (207 kPa)],
then shut off the pumpout. Warm condenser water will
boil off any entrapped liquid refrigerant and machine
pressure will rise.
e. When the pressure rises to 70 psig (483 kPa) [40 psig
(276 kPa)], turn on the pumpout compressor until the
pressure again reaches 65 psig (448 kPa) [30 psig
(207 kPa)], and then turn off the compressor.
Repeat this process until the pressure no longer rises,
then turn on the pumpout compressor and pumpout until the pressure reaches the pressure level specified by
the U.S. EPA’s latest publication of 40 CFR
part 80.
f. Close valves 1a, 1b, 3, 4, and 6.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C
C
C
2. Transfer remaining refrigerant.
a. Close valve 5 and open valve 4.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C
C
C
b. Turn off the water pumps through the LID.
c. Turn off the pumpout condenser water, and turn on
the pumpout compressor to push liquid out of the storage tank.
d. Close liquid line valves 7a and 7b.
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 7a 7b 8 11 12 13 14 15 16 17
CONDITION C C C C C C C C C C
g. Turn off the pumpout condenser water and continue
with the Control Test for Pumpdown, which will lock
out the machine compressor for operation.
4. Establish vacuum for service.
a. In order to conserve refrigerant, operate the pumpout
compressor until the machine pressure is reduced to
18 in. Hg vac., ref 30 in. bar. (40 kPa. abs.) following
Step 3e.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C C
C C C
h. Turn on pumpout condenser water.
i. Run the pumpout compressor until the storage tank
pressure reaches 5 psig (34 kPa) (18 in. Hg [40 kPa
abs.] if repairing the tank).
j. Turn off the pumpout compressor.
k. Close valves 1a, 1b, 2, 5, and 6.
l. Turn off pumpout condenser water.
Machines with Isolation Valves — Transfer all refrigerant to condenser vessel.
NOTE: Valve 14 is only available or Frame 1 and 2 machines. Valves 16 and 17 are only available on Frame 4 machines.
1. Push refrigerant into condenser.
a. Valve positions:
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION C C C C C C C C C C
TRANSFER THE REFRIGERANT FROM MACHINE TO
STORAGE TANK
1. Equalize refrigerant pressure.
a. Valve positions:
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION
C C
C
C C C C C C
b. Turn off machine water pumps and pumpout condenser water.
c. Turn on pumpout compressor to push liquid out of the
cooler/compressor.
d. When all liquid has been pushed into the condenser,
close cooler isolation valve 11.
e. Access the Control Test Pumpdown table on the LID
display to turn on the machine water pumps.
f. Turn off the pumpout compressor.
2. Evacuate gas from cooler/compressor vessel.
a. Close pumpout valves 2 and 5, and open valves 3 and
4.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C
C C
C C C
b. Slowly open valve 5 and liquid line valves 7a and 7b
to allow liquid refrigerant to drain by gravity into the
storage tank.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C
C
C
2. Transfer the remaining liquid.
a. Turn off pumpout condenser water. Place valves in the
following positions:
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C C
C
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION
C
C C C C C C C C C
b. Run the pumpout compressor for 30 minutes then close
valves 7a and 7b.
c. Turn off the pumpout compressor.
b. Turn on pumpout condenser water.
c. Run pumpout until the compressor reaches 18 in. Hg
vac (40 kPa abs.). Monitor pressures on the LID and
on refrigerant gages.
d. Close valve 1a.
e. Turn off pumpout compressor.
f. Close valves 1b, 3, and 4.
VALVE
1a 1b 2 3 4 5 6 7a 7b 8 11 12 13 14 15 16 17
CONDITION
C C
C C C
3. Remove any remaining refrigerant.
a. Turn on water pumps through the use of the Control
Test, Pumpdown table.
62
6. Open valve 5 fully.
g. Turn off pumpout condenser water.
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION C C C C C C C C C C C C C C
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION
C
C
C C C C C C C C
7. Open valve 11 to equalize the liquid refrigerant level
between vessels.
8. Close valves 1a, 1b, 3, and 5.
9. Open isolation valves 12 and 13.
h. Proceed to Pumpdown test on the LID to turn off machine water pumps and lock out machine
compressor.
TRANSFER ALL REFRIGERANT TO COOLER/
COMPRESSOR VESSEL
1. Push refrigerant into the cooler vessel.
a. Valve positions:
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION C C C C C C C
C C C C
10. Proceed to Control Test Terminate Lockout table to turn
off water pumps and enable the machine compressor for
start-up.
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION
C
C C
C C C C C C
b. Turn off machine water pumps and pumpout condenser water.
c. Turn on pumpout compressor to push refrigerant out
of the condenser.
d. When all liquid is out of the condenser close cooler
isolation valve 11.
e. Turn off the pumpout compressor.
2. Evacuate gas from the condenser vessel.
a. Access the Control Test, Pumpdown table on the LID
display to turn on the machine water pumps.
b. Close pumpout valves 3 and 4; open valves 2 and 5.
GENERAL MAINTENANCE
Refrigerant Properties — HCFC-22 and HFC-134a
are the standard refrigerants in the 23XL. At normal atmospheric pressure, HCFC-22 will boil at −41 F (−40.5 C) and
HFC-134a will boil at −14 F (−25 C), and must, therefore,
be kept in pressurized containers or storage tanks. The refrigerants are practically odorless when mixed with air. Both
refrigerants are non-combustible at atmospheric pressure. Read
the Material Safety Data Sheet and the latest ASHRAE Safety
Guide for Mechanical Refrigeration to learn more about safely
handling of these refrigerants.
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION
C C
C C C C C C C C
HCFC-22 and HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. In handling this refrigerant, protect the hands and
eyes and avoid breathing fumes.
c. Turn on pumpout condenser water.
d. Run the pumpout until the compressor reaches 18 in.
Hg vac (40 kPa abs.). Monitor pressure at the LID and
refrigerant gages.
e. Close valve 1b.
f. Turn off pumpout compressor.
g. Close valves 1a, 2, and 5.
Adding Refrigerant — Follow the procedures described in the Charge Refrigerant into Machine section,
page 55.
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION C C C C C C C C C C C C C C
Always use the compressor pumpdown function in the
Control Test mode to turn on the evaporator pump and
lock out the compressor when transferring refrigerant.
Liquid refrigerant may flash into a gas and cause possible freeze-up when the machine pressure is below
65 psig (448 kPa) [30 psig (207 kPa)].
h. Turn off pumpout condenser water.
i. Proceed to Pumpdown test on the LID to turn off
machine water pumps and lockout machine
compressor.
Removing Refrigerant — If the optional pumpout system is used, the 23XL refrigerant charge may be transferred
to a storage vessel or within the condenser or cooler if isolation valves are present. Follow procedures in the Pumpout
and Refrigerant Transfer Procedures section when removing
refrigerant from the storage tank to the machine.
Return Refrigerant to Normal Operating
Conditions
NOTE: Valve 14 is only available on Frame 1 and 2 machines. Valves 16 and 17 are only available on Frame 4 machines.
1. Be sure that the vessel that was opened has been
evacuated.
2. Access the Control Test, Terminate Lockout table to view
vessel pressures and turn on machine water pumps.
3. Open valves 1a, 1b, and 3.
Adjusting the Refrigerant Charge — If the addition or removal of refrigerant is required for improved machine performance, follow the procedures given under the
Trim Refrigerant Charge section, on page 64.
Refrigerant Leak Testing — Because HCFC-22 and
HFC-134a are above atmospheric pressure at room temperature, leak testing can be performed with refrigerant in the
machine. Use an electronic leak detector, halide leak detector, soap bubble solution, or ultra-sonic leak detector. Be sure
that the room is well ventilated and free from concentration
of refrigerant to keep false readings to a minimum. Before
making any necessary repairs to a leak, transfer all refrigerant from the leaking vessel.
VALVE
1a 1b 2 3 4 5 8 11 12 13 14 15 16 17
CONDITION
C
C C C C C C C C C C
4. Crack open valve 5, gradually increasing pressure in the
evacuated vessel to 68 psig (469 kPa) [35 psig
(141 kPa)]. Feed refrigerant slowly to prevent tube freeze
up.
5. Leak test to ensure vessel integrity.
63
Refrigerant Leak Rate — ASHRAE recommends that
WEEKLY MAINTENANCE
machines should be immediately taken off line and repaired
if the refrigerant leakage rate for the entire machine is more
than 10% of the operating refrigerant charge per year.
Additionally, Carrier recommends that leaks totalling less
than the above rate but more than a rate of 1 lb (0.5 kg) per
year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work.
Check the Lubrication System — Mark the oil level
on the sight glasses and observe the level each week while
the machine is shut down.
If the level goes below the sight glass, the oil reclaim system will need to be checked for proper operation. If additional oil is required, add it through the oil charging valve
(Fig. 2A and 2B). A hand pump is required for adding oil
against refrigerant pressure. The oil charge is approximately
4.2 gal (15.9 L) for Frame 1 and 2 machines and 10 gal
(38 L) for Frame 4 machines. The oil must meet Carrier’s
specifications for the 23XL. Refer to Changing Oil and Oil
Filter section. Any oil that is added should be logged by noting the amount and date in Fig. 40 on page 60. Any oil that
is added due to oil loss not related to service will eventually
return to the sump. It must be removed when the level is
above the sight glass.
NOTE: Frame 4 machines do not use an oil heater.
On Frame 1 and 2 machines, a 500-watt oil heater is controlled by the PIC to maintain oil temperature above 140 F
(60 C) [120 F (48.9 C)] or refrigerant temperature plus
60 F (15.6 C) [40 F (4.4 C)] when the compressor is off (see
the Controls section on page 13). The LID Status02 table
displays whether the heater is energized or not. If the PIC
shows that the heater is energized, but the sump is not heating up. If the sump is not heating up, the power to the oil
heater may be off or the oil level may be too low. Check the
oil level, the oil heater contactor voltage, and oil heater
resistance.
The PIC will not permit compressor start-up if the oil temperature is too low (Fame 1 and 2 machines). The control
will continue with start-up only after the temperature is within
limits.
Test After Service, Repair, or Major Leak — If
all refrigerant has been lost or if the machine has been opened
for service, the machine or the affected vessels must be pressured and leak tested. Refer to the Leak Test Machine section to perform a leak test.
HCFC-22 and HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. In handling this refrigerant, protect the hands and
eyes and avoid breathing fumes.
REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test procedures.
TO PRESSURIZE WITH DRY NITROGEN — Another
method of leak testing is to pressure with nitrogen only and
use soap bubble solution or an ultrasonic leak detector to
determine if leaks are present. This should only be done if
all refrigerant has been evacuated from the vessel.
1. Connect a copper tube from the pressure regulator on the
cylinder to the refrigerant charging valve. Never apply
full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the machine and close the
regulating valve when the pressure reaches test level. Do
not exceed 140 psig (965 kPa).
5. Close the charging valve on the machine. Remove the
copper tube if no longer required.
SCHEDULED MAINTENANCE
Establish a regular maintenance schedule based on the actual machine requirements such as machine load, run hours,
and water quality. The time intervals listed in this section are
offered as guides to service only.
Service Ontime — The LID will display a SERVICE
ONTIME value on the Status01 table. This value should be
reset to zero by the service person or the operator each time
major service work is completed so that time between service can be seen.
Repair the Refrigerant Leak, Retest, and Apply
Standing Vacuum Test — After pressurizing the machine, test for leaks with a soap bubble solution, an electronic leak detector, a halide torch, or an ultrasonic leak detector. Bring the machine back to atmospheric pressure, repair
any leaks found, and retest.
After retesting and finding no leaks, apply a standing vacuum
test. Then dehydrate the machine. Refer to the Standing Vacuum
Test and Machine Dehydration in the Before Initial Start-Up
section, page 48.
Inspect the Control Center — Maintenance is generally limited to general cleaning and tightening of connections. Vacuum the cabinet to eliminate dust build-up.
In the event of machine control malfunctions, refer to the
Troubleshooting Guide section for control checks and
adjustments.
Trim Refrigerant Charge — If it becomes necessary
to adjust the refrigerant charge to obtain optimum machine
performance, operate the machine at design load and then
add or remove refrigerant slowly until the difference between leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions. Do not
overcharge. For superheat information, see the Troubleshooting section on page 68.
Refrigerant may be added either through the optional storage tank or directly into the machine as described in the section entitled, Refrigerant Charging.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Machine to Storage Tank section,
Steps 1a, b on page 62.
Be sure power to the control center is off when
cleaning and tightening connections inside the control
center.
Check Safety and Operating Controls Monthly
— To ensure machine protection, the Automated Control
Test in the service menu should be done at least once per
month. See Table 4 for safety control settings.
Changing Oil and Oil Filter — If the pressure drop
across the filter has approached the OIL FILTER PRESS
ALERT value on the Equipment Service, Service1 table, change
oil filter as needed. Otherwise, change the oil filter on a yearly
basis.
64
8. Remove the oil filter retaining spring. Remove and properly discard the oil filter.
9. Insert a new oil filter. Seat the filter retaining spring against
the flange stop. Install the oil sump cover with a new
O-ring. Insert and tighten the 6 bolts that secure the oil
sump cover.
10. Evacuate the oil sump by placing a vacuum pump on
the drain valve. Follow normal evacuation procedures.
Shut off the drain valve when the oil sump has been evacuated. Charge new oil through the drain valve.
11. Add oil (approximately 4.2 gal [15.9 L]) until it can be
seen at the lower edge of the oil sump sight glass.
The oil sight glass will not fill completely since a small
amount of gas will be trapped inside, even under vacuum
conditions.
12. Open all 3 isolation valves (previously closed in
Step 3). Apply power to the controls and oil heater.
13. The oil level will rise once the refrigerant gets absorbed
into the oil.
FRAME 4 MACHINES — Use the following procedures to
change the oil filter and/or oil on Frame 4 machines. Oil can
remain in Frame 4 machines when changing the oil
filter. Refer to Fig. 2B and 4.
Changing Oil Filter
1. Make sure the compressor is off and the disconnect for
the compressor starter is open.
2. Close both oil filter isolation valves. See Fig. 4.
3. Place a container underneath the oil filter assembly.
4. Slowly open the vent plug, located on top of the oil filter
housing, to relieve pressure. Do not remove the plug. When
a Schrader valve is provided, use it to relieve the
pressure.
5. Remove the filter canisters by unscrewing the retainer nut.
The filter may now be removed and disposed of properly.
6. Install new oil filter. Install the new O-ring. Tighten the
retainer nut.
7. Partially open the isolation valve located near the oil separator. Bleed the excess air from the vent plug. Once
oil starts escaping from the vent plug, close the isolation
valve. Tighten the vent plug on top of the oil filter
housing.
8. If a Schrader valve is supplied, evacuate the oil filter by
connecting the vacuum pump to the Schrader valve.
Changing Oil
NOTE: A hand pump or portable electric oil pump will be
required to complete the following operation.
1. Transfer the refrigerant into the condenser (for vessel that
can be isolated) or storage tank.
2. When the machine pressure equals a maximum of 5 psi
(34 kPa), drain the oil by opening the oil charging valve,
located on the bottom of the oil separator.
3. Change the oil filter as described in the Changing Oil Filter section for Frame 4 machines.
4. Charge the oil separator with approximately 10 gal
(39 L) of oil. The oil level should be in the center of the
lower sight glass.
Change the oil after the first year of operation. Then, change
the oil at least every three years, or as needed. However, if
a continuous oil monitoring system is present and/or a yearly
oil analysis is performed, the time between oil changes may
be extended. The 23XL Frame 1 and 2 machines use approximately 4.2 gal (15.9 L) of oil. The 23XL Frame 4 machines use approximately 10 gal (38 L) of oil. See
Oil Specification section on page 66 for additional
information.
This product is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
FRAME 1 AND 2 MACHINES — The 23XL oil sump can
be isolated to change the oil filter and oil while the refrigerant remains inside the machine. Use the following procedure to change the oil and oil filter (if required):
IMPORTANT: Remove oil from Frame 1 and 2 machines before changing the oil filter. Refer to Fig. 2A
and 3.
1. Make sure the compressor is off and the disconnect for
the compressor is open.
2. Open the control and oil heater circuit breaker in order
to turn off the power to the oil heater.
3. Close the 3 oil sump isolation valves. One isolation valve
is upstream and one isolation valve is downstream of
the oil sump. The third isolation valve is in the oil sump
vent line.
Be sure the power to the oil heater is off when the
oil sump is isolated and full. If the oil heater remains energized, over-pressurization of the oil sump
could result in the failure of the oil solenoid valve,
discharge of hot oil, and personal injury.
4. Connect an oil charging hose to the oil drain valve. See
Fig. 3. Place the other end of the oil charging hose in a
clean container suitable for used oil. A portion of the oil
drained from the sump should be used as an oil sample
and should be sent to a laboratory for proper analysis.
Do not contaminate this sample.
5. Slowly open the drain valve in order to drain the oil from
the sump.
The oil sump is at high pressure. Relieve pressure
slowly.
6. Once the oil has been drained, place absorbent material
under the oil sump to catch any oil that may leak out
once the oil sump cover is opened. Continue with Steps
7, 8, and 9 if a new oil filter is required. Proceed to Step
10 if no oil filter change is required.
7. Remove the 6 bolts from the end of the oil sump and
remove the oil sump cover.
65
Oil Specification — If oil is to be added, it must meet
the following Carrier specifications:
• Carrier Part Number . . . . . . . . . . . . . . . . . . . PP23BZ104
• Oil type . . . . . . . . . . . . . . . . . Inhibited polyolester-based
synthetic compressor lubricant suitable for use
in screw compressors where high viscosity
and compatibility with HCFC 22 and HFC-134a
refrigerants is required.
• ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . 220
• Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.981
• Viscosity, cSt at 40 C (104 F) . . . . . . . . . . . . 210 to 230
cSt at 100 C (212 F) . . . . . . . . . . . . 18 to 21
SSU at 100 F (38 C) . . . . . . . . . . 1005 ± 45
SSU at 210 F (99 C) . . . . . . . . . . . . . 91 ± 7
• Floc Point (maximum) . . . . . . . . . . . . . . . −90 F (−68 C)
• Pour Point (maximum) . . . . . . . . . . . . . . . −6 F (−21 C)
• Flash Point (minimum) . . . . . . . . . . . . . . . 428 F (220 C)
• Moisture Content (maximum) . . . . . . . . . . . . . . 100 ppm
• Acid Number (maximum) . . . . . . . . . 0.5 mg KOH/gram
• Miscibility Range with HCFC-22 . . . . . . . −90 to 200 F
(−68 to 93 C)
with HFC-134a . . . . . . . −4 to 180 F
(−2 to 82 C)
Inspect Relief Valves and Piping — The relief valves
on this machine protect the system against the potentially
dangerous effects of overpressure. To ensure against damage to the equipment and possible injury to personnel, these
devices must be kept in peak operating condition.
As a minimum, the following maintenance is required.
1. At least once a year, disconnect the vent piping at the
valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt,
scale, leakage, etc.
2. If corrosion or foreign material is found, do not attempt
to repair or recondition. Replace the valve.
3. If the machine is installed in a corrosive atmosphere or
the relief valves are vented into a corrosive atmosphere,
make valve inspections at more frequent intervals.
Compressor Bearing Maintenance — The key to
good bearing maintenance is proper lubrication. Use the proper
grade of oil, maintained at recommended level, temperature,
and pressure. Inspect the lubrication system regularly and
thoroughly.
Excessive bearing wear can be detected through increased vibration. If this symptom appears, contact an experienced and responsible service organization to perform
vibration analysis on the compressor.
This product is hygroscopic. Containers should remain
tightly sealed in a clean and dry environment to prevent
moisture absorption from the air.
Compressor Rotor Check — Use Carrier specified
oil. Excessive compressor rotor wear is shown by a lack of
performance. If a lack of performance is noted, have the compressor rotors inspected by a trained service person.
The rotors can be visually inspected once every 5 to
10 years or as needed depending on machine operating
conditions.
This oil (part number PP-23-BZ-104) may be ordered from
your local Carrier represesentative.
Oil Separator Coalescer
FRAME 1 AND 2 MACHINES — The oil separator coalescing element is replaceable and has an estimated life of
15 years. Proper maintenance procedures require the coalescer to be changed approximately 100 hours after a major
compressor teardown or machine overhaul.
FRAME 4 MACHINES — Frame 4 machines do not have
a replaceable oil coalescer.
Inspect the Heat Exchanger Tubes
COOLER — Inspect and clean the cooler tubes at the end of
the first operating season. Because these tubes have internal
ridges, a rotary-type tube cleaning system is necessary to fully
clean the tubes. Upon inspection, the tube condition will determine the scheduled frequency for cleaning, and will indicate whether water treatment is adequate in the chilled water/
brine circuit. Inspect the entering and leaving chilled water
temperature sensors for signs of corrosion or scale. Replace
the sensor if corroded or remove any scale if found.
CONDENSER — Since this water circuit is usually an opentype system, the tubes may be subject to contamination and
scale. Clean the condenser tubes with a rotary tube cleaning
system at least once per year and more often if the water is
contaminated. Inspect the entering and leaving condenser water sensors for signs of corrosion or scale. Replace the sensor if corroded or remove any scale if found.
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the machine. If the refrigeration log indicates
a rise above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser
water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes
may be dirty or water flow may be incorrect. Because HCFC-22
and HFC-134a are high-pressure refrigerants, air usually does
not enter the machine; instead the refrigerant leaks out.
During the tube cleaning process, use brushes especially
designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do
not use wire brushes.
Refrigerant Filter/Drier — A refrigerant filter/drier, located on the motor cooling line should be changed once a
year, or as necessary, if filter condition indicates a need for
less or more frequent replacement. Change the filter with the
machine pressure at 0 psig (0 kPa) by transferring the refrigerant to the condenser vessel, (if isolation valves are present)
or a storage tank. A moisture indicator (dry eye) sight glass
is located beyond this filter to indicate the volume of moisture in the refrigerant. If the moisture indicator indicates moisture, locate the source of water immediately by performing
a thorough leak check.
Refrigerant Strainers (Frame 1 and 2 Machines
Only) — The oil reclaim system has two strainers. One is
located on the eductor suction line, and one on the condenser gas line. Replace these strainers once per year, or as
necessary if strainer condition indicates a need for less or
more frequent replacement. Change these strainers with the
cooler/compressor vessel at 0 psig (0 kPa) by transferring
the refrigerant charge to a storage vessel or the condenser.
Inspect Refrigerant Float System — Perform inspection every 5 years, if required, or when the machine is
opened for service.
Transfer the refrigerant into the cooler vessel (if isolation
valves are present) or into a storage tank. Remove the float
access cover. Clean the chamber and valve assembly thoroughly. Be sure that the valve moves freely. Ensure that all
openings are free of obstructions. Examine the cover gasket
and replace if necessary.
66
Optional Pumpout System Maintenance —
For compressor maintenance details, refer to the 06D, 07D
Installation, Start-Up, and Service Instructions.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows:
• HCFC-22 and HFC-134a
ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Viscosity SSU 100 F (38 C). . . . . . . . . . . . . . . . . . . . 300
Carrier Part Number . . . . . . . . . . . . . . . . . . PP23BZ-103
The total oil charge, 4.5 pints (2.6 L), consists of
3.5 pints (2.0 L) for the compressor and one additional pint
(0.6 L) for the oil separator.
Oil should be visible in one of the compressor sight glasses
during operation and at shutdown. Always check the oil level
before operating the compressor. Before adding or changing
oil, relieve the refrigerant pressure as follows:
1. Attach a pressure gage to the gage port of either compressor service valve.
2. Close the suction service valve and open the discharge
line to the storage tank or the machine.
3. Operate the compressor until the crankcase pressure drops
to 2 psig (13 kPa).
4. Stop the compressor and isolate the system by closing
the discharge service valve.
5. Slowly remove the oil return line connection (Fig. 42).
Add oil as required.
6. Replace the connection and reopen the compressor service valves.
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
(Fig. 43) — The optional pumpout system high-pressure switch
should open at 220 ± 5 psig (1517 ± 34 kPa) and should
reset automatically on pressure drop to 190 psig
(1310 kPa) for HCFC-22 machines. For machines using
HFC-134a, the switch opens at 161 psig (1110 kPa) and closes
at 130 psig (896 kPa). Check the switch setting by operating
the pumpout compressor and slowly throttling the pumpout
condenser water.
Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist
for proper treatment.
Water Leaks — Water is indicated during machine operation by the refrigerant moisture indicator on the refrigerant motor cooling line. See Fig. 11 and 12. Water leaks
should be repaired immediately.
Machine must be dehydrated after repair of water leaks.
See Machine Dehydration section, page 48.
Water Treatment — Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The
services of a qualified water treatment specialist should be
obtained to develop and monitor a treatment program.
Water must be within design flow limits, clean, and treated
to ensure proper machine performance and to reduce the
potential of tubing damage due to corrosion, scaling, erosion, and algae. Carrier assumes no responsibility for
chiller damage resulting from untreated or improperly
treated water.
Inspect the Starting Equipment — Before working on any starter, shut off the machine, and open all disconnects supplying power to the starter.
The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter.
Never open isolating knife switches while equipment is
operating. Electrical arcing can cause serious injury.
Inspect starter contact surfaces for wear or pitting on
mechanical-type starters. Do not sandpaper or file silverplated contacts. Follow the starter manufacturer’s instructions for contact replacement, lubrication, spare parts ordering, and other maintenance requirements.
Periodically vacuum or blow off accumulated debris on
the internal parts with a high-velocity, low-pressure blower.
Power connections on newly installed starters may relax
and loosen after a month of operation. Turn power off and
retighten. Recheck annually thereafter.
Loose power connections can cause voltage spikes, overheating, malfunctioning, or failures.
Check Pressure Transducers — Once a year, the
pressure transducers should be checked against a pressure
gage reading. Check all three transducers: oil pressure, discharge pressure, cooler pressure.
Note the appropriate pressure reading on the Status01 table
on the LID. Attach an accurate refrigeration gage to the corresponding pressure fitting. Compare the two readings. If there
is a difference in readings, the transducer can be calibrated
as described in the Troubleshooting Guide section.
Fig. 43 — Optional Pumpout System Controls
67
VOLTAGE DROP — Using a digital voltmeter, the voltage
drop across any energized sensor can be measured while the
control is energized. Tables 11 and 12 list the relationship
between temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Voltage should also be checked
at the sensor plugs. Check the sensor wire at the sensor for
5 vdc if the control is powered.
Ordering Replacement Chiller Parts — When ordering Carrier specified parts, the following information must
accompany an order.
• machine 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 has many features to aid the operator and the technician in troubleshooting a 23XL
machine.
• By using the LID display, the chiller actual operating conditions can be viewed while the unit is running.
• When an alarm occurs, the default LID screen will freeze
at the time of alarm. The freeze enables the operator to
view the machine conditions at the time of alarm. The Status tables will still show the current information. Once all
alarms have been cleared, the default LID screens will return to normal operation.
• The Control Algorithm Status tables will display various
screens of information in order to diagnose problems with
chilled water temperature control, chilled water temperature control overrides, hot gas bypass, and time schedule
operation.
• The Control Test feature allows proper operation and testing of temperature sensors, pressure transducers, the slide
valve solenoids, water pumps, tower control, and other on/
off outputs while the compressor is stopped. It also has the
ability to lock off the compressor and turn on water pumps
for pumpout operation. The display will show the required
temperatures and pressures during these operations.
• Other Service menu tables can access configured items,
such as chilled water resets, override set points, etc.
• If an operating fault is detected, an alarm message is generated and displayed on the LID default screen. A more
detailed message — along with a diagnostic message —
also is stored into the Alarm History table.
Relieve all refrigerant pressure or drain the water prior
to replacing the temperature sensors.
CHECK SENSOR ACCURACY — Place the sensor in a
medium of a known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5 F (.25 C) graduations. The sensor in
question should be accurate to within 2 F (1.2 C).
See Fig. 11 and 12 for sensor locations. The sensors are
immersed directly in the refrigerant or water circuits. The
wiring at each sensor is easily disconnected by unlatching
the connector. These connectors allow only one-way connection to the sensor. When installing a new sensor, apply a
pipe sealant or thread sealant to the sensor threads.
DUAL TEMPERATURE SENSORS — Two motor temperature sensors are provided for service convenience. In case
one of the dual sensors is damaged, the other one can be
used by moving a wire.
The number 1 terminal in the sensor terminal box is the
common line. To use the second sensor, move the wire from
the number 2 position to the number 3 position.
Checking Pressure Transducers — There are 3 pressure transducers on the 23XL. These determine cooler, discharge, and oil pressure. The PIC uses the discharge pressure transducer to determine condenser pressure. The PIC
also determines refrigerant temperatures from cooler and condenser pressure. All 3 can be calibrated if necessary. It is not
usually necessary to calibrate at initial start-up. However, at
high altitude locations, calibration of the transducer will be
necessary to ensure the proper refrigerant temperature/
pressure relationship. Each transducer is supplied with
5 vdc power from a power supply. If the power supply fails,
a transducer voltage reference alarm will occur. If the transducer reading is suspected of being faulty, check the supply
voltage. It should be 5 vdc ± .5 v. If the supply voltage is
correct, the transducer should be recalibrated or replaced.
Calibration can be checked by comparing the pressure readings from the transducer against an accurate refrigeration gage.
These readings are all viewed or calibrated from the Status01 table on the LID. The transducer can be checked and
calibrated at 2 pressure points. These calibration points are
0 psig (0 kPa) and 250 ± 10 psig (1724 ± 69 kPa). To calibrate these transducers:
1. Shut down the compressor.
2. Disconnect the transducer in question from its Schrader
fitting.
3. Access the Status01 table, and view the particular transducer reading; it should read 0 psig (0 kPa). If the reading is not 0 psig (0 kPa), but within ± 5 psi (35 kPa), the
value may be zeroed by pressing the SELECT softkey
while the highlight bar is located on the transducer, and
then by pressing the ENTER softkey.
Checking the Display Messages — The first area
to check when troubleshooting the 23XL is the LID display.
If the alarm light is flashing, check the primary and secondary message lines on the LID default screen (Fig. 17). These
messages will indicate where the fault is occurring. The Alarm
History table on the LID Service menu will also carry an
alarm message to further expand on this alarm. For a complete listing of messages, see Table 10. If the alarm light
starts to flash while accessing a menu screen, depress
EXIT to return to the Default screen to read the failure
message. The compressor will not run with an alarm condition existing, unless the alarm type is an unauthorized start
or a failure to shut down.
Checking Temperature Sensors — All temperature sensors are of the thermistor type. This means that
the resistance of the sensor varies with temperature. All
sensors have the same resistance characteristics. Determine
sensor temperature by measuring voltage drop if the controls are powered, or resistance if the controls are powered
off. Compare the readings to the values listed in Tables 11
and 12.
RESISTANCE CHECK — Turn off the control power and
disconnect the terminal plug of the sensor in question from
the module. Measure sensor resistance between receptacles
designated by the wiring diagram with a digital ohmmeter.
The resistance and corresponding temperature is listed in Tables
11 and 12. Check the resistance of both wires to ground.
This resistance should be infinite.
68
If the transducer value does not move to 0 psig (0 kPa),
the transducer will return to the original reading. If the
pressure is within the allowed range, check the voltage
ratio of the transducer. To obtain the voltage ratio, divide
the voltage (dc) input from the transducer by the supply
voltage signal, measured at the PSIO terminals J7-J34 and
J7-J35. For example, the condenser transducer voltage input is measured at PSIO terminals J7-1 and J7-2. The voltage ratio must be between 0.80 vdc and 0.11 vdc for the
software to allow calibration. Pressurize the transducer
until the ratio is within range. Then attempt calibration
again.
4. A high pressure point can also be calibrated between 240
and 260 psig (1655 and 1793 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). The high pressure point can be calibrated
by accessing the transducer on the Status01 table,
highlighting the transducer, pressing the SELECT softkey, and then increasing or decreasing the value to the
exact pressure on the refrigerant gage. Press ENTER to
finish. High altitude locations must compensate the pressure so that the temperature/pressure relationship is
correct.
If the transducer reading returns to the previous value and
the pressure is within the allowed range, check the voltage ratio of the transducer. Refer to Step 3 above. The
voltage ratio for this high pressure calibration must be
between 0.536 and 0.634 vdc to allow calibration. Change
the pressure at the transducer until the ratio is within the
acceptable range. Then attempt to calibrate to the new
pressure input.
The PIC will not allow calibration if the transducer is too
far out of calibration. A new transducer must be installed
and re-calibrated.
TRANSDUCER REPLACEMENT — Since the transducers are mounted on Schrader-type fittings, there is no need
to remove refrigerant from the vessel. Disconnect the transducer wiring by pulling up on the locking tab while pulling
up on the weather-tight connecting plug from the end of the
transducer. Do not pull on the transducer wires. Unscrew
the transducer from the Schrader fitting. When installing a
new transducer, do not use pipe sealer, which can plug the
sensor. Put the plug connector back on the sensor and snap
into place. Check for refrigerant leaks.
Control Algorithms Checkout Procedure — In
the LID Service menu, one of the tables is Control Algorithm Status. This table contains 4 maintenance tables which
may be viewed in order to see how the particular control
algorithm is operating. The 4 tables are:
MAINT01
MAINT02
MAINT03
MAINT04
(PSIO
Software
Version 13
and higher)
OCCDEFM
Capacity
Control
This table shows all values that are used
to calculate the chilled water/brine control point.
Override
Details of all chilled water control overStatus
ride values are viewed here.
HGBP Status The hot gas bypass control algorithm
status is viewed from this screen.
All values dealing with this control are
displayed.
LEAD/LAG
This table shows the condition of LEAD/
STATUS
LAG operation.
Time
Schedules
Status
The Local and CCN occupied schedules are displayed here in a manner
that the operator can quickly determine whether the schedule is in the OCCUPIED mode or not.
These maintenance tables are very useful in determining
how the control temperature is calculated, slide valve positioning reaction from load changes, control point overrides,
hot gas bypass reaction, etc.
Control Test — The Control Test feature can check all
of the thermistor temperature sensors, including those on the
Options modules, pressure transducers, pumps and their associated flow switches, slide valve assembly, and other control outputs, such as hot gas bypass. The test can help to
determine whether a switch is defective, or a pump relay is
not operating, among other troubleshooting tests. During pumpdown operations, the pumps are energized to prevent freeze-up
and the vessel pressures and temperatures are displayed. The
lockout feature will prevent start-up of the compressor when
no refrigerant is present in the machine, or if the vessels are
isolated. The lockout is then terminated by the operator by
using the Terminate Lockout function after the pumpdown
procedure is reversed and refrigerant is added.
Make sure to use a backup wrench on the Schrader fitting whenever removing a transducer.
69
LEGEND FOR TABLE 10, A - N
1CR AUX
CA P
CDFL
CHIL S S
CHWS
CHWR
CMPD
CR AUX
CRP
CRT
DEM LIM
ERT
EVFL
LID
MTRW
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
1CR Compressor Start Contact
Compressor Current
Condenser Water Flow
Chiller Start/Stop
Chiller Water Supply
Chiller Water Return
Compressor Discharge Temperature
1CR Compressor Start Contact
Condenser Refrigerant Pressure
Condenser Temperature
Demand Limit
Evaporator Refrigerant Temperature
Evaporator Water Flow
Local Interface Device
Motor Winding Temperature
OILP
OILPD
OILSS
OILT
PIC
PRS TRIP
PSIO
RLA
RUN AUX
SPR PL
SMM
STR FLT
SV MAN
V P
V REF
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Oil Pressure
Oil Pressure Differential
Oil Level Switch
Oil Temperature
Product Integrated Control
High Condenser Pressure Trip Switch
Processor Sensor Input/Output Module
Rated Load Amps
Compressor Run Contact
Spare Protective Limit Input
Starter Management Module
Starter Fault
Manual Slide Valve
Line Voltage
Voltage Reference
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides
A. SHUTDOWN WITH ON/OFF/RESET-OFF
PRIMARY MESSAGE
SECONDARY MESSAGE
MANUALLY STOPPED — PRESS
CCN OR LOCAL TO START
TERMINATE PUMPDOWN MODE
TO SELECT CCN OR LOCAL
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
SHUTDOWN IN PROGRESS
COMPRESSOR DEENERGIZED
ICE BUILD
OPERATION COMPLETE
PROBABLE CAUSE/REMEDY
PIC in OFF mode; press the CCN or local soft key to
start unit.
Enter the Control Test menu and select Terminate Lockout to
unlock compressor, and place in OFF mode.
Machine unloading before shutdown due to soft stop feature.
Machine compressor is being commanded to stop.
Water pumps are deenergized within one minute.
Machine shutdown from Ice Build operation.
B. TIMING OUT OR TIMED OUT
PRIMARY MESSAGE
SECONDARY MESSAGE
READY TO START IN XX MIN
UNOCCUPIED MODE
READY TO START IN XX MIN
REMOTE CONTACTS OPEN
READY TO START IN XX MIN
STOP COMMAND IN EFFECT
READY TO START IN XX MIN
RECYCLE RESTART PENDING
READY TO START
UNOCCUPIED MODE
READY TO START
REMOTE CONTACTS OPEN
READY TO START
STOP COMMAND IN EFFECT
READY TO START IN XX MIN
READY TO START IN XX MIN
READY TO START
READY TO START
STARTUP INHIBITED
REMOTE CONTACTS CLOSED
OCCUPIED MODE
REMOTE CONTACTS CLOSED
OCCUPIED MODE
LOADSHED IN EFFECT
READY TO START IN XX MIN
START COMMAND IN EFFECT
PROBABLE CAUSE/REMEDY
Time schedule for PIC is unoccupied.
Machines will start only when occupied.
Remote contacts have stopped machine. Close contacts to
start.
Chiller START/STOP on Status01 manually forced to stop.
Release value to start.
Machine in recycle mode.
Time schedule for PIC is UNOCCUPIED. Machine will start
when occupied.
Remote contacts have stopped machine. Close contacts to
start.
Chiller START/STOP on Status01 manually forced to stop.
Release value to start.
Machine timer counting down unit. Ready for start.
Machine timer counting down unit. Ready for start.
Machine timers complete, unit start will commence.
Machine timers complete, unit start will commence.
CCN loadshed module commanding chiller to stop.
Chiller START/STOP on Status01 has been manually forced
to start. Machine will start regardless of time schedule or
remote contact status.
C. IN RECYCLE SHUTDOWN
PRIMARY MESSAGE
SECONDARY MESSAGE
RECYCLE RESTART PENDING
OCCUPIED MODE
RECYCLE RESTART PENDING
REMOTE CONTACT CLOSED
RECYCLE RESTART PENDING
START COMMAND IN EFFECT
RECYCLE RESTART PENDING
ICE BUILD MODE
70
PROBABLE CAUSE/REMEDY
Unit in recycle mode, chilled water temperature is not high
enough to start.
Unit in recycle mode, chilled water temperature is not high
enough to start.
Chiller START/STOP on Status01 manually forced to start,
chilled water temperature is not high enough to start.
Machine in ICE BUILD mode. Chilled water/brine temperature is satisfied for ice build set point temperature.
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides (cont)
D. PRE-START FAILURES
PRIMARY MESSAGE
SECONDARY MESSAGE
PRESTART ALERT
STARTS LIMIT EXCEEDED
PRESTART ALERT
PRESTART ALERT
PRESTART ALERT
PRESTART ALERT
PRESTART ALERT†
PRESTART ALERT
PRESTART ALERT
PRESTART ALERT
PRESTART ALERT
ALARM MESSAGE/PRIMARY CAUSE
STARTS EXCESSIVE Compressor Starts
(8 in 12 hours)
MTRW VALUE exceeded limit of [LIMIT]*.
Check motor temperature.
ADDITIONAL CAUSE/REMEDY
Depress the reset softkey if additional start
is required.
HIGH MOTOR TEMPERATURE
Check motor cooling line for proper operation. Check for excessive starts within
a short time span.
OIL PRESS./LEVEL SAFETY
OILSS check oil level in sump.
Check for low oil level. Check oil level switch
operation.
HIGH DISCHARGE TEMP
CMPD VALUE exceeded limit of [LIMIT]*. Check sensor accuracy.
Check condenser temperature.
LOW REFRIGERANT TEMP
ERT VALUE exceeded limit of [LIMIT]*. Check transducer accuracy. Check for low
Check refrigerant temperature.
chilled water/brine supply temperature.
LOW OIL TEMPERATURE
OILT VALUE exceeded limit of [LIMIT]*. Check oil heater power under oil sump temCheck oil temperature.
perature control (see page 29), oil heater
relay.
LOW LINE VOLTAGE
V P VALUE exceeded limit of [LIMIT]*. Check voltage supply. Check voltage transCheck voltage supply.
formers. Consult power utility if voltage is
low.
HIGH LINE VOLTAGE
V P VALUE exceeded limit of [LIMIT]*. Same as above.
Check voltage supply.
LOADSHED/RED LINE ACTIVE
DEM LIM Redline and/or
Check Loadshed function on Config
Loadshed active.
table is disabled. Send a Cancel Redline
or Cancel Loadshed command. Check
MAXIMUM LOADSHED TIME has elapsed.
HIGH CONDENSER PRESSURE CRP VALUE exceeded limit of [LIMIT]*. Check for high condenser water temperaCheck condenser water and transducer. ture. Check transducer accuracy.
*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.
†Applicable to Frame 1 and 2 machines only.
E. NORMAL OR AUTO.-RESTART
PRIMARY MESSAGE
STARTUP IN PROGRESS
STARTUP IN PROGRESS
SECONDARY MESSAGE
OCCUPIED MODE
REMOTE CONTACT CLOSED
STARTUP IN PROGRESS
START COMMAND IN EFFECT
AUTORESTART IN PROGRESS
AUTORESTART IN PROGRESS
OCCUPIED MODE
REMOTE CONTACT CLOSED
AUTORESTART IN PROGRESS
START COMMAND IN EFFECT
71
STATUS
Machine starting. Time schedule is occupied.
Machine starting. Remote contacts are closed.
Machine starting. Chiller START/STOP on Status01 manually forced to start.
Machine starting. Time schedule is occupied.
Machine starting. Remote contacts are closed.
Machine starting. Chiller START/STOP on Status01 manually forced to start.
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides (cont)
F. START-UP FAILURES
PRIMARY MESSAGE
SECONDARY MESSAGE
FAILURE TO START NO OIL PRESSURE
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
FAILURE TO START
ALARM MESSAGE/PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
OILPD VALUE exceeded limit of [LIMIT]*. Check solenoid valve operation. Check for
Check oil filter, oil solenoid or shutoff valve. closed oil supply valves. Check oil filter.
Check for low oil temperature. Check transducer accuracy. Check oil supply valves,
oil filter, low oil temperature, transducer accuracy, entering condenser water temperature, and hot gas bypass.
OIL PRESS SENSOR FAULT
OILP Check oil pressure transducer.
Check for excessive refrigerant in oil sump.
Check transducer for power supply. Check
wiring. Replace transducer if necessary.
LOW CHILLED WATER FLOW
EVFL Evap Flow Fault: Check water pump/ Verify chilled water flow. Make sure pump
flow switch.
is operating properly. Check wiring to flow
switch. Check through controls test for
proper switch operation.
LOW CONDENSER
CDFL Cond. Flow Fault: Check water Same as above.
WATER FLOW
pump/flow switch.
STARTER FAULT
STR FLT Starter Fault: Check Starter for Starter fault switch has opened. Check
Fault Source.
starter for ground fault, voltage trip, temperature trip, etc.
STARTER OVERLOAD TRIP
STR FLT Starter Overload Trip: Check Reset overloads before restart. Check moamps calibration/reset overload.
tor current calibration.
LINE VOLTAGE DROPOUT
V P Single-Cycle Dropout Detected: Check voltage supply. Check transformCheck voltage supply.
ers for supply. Check with utility if voltage
supply is erratic. Monitor must be installed to confirm consistent, single-cycle
dropouts.
HIGH CONDENSER PRESSURE CRP High Condenser Pressure: Check Check for proper design condenser flow
switch and water temp/flow.
and temperature. Check condenser approach. Check 2C auxiliary contacts.
EXCESS ACCELERATION TIME CA P Excess Acceleration: Check slide Check that slide valve is opened at startvalve closure at start-up.
up. Check starter for proper operation. Reduce unit pressure if possible. Check power
supply.
STARTER TRANSITION FAULT
RUN AUX Starter Transition Fault: Check Check starter for proper operation. Run
1CR/1M/Interlock mechanism
contact failed to close.
1CR AUX CONTACT FAULT
CR AUX Starter Contact Fault: Check Check starter for proper operation. Start
1CR/1M aux. contacts.
contact failed to close.
MOTOR AMPS NOT SENSED
CA P Motor Amps Not Sensed: Check Check for proper motor amps signal to
motor load signal.
SMM.
MOTOR WIRING INCORRECT
Check motor wiring for phase reversal.
Check incoming power leads to starter.
LOW OIL PRESSURE
OILPD VALUE exceeded limit of [LIMIT]. Minimum oil pressure requirement was not
Check oil system, oil solenoid and
met during the first 120 seconds of starttransducer.
up. Check entering condenser water temperature requirement. See Table 1.
CHECK REFRIGERANT TYPE
STARTUP TERMINATED: Check refrig- Check for proper refrigerant
erant type
configuration.
*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.
72
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides (cont)
G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION
PRIMARY MESSAGE
SECONDARY MESSAGE
ALARM MESSAGE/
ADDITIONAL CAUSE/REMEDY
PRIMARY CAUSE
UNAUTHORIZED
UNIT SHOULD BE STOPPED
CA P Emergency: Compressor run- Compressor is running with more than 10%
OPERATION
ning without control authorization.
RLA and control is trying to shut it
down. Throw power off to compressor if
unable to stop. Determine cause before
repowering.
POTENTIAL FREEZE-UP EVAP PRESS/TEMP
ERT Emergency: Freeze-up
Determine cause. If pumping refrigerant
TOO LOW
prevention.
out of machine, stop operation and go over
pumpout procedures.
FAILURE TO STOP
DISCONNECT POWER
RUN AUX Emergency: DISCON- Starter and run and start contacts are enNECT POWER.
ergized while control tried to shut down.
Disconnect power to starter.
LOSS OF
WITH STARTER
Loss of Communication with Starter: Check wiring from PSIO to SMM. Check
COMMUNICATION
Check machine.
SMM module troubleshooting procedures.
STARTER CONTACT
ABNORMAL 1CR OR
CR AUX Starter Contact Fault: Check Starter run and start contacts energized
FAULT
RUN AUX
1CR/1M aux. contacts.
while machine was off. Disconnect power.
POTENTIAL FREEZE-UP COND PRESS/TEMP TOO LOW CRT Emergency: Freeze-up
The condenser pressure transducer is readprevention.
ing a pressure that could freeze the water
in the condenser tubes. Check for condenser refrigerant leaks, bad transducers, or transferred refrigerant. Place unit
in Pumpdown mode to eliminate ALARM
if vessel is evacuated.
H. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND
PRIMARY MESSAGE
RUNNING — RESET ACTIVE
RUNNING — RESET ACTIVE
RUNNING — RESET ACTIVE
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — TEMP CONTROL
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
RUNNING — DEMAND LIMITED
SECONDARY MESSAGE
4-20MA SIGNAL
REMOTE SENSOR CONTROL
CHW TEMP DIFFERENCE
LEAVING CHILLED WATER
ENTERING CHILLED WATER
TEMPERATURE RAMP LOADING
BY DEMAND RAMP LOADING
BY LOCAL DEMAND SETPOINT
BY 4-20MA SIGNAL
BY CCN SIGNAL
BY LOADSHED/REDLINE
RUNNING — TEMP CONTROL
HOT GAS BYPASS
RUNNING — DEMAND LIMITED
RUNNING — TEMP CONTROL
BY LOCAL SIGNAL
ICE BUILD
PROBABLE CAUSE/REMEDY
Reset program active based upon CONFIG table set-up.
Default method of temperature control.
ECW control activated on CONFIG table.
Ramp loading in effect. Use Service1 table to modify.
Ramp loading in effect. Use Service1 table to modify.
Demand limit set point is , actual demand.
Demand limit is active based on CONFIG table set-up.
Hot Gas Bypass is energized. See surge prevention in the
control section.
Active demand limit manually overridden or Status01 table.
Machine in Ice Build temperature control.
73
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides (cont)
I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)
PRIMARY MESSAGE
SECONDARY MESSAGE
ALARM MESSAGE/PRIMARY CAUSE
ADDITIONAL CAUSE/REMEDY
RUN CAPACITY LIMITED HIGH CONDENSER PRESSURE CRP VALUE exceeded limit of [LIMIT]*.
Condenser pressure override.
RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE MTRW VALUE exceeded limit of [LIMIT]*.
Motor temperature override.
See Capacity Overrides, Table 5.
RUN CAPACITY LIMITED LOW EVAP REFRIG TEMP
ERT VALUE exceeded limit of [LIMIT]*. Correct operating condition.
Check refrigerant charge level.
RUN CAPACITY LIMITED MANUAL SLIDE VALVE
SV MAN Run Capacity Limited: Manual
slide valve control.
*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.
J. OUT-OF-RANGE SENSOR FAILURES
PRIMARY MESSAGE
SENSOR FAULT
SECONDARY MESSAGE
LEAVING CHW TEMPERATURE
SENSOR FAULT
ENTERING CHW TEMPERATURE
SENSOR FAULT
CONDENSER PRESSURE
SENSOR FAULT
EVAPORATOR PRESSURE
SENSOR FAULT
SENSOR FAULT
MOTOR WINDING TEMP
ROTOR INLET TEMPERATURE
SENSOR FAULT
OIL SUMP TEMPERATURE
SENSOR FAULT
OIL PRESSURE TRANSDUCER
ALARM MESSAGE/PRIMARY CAUSE
Sensor Fault: Check leaving CHW
sensor.
Sensor Fault: Check entering CHW
sensor.
Sensor Fault: Check cond pressure
transducer.
Sensor Fault: Check evap pressure
transducer.
Sensor Fault: Check motor temp sensor.
Sensor Fault: Check rotor inlet temp
sensor.
Sensor Fault: Check oil sump temp
sensor.
Sensor Fault: Check oil pressure
transducer.
74
ADDITIONAL CAUSE/REMEDY
See sensor test procedure and check
sensors for proper operation and
wiring.
K. MACHINE PROTECT LIMIT FAULTS
Excessive numbers of the same fault can lead to severe
machine damage. Seek service expertise.
PRIMARY MESSAGE
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE LIMIT
PROTECTIVE UNIT†
SECONDARY MESSAGE
HIGH DISCHARGE TEMP
ALARM MESSAGE/
PRIMARY CAUSE
CMPD VALUE exceeded
limit of [LIMIT]*. Check oil
temperature.
ADDITIONAL CAUSE/REMEDY
Check discharge temperature immediately. Check
for sensor accuracy. Check for proper condenser flow and temperature, check oil sump temperature. Check condenser for fouled tubes or
air in machine.
LOW REFRIGERANT TEMP
ERT VALUE exceeded limit of Check for proper amount of refrigerant charge,
[LIMIT]*. Check evap pump and check for proper water flow and temperatures.
flow switch.
Check for proper slide valve operation.
HIGH MOTOR TEMPERATURE
MTRW VALUE exceeded limit Check motor temperature immediately. Check senof [LIMIT]*. Check motor
sor for accuracy. Check for proper condenser flow
cooling.
and temperature. Check motor cooling system
for restrictions. Check refrigerant filter.
OIL LEVEL SENSOR
OILSS check oil level in sepa- Check for low oil level. Check oil level switch oprator.
eration.
LOW OIL PRESSURE
OILPD VALUE exceeded limit Check oil level, check for dirty filter. Check tower
of [LIMIT]*. Check oil system, oil water temperature.
solenoid, and transducer.
NO MOTOR CURRENT
CA P Loss of Motor Current: Check wiring: Check torque setting on solid state
Check sensor and signal.
starter. Check for main circuit breaker trip. Check
power supply to PSIO module.
POWER LOSS
V P Power Loss: Check voltage supply.
LOW LINE VOLTAGE
V P VALUE exceeded limit of Check 24-vdc input sensor on the SMM; adjust
potentiometer if necessary. Check transformers
[LIMIT]*. Check voltage
to SMM. Check distribution bus. Consult power
supply.
HIGH LINE VOLTAGE
V P VALUE exceeded limit company.
of [LIMIT]*. Check voltage
supply.
LOW CHILLED WATER FLOW
EVFL Flow Fault: Check evap.
Perform pumps control test and verify proper switch
pump/flow switch.
operation. Check all water valves and pump opLOW CONDENSER WATER FLOW CDFL Flow Fault: Check cond. eration.
pump/flow switch.
HIGH CONDENSER PRESSURE
PRS TRIP High Condenser Condenser pressure transducer tripped maPressure: Check switch and chine. Check for proper condenser water flows
water temp/flow.
and temperature. Check high-pressure switch.
HIGH CONDENSER PRESSURE
CRP VALUE exceeded limit Check discharge pressure switch. Check for proper
of [LIMIT]*. Check condenser condenser flow and temperature. Check for fouled
water and transducer.
tubes.
1CR AUX CONTACT FAULT
CR AUX Starter Contact Fault: 1CR auxiliary contact opened while machine was
Check 1CR/1M aux contacts. running. Check starter for proper operation.
RUN AUX CONTACT FAULT
RUN AUX Starter Contact Run auxiliary contact opened while machine was
Fault: Check 1CR/1M aux running. Check starter for proper operation.
contacts.
CCN OVERRIDE STOP
CHIL S S CCN Override CCN has signaled machine to stop. Reset and
Stop while in LOCAL run mode. restart when ready. If the signal was sent by the
LID, release the Stop signal on STATUS01 screen.
SPARE SAFETY DEVICE
SRP PL Spare Safety Fault: Spare safety input has tripped or factory-installed
Check contacts.
jumper not present.
EXCESSIVE MOTOR AMPS
CA P VALUE exceeded limit Check motor current for proper calibration. Check
of [LIMIT]*. High Amps; Check slide valve for proper operation.
slide valve.
STARTER FAULT
STR FLT Starter Fault: Check Check starter for possible ground fault, reverse
starter for fault source.
rotation, voltage trip, etc.
STARTER OVERLOAD TRIP
STR FLT Starter Overload Reset overloads and reset alarm. Check motor
Trip: Check amps calibration/ current calibration or overload calibration (do not
reset overload.
field-calibrate overloads).
TRANSDUCER VOLTAGE FAULT
V REF VALUE exceeded limit Check transformer power (5 vdc) supply to
of [LIMIT]*. Check transducer transducers. Power must be 4.5 to 5.5 vdc.
power supply.
DIRTY OIL FILTER
OILP exceeded limit of [LIMIT]*. Check oil filter. Check solenoid valve operation.
Replace oil filter.
Check oil supply valves. Check discharge and
oil transducer accuracy.
LOW DISCHARGE SUPERHEAT
Low discharge superheat. Check Excessive oil/refrigerant charge, low load operarefrigerant and oil charges.
tion. Reclaim oil lost to refrigerant circuit; remove excess oil. Do not operate machine below
minimum load. Check tower control operation.
*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.
†Applicable to Frame 1 and 2 units only.
75
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides (cont)
L. MACHINE ALERTS
PRIMARY MESSAGE
SECONDARY MESSAGE
ALARM MESSAGE/
ADDITIONAL CAUSE/REMEDY
PRIMARY CAUSE
RECYCLE ALERT
HIGH AMPS AT SHUTDOWN*
High Amps at Recycle: Check slide Check that slide valve is opening. Check
valve.
motor amps correction calibration is
correct.
SENSOR FAULT ALERT
LEAVING COND WATER TEMP
Sensor Fault: Check leaving condenser water sensor.
Check sensor: See sensor test
SENSOR FAULT ALERT
ENTERING COND WATER TEMP Sensor Fault: Check entering con- procedure.
denser water sensor.
DIRTY OIL FILTER
HIGH OIL PRESSURE DROP
Replace oil filter.
Condenser pressure minus oil filter presALERT
sure alert greater than oil pressure transducer. Reconfigure oil filter pressure alert
on Service1 or change oil filter.
AUTORESTART PENDING POWER LOSS
V P Power Loss: Check voltage
supply.
AUTORESTART PENDING LOW LINE VOLTAGE
V P VALUE exceeded limit of Check power supply if there are excessive compressor starts occuring.
[LIMIT]†. Check voltage supply.
AUTORESTART PENDING HIGH LINE VOLTAGE
V P VALUE exceeded limit of
[LIMIT]†. Check voltage supply.
SENSOR ALERT
HIGH DISCHARGE TEMP
CMPD VALUE exceeded limit of Discharge temperature exceeded the alert
[LIMIT]†. Check oil temperature. threshold. Check entering condenser water temperature.
SENSOR ALERT
LOW OIL PRESSURE
OILPD VALUE exceeded limit of Check that oil pressure transducer and/or
[LIMIT]†. Low oil pressure alert.
evaporator pressure transducer are not out
of range. Check entering condenser water temperature.
CONDENSER PRESSURE PUMP RELAY ENERGIZED
CRP High Condenser Pressure, Check ambient conditions. Check conALERT
[VALUE] Pump energized to re- denser pressure for accuracy.
duce pressure.
RECYCLE ALERT
EXCESSIVE RECYCLE STARTS EXCESSIVE RECYCLE STARTS The machine load is too small to keep the
machine on line. More than 5 restarts have
occurred in 4 hours. Increase machine load,
adjust hot gas bypass, increase RECYCLE
RESTART DELTA T temperature. Do not
start chiller until minimum load is available.
POTENTIAL FREEZE-UP
COND PRESS/TEMP TOO LOW
CONDENSER freeze-up
Check condenser water pump operation.
protection.
Refer to Condenser Freeze Protection section on page 31.
*Only applicable PSIO Software Version 13 and lower.
†[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.
M. SPARE SENSOR ALERT MESSAGES
PRIMARY MESSAGE
SECONDARY MESSAGE
SPARE SENSOR ALERT COMMON CHWS SENSOR
SPARE SENSOR ALERT COMMON CHWR SENSOR
SPARE SENSOR ALERT REMOTE RESET SENSOR
SPARE SENSOR ALERT TEMP SENSOR — SPARE 1
SPARE SENSOR ALERT TEMP SENSOR — SPARE 2
SPARE SENSOR ALERT TEMP SENSOR — SPARE 3
SPARE SENSOR ALERT TEMP SENSOR — SPARE 4
SPARE SENSOR ALERT TEMP SENSOR — SPARE 5
SPARE SENSOR ALERT TEMP SENSOR — SPARE 6
SPARE SENSOR ALERT TEMP SENSOR — SPARE 7
SPARE SENSOR ALERT TEMP SENSOR — SPARE 8
SPARE SENSOR ALERT TEMP SENSOR — SPARE 9
ALARM MESSAGE/
PRIMARY CAUSE
Sensor Fault: Check common
CHWS sensor.
Sensor Fault: Check common
CHWR sensor.
Sensor Fault: Check remote reset
temperature sensor.
Sensor Fault: Check temperature
sensor — Spare 1.
Sensor Fault: Check temperature
sensor — Spare 2.
Sensor Fault: Check temperature
sensor — Spare 3.
Sensor Fault: Check temperature
sensor — Spare 4.
Sensor Fault: Check temperature
sensor — Spare 5.
Sensor Fault: Check temperature
sensor — Spare 6.
Sensor Fault: Check temperature
sensor — Spare 7.
Sensor Fault: Check temperature
sensor — Spare 8.
Sensor Fault: Check temperature
sensor — Spare 9.
76
ADDITIONAL CAUSE/REMEDY
Check alert temperature set points on Equipment Service Service2 LID screen.
Check sensor for accuracy if reading is not
accurate.
Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages
with Troubleshooting Guides (cont)
N. ADDITIONAL TROUBLESHOOTING INFORMATION
DESCRIPTION
At power-up, default screen does not appear. Instead, ‘‘Uploading Tables’’ message continually appears.
Blank LID screen.
Scrambled LID display screens.
SMM communications failure.
‘‘Communications Failure’’ highlighted
message at bottom of LID.
‘‘Control Test Disabled’’ message.
Slide valve solenoid will not
energize in Control Test.
Pressure transducers will not
calibrate.
Pressure transducers are not
reading correctly.
Sensor reads −40 F (−40 C).
Nuisance high-pressure switch trips.
Discharge isolation valve appears to be
installed backwards.
Refrigerant appears to be leaking through
machine insulation.
Low megger reading on motor.
Machine never comes out of
UNOCCUPIED mode.
Holiday Scheduling and Daylight
Savings Time is not acknowledged.
Nuisance water/brine flow trips.
Shutdown on low oil pressure at
start-up.
Shutdown on low discharge superheat.
(Applicable to Frame 1 and 2 machines
only.)
‘‘Starter Fault’’ message.
Compressor starts when starter is
reset after alarm shutdown.
Default screen readings are locked up
while Status01 screen readings are fine.
CHILLED WATER/BRINE temperature too
high (machine running).
CHILLED WATER/BRINE temperature tool
low (machine running).
CHILLED WATER/BRINE temperature
fluctuates; slide valve hunts.
Kilowatt reading on Status01 table does
not change during operation.
REMEDY
Check for proper communications wiring on PSIO module. Check that the Level I communications wires are terminated to the
Level I PSIO connection.
Check red LED on LID (power supply) for proper operation. If LED is blinking, but green LEDs are not, replace LID module
(memory failure).
Attach to the local PSIO bus/address on the Attach to Network Device table of the Service menu.
Check that PSIO communication plugs are connected correctly. Check SMM communication plug. Check for proper SMM power
supply. See Troubleshooting Guide on page 68. If battery was removed or battery terminals shorted, module has been erased;
replace. Check that wire strands are not crossing over to other terminal pin connections.
LID is not properly addressed to the PSIO. Make sure that the Local Device on the Attach to Network Device table is set to read
the PSIO bus/address. Check LEDs on PSIO. Is red LED operating properly? Are green LEDs blinking? See Troubleshooting
Guide on page 68. If battery was removed or battery terminals shorted, module has been erased. Replace, if necessary.
Press the STOP softkey. The PIC must be in the OFF mode for the Control Test to operate. Clear all alarms. Check line voltage
percent on Status01 screen. The value must be within 90% to 110%. Check voltage input to SMM. Calibrate starter voltage
potentiometer for accuracy.
Put machine into pumpdown mode or equalize the pressure. Check slide valve actuator solenoid wiring.
At 0 psi (0 kPa), simply SELECT the transducer then press ENTER softkey. Pressing the INCREASE or DECREASE softkeys
may cause calibration errors. Only use the INCREASE and DECREASE softkeys at the high pressure calibration point.
Schrader fittings can be installed too deep. Check that the transducer can fully depress the Schrader valve depressor pin. The
top of the pin should be between .010 in. above the top of the valve body to .035 in. below the top of the valve body. Use a
Schrader fitting installation tool.
Indicates the loop is open. Check for proper connections and wire placement.
Check Schrader fitting on discharge pressure switch.
There is a small arrow on the discharge isolation valve which would normally indicate the direction of gas flow through the valve.
However, the valve is correctly installed with the arrow pointing upward. This is because the better scaling surface is on the high
pressure side which sees refrigerant pressure during shipment. During machine operation, flow through the valve will not be
restricted and damage to the valve will not be incurred. Refrigerant can be isolated in the cooler since the valve operates reliably
in either direction.
Gas-off of insulation glue may activate a refrigerant leak detector.
Liquid refrigerant will remain on bottom of motor housing. Terminal no. 3 will be submerged. May have as low as 1 to 2 megohm
readings on terminal no. 3 and corresponding terminal no. 6 only. Check for power factor correction capacitors on starter.
Configure time and date by selecting Time and Date from the Service menu.
The broadcast acknowledger on the Equipment Configuration BRODEFS table must be active. Only one broadcast acknowledger per communication network should be active.
Check that flow switch contacts are gold plated. Recommended Delta-Pro switch comes preset to make at 2 psid.
(14 kPad) It is possible to adjust this setting lower even though the specification states that 2 psid (14 kPad) is the lower limit.
Turn the calibration set screw (counter) clockwise to (decrease) increase the acting.
Oil pressure created by system pressure differential. System pressure differential established by the difference between leaving
condenser water temperature and leaving chilled water temperature. Minimum differential must exist between ECDW and LCW.
Minimum ECDW at start-up is dependent on several factors (see Oil Cycle section). * Do not defeat machine control timers.
Increase ramp loading rate. Open cooling tower bypass. Decrease flow rates. Check for dirty oil filter. Later machines include
head pressure control poppet valve. Check that starter transition timer is set such that motor is up to full speed within 5 seconds.
Check economizer back-pressure valve operation, if applicable. Check hot gas bypass ball valve.
Excessive oil charge. Refrigerant migration into oil causes oil to rise above baffle in separator, which results in oil floodback.
Oil is lost to refrigerant circuit; cooler foams up; discharge temperature goes to zero superheat; wet discharge; diluted oil. Oil
must be heated to 35 F (19 C) above evaporator refrigerant temperature to boil off excess refrigerant. Manually reclaim oil from
refrigerant circuit. Remove excess oil. Machine will alarm or indicate low oil level if there was excess oil loss. Check refrigerant
charge.
Starter Fault switch on the front of the starter (if applicable) may be faulty. This Starter Fault switch only indicates a problem
with transition. Other causes of Start Fault are ground fault, under/over voltage relays, and phase relays.
When a starter trip occurs, the SMM deliberately maintains its 24-v output to the 1CR relay for up to 10 seconds in order to
determine the type of fault that has occurred.
Reset all alarms. Default screen reading freeze when an alarm occurs.
1. Chilled water set point set too high. Access set point on LID and verify.
2. Capacity override or excessive cooling load (machine at design capacity). Check LID status messages. Check for outside
air infiltration into conditioned space.
3. Condenser temperature too high. Check for proper flow; examine cooling tower operation; check for air or water leaks.
Check for fouled tubes.
4. Refrigerant level low. Check for leads. Add refrigerant. Trim charge.
5. Liquid bypass in waterbox. Examine division plates and gaskets for leaks.
6. Slide valve fails to close (load). Use Control Test to check operation.
7. Chilled water control point too high. Access Control Algorithm Status to check chilled water control operation.
8. Slide valve fails to close (load) fully. Be sure that the manual slide valve count is released. Check slide valve solenoids.
Check that sensor is in the proper terminals.
1. Chilled water set point set too high. Access set point on LID and verify.
2. Chilled water control point too low. Access Control Algorithm Status table to check chilled water control for proper resets.
3. Slide valve fails to open (unload). Be sure that manual slide valve count is released. Check chilled water sensor accuracy.
Check slide valve solenoids.
1. Deadband too narrow. Configure LID for a larger deadband.
2. Proportional band too narrow. Either INC or DEC proportional bands should be widened.
3. Defective slide valve actuator. Check through Control Test.
4. Defective temperature sensor. Check sensor accuracy.
This feature is only active when the starter is provided with an optional 4-10 mA kW transducer wired to the SMM.
LEGEND
LED — Light-Emitting Diode
LID
— Local Interface Device
PSIO — Processor Sensor Input/Output Module
SMM — Starter Management Module
*A field supplied, water temperature control system should be installed. The system should maintain the leaving condenser water temperature at a temperature that is
18 F (10 C) above the leaving chilled water temperature.
77
Table 11 — Thermistor Temperature (F) vs Resistance/Voltage Drop
TEMPERATURE
(F)
−25.0
−24.0
−23.0
−22.0
−21.0
−20.0
−19.0
−18.0
−17.0
−16.0
−15.0
−14.0
−13.0
−12.0
−11.0
−10.0
−9.0
−8.0
−7.0
−6.0
−5.0
−4.0
−3.0
−2.0
−1.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
27.0
28.0
29.0
30.0
31.0
32.0
33.0
34.0
35.0
36.0
37.0
38.0
39.0
40.0
41.0
42.0
43.0
44.0
45.0
46.0
47.0
48.0
49.0
50.0
51.0
52.0
53.0
54.0
55.0
56.0
57.0
58.0
59.0
60.0
61.0
62.0
63.0
64.0
65.0
66.0
67.0
68.0
69.0
70.0
VOLTAGE
DROP (V)
4.821
4.818
4.814
4.806
4.800
4.793
4.786
4.779
4.772
4.764
4.757
4.749
4.740
4.734
4.724
4.715
4.705
4.696
4.688
4.676
4.666
4.657
4.648
4.636
4.624
4.613
4.602
4.592
4.579
4.567
4.554
4.540
4.527
4.514
4.501
4.487
4.472
4.457
4.442
4.427
4.413
4.397
4.381
4.366
4.348
4.330
4.313
4.295
4.278
4.258
4.241
4.223
4.202
4.184
4.165
4.145
4.125
4.103
4.082
4.059
4.037
4.017
3.994
3.968
3.948
3.927
3.902
3.878
3.854
3.828
3.805
3.781
3.757
3.729
3.705
3.679
3.653
3.627
3.600
3.575
3.547
3.520
3.493
3.464
3.437
3.409
3.382
3.353
3.323
3.295
3.267
3.238
3.210
3.181
3.152
3.123
RESISTANCE
(OHMS)
98010
94707
91522
88449
85486
82627
79871
77212
74648
72175
69790
67490
65272
63133
61070
59081
57162
55311
53526
51804
50143
48541
46996
45505
44066
42679
41339
40047
38800
37596
36435
35313
34231
33185
32176
31202
30260
29351
28473
27624
26804
26011
25245
24505
23789
23096
22427
21779
21153
20547
19960
19393
18843
18311
17796
17297
16814
16346
15892
15453
15027
14614
14214
13826
13449
13084
12730
12387
12053
11730
11416
11112
10816
10529
10250
9979
9717
9461
9213
8973
8739
8511
8291
8076
7868
7665
7468
7277
7091
6911
6735
6564
6399
6238
6081
5929
TEMPERATURE
(F)
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
VOLTAGE
DROP (V)
3.093
3.064
3.034
3.005
2.977
2.947
2.917
2.884
2.857
2.827
2.797
2.766
2.738
2.708
2.679
2.650
2.622
2.593
2.563
2.533
2.505
2.476
2.447
2.417
2.388
2.360
2.332
2.305
2.277
2.251
2.217
2.189
2.162
2.136
2.107
2.080
2.053
2.028
2.001
1.973
1.946
1.919
1.897
1.870
1.846
1.822
1.792
1.771
1.748
1.724
1.702
1.676
1.653
1.630
1.607
1.585
1.562
1.538
1.517
1.496
1.474
1.453
1.431
1.408
1.389
1.369
1.348
1.327
1.308
1.291
1.289
1.269
1.250
1.230
1.211
1.192
1.173
1.155
1.136
1.118
1.100
1.082
1.064
1.047
1.029
1.012
0.995
0.978
0.962
0.945
0.929
0.914
0.898
0.883
0.868
0.853
78
RESISTANCE
(OHMS)
5781
5637
5497
5361
5229
5101
4976
4855
4737
4622
4511
4403
4298
4196
4096
4000
3906
3814
3726
3640
3556
3474
3395
3318
3243
3170
3099
3031
2964
2898
2835
2773
2713
2655
2597
2542
2488
2436
2385
2335
2286
2239
2192
2147
2103
2060
2018
1977
1937
1898
1860
1822
1786
1750
1715
1680
1647
1614
1582
1550
1519
1489
1459
1430
1401
1373
1345
1318
1291
1265
1240
1214
1190
1165
1141
1118
1095
1072
1050
1029
1007
986
965
945
925
906
887
868
850
832
815
798
782
765
750
734
TEMPERATURE
(F)
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
VOLTAGE
DROP (V)
0.838
0.824
0.810
0.797
0.783
0.770
0.758
0.745
0.734
0.722
0.710
0.700
0.689
0.678
0.668
0.659
0.649
0.640
0.632
0.623
0.615
0.607
0.600
0.592
0.585
0.579
0.572
0.566
0.560
0.554
0.548
0.542
0.537
0.531
0.526
0.520
0.515
0.510
0.505
0.499
0.494
0.488
0.483
0.477
0.471
0.465
0.459
0.453
0.446
0.439
0.432
0.425
0.417
0.409
0.401
0.393
0.384
0.375
0.366
RESISTANCE
(OHMS)
719
705
690
677
663
650
638
626
614
602
591
581
570
561
551
542
533
524
516
508
501
494
487
480
473
467
461
456
450
445
439
434
429
424
419
415
410
405
401
396
391
386
382
377
372
367
361
356
350
344
338
332
325
318
311
304
297
289
282
Table 12 — Thermistor Temperature (C) vs Resistance/Voltage Drop
TEMPERATURE
(C)
−40
−39
−38
−37
−36
−35
−34
−33
−32
−31
−30
−29
−28
−27
−26
−25
−24
−23
−22
−21
−20
−19
−18
−17
−16
−15
−14
−13
−12
−11
−10
−9
−8
−7
−6
−5
−4
−3
−2
−1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
VOLTAGE
DROP (V)
4.896
4.889
4.882
4.874
4.866
4.857
4.848
4.838
4.828
4.817
4.806
4.794
4.782
4.769
4.755
4.740
4.725
4.710
4.693
4.676
4.657
4.639
4.619
4.598
4.577
4.554
4.531
4.507
4.482
4.456
4.428
4.400
4.371
4.341
4.310
4.278
4.245
4.211
4.176
4.140
4.103
4.065
4.026
3.986
3.945
3.903
3.860
3.816
3.771
3.726
3.680
3.633
3.585
3.537
3.487
3.438
3.387
3.337
3.285
3.234
3.181
3.129
3.076
3.023
2.970
2.917
2.864
2.810
2.757
2.704
2.651
2.598
2.545
2.493
2.441
2.389
2.337
2.286
2.236
2.186
2.137
2.087
2.039
1.991
1.944
RESISTANCE
(Ohms)
168 230
157 440
147 410
138 090
129 410
121 330
113 810
106 880
100 260
94 165
88 480
83 170
78 125
73 580
69 250
65 205
61 420
57 875
54 555
51 450
48 536
45 807
43 247
40 845
38 592
38 476
34 489
32 621
30 866
29 216
27 633
26 202
24 827
23 532
22 313
21 163
20 079
19 058
18 094
17 184
16 325
15 515
14 749
14 026
13 342
12 696
12 085
11 506
10 959
10 441
9 949
9 485
9 044
8 627
8 231
7 855
7 499
7 161
6 840
6 536
6 246
5 971
5 710
5 461
5 225
5 000
4 786
4 583
4 389
4 204
4 028
3 861
3 701
3 549
3 404
3 266
3 134
3 008
2 888
2 773
2 663
2 559
2 459
2 363
2 272
TEMPERATURE
(C)
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
79
VOLTAGE
DROP (V)
1.898
1.852
1.807
1.763
1.719
1.677
1.635
1.594
1.553
1.513
1.474
1.436
1.399
1.363
1.327
1.291
1.258
1.225
1.192
1.160
1.129
1.099
1.069
1.040
1.012
0.984
0.949
0.920
0.892
0.865
0.838
0.813
0.789
0.765
0.743
0.722
0.702
0.683
0.665
0.648
0.632
0.617
0.603
0.590
0.577
0.566
0.555
0.545
0.535
0.525
0.515
0.506
0.496
0.486
0.476
0.466
0.454
0.442
0.429
0.416
0.401
0.386
0.370
RESISTANCE
(Ohms)
2 184
2 101
2 021
1 944
1 871
1 801
1 734
1 670
1 609
1 550
1 493
1 439
1 387
1 337
1 290
1 244
1 200
1 158
1 118
1 079
1 041
1 006
971
938
906
876
836
805
775
747
719
693
669
645
623
602
583
564
547
531
516
502
489
477
466
456
446
436
427
419
410
402
393
385
376
367
357
346
335
324
312
299
285
If all modules indicate communications failure, check communications plug on the PSIO module for proper seating.
Also check the wiring terminations (Level II — 1:red,
2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a
good connection is assured and the condition persists, perform an Attach to Network Device upload of the PSIO
module. The correct PSIO module address must be known
to perform this function if the Attach to Network Device
selection is not functioning, replace the module.
If only one 8-input module or SMM indicates communication failure, check the communications plug on that
module. Make sure wiring is properly connected. Communications plug must be connected to the correct socket.
If a good connection is assured and the condition persists, replace the module.
All system operating intelligence rests in the PSIO module. Some safety shutdown logic resides in the SMM in
case communications are lost between the 2 modules. The
PSIO monitors conditions using input ports on the PSIO,
the SMM, and the 8-input modules. Outputs are controlled by the PSIO and SMM as well.
3. Power is supplied to modules within the control panel via
21-vac power sources.
The transformers are located within the power panel, with
the exception of the SMM, which operates from a 24-vac
power source and has its own 24-vac transformer located
within the starter.
Within the power panel, T1 supplies power to the LID,
the PSIO, and the 5-vac power supply for the transducers. The other 21-vac transformer is T4, which supplies
power to both 8-input modules (if present). T4 is capable
of supplying power to two modules; if additional modules are added, another power supply will be required.
Power is connected to Terminals 1 and 2 of the power
input connection on each module.
Control Modules
Turn controller power off before servicing controls. This
ensures safety and prevents damage to controller.
The Processor module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous diagnostic
evaluations of the hardware to determine its condition. Proper
operation of all modules is indicated by LEDs (lightemitting diodes) located on the side of the LID, and on the
top horizontal surface of the PSIO, SMM, and 8-input
modules.
RED LED — If the LED is blinking continuously at a
2-second rate, it is indicating proper operation. If it is lit continuously, it indicates a problem requiring replacement of the
module. If the red LED blinks 3 times per second, a software error has been discovered and the module should be
replaced. Off continuously indicates that the power should
be checked. If there is no input power, check fuses and the
circuit breaker. If fuse is good, check for shorted secondary
of transformer Or, if power is present to the module, replace
the module.
GREEN LEDs — There are one or 2 green LEDs on each
type of module. These LEDs indicate communication status
between different parts of the controller and the network modules as follows:
LID Module
Upper LED — Communication with CCN network, if present;
blinks when communication occurs.
Lower LED — Communication with PSIO module; must blink
every 3 to 5 seconds.
PSIO Module
Green LED closest to communications connection — Communication with SMM and 8-input module; must blink continuously.
Other Green LED — Communication with LID. This green
LED must blink every 3 to 5 seconds.
8-Input Modules and SMM
Green LED — Communication with PSIO module. This green
LED will blink continuously.
Notes on Module Operation
1. The machine operator monitors and modifies configurations in the microprocessor through the 4 softkeys and
the LID. Communication with the LID and the PSIO is
accomplished through the CCN (Level II) bus. The communication between the PSIO, SMM, and both 8-input
modules is accomplished through the sensor bus, which
is a 3-wire cable. This sensor bus runs in parallel between modules.
On sensor bus terminal strips, Terminal 1 of PSIO module is connected to Terminal 1 of each of the other modules. Terminals 2 and 3 are connected in the same manner. See Fig. 44-47. If a Terminal 2 wire is connected to
Terminal 1, the system does not work.
2. If a green LED is solid on, check communication wiring.
If a green LED is off, check the red LED. If the red LED
is normal, check the module address switches
(Fig. 44-47). Proper addresses are:
MODULE
LID (Local Interface Device)
PSIO (Processor Sensor, Input/Output Module)
SMM (Starter Management Module)
8-input Options Module 1
8-input Options Module 2
ADDRESS
SW1
SW2
E
6
5
A
3
2
6
4
7
2
Fig. 44 — PSIO Module Address Selector Switch
Locations and LED Locations
80
Starter Management Module (SMM) (Fig. 47)
INPUTS — Inputs on strips J2 and J3 are a mix of analog
and discrete (on/off) inputs. Application of the machine determines which terminals are used. Always refer to the individual unit’s wiring for terminal numbers.
OUTPUTS — Outputs are 24 vdc and wired to strip J1. There
are 2 terminals used per output.
NOTE: LID address switches are factory set as follows: S1 is set at
E; S2 is set at 6.
Fig. 45 — LID Module and Address Selector
Switch Locations (Rear View) and LED Locations
Processor Module (PSIO) (Fig. 46)
INPUTS — Each input channel has 3 terminals; only 2 of
the terminals are used. Application of machine determines
which terminals are normally used. Always refer to individual unit wiring for terminal numbers.
OUTPUTS — Output is 20 vdc. There are 3 terminals per
output, only 2 of which are used, depending on application.
Refer to unit wiring diagram.
NOTE: SMM address switches should be set as follows: S1 set at 3;
S2 set at 2.
Fig. 47 — Starter Management Module (SMM)
Options Modules (8-input) — The Options modules
are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, and demand limit
inputs. Each option module contains 8 inputs, each input meant
for a specific duty. See the wiring diagram for exact module
wire terminations. Inputs for each of the options modules
available include the following:
OPTION MODULE 1
4 to 20 mA Auto. Demand Reset
4 to 20 mA Auto. Chilled Water Reset
Common Chilled Water Supply Temperature
Common Chilled Water Return Temperature
Remote Temperature Reset Sensor
Spare Temperature 1
Spare Temperature 2
Spare Temperature 3
OPTION MODULE 2
4 to 20 mA Spare 1
4 to 20 mA Spare 2
Spare Temperature 4
Spare Temperature 5
Spare Temperature 6
Spare Temperature 7
Spare Temperature 8
Spare Temperature 9
NOTE: PSIO address switches are factory set as follows: S1 is set at
5; S2 is set at A.
Fig. 46 — Processor (PSIO) Module
81
Terminal block connections are provided on the options
modules. All sensor inputs are field wired and installed. Options module number 1 can be factory or field installed. Options module 2 is shipped separately and must be field installed. For installation, refer to unit or field wiring diagrams.
Be sure to address the module for the proper module number
(Fig. 48) and to configure the chiller for each feature being
used.
INSTALLATION
1. Verify if the existing PSIO module is defective, by using the procedure described in the Troubleshooting Guide
section, page 68, and Control Modules section,
page 80. Do not select the Attach to Network Device
from the service menu if the LID displays communication failure.
2. Data regarding the PSIO configuration should have been
recorded and saved. This data will have to be reconfigured into the LID. If this data is not available, follow
the procedures described in the Set Up Machine Control
Configuration section on page 50.
If a CCN Building Supervisor or Service Tool is present,
the module configuration should have already been uploaded into memory; then, when the new module is installed, the configuration can be downloaded from the
computer.
Any communication wires from other machines or CCN
modules should be disconnected to prevent the new PSIO
module from uploading incorrect run hours into
memory.
3. Check that all power to the unit is off. Carefully disconnect all wires from the defective module by unplugging the 6 connectors. It is not necessary to remove any
of the individual wires from the connectors.
4. Remove defective PSIO by removing its mounting screw
with a long-shaft Phillips screwdriver, and removing the
module from the control center. Save the screw for later
use. The green ground wire is held in place with the module mounting screw.
5. Package the defective module in the carton of the new
module for return to Carrier.
6. Mount the new module in the unit control center using
a long-shaft Phillips screwdriver and the screw saved in
Step 4 above. Make sure that the green grounding wire
is reinstalled along with the mounting screw.
7. Connect the LID communication wires (Level II bus)
and the power wires only. If CCN wiring has been attached to the Level II bus, disconnect the wires.
8. Carefully check all wiring connections before restoring
power.
9. Restore control power and verify that the red and green
LEDs on the PSIO are functioning properly.
10. Access the Attach to Network Device table on the LID
Service menu. Set the local device address to Bus
0, Address 90. Press the ATTACH softkey to upload
the PSIO into the LID.
11. Change the address of the PSIO in the Config table of
the Equipment Configuration table back to the previous
value. Write the address on the PSIO.
12. Use the configuration sheets to input set point, configuration, and schedule information into the PSIO. Time
and Date also must be set through the service menu. A
Building Supervisor can be used to download the old
configuration into the PSIO.
13. Perform a Control Test and verify all tests. Select Control Test from the service menu
If the software version has been updated, a CCN download of the configuration will not be allowed. Configure
the PSIO by hand, and upload the PSIO into the network by using the Attach to Network Device table.
14. Restore chiller to normal operation, calibrate motor amps.
NOTE: Options module address switches should be set as follows:
SWITCH
SETTING
S1
S2
OPTION
MODULE 1
6
4
OPTION
MODULE 2
7
2
Fig. 48 — Options Module
Replacing Defective Processor Modules — The
replacement part number is printed in a small label on front
of the PSIO module. The model and serial numbers are printed
on the unit nameplate located on an exterior corner post. The
proper software is factory installed by Carrier in the replacement module. When ordering a replacement processor module (PSIO), specify complete replacement part number, full
unit model number, and serial number. This new unit requires reconfiguration to the original machine’s data by the
installer.
Electrical shock can cause personal injury. Disconnect
all electrical power before servicing.
82
Solid-State Starters — Troubleshooting guides pertaining to the operation of the solid-state starters may be found
in Fig. 49-55 and Tables 13 and 14.
Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting
tables.
When the power is off:
• Inspect for physical damage and signs of arcing, overheating, etc.
• Is the wiring to the starter correct?
• Are all connections in the starter tight?
• Is the current feedback resistor properly adjusted and
installed?
• Is a heater coil installed in each leg of the motor?
• Is the control transformer fuse blown?
• Is the motor connected to the starter?
TESTING SILICON CONTROL RECTIFIERS IN BENSHAW, INC. SOLID-STATE STARTERS — If a silicon control rectifier (SCR) is suspected of being defective, use the
following procedure as part of a general troubleshooting guide.
SCR — Silicon Control Rectifier
Fig. 49 — Typical Benshaw, Inc. Solid-State Starter
(Internal View)
IMPORTANT: Before performing the SCR check below, remove power from the starter and disconnect the
motor terminals T1, T2, and T3.
2. Connect ohmmeter across terminals L2 and T2. Check
the resistance reading. Resistance reading should be greater
than 10,000 ohms.
3. Connect ohmmeter across terminals L3 and T3. Check
the resistance reading. Resistance reading should be greater
than 10,000 ohms.
If the SCRs tested were not defective, but the problem
persists, refer to Steps 4-8.
4. Connect the T1, T2, and T3 terminals on the starter to the
motor.
5. Disconnect one of the wires to the shunt trip contact on
the starter. This wire is disconnected to prevent the shorted
SCR detection from operating the disconnect device while
this test is being performed.
6. Close the disconnect breaker. Check the voltage from the
starter line terminal to load terminal on each phase. The
measured voltage should be approximately 0.58 times the
system line-to-line voltage. If the voltage on any power
pole is significantly less, one or both SCRs in the power
pole may be shorted. See Fig. 51.
7. If a shorted SCR is detected, check for possible shorted
connections, system grounds, or any other condition that
might be causing the short. Replacement of SCRs or power
poles without determining the cause of the failure may
result in repeated failure of the SCRs.
8. When the starter is running, measure the voltage from the
line side to the load side of each starter power pole. The
voltage should be approximately 1 to 1.5 vac.
1. Connect ohmmeter across terminals L1 and T1. Resistance reading should be greater than 50,000 ohms.
2. If reading is less than 50,000 ohms, remove connecting
bus heatsink between SCR3 and SCR6 and check anode
to cathode of SCR3 and SCR6 separately to determine
which device is defective. See Fig. 49. Replace defective
device and retest controller.
3. Repeat Steps 1 and 2 across terminals L2 and T2 for SCRs
2 and 5.
4. Repeat Steps 1 and 2 across terminals L3 and T3 for SCRs
1 and 3.
If the SCRs tested were not defective but the problem
still persists, refer to the following Steps 5 and 6.
5. Disconnect the SCR1 from the white gate and red cathode wires on the control logic card BIPCRS6. With an
ohmmeter set on Rx1, check between white and red wires.
Resistance should normally be between 8 and 20 ohms
average. Excessively high or low resistance may be indicative of a defective device. Replace and retest.
6. Repeat Step 5 for SCR leads 2 through 6. Care should be
taken to ensure that the gate and cathode wires are replaced exactly as they were: white wire to gate
(G1 through G6); red wire to cathode (K1 through K6).
Damage to the starter may result if wires are
reversed.
When measuring voltage from line side to load side, observe proper electrical safety procedures since the power
poles have voltage applied. This voltage could be as high
as 600 v. Personal injury could result.
If problem is still not resolved, consult the starter manufacturer for servicing.
TESTING SILICON CONTROL RECTIFIERS (SCRs) IN
CUTLER-HAMMERt SOLID-STATE STARTERS — To
check for a shorted SCR refer to Steps 1-3 and
Fig. 50-53.
NOTE: Do not megger (high voltage insulation test) the starter.
1. Connect ohmmeter across terminals L1 and T1. Check
the resistance reading. Resistance reading should be greater
than 10,000 ohms.
If one of the voltages is higher than 2 v, but the voltages
of the 3 power poles are approximately equal, the starter is
probably still in current limit. If the voltage is higher than
2 v on only 1 or 2 power poles, not all SCRs are firing properly. Make sure the gate lead connections are tight. If all 3
power poles have less than a 2 v drop from line side to load
side of each starter power pole when the motor is up to speed,
any current unbalance in the motor is caused by the motor
or an unbalanced line voltage.
83
ELECTRONIC PROTECTION RELAY (EPR) — On CutlerHammer solid state starters, the EPR is designed to provide
an alternative to conventional motor protection due to overcurrent. See Fig. 53. It performs the following functions:
Test Button — The TEST button provides testing of the EPR’s
ability to detect overload, test relay operation, and simulate
motor load.
System Ready (SYST RDY) — This light-emitting diode (LED)
provides a visual indication that the EPR is
functioning.
Trip Time Potentiometer — The Trip Time potentiometer has
50 selectable overload trip classes ranging from 1 to
50 seconds.
Reset Time Potentiometer — The Reset Time potentiometer
has 5 to 120 minutes of motor cooling reset.
Full Load Amperes (FLA) — The FLA potentiometer is adjustable from 1 to 1,500 amps, based on overload frame size.
Trip LED — The Trip LED provides a visual indication that
the EPR has detected an overload condition and tripped.
Fault (FLT) LED — The FLT LED is an indicator light.
Reset Button — The RESET button allows for the manual
reset of the EPR.
Trip, Common (COM), and FLA Test Terminals — The Trip,
COM, and FLA test terminals provide for Digital Voltmeter
(DVM) calibration.
Terminal 1 (TB1) — Terminal 1 is the 120 vac connection
to power the EPR.
Terminal 4 (TB4) — Terminal 4 is the normally closed, electronically isolated EPR contact for overload trip.
NOTE: When the System Ready (SYST RDY) LED is a steady
green light, no fault has been found in the solid-state starter
operation. When the SYST RDY LED is a steady green light
and the fault indicator (FLT) is a flashing red light, the a
motor overload trip is approaching. When the FLT LED is
a solid red light and the SYST RDY LED is a flashing green
light, a motor overload trip has occurred. When the FLT LED
is a solid red light and the SYST RDY LED is a solid green
light, the overload has tripped because of a phase unbalance.
Fig. 50 — Resistance Check
SCR — Silicon Control Rectifier
Fig. 51 — SCR and Power Poles
FLT — Fault LED
Fig. 53 — Cutler-Hammer Terminal Functions
SCR — Silicon Control Rectifier
Fig. 52 — Typical Cutler-HammerT Solid-State Starter
(Internal View)
84
Table 13 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide
PROBLEM
BIPCRS6AK board phase correct
not on.
PROBABLE CAUSES
1. L1 and L3 switch phases
reversed.
2. Missing phase voltage.
3. Improper line voltage.
BIPCRS6AK board relay not on.
Ribbon cable not properly
seated.
1. Improper line voltage.
2. Transformer malfunction.
BIPCRS6AK board power
+15 vdc not on.
BIPCDVDT1/1L boards LEDs not
on.
1. A short exists between line
and load terminals.
2. An SCR is shorted in the
phase assembly.
BIPCRS6BC board overtemperature LED (L3) on prior to
run command.
1. Temperature switch not
functioning properly.
2. BIPCRS6BC board not
functioning properly.
BIPCRS6BC board LEDs on
prior to run command.
BIPCRS6BC board LEDs not on
after run command but before
starter reaches full voltage.
BIPCRS6BC board not
functioning properly.
1. Phase assembly malfunction.
2. BIPCRS6BC board not
functioning properly.
BIPCDVDT1/1L board LEDs remain on after starter reaches full
voltage.
BIPCRS6BC board run LED (L5)
not lit.
BIPCRS6AK board power applied, run command given,
starter at full voltage, but aux
LED not lit.
BIPCDVDT1/1L boards LEDs lit.
Imbalance between phases exists in motor terminal voltages.
BIPCRS6BC board LED L4 and
L5 not lit.
BIPCRS6BC board LED L3 lit.
BIPCRS6BC board not
functioning properly.
1. FU5 and FU6 fuses not
functioning properly.
2. Phase assembly not
functioning properly.
3. Fan not functioning properly.
BIPCRS6BC board L2 lit.
SCR phases not functioning
properly.
Motor lead grounded.
Motor does not begin rotation.
BIPCRS6BC board L1 lit.
Start command given.
BIPCRS6BC board not
functioning properly.
BIPCRS6AK board not
functioning properly.
Measure 24 vdc at TB11-8 to TB11-4. If voltage is present,
replace board. If not present, replace relay 1CR.
Replace board.
Motor terminal voltage phase
imbalance exists.
Check motor terminal voltages for imbalance between
phases. If an imbalance exists, check for loose SCR gate or
open SCR gate. Replace phase assembly, if necessary.
Replace board.
Motor does not reach full speed
within 25 seconds.
Ramp up setting is not correct.
115 vac missing from LL1 and
LL2.
1.
2.
1.
2.
SMM not responding.
AREA OF CORRECTION
1. Switch incoming phases L1 and L3 at top of CD1 or
CB1.
2. Check for missing phase voltage.
3. Verify proper line voltage applied against synchronizing
transformer voltage.
Check ribbon cable for proper seating. Replace board if
necessary.
1. Make sure proper line voltage is present at primary synchronizing transformer.
2. Check synchronizing transformer secondary voltage as
follows: On the BIPCRS6BC board, measure from
TB11-1 to TB11-2 and TB11-3 TB11-1 to TB11-3. Both
readings should be within 30 to 36 vac. On the
BIPCRS6BC board, measure from TB11-1 to TB11-4 and
TB11-2 to TB11-4. Both readings should be within 18 to
24 vac. Replace synchronizing transformer if voltages are
not within the specified tolerances.
1. Remove power and check resistance with ohmmeter.
Locate and remove stray wire strands if required.
2. Remove power. Use ohmmeter to measure the resistance or each SCR phase assembly from anode to
cathode. The reading should be 50,000 ohm or greater. If
not, replace phase assembly.
1. Disconnect power and check for continuity between
TB11-10 and TB11-11. If no continuity exists, the overtemperature switch is not functioning properly. Replace
defective switch if necessary.
2. Make sure BIPCRS6BC board is functioning properly.
Replace board if necessary.
Board not functioning properly. Replace board, if
necessary.
1. Remove power and check SCRs. Ohmmeter reading of
each SCR gate to cathode resistance at terminals is
8 to 20 ohm. If not, replace the phase assembly.
2. Replace board, if necessary.
Check for loose SCR gate lead or open SCR gate. Replace
phase assembly, if necessary.
CB2 is not on.
Fuse no. 4 (FU4) blown.
CB4 is not on.
Potentiometer RV1 needs
adjustment.
LEGEND
LED — Light-Emitting Diode
SCR — Silicon Control Rectifier
SMM — Starter Management Module
85
1. Check fuses FU5 and FU6. Replace if necessary.
2. Verify that bypass is pulling in by measuring the voltage
drop across the contacts. The reading should be 50 mV
or less. Replace phase assembly, if necessary.
3. Verify fan operation on each phase for 200 amp units.
Replace fan, if necessary.
Measure resistance from anode to cathode for each SCR
phase assembly. Replace shorted phase, if necessary.
Megger motor to test for motor lead going to ground.
Turn ‘Starting Torque’ potentiometer RV2 clockwise until
motor rotation begins.
Turn ‘Ramp’ potentiometer RV1 counterclockwise. Restart
motor and verify that motor reaches full speed within
25 seconds.
1. Verify CB2 is on.
2. Check FU4 for continuity. Replace, if necessary.
1. Verify CB4 is on.
2. Adjust potentiometer RV1 for 24 vac at SMM terminals
J3-23 and J3-24.
Table 14 — Cutler-HammerT Solid-State Starter Troubleshooting Guide
PROBLEM
(CB) trips (electrically operated
disconnecting means opens) as
it is closed.
CB trips while motor is
running.
CB trips when STOP is pressed.
Starter does not pick up and
maintain.
PROBABLE CAUSE
Motor is not connected.
Incorrect phase sequence to the starter, 3-phase
power not connected, or terminal loose.
Shorted SCR.
Shunt trip contact between terminals closes due
to shorted SCR.
Shunt trip latching relay not reset (if used).
Microprocessor detected non-standard operation.
Voltage drop across SCR (looks like shorted
SCR).
Line voltage is not applied.
Overload is not reset.
120 v control voltage is not present.
Heatsink overtemperature switches are open.
Starter maintains but motor does
not accelerate or does not attain
full speed (stalls).
Insufficient Torque.
Motor accelerates too slowly.
Motor accelerates too quickly.
Current limit adjustment has no
effect during acceleration.
Starter or motor is noisy or vibrates when starting.
Mechanical shock to machine.
End of limit contact does not
close.
Current trip contact does not
close when current goes above
the trip setting.
Current trip contact closes when
current is below trip setting.
Motor current, voltage, and
speed oscillate.
Overload relay trips when
starting.
Overload relay trips when running.
Heatsink overtemperature switch
opens.
Erratic operation.
Current limit is too low.
Improper current feedback.
High breakaway torque required.
Current limit is too low.
Ramp time is too long.
Broken current feedback resistor.
Current limit is too high.
Improper current feedback.
Pulse start setting is too long.
Broken current feedback transformer wire.
Improper current feedback.
Single phasing due to open phase.
Single phasing or unbalanced current due to nonfiring SCR.
Defective motor.
Current increases too quickly.
AREA OF CORRECTION
Connect motor to starter.
Switch two incoming power leads. The 50 and 51
corresponding motor leads must also be switched to
maintain the same motor rotation.
Perform shorted SCR check.
Perform shorted SCR check.
Reset STR relay by pushing RESET button on relay.
Check wiring to logic module or replace logic
module.
Check SCR.
Check incoming lines for proper voltage.
Reset overload.
Check control transformer fuse. Check control
circuits.
Check for continuity through overtemperature
switches. Check that all fans are rotating freely.
Check for excessive motor current draw.
Increase current limit setting clockwise. Set ramp
time to minimum (counterclockwise).
Check current feedback resistor for proper
calibration.
Load is not suitable for reduced voltage starting.
Increase current limit setting clockwise.
Decrease ramp time setting counterclockwise.
Check by recalibrating CFR.
Decrease current limit setting counterclockwise.
Check current calibrator for proper resistance value.
Decrease pulse start time counterclockwise.
Check for a broken current feedback transformer
wire.
Check current calibrator for proper resistance value.
Check wiring and overload heater coils.
Check gate lead wiring to SCRs.
Starter is in current limit.
Check motor for shorts, opens, and grounds.
Decrease starting current counterclockwise. If necessary, increase ramp time clockwise.
Perform SCR full voltage test.
Improper current feedback.
Check current calibrator for proper resistance value.
Improper current feedback.
Check current calibrator for proper resistance value.
Power saver is misadjusted.
Turn power saver adjustment CCW until oscillations
cease.
Check heater coil rating.
Tighten heater coil.
Motor and starter thermal capabilities must be evaluated before extending overload trip times.
Check machinery for binding or excessive loading.
See ‘‘Starter or motor is noisy or vibrates when starting’’ symptom in troubleshooting table.
Increase current limit setting clockwise.
Incorrect heater coils (melting allow).
Loose heater coil.
Long starting time (high inertia applications may
require slow trip overload and oversize starter).
Mechanical problems.
Single phasing.
Excessive starting time (current limit may be set
too low).
Incorrect heater coils (melting alloy).
Mechanical problems.
Single phasing.
Excessive current.
Defective heatsink, fan.
Loose connections.
LEGEND
CCW — Counter Clockwise
CFR — Current Feedback Resistor
STR — Shunt Trip Relay
86
Check heater coil rating.
Check machinery for binding or excessive loading.
See ‘‘Starter or motor is noisy or vibrates when starting’’ problem in troubleshooting table.
Check motor current draw.
Check that all fans are rotating freely.
Check all connections.
SCR — Silicon Control Rectifier
Fig. 54 — Typical Solid-State Starter, General Operation Troubleshooting Guide
87
Fig. 55 — Typical Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide
88
fications, physical data, electrical data, and wiring schematics may be found in Tables 15-21 and Fig. 56-62.
Physical Data — For operator convenience during troubleshooting, additional details regarding compressor torque speci-
Table 15 — 23XL Heat Exchanger Weights
Dry Wt (lb)*
SIZE
Cooler Cond
Only† Only
10
11
20
21
40
41
42
43
2480
2650
2845
3000
5030
5180
5345
5525
2890
3020
3250
3445
4690
4835
5005
5185
ENGLISH
Machine Charge
Refrigerant (lb)
Water
Economizer
No Economizer
Cooler
HCFC-22 HFC-134a HCFC-22 HFC-134a
650
**
600
**
34
650
**
600
**
40
750
**
700
**
45
750
**
700
**
49
1000
850
900
800
49.2
1100
900
1000
850
54
1200
950
1100
900
60
1300
1000
1200
950
66
Dry Wt (kg)*
(gal)
Cooler Cond
Cond Only† Only
39.2
44.4
49.2
56.4
51.6
57
63
70
1125
1202
1291
1361
2282
2350
2424
2506
1310
1370
1474
1563
2127
2193
2270
2352
SI
Machine Charge
Refrigerant (kg)
Water (L)
Economizer
No Economizer
Cooler Cond
HCFC-22 HFC-134a HCFC-22 HFC-134a
295
**
272
**
130
150
295
**
272
**
152
168
340
**
318
**
170
186
340
**
318
**
186
214
454
386
408
363
186
195
499
408
454
386
204
216
544
431
499
408
227
239
590
454
544
431
250
264
NIH — Nozzle-In-Head
*Weight based on: .035 in. wall copper Turbo-B2 tubes in cooler, Turbo chill in condenser.
2-pass, 150 psi NIH waterbox arrangements (sizes 10, 11, 20, 21)
3-pass, 300 psi NIH waterbox arrangements (sizes 40, 41, 42, 43)
†Weight of optional economizer is not included and must be added to cooler weight.
**Not available.
NOTE: Standard shipment is with refrigerant charged, so be sure to add refrigerant charge to dry weight.
Table 16 — 23XL Compressor Weights
23XL
UNIT
ASSEMBLY
COMPRESSOR SIZE (Tons)
lb
2270
2300
2400
3300
3400
C2
C4
C6
D4
D6
Frame 1
Frame 2
Frame 4
kg
1029
1043
1088
1497
1542
Table 17 — 23XL Component Weights
COMPONENT
Oil Separator
Economizer†
Muffler
Discharge Piping:
Pipe
Isolation Valve†
Adaptor Flange
Power Panel
Starter†
Control Center
FRAME 1 AND 2
lb
kg
1180
535
296
134
170
77
44
30
76
20
500
31
20
14
34
9
227
14
*The Frame 4 muffler is included in the oil separator weight.
†Optional.
89
FRAME 4
lb
2880*
560
*
kg
1306*
254
*
—
30
76
20
500
31
—
14
34
9
227
14
Table 18 — Optional Storage Tank and/or Pumpout System Physical Data
UNIT
SIZE
28
52
TANK OUTSIDE
DIAMETER
DRY WEIGHT
in.
24.00
27.25
lb
2200
3270
mm
610
692
kg
998
1606
MAXIMUM REFRIGERANT CAPACITY
ASHRAE/ANSI 15
ARI 495
HCFC-22
HFC-134a
HCFC-22
HFC-134a
lb
kg
lb
kg
lb
kg
lb
kg
1840
835
1865
845
1645
747
1665
755
3525
1599
3570
1619
3155
1431
3195
1449
LEGEND
ANSI
— American National Standards Institute
ARI
— Air Conditioning and Refrigeration Institute
ASHRAE — American Society of Heating, Refrigeration, and
Air Conditioning Engineers
NOTES:
1. ANSI/ASHRAE 15 — Safety Code for Mechanical Refrigeration
2. Dry weights include the pumpout condensing unit weight of 210 lbs (95 kg).
Table 19 — Optional Storage Tank and/or
Pumpout System Electrical Data
MOTOR CODE
1
4
5
6
CONDENSER UNIT
19EA47-748
19EA42-748
19EA44-748
19EA46-748
LRA — Locked Rotor Amps
RLA — Rated Load Amps
90
VOLTS-PH-HZ
575-3-60
200/208-3-60
230-3-60
400/460-3-50/60
MAX RLA
3.8
10.9
9.5
4.7
LRA
23.0
63.5
57.5
28.8
Table 20A — 23XL Waterbox Cover Weights (Frame 1 and 2 Machines)*
HEAT EXCHANGER
WATERBOX
DESCRIPTION
PSI
(kPa)
Cooler or
Condenser
NIH, 1 Pass
NIH, 2 Pass (Plain)
NIH, 2 Pass (With Pipe Nozzles)
150
(1034)
NIH, 3 Pass
150
(1034)
FRAME 1
lbs
kg
118
54
100
46
185
84
FRAME 2
lbs
kg
128
58
148
67
200
91
166
180
76
82
LEGEND
NIH — Nozzle-In-Head
*These weights are given for reference only. They have been included in heat exchanger weights
shown in Table 15.
NOTE: Add 30 lb (14 Kg) for bolts.
Table 20B — 23XL Waterbox Cover Weight (Frame 4 Machines)*
HEAT
EXCHANGER
COOLER
CONDENSER
WATERBOX
DESCRIPTION
NIH, 1 Pass Cover
NIH, 2 Pass Cover
NIH, 3 Pass Cover
NIH, Plain End Cover
MWB Cover
Plain End Cover
NIH, 1 Pass Cover
NIH, 2 Pass Cover
NIH, 3 Pass Cover
NIH, Plain End Cover
MWB Cover
Plain End Cover
ENGLISH (lb)
Frame 4,
Frame 4,
Std Nozzles
Flanged
150 psig 300 psig 150 psig 300 psig
284
414
324
491
285
411
341
523
292
433
309
469
243
292
243
292
CS
621
CS
621
CS
482
CS
482
306
446
346
523
288
435
344
547
319
466
336
502
226
271
226
271
CS
474
CS
474
CS
359
CS
359
SI (kg)
Frame 4,
Frame 4,
Std Nozzles
Flanged
1034 kPa 2068 kPa 1034 kPa 2068 kPa
129
188
147
223
129
187
155
237
133
197
140
213
110
133
110
133
CS
282
CS
282
CS
219
CS
219
139
202
157
237
131
197
156
248
145
212
153
228
103
123
103
123
CS
215
CS
215
CS
163
CS
163
LEGEND
CS
— Contact Syracuse
MWB — Marine Waterbox
NIH
— Nozzle-In-Head
*These weights are given for reference only. The 150 psig (1034 kPa) standard waterbox cover
weights have been included in the heat exchanger weights shown in Table 15.
91
Table 21 — 23XL Compressor Torque Specification Chart for Metric and American Fasteners
ITEM
CAP SCREW
SIZE AND TYPE
GRADE
1.
2.
1.
2.
M5 X 0.8 X 12 S.H.
M6 X 1 X 16 S.H.
M10 X 1.5 X 35 H.H.
M10 X 1.5 X 40 S.H.
M10 X 1.5 X 50 H.H.
M12 X 1.75 X 40 S.H.
M12 X 1.75 X 50 S.H.
CAP SCREW
10.9
M12 X 1.75 X 60 S.H.
M12 X 1.75 X 70 S.H.
M12 X 1.75 X 80 S.H.
M12 X 1.75 X 90 S.H.
FRAME 1 AND 2
M16 X 2 X 55 S.H.
FRAME 4
M16 X 2 X 70 S.H.
M20 X 2.5 X 70 S.H.
M10 X 1.5 X 16 S.S.
10.9
M10 X 1.5 X 30 S.S.
1⁄8 NPTF
PIPE PLUG
⁄ NPTF
14
N/A
⁄ -20
7 16
⁄ -18
9 16
HEX PLUG
⁄ -16
34
N/A
11⁄16-12
13⁄16-12
⁄ -11
58
N/A
TERMINAL PIN
13⁄16-12
RELIEF VALVE
M20 X 1
M35 X 1.5
1-5⁄8-12 UN-2A
N/A
PLUG, ORIFICE
M8 X 1.25
N/A
WAFER HEAD SCREW
M6 X 1
N/A
LOCKNUT
FUSITE-MOTOR CASING
SLIDE SEAL RETAINER-CYLINDER STOP
CONTROL VALVES-SLIDE CASING
SLIDE SEAL ADAPTOR-SEPARATOR PLATE
(FRAME 1 AND 2 ONLY)
3. SLIDE SEAL ADAPTOR-SLIDE CASING PLUG
(FRAME 4 ONLY)
1. BRG RETAINER-MALE ROTOR
2. BRG RETAINER-FEMALE ROTOR
1. SLIDE VALVE COVER-SLIDE CASING
2. SLIDE CASING-SEPARATOR PLATE (FRAME 1 AND 2
ONLY)
1. MOTOR ROTOR-MALE ROTOR
1. SERVICE VALVE PAD-MOTOR COVER
FRAME 1 AND 2 ONLY
1. MOTOR COVER-MOTOR CASING
2. SEPARATOR PLATE-OUTLET CASING
3. DISCHARGE COVER-OUTLET CASING
1. MOTOR END PLATE-MOTOR COVER-MOTOR CASING
(FRAME 1 AND 2 ONLY)
2. MOTOR COVER-MOTOR CASING (FRAME 4 ONLY)
3. SLIDE CASING-OUTLET CASING (FRAME 4 ONLY)
FRAME 4 ONLY
1. MOTOR END PLATE-MOTOR COVER-MOTOR CASING
FRAME 1 AND 2 ONLY
1. SLIDE CASING-SEPARATOR PLATE-OUTLET CASING
FRAME 4 ONLY
1. SLIDE CASING (BOTTOM)-OUTLET CASING
1.
2.
3.
4.
M22 X 2.5 X 80 S.H.
SET SCREW
ASSEMBLY LOCATION
N/A
ROTOR CASING-INLET CASING AND OUTLET CASING
MOTOR CASING-INLET CASING
OPEN DRIVE END COVER-INLET CASING
DISCHARGE COVER-OUTLET CASING (FRAME 4 ONLY)
1. INLET FLANGES-INLET CASING (FRAME 1 AND 2 ONLY)
FRAME 4 ONLY
1. INLET FLANGES-INLET CASING
FRAME 4 ONLY
1. OPEN DRIVE SEAL ADAPTER
1. STATOR KEY LOCK
1. INLET CASING
FRAME 4 ONLY
1. SLIDE CASING
1. INLET CASING
2. SLIDE CASING
1. MOTOR CASING
2. OUTLET CASING
3. ROTOR CASING
4. SLIDE CASING
1. OUTLET CASING
2. SLIDE CASING (FRAME 1 AND 2 ONLY)
1. INLET CASING
2. ROTOR CASING
3. OUTLET CASING
FRAME 4 ONLY
1. OUTLET CASING
1. TERMINAL NUTS
2. MOTOR LEAD
1. TERMINAL PIN BODY
2. MOTOR CASING
1. SLIDE VALVE ASSEMBLY
1. SLIDE VALVE ASSEMBLY
1. ROTOR CASING
1. INLET CASING
2. OPEN DRIVE END COVER (FRAME 1 AND 2 ONLY)
FRAME 4 ONLY
1. SLIDE VALVE ASSEMBLY
92
Nm
TORQUE
Lb-Ft
Lb-in.
4.1-5.4
3-4
36-48
6.8-9.6
5-7
60-84
41-47
30-35
N/A
61-68
45-50
N/A
20-27
15-20
N/A
103-115
75-85
N/A
252-280
185-205
N/A
485-513
355-375
N/A
697-724
510-530
N/A
41-47
30-35
N/A
13-20
20-27
10-15
15-20
120-180
180-240
27-34
20-25
240-300
13-16
10-12
130-140
23-26
17-19
210-230
60-65
44-48
530-570
112-125
83-92
1000-1100
125-140
92-103
1100-1240
23-26
17-19
N/A
27-34
20-25
N/A
68-75
95-102
345-379
50-55
70-75
254-279
N/A
N/A
N/A
19-24
14-18
168-216
13-15
10-11
120-130
3.1 Chilled water and condenser water flow switch contacts, optional remote start device contacts and optional spare safety device contacts, must have 24 vdc rating.
Max current is 60 ma, nominal current is 10 ma. Switches with gold plated bifurcated contacts are recommended.
3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties between these terminals.
3.3 Pilot relays can control cooler and condenser pump and tower fan motor contactor
coil loads rated 10 amps at 115 vac up to 3 amps at 600 vac. Control wiring required
for Carrier to start pumps and tower fan motors must be provided to assure machine
protection. If primary pump and tower fan motor control is by other means, also
provide a parallel means for control by Carrier. Do not use starter control transformer as the power source for pilot relay loads.
3.4 Do not route control wiring carrying 30 v or less within a conduit which has wires
carrying 50 v or higher or along side wires carrying 50 v or higher.
3.5 Voltage selector switch in machine power panel is factory set for 115 v control power
source. When 230 v control power source is used, set switch to 230 v
position.
3.6 Control wiring cables between starter and power panel must be shielded with minimum rating of 600 v, 80 C. Ground shield at starter.
IV. POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR
4.0 Low voltage (600 v or less) compressor motors have (6) 1⁄2 in. terminal studs (lead
connectors not supplied by Carrier). Either 3 or 6 leads must be run between compressor motor and starter, depending on type of motor starter employed. If only 3
leads are required, jumper motor terminals as follows: 1 to 6, 2 to 4, 3 to 5. Center
to center distance between terminals is 2.73 inches. Compressor motor starter must
have nameplate stamped as to conforming with Carrier requirement ‘‘Z-375.’’
4.1 When more than one conduit is used to run conductors from starter to compressor
motor terminal box, one conductor from each phase must be in each conduit, to
prevent excessive heating. (e.g., conductors to motor terminals 1, 2 and 3 in one
conduit, and these to 4, 5 and 6 in another.)
4.2 Compressor motor power connections can be made through top, bottom, or right
side of compressor motor terminal box by rotating the terminal box and using holes
cut by contractor to suit conduit. Flexible conduit should be used for the last few feet
to the terminal box for unit vibration isolation. Use of stress cones or 12 conductors
larger than 500 MCM may require an oversize (special) motor terminal box (not
supplied by Carrier). Lead connections between 3-phase motors and their
starters must not be insulated until Carrier personnel have checked compressor
rotation.
4.3 Compressor motor frame to be grounded in accordance with the National Electrical
Code (NFPA-70) and applicable codes. Means for grounding compressor motor is
(2) Thomas and Betts pressure connectors for 350 to 800 MCM wire, supplied and
located in the back upper and lower right side corners of the compressor motor
terminal box.
4.4 Do not allow motor terminals to support weight of wire cables. Use cable supports
and strain reliefs as required.
4.5 Use back up wrench when tightening lead connectors to motor terminal studs. Torque
to 10-15 lb-ft max.
IMPORTANT: Refer to certified drawings for additional information. Certified drawings are available upon
request.
LEGEND
Required Power Wiring
Required Control Wiring
Options Wiring
NOTES:
I. GENERAL
1.0 Starters shall be designed and manufactured in accordance with Carrier Engineering Requirement Z-375.
1.1 All field-supplied conductors, devices, field-installation wiring, and termination of conductors and devices, must be in compliance with all applicable codes and job specifications.
1.2 The routing of field-installed conduit and conductors and the location of fieldinstalled devices, must not interfere with equipment access or the reading, adjusting, or servicing of any component.
1.3 Equipment, installation, and all starting and control devices must comply with details in equipment submittal drawings and literature.
1.4 Contacts and switches are shown in the position they would assume with the circuit
deenergized and the chiller shut down.
1.5 WARNING — Do not use aluminum conductors.
1.6 Installer is responsible for any damage caused by improper wiring between starter
and machine.
II. POWER WIRING TO STARTER
2.0 Power conductor rating must meet minimum unit nameplate voltage and compressor motor RLA (rated load amps).
When (3) conductors are used:
Minimum ampacity per conductor = 1.25 x compressor RLA
When (6) conductors are used:
Minimum ampacity per conductor = 0.721 x compressor RLA
2.1 Lug adapters may be required if installation conditions dictate that conductors be
sized beyond the minimum ampacity required. Contact starter supplier for lug
information.
2.2 Compressor motor and controls must be grounded by using equipment grounding
lugs provided inside starter enclosure.
III. CONTROL WIRING
3.0 Field supplied control conductors to be at least 18 AWG (American Wire Gage) or
larger.
Fig. 56 — 23XL Typical Field Wiring with Free-Standing Starter (Frame 1 and 2 Machines Shown)
93
2.1 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Solid-state
starters are provided with:
A. Two (2) 0-250 MCM lugs provided per phase for power conductor
terminations when compressor motor RLA is 400 amps or less.
B. Three (3), 250-500 MCM lugs provided per phase for power conductor terminations when compressor motor RLA is more than
400 amps.
Wye-Delta starters are provided with:
A. Two (2) 250-500 MCM lugs provided per phase for power conductor terminators when compressor motor RLA is 420 amps or less.
B. Two (2) #1-500 MCM lugs provided per phase for power conductor
terminations when compressor motor RLA is more than
420 amps.
2.2 Power conductors to starter must enter through top of enclosure. Flexible conduit should be used for the last few feet to the enclosure to
provide unit vibration isolation.
2.3 Compressor motor and controls must be grounded by using equipment grounding lugs provided inside starter enclosure.
2.4 Wye-Delta starters require the assembly and the installation of a ‘‘Top
Hat’’ (located inside enclosure) to provide the required wire bending
space for incoming power leads.
III. CONTROL WIRING
3.0 Field supplied control conductors to be at least 18 AWG (American Wire
Gage) or larger.
3.1 Chilled water and condenser water flow switch contacts, optional remote start device contacts and optional spare safety device contacts,
must have 24 vdc rating. Max current is 60 ma, nominal current
is 10 ma. Switches with gold plated bifurcated contacts are
recommended.
3.2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties between these terminals.
3.3 Pilot relays can control cooler and condenser pump and tower fan motor contactor coil loads rated 10 amps at 115 vac up to 3 amps at 600
vac. Control wiring required for Carrier to start pumps and tower fan
motors must be provided to assure machine protection. If primary pump
and tower fan motor control is by other means, also provide a parallel
means for control by Carrier. Do not use starter control transformer as
the power source for pilot relay loads.
3.4 Do not route control wiring carrying 30 v or less within a conduit which
has wires carrying 50 v or higher or along side wires carrying 50 v or
higher.
IMPORTANT: Refer to certified drawings for additional information. Certified drawings are available upon
request.
LEGEND
Required Power Wiring
Required Control Wiring
Options Wiring
NOTES:
I. GENERAL
1.0 Starters shall be designed and manufactured in accordance with
Carrier Engineering Requirement Z-375.
1.1 All field-supplied conductors, devices, field-installation wiring, and termination of conductors and devices, must be in compliance with all
applicable codes and job specifications.
1.2 The routing of field-installed conduit and conductors and the location
of field-installed, devices must not interfere with equipment access or
the reading, adjusting, or servicing of any component.
1.3 Equipment installation and all starting and control devices must comply with details in equipment submittal drawings and literature.
1.4 Contacts and switches are shown in the position they would assume
with the circuit deenergized and the chiller shut down.
1.5 WARNING — Do not use aluminum conductors.
II. POWER WIRING TO STARTER
2.0 Power conductor rating must meet minimum unit nameplate voltage
and compressor motor RLA (rated load amps).
When (3) conductors are used:
Minimum ampacity per conductor = 1.25 x compressor RLA
When (6) conductors are used:
Minimum ampacity per conductor = 0.721 x compressor RLA
Fig. 57 — 23XL Typical Field Wiring with Optional Unit-Mounted Starter (Frame 1 and 2 Machines Shown)
94
Fig. 58 — Typical Electronic PIC Controls Wiring Schematic (Frame 1 and 2 Machines)
95
Fig. 58 — Typical Electronic PIC Controls Wiring Schematic (Frame 1 and 2 Machines) (cont)
96
Fig. 59 — Typical Electronic PIC Controls Wiring Schematic (Frame 4 Machines)
97
Fig. 59 — Typical Electronic PIC Controls Wiring Schematic (Frame 4 Machines) (cont)
98
99
Fig. 60 — Typical Machine Power Panel, Starter Assembly, and Motor (Frame 1 and 2 Machines)
100
Fig. 61 — Typical Machine Power Panel, Starter Assembly, and Motor (Frame 4 Machines)
101
Fig. 62 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic
102
Fig. 62 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic (cont)
INDEX
23XL Machine Familiarization, 4
Abbreviations and Explanations, 4
Adding Refrigerant, 63
Adjusting the Refrigerant Charge, 63
After Extended Shutdown, 58
After Limited Shutdown, 58
Attach To Network Device Control, 35
Automatic Soft Stop Amps Threshold, 38
Auto.-Restart After Power Failure, 31
Before Initial Start-Up, 39
Calibrate Motor Current Demand Setting, 57
Capacity Overrides, 29
Carrier Comfort Network Interface, 49
Changing Oil and Oil Filter, 64
Charge Refrigerant Into Machine, 55
Chilled Water Recycle Mode, 38
Cold Weather Operation, 59
Compressor Bearing Maintenance, 66
Compressor Rotor Check, 66
Condenser, 7
Condenser Freeze Prevention, 31
Condenser Pump Control, 29
Control Algorithm Checkout Procedure, 69
Control Center, 7, 64
Control Modules, 80
Controls, 13
Controls Definitions, 13
Control Test, 69
Cooler, 7
Demand Limit Control, Option, 32
Design Set Points (Input), 52
Details (Lubrication Cycle), 7
Display Messages (Check), 68
Dry Run to Test Start-Up Sequence, 56
Extended Shutdown, 58
Factory-Mounted Starter, 7
Field Supplied Equipment Required, 39
General Controls Overview, 13
General Maintenance, 63
Heat Exchanger Tubes (Inspect), 66
High Altitude Locations, 52
Hot Gas Bypass Algorithm, 32
Ice Build Control, 34
Initial Start-Up, 56
Instruct the Operator, 57
Introduction, 4
Job Data Required, 39
Lead/Lag Control, 33
Leak Test Machine, 40
LID Operation and Menus, 17
Local Occupied Schedule (Input), 52
Local Start-Up, 37
Lubrication Cycle, 7
Lubrication System (Check), 64
Machine Dehydration, 48
Machine Identification Nameplate, 4
Machine Operating Conditions (Check), 57
Machine Tightness (Check), 39
Machines with Isolation Valves, 62
Machines with Storage Tanks, 61
Motor Cooling Cycle, 7
Motor-Compressor, 7
Muffler-Oil Separator, 7
Notes on Module Operation, 80
Oil Charge, 50
Oil Loss Prevention, 8
Oil Pressure and Compressor Stop (Check), 57
Oil Reclaim System, 8
Oil Separator Coalescer, 66
Oil Specification, 66
Oil Sump Temperature Control, 29
Open Oil Circuit Valves, 39
Operating Instructions, 58
Operating the Optional Pumpout Compressor, 61
Operator Duties, 58
Optional Pumpout Compressor Water Piping (Check), 48
Optional Pumpout System Controls and
Compressor (Check), 55
Optional Pumpout System Maintenance, 67
Options Modules (8-Input), 81
Ordering Replacement Chiller Parts, 68
Overview (Troubleshooting Guide), 68
Physical Data, 89
PIC System Components, 13
PIC System Functions, 22
Power Up the Controls and Check the Oil Heater, 50
Preparation (for Initial Start-Up), 56
Preparation (for Pumpout and Refrigeration
Transfer Procedures), 61
Prepare the Machine for Start-Up, 58
Pressure Transducers (Check), 67, 68
Processor Module (PSIO), 81
Pumpout and Refrigerant Transfer Procedures, 61
Ramp Loading Control, 29
Refrigerant Charge (Trim), 64
Refrigerant Filter/Drier, 66
Refrigerant Float System (Inspect), 66
Refrigerant Leak Testing, 63
Refrigerant Leak Rate, 64
Refrigerant Properties, 63
Refrigerant Strainers, 66
Refrigerant Tracer, 39
Refrigeration Cycle, 7
Refrigeration Log, 59
Relief Devices (Check), 48
Relief Valves and Piping (Inspect), 66
Remote Start/Stop Controls, 29
Remove Shipping Packaging, 39
Removing Refrigerant, 63
Repair Refrigerant Leak, Retest, and Apply Standing
Vacuum Test, 64
Replacing Defective Processor Modules, 82
Return Refrigerant to Normal Operating Conditions, 63
Rotation (Check), 56
Running System (Check), 58
Safety and Operating Controls (Check), 64
Safety Considerations, 1
Safety Controls, 23
Safety Shutdown, 39
Scheduled Maintenance, 64
Service Configurations, 53
Service Ontime, 64
Service Operation, 36
Selecting Refrigerant Type, 53
Set Up Machine Control Configuration, 50
Shutdown Sequence, 38
Slide Valve Operation, 59
Slide Valve Principle, 11
Solid-State Starters, 83
Spare Safety Inputs, 29
Standing Vacuum Test, 48
Starter (Check), 49
Starter Management Module (SMM), 81
Starting Equipment, 11, 67
Start-Up/Shutdown/Recycle Sequence, 37
Storage Vessel, 7
System Components, 4
Summary (Lubrication Cycle), 7
Temperature Sensors (Check), 68
Test After Service, Repair, or Major Leak, 64
To Prevent Accidental Start-Up, 57
To Start the Machine, 58
103
To Stop the Machine, 58
Tower-Fan Relay, 31
Troubleshooting Guide, 68
Unit Mounted Solide-State Starter, 11
Unit Mounted Wye Delta Starter, 12
Using The Optional Storage Tank and Pumpout System, 39
Water/Brine Reset, 32
Water Leaks, 67
Water Piping (Inspect), 48
Water Treatment, 67
Weekly Maintenance, 64
Wiring (Inspect), 49
Copyright 1994 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 211
Catalog No. 532-302
Printed U.S.A.
Form 23XL-2SS
Pg 104
12-94
Replaces: 23XL-1SS
Tab 5e