Carrier 19XRV Specifications

19XR,XRV
Hermetic Centrifugal Liquid Chillers
50/60 Hz
With PIC II Controls and HFC-134a
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifications. When operating this equipment, use good judgment
and safety precautions to avoid damage to equipment and
property or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions as
well as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet
from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American
National Standards Institute/American Society of Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause 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 chiller for
any purpose. Oxygen gas reacts violently with oil, grease, and other
common substances.
NEVER EXCEED specified test pressures, VERIFY the allowable
test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry
nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High voltage is
present on motor leads even though the motor is not running when a
solid-state or inside-delta mechanical starter is used. Open the power
supply disconnect before touching motor leads or terminals.
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 chiller 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 panels, switches, starters, or oil heater until you are sure ALL POWER IS
OFF and no residual voltage can leak from capacitors or solid-state
components.
LOCK OPEN AND TAG electrical circuits during servicing. IF
WORK IS INTERRUPTED, confirm that all circuits are deenergized
before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with
soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause damage or malfunction to this chiller.
Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE 15 (latest edition).
Contact Carrier for further information on use of this chiller with other
refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
chiller is under pressure or while chiller is running. Be sure pressure is
at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act
as projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the starter, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements
of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines,
liquid, gases, or semisolids without the permission of your process
control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or
other items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut
has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 211
Catalog No. 531-982
Printed in U.S.A.
Form 19XR-5SS
Pg 1
6-01
Replaces: 19XR-4SS
Book 2
Tab 5a
CONTENTS
Page
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Discharge Temperature Control . . . . . . . . . . . . 36
Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 37
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 37
Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 37
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 37
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 38
Evaporator Freeze Protection (ICVC Only) . . . . . . . 38
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 38
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 38
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 39
Surge Prevention Algorithm
(Fixed Speed Chiller) . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Surge Prevention Algorithm with VFD . . . . . . . . . . . 40
Surge Protection VFD Units . . . . . . . . . . . . . . . . . . . . . 40
Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 40
• HEAD PRESSURE REFERENCE OUTPUT
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
• COMMON POINT SENSOR INSTALLATION
• CHILLER COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
• ICE BUILD INITIATION
• START-UP/RECYCLE OPERATION
• TEMPERATURE CONTROL DURING ICE BUILD
• TERMINATION OF ICE BUILD
• RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . . . . 44
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 47
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 48
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 48
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Factory-Mounted Starter or Variable
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
MOTOR AND LUBRICATING OIL
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10
Unit-Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit-Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
• ANALOG SIGNAL
• DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 11
• CHILLER VISUAL CONTROLLER (CVC)
• INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
• INTEGRATED STARTER MODULE (ISM)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• CONTROL TRANSFORMERS (T1, T2)
• OPTIONAL TRANSFORMER (T3)
CVC/ICVC Operation and Menus. . . . . . . . . . . . . . . . . 15
• GENERAL
• ALARMS AND ALERTS
• CVC/ICVC MENU ITEMS
• BASIC CVC/ICVC OPERATIONS (Using the Softkeys)
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33
• CAPACITY CONTROL FIXED SPEED
• CAPACITY CONTROL VFD
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
• DIFFUSER CONTROL
• PROPORTIONAL BANDS AND GAIN
• DEMAND LIMITING
• CHILLER TIMERS
• OCCUPANCY SCHEDULE
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2
CONTENTS (cont)
Page
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
• MECHANICAL STARTER
• BENSHAW, INC. RediStart MICRO™
SOLID-STATE STARTER
• VFD STARTER
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55
• SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55
• PASSWORD
• INPUT TIME AND DATE
• CHANGE CVC/ICVC CONFIGURATION
IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE CVC/ICVC DISPLAY FROM
ENGLISH TO METRIC UNITS
• CHANGE LANGUAGE (ICVC ONLY)
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• CHANGE THE BENSHAW, INC., RediStart
MICRO SOFTWARE CONFIGURATION
IF NECESSARY
• VERIFY VFD CONFIGURATION AND CHANGE
PARAMETERS IF NECESSARY
• VFD CHILLER FIELD SET UP AND VERIFICATION
• VFD CONTROL VERIFICATION (Non-Running)
• VFD CONTROL VERIFICATION (Running)
• CONFIGURE DIFFUSER CONTROL IF
NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62
• COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH
PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check Oil Pressure and Compressor Stop . . . . . . 65
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65
Check Chiller Operating Condition . . . . . . . . . . . . . . 65
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65
• COOLER-CONDENSER
• OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
• MOTOR COMPRESSOR ASSEMBLY
Page
• MOTOR COMPRESSOR LUBRICATION
SYSTEM
• CONTROL SYSTEM
• AUXILIARY EQUIPMENT
• DESCRIBE CHILLER CYCLES
• REVIEW MAINTENANCE
• SAFETY DEVICES AND PROCEDURES
• CHECK OPERATOR KNOWLEDGE
• REVIEW THE START-UP, OPERATION, AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66
Preparation for Extended Shutdown . . . . . . . . . . . . 66
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operating the Optional Pumpout Unit . . . . . . . . . . . 67
• TO READ REFRIGERANT PRESSURES
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69
• TRANSFER REFRIGERANT FROM
PUMPOUT STORAGE TANK TO CHILLER
• TRANSFER REFRIGERANT FROM
CHILLER TO PUMPOUT STORAGE TANK
Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70
• TRANSFER ALL REFRIGERANT TO
CHILLER CONDENSER VESSEL
• TRANSFER ALL REFRIGERANT TO
CHILLER COOLER VESSEL
• RETURN CHILLER TO NORMAL
OPERATING CONDITIONS
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Test After Service, Repair, or Major Leak . . . . . . . . 71
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72
Check the Lubrication System . . . . . . . . . . . . . . . . . . 72
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74
3
CONTENTS (cont)
Page
Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
• COOLER AND FLOW DEVICES
• CONDENSER AND FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75
Optional Pumpout System Maintenance . . . . . . . . . 75
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76
• UNITS EQUIPPED WITH CVC
• UNITS EQUIPPED WITH ICVC
• TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 77
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88
• INPUTS
• OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . . 88
• INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
• TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124
INITIAL START-UP CHECKLIST FOR
19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dissipate body electrostatic charge before working inside control center.
Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may cause interference to radio communications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when
operated in a commercial environment. Operation of this
equipment in a residential area is likely to cause interference, in which case the user, at his own expense, will be
required to take whatever measures may be required to correct the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
CCM
CCN
CCW
CVC
CW
ECDW
ECW
EMS
HGBP
I/O
ICVC
ISM
LCD
LCDW
LCW
LED
OLTA
PIC II
RLA
SCR
SI
TXV
VFD
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Chiller Control Module
Carrier Comfort Network
Counterclockwise
Chiller Visual Controller
Clockwise
Entering Condenser Water
Entering Chilled Water
Energy Management System
Hot Gas Bypass
Input/Output
International Chiller Visual Controller
Integrated Starter Module
Liquid Crystal Display
Leaving Condenser Water
Leaving Chilled Water
Light-Emitting Diode
Overload Trip Amps
Product Integrated Controls II
Rated Load Amps
Silicon Controlled Rectifier
International System of Units
Thermostatic Expansion Valve
Variable Frequency Drive
Words printed in all capital letters or in italics may be
viewed on the Chiller Visual Controller/International Chiller
Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN,
ALARM, etc.).
Words printed in both all capital letters and italics can also
be viewed on the CVC/ICVC and are parameters (e.g., CONTROL MODE, COMPRESSOR START RELAY, ICE BUILD
OPTION, etc.) with associated values (e.g., modes, temperatures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the CVC/ICVC control panel (e.g., ENTER ,
EXIT , INCREASE , QUIT , etc.).
INTRODUCTION
Prior to initial start-up of the 19XR unit, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the startup, operation and maintenance of the unit with the control system before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
4
through its internal tubes in order to remove heat from the
refrigerant.
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed additional components are referred to as accessories.
The chiller software part number of the 19XR unit is located
on the back of the CVC/ICVC.
Motor-Compressor — This component maintains system temperature and pressure differences and moves the heatcarrying refrigerant from the cooler to the condenser.
Control Panel — The control panel is the user interface
for controlling the chiller. It regulates the chiller’s capacity as
required to maintain proper leaving chilled water temperature.
The control panel:
• registers cooler, condenser, and lubricating system
pressures
• shows chiller operating condition and alarm shutdown
conditions
• records the total chiller operating hours
• sequences chiller start, stop, and recycle under microprocessor control
• displays status of motor starter
• provides access to other CCN (Carrier Comfort Network) devices and energy management systems
• Languages pre-installed at factory include: English, Chinese, Japanese, and Korean (ICVC only).
• International language translator (ILT) is available for
conversion of extended ASCII characters (ICVC only).
CHILLER FAMILIARIZATION
(Fig. 1 and 2)
Chiller Information Nameplate — The information
nameplate is located on the right side of the chiller control
panel.
System Components — The components include the
cooler and condenser heat exchangers in separate vessels,
motor-compressor, lubrication package, control panel, and motor starter. All connections from pressure vessels have external
threads to enable each component to be pressure tested with a
threaded pipe cap during factory assembly.
Cooler — This vessel (also known as the evaporator) is located underneath the compressor. The cooler is maintained at
lower temperature/pressure so evaporating refrigerant can remove heat from water flowing through its internal tubes.
Condenser — The condenser operates at a higher
temperature/pressure than the cooler and has water flowing
19XRV
52
51
473
DG
H
64
–
19XR- — High Efficiency Hermetic
Centrifugal Liquid Chiller
19XRV — High Efficiency Hermetic
Centrifugal Liquid Chiller with
Variable Frequency Drive
Unit-Mounted
Cooler Size
10-12 (Frame 1 XR)
15-17 (Frame 1 XR)
20-22 (Frame 2 XR)
30-32 (Frame 3 XR)
35-37 (Frame 3 XR)
40-42 (Frame 4 XR)
45-47 (Frame 4 XR)
50-52 (Frame 5 XR)
5A (Frame 5 XR)
5B (Frame 5 XR)
5C (Frame 5 XR)
Special Order Indicator
– — Standard
S — Special Order
Motor Voltage Code
Code Volts-Phase-Hertz
60 — 200-3-60
61 — 230-3-60
62 — 380-3-60
63 — 416-3-60
64 — 460-3-60
65 — 575-3-60
66 — 2400-3-60
67 — 3300-3-60
68 — 4160-3-60
69 — 6900-3-60
50 — 230-3-50
51 — 346-3-50
52 — 400-3-50
53 — 3000-3-50
54 — 3300-3-50
55 — 6300-3-50
55-57 (Frame 5 XR)
5F (Frame 5 XR)
5G (Frame 5 XR)
5H (Frame 5 XR)
60-62 (Frame 6 XR)
65-67 (Frame 6 XR)
70-72 (Frame 7 XR)
75-77 (Frame 7 XR)
80-82 (Frame 8 XR)
85-87 (Frame 8 XR)
Condenser Size
10-12 (Frame 1 XR)
15-17 (Frame 1 XR)
20-22 (Frame 2 XR)
30-32 (Frame 3 XR)
35-37 (Frame 3 XR)
40-42 (Frame 4 XR)
45-47 (Frame 4 XR)
50-52 (Frame 5 XR)
55-57 (Frame 5 XR)
60-62 (Frame 6 XR)
65-67 (Frame 6 XR)
70-72 (Frame 7 XR)
75-77 (Frame 7 XR)
80-82 (Frame 8 XR)
85-87 (Frame 8 XR)
Motor Efficiency Code
H — High Efficiency
S — Standard Efficiency
Motor Code
BD
CD
BE
CE
BF
CL
BG CM
BH
CN
CP
CQ
Compressor Code
(First Digit Indicates Compressor Frame Size)*
*Second digit will be a letter (example 4G3)
on units equipped with split ring diffuser.
MODEL NUMBER NOMENCLATURE
27 99 Q
59843
Week of Year
Unique Number
Year of Manufacture
Place of Manufacture
SERIAL NUMBER BREAKDOWN
Fig. 1 — 19XR Identification
5
DB
DC
DD
DE
DF
DG
DH
DJ
EH
EJ
EK
EL
EM
EN
EP
FRONT VIEW
1
2
3
4
5
17
6
16
7
8
15 14
13
12
LEGEND
1 — Guide Vane Actuator
2 — Suction Elbow
3 — Chiller Visual Controller/ International Chiller
Visual Control (CVC/ICVC)
4 — Chiller Identification Nameplate
5 — Cooler, Auto Reset Relief Valves
6 — Cooler Pressure Transducer
7 — Condenser In/Out Temperature Thermistors
8 — Condenser Waterflow Device (ICVC Inputs
available)
9 — Cooler In/Out Temperature Thermistors
10 — Cooler Waterflow Device (ICVC Inputs available)
11 — Refrigerant Charging Valve
12 — Typical Flange Connection
13 — Oil Drain Charging Valve
14 — Oil Level Sight Glasses
15 — Refrigerant Oil Cooler (Hidden)
16 — Auxiliary Power Panel
17 — Compressor Motor Housing
9
11
10
REAR VIEW
19
18
20 21
22
34
23
18
19
20
21
—
—
—
—
22
23
24
25
26
27
28
29
30
31
32
33
34
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Condenser Auto. Reset Relief Valves
Compressor Motor Circuit Breaker
Solid-State Starter Control Display
Unit-Mounted Starter (Optional)
Solid-State Starter Shown
Motor Sight Glass
Cooler Return-End Waterbox Cover
ASME Nameplate (One Hidden)
Typical Waterbox Drain Port
Condenser Return-End Waterbox Cover
Refrigerant Moisture/Flow Indicator
Refrigerant Filter/Drier
Liquid Line Isolation Valve (Optional)
Linear Float Valve Chamber
Vessel Take-Apart Connector
Discharge Isolation Valve (Optional)
Pumpout Valve
Condenser Pressure Transducer
24
33
32
31
30
29
28 27
26
25
24
Fig. 2 — Typical 19XR Components
6
Factory-Mounted Starter or Variable Frequency Drive (Optional) — The starter allows for the
refrigerant is quite warm (typically 98 to 102 F [37 to 40 C])
when it is discharged from the compressor into the condenser.
Relatively cool (typically 65 to 90 F [18 to 32 C]) water
flowing into the condenser tubes removes heat from the refrigerant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC
chamber is at a lower pressure, part of the liquid refrigerant
flashes to vapor, thereby cooling the remaining liquid. The
FLASC vapor is recondensed on the tubes which are cooled by
entering condenser water. The liquid drains into a float chamber between the FLASC chamber and cooler. Here a float valve
forms a liquid seal to keep FLASC chamber vapor from entering the cooler. When liquid refrigerant passes through the
valve, some of it flashes to vapor in the reduced pressure on the
cooler side. In flashing, it removes heat from the remaining liquid. The refrigerant is now at a temperature and pressure at
which the cycle began.
proper start and disconnect of electrical energy for the compressor-motor, oil pump, oil heater, and control panel.
Storage Vessel (Optional) — There are 2 sizes of
storage vessels available. The vessels have double relief valves,
a magnetically-coupled dial-type refrigerant level gage, a
one-inch FPT drain valve, and a 1/2-in. male flare vapor connection for the pumpout unit.
NOTE: If a storage vessel is not used at the jobsite, factoryinstalled isolation valves on the chiller may be used to isolate
the chiller charge in either the cooler or condenser. An optional
pumpout system is used to transfer refrigerant from vessel to
vessel.
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from
the cooler at a rate set by the amount of guide vane opening or
compressor speed (19XRV only). As the compressor suction
reduces the pressure in the cooler, the remaining refrigerant
boils at a fairly low temperature (typically 38 to 42 F [3 to
6 C]). The energy required for boiling is obtained from the water flowing through the cooler tubes. With heat energy removed, the water becomes cold enough to use in an air conditioning circuit or for process liquid cooling.
After taking heat from the water, the refrigerant vapor is
compressed. Compression adds still more heat energy, and the
MOTOR AND LUBRICATING OIL
COOLING CYCLE
The motor and the lubricating oil are cooled by liquid refrigerant taken from the bottom of the condenser vessel
(Fig. 3). Refrigerant flow is maintained by the pressure differential that exists due to compressor operation. After the refrigerant flows past an isolation valve, an in-line filter, and a sight
glass/moisture indicator, the flow is split between the motor
cooling and oil cooling systems.
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
7
LUBRICATION CYCLE
cooler heat exchanger. The oil cooler uses refrigerant from the
condenser as the coolant. The refrigerant cools the oil to a temperature between 120 and 140 F (49 to 60 C).
As the oil leaves the oil cooler, it passes the oil pressure
transducer and the thermal bulb for the refrigerant expansion
valve on the oil cooler. The oil is then divided. Part of the oil
flows to the thrust bearing, forward pinion bearing, and gear
spray. The rest of the oil lubricates the motor shaft bearings and
the rear pinion bearing. The oil temperature is measured in the
bearing housing as it leaves the thrust and forward journal
bearings. The oil then drains into the oil reservoir at the base of
the compressor. The PIC II (Product Integrated Control II)
measures the temperature of the oil in the sump and maintains
the temperature during shutdown (see Oil Sump Temperature
Control section, page 36). This temperature is read on the
CVC/ICVC default screen.
During the chiller start-up, the PIC II energizes the oil pump
and provides 45 seconds of pre-lubrication to the bearings after
pressure is verified before starting the compressor. During
shutdown, the oil pump will run for 60 seconds to postlubricate after the compressor shuts down. The oil pump can
also be energized for testing purposes during a Control Test.
Ramp loading can slow the rate of guide vane opening to
minimize oil foaming at start-up. If the guide vanes open
quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to flash. The resulting oil foam cannot be
pumped efficiently; therefore, oil pressure falls off and lubrication is poor. If oil pressure falls below 15 psid (103 kPad) differential, the PIC II will shut down the compressor.
If the controls are subject to a power failure that lasts more
than 3 hours, the oil pump will be energized periodically when
the power is restored. This helps to eliminate refrigerant that
has migrated to the oil sump during the power failure. The controls energize the pump for 60 seconds every 30 minutes until
the chiller is started.
Summary — The oil pump, oil filter, and oil cooler make
Oil Reclaim System — The oil reclaim system returns
Flow to the motor cooling system passes through an orifice
and into the motor. Once past the orifice, the refrigerant is
directed over the motor by a spray nozzle. The refrigerant
collects in the bottom of the motor casing and is then drained
back into the cooler through the motor refrigerant drain line.
An orifice (in the motor shell) maintains a higher pressure in
the motor shell than in the cooler. The motor is protected by a
temperature sensor imbedded in the stator windings. An
increase in motor winding temperature past the motor override
set point overrides the temperature capacity control to hold,
and if the motor temperature rises 10° F (5.5° C) above this set
point, closes the inlet guide vanes. If the temperature rises
above the safety limit, the compressor shuts down.
Refrigerant that flows to the oil cooling system is regulated
by thermostatic expansion valves (TXVs). The TXVs regulate
flow into the oil/refrigerant plate and frame-type heat exchanger (the oil cooler in Fig. 3). The expansion valve bulbs control
oil temperature to the bearings. The refrigerant leaving the oil
cooler heat exchanger returns to the chiller cooler.
VFD COOLING CYCLE
The unit-mounted variable frequency drive (VFD) is cooled
in a manner similar to the motor and lubricating oil cooling
cycle (Fig. 3).
If equipped with a unit-mounted VFD, the refrigerant line
that feeds the motor cooling and oil cooler also feeds the heat
exchanger on the unit-mounted VFD. Refrigerant is metered
through a thermostatic expansion valve (TXV). To maintain
proper operating temperature in the VFD, the TXV bulb is
mounted to the heat exchanger to regulate the flow of refrigerant. The refrigerant leaving the heat exchanger returns to the
cooler.
up a package located partially in the transmission casing of the
compressor-motor assembly. The oil is pumped into a filter
assembly to remove foreign particles and is then forced into an
oil cooler heat exchanger where the oil is cooled to proper
operational temperatures. After the oil cooler, part of the flow
is directed to the gears and the high speed shaft bearings; the
remaining flow is directed to the motor shaft bearings. Oil
drains into the transmission oil sump to complete the cycle
(Fig. 4).
oil lost from the compressor housing back to the oil reservoir
by recovering the oil from 2 areas on the chiller. The guide
vane housing is the primary area of recovery. Oil is also recovered by skimming it from the operating refrigerant level in the
cooler vessel.
PRIMARY OIL RECOVERY MODE — Oil is normally recovered through the guide vane housing on the chiller. This is
possible because oil is normally entrained with refrigerant in
the chiller. As the compressor pulls the refrigerant up from the
cooler into the guide vane housing to be compressed, the oil
normally drops out at this point and falls to the bottom of the
guide vane housing where it accumulates. Using discharge gas
pressure to power an eductor, the oil is drawn from the housing
and is discharged into the oil reservoir.
SECONDARY OIL RECOVERY METHOD — The secondary method of oil recovery is significant under light load
conditions, when the refrigerant going up to the compressor
suction does not have enough velocity to bring oil along. Under
these conditions, oil collects in a greater concentration at the
top level of the refrigerant in the cooler. This oil and refrigerant
mixture is skimmed from the side of the cooler and is then
drawn up to the guide vane housing. There is a filter in this line.
Because the guide vane housing pressure is much lower than
the cooler pressure, the refrigerant boils off, leaving the oil behind to be collected by the primary oil recovery method.
Details — Oil is charged into the lubrication system through
a hand valve. Two sight glasses in the oil reservoir permit oil
level observation. Normal oil level is between the middle of the
upper sight glass and the top of the lower sight glass when the
compressor is shut down. The oil level should be visible in at
least one of the 2 sight glasses during operation. Oil sump temperature is displayed on the CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller) default screen.
During compressor operation, the oil sump temperature ranges
between 125 to 150 F (52 to 66 C).
The oil pump suction is fed from the oil reservoir. An oil
pressure relief valve maintains 18 to 25 psid (124 to172 kPad)
differential pressure in the system at the pump discharge. This
differential pressure can be read directly from the CVC/ICVC
default screen. The oil pump discharges oil to the oil filter assembly. This filter can be closed to permit removal of the filter
without draining the entire oil system (see Maintenance sections, pages 71 to 75, for details). The oil is then piped to the oil
8
REAR MOTOR
BEARING
FWD MOTOR
BEARING
LABYRINTH
GAS LINE
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
MOTOR
COOLING LINE
ISOLATION
VALVE
TXV BULB
PRESSURE
TRANSDUCER
OIL
PUMP
ISOLATION
VALVE
OIL
COOLER
OIL PUMP
MOTOR
FILTER
OIL
HEATER
EDUCTOR FILTER
SIGHT GLASS
SIGHT
GLASS
ISOLATION
VALVE
OIL SKIMMER LINE
Fig. 4 — Lubrication System
solid-state starters. This module controls and monitors all aspects of the starter. See the Controls section on page 10 for additional ISM information. All starter replacement parts are supplied by the starter manufacturer excluding the ISM (contact
Carrier’s Replacement Component Division [RCD]).
STARTING EQUIPMENT
The 19XR requires a motor starter to operate the centrifugal
hermetic compressor motor, the oil pump, and various auxiliary equipment. The starter is the main field wiring interface for
the contractor.
See Carrier Specification Z-415 for specific starter requirements, Z-416 for free-standing VFD requirements and Z-417
for unit-mounted VFD requirements. All starters must meet
these specifications in order to properly start and satisfy mechanical safety requirements. Starters may be supplied as separate, free-standing units or may be mounted directly on the
chiller (unit mounted) for low voltage units only.
Three separate circuit breakers are inside the starter. Circuit
breaker CB1 is the compressor motor circuit breaker. The disconnect switch on the starter front cover is connected to this
breaker. Circuit breaker CB1 supplies power to the compressor
motor.
Unit-Mounted Solid-State Starter (Optional) —
The 19XR chiller may be equipped with a solid-state, reducedvoltage starter (Fig. 5 and 6). This starter’s primary function is
to provide on-off control of the compressor motor. This type of
starter reduces the peak starting torque, reduces the motor inrush current, and decreases mechanical shock. This capability
is summed up by the phrase “soft starting.” The solid-state
starter is available as a 19XR option (factory supplied and installed). The solid-state starters manufacturer name is located
inside the starter access door.
A solid-state, reduced-voltage starter operates by reducing
the starting voltage. The starting torque of a motor at full voltage is typically 125% to 175% of the running torque. When the
voltage and the current are reduced at start-up, the starting
torque is reduced as well. The object is to reduce the starting
voltage to just the voltage necessary to develop the torque required to get the motor moving. The voltage is reduced by silicon controlled rectifiers (SCRs). The voltage and current are
then ramped up in a desired period of time. Once full voltage is
reached, a bypass contactor is energized to bypass the SCRs.
The main circuit breaker (CB1) on the front of the starter
disconnects the main motor current only. Power is still
energized for the other circuits. Two more circuit breakers
inside the starter must be turned off to disconnect power to
the oil pump, PIC II controls, and oil heater.
Circuit breaker CB2 supplies power to the control panel, oil
heater, and portions of the starter controls.
Circuit breaker CB3 supplies power to the oil pump. Both
CB2 and CB3 are wired in parallel with CB1 so that power is
supplied to them if the CB1 disconnect is open.
All starters must include a Carrier control module called the
Integrated Starter Module (ISM), excluding the Benshaw
When voltage is supplied to the solid-state circuitry (CB1
is closed), the heat sinks in the starter as well as the wires
leading to the motor and the motor terminal are at line voltage. Do not touch the heat sinks, power wiring, or motor
terminals while voltage is present or serious injury will
result.
9
There is a display on the front of the Benshaw, Inc., solidstate starters that is useful for troubleshooting and starter
checkout. The display indicates:
• voltage to the SCRs
• SCR control voltage
• power indication
• proper phasing for rotation
• start circuit energized
• over-temperature
• ground fault
• current unbalance
• run state
• software configuration
The starter is further explained in the Check Starter and
Troubleshooting Guide sections, pages 54 and 76.
7
1
2
3
4
Unit-Mounted Wye-Delta Starter (Optional) —
6
The 19XR chiller may be equipped with a wye-delta starter
mounted on the unit. This starter is used with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration. This occurs during the starting period when the motor is
accelerating up to speed. Once the motor is up to speed, the
starter automatically connects the phase windings into a delta
configuration. Starter control, monitoring, and motor protection is provided by Carrier’s Integrated Starter Module (ISM).
5
1
2
3
4
5
6
7
—
—
—
—
—
—
—
Unit-Mounted VFD (Optional) — The 19XRV unit
will be equipped with a variable frequency drive motor controller mounted on the unit. See Fig. 7 and 8. This VFD is used
with low voltage motors between 380 and 480 VAC. It reduces
the starting current inrush by controlling the voltage and frequency to the compressor motor. Once the motor has accelerated to minimum speed the PIC II modulates the compressor
speed and guide vane position to control chilled water temperature. The VFD is further explained in the Controls section and
Troubleshooting Guide section, pages 10 and 76.
There is a separate display located on the unit-mounted
VFD. Operational parameters and fault codes are displayed relative to the drive. Refer to specific drive literature along with
troubleshooting sections. The display is also the interface for
entering specific chiller operational parameters. These parameters have been preprogrammed at the factory. An adhesive
backed label on the inside of the drive has been provided for
verification of the specific job parameters. See Initial Start-Up
Checklist section for details.
LEGEND
RediStart MICRO™ Input/Output Card
Fuses 1-4 (Hidden, not depicted)
Circuit Breaker 2 (CB2): Machine Control and Heater Power
Circuit Breaker 3 (CB3): Oil Pump Power
RediStart MICRO Central Processing Unit Card (CPU)
RediStart MICRO Power Card (hidden, not depicted)
RediStart MICRO Bypass Card (hidden, not depicted)
Fig. 5 — Solid-State Starter Box,
Internal View
CONTROLS
Definitions
ANALOG SIGNAL — An analog signal varies in proportion
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device because its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL — A discrete signal is a 2-position representation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
Fig. 6 — Typical Starter External View
(Solid-State Starter Shown)
10
SPEED
VOLTS
AMPS
Hz
RUNNING
AUTO
MAN
Forward
Reverse
REMOTE
JOG
AUTO
PROGRAM
RUN
JOB
Kw
TORQUE
FORWARD
REVERSE
Password
PROGRAM
SPEED
RUNNING
VOLTS
AMPS
Hz
REMOTE
JOG
AUTO
Kw
TORQUE
FORWARD
REVERSE
Password
PROGRAM
AUTO
MAN
Forward
Reverse
PROGRAM
RUN
JOB
ENTER
ENTER
OPTIONAL
METER
PACKAGE
MANUAL RESET
Fig. 7 — Variable Frequency Drive (VFD)
+ DC BUS BAR
MEASUREMENT
- POINT
INTEGRATED
STARTER
MODULE
(ISM)
INITIAL DC BUS
MEASUREMENT
POINT
+ DANGER -
OIL PUMP
DISCONNECT
CONTROL
AND OIL
HEATER
DISCONNECT
HIGH VOLTAGE
SPEED
VOLTS
AMPS
Hz
LINE
RUNNING
REMOTE
JOG
AUTO
Kw
TORQUE
FORWARD
REVERSE
Password
PROGRAM
AUTO
MAN
Forward
Reverse
PROGRAM
RUN
JOB
ENTER
VFD
MODULE
LOAD
COOLING LINES
COMPRESSOR
MOTOR
DISCONNECT
TXV
Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View
General — The 19XR hermetic centrifugal liquid chiller
contains a microprocessor-based control center that monitors
and controls all operations of the chiller (see Fig. 9). The
microprocessor control system matches the cooling capacity of
the chiller to the cooling load while providing state-of-the-art
chiller protection. The system controls cooling load within the
set point plus the deadband by sensing the leaving chilled water
or brine temperature and regulating the inlet guide vane via a
mechanically linked actuator motor. The guide vane is a variable flow pre-whirl assembly that controls the refrigeration effect in the cooler by regulating the amount of refrigerant vapor
flow into the compressor. An increase in guide vane opening
increases capacity. A decrease in guide vane opening decreases
capacity. The microprocessor-based control center protects the
chiller by monitoring the digital and analog inputs and executing capacity overrides or safety shutdowns, if required.
PIC II System Components — The chiller control
system is called the PIC II (Product Integrated Control II). See
Table 1. The PIC II controls the operation of the chiller by
monitoring all operating conditions. The PIC II can diagnose a
problem and let the operator know what the problem is and
what to check. It promptly positions the guide vanes to maintain leaving chilled water temperature. It can interface with
auxiliary equipment such as pumps and cooling tower fans to
turn them on when required. It continually checks all safeties to
prevent any unsafe operating condition. It also regulates the oil
heater while the compressor is off and regulates the hot gas bypass valve, if installed. The PIC II controls provide critical protection for the compressor motor and controls the motor starter.
11
FITTING (HIDDEN)
PANEL
ACTUATOR CABLE
PANEL
CABLE
WATER
SENSOR
CABLES
WATER
SENSOR
CABLES
COOLER
PRESSURE
TRANSDUCER
CONNECTION
CONDENSER
PRESSURE
CABLE
SCHRADER
FITTING (HIDDEN)
CONDENSER
PRESSURE
TRANSDUCER
CONNECTION
CONDENSER
SERVICE
VALVE
DISCHARGE
ISOLATION
VALVE
(OPTIONAL)
COMPRESSOR
DISCHARGE
ELBOW JOINTS
TOP VIEW
COMPRESSOR DETAIL
Fig. 9 — 19XR Controls and Sensor Locations
12
MOTOR WINDING
TEMPERATURE
CABLE
ground fault, remote start contact, spare safety, condenser high
pressure, oil pump interlock, starter 1M, and run contacts. The
ISM contains logic capable of safety shutdown. It shuts down
the chiller if communications with the CVC/ICVC are lost.
The ISM can also act as the interface for PIC II to the VFD
controller.
CHILLER CONTROL MODULE (CCM) — This module is
located in the control panel. The CCM provides the input and
outputs necessary to control the chiller. This module monitors
refrigerant pressure, entering and leaving water temperatures,
and outputs control for the guide vane actuator, oil heaters, and
oil pump. The CCM is the connection point for optional demand limit, chilled water reset, remote temperature reset, refrigerant leak sensor and motor kilowatt output.
OIL HEATER CONTACTOR (1C) — This contactor is located in the power panel (Fig. 13) and operates the heater at
either 115 or 230 v. It is controlled by the PIC II to maintain oil
temperature during chiller shutdown. The XR4 with split ring
diffuser has a line voltage oil heater. Refer to the control panel
wiring schematic.
OIL PUMP CONTACTOR (2C) — This contactor is located
in the power panel. It operates all 200 to 575-v oil pumps.
The PIC II energizes the contactor to turn on the oil pump as
necessary.
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional) — This relay, located in the power panel, controls
the opening of the hot gas bypass valve. The PIC II energizes
the relay during low load, high lift conditions.
CONTROL TRANSFORMERS (T1, T2) — These transformers convert incoming control voltage to 24 vac power for the
3 power panel contactor relays, CCM, and CVC/ICVC.
OPTIONAL TRANSFORMER (T3) — This transformer provides control power to Dataport™/DataLINK™ modules.
The PIC II can interface with the Carrier Comfort Network
(CCN) if desired. It can communicate with other PIC I or PIC
II equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
• control panel
— all extra low-voltage wiring (24 v or less)
• power panel
— 230 or 115 v control voltage (per job requirement)
— up to 600 v for oil pump power
• starter cabinet
— chiller power wiring (per job requirement)
Table 1 — Major PIC II Components and
Panel Locations*
PIC II COMPONENT
Chiller Visual Controller (CVC/ICVC) and
Display
Integrated Starter Module (ISM)
Chiller Control Module (CCM)
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Relay (3C) (Optional)
Control Transformers (T1, T2)
Temperature Sensors
Pressure Transducers
PANEL LOCATION
Control Panel
Starter Cabinet
Control Panel
Power Panel
Power Panel
Power Panel
Power Panel
See Fig. 9.
See Fig. 9.
*See Fig. 8-13.
CHILLER VISUAL CONTROLLER (CVC) — The CVC is
the “brain” of the PIC II. This module contains all the operating
software needed to control the chiller. The CVC is mounted to
the control panel (Fig. 12) and is the input center for all local
chiller set points, schedules, configurable functions, and options. The CVC has a stop button, an alarm light, four buttons
for logic inputs, and a backlight display. The backlight will automatically turn off after 15 minutes of non-use. The functions
of the four buttons or “softkeys” are menu driven and are
shown on the display directly above the softkeys.
The viewing angle of the CVC can be adjusted for optimum
viewing. Remove the 2 bolts connecting the control panel to
the brackets attached to the cooler. Place them in one of the
holes to pivot the control panel forward to backward to change
the viewing angle. See Fig. 12. To change the contrast of the
display, access the adjustment on the back of the CVC. See
Fig. 12.
INTERNATIONAL CHILLER VISUAL CONTROLLER
(ICVC) — Incorporates all of the functions and operating software of the CVC with the added feature of 4 factory programmed languages:
English (default)
Chinese
Japanese
Korean
NOTE: Pressing any one of the four softkey buttons will activate the backlight display without implementing a softkey
function.
INTEGRATED STARTER MODULE (ISM) — This module is located in the starter cabinet. This module initiates commands from the CVC/ICVC for starter functions such as starting and stopping the compressor, condenser, chilled water
pumps, tower fan, spare alarm contacts, and the shunt trip. The
ISM monitors starter inputs such as line voltage, motor current,
Fig. 10 — Control Sensors (Temperature)
Fig. 11 — Control Sensors
(Pressure Transducers, Typical)
13
Fig. 12 — Control Panel
Fig. 13 — Power Panel
14
CVC/ICVC Operation and Menus (Fig. 14-20)
For more
information
menu structures,
PRIMARY
STATUS on the
COMPRESSOR
DATE refer
TIMEto
ON TIME
Fig. 17. MESSAGE
GENERAL
• The CVC/ICVC display automatically reverts to the
default screen after 15 minutes if no softkey activity
takes place and if the chiller is not in the pumpdown
mode (Fig. 14).
• If a screen other than the default screen is displayed on
the CVC/ICVC, the name of that screen is in the upper
right corner (Fig. 15).
• The CVC/ICVC may be set to display either English or
SI units. Use the CVC/ICVC configuration screen
(accessed from the Service menu) to change the units.
See the Service Operation section, page 45.
• Local Operation — The PIC II can be placed in local
operating mode by pressing the LOCAL softkey. The
PIC II then accepts commands from the CVC/ICVC only
and uses the Local Time Schedule to determine chiller
start and stop times.
• CCN Operation — The PIC II can be placed in the CCN
operating mode by pressing the CCN softkey. The PIC
II then accepts modifications from any CCN interface or
module (with the proper authority), as well as from the
CVC/ICVC. The PIC II uses the CCN time schedule to
determine start and stop times.
ALARMS AND ALERTS — An alarm shuts down the compressor. An alert does not shut down the compressor, but it notifies the operator that an unusual condition has occurred. An
alarm (*) or alert (!) is indicated on the STATUS screens on the
far right field of the CVC/ICVC display screen.
Alarms are indicated when the control center alarm light (!)
flashes. The primary alarm message is displayed on the default
screen. An additional, secondary message and troubleshooting
information are sent to the ALARM HISTORY table.
When an alarm is detected, the CVC/ICVC default screen
will freeze (stop updating) at the time of alarm. The freeze enables the operator to view the chiller conditions at the time of
alarm. The STATUS tables will show the updated information.
Once all alarms have been cleared (by pressing the RESET
softkey), the default CVC/ICVC screen will return to normal
operation.
CVC/ICVC MENU ITEMS — To perform any of the operations described below, the PIC II must be powered up and have
successfully completed its self test. The self test takes place automatically, after power-up.
Press the MENU softkey to view the list of menu structures: STATUS , SCHEDULE , SETPOINT , and
SERVICE .
• The STATUS menu allows viewing and limited calibration or modification of control points and sensors, relays
and contacts, and the options board.
• The SCHEDULE menu allows viewing and modification
of the local and CCN time schedules and Ice Build time
schedules.
• The SETPOINT menu allows set point adjustments, such
as the entering chilled water and leaving chilled water set
points.
• The SERVICE menu can be used to view or modify
information on the Alarm History, Control Test, Control
Algorithm Status, Equipment Configuration, ISM Starter
Configuration data, Equipment Service, Time and Date,
Attach to Network Device, Log Out of Network Device,
and CVC/ICVC Configuration screens.
SECONDARY
STATUS
MESSAGE
RUNNING TEMP CONTROL
LEAVING CHILLED WATER
CHW IN
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
55.1
CDW IN
OIL PRESS
21.8
CCN
EVAP REF
44.1
CDW OUT
85.0
CONTINUOUSLY
• BLINKS
ON FOR AN ALARM
ONCE TO
• BLINKS
CONFIRM A STOP
01-01-95 11:48
28.8 HOURS
CHW OUT
40.7
COND REF
95.0
98.1
OIL TEMP
AMPS %
132.9
LOCAL
RESET
93
MENU
STOP BUTTON
FOR ONE
• HOLD
SECOND TO STOP
SOFT KEYS
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
MENU
LINE
Fig. 14 — CVC/ICVC Default Screen
19XR_II
SERVICE
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
Fig. 15 — CVC/ICVC Service Screen
Press the softkey that corresponds to the menu structure to
be viewed: STATUS SCHEDULE , SETPOINT , or
SERVICE . To view or change parameters within any of these
menu structures, use the NEXT and PREVIOUS softkeys
to scroll down to the desired item or table. Use the SELECT
softkey to select that item. The softkey choices that then appear
depend on the selected table or menu. The softkey choices and
their functions are described below.
BASIC CVC/ICVC OPERATIONS (Using the Softkeys) — To perform any of the operations described below,
the PIC II must be powered up and have successfully completed its self test.
15
• Press QUIT to leave the selected decision or field without saving any changes.
2. Press NEXT or PREVIOUS to highlight the desired
status table. The list of tables is:
•MAINSTAT — Overall chiller status
•STARTUP — Status required to perform start-up of
chiller
•COMPRESS — Status of sensors related to the
compressor
•HEAT_EX — Status of sensors related to the heat
exchangers
•POWER — Status of motor input power
•ISM_STAT — Status of motor starter
•CVC_PSWD — Service menu password forcing
access screen
•ICVC_PSWD — Service menu password forcing
access screen
• Press ENTER to leave the selected decision or field and
save changes.
• Press NEXT to scroll the cursor bar down in order to
highlight a point or to view more points below the current screen.
3. Press SELECT to view the desired point status table.
• Press PREVIOUS to scroll the cursor bar up in order to
highlight a point or to view points above the current
screen.
4. On the point status table, press NEXT or PREVIOUS
until the desired point is displayed on the screen.
• Press SELECT to view the next screen level (highlighted with the cursor bar), or to override (if allowable)
the highlighted point value.
19XR_II MAINSTAT
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
Chiller Start/Stop
Remote Start Contact
Temperature Reset
Control Point
Chilled Water Temp
Active Demand Limit
Average Line Current
• Press EXIT to return to the previous screen level.
POINT STATUS
OFF
Ready
0.0 Min
NO
NORMAL
STOP
Open
0.0 F
44.0 F
44.6 F
100%
0.0%
• Press INCREASE or DECREASE to change the highlighted point value.
Fig. 16 — Example of Status Screen
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press NEXT
PREVIOUS to highlight the desired value.
TO VIEW STATUS (Fig. 16) — The status table shows the
actual value of overall chiller status such as CONTROL
MODE, RUN STATUS, AUTO CHILLED WATER RESET,
and REMOTE RESET SENSOR.
1. On the menu screen, press STATUS to view the list of
point status tables.
2. Press SELECT to select the highlighted value. Then:
16
or
•
DEFAULT SCREEN
LOCAL
CCN
RESET
MENU
(SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms
Access Main Menu
STATUS
SCHEDULE
SETPOINT
1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)
List the
Status Tables
List the Service Tables
Display The Setpoint Table
• MAINSTAT
• STARTUP
• COMPRESS
• HEAT_EX
• POWER
• ISM_STAT
• CVC_PSWD
Select a Status Table
PREVIOUS
NEXT
Select a Modification Point
PREVIOUS
NEXT
Modify a Discrete Point
START
STOP
ON
OFF
Modify an Analog Point
INCREASE DECREASE
Modify Control Options
DISABLE
ENABLE
SERVICE
List the Schedules
EXIT
• Base Demand Limit
• LCW Setpoint
• ECW Setpoint
• Ice Build Setpoint
• Tower Fan High Setpoint
Select the Setpoint
SELECT
PREVIOUS
NEXT
SELECT
EXIT
Modify the Setpoint
INCREASE DECREASE
RELEASE
ENTER
RELEASE
ENTER
QUIT
ENTER
SELECT
EXIT
ENTER
QUIT
• OCCPC01S – LOCAL TIME SCHEDULE
• OCCPC02S – ICE BUILD TIME SCHEDULE
• OCCPC03S – CCN TIME SCHEDULE
Select a Schedule
SELECT
PREVIOUS
EXIT
NEXT
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override
SELECT
PREVIOUS
NEXT
EXIT
Modify a Schedule Time
INCREASE DECREASE
ENTER
EXIT
(ANALOG VALUES)
Add/Eliminate a Day
ENABLE
DISABLE
ENTER
EXIT
(DISCRETE VALUES)
ALARM HISTORY
CONTROL TEST
CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
TIME AND DATE
ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
CVC CONFIGURATION
ICVC CONFIGURATION
NEXT
PREVIOUS
SELECT
SEE FIGURE 18
Fig. 17 — 19XR Chiller Display Menu Structure (CVC/ICVC)
17
EXIT
•
SERVICE TABLE
NEXT
PREVIOUS
SELECT
EXIT
ALARM HISTORY
Display Alarm History
(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CONTROL TEST
List the Control Tests
• CCM Thermistors
• CCM Pressure Transducers
• Pumps
• Discrete Outputs
• Guide Vane Actuator
• Diffuser Actuator
• Pumpdown/Lockout
• Terminate Lockout
• Guide Vane Calibration
CONTROL ALGORITHM STATUS
List the Control Algorithm Status Tables
• CAPACITY (Capacity Control)
• OVERRIDE (Override Status)
• LL_MAINT (Lead Lag Status)
• ISM_HIST (ISM Alarm History)
• LOADSHED
• WSMDEFME (Water System Manager Control Status)
• OCCDEFCM (Time Schedule Status)
Select a Table
SELECT
PREVIOUS
EXIT
NEXT
Select a Test
NEXT
PREVIOUS
SELECT
EXIT
OCCDEFM (Time Schedule Status)
Data Select Table
PREVIOUS
NEXT
SELECT
• CAPACITY (Capacity Control Algorithm)
• OVERRIDE (Override Status)
• LL_MAINT (LEADLAG Status)
• WSMDEFM2 (Water System Manager Control Status)
EXIT
OCCPC01S (Local Status)
OCCPC02S (CCN, ICE BUILD Status)
OCCPC03S (CCN Status)
EQUIPMENT CONFIGURATION
Maintenance Table Data
List the Equipment Configuration Tables
• NET_OPT
• BRODEF
• OCCEFCS
• HOLIDAYS
• CONSUME
• RUNTIME
Select a Table
PREVIOUS
NEXT
SELECT
Select a Parameter
PREVIOUS
NEXT
ICVC CONFIGURATION
CONTINUED
ON NEXT PAGE
SELECT
Modify a Parameter
INCREASE DECREASE
ENABLE
EXIT
DISABLE
QUIT
ENTER
(ANALOG VALUES)
QUIT
ENTER
(DISCRETE VALUES)
SELECT (USE ENTER) TO SCROLL DOWN
LID LANGUAGE
INCREASE
DECREASE
ENTER
EXIT
Fig. 18 — 19XR Service Menu Structure
18
EXIT
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)
Service Tables:
• OPTIONS
• SETUP1
• SETUP2
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table
PREVIOUS
NEXT
Service Tables:
• ISM (STARTER) CONFIG PASSWORD
• ISM_CONF
SELECT
EXIT
Select a Service Table Parameter
SELECT
PREVIOUS
NEXT
EXIT
Modify a Service Table Parameter
INCREASE DECREASE
QUIT
ENABLE
DISABLE
QUIT
ENTER
(ANALOG VALUES)
ENTER
(DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:
• To Modify — Current Time
— Current Date
ENTER
INCREASE DECREASE
ATTACH TO NETWORK DEVICE
List Network Devices
• Local
• Device 6
• Device 1 • Device 7
• Device 2 • Device 8
• Device 3 • Device 9
• Device 4
• Device 5
Select a Device
PREVIOUS
NEXT
YES
SELECT
NO
ENTER
— Day of Week
— Holiday Today
EXIT
(ANALOG VALUE)
EXIT
(DISCRETE VALUE)
ATTACH
Modify Device Address
INCREASE DECREASE
ENTER
EXIT
• Use to attach CVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
LOCAL
CCN
RESET
MENU
CVC CONFIGURATION
CVC Configuration Table
INCREASE DECREASE
ENTER
EXIT
• To View — CVC Software Version
• To Modify — CVC CCN Address
(last 2 digits of part number
— English (U.S. IMP.) or S.I. Metric Units
indicate software version)
— Password
CCN
CVC
ICVC
ISM
PIC II
—
—
—
—
—
LEGEND
Carrier Comfort Network
Chiller Visual Controller
International Chiller Visual Controller
Integrated Starter Module
Product Integrated Control II
Fig. 18 — 19XR Service Menu Structure (cont)
19
OCCPC02S — ICE BUILD Time Schedule
OCCPC03S — CCN Time Schedule
For Discrete Points — Press START or STOP to select the desired state.
For Analog Points — Press INCREASE
DECREASE to select the desired value.
or
3. Press SELECT to view the desired time schedule.
4. Press NEXT or PREVIOUS to highlight the desired
period or override to change.
3. Press ENTER to register the new value.
NOTE: When overriding or changing metric values, it is necessary to hold down the softkey for a few seconds in order to
see a value change, especially on kilopascal values.
To Remove an Override
1. On the point status table press NEXT or PREVIOUS
to highlight the desired value.
5. Press SELECT to access the highlighted period or
override.
6. a. Press INCREASE or DECREASE to change the
time values. Override values are in one-hour
increments, up to 4 hours.
2. Press SELECT to access the highlighted value.
b. Press ENABLE to select days in the day-of-week
fields. Press DISABLE to eliminate days from the
period.
3. Press RELEASE to remove the override and return the
point to the PIC II’s automatic control.
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. 19)
1. On the Menu screen, press SCHEDULE .
2. Press NEXT or PREVIOUS to highlight the desired
schedule.
OCCPC01S — LOCAL Time Schedule
Fig. 19 — Example of Time Schedule
Operation Screen
20
2. There are 5 set points on this screen: BASE DEMAND
LIMIT, LCW SETPOINT (leaving chilled water set
point), ECW SETPOINT (entering chilled water set
point), ICE BUILD SETPOINT, and TOWER FAN
HIGH SETPOINT. Only one of the chilled water set
points can be active at one time. The set point that is
active is determined from the SERVICE menu. See the
Service Operation section, page 45. The ice build (ICE
BUILD) function is also activated and configured from
the SERVICE menu.
3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
7. Press ENTER to register the values and to move horizontally (left to right) within a period.
8. Press EXIT to leave the period or override.
9. Either return to Step 4 to select another period or override, or press EXIT again to leave the current time
schedule screen and save the changes.
4. Press SELECT to modify the highlighted set point.
10. The Holiday Designation (HOLIDEF table) may be
found in the Service Operation section, page 45. The
month, day, and duration for the holiday must be
assigned. The Broadcast function in the BRODEF
table also must be enabled for holiday periods to
function.
TO VIEW AND CHANGE SET POINTS (Fig. 20)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
19XR_II
SETPOINT
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
ICE BUILD Setpoint
Tower Fan High Setpoint
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 45. For examples of CVC/ICVC display screens,
see Table 2.
SETPOINT SELECT
100%
50.0 F
60.0 F
40.0 F
85.0 F
Fig. 20 — Example of Set Point Screen
21
Table 2 — CVC/ICVC Display Data
6. Reference Point Names shown in these tables in all capital letters can be read by CCN and BS software. Of these capitalized
names, those preceded by a dagger can also be changed (that
is, written to) by the CCN, BS, and the CVC/ICVC. Capitalized
Reference Point Names preceded by two asterisks can be
changed only from the CVC/ICVC. Reference Point Names in
lower case type can be viewed by CCN or BS only by viewing the
whole table.
7. Alarms and Alerts: An asterisk in the far right field of a CVC/
ICVC status screen indicates that the chiller is in an alarm state;
an exclamation point in the far right field of the CVC/ICVC screen
indicates an alert state. The asterisk (or exclamation point) indicates that the value on that line has exceeded (or is approaching) a limit. For more information on alarms and alerts, see the
Alarms and Alerts section, page 15.
LEGEND
CCN
— Carrier Comfort Network
CHW
— Chilled Water
CHWR — Chilled Water Return
CHWS — Chilled Water Supply
CVC
— Chiller Visual Controller
CT
— Current Transformer
ECW
— Entering Chilled Water
HGBP — Hot Gas Bypass
ICVC
— International Chiller Visual Controller
ISM
— Integrated Starter Module
LCW
— Leaving Chilled Water
LRA
— Locked Rotor Amps
mA
— Milliamps
P
— Pressure
PIC II — Product Integrated Controls II
SS
— Solid State
T
— Temperature
VFD
— Variable Frequency Drive
WSM — Water System Manager
IMPORTANT: The following notes apply to all Table 2
examples.
1. Only 12 lines of information appear on the chiller display screen
at any one time. Press the NEXT or PREVIOUS softkey to
highlight a point or to view items below or above the current
screen. Press the NEXT softkey twice to page forward; press
the PREVIOUS softkey twice to page back.
2. To access the information shown in Examples 10 through 22,
enter your 4-digit password after pressing the SERVICE softkey. If no softkeys are pressed for 15 minutes, the CVC/ICVC
automatically logs off (to prevent unrestricted access to PIC II
controls) and reverts to the default screen. If this happens, you
must re-enter your password to access the tables shown in
Examples 10 through 22.
3. Terms in the Description column of these tables are listed as they
appear on the chiller display screen.
4. The CVC/ICVC may be configured in English or Metric (SI) units
using the CVC/ICVC CONFIGURATION screen. See the Service
Operation section, page 45, for instructions on making this
change.
5. The items in the Reference Point Name column do not appear on
the chiller display screen. They are data or variable names used
in CCN or Building Supervisor (BS) software. They are listed in
these tables as a convenience to the operator if it is necessary to
cross reference CCN/BS documentation or use CCN/BS programs. For more information, see the 19XR CCN literature.
EXAMPLE 1 — CHILLER DISPLAY DEFAULT SCREEN
The following data is displayed in the Default screen.
DESCRIPTION
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime
Entering Chilled Water
Leaving Chilled Water
Evaporator Temperature
Entering Condenser Water
Leaving Condenser Water
Condenser Temperature
Oil Pressure
Oil Sump Temp
Average Line Current
STATUS
UNITS
REFERENCE POINT NAME
(ALARM HISTORY)
0-500000.0
–40-245
–40-245
–40-245
–40-245
–40-245
–40-245
0-420
40-245
0-999
0-1
0-1
0-1
HOURS
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
PSI
DEG F
%
C_HRS
ECW
LCW
ERT
ECDW
LCDW
CRT
OILPD
OILT
AMPS_%
CCN
LOCAL
RESET
DISPLAY
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS%
NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC/ICVC only.
22
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .
DESCRIPTION
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
*Chiller Start/Stop
*Remote Start Contact
Temperature Reset
*Control Point
Chilled Water Temp
*Active Demand Limit
Average Line Current
Motor Percent Kilowatts
Auto Demand Limit Input
Auto Chilled Water Reset
Remote Reset Sensor
Total Compressor Starts
Starts in 12 Hours
Compressor Ontime
*Service Ontime
Ice Build Contact
Refrigerant Leak Sensor
STATUS
NOTE 1
NOTE 2
0-15
0/1
0-2
0/1
0/1
–30-30
10-120
–40-245
40-100
0-999
0-999
4-20
4-20
–40-245
0-99999
0-8
0-500000.0
0-32767
0-1
0-20
UNITS
NOTE 1
NOTE 2
min
NO/YES
NOTE 3
STOP/START
OPEN/CLOSE
DEG F
DEG F
DEG F
%
%
%
mA
mA
DEG F
HOURS
HOURS
OPEN/CLOSE
mA
POINT
MODE
STATUS
T_START
OCC
SYS_ALM
CHIL_S_S
REMCON
T_RESET
LCW_STPT
CHW_TMP
DEM_LIM
%_AMPS
KW_P
AUTODEM
AUTORES
R_RESET
c_starts
STARTS
c_hrs
S_HRS
ICE_CON
REF_LEAK
NOTES:
1. Reset, Off, Local, CCN
2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
3. Normal, Alert, Alarm
4. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN
devices.
EXAMPLE 3 — STARTUP DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP .
4. Press SELECT .
DESCRIPTION
Actual Guide Vane Pos
**Chilled Water Pump
Chilled Water Flow
**Condenser Water Pump
Condenser Water Flow
Oil Pump Relay
**Oil Pump Delta P
Compressor Start Relay
Compressor Start Contact
Starter Trans Relay
Compressor Run Contact
**Tower Fan Relay Low
**Tower Fan Relay High
Starter Fault
Spare Safety Input
Shunt Trip Relay
ISM Fault Status
STATUS
0-100
0-1
0-1
0-1
0-1
0-1
–6.7-200
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-255
UNITS
%
OFF/ON
NO/YES
OFF/ON
NO/YES
OFF/ON
^PSI
OFF/ON
OPEN/CLOSED
OFF/ON
OPEN/CLOSED
OFF/ON
OFF/ON
ALARM/NORMAL
ALARM/NORMAL
OFF/ON
POINT
GV_ACT
CHWP
CHW_FLOW
CDP
CDW_FLOW
OILR
OILPD
CMPR
CR_AUX
CMPTRANS
RUN_AUX
TFR_LOW
TFR_HIGH
STR_FLT
SAFETY
TRIPR
STRSTAT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write
operations for the CVC/ICVC only.
23
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .
DESCRIPTION
Actual Guide Vane Pos
Guide Vane Delta
**Target Guide Vane Pos
Oil Sump Temp
**Oil Pump Delta P
Comp Discharge Temp
Comp Thrust Brg Temp
Comp Motor Winding Temp
Spare Temperature 1
Spare Temperature 2
Oil Heater Relay
Diffuser Actuator
**Target VFD Speed
**Actual VFD Speed
Surge Protection Counts
STATUS
0-100
0-100
0-100
–40-245
–6.7-200
–40-245
–40-245
–40-245
–40-245
–40-245
0/1
0-100
0-100
0-110
0-5
UNITS
%
%
%
DEG F
^PSI
DEG F
DEG F
DEG F
DEG F
DEG F
OFF/ON
%
%
%
POINT
GV_ACT
GV_DELTA
GV_TRG
OILT
OILPD
CMPD
MTRB
MTRW
SPARE1
SPARE2
OILH
DIFF_ACT
VFD_OUT
VFD_ACT
SPC
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the CVC/ICVC only.
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT_EX .
4. Press SELECT .
DESCRIPTION
**Chilled Water Delta P
Entering Chilled Water
Leaving Chilled Water
Chilled Water Delta T
Chill Water Pulldown/Min
Evaporator Refrig Temp
**Evaporator Pressure
Evaporator Approach
**Condenser Water Delta P
Entering Condenser Water
Leaving Condenser Water
Condenser Refrig Temp
**Condenser Pressure
Condenser Approach
Hot Gas Bypass Relay
Surge / HGBP Active?
Active Delta P
Active Delta T
Surge / HGBP Delta T
Head Pressure Reference
Evaporator Saturation Temp
(ICVC only)
STATUS
–6.7-420
–40-245
–40-245
–6.7-420
–20-20
–40-245
–6.7-420
0-99
–6.7-420
–40-245
–40-245
–40-245
–6.7-420
0-99
0/1
0/1
0-200
0-200
0-200
0-100
–40-245
UNITS
PSI
DEG F
DEG F
^F
^F
DEG F
PSI
^F
PSI
DEG F
DEG F
DEG F
PSI
^F
OFF/ON
NO/YES
PSI
DEG F
DEG F
%
^F
POINT
CHW_PD
ECW
LCW
CHW_DT
CHW_PULL
ERT
ERP
EVAP_APP
COND_PD
ECDW
LCDW
CRT
CRP
COND_APP
HGBR
SHG_ACT
dp_a
dt_a
dt_c
hpr
EST
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the CVC/ICVC only.
24
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 6 — POWER DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .
DESCRIPTION
Average Line Current
Actual Line Current
Average Line Voltage
Actual Line Voltage
Power Factor
Motor Kilowatts
**Motor Kilowatt-Hours
Demand Kilowatts
Line Current Phase 1
Line Current Phase 2
Line Current Phase 3
Line Voltage Phase 1
Line Voltage Phase 2
Line Voltage Phase 3
Ground Fault Phase 1
Ground Fault Phase 2
Ground Fault Phase 3
Frequency
I2T Sum Heat-Phase 1
I2T Sum Heat-Phase 2
I2T Sum Heat-Phase 3
STATUS
0-999
0-99999
0-999
0-99999
0.0-1.0
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-999
0-999
0-99
0-200
0-200
0-200
UNITS
%
AMPS
%
VOLTS
kW
kWH
kWH
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
AMPS
Hz
%
%
%
POINT
%_AMPS
AMP_A
VOLT_P
VOLT_A
PF
KW_A
KWH
DEM_KWH
AMPS_1
AMPS_2
AMPS_3
VOLTS_1
VOLTS_2
VOLTS_3
GF_1
GF_2
GF_3
FREQ
HEAT1SUM
HEAT2SUM
HEAT3SUM
NOTES:
1. All variables with CAPITAL LETTER point names are available for CCN read operation.
2. Those shown with (**) shall support write operations for CVC/ICVC only.
EXAMPLE 7 — ISM_STAT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ISM_STAT .
4. Press SELECT .
DESCRIPTION
ISM Fault Status
Single Cycle Dropout
Phase Loss
Overvoltage
Undervoltage
Current Imbalance
Voltage Imbalance
Overload Trip
Locked Rotor Trip
Starter LRA Trip
Ground Fault
Phase Reversal
Frequency Out of Range
ISM Power on Reset
Phase 1 Fault
Phase 2 Fault
Phase 3 Fault
1CR Start Complete
1M Start/Run Fault
2M Start/Run Fault
Pressure Trip Contact
Starter Fault
Motor Amps Not Sensed
Starter Acceleration Fault
High Motor Amps
1CR Stop Complete
1M/2M Stop Fault
Motor Amps When Stopped
Hardware Failure
STATUS
0-223
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
UNITS
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
FALSE/TRUE
NORMAL/ALARM
NORMAL/ALARM
NORMAL/ALARM
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
25
POINT
ISMFLT
CYCLE_1
PH_LOSS
OV_VOLT
UN_VOLT
AMP_UNB
VOLT_UNB
OVERLOAD
LRATRIP
SLRATRIP
GRND_FLT
PH_REV
FREQFLT
ISM_POR
PHASE_1
PHASE_2
PHASE_3
START_OK
1M_FLT
2M_FLT
PRS_RIP
STRT_FLT
NO_AMPS
ACCELFLT
HIGHAMPS
STOP_OK
1M2MSTOP
AMPSTOP
HARDWARE
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 8 — CVC/ICVC_PSWD DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight CVC .or ICVC
4. Press SELECT .
DESCRIPTION
Disable Service Password
**Remote Reset Option
Reset Alarm?
CCN Mode?
STATUS
0-1
0-1
0-1
0-1
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
NO/YES
NO/YES
POINT
PSWD_DIS
RESETOPT
REMRESET
REM_CCN
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the CVC/ICVC only.
EXAMPLE 9 — SETPOINT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press SETPOINT .
3. Press SELECT .
DESCRIPTION
Base Demand Limit
Control Point
ECW Setpoint
LCW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
STATUS
40-100
UNITS
%
POINT
DLM
DEFAULT
100
15-120
10-120
15-60
55-105
DEG F
DEG F
DEG F
DEG F
ecw_sp
lcw_sp
ice_sp
tf2_sp
60.0
50.0
40.0
75
NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 10 — CAPACITY DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight CAPACITY .
Press SELECT .
DESCRIPTION
Entering Chilled Water
Leaving Chilled Water
Capacity Control
Control Point
Control Point Error
ECW Delta T
ECW Reset
LCW Reset
Total Error + Resets
Guide Vane Delta
Target Guide Vane Pos
Actual Guide Vane Pos
Target VFD Speed
Actual VFD Speed
VFD Gain
Demand Limit Inhibit
Amps/kW Ramp
VFD Load Factor
STATUS
–40-245
–40-245
UNITS
DEG F
DEG F
POINT
ECW
LCW
10-120
–99-99
–99-99
–99-99
–99-99
–99-99
–2-2
0-100
0-100
0-100
0-100
0.1-1.5
0-100
0-100
0-200
DEG F
^F
^F
^F
^F
^F
%
%
%
%
%
ctrlpt
cperr
ecwdt
ecwres
lcwres
error
gvd
GV_TRG
GV_ACT
VFD_IN
VFD_ACT
vfd_gain
DEM_INH
DMD_RAMP
VFD_LF
%
%
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
26
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 11 — OVERRIDE DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight OVERRIDE .
Press SELECT .
DESCRIPTION
Comp Motor Winding Temp
Comp Motor Temp Override
Condenser Pressure
Cond Press Override
Evaporator Refrig Temp
Evap Ref Override Temp
Comp Discharge Temp
Comp Discharge Alert
Comp Thrust Brg Temp
Comp Thrust Brg Alert
Actual Superheat
Superheat Required
Condenser Refrig Temp
STATUS
–40-245
150-200
0-420
90-180
–40-245
2-45
–40-245
125-200
–40-245
165-185
–20-99
6-99
–40-245
UNITS
DEG F
DEG F
PSI
PSI
DEG F
DEG F
DEG F
DEG F
DEG F
DEG F
^F
^F
DEG F
POINT
MTRW
mt_over
CRP
cp_over
ERT
rt_over
CMPD
cd_alert
MTRB
tb_alert
SUPRHEAT
SUPR_REQ
CRT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
EXAMPLE 12 — LL_MAINT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight LL_MAINT.
Press SELECT .
DESCRIPTION
LeadLag Control
LEADLAG: 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
Spare Temperature 1
Spare Temperature 2
STATUS
UNITS
NOTE 1
NOTE 2
0/1
2-60
2-60
2-30
x.xx
0/1
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
NOTE 3
NOTE 4
NOTE 5
0/1
–40-245
–40-245
DSABLE/ENABLE
MIN
MIN
MIN
^F
NO/YES
NO/YES
NO/YES
NO/YES
DEG F
DEG F
POINT
leadlag
llmode
loadbal
lagstart
lagstop
preflt
pull_dt
pull_sat
leadctrl
lagmode
lagstat
lag_s_s
lag_rec
stdmode
stdstat
Std_s_s
std_rec
SPARE_1
SPARE_2
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
27
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 13 — ISM_HIST DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight ISM_HIST .
Press SELECT .
DESCRIPTION
ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1
Line Current Phase 2
Line Current Phase 3
Line Voltage Phase 1
Line Voltage Phase 2
Line Voltage Phase 3
Ground Fault Phase 1
Ground Fault Phase 2
Ground Fault Phase 3
I2T Sum Heat-Phase 1
I2T Sum Heat-Phase 2
I2T Sum Heat-Phase 3
Phase 1 Faulted?
Phase 2 Faulted?
Phase 3 Faulted?
Line Frequency
ISM Fault Status
STATUS
UNITS
0-99999
0-99999
0-99999
0-99999
0-99999
0-99999
0-999
0-999
0-999
0-200
0-200
0-200
0/1
0/1
0/1
0-99
0-9999
AMPS
AMPS
AMPS
VOLTS
VOLTS
VOLTS
AMPS
AMPS
AMPS
%
%
%
NO/YES
NO/YES
NO/YES
Hz
POINT
AMPS_1F
AMPS_2F
AMPS_3F
VOLTS_1F
VOLTS_2F
VOLTS_3F
GF_1F
GF_2F
GF_3F
HEAT1SUMF
HEAT2SUMF
HEAT3SUMF
PH1_FLT
PH2_FLT
PH3_FLT
FREQ_ F
ISM_STAT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
EXAMPLE 14 — WSMDEFME DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight CONTROL ALGORITHM STATUS .
Press SELECT .
Scroll down to highlight WSMDEFME .
Press SELECT .
DESCRIPTION
WSM Active?
Chilled Water Temp
Equipment Status
Commanded State
CHW setpt Reset Value
Current CHW Set Point
STATUS
0/1
0.0-99.9
0/1
XXXXXXXX
0.0-25.0
0.0-99.9
UNITS
NO/YES
DEG F
OFF/ON
TEXT
DEG F
DEG F
POINT
WSMSTAT
CHWTEMP
CHLRST
CHLRENA
CHWRVAL
CHWSTPT
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screens.
28
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 15 — NET_OPT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET_OPT .
6. Press SELECT .
DESCRIPTION
Loadshed Function
Group Number
Demand Limit Decrease
Maximum Loadshed Time
CCN Occupancy Config:
Schedule Number
Broadcast Option
Alarm Configuration
Re-Alarm Time
Alarm Routing
STATUS
UNITS
POINT
DEFAULT
0-99
0-60
0-120
%
MIN
ldsgrp
ldsdelta
maxldstm
0
20
60
3-99
0-1
DSABLE/ENABLE
occpcxxe
occbrcst
3
DSABLE
0-1440
0-1
MIN
30
10000000
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 16 — ISM_CONF DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
Press SERVICE .
Scroll down to highlight ISM (STARTER) CONFIG DATA .
Press SELECT .
Enter password (4444 Factory Default).
6. Scroll down to highlight ISM_CONF .
7. Press SELECT .
DESCRIPTION
Starter Type
(0 = Full, 1 = Red, 2 = SS/VFD)
Motor Rated Line Voltage
Volt Transformer Ratio:1
Overvoltage Threshold
Undervoltage Threshold
Over/Under Volt Time
Voltage % Imbalance
Voltage Imbalance Time
Motor Rated Load Amps
Motor Locked Rotor Trip
Locked Rotor Start Delay
Starter LRA Rating
Motor Current CT Ratio:1
Current % Imbalance
Current Imbalance Time
Grnd Fault CT’s?
Ground Fault CT Ratio:1
Ground Fault Current
Ground Fault Start Delay
Ground Fault Persistence
Single Cycle Dropout
Frequency = 60 Hz? (No = 50)
Line Frequency Faulting
STATUS
0-2
200-13200
1-35
105-115
85-95
1-10
1-10
1-10
10-5000
100-60000
1-10
100-60000
3-1000
5-40
1-10
0-1
150
1-25
1-20
1-10
0/1
0/1
0/1
UNITS
VOLTS
%
%
SEC
%
SEC
AMPS
AMPS
cycles
AMPS
%
SEC
NO/YES
AMPS
cycles
cycles
DSABLE/ENABLE
NO/YES
DSABLE/ENABLE
29
POINT
starter
DEFAULT
1
v_fs
vt_rat
overvolt
undvolt
uvuntime
v_unbal
v_time
a_fs
motor_lr
lrdelay
start_lr
ct_turns
c_unbal
c_time
gf_phase
gf_ctr
gf_amps
gf_delay
gf_pers
cycdrop
freq
freq_en
460
1
115
85
5
10
5
200
1000
5
2000
100
15
5
YES
150
15
10
5
DSABLE
YES
DSABLE
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 17 — OPTIONS DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight OPTIONS .
Press SELECT .
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge / Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
Min. Load Point (T1,P1)
Surge/HGBP Delta T1
Surge/HGBP Delta P1
Full Load Point (T2,P2)
Surge/HGBP Delta T2
Surge/HGBP Delta P2
Surge/HGBP Deadband
Surge Protection
Surge Delta% Amps
Surge Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle
Refrigerant Leak Option
Refrigerant Leak Alarm mA
Head Pressure Reference
Delta P at 0% (4mA)
Delta P at 100% (20mA)
Minimum Output
STATUS
0/1
0/1
40-100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
0/1
POINT
start
r_contact
softstop
DEFAULT
DSABLE
DSABLE
100
srg_hgbp
0
0.5-20
30-170
^F
PSI
hgb_dt1
hgb_dp1
1.5
50
0.5-20
50-170
0.5-3
^F
PSI
^F
hbg_dt2
hgb_dp2
hbg_db
10
85
1
5-20
7-10
%
MIN
surge_a
surge_t
10
8
0/1
0-2
DSABLE/ENABLE
ibopt
ibterm
DSABLE
0
0/1
0/1
4-20
DSABLE/ENABLE
DSABLE/ENABLE
mA
ibrecyc
REF_LEAK
DSABLE
DSABLE
20
20-60
20-60
0-100
PSI
PSI
%
HPDPO
HPDP100
HPDPMIN%
25
35
0
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 18 — SETUP1 DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight SETUP1 .
Press SELECT .
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Comp Discharge Alert
Comp Thrust Brg Alert
STATUS
150-200
90-165
125-200
165-185
UNITS
DEG F
PSI
DEG F
DEG F
POINT
mt_over
cp_over
cd_alert
tb_alert
DEFAULT
200
125
200
175
Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Condenser Freeze Point
0/1
.5-2.0
0.0-40.0
2.0-5.0
–20 - 35
WATER/BRINE
^F
DEG F
^F
DEG F
medium
cw _db
ert_trip
ref_over
cdfreeze
WATER
1.0
33
3
34
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Water Flow Verify Time
Oil Pressure Verify Time
Recycle Control
Restart Delta T
Shutdown Delta T
0.5 - 50.0
0.5 - 50.0
0.5-5
15-300
PSI
PSI
MIN
SEC
evap_cut
cond_cut
wflow_t
oilpr_t
5.0
5.0
5
40
2.0-10.0
0.5-4.0
DEG F
DEG F
rcycr_dt
rcycs_dt
5
1
sp1_en
sp1_lim
sp2_ en
sp2_ lim
0
245
0
245
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Enable
Spare Temp #2 Limit
0-4
–40-245
0-4
–40-245
DEG F
DEG F
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
30
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 19 — SETUP2 DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight SETUP2 .
Press SELECT .
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional DEC Band
Proportional ECW Band
STATUS
Guide Vane Travel Limit
30-100
Diffuser Control
Diffuser Option
Guide Vane 25% Load Pt
Diffuser 25% Load Point
Guide Vane 50% Load Pt
Diffuser 50% Load Point
Guide Vane 75% Load Pt
Diffuser 75% Load Point
Diffuser Full Span mA
VFD Speed Control
VFD Option
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
VFD Current Limit
UNITS
POINT
DEFAULT
gv_inc
gv_dec
gw_ecw
6.5
6.0
2
%
gv_lim
80
0-1
0-78
0-100
0-78
0-100
0-78
0-100
15-22
DSABLE/ENABLE
%
%
%
%
%
%
mA
diff_opt
gv_25
df_25
gv_50
df_50
gv_75
df_75
diff_ma
DSABLE
25
0
50
0
75
0
18
0/1
0.1-1.5
1-5
65-100
90-100
0-99999
DSABLE/ENABLE
vfd_opt
vfd_gain
vfd_step
vfd_min
vfd_max
vfdlim_i
DSABLE
0.75
2
70
100
250
2-10
2-10
1-3
%
%
%
Amps
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 20 — LEADLAG DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight LEADLAG .
Press SELECT .
DESCRIPTION
Lead Lag Control
LEAD/LAG: Configuration
DSABLE=0, Lead=1
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG % Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
STANDBY Chiller Option
STANDBY % Capacity
STANDBY Address
STATUS
UNITS
0-3
0/1
0/1
25-75
1-236
2-60
2-60
2-30
0/1
25-75
1-236
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
NOTE: No variables are available for CCN read or write operation.
31
POINT
DEFAULT
leadlag
0
load/bal
commsens
lag_per
lag_add
lagstart
lagstop
preft
stndopt
stnd_per
stnd_add
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
Table 2 — CVC/ICVC Display Data (cont)
EXAMPLE 21 — RAMP_DEM DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight RAMP_DEM .
Press SELECT .
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Motor Load Ramp% Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Motor Rated Kilowatts
Demand Watts Interval
STATUS
0/1
UNITS
0/1
5-20
3-15
40-100
0/1
50-9999
5-60
%
%
DSABLE/ENABLE
kW
MIN
POINT
ramp_opt
DEFAULT
1
dem_src
0
kw_ramp
dem_prop
dem_20ma
dem_sel
motor_kw
dw_int
10
10
40
DSABLE
145
15
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 22 — TEMP_CTL DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press MENU .
2.
3.
4.
5.
6.
Press SERVICE .
Scroll down to highlight EQUIPMENT SERVICE .
Press SELECT .
Scroll down to highlight TEMP_CTL .
Press SELECT .
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
Temperature Reset
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
STATUS
UNITS
POINT
DEFAULT
0/1
2-10
DSABLE/ENABLE
^F
ecw_opt
temp_ramp
DSABLE
3
–30- 30
^F
deg_20ma
10
–40-245
–40-245
–30-30
DEG F
DEG F
^F
res_rt1
res_rt2
deg_rt
85
65
10
0-15
0-15
–30-30
^F
^F
^F
restd_1
restd_2
deg_chw
10
0
5
res_sel
0
0-3
32
PIC II System Functions
display screen. The TARGET VFD SPEED can be manually
overridden by the operator from the COMPRESS screen. The
VFD MINIMUM SPEED, MAXIMUM SPEED, VFD GAIN
and INCREASE STEP can be viewed and modified in the
SETUP2 display screen. TARGET and ACTUAL VFD SPEED
can be viewed in the COMPRESS screen.
ECW CONTROL OPTION — If this option is enabled, the
PIC II uses the ENTERING CHILLED WATER temperature to
modulate the vanes instead of the LEAVING CHILLED
WATER temperature. The ECW CONTROL OPTION may be
viewed on the TEMP_CTL screen, which is accessed from the
EQUIPMENT SERVICE screen.
CONTROL POINT DEADBAND — This is the tolerance
range on the chilled water/brine temperature control point. If
the water temperature goes outside the CHILLED WATER
DEADBAND, the PIC II opens or closes the guide vanes until
the temperature is within tolerance. The PIC II may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED
WATER DEADBAND may be viewed or modified on the
SETUP1 screen, which is accessed from the EQUIPMENT
SERVICE table.
For example, a 1° F (0.6° C) deadband setting controls the
water temperature within ±0.5° F (0.3° C) of the control point.
This may cause frequent guide vane movement if the chilled
water load fluctuates frequently. A value of 1° F (0.6° C) is the
default setting.
DIFFUSER CONTROL — On 19XR FRAME sizes 4 and
5 compressors equipped with a variable discharge diffuser, the
PIC II adjusts the diffuser actuator position (DIFFUSER
ACTUATOR on the COMPRESS screen) to correspond to the
actual guide vane position (ACTUAL GUIDE VANE POS on
the COMPRESS screen).
The diffuser control can be enabled or disabled from the
SETUP2 screen. See Table 2, Example 19. In addition, the diffuser and guide vane load points may be viewed and modified
from this screen. These points must be correct for the compressor size. The diffuser opening can be incremented from fully
open to completely closed. A 0% setting is fully open; a 100%
setting is completely closed. To obtain the proper settings for
Diffuser Control, contact a Carrier Engineering representative.
PROPORTIONAL BANDS AND GAIN — Proportional band
is the rate at which the guide vane position is corrected in proportion to how far the chilled water/brine temperature is from
the control point. Proportional gain determines how quickly the
guide vanes react to how quickly the temperature is moving
from the CONTROL POINT. The proportional bands and gain
may be viewed or modified from the SETUP2 screen, which is
accessed from the EQUIPMENT SERVICE table.
The Proportional Band — There are two response modes, one
for temperature response above the control point, the other for
the response below the control point.
The temperature response above the control point is called
the PROPORTIONAL INC BAND, and it can slow or quicken
guide vane response to chilled water/brine temperatures above
the DEADBAND. The PROPORTIONAL INC BAND can be
adjusted from a setting of 2 to 10; the default setting is 6.5.
The response below the control point is called the PROPORTIONAL DEC BAND, and it can slow or quicken the
guide vane response to chilled water temperature below the
deadband plus the control point. The PROPORTIONAL DEC
BAND can be adjusted on the CVC/ICVC from a setting of 2 to
10. The default setting is 6.0.
NOTE: Increasing either of these settings causes the guide
vanes to respond more slowly than they would at a lower
setting.
NOTE: Words not part of paragraph headings and printed in all
capital letters can be viewed on the CVC/ICVC (e.g., LOCAL,
CCN, RUNNING, ALARM, etc.). Words printed both in all
capital letters and italics can also be viewed on the CVC/ICVC
and are parameters (CONTROL MODE, TARGET GUIDE
VANE POS, etc.) with associated values (e.g., modes, temperatures, pressures, percentages, on, off, enable, disable, etc.).
Words printed in all capital letters and in a box represent softkeys on the CVC/ICVC (e.g., ENTER and EXIT ). See
Table 2 for examples of the type of information that can appear
on the CVC/ICVC screens. Figures 14-20 give an overview of
CVC/ICVC operations and menus.
CAPACITY CONTROL FIXED SPEED — The PIC II controls the chiller capacity by modulating the inlet guide vanes in
response to chilled water temperature deviation from the CONTROL POINT. The CONTROL POINT may be changed by a
CCN network device or is determined by the PIC II adding any
active chilled water reset to the SET POINT. The PIC II uses
the PROPORTIONAL INC (Increase) BAND, 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 or overridden from the MAINSTAT screen.
CAPACITY CONTROL VFD — The PIC II controls the
machine capacity by modulating the motor speed and inlet
guide vanes in response to chilled water temperature deviation
from the CONTROL POINT. The controller will maintain the
highest inlet guide vane setting at the lowest speed to maximize efficiency while avoiding surge. The CONTROL POINT
may be changed by a CCN network device or is determined by
the PIC II adding any active chilled water reset to the to the
SET POINT. CONTROL POINT may be viewed or overridden
from the MAINSTAT screen. The PIC II uses the PROPORTIONAL INC (Increase) BAND, PROP DEC (Decrease)
BAND, and the PROPORTIONAL ECW (Entering Chilled
Water) GAIN to determine how fast or slow it takes the system
to respond. The VFD GAIN allows for additional adjustment of
the VFD response. At start-up, the inlet guide vanes (IGV)
start in the closed position and the VFD ramps to its minimum
speed setting.
The PIC II controller then initiates the Capacity Control algorithm to maintain the chilled water temperature at the CONTROL POINT. During operation when the CONTROL POINT
is not met, the controller will establish a GUIDE VANE DELTA
which will either affect a percentage change to the GUIDE
VANES or the VFD TARGET SPEED. Any change that will be
made to the IGV position or the VFD SPEED will depend on
whether the GUIDE VANE DELTA is positive or negative, and
the status of the Surge Control Algorithm. The Surge Control
Algorithm determines if the chiller should operate in Normal
Mode or Surge Prevention Mode. The logic for how the IGV’s
and VFD SPEED will be affected by the GUIDE VANE DELTA and the Surge Control Algorithm can be seen below:
GUIDE VANE
DELTA
From +0.2 to +2.0
From –0.2 to –2.0
NORMAL
CONTROL
MODE
IGV
VFD
1st
2nd
2nd
1st
SURGE
PREVENTION
MODE
IGV
VFD
2nd
1st
1st
—
Normal Control mode occurs when ACTIVE DELTA T >
SURGE/HGBP DELTA T.
Surge Prevention Mode occurs when ACTIVE DELTA T
≤ SURGE/HGBP DELTA T.
The TARGET VFD SPEED, ACTUAL VFD SPEED and the
VFD GAIN can be viewed and modified in the CAPACITY
33
ICE BUILD mode, it uses Occupancy Schedule 02
(OCCPC02S). When the chiller is in CCN mode, it uses
Occupancy Schedule 03 (OCCPC03S).
The CCN SCHEDULE NUMBER is configured on the
NET_OPT display screen, accessed from the EQUIPMENT
CONFIGURATION table. See Table 2, Example 15. SCHEDULE NUMBER can be changed to any value from 03 to 99. If
this number is changed on the NET_OPT screen, the operator
must go to the ATTACH TO NETWORK DEVICE screen to
upload the new number into the SCHEDULE screen. See
Fig. 18.
The PROPORTIONAL ECW GAIN can be adjusted on the
CVC/ICVC display for values of 1, 2, or 3; the default setting
is 2. Increase this setting to increase guide vane response to a
change in entering chilled water temperature.
DEMAND LIMITING — The PIC II responds to the ACTIVE
DEMAND LIMIT set point by limiting the opening of the
guide vanes. It compares the ACTIVE DEMAND LIMIT set
point to the DEMAND LIMIT SOURCE (either the AVERAGE
LINE CURRENT or the MOTOR KW). Depending on how the
control is configured. DEMAND LIMIT SOURCE is on the
RAMP_DEM screen. The default source is the compressor
motor current.
CHILLER TIMERS — The PIC II maintains 2 run time
clocks, known as COMPRESSOR ONTIME and SERVICE
ONTIME. COMPRESSOR ONTIME indicates the total lifetime compressor run hours. This timer can register up to
500,000 hours before the clock turns back to zero. The SERVICE ONTIME is a reset table timer that can be used to indicate the hours since the last service visit or any other event.
The time can be changed from the CVC/ICVC to whatever
value is desired. This timer can register up to 32,767 hours
before it rolls over to zero.
The chiller also maintains a start-to-start timer and a stopto-start timer. These timers limit how soon the chiller can be
started. START INHIBIT TIMER is displayed on the MAINSTAT screen. See the Start-Up/Shutdown/Recycle Sequence
section, page 46, for more information on this topic.
OCCUPANCY SCHEDULE — The chiller schedule, described in the Time Schedule Operation section (page 20), determines when the chiller can run. Each schedule consists of
from 1 to 8 occupied or unoccupied time periods, set by the operator. The chiller can be started and run during an occupied
time period (when OCCUPIED? is set to YES on the MAINSTAT display screen). It cannot be started or run during an unoccupied time period (when OCCUPIED? is set to NO on the
MAINSTAT display screen). These time periods can be set for
each day of the week and for holidays. The day begins with
0000 hours and ends with 2400 hours. The default setting for
OCCUPIED? is YES, unless an unoccupied time period is in
effect.
These schedules can be set up to follow a building’s occupancy schedule, or the chiller can be set so to run 100% of the
time, if the operator wishes. The schedules also can be bypassed by forcing the CHILLER START/STOP parameter on
the MAINSTAT screen to START. For more information on
forced starts, see Local Start-Up, page 46.
The schedules also can be overridden to keep the chiller in
an occupied state for up to 4 hours, on a one time basis. See the
Time Schedule Operation section, page 20.
Figure 19 shows a schedule for a typical office building
with a 3-hour, off-peak, cool-down period from midnight to
3 a.m., following a weekend shutdown. Holiday periods are in
an unoccupied state 24 hours per day. The building operates
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays
from 6:00 a.m. to 1:00 p.m. This schedule also 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.
Whenever the chiller is in the LOCAL mode, it uses Occupancy Schedule 01 (OCCPC01S). When the chiller is in the
Safety Controls — The PIC II monitors all safety control
inputs and, if required, shuts down the chiller or limits the
guide vanes to protect the chiller from possible damage from
any of the following conditions:
• high bearing temperature
• high motor winding temperature
• high discharge temperature
• low discharge superheat*
• low oil pressure
• low cooler refrigerant temperature/pressure
• condenser high pressure or low pressure
• inadequate water/brine cooler and condenser flow
• high, low, or loss of voltage
• ground fault
• voltage imbalance
• current imbalance
• excessive motor acceleration time
• excessive starter transition time
• lack of motor current signal
• excessive motor amps
• excessive compressor surge
• temperature and transducer faults
*Superheat is the difference between saturation temperature
and sensible temperature. The high discharge temperature
safety measures only sensible temperature.
Starter faults or optional protective devices within the starter
can shut down the chiller. The protective devices you have for
your application depend on what options were purchased.
If compressor motor overload occurs, check the motor for
grounded or open phases before attempting a restart.
If the PIC II control initiates a safety shutdown, it displays
the reason for the shutdown (the fault) on the CVC/ICVC display screen along with a primary and secondary message, energizes an alarm relay in the starter, and blinks the alarm light on
the control panel. The alarm is stored in memory and can be
viewed on the ALARM HISTORY and ISM_HIST screens on
the CVC/ICVC, along with a message for troubleshooting. If
the safety shutdown was also initiated by a fault detected in the
motor starter, the conditions at the time of the fault will be
stored in ISM_HIST.
To give more precise information or warnings on the
chiller’s operating condition, the operator can define alert limits on various monitored inputs. Safety contact and alert limits
are defined in Table 3. Alarm and alert messages are listed in
the Troubleshooting Guide section, page 76.
34
Table 3 — Protective Safety Limits and Control Settings
MONITORED PARAMETER
TEMPERATURE SENSORS OUT OF
RANGE
PRESSURE TRANSDUCERS OUT OF
RANGE
COMPRESSOR DISCHARGE
TEMPERATURE
MOTOR WINDING TEMPERATURE
BEARING TEMPERATURE
EVAPORATOR REFRIGERANT
TEMPERATURE
LIMIT
–40 to 245 F (–40 to 118.3 C)
APPLICABLE COMMENTS
Must be outside range for 2 seconds
0.06 to 0.98 Voltage Ratio
Must be outside range for 3 seconds.
Ratio = Input Voltage ÷ Voltage Reference
Preset, alert setting configurable
>220 F (104.4 C)
>220 F (104.4 C)
>185 F (85 C)
<33 F (for water chilling) (0.6°C)
<EVAP REFRIG TRIPPOINT (set point adjustable
from 0 to 40 F [–18 to 4 C]) for brine chilling)
TRANSDUCER VOLTAGE
CONDENSER PRESSURE — SWITCH
— CONTROL
OIL PRESSURE
LINE VOLTAGE — HIGH
— LOW
— SINGLE-CYCLE
COMPRESSOR MOTOR LOAD
STARTER ACCELERATION TIME
(Determined by inrush current)
STARTER TRANSITION
CONDENSER FREEZE PROTECTION
DISCHARGE SUPERHEAT
VARIABLE DIFFUSER OPERATION
<4.5 vdc> 5.5 vdc
165 ± 5 psig (1138 ± 34 kPa), reset at
110 ± 7 psig (758 ± 48 kPa)
165 psig (1138 kPa)
Cutout <15 psid (103 kPad)
Alert <18 psid (124 kPad)
>150% for one second or >115% for ten seconds
<85% for ten seconds or ≤80 for 5 seconds or
<75% for one second
<50% for one cycle (if enabled)
>110% for 30 seconds
<15% with compressor running
>15% with compressor off
150% RLA for 20 sec.
>100% RLA for 45 sec.
>100% RLA for 10 sec.
If ISM contact open >20 sec.
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.
Minimum value calculated based on
operating conditions and then compared
to actual superheat.
Detects discharge pulses caused by
incorrect diffuser position.
Shunt Trip (Option) — The function of the shunt trip
option on the PIC II is to act as a safety trip. The shunt trip is
wired from an output on the ISM to a shunt trip equipped motor circuit breaker. If the PIC II tries to shut down the compressor using a normal shutdown procedure but is unsuccessful for
20 seconds, the shunt trip output is energized and causes the
circuit breaker to trip off. If ground fault protection has been
applied to the starter, the ground fault trip also energizes the
shunt trip to trip the circuit breaker. Protective devices in the
starter can also energize the shunt trip. The shunt trip feature
can be tested using the Control Test feature.
Preset, alert setting configurable
Preset, alert setting configurable
Preset, configurable chilled medium for water
(SETUP1 table)
Configure chilled medium for brine (SETUP1
table). Adjust EVAP REFRIG TRIPPOINT for
proper cutout
Preset
Preset
Preset
Preset
Preset, based on transformed line voltage
to ISM. Also monitored at CVC/ICVC and
CCM power input.
Default is disabled.
Preset
Preset
Preset
For chillers with reduced voltage mechanical
and solid-state starters
For chillers with full voltage starters
(Configures on ISM_CONF table).
Reduced voltage starters only
CONDENSER FREEZE POINT configured in
SETUP1 table with a default setting of 34 F
(1 C).
Calculated minimum required superheat
and actual superheat are shown on
OVERRIDE screen.
Preset, no calibration needed.
caused the alarm is remedied by the operator. Use CVC/ICVC
display and alarm shutdown record sheet (CL-13) to record all
values from default screen freeze.
Knowledge of the operating state of the chiller at the time an
alarm occurs is useful when troubleshooting. Additional chiller
information can be viewed on the status screens and the
ISM_HIST screen. Troubleshooting information is recorded in
the ALARM HISTORY table, which can be accessed from the
SERVICE menu.
To determine what caused the alarm, the operator should
read both the primary and secondary default screen messages,
as well as the alarm history. The primary message indicates the
most recent alarm condition. The secondary message gives
more detail on the alarm condition. Since there may be more
than one alarm condition, another alarm message may appear
after the first condition is cleared. Check the ALARM HISTORY screen for additional help in determining the reasons for the
alarms. Once all existing alarms are cleared (by pressing the
RESET softkey), the default CVC/ICVC display returns to
normal operation.
Default Screen Freeze — When the chiller is in an
alarm state, the default CVC/ICVC display “freezes,” that is, it
stops updating. The first line of the CVC/ICVC default screen
displays a primary alarm message; the second line displays a
secondary alarm message.
The CVC/ICVC default screen freezes to enable the operator to see the conditions of the chiller at the time of the alarm. If
the value in alarm is one normally displayed on the default
screen, it flashes between normal and reverse video. The CVC/
ICVC default screen remains frozen until the condition that
35
Ramp Loading — The ramp loading control slows down
the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of
time when the chiller is started and the chilled water loop has to
be brought down to CONTROL POINT. This helps reduce
electrical demand charges by slowly bringing the chilled water
to CONTROL POINT. The total power draw during this period
remains almost unchanged.
There are two methods of ramp loading with the PIC II.
Ramp loading can be based on chilled water temperature or on
motor load. Either method is selected from the RAMP__DEM
screen.
1. Temperature ramp loading (TEMP PULLDOWN DEG/
MIN) limits the degrees per minute rate at which either
leaving chilled water or entering chilled water temperature decreases. This rate is configured by the operator on
the TEMP_CTL screen. The lowest temperature ramp
rate will also be used if chiller power has been off for
3 hours or more (even if the motor ramp load is selected
as the ramp loading method).
2. Motor load ramp loading (LOAD PULLDOWN) limits
the degrees per minute rate at which the compressor motor current or compressor motor load increases. The
LOAD PULLDOWN rate is configured by the operator
on the RAMP_DEM screen in amps or kilowatts. The
point name is MOTOR LOAD RAMP%/MIN.
If kilowatts is selected for the DEMAND LIMIT SOURCE,
the MOTOR RATED KILOWATTS must be entered (information found on the chiller Requisition form).
The TEMP PULLDOWN DEG/MIN may be viewed or
modified on the TEMP_CTL screen which is accessed from
the EQUIPMENT SERVICE screen. PULLDOWN RAMP
TYPE, DEMAND LIMIT SOURCE, and MOTOR LOAD
RAMP %/MIN may be viewed or modified on the
RAMP_DEM screen.
As part of the pre-start checks executed by the controls, the
oil sump temperature (OIL SUMP TEMP) is compared to the
cooler refrigerant temperature (EVAPORATOR REFRIG
TEMP). If the difference between these 2 temperatures is 50 F
(27.8 C) or less, the start-up will be delayed until the oil temperature is 50 F (27.8 C) or more. Once this temperature is confirmed, the start-up continues.
The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than 140 F
(60.0 C) or the oil sump temperature is less than the cooler refrigerant temperature plus 53° F (11.7° C). The oil heater is
turned off when the oil sump temperature is either
• more than 152 F (66.7 C), or
• more than 142 F (61.1 C) and more than the cooler
refrigerant temperature plus 55° F (12.8° C).
The oil heater is always off during start-up or when the
compressor is running.
The oil pump is also energized during the time the oil is being heated (for 60 seconds at the end of every 30 minutes).
Oil Cooler — The oil must be cooled when the compressor is running. This is accomplished through a small, plate-type
heat exchanger (also called the oil cooler) located behind the
oil pump. The heat exchanger uses liquid condenser refrigerant
as the cooling liquid. Refrigerant thermostatic expansion
valves (TXVs) regulate refrigerant flow to control the oil temperature entering the bearings. The bulbs for the expansion
valves are strapped to the oil supply line leaving the heat exchanger, and the valves are set to maintain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump temperature may be at a lower temperature during compressor
operations.
Remote Start/Stop Controls — A remote device, such
as a timeclock that uses a set of contacts, may be used to start
and stop the chiller. However, the device should not be programmed to start and stop the chiller in excess of 2 or 3 times
every 12 hours. If more than 8 starts in 12 hours (the STARTS
IN 12 HOURS parameter on the MAINSTAT screen) occur, an
excessive starts alarm displays, preventing the chiller from
starting. The operator must press the RESET softkey on the
CVC/ICVC to override the starts counter and start the chiller.
If the chiller records 12 starts (excluding recycle starts) in a
sliding 12-hour period, it can be restarted only by pressing the
RESET softkey followed by the LOCAL or CCN softkey.
This ensures that, if the automatic system is malfunctioning,
the chiller will not repeatedly cycle on and off. If the automatic
restart after a power failure option (AUTO RESTART OPTION
on the OPTIONS screen) is not activated when a power failure
occurs, and if the remote contact is closed, the chiller will indicate an alarm because of the loss of voltage.
The contacts for remote start are wired into the starter at terminal strip J2, terminals 5 and 6 on the ISM. See the certified
drawings for further details on contact ratings. The contacts
must have 24 vac dry contact rating.
Capacity Override (Table 4) — Capacity overrides can
prevent some safety shutdowns caused by exceeding the motor
amperage limit, refrigerant low temperature safety limit, motor
high temperature safety limit, and condenser high pressure
limit. In all cases there are 2 stages of compressor vane control.
1. The vanes are prevented from opening further, and the
status line on the CVC/ICVC indicates the reason for the
override.
2. The vanes are closed until the condition decreases to below the first step set point. Then the vanes are released to
normal capacity control.
Whenever the motor current demand limit set point
(ACTIVE DEMAND LIMIT) is reached, it activates a capacity
override, again, with a 2-step process. Exceeding 110% of the
rated load amps for more than 30 seconds will initiate a safety
shutdown.
The compressor high lift (surge prevention) set point will
cause a capacity override as well. When the surge prevention
set point is reached, the controller normally will only prevent
the guide vanes from opening. If so equipped, the hot gas bypass valve will open instead of holding the vanes. See the
Surge Prevention Algorithm section, page 39.
Spare Safety Inputs — Normally closed (NC) discrete
inputs for additional field-supplied safeties may be wired to the
spare protective limits input channel in place of the factoryinstalled jumper. (Wire multiple inputs in series.) The opening
of any contact will result in a safety shutdown and a display on
the CVC/ICVC. Refer to the certified drawings for safety contact ratings.
Analog temperature sensors may also be added to the module (SPARE TEMP #1 and #2). The analog temperature sensors may be configured to cause an alert or alarm on the CCN
network. The alert will not shut the chiller down. Configuring
for alarm state will cause the chiller to shut down.
High Discharge Temperature Control — If the
discharge temperature increases above 160 F (71.1 C), the
guide vanes are proportionally opened to increase gas flow
through the compressor. If the leaving chilled water temperature is then brought 5° F (2.8° C) below the control set point
temperature, the PIC II will bring the chiller into the recycle
mode.
Oil Sump Temperature Control — The oil sump
temperature control is regulated by the PIC II, which uses the
oil heater relay when the chiller is shut down.
36
Table 4 — Capacity Overrides
FIRST STAGE SET POINT
OVERRIDE
CAPACITY CONTROL
SECOND STAGE SET
POINT
OVERRIDE
TERMINATION
View/Modify
on CVC/ICVC
Screen
Default
Value
Configurable
Range
Value
Value
HIGH CONDENSER
PRESSURE
SETUP1
125 psig
(862 kPa)
90 to 165 psig
(620 to 1138 kPa)
>Override
Set Point
+2.4 psid (16.5 kPad)
<Override
Set Point
HIGH MOTOR
TEMPERATURE
SETUP1
>200 F
(93.3 C)
150 to 200 F
(66 to 93 C)
>Override
Set Point
+10° F (6° C)
<Override
Set Point
LOW REFRIGERANT
TEMPERATURE
(Refrigerant
Override Delta
Temperature)
SETUP1
3° F (1.6° C)
2° to 5° F
(1° to 3° C)
≤Trippoint
+ Override
∆T –1° F (0.56° C)
>Trippoint
+ Override
∆T+2° F (1.2° C)
0.5° to 20° F
(0.3° to 8.3° C)
30 to 170 psid
(207 to 1172 kPad)
0.5° to 20° F
(0.3° to 8.3° C)
50 to 170 psid
(348 to 1172 kPad)
None
Within Lift Limits
Plus Surge/HGBP
Deadband Setting
Min: T1 — 1.5° F
(0.8° C)
P1 — 50 psid
(345 kPad)
Max: T2 — 10° F
(5.6° C)
P2 — 85 psid
(586 kPad)
HIGH COMPRESSOR
LIFT
(Surge Prevention)
OPTIONS
MANUAL GUIDE VANE
TARGET
CAPACITY
Automatic
0 to 100%
None
Release of
Manual Control
MOTOR LOAD —
ACTIVE DEMAND LIMIT
MAINSTAT
100%
40 to 100%
≥5% of
Set Point
2% Lower
Than Set Point
LOW DISCHARGE
SUPERHEAT
OVERRIDE
Calculated Minimum
Superheat for
Conditions
None
2° F (1.1° C)
Below Calculated
Minimum Superheat
1° F (0.56° C)
Above Calculated
Minimum Superheat
Alarm (Trip) Output Contacts — One set of alarm
Third party software from building automation systems (BAS)
or energy management systems (EMS) can also access the
PIC II controls through a Carrier DataLINK™ module and reset the fault displayed. Both methods would access the
CVC_PSWD/ICVC_PSWD screen and force the RESET
ALARM? point to YES to reset the fault condition. If the PIC II
controls have determined that is safe to start the chiller the
CCN MODE? point (CVC_PSWD/ICVC_PSWD screen) can
be forced to YES to place the chiller back into normal CCN operating mode. The only exceptions are the following alarms
that cannot be reset from a remote location: STATE #100, 205,
217-220, 223, 233, 234, 247, and 250. To view alarm codes, refer to Troubleshooting Guide, Checking Display Messages,
page 76. After the alarm has been reset the PIC II control will
increment the Starts in 12 Hours counter by one upon restart. If
the limit of 8 starts in a 12-hour period occurs the alarm will be
required to be reset at the chiller control panel (CVC/ICVC).
contacts is provided in the starter. The contact ratings are provided in the certified drawings. The contacts are located on terminal strip J9, terminals 15 and 16.
Refrigerant Leak Detector — An input is available
on the CCM module [terminal J5-5 (–) and J5-6 (+)] for a
refrigerant leak detector. Enabling REFRIGERANT LEAK
OPTION (OPTIONS screen) will allow the PIC II controls to
go into an alarm state at a user configured level (REFRIGERANT LEAK ALARM mA). The input is configured for 4 to
20 mA by setting the DIP switch 1 on SW2 at the ON position,
or configured for 1 to 5 vdc by setting switch 1 at the OFF position. The output of the refrigerant leak detector is displayed as
REFRIGERANT LEAK SENSOR on the MAINSTAT screen.
For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed
and 5 vdc input represents 20 mA displayed.
Kilowatt Output — An output is available on the CCM
Condenser Pump Control — The chiller will monitor the condenser pressure (CONDENSER PRESSURE) and
may turn on the condenser pump if the condenser pressure becomes too high while the compressor is shut down. The condenser pressure override (COND PRESS OVERRIDE) parameter is used to determine this pressure point. COND PRESS
OVERRIDE is found in the SETUP1 display screen, which is
accessed from the EQUIPMENT SERVICE table. The default
value is 125 psig (862 kPa).
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, and the entering condenser
water temperature (ENTERING CONDENSER WATER) is less
than 115 F (46 C), the condenser pump will energize to try to
decrease the pressure. The pump will turn off when the condenser pressure is 3.5 psi (24.1 kPa) less than the pressure override or when the condenser refrigerant temperature (CONDENSER REFRIG TEMP) is within 3° F (1.7° C) of the entering condenser water temperature (ENTERING CONDENSER
WATER).
module [Terminal J8-1 (+) and J8-2 (–)] to represent the power
consumption of the chiller. The 4 to 20 mA signal generated by
the CCM module can be wired to the building automation or
energy management system to monitor the chiller’s energy
consumption. A 4 mA signal represents the chiller in an off
state and a 20 mA signal represents the chiller operating at its
rated peak kilowatt consumption. The rated peak kilowatt consumption is configured by the user in the RAMP_DEM display
screen by the setting the MOTOR RATED KILOWATTS from
the job data sheet.
Remote Reset of Alarms — A standard feature of the
PIC II controls is the ability to reset a chiller in a shutdown
alarm state from a remote location. If the condition which
caused the alarm has cleared the chiller can be placed back into
a normal CCN operating mode when the REMOTE RESET
OPTION (CVC_PSWD/ICVC_PSWD menu) is set to ENABLE. A variety of Carrier Comfort Network software systems including ComfortVIEW™ or Network Service Tool™
can access the PIC II controls and reset the displayed alarm.
37
Condenser Freeze Prevention — This control algo-
The TOWER FAN RELAY LOW and HIGH parameters are
accessed from the STARTUP screen.
rithm helps prevent condenser tube freeze-up by energizing the
condenser pump relay. The PIC II controls the pump and, by
starting it, helps to prevent the water in the condenser from
freezing. The PIC II can perform this function whenever the
chiller is not running except when it is either actively in pumpdown or in pumpdown/lockout with the freeze prevention
disabled.
When the CONDENSER REFRIG TEMP is less than or
equal to the CONDENSER FREEZE POINT, the CONDENSER WATER PUMP is energized until the CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE
POINT plus 5° F (2.7° C) and the ENTERING CONDENSER
WATER TEMPERATURE is less than or equal to the CONDENSER FREEZE POINT. An alarm is generated if the chiller
is in PUMPDOWN mode and the pump is energized. An alert
is generated if the chiller is not in PUMPDOWN mode and the
pump is energized. If the chiller is in RECYCLE SHUTDOWN mode, the mode will transition to a non-recycle
shutdown.
IMPORTANT: A field-supplied water temperature control
system for condenser water should be installed. The system
should maintain the leaving condenser water temperature
at a temperature that is 20° F (11° C) above the leaving
chilled water temperature.
The tower fan relay control is not a substitute for a condenser water temperature control. When used with a water
temperature control system, the tower fan relay control can
be used to help prevent low condenser water temperatures.
Auto. Restart After Power Failure — This option
may be enabled or disabled and may be viewed or modified on
the OPTIONS screen, which is accessed from the EQUIPMENT CONFIGURATION table. If the AUTO. RESTART
OPTION is enabled, the chiller will start up automatically after a
power failure has occurred (after a single cycle dropout; low,
high, or loss of voltage; and the power is within ± 15% of normal). The 15- and 5-minute inhibit timers are ignored during this
type of start-up.
When power is restored after the power failure and if the
compressor had been running, the oil pump will energize for
one minute before energizing the cooler pump. AUTO.
RESTART will then continue like a normal start-up.
If power to the CVC/ICVC module has been off for more
than 3 hours or the timeclock has been set for the first time,
start the compressor with the slowest temperature-based ramp
load rate possible in order to minimize oil foaming.
The oil pump is energized occasionally during the time the
oil is being brought up to proper temperature in order to eliminate refrigerant that has migrated to the oil sump during the
power failure. The pump turns on for 60 seconds at the end of
every 30-minute period until the chiller is started.
Evaporator Freeze Protection (ICVC only) — A
refrigerant temperature sensor is installed at the bottom of the
cooler to provide redundant freeze protection. In place of the
cooler and condenser water pressure transducer inputs on the
CCM is a 4.3k ohm resister and a jumper lead. When the
EVAPORATOR REFRIGERANT TEMPERATURE is less
than the EVAP REFRIG TRIPPOINT plus the REFRIG
OVERRIDE DELTA T (configurable from 2° to 5°), state 122
will be displayed and a capacity override will occur. If the
EVAPORATOR REFRIG TEMP is equal to or less than the
EVAP Refrig TRIPPOINT, Protective Limit ALARM STATE
232 will be displayed and the unit will shut down.
Tower Fan Relay Low and High — Low condenser
water temperature can cause the chiller to shut down when refrigerant temperature is low. The tower fan relays, located in
the starter, are controlled by the PIC II to energize and deenergize as the pressure differential between cooler and condenser
vessels changes. This prevents low condenser water temperature and maximizes chiller efficiency. The tower fan relay can
only accomplish this if the relay has been added to the cooling
tower temperature controller.
The tower fan relay low is turned on whenever the condenser water pump is running, flow is verified, and the difference
between cooler and condenser pressure is more than 30 psid
(207 kPad) for entering condenser water temperature greater
than 65 F (18.3 C).
The tower fan relay low is turned off when the condenser
pump is off, flow is stopped, or the cooler refrigerant temperature is less than the override temperature for ENTERING CONDENSER WATER temperature less than 62 F (16.7 C), or the
differential pressure is less than 25 psid (172.4 kPad) for entering condenser water less than 80 F (27 C).
The tower fan relay high is turned on whenever the
condenser water pump is running, flow is verified and the difference between cooler and condenser pressure is more than
35 psid (241.3 kPa) for entering condenser water temperature
greater than the TOWER FAN HIGH SETPOINT (SETPOINT
menu, default 75 F [23.9 C]).
The tower fan relay high is turned off when the condenser
pump is off, flow is stopped, or the cooler refrigerant temperature is less than the override temperature and ENTERING
CONDENSER WATER is less than 70 F (21.1 C), or the difference between cooler and condenser pressure is less than
28 Psid (193 kPa), or ENTERING CONDENSER WATER
temperature is less than TOWER FAN HIGH SETPOINT
minus 3 F (–16.1 C).
Water/Brine Reset — Three types of chilled water or
brine reset are available and can be viewed or modified on the
TEMP_CTL screen, which is accessed from the EQUIPMENT
SERVICE table.
The CVC/ICVC default screen indicates when the chilled
water reset is active. TEMPERATURE RESET on the MAINSTAT screen indicates the amount of reset. The CONTROL
POINT will be determined by adding the TEMPERATURE
RESET to the SETPOINT.
To activate a reset type, access the TEMP_CTL screen and
input all configuration information for that reset type. Then, input the reset type number (1, 2, or 3) in the SELECT/ENABLE
RESET TYPE input line.
RESET TYPE 1: 4 to 20 mA (1 to 5 vdc) TEMPERATURE
RESET — Reset Type 1 is an automatic chilled water temperature reset based on a remote temperature sensor input configured for either an externally powered 4 to 20 mA or a 1 to
5 vdc signal. Reset Type 1 permits up to ±30 F (±16 C) of
automatic reset to the chilled water set point.
The auto, chilled water reset is hardwired to terminals
J5-3 (–) and J5-4 (+) on the CCM. Switch setting number 2 on
SW2 will determine the type of input signal. With the switch
set at the ON position the input is configured for an externally
powered 4 to 20 mA signal. With the switch in the OFF position the input is configured for an external 1 to 5 vdc signal.
RESET TYPE 2: REMOTE TEMPERATURE RESET —
Reset Type 2 is an automatic chilled water temperature reset
based on a remote temperature sensor input signal. Reset Type
2 permits ± 30° F (± 16° C) of automatic reset to the set point
based on a temperature sensor wired to the CCM module
38
where the HOT GAS BYPASS/SURGE PREVENTION is off,
the point must pass through the deadband region to the line
determined by the configured values before the HOT GAS
BYPASS/SURGE PREVENTION will be turned on. As the
point moves from the region where the HOT GAS BYPASS/
SURGE PREVENTION is on, the point must pass through the
deadband region before the HOT GAS BYPASS/SURGE
PREVENTION is turned off. Information on modifying the default set points of the minimum and full load points may be
found in the Input Service Configurations section, page 55.
The state of the surge/hot gas bypass algorithm on the
HEAT_EX DISPLAY SCREEN (Surge/HGBP Active?).
Corrective action can be taken by making one of 2 choices.
If a hot gas bypass line is present and the hot gas option is
selected on the OPTIONS table (SURGE LIMIT/HGBP
OPTION is set to 1), the hot gas bypass valve can be energized.
If the hot gas bypass option is not selected (SURGE LIMIT/
HGBP OPTION is set to 0), hold the guide vanes. See Table 4,
(see wiring diagrams or certified drawings). The temperature
sensor must be wired to terminal J4-13 and J4-14. To configure
Reset Type 2, enter the temperature of the remote sensor at the
point where no temperature reset will occur (REMOTE TEMP
–> NO RESET). Next, enter the temperature at which the full
amount of reset will occur (REMOTE TEMP –> FULL
RESET). Then, enter the maximum amount of reset required to
operate the chiller (DEGREES RESET). Reset Type 2 can now
be activated.
RESET TYPE 3 — Reset Type 3 is an automatic chilled water
temperature reset based on cooler temperature difference.
Reset Type 3 adds ± 30° F (± 16° C) based on the temperature
difference between the entering and leaving chilled water
temperature.
To configure Reset Type 3, enter the chilled water temperature difference (the difference between entering and leaving
chilled water) at which no temperature reset occurs (CHW
DELTA T –> NO RESET). This chilled water temperature difference is usually the full design load temperature difference.
Next, enter the difference in chilled water temperature at which
the full amount of reset occurs (CHW DELTA T –> FULL RESET). Finally, enter the amount of reset (DEGREES RESET).
Reset Type 3 can now be activated.
Demand Limit Control Option — The demand limit
control option (20 mA DEMAND LIMIT OPT) is externally
controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy
management system (EMS). The option is set up on the
RAMP_DEM screen. When enabled, 4 mA is the 100% demand set point with an operator-configured minimum demand
at a 20 mA set point (DEMAND LIMIT AT 20 mA).
The auto. demand limit is hardwired to terminals J5-1 (–)
and J5-2 (+) on the CCM. Switch setting number 1 on SW2
will determine the type of input signal. With the switch set at
the ON position the input is configured for an externally powered 4 to 20 mA signal. With the switch in the OFF position the
input is configured for an external 1 to 5 vdc signal.
LEGEND
— Entering Chilled Water
— Hot Gas Bypass
— Leaving Chilled Water
ECW
HGBP
LCW
Surge Prevention Algorithm (Fixed Speed
Chiller) — This is an operator-configurable feature that can
∆P = (Condenser Psi) – (Cooler Psi)
∆T = (ECW) – (LCW)
determine if lift conditions are too high for the compressor and
then take corrective action. Lift is defined as the difference between the pressure at the impeller eye and at the impeller
discharge. The maximum lift a particular impeller wheel can
perform varies with the gas flow across the impeller and the
size of the wheel.
A surge condition occurs when the lift becomes so high the
gas flow across the impeller reverses. This condition can eventually cause chiller damage. The surge prevention algorithm
notifies the operator that chiller operating conditions are marginal and to take action to help prevent chiller damage such as
lowering entering condenser water temperature.
The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks 2 sets of operator-configured data points, the minimum load points (MIN.
LOAD POINT [T1,P1]) and the full load points (FULL LOAD
POINT [T2,P2]). These points have default settings as defined
on the OPTIONS screen or on Table 4.
The surge prevention algorithm function and settings are
graphically displayed in Fig. 21 and 22. The two sets of load
points on the graph (default settings are shown) describe a line
the algorithm uses to determine the maximum lift of the compressor. When the actual differential pressure between the cooler and condenser and the temperature difference between the
entering and leaving chilled water are above the line on the
graph (as defined by the minimum and full load points), the algorithm goes into a corrective action mode. If the actual values
are below the line and outside of the deadband region, the algorithm takes no action. When the point defined by the ACTIVE
DELTA P and ACTIVE DELTA T, moves from the region
Fig. 21 — 19XR Hot Gas Bypass/Surge
Prevention with Default English Settings
ECW
HGBP
LCW
LEGEND
— Entering Chilled Water
— Hot Gas Bypass
— Leaving Chilled Water
∆P = (Condenser kPa) – (Cooler kPa)
∆T = (ECW) – (LCW)
Fig. 22 — 19XR Hot Gas Bypass/Surge
Prevention with Default Metric Settings
39
Capacity Overrides. Both of these corrective actions try to
reduce the lift experienced by the compressor and help prevent
a surge condition.
parameter, and use the INCREASE or DECREASE softkey
to adjust the amount of time. The default setting is 8 minutes.
Access the display screen (COMPRESS) to monitor the
surge count (SURGE PROTECTION COUNTS).
Surge Prevention Algorithm with VFD — This is
an operator configurable feature that can determine if lift conditions are too high for the compressor and then take corrective
action. Lift is defined as the difference between the pressure at
the impeller eye and at the impeller discharge. The maximum
lift a particular impeller wheel can perform varies with the gas
flow through the impeller and the diameter of the impeller.
A surge condition occurs when the lift becomes so high the
gas flow across the impeller reverses. This condition can eventually cause chiller damage. When enabled, the Surge Prevention Algorithm will adjust either the inlet guide vane (IGV)
position or compressor speed to maintain the compressor at a
safe distance from surge while maintaining machine efficiency.
If the surge condition degrades then the algorithm will move
aggressively away from surge. This condition can be identified
when the SURGE/HGBP ACTIVE? on the HEAT_EX display
screen displays a YES.
The surge prevention algorithm first determines if corrective action is necessary. The algorithm checks two sets of
operator-configured data points, the lower surge point (MIN.
LOAD POINT [T1,P1]) and the upper surge point (FULL
LOAD POINT [T2,P2]). The surge characteristics vary between different chiller configurations and operating conditions.
The surge characteristics are factory set based on the original
selection with the values displayed inside the control panel of
the chiller. Since operating conditions may affect the surge prevention algorithm, some field adjustments may be necessary.
The surge prevention algorithm function and settings are
graphically displayed on Fig. 21 and 22. The two sets of load
points on the graph (default settings are shown) describe a line
the algorithm uses to determine the maximum lift of the compressor for the particular maximum operating speed. When the
actual differential pressure between the cooler and condenser
and the temperature difference between the entering and leaving chilled water are above the line on the graph (as defined by
the minimum and full load points), the algorithm operates in
Surge Prevention mode. This is determined when the ACTIVE
DELTA T is less than SURGE/HGBP DELTA T minus the
deadband.
When in Surge Prevention mode, with a command to increase capacity, the VFD speed will increase until maximum
VFD speed is reached. At VFD MAXIMUM SPEED, when Capacity still needs to increase, the IGV’s open. When in Surge
Prevention mode, with a command to decrease capacity only
the IGVs will close.
Surge Protection (Fixed Speed Chiller) — The
PIC II monitors surge, which is a fluctuation in compressor
motor amperage. Each time the fluctuation exceeds an
operator-specified limit (SURGE DELTA % AMPS), the PIC II
counts the surge. If more than 5 surges occur within an
operator-specified time (SURGE TIME PERIOD), the PIC II
initiates a surge protection shutdown of the chiller.
The surge limit can be adjusted from the OPTIONS screen.
Scroll down to the SURGE DELTA % AMPS parameter, and
use the INCREASE or DECREASE softkey to adjust the
percent of surge. The default setting is 10% amps.
The surge time period can also be adjusted from the
OPTIONS screen. Scroll to the SURGE TIME PERIOD
parameter, and use the INCREASE or DECREASE softkey
to adjust the amount of time. The default setting is 8 minutes.
Access the display screen (COMPRESS) to monitor the
surge count (SURGE PROTECTION COUNTS).
HEAD PRESSURE REFERENCE OUTPUT (See
Fig. 23) — The PIC II control outputs a 4 to 20 mA signal for
the configurable Delta P (condenser pressure minus evaporator
pressure) reference curve shown in Fig. 23. An output is available on the ISM module [Terminal J8 (+), J8 (–) labeled spare].
For chillers with Benshaw Inc. solid-state starters terminal strip
labeled J8 (+), J8 (–) located next to the RediStart MICRO™
input/output card is provided. The Delta P at 100% (chiller at
maximum load condition default at 35 psi), DELTA P AT 0%
(chiller at minimum load condition default at 25 psi) and MINIMUM OUTPUT points are configurable in the EQUIPMENT
SERVICE-OPTIONS table. When configuring this output ensure that minimum requirements for oil pressure and proper
condenser FLASC orifice performance are maintained. The 4
to 20 mA output can be used as a reference to control a
tower bypass valve, tower speed control, or condenser pump
speed control.
Lead/Lag Control — The lead/lag control system automatically starts and stops a lag or second chiller in a 2-chiller
water system. A third chiller can be 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. Refer to Fig. 17 and 18 for menu,
table, and screen selection information.
DELTA P
AT 100%
Surge Protection VFD Units — The PIC II monitors
surge, which is detected as a fluctuation in compressor motor
amperage. Each time the fluctuation exceeds an operatorspecified limit (SURGE DELTA % AMPS), the PIC II registers
a surge protection count. If more than 5 surges occur within an
operator-specified time (SURGE TIME PERIOD), the PIC II
initiates a surge protection shutdown of the chiller.
On VFD units, if a surge count is registered and if ACTUAL
VFD SPEED is less than VFD MAXIMUM SPEED then motor
speed will be increased by the configured VFD increase step.
While the SURGE PROTECTION COUNTS are >0, a speed
decrease will not be honored.
The surge limit can be adjusted from the OPTIONS screen
(see Table 2). Scroll down to the SURGE DELTA % AMPS
parameter, and use the INCREASE or DECREASE softkey
to adjust the percent of surge. The default setting is 10% amps.
The surge time period can also be adjusted from the
OPTIONS screen. Scroll to the SURGE TIME PERIOD
DELTA P
MINIMUM
REFERENCE
OUTPUT
DELTA P
AT 0%
0 mA 2 mA 4 mA
(0%)
4 T0 20 mA OUTPUT
20 mA
(100%)
Fig. 23 — Head Pressure Reference Output
40
LEAD/LAG OPERATION — The PIC II not only has the
ability to operate 2 chillers in lead/lag, but it can also start a
designated standby chiller when either the lead or lag chiller is
faulted and capacity requirements are not met. The lead/lag option only operates when the chillers are in CCN mode. If any
other chiller configured for lead/lag is set to the LOCAL or
OFF modes, it will be unavailable for lead/lag operation.
Lead/Lag Chiller Configuration and Operation
• A chiller is designated the lead chiller when its
LEADLAG: CONFIGURATION value on the LEADLAG screen is set to “1.”
• A chiller is designated the lag chiller when its
LEADLAG: CONFIGURATION value is set to “2.”
• A chiller is designated as a standby chiller when its
LEADLAG: CONFIGURATION value is set to “3.”
• A value of “0” disables the lead/lag designation of a
chiller.
To configure the LAG ADDRESS value on the LEADLAG
screen, always enter the address of the other chiller on the system. For example, if you are configuring chiller A, enter the address for chiller B as the lag address. If you are configuring
chiller B, enter the address for chiller A as the lag address. This
makes it easier to rotate the lead and lag chillers.
If the address assignments in the LAG ADDRESS and
STANDBY ADDRESS parameters conflict, the lead/lag function is disabled and an alert (!) message displays. For example,
if the LAG ADDRESS matches the lead chiller’s address, the
lead/lag will be disabled and an alert (!) message displayed.
The lead/lag maintenance screen (LL_MAINT) displays the
message ‘INVALID CONFIG’ in the LEADLAG: CONFIGURATION and CURRENT MODE fields.
The lead chiller responds to normal start/stop controls such
as the occupancy schedule, a forced start or stop, and remote
start contact inputs. After completing start-up and ramp loading, the PIC II evaluates the need for additional capacity. If additional capacity is needed, the PIC II initiates the start-up of
the chiller configured at the LAG ADDRESS. If the lag chiller
is faulted (in alarm) or is in the OFF or LOCAL modes, the
chiller at the STANDBY ADDRESS (if configured) is requested
to start. After the second chiller is started and is running, the
lead chiller monitors conditions and evaluates whether the capacity has been reduced enough for the lead chiller to sustain
the system alone. If the capacity is reduced enough for the lead
chiller to sustain the CONTROL POINT temperatures alone,
then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarm condition, the configured lag chiller takes the lead chiller’s place as the lead chiller, and the standby chiller serves as
the lag chiller.
If the configured lead chiller does not complete the start-up
before the PRESTART FAULT TIMER (a user-configured
value) elapses, then the lag chiller starts and the lead chiller
shuts down. The lead chiller then monitors the start request
from the acting lead chiller. The PRESTART FAULT TIMER is
initiated at the time of a start request. The PRESTART FAULT
TIMER provides a timeout if there is a prestart alert condition
that prevents the chiller from starting in a timely manner. The
PRESTART FAULT TIMER parameter is on the LEADLAG
screen, which is accessed from the EQUIPMENT SERVICE
table of the SERVICE menu.
If the lag chiller does not achieve start-up before the PRESTART FAULT TIMER elapses, the lag chiller stops, and the
standby chiller is requested to start, if configured and ready.
NOTE: The lead/lag function can be configured on the LEADLAG screen, which is accessed from the SERVICE menu and
EQUIPMENT SERVICE table. See Table 2, Example 20.
Lead/lag status during chiller operation can be viewed on the
LL_MAINT display screen, which is accessed from the SERVICE menu and CONTROL ALGORITHM STATUS table.
See Table 2, Example 12.
Lead/Lag System Requirements:
• all chillers in the system must have software capable of
performing the lead/lag function
• water pumps MUST be energized from the PIC II
controls
• water flows should be constant
• the CCN time schedules for all chillers must be identical
Operation Features:
• 2 chiller lead/lag
• addition of a third chiller for backup
• manual rotation of lead chiller
• load balancing if configured
• staggered restart of the chillers after a power failure
• chillers may be piped in parallel or in series chilled water
flow
COMMON POINT SENSOR INSTALLATION — Lead/lag
operation does not require a common chilled water point sensor. Common point sensors (Spare Temp #1 and #2) can be
added to the CCM module, if desired. Spare Temp #1 and #2
are wired to plug J4 terminals 25-26 and 27-28 (J4 lower,
respectively).
NOTE: If the common point sensor option is chosen on a
chilled water system, each chiller should have its own common
point sensor installed. Each chiller uses its own common point
sensor for control when that chiller is designated as the lead
chiller. The PIC II cannot read the value of common point sensors installed on the other chillers in the chilled water system.
If leaving chilled water control (ECW CONTROL OPTION
is set to 0 [DSABLE] TEMP_CTL screen) and a common
point sensor is desired (COMMON SENSOR OPTION in
LEADLAG screen selected as 1) then the sensor is wired in
Spare Temp #1 position on the CCM.
If the entering chilled water control option (ECW CONTROL OPTION) is enabled (configured in TEMP_CTL
screen) and a common point sensor is desired (COMMON
SENSOR OPTION in LEADLAG screen selected as 1) then
the sensor is wired in Spare Temp #2 position on the CCM.
When installing chillers in series, a common point sensor
should be used. If a common point sensor is not used, the leaving chilled water sensor of the upstream chiller must be moved
into the leaving chilled water pipe of the downstream chiller.
If return chilled water control is required on chillers piped in
series, the common point return chilled water sensor should be
installed. If this sensor is not installed, the return chilled water
sensor of the downstream chiller must be relocated to the return
chilled water pipe of the upstream chiller.
To properly control the common supply point temperature
sensor when chillers are piped in parallel, the water flow
through the shutdown chillers must be isolated so no water bypass around the operating chiller occurs. The common point
sensor option must not be used if water bypass around the operating chiller is occurring.
CHILLER COMMUNICATION WIRING — Refer to the
chiller’s Installation Instructions, Carrier Comfort Network
Interface section for information on chiller communication
wiring.
41
NOTE: Lead chiller percent capacity = 115 – LAG % CAPACITY. The LAG % CAPACITY parameter is on the LEADLAG
screen, which is accessed from the EQUIPMENT SERVICE
table on the SERVICE menu.
FAULTED CHILLER OPERATION — If the lead chiller
shuts down because of an alarm (*) condition, it stops communicating to the lag and standby chillers. After 30 seconds, the
lag chiller becomes the acting lead chiller and starts and stops
the standby chiller, if necessary.
If the lag chiller goes into alarm when the lead chiller is also
in alarm, the standby chiller reverts to a stand-alone CCN
mode of operation.
If the lead chiller is in an alarm (*) condition (as shown on
the CVC/ICVC panel), press the RESET softkey to clear the
alarm. The chiller is placed in CCN mode. The lead chiller
communicates and monitors the RUN STATUS of the lag and
standby chillers. If both the lag and standby chillers are running, the lead chiller does not attempt to start and does not assume the role of lead chiller until either the lag or standby chiller shuts down. If only one chiller is running, the lead chiller
waits for a start request from the operating chiller. When the
configured lead chiller starts, it assumes its role as lead chiller.
If the lag chiller is the only chiller running when the lead
chiller assumes its role as a lead chiller then the lag chiller will
perform a RECOVERY START REQUEST (LL_MAINT
screen). The lead chiller will start up when the following conditions are met.
1. Lag chiller ramp loading must be complete.
2. Lag CHILLED WATER TEMP (MAINSTAT screen) is
greater than CONTROL POINT plus 1/2 the CHILLED
WATER DEADBAND temperature.
3. Lag chiller ACTIVE DEMAND LIMIT value must be
greater than 95% of full load amps.
4. Lag chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN) of the chilled water temperature is
less than 0.5 F (0.27 C) per minute.
5. The standby chiller is not running as a lag chiller.
6. The configured LAG START TIMER has elapsed. The
LAG START TIMER is started when ramp loading is
completed.
LOAD BALANCING — When the LOAD BALANCE
OPTION (see LEADLAG screen) is enabled, the lead chiller
sets the ACTIVE DEMAND LIMIT in the lag chiller to the lead
chiller’s compressor motor load value MOTOR PERCENT
KILOWATTS or AVERAGE LINE CURRENT on the MAINSTAT screen). This value has limits of 40% to 100%. When the
lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL
POINT must be modified to a value of 3° F (1.67° C) less than
the lead chiller’s 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.
AUTO. RESTART AFTER POWER FAILURE — When an
auto. restart condition occurs, each chiller may have a delay
added to the start-up sequence, depending on its lead/lag configuration. The lead chiller does not have a delay. The lag chiller has a 45-second delay. The standby chiller has a 90-second
delay. The delay time is added after the chiller water flow is
verified. The PIC II ensures the guide vanes are closed. After
the guide vane position is confirmed, the delay for lag and
standby chillers occurs prior to energizing the oil pump. The
normal start-up sequence then continues. The auto. restart delay sequence occurs whether the chiller is in CCN or LOCAL
mode and is intended to stagger the compressor motor starts.
Preventing the motors from starting simultaneously helps reduce the inrush demands on the building power system.
Standby Chiller Configuration and Operation — A chiller is
designated as a standby chiller when its LEADLAG: CONFIGURATION value on the LEADLAG screen is set to “3.” The
standby chiller can operate as a replacement for the lag chiller
only if one of the other two chillers is in an alarm (*) condition
(as shown on the CVC/ICVC panel). If both lead and lag chillers are in an alarm (*) condition, the standby chiller defaults to
operate in CCN mode, based on its configured occupancy
schedule and remote contacts input.
Lag Chiller Start-Up Requirements — Before the lag chiller
can be started, the following conditions must be met:
1. Lead chiller ramp loading must be complete.
2. Lead chilled water temperature must be greater than the
CONTROL POINT temperature (see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND
temperature (see the SETUP1 screen).
NOTE: The chilled water temperature sensor may be 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 (see the MAINSTAT screen) value must be greater than 95% of full load
amps.
4. Lead chiller temperature pulldown rate (TEMP PULLDOWN DEG/MIN on the TEMP_CTL screen) 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 in an alarm condition. If the current lag chiller is in an
alarm condition, the standby chiller becomes the active
lag chiller, if it is configured and available.
6. The configured LAG START TIMER entry has elapsed.
The LAG START TIMER starts when the lead chiller ramp
loading is completed. The LAG START TIMER entry is
on the LEADLAG screen, which is accessed from the
EQUIPMENT SERVICE table of the SERVICE menu.
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (SUPVSR flashing
next to the point value on the STATUS table). The PIC II control then monitors the lag chiller for a successful start. If the lag
chiller fails to start, the standby chiller, if configured, is started.
Lag Chiller Shutdown Requirements — The following conditions must be met in order for the lag chiller to be stopped.
1. Lead chiller compressor motor average line current or
load value (MOTOR PERCENT KILOWATTS on the
MAINSTAT screen) is less than the lead chiller percent
capacity.
NOTE: Lead chiller percent capacity = 115 – LAG % CAPACITY. The LAG % CAPACITY parameter is on the
LEADLAG screen, which is accessed from the EQUIPMENT SERVICE table on the SERVICE menu.
2. The lead chiller chilled water temperature is less than the
CONTROL POINT temperature (see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND temperature (see the SETUP1 screen).
3. The configured LAG STOP TIMER entry has elapsed.
The LAG STOP TIMER starts when the lead chiller
chilled water temperature is less than the chilled water
CONTROL POINT plus 1/2 of the CHILLED WATER
DEADBAND and the lead chiller compressor motor load
(MOTOR PERCENT KILOWATT or AVERAGE LINE
CURRENT on the MAINSTAT screen) is less than the
lead chiller percent capacity.
42
Ice Build Control — The ice build control option automatically sets the CONTROL POINT of the chiller to a temperature that allows ice building for thermal storage.
NOTE: For ice build control to operate properly, the PIC II
must be in CCN mode.
NOTE: See Fig. 17 and 18 for more information on ice buildrelated menus.
The PIC II can be configured for ice build operation.
• From the SERVICE menu, access the EQUIPMENT
SERVICE table. From there, select the OPTIONS screen
to enable or disable the ICE BUILD OPTION. See
Table 2, Example 17.
• The ICE BUILD SETPOINT can be configured from the
SETPOINT display, which is accessed from the PIC II
main menu. See Table 2, Example 9.
• The ice build schedule can be viewed or modified from
the SCHEDULE table. From this table, select the ice
build schedule (OCCPC02S) screen. See Fig. 19 and the
section on Time Schedule Operation, page 20, for more
information on modifying chiller schedules.
The ice build time schedule defines the period(s) during
which ice build is active if the ice build option is enabled. If the
ice build time schedule overlaps other schedules, the ice build
time schedule takes priority. During the ice build period, the
CONTROL POINT is set to the ICE BUILD SETPOINT for
temperature control. The ICE BUILD RECYCLE and ICE
BUILD TERMINATION parameters, accessed from the
OPTIONS screen, allow the chiller operator to recycle or terminate the ice build cycle. The ice build cycle can be configured to terminate if:
• the ENTERING CHILLED WATER temperature is less
than the ICE BUILD SETPOINT. In this case, the operator sets the ICE BUILD TERMINATION parameter to 0
on the OPTIONS screen.
• the REMOTE CONTACT inputs from an ice level indicator are opened. In this case, the operator sets the ICE
BUILD TERMINATION parameter to 1 on the OPTIONS
screen.
• the chilled water temperature is less than the ice build set
point and the remote contact inputs from an ice level
indicator are open. In this case, the operator sets the ICE
BUILD TERMINATION parameter to 2 on the OPTIONS
screen.
• the end of the ice build time schedule has been reached.
ICE BUILD INITIATION — The ice build time schedule
(OCCPC02S) is the means for activating the ice build option.
The ice build option is enabled if:
• a day of the week and a time period on the ice build time
schedule are enabled. The SCHEDULE screen shows an
X in the day field and ON/OFF times are designated for
the day(s),
• and the ICE BUILD OPTION is enabled.
The following events take place (unless overridden by a
higher authority CCN device).
• CHILLER START/STOP is forced to START.
• The CONTROL POINT is forced to the ICE BUILD SETPOINT.
• Any force (Auto) is removed from the ACTIVE
DEMAND LIMIT.
NOTE: A parameter’s value can be forced, that is, the value
can be manually changed at the CVC/ICVC by an operator,
changed from another CCN device, or changed by other algorithms in the PIC II control system.
NOTE: The Ice Build steps do not occur if the chiller is configured and operating as a lag or standby chiller for lead/lag operation and is actively being controlled by a lead chiller. The lead
chiller communicates the ICE BUILD SET POINT, the desired
CHILLER START/STOP state, and the ACTIVE DEMAND
LIMIT to the lag or standby chiller as required for ice build, if
configured to do so.
START-UP/RECYCLE OPERATION — If the chiller is not
running when ice build activates, the PIC II checks the following conditions, based on the ICE BUILD TERMINATION
value, to avoid starting the compressor unnecessarily:
• if ICE BUILD TERMINATION is set to the TEMP option
and the ENTERING CHILLED WATER temperature is
less than or equal to the ICE BUILD SETPOINT;
• if ICE BUILD TERMINATION is set to the CONTACTS
option and the remote contacts are open;
• if the ICE BUILD TERMINATION is set to the BOTH
(temperature and contacts) option and the ENTERING
CHILLED WATER temperature is less than or equal to
the ICE BUILD SETPOINT and the remote contacts are
open.
The ICE BUILD RECYCLE on the OPTIONS screen determines whether or not the chiller will go into an ice build RECYCLE mode.
• If the ICE BUILD RECYCLE is set to DSABLE (disable), the PIC II reverts to normal temperature control
when the ice build function terminates.
• If the ICE BUILD RECYCLE is set to ENABLE, the PIC
II goes into an ICE BUILD RECYCLE mode and the
chilled water pump relay remains energized to keep the
chilled water flowing when the ice build function terminates. If the temperature of the ENTERING CHILLED
WATER increases above the ICE BUILD SETPOINT plus
the RECYCLE RESTART DELTA T value, the compressor restarts and controls the chilled water/brine temperature to the ICE BUILD SETPOINT.
TEMPERATURE CONTROL DURING ICE BUILD —
During ice build, the capacity control algorithm shall use the
CONTROL POINT minus 5 F (–2.8 C) for control of the
LEAVING CHILLED WATER temperature. (See Table 2, example 10, the CAPACITY CONTROL parameter on the CAPACITY screen.) The ECW CONTROL OPTION and any temperature reset option shall be ignored, if enabled, during ice
build. The AUTO DEMAND LIMIT INPUT shall also be
ignored if enabled during ice build.
• ECW CONTROL OPTION and any temperature reset
options (configured on TEMP_CTL screen).
• 20 mA DEMAND LIMIT OPT (configured on
RAMP_DEM screen).
TERMINATION OF ICE BUILD — The ice build function
terminates under the following conditions:
1. Time Schedule — When the current time on the ice build
time schedule (OCCPC02S) is not set as an ice build time
period.
2. Entering Chilled Water Temperature — Compressor
operation terminates, based on temperature, if the ICE
BUILD TERMINATION parameter is set to 0 (TEMP),
the ENTERING CHILLED WATER temperature is less
than the ICE BUILD SETPOINT, and the ICE BUILD
RECYCLE is set to DSABLE. If the ICE BUILD RECYCLE OPTION is set to ENABLE, a recycle shutdown occurs and recycle start-up depends on the LEAVING
CHILLED WATER temperature being greater than the
water/brine CONTROL POINT plus the RESTART
DELTA T temperature.
3. Remote Contacts/Ice Level Input — Compressor operation terminates when the ICE BUILD TERMINATION
parameter is set to 1 (CONTACTS) and the remote contacts are open and the ICE BUILD RECYCLE is set to
DSABLE (0). In this case, the contacts provide ice level
termination control. The contacts are used to stop the ice
build function when a time period on the ice build schedule (OCCPC02S) is set for ice build operation. The remote contacts can still be opened and closed to start and
43
stop the chiller when a specific time period on the ice
build schedule is not set for ice build.
4. Entering Chilled Water Temperature and ICE BUILD
Contacts — Compressor operation terminates when the
ICE BUILD TERMINATION parameter is set to
2 (BOTH) and the conditions described above in items
2 and 3 for entering chilled water temperature and remote
contacts have occurred.
NOTE: It is not possible to override the CHILLER START/
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT
variables from CCN devices (with a priority 4 or greater) during the ice build period. However, a CCN device can override
these settings during 2-chiller lead/lag operation.
RETURN TO NON-ICE BUILD OPERATIONS — The ice
build function forces the chiller to start, even if all other schedules indicate that the chiller should stop. When the ice build
function terminates, the chiller returns to normal temperature
control and start/stop schedule operation. The CHILLER
START/STOP and CONTROL POINT return to normal operation. If the CHILLER START/STOP or CONTROL POINT has
been forced (with a device of less than 4 priority) before the ice
build function started, when the ice build function ends, the
previous forces (of less than 4 priority) are not automatically
restored.
Fig. 24 — Example of Attach to Network
Device Screen
module address cannot be found, the message “COMMUNICATION FAILURE” appears. The CVC/ICVC then reverts
back to the ATTACH TO DEVICE screen. Try another device
or check the address of the device that would not attach. The
upload process time for each CCN module is different. In general, the uploading process takes 1 to 2 minutes. Before leaving
the ATTACH TO NETWORK DEVICE screen, select the local device. Otherwise, the CVC/ICVC will be unable to display
information on the local chiller.
ATTACHING TO OTHER CCN MODULES — If the chiller CVC/ICVC has been connected to a CCN Network or other
PIC controlled chillers through CCN wiring, the CVC/ICVC
can be used to view or change parameters on the other controllers. Other PIC II chillers can be viewed and set points changed
(if the other unit is in CCN control), if desired, from this particular CVC/ICVC module.
If the module number is not valid, the “COMMUNICATION FAILURE” message will show and a new address number must be entered or the wiring checked. If the module is
communicating properly, the “UPLOAD IN PROGRESS”
message will flash and the new module can now be viewed.
Whenever there is a question regarding which module on
the CVC/ICVC is currently being shown, check the device
name descriptor on the upper left hand corner of the CVC/
ICVC screen. See Fig. 24.
When the CCN device has been viewed, the ATTACH TO
NETWORK DEVICE table should be used to attach to the PIC
that is on the chiller. Move to the ATTACH TO NETWORK
DEVICE table (LOCAL should be highlighted) and press the
ATTACH softkey to upload the LOCAL device. The CVC/
ICVC for the 19XR will be uploaded and default screen will
display.
NOTE: The CVC/ICVC will not automatically reattach to the
local module on the chiller. Press the ATTACH softkey to
attach to the LOCAL device and view the chiller operation.
Attach to Network Device Control — The Service
menu includes the ATTACH TO NETWORK DEVICE
screen. From this screen, the operator can:
• enter the time schedule number (if changed) for
OCCPC03S, as defined in the NET_OPT screen
• attach the CVC/ICVC to any CCN device, if the chiller
has been connected to a CCN network. This may include
other PIC-controlled chillers.
• upgrade software
Figure 24 shows the ATTACH TO NETWORK DEVICE
screen. The LOCAL parameter is always the CVC/ICVC module address of the chiller on which it is mounted. Whenever the
controller identification of the CVC/ICVC changes, the change
is reflected automatically in the BUS and ADDRESS columns
for the local device. See Fig. 18. Default address for local device is BUS 0 ADDRESS 1.
When the ATTACH TO NETWORK DEVICE screen is accessed, information can not be read from the CVC/ICVC on
any device until one of the devices listed on that screen is attached. The CVC/ICVC erases information about the module
to which it was attached to make room for information on another device. Therefore, a CCN module must be attached when
this screen is entered.
To attach any CCN device, highlight it using the SELECT
softkey and press the ATTACH softkey. The message “UPLOADING TABLES, PLEASE WAIT” displays. The CVC/
ICVC then uploads the highlighted device or module. If the
44
Service Operation — An overview of the tables and
screens available for the SERVICE function is shown in
Fig. 18.
TO ACCESS THE SERVICE SCREENS — When the SERVICE screens are accessed, a password must be entered.
1. From the main MENU screen, press the SERVICE
softkey. The softkeys now correspond to the numerals
1, 2, 3, 4.
HOLIDAY SCHEDULING (Fig. 25) — 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. 19.)
The broadcast function must be activated for the holidays
configured on the HOLIDEF screen to work properly. Access
the BRODEF screen from the EQUIPMENT CONFIGURATION table and select ENABLE to activate function. Note that
when the chiller is connected to a CCN Network, only one
chiller or CCN device can be configured as the broadcast device. The controller that is configured as the broadcaster is the
device responsible for transmitting holiday, time, and daylightsavings dates throughout the network.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 18.
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.
2. If not logged on, follow the instructions for Attach to Network Device or To Log Out. Once logged on, press
NEXT until Equipment Configuration is highlighted.
3. Once Equipment Configuration is highlighted, press
SELECT to access.
4. Press NEXT until HOLIDAYS 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 is to be
viewed or changed. Each table is one holiday period,
starting on a specific date, and lasting up to 99 days.
7. Press SELECT to access the holiday table. The Configuration Select table now shows the holiday start month
and day, and how many days the holiday period will last.
8. Press NEXT or PREVIOUS to highlight the month,
day, or duration.
9. Press SELECT to modify the month, day, or duration.
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.
2. Press the four digits of the password, one at a time. An
asterisk (*) appears as each digit is entered
NOTE: The initial factory-set password is 1-1-1-1. If the
password is incorrect, an error message is displayed
If this occurs, return to Step 1 and try to access the SERVICE screens again. If the password is correct, the softkey labels change to:
NOTE: The SERVICE screen password can be changed
by entering the CVC/ICVC CONFIGURATION screen
under SERVICE menu. The password is located at the
bottom of the menu.
The CVC/ICVC screen displays the following list of
available SERVICE screens:
• Alarm History
• Control Test
• Control Algorithm Status
• Equipment Configuration
• ISM (Starter) Config Data
• Equipment Service
• Time and Date
• Attach to Network Device
• Log Out of Device
• CVC/ICVC Configuration
See Fig. 18 for additional screens and tables available from
the SERVICE screens listed above. Use the EXIT softkey to
return to the main MENU screen.
NOTE: To prevent unauthorized persons from accessing the
CVC/ICVC service screens, the CVC/ICVC automatically
signs off and password-protects itself if a key has not been
pressed for 15 minutes. The sequence is as follows. Fifteen
minutes after the last key is pressed, the default screen displays, the CVC/ICVC screen light goes out (analogous to a
screen saver), and the CVC/ICVC logs out of the passwordprotected SERVICE menu. Other screen and menus, such as
the STATUS screen can be accessed without the password by
pressing the appropriate softkey.
TO LOG OUT OF NETWORK DEVICE — To access this
screen and log out of a network device, from the default CVC/
ICVC screen, press the MENU and SERVICE softkeys.
Enter the password and, from the SERVICE menu, highlight
LOG OUT OF NETWORK DEVICE and press the SELECT
softkey. The CVC/ICVC default screen will now be displayed.
Fig. 25 — Example of Holiday Period Screen
45
START-UP/SHUTDOWN/
RECYCLE SEQUENCE (Fig. 26)
Local Start-Up — Local start-up (or a manual start-up) is
NOTE: Units equipped with ICVC are not available with factory installed chilled water or condenser water flow devices
(available as an accessory for use with the CCM Control
board).
If the water/brine temperature is high enough, the start-up
sequence continues and checks the guide vane position. If the
guide vanes are more than 4% open, the start-up waits until the
PIC II closes the vanes. If the vanes are closed and the oil pump
pressure is less than 4 psi (28 kPa), the oil pump relay energizes. The PIC II then waits until the oil pressure (OIL PRESS
VERIFY TIME, operator-configured, default of 40 seconds)
reaches a maximum of 18 psi (124 kPa). After oil pressure is
verified, the PIC II waits 40 seconds, and the compressor start
relay (1CR) energizes to start the compressor.
Compressor ontime and service ontime timers start, and the
compressor STARTS IN 12 HOURS counter and the number of
starts over a 12-hour period counter advance by one.
Failure to verify any of the requirements up to this point will
result in the PIC II aborting the start and displaying the applicable pre-start mode of failure on the CVC/ICVC default screen.
A pre-start failure does not advance the STARTS IN 12 HOURS
counter. Any failure after the 1CR relay has energized results in
a safety shutdown, advances the starts in 12 hours counter by
one, and displays the applicable shutdown status on the CVC/
ICVC display.
initiated by pressing the LOCAL menu softkey on the default
CVC/ICVC screen. Local start-up can proceed when the chiller
schedule indicates that the current time and date have been
established as a run time and date, and after the internal
15-minute start-to-start and the 1-minute stop-to-start inhibit
timers have expired. These timers are represented in the START
INHIBIT TIMER and can be viewed on the MAINSTAT screen
and DEFAULT screen. The timer must expire before the chiller
will start. If the timers have not expired the RUN STATUS parameter on the MAINSTAT screen now reads TIMEOUT.
NOTE: The time schedule is said to be “occupied” if the
OCCUPIED ? parameter on the MAINSTAT screen is set to
YES. For more information on occupancy schedules, see the
sections on Time Schedule Operation (page 20), Occupancy
Schedule (page 34), and To Prevent Accidental Start-Up
(page 65), and Fig. 19.
If the OCCUPIED ? parameter on the MAINSTAT screen
is set to NO, the chiller can be forced to start as follows. From
the default CVC/ICVC screen, press the MENU and
STATUS softkeys. Scroll to highlight MAINSTAT. Press the
SELECT softkey. Scroll to highlight CHILLER START/STOP.
Press the START softkey to override the schedule and start
the chiller.
NOTE: The chiller will continue to run until this forced start is
released, regardless of the programmed schedule. To release
the forced start, highlight CHILLER START/STOP from the
MAINSTAT screen and press the RELEASE softkey. This
action returns the chiller to the start and stop times established
by the schedule.
The chiller may also be started by overriding the time
schedule. From the default screen, press the MENU and
SCHEDULE softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desired override
time.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the EQUIPMENT SERVICE screen set to ENABLE. For these chillers,
the REMOTE START CONTACT parameter on the MAINSTAT screen must be CLOSED. From the CVC/ICVC default
screen, press the MENU and STATUS softkeys. Scroll to
highlight MAINSTAT and press the SELECT softkey. Scroll
down the MAINSTAT screen to highlight REMOTE START
CONTACT and press the SELECT softkey. Then, press the
CLOSE softkey. To end the override, select REMOTE CONTACTS INPUT and press the RELEASE softkey.
Once local start-up begins, the PIC II performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 4. The RUN STATUS parameter on the MAINSTAT screen line now reads PRESTART. If a
test is not successful, the start-up is delayed or aborted. If the
tests are successful, the chilled water/brine pump relay energizes, and the MAINSTAT screen line now reads STARTUP.
Five seconds later, the condenser pump relay energizes.
Thirty seconds later the PIC II monitors the chilled water and
condenser water flow devices and waits until the WATER
FLOW VERIFY TIME (operator-configured, default 5 minutes)
expires to confirm flow. After flow is verified, the chilled water
temperature is compared to CONTROL POINT plus 1/2
CHILLED WATER DEADBAND. If the temperature is less
than or equal to this value, the PIC II turns off the condenser
pump relay and goes into a RECYCLE mode.
A
— START INITIATED: Pre-start checks are made; evaporator pump
started.
B — Condenser water pump started (5 seconds after A).
C — Water flows verified (30 seconds to 5 minutes maximum after B).
Chilled water temperatures checked against control point. Guide
vanes checked for closure. Oil pump started; tower fan control
enabled.
D — Oil pressure verified (15 seconds minimum, 300 seconds maximum
after C).
E — Compressor motor starts; compressor ontime and service ontime
start, 15-minute inhibit timer starts (10 seconds after D), total compressor starts advances by one, and the number of starts over a
12-hour period advances by one.
F — SHUTDOWN INITIATED — Compressor motor stops; compressor
ontime and service ontime stop, and 1-minute inhibit timer starts.
G — Oil pump and evaporator pumps deenergized (60 seconds after F).
Condenser pump and tower fan control may continue to operate if
condenser pressure is high. Evaporator pump may continue if in
RECYCLE mode.
O/A — Restart permitted (both inhibit timers expired: minimum of 15 minutes
after E; minimum of 1 minute after F).
Fig. 26 — Control Sequence
46
Shutdown Sequence — Chiller shutdown begins if
any of the following occurs:
• the STOP button is pressed for at least one second (the
alarm light blinks once to confirm the stop command)
• a recycle condition is present (see Chilled Water Recycle
Mode section)
• the time schedule has gone into unoccupied mode
• the chiller protective limit has been reached and chiller is
in alarm
• the start/stop status is overridden to stop from the CCN
network or the CVC/ICVC
When a stop signal occurs, the shutdown sequence first
stops the compressor by deactivating the start relay (1CR). A
status message of “SHUTDOWN IN PROGRESS, COMPRESSOR DEENERGIZED” is displayed, and the compressor ontime and service ontime stop. The guide vanes are then
brought to the closed position. The oil pump relay and the
chilled water/brine pump relay shut down 60 seconds after the
compressor stops. The condenser water pump shuts down at
the same time if the ENTERING CONDENSER WATER temperature is greater than or equal to 115 F (46.1 C) and the
CONDENSER REFRIG TEMP is greater than the CONDENSER FREEZE POINT plus 5 F (–15.0 C). The stop-to-start timer
now begins to count down. If the start-to-start timer value is
still greater than the value of the start-to-stop timer, then this
time displays on the CVC/ICVC.
Certain conditions that occur during shutdown can change
this sequence.
• If the AVERAGE LINE CURRENT is greater than 5%
after shutdown, or the starter contacts remain energized,
the oil pump and chilled water pump remain energized
and the alarm is displayed.
• The condenser pump shuts down when the CONDENSER PRESSURE is less than the COND PRESS
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the
CONDENSER REFRIG TEMP is less than or equal to the
ENTERING CONDENSER WATER temperature plus
3° F (–1.6° C).
• If the chiller shuts down due to low refrigerant temperature, the chilled water pump continues to run until the
LEAVING CHILLED WATER temperature is greater than
the CONTROL POINT temperature, plus 5° F (3° C).
Chilled Water Recycle Mode — The chiller may
cycle off and wait until the load increases to restart when the
compressor is running in a lightly loaded condition. This cycling is normal and is known as “recycle.” A recycle shutdown
is initiated when any of the following conditions are true:
• the chiller is in LCW control, the difference between the
LEAVING CHILLED WATER temperature and ENTERING CHILLED WATER temperature is less than the
RECYCLE SHUTDOWN DELTA T (found in the
SETUP1 table) the LEAVING CHILLED WATER temperature is 5° F (2.8° C) below the CONTROL POINT,
the CONTROL POINT has not increased in the last
5 minutes and ICE BUILD is not active.
• the ECW CONTROL OPTION is enabled, the difference
between the ENTERING CHILLED WATER temperature
and the LEAVING CHILLED WATER temperature is less
than the RECYCLE SHUTDOWN DELTA T (found in the
SETUP1 table), the ENTERING CHILLED WATER temperature is 5° F (2.8° C) below the CONTROL POINT,
and the CONTROL POINT has not increased in the last
5 minutes.
• the LEAVING CHILLED WATER temperature is within
3° F (2° C) of the EVAP REFRIG TRIPPOINT.
When the chiller is in RECYCLE mode, the chilled water
pump relay remains energized so the chilled water temperature
can be monitored for increasing load. The recycle control uses
RESTART DELTA T to check when the compressor should be
restarted. This is an operator-configured function which defaults to 5° F (3° C). This value can be viewed or modified on
the SETUP1 table. The compressor will restart when the chiller
is:
• in LCW CONTROL and the LEAVING CHILLED
WATER temperature is greater than the CONTROL
POINT plus the RECYCLE RESTART DELTA T.
• in ECW CONTROL and the ENTERING CHILLED
WATER temperature is greater than the CONTROL
POINT plus the RECYCLE RESTART DELTA T.
Once these conditions are met, the compressor initiates a
start-up with a normal start-up sequence.
An alert condition may be generated if 5 or more recycle
start-ups occur in less than 4 hours. Excessive recycling can
reduce chiller life; therefore, compressor recycling due to extremely low loads should be reduced.
To reduce compressor recycling, use the time schedule to
shut the chiller down during known low load operation period,
or increase the chiller load by running the fan systems. If the
hot gas bypass is installed, adjust the values to ensure that hot
gas is energized during light load conditions. Increase the
RECYCLE RESTART DELTA T on the SETUP1 table to
lengthen the time between restarts.
The chiller should not be operated below design minimum
load without a hot gas bypass installed.
Automatic Soft Stop Amps Threshold — The soft
stop amps threshold feature closes the guide vanes of the compressor automatically if a non-recycle, non-alarm stop signal
occurs before the compressor motor is deenergized.
If the STOP button is pressed, the guide vanes close to a
preset amperage percent until the guide vane is less than 4%
open or 4 minutes have passed. The compressor then shuts off.
If the chiller enters an alarm state or if the compressor enters
a RECYCLE mode, the compressor deenergizes immediately.
To activate the soft stop amps threshold feature, scroll to the
bottom of OPTIONS screen on the CVC/ICVC. Use the
INCREASE or DECREASE softkey to set the SOFT STOP
AMPS THRESHOLD parameter to the percent of amps at
which the motor will shut down. The default setting is 100%
amps (no soft stop). The range is 40 to 100%.
When the soft stop amps threshold feature is being applied,
a status message, “SHUTDOWN IN PROGRESS, COMPRESSOR UNLOADING” displays on the CVC/ICVC.
The soft stop amps threshold function can be terminated and
the compressor motor deenergized immediately by depressing
the STOP button twice.
Safety Shutdown — A safety shutdown is identical to
a manual shutdown with the exception that, during a safety
shutdown, the CVC/ICVC displays the reason for the shutdown, the alarm light blinks continuously, and the spare alarm
contacts are energized.
After a safety shutdown, the RESET softkey must be
pressed to clear the alarm. If the alarm condition is still present,
the alarm light continues to blink. Once the alarm is cleared,
the operator must press the CCN or LOCAL softkeys to restart the chiller.
47
BEFORE INITIAL START-UP
To determine if there are any leaks, the chiller should be
charged with refrigerant. Use an electronic leak detector to
check all flanges and solder joints after the chiller is pressurized. If any leaks are detected, follow the leak test procedure.
If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and damage
during the transfer of refrigerant from vessel to vessel during
the leak test process, or any time refrigerant is being transferred. Adjust the springs when the refrigerant is in operating
condition and the water circuits are full.
Job Data Required
• list of applicable design temperatures and pressures
(product data submittal)
• chiller certified prints
• starting equipment details and wiring diagrams
• diagrams and instructions for special controls or options
• 19XR Installation Instructions
• pumpout unit instructions
Equipment Required
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 can also be used if the chiller is
under pressure.
•
•
•
•
•
mechanic’s tools (refrigeration)
digital volt-ohmmeter (DVM)
clamp-on ammeter
electronic leak detector
absolute pressure manometer or wet-bulb vacuum indicator (Fig. 27)
• 500-v insulation tester (megohmmeter) for compressor
motors with nameplate voltage of 600 v or less, or a
5000-v insulation tester for compressor motor rated
above 600 v
Do not use air or oxygen as a means of pressurizing
the chiller. Mixtures of HFC-134a and air can undergo
combustion.
Using the Optional Storage Tank and Pumpout System — Refer to Chillers with Storage Tanks section, page 69 for pumpout system preparation, refrigerant
transfer, and chiller evacuation.
Remove Shipping Packaging — Remove any packaging material from the control center, power panel, guide vane
actuator, motor cooling and oil reclaim solenoids, motor and
bearing temperature sensor covers, and the factory-mounted
starter.
Open Oil Circuit Valves — Check to ensure the oil filter isolation valves (Fig. 4) are open by removing the valve cap
and checking the valve stem.
Tighten All Gasketed Joints and Guide Vane
Shaft Packing — Gaskets and packing normally relax by
the time the chiller arrives at the jobsite. Tighten all gasketed
joints and the guide vane shaft packing to ensure a leak-tight
chiller.
Check Chiller Tightness — Figure 28 outlines the
proper sequence and procedures for leak testing.
The 19XR chillers are shipped with the refrigerant contained in the condenser shell and the oil charge in the compressor. The cooler is shipped with a 15 psig (103 kPa) refrigerant
charge. Units may be ordered with the refrigerant shipped separately, along with a 15 psig (103 kPa) nitrogen-holding charge
in each vessel.
Fig. 27 — Typical Wet-Bulb Type
Vacuum Indicator
48
49
Fig. 28 — 19XR Leak Test Procedures
Leak Test Chiller — Due to regulations regarding refrigerant emissions and the difficulties associated with separating
contaminants from the refrigerant, Carrier recommends the
following leak test procedure. See Fig. 28 for an outline of the
leak test procedure. Refer to Fig. 29 and 30 during pumpout
procedures and Tables 5A and 5B for refrigerant pressure/
temperature values.
1. If the pressure readings are normal for the chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at the equivalent saturated pressure for the surrounding temperature.
Follow the pumpout procedures in the Transfer
Refrigerant from Pumpout Storage Tank to Chiller
section, Steps 1a - e, page 69.
5. If no leak is found during the initial start-up procedures,
complete the transfer of refrigerant gas from the pumpout
storage tank to the chiller (see Transfer Refrigerant from
Pumpout Storage Tank to Chiller section, page 69). Retest for leaks.
6. If no leak is found after a retest:
a. Transfer the refrigerant to the pumpout storage
tank and perform a standing vacuum test as outlined in the Standing Vacuum Test section, below.
b. If the chiller fails the standing vacuum test, check
for large leaks (Step 2b).
c. If the chiller passes the standing vacuum test,
dehydrate the chiller. Follow the procedure in
the Chiller Dehydration section. Charge the chiller
with refrigerant (see Transfer Refrigerant from
Pumpout Storage Tank to Chiller section,
page 69).
7. If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
present, pump the refrigerant into the non-leaking
vessel (see Pumpout and Refrigerant Transfer procedures
section).
8. Transfer the refrigerant until the chiller pressure is at
18 in. Hg (40 kPa absolute).
9. Repair the leak and repeat the procedure, beginning from
Step 2h, to ensure a leak-tight repair. (If the chiller is
opened to the atmosphere for an extended period, evacuate it before repeating the leak test.)
Never charge liquid refrigerant into the chiller if the pressure in the chiller is less than 35 psig (241 kPa) for
HFC-134a. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using
PUMPDOWN LOCKOUT and TERMINATE LOCKOUT mode on the PIC II. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.
c. Leak test chiller as outlined in Steps 3 - 9.
2. If the pressure readings are abnormal for the chiller
condition:
a. Prepare to leak test chillers shipped with refrigerant (Step 2h).
b. Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 30 psig (207 kPa). Soap
test all joints. If the test pressure holds for 30 minutes,
prepare the test for small leaks (Steps 2g - h).
c. Plainly mark any leaks that are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest the joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished by
following the dehydration procedure, outlined in
the Chiller Dehydration section, page 53.
h. Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).
3. Check the chiller carefully with an electronic leak detector, halide torch, or soap bubble solution.
4. Leak Determination — If an electronic leak detector indicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
at rates greater than 1 lb./year (0.45 kg/year) for the entire
chiller must be repaired. Note the total chiller leak rate on
the start-up report.
Standing Vacuum Test — When performing the
standing vacuum test or chiller dehydration, use a manometer
or a wet bulb indicator. Dial gages cannot indicate the small
amount of acceptable leakage during a short period of time.
1. Attach an absolute pressure manometer or wet bulb indicator to the chiller.
2. Evacuate the vessel (see Pumpout and Refrigerant Transfer Procedures section, page 67) to at least 18 in. Hg vac,
ref 30-in. bar (41 kPa), using a vacuum pump or the
pump out unit.
3. Valve off the pump to hold the vacuum and record the
manometer or indicator reading.
4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in
24 hours, the chiller is sufficiently tight.
b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in
24 hours, repressurize the vessel and test for leaks.
If refrigerant is available in the other vessel, pressurize by following Steps 2-10 of Return Chiller To
Normal Operating Conditions section, page 71. If
not, use nitrogen and a refrigerant tracer. Raise the
vessel pressure in increments until the leak is
detected. If refrigerant is used, the maximum gas
pressure is approximately 70 psig (483 kPa) for
HFC-134a at normal ambient temperature. If nitrogen is used, limit the leak test pressure to 230 psig
(1585 kPa) maximum.
5. Repair the leak, retest, and proceed with dehydration.
50
Fig. 29 — Typical Optional Pumpout System Piping Schematic with Storage Tank
Fig. 30 — Typical Optional Pumpout System Piping Schematic without Storage Tank
51
Table 5A — 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 5B — 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
52
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
Chiller Dehydration — Dehydration is recommended if
the chiller has been open for a considerable period of time, if
the chiller is known to contain moisture, or if there has been a
complete loss of chiller holding charge or refrigerant pressure.
Do not start or megohm-test the compressor motor or oil
pump motor, even for a rotation check, if the chiller is
under dehydration vacuum. Insulation breakdown and
severe damage may result.
Fig. 31 — Dehydration Cold Trap
Inspect Water Piping — Refer to piping diagrams pro-
Inside-delta type starters must be disconnected by an isolation switch before placing the machine under a vacuum
because one lead of each phase is live with respect to
ground even though there is not a complete circuit to run
the motor. To be safe, isolate any starter before evacuating
the chiller if you are not sure if there are live leads to the
hermetic motor.
vided in the certified drawings and the piping instructions in
the 19XR Installation Instructions manual. Inspect the piping to
the cooler and condenser. Be sure that the flow directions are
correct and that all piping specifications have been met.
Piping systems must be properly vented with no stress on
waterbox nozzles and covers. Water flows through the cooler
and condenser must meet job requirements. Measure the pressure drop across the cooler and the condenser.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 31) may substantially reduce the time required
to complete the dehydration. The higher the room temperature,
the faster dehydration takes place. At low room temperatures, a
very deep vacuum is required to boil off any moisture. If low
ambient temperatures are 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. 2). Tubing from the pump to the chiller should
be as short in length and as large in diameter as possible to
provide least resistance to gas flow.
2. Use an absolute pressure manometer or a wet bulb vacuum indicator to measure the vacuum. Open the shutoff
valve to the vacuum indicator only when taking a reading. Leave the valve open for 3 minutes to allow the indicator vacuum to equalize with the chiller vacuum.
3. If the entire chiller is to be dehydrated, open all isolation
valves (if present).
4. With the chiller ambient temperature at 60 F (15.6 C) or
higher, operate the vacuum pump until the manometer
reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)
(–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C).
Operate the pump an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure, isolated pockets of moisture can turn into ice. The slow rate
of evaporation (sublimation) of ice at these low temperatures and pressures greatly increases dehydration time.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If
the reading indicates vacuum loss, repeat Steps 4 and 5.
7. If the reading continues to change after several attempts,
perform a leak test up to the maximum 160 psig
(1103 kPa) pressure. Locate and repair the leak, and repeat dehydration.
Water must be within design limits, clean, and treated to
ensure proper chiller performance and to reduce the potential of tube damage due to corrosion, 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 pumpout 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. See Fig. 29
and 30.
Check Relief Valves — Be sure the relief valves 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.
The 19XR relief valves are set to relieve at the 185 psig
(1275 kPa) chiller design pressure.
Inspect Wiring
Do not check the voltage supply without proper equipment
and precautions. Serious injury may result. Follow power
company recommendations.
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insulation breakdown and serious damage may result.
1. Examine the wiring for conformance to the job wiring diagrams and all applicable electrical codes.
53
11. On chillers with free-standing starters, inspect the power
panel to ensure that the contractor has fed the wires into
the bottom of the panel. Wiring into the top of the panel
can cause debris to fall into the contactors. Clean and inspect the contactors if this has occurred.
2. On low-voltage compressors (600 v or less) connect a
voltmeter across the power wires to the compressor starter and measure the voltage. Compare this reading to the
voltage rating on the compressor and starter nameplates.
3. Compare the ampere rating on the starter nameplate to
rating on the compressor nameplate. The overload trip
amps must be 108% to 120% of the rated load amps.
4. The starter for a centrifugal compressor motor must
contain the components and terminals required for PIC II
refrigeration control. Check the certified drawings.
5. Check the voltage to the following components and
compare it to the nameplate values: oil pump contact,
pumpout compressor starter, and power panel.
6. Ensure that fused disconnects or circuit breakers have
been supplied for the oil pump, power panel, and
pumpout unit.
7. Ensure all electrical equipment and controls are properly
grounded in accordance with job drawings, certified
drawings, and all applicable electrical codes.
8. Ensure the customer’s contractor has verified proper operation of the pumps, cooling tower fans, and associated
auxiliary equipment. This includes ensuring motors are
properly lubricated and have proper electrical supply and
proper rotation.
9. For field-installed starters only, test the chiller compressor motor and its power lead insulation resistance with a
500-v insulation tester such as a megohmmeter. (Use a
5000-v tester for motors rated over 600 v.) Factorymounted starters do not require a megohm test.
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
Carrier Comfort Network Interface — The Carrier
Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication
bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the
positive pins of the system element on either side of it. The
negative pins must be wired to the negative pins. The signal
ground pins must be wired to the signal ground pins. See installation manual.
NOTE: Conductors and drain wire must be 20 AWG
(American Wire Gage) minimum stranded, tinned copper.
Individual conductors must be insulated with PVC, PVC/
nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester
100% foil shield and an outer jacket of PVC, PVC/nylon,
chrome vinyl, or Teflon with a minimum operating temperature range of –4 F to 140 F (–20 C to 60 C) is required. See
table below for cables that meet the requirements.
MANUFACTURER
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:
If the motor starter is a solid-state starter, the motor leads
must be disconnected from the starter before an insulation
test is performed. The voltage generated from the tester can
damage the starter solid-state components.
SIGNAL TYPE
b. With the tester connected to the motor leads, take
10-second and 60-second megohm readings as
follows:
6-Lead Motor — Tie all 6 leads together and test
between the lead group and ground. Next tie the
leads in pairs: 1 and 4, 2 and 5, and 3 and 6. Test
between each pair while grounding the third pair.
3-Lead Motor — Tie terminals 1, 2, and 3 together
and test between the group and ground.
c. Divide the 60-second resistance reading by the
10-second reading. The ratio, or polarization
index, must be one or higher. Both the 10- and
60-second readings must be at least 50 megohms.
If the readings on a field-installed starter are unsatisfactory, repeat the test at the motor with the
power leads disconnected. Satisfactory readings in
this second test indicate the fault is in the power
leads.
NOTE: Unit-mounted starters do not have to be
megohm tested.
10. Tighten all wiring connections to the plugs on the ISM
and CCM modules.
+
Ground
–
CCN BUS
CONDUCTOR
INSULATION
COLOR
Red
White
Black
CCN TERMINAL
CONNECTION
RED (+)
WHITE (G)
BLACK (–)
Check Starter
BE AWARE that certain automatic start arrangements can
engage the starter. Open the disconnect ahead of the starter
in addition to shutting off the chiller or pump.
Use the instruction and service manual supplied by the starter manufacturer to verify the starter has been installed correctly, to set up and calibrate the starter, and for complete troubleshooting information.
The main disconnect on the starter front panel may not
deenergize all internal circuits. Open all internal and
remote disconnects before servicing the starter.
54
MECHANICAL STARTER
1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection.
2. Check the contactor(s) to ensure they move freely. Check
the mechanical interlock between contactors to ensure
that 1S and 2M contactors cannot be closed at the same
time. Check all other electro-mechanical devices, such as
relays, for free movement. If the devices do not move
freely, contact the starter manufacturer for replacement
components.
3. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through a
complete and proper start cycle.
BENSHAW, INC. RediStart MICRO™ SOLID-STATE
STARTER
powered, the CVC/ICVC 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 II and is powered through a contactor in the power panel.
Starters contain a separate circuit breaker to power the heater
and the control circuit. This arrangement allows the heater to
energize when the main motor circuit breaker is off for service
work or extended shutdowns. The oil heater relay status (OIL
HEATER RELAY) can be viewed on the COMPRESS table on
the CVC/ICVC. Oil sump temperature can be viewed on the
CVC/ICVC default screen.
SOFTWARE VERSION — The software part number is labeled on the backside of the CVC/ICVC module. The software
version also appears on the CVC/ICVC configuration screen as
the last two digits of the software part number.
Software Configuration
This equipment is at line voltage when AC power is connected. Pressing the STOP button does not remove voltage.
Do not operate the chiller before the control configurations
have been checked and a Control Test has been
satisfactorily completed. Protection by safety controls cannot be assumed until all control configurations have been
confirmed.
1. Ensure all wiring connections are properly terminated to
the starter.
2. Verify the ground wire to the starter is installed properly
and is sufficient size.
3. Verify the motors are properly grounded to the starter.
4. Verify the proper ac input voltage is brought into the starter according to the certified drawings.
5. Apply power to the starter
VFD STARTER
1. Turn off unit, tag and lock disconnects and wait 5 minutes.
2. Verify that the DC voltage is zero.
3. Ensure there is adequate clearance around the drive.
4. Verify that the wiring to the terminal strip and power terminals is correct.
5. Verify that wire size is within the terminal specification
and the wires are secure.
6. Inspect the field supplied branch circuit protection is
properly rated and installed.
7. Verify that the system is properly grounded.
8. Inspect all liquid cooling connections for leaks.
As the 19XR unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-16, provides a list for configuration values.
Input the Design Set Points — Access the CVC/
ICVC set point screen and view/modify the base demand limit
set point, and either the LCW set point or the ECW set point.
The PIC II can control a set point to either the leaving or entering chilled water. This control method is set in the EQUIPMENT SERVICE (TEMP_CTL) table.
Input the Local Occupied Schedule (OCCPC01S) —
Access the schedule OCCPC01S screen on the CVC/ICVC
and set up the occupied time schedule according to the customer’s requirements. If no schedule is available, the default is factory set for 24 hours occupied, 7 days per week including
holidays.
For more information about how to set up a time schedule,
see the Controls section, page 10.
The CCN Occupied Schedule (OCCPC03S) should be configured if a CCN system is being installed or if a secondary
time schedule is needed.
NOTE: The default CCN Occupied Schedule OCCPC03S is
configured to be unoccupied.
Oil Charge — The oil charge for the 19XR compressor depends on the compressor Frame size:
• Frame 2 compressor — 5 gal (18.9 L)
• Frame 3 compressor — 8 gal (30 L)
• Frame 4 compressor — 10 gal (37.8 L)
• Frame 5 compressor — 18 gal (67.8 L)
The chiller is shipped with oil in the compressor. When the
sump is full, the oil level should be no higher than the middle
of the upper sight glass, and minimum level is the bottom
of the lower sight glass (Fig. 2). If oil is added, it must meet
Carrier’s specification for centrifugal compressor use as described in the Oil Specification section. Charge the oil through
the oil charging valve located near the bottom of the transmission housing (Fig. 2). The oil must be pumped from the oil
container through the charging valve due to higher refrigerant
pressure. The pumping device must be able to lift from 0 to
200 psig (0 to 1380 kPa) or above unit pressure. Oil should
only be charged or removed when the chiller is shut down.
Input Service Configurations — The following configurations require the CVC/ICVC screen to be in the SERVICE portion of the menu.
• password
• input time and date
• CVC/ICVC configuration
• service parameters
• equipment configuration
• automated control test
PASSWORD — When accessing the SERVICE tables, a password must be entered. All CVC/ICVC are initially set for a
password of 1-1-1-1.
INPUT TIME AND DATE — Access the TIME AND DATE
table on the SERVICE menu. Input the present time of day,
date, and day of the week. The HOLIDAY TODAY parameter
should only be configured to YES if the present day is a
holiday.
Power Up the Controls and Check the Oil
Heater — Ensure that an oil level is visible in the compressor before energizing the controls. A circuit breaker in the starter energizes the oil heater and the control circuit. When first
55
address for each chiller if there is more than one chiller at the
jobsite. Write the new address on the CVC/ICVC module for
future reference.
INPUT EQUIPMENT SERVICE PARAMETERS IF NECESSARY — The EQUIPMENT SERVICE table has six
service tables.
Configure SERVICE Tables — Access the SERVICE tables,
shown in Table 2, to modify or view job site parameters:
NOTE: Because a schedule is integral to the chiller control
sequence, the chiller will not start until the time and date have
been set.
CHANGE CVC/ICVC CONFIGURATION IF NECESSARY — From the SERVICE table, access the CVC/ICVC
CONFIGU-RATION screen. From there, view or modify the
CVC/ICVC CCN address, change to English or SI units, and
change the password. If there is more than one chiller at the
jobsite, change the CVC/ICVC address on each chiller so that
each chiller has its own address. Note and record the new
address. Change the screen to SI units as required, and change
the password if desired.
TO CHANGE THE PASSWORD — The password may be
changed from the CVC/ICVC CONFIGURATION screen.
1. Press the MENU and SERVICE softkeys. Enter the
current password and highlight CVC/ICVC CONFIGURATION. Press the SELECT softkey. Only the last
5 entries on the CVC/ICVC CONFIG screen can be
changed: BUS #, ADDRESS #, BAUD RATE, US IMP/
METRIC, and PASSWORD.
2. Use the ENTER softkey to scroll to PASSWORD. The
first digit of the password is highlighted on the screen.
3. To change the digit, press the INCREASE or
DECREASE softkey. When the desired digit is seen,
press the ENTER softkey.
4. The next digit is highlighted. Change it, and the third and
fourth digits in the same way the first was changed.
5. After the last digit is changed, the CVC/ICVC goes to the
BUS parameter. Press the EXIT softkey to leave that
screen and return to the SERVICE menu.
PARAMETER
Starter Type
Motor Rated Line
Voltage
Volt Transformer
Ratio
Motor Rated
Load Amps
Motor Locked
Rotor Trip
Starter LRA
Rating
Motor Current
CT Ratio
Ground Fault
Current
Transformers
Ground Fault
CT Ratio
Single Cycle
Dropout
Line Frequency
Be sure to remember the password. Retain a copy
for future reference. Without the password, access to the
SERVICE menu will not be possible unless the CVC/
ICVC_PSWD menu on the STATUS screen is accessed by
a Carrier representative.
Line Frequency
Faulting
Surge Limiting or
Hot Gas Bypass
Option
Minimum Load
Points (T1, P1)
TO CHANGE THE CVC/ICVC DISPLAY FROM
ENGLISH TO METRIC UNITS — By default, the CVC/
ICVC displays information in English units. To change to metric units, access the CVC/ICVC CONFIGURATION screen:
1. Press the MENU and SERVICE softkeys. Enter the
password and highlight CVC/ICVC CONFIGURATION.
Press the SELECT softkey.
2. Use the ENTER softkey to scroll to US IMP/METRIC.
3. Press the softkey that corresponds to the units desired for
display on the CVC/ICVC (e.g., US or METRIC).
CHANGE LANGUAGE (ICVC Only) — By default, the
ICVC displays information in English. To change to another
Language, access the ICVC CONFIGURATION screen:
1. Press the MENU and SERVICE softkeys. Enter the
password and highlight ICVC CONFIGURATION. Press
the SELECT softkey.
2. Use the ENTER softkey to scroll to LID LANGUAGE.
3. Press the INCREASE or DECREASE softkey until the
desired language is displayed. Press ENTER to confirm
desired language.
MODIFY CONTROLLER IDENTIFICATION IF NECESSARY — The CVC/ICVC module address can be changed
from the CVC/ICVC CONFIGURATION screen. Change this
Full (Maximum)
Load Points (T2, P2)
Chilled Medium
Evaporator
Refrigerant
Trippoint
Evaporator Flow
Delta P Cutout
TABLE
ISM_CONF — Select 0 for full voltage, 1 for
reduced voltage, or 2 for solid state/variable frequency drive.
ISM_CONF — Motor rated voltage from chiller
information nameplate.
ISM_CONF — Enter ratio (reduced to a ratio to
1) of power transformer wired to terminal J3 of
ISM. If no transformer is used enter 1.
ISM_CONF — Per chiller identification nameplate data.
ISM_CONF — Per chiller identification nameplate data. Enter locked rotor delta amps (LR
AMPS D-).
ISM_CONF — Enter value from nameplate in
starter cabinet
Allen -Bradley this appears as “max locked rotor
current @100% nom. voltage.”
Benshaw Starters: value is entered as 9999.
ISM_CONF — Enter ratio (reduced to a ratio to
1) of current transformers wired to terminal J4 of
ISM. For Benshaw Inc. RediStart MICRO™
Starters set to 100.
ISM_CONF — Enter 0 if no ground fault CTs are
wired to terminal J5 of ISM. Enter 1 if ground
fault CTs are used.
ISM_CONF — Enter ratio (reduced to a ratio to
1) of ground fault CT.
ISM_CONF — ENABLE if motor protection
required from drop in line voltage within one
cycle.
ISM_CONF — Enter YES for 60 Hz or NO for 50
Hz.
ISM_CONF — ENABLE if motor
protection required for drop in line
frequency.
OPTIONS — Enter 1 if HGBP is installed.
OPTIONS — Per Chiller Requisition (DT1, DP2)
if available or per job data — See modify load
points section.
OPTIONS — Per Chiller Requisition (DT2, DP2)
if available or per job data — See modify load
points section. For VFD units refer to table
located in control panel.
SETUP1 — Enter water or brine.
SETUP1 — Usually 3° F (1.7° C) below design
refrigerant temperature.
SETUP1 — Per Chiller Requisition if available or
enter 50% of design pressure drop to 0.5 psi (3.4
kPa).*
Condenser Flow
SETUP1 — Per Chiller Requisition if available or
Delta P Cutout
enter 50% of design pressure drop to 0.5 psi (3.4
kPa).*
Diffuser Option
SETUP2 — ENABLE for 4 and 5 size compres(Compressors with Split sor. See model number nomenclature.
Ring Diffusers)
SETUP2 — Enter diffuser actuator full span mA
Diffuser Full Span
rating for 4 and 5 size compressor. Value is
mA Rating
(Compressors with Split located on label on side of diffuser actuator
motor.
Ring Diffusers)
Motor Rated
RAMP_DEM — Enter value from chiller requisiKilowatts
tion form (product data submittal) if kilowatt ramp
demand is enabled.
*With variable flow systems this point may be configured to the lower end of
the range.
NOTE: Other parameters: Screens are normally left at the default settings; they
may be changed by the operator as required. The time and persistence settings on the ISM_CONF table can be adjusted to increase or decrease the sensitivity to a fault condition. Increasing time or persistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault condition.
56
CHANGE THE BENSHAW INC., RediStart MICRO™
SOFTWARE CONFIGURATION IF NECESSARY — Benshaw starter configurations are checked and modified from the
menus in the Benshaw Redistart MICRO Default Display. See
Fig. 32 and Table 6 for default display and menu items. To access the menus to perform checks and modifications, the Benshaw starter must be powered up and its self-test must have
been successfully completed. The self-test takes place automatically after power-up. Current transformer ratio configurations
and hardware switch settings checks are performed in the
MENU1 display screen. See Table 7 for menu structure and
Table 8 for switch settings.
1. Press the MENU softkey until the desired menu is selected on the display.
2. Press the ENTER softkey to access the displayed menu
items (Table 6).
To view other settings and troubleshooting guide consult the
Benshaw RediStart MICRO instructional manual included in
the starter.
DISPLAY
RediStart MICRO
STOP
READY
SCROLL UP
I = OA
V = 461V
MENU
SCROLL DOWN
3. Use the ↓ or ↑ arrow keys to scroll between menu
items until the desired item is reached on the display.
4. Press the ENTER softkey to access the value to be
changed.
MENU
SELECTION
FAULT
RESET
ENTER
MENU ENTRY
DATA ENTRY
Fig. 32 — Benshaw RediStart
MICRO Default Display
5. Use the ↑ or ↓ arrow keys to adjust the new displayed
value. The ↑ key increases the value while the ↓ key
decreases the value. Holding the arrow key will progressively increase the rate of change. The value will stop
changing when either the factory set minimum or maximum value is reached. To make fine adjustments press
and release the arrow key.
6. When the correct value has been selected, press the
ENTER key to store the new configuration. At this
point, there are two options. The MENU key will return
the display to the main display. The ↑ or ↓ arrow keys
will move the display to the next menu item. When finished press the MENU key to return to the main display.
Table 6 — Benshaw RediStart
MICRO Menu Structure
MENU 1
Starter Setup
MENU 2
Meter Setup
Initial Current
as % RLA
Max. Cur
As% LRA
Ramp Time
(sec.)
CT Ratio: 1
Meter #1
display
Meter #2
display
MENU 3
Event
Recorder
Events 1-99
MENU 4
Dry Run
Mode
Dry Run
Mode
Table 7 — Benshaw RediStart MICRO Menu Items*
DESCRIPTION
INITIAL CURRENT
MAX. CURR AS % LRA
RAMP TIME
CT RATIO
RANGE
50-300
30-70
5-30
2640-5760
UNITS
%
%
SEC
DEFAULT
125
55
15
Enter Value from Table 8.
*These values are not displayed in the ISM_CONFIG table.
Table 8 — Benshaw RediStart MICRO Current Transformer DIP Switch Settings
CURRENT TRANSFORMER CT1-CT3
Starter
Frame Size
(Amps)
200 Amps
300 Amps
480 Amps
600 Amps
740 Amps
1250 Amps
Motor
RLA Range
(Amps)
CT
Ratio
95- 135 Amps
136- 200 Amps
201- 231 Amps
232- 300 Amps
301- 340 Amps
341- 480 Amps
481- 580 Amps
581- 600 Amps
601- 740 Amps
741- 855 Amps
856-1250 Amps
3900:1
5760:1
2640:1
3900:1
3900:1
5760:1
2640:1
3900:1
3900:1
3900:1
5760:1
LEGEND
CT — Current Transformer
57
MIcro Power Card (BIPCMIPWR-C4)
Overload Switch Settings
SW1-1
SW1-2
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
VERIFY VFD CONFIGURATION
PARAMETERS IF NECESSARY
AND
Accessing Password Protected Parameters — Although the
VFD controller has been preconfigured as the factory, the user
will need to be able to access the parameters to verify the job
specific parameters are correct, tune the controller or correct a
problem. The two passwords protecting the VFD configuration
are Parameter Set Display password and Program Disable
password. The Parameter Set Display password restricts viewing. P.nnn parameters above 007 and all H.nnn and R.nnn
screens. The password can be accessed at parameter P.006 and
will switch between enabled and disabled each time the password 107 is entered. The Program Disable password restricts
the changing of the drive parameter set. To enable or disable
changes select parameter P.051 and enter the password 26.
NOTE: Some of the parameters can be changed only when the
drive is stopped.
CHANGE
IMPORTANT: The VFD controller has been factory configured for use and communications to the Chiller Visual
Controller/International Chiller Visual Controller (CVC/
ICVC). Some parameters are specific to the chiller configuration and will need to be verified prior to operation.
Speed control and starting the drive have been disabled at
the VFD keypad. All command functions must be initiated
from the CVC/ICVC.
Using the Keypad — The keypad display is used to monitor,
view fault history and adjust the program of the VFD
microprocessor. It operates in two modes: Monitor mode and
Program mode:
Use the ↑ and ↓ keys to:
• Step through the drive parameter menus and error log
when the keypad/display is in Program mode.
• Increase or decrease a numeric value such as the reference or parameter value.
• Hold down these keys to increase the scroll speed.
Use the ENTER softkey to:
• Display a parameter or a selection value in Program
mode.
• Save a value.
• Move through each monitor display item when in Monitor mode.
Monitor Mode (Default Mode) — Specific drive conditions
may be monitored on the keypad when in this mode. An LED
will be illuminated next to the description of what is displayed
on the keypad. Use the ENTER softkey to scroll through and
monitor the following selections:
• All LEDs on — Speed request from the CVC/ICVC
• Motor Speed
• Output Frequency
• Output Voltage
• Output Current
Program Mode — This mode displays and modifies the configuration parameters of the VFD microprocessor. Particular
parameters, parameter numbers, and error log information can
be displayed when in Program mode.
Press the PROGRAM softkey until the PROGRAM LED is
illuminated to enter the Program mode.
It is the operator’s responsibility to distribute access to the
passwords. Carrier is not responsible for unauthorized
access violations within the operator’s organization. Failure
to observe this warning could result in bodily injury.
See the Initial Start-Up Checklist section for VFD Job Specific
Configuration table. For job specific parameters see inside of
the VFD enclosure door, next to the keypad. Refer to the VFD
Configuration table for the entire list of parameters.
Restoring the default parameter P.050 will require all the
Carrier default parameters to be restored manually.
VFD CHILLER FIELD SET UP AND VERIFICATION
Label Locations — Verify the following labels have been
installed properly and match the chiller requisition:
• Surge parameters — Located inside the control panel.
• Chiller identification nameplate — Located on the right
side of the control panel.
• VFD Parameter — Located to the right of the VFD controller keypad on the VFD module.
• VFD Nameplate — Located on the right side of the VFD
as viewed from its front.
• Record all nameplate information on the Reliance Configuration sheet.
Drive Protection and Other Incoming Wiring
1. Verify that the branch disconnects or other local disconnects are open and properly tagged out.
2. Verify that the branch circuit protection and AC input
wiring to the VFD are in accordance with NEC/CEC
(National Electrical Code/California Energy Commission) and all other local codes.
3. Verify that the fuses are per the field wiring diagram.
4. Verify that the incoming source does not exceed 85 kA.
5. Verify the power lugs in the VFD and branch protection
are properly secured. Inspect the ground cable and ensure
it is properly connected at the branch and to the ground
lug in the VFD.
6. Verify the conduit for the power wiring in securely connected to the VFD flanged cover and runs continuously to
the branch protection.
7. Verify that the incoming and outgoing wires have been
properly connected inside of the reactor enclosure if a
separate line reactor has been added to the chiller.
8. Ensure the control and signal wires connected to the chiller controller or the VFD are in separate conduit.
Use the ↑ and ↓ keys to move through the menus
Press ENTER softkey to select the desired menu.
Press ↑ and
P.nnn
U.nnn
H.nnn
R.nnn
E.nnn
↓ keys to move through following parameters.
— General Parameters
— Vector Control Parameters*
— Volts/Hertz Control Parameters
— RMI Remote Monitor Interface
Parameters
— Error Log (See fault codes)
*Vector control is not used in this configuration.
Press ENTER softkey to select a parameter menu screen.
Press ↑ and ↓ keys to adjust the selected parameter.
Press the PROGRAM softkey until the PROGRAM LED
turns off to exit the program.
Changing parameters may adversely affect chiller
operation.
58
Configure Chiller Visual Controller Parameter — The chiller
controller must have its job specific parameters set as defined
by the job sheet or installed nameplates. Below are the job specific parameters that must be set:
To access the ISM_CONF screen:
1. Press ENTER .
2. Press SERVICE .
3. Enter the password 1111.
4. Select ISM (CONFIG STARTER DATA)
5. Scroll down and select the ISM_CONF DATA screen to
modify or view the ISM parameters:
VFD Cooling System Leak Inspection
1. Check for leaks on the refrigerant cooling flange connections to the VFD enclosure.
2. Check for leaks on all tubing internal to the VFD enclosure, the tubing flair connection to the VFD module and
the TXV valve.
3. Verify that the VFD refrigerant cooling system TXV
valve control bulb is securely inserted into the VFD drive
module heat sink.
Power Up Verification
1. Inspect control wiring inside the VFD and verify the integrity of the connections between the integrated starter
module (ISM) and the VFD module.
2. Close the control power switch in the VFD enclosure.
3. Close the oil pump power switch inside the VFD
enclosure.
4. Verify the VFD disconnect switch is in the open position.
5. Close and latch the doors of the VFD enclosure.
6. Apply power to the VFD enclosure. Remove lock outs
and close all disconnects.
7. Verify that the CVC/ICVC display powers up and goes to
the default screen.
8. Close the VFD disconnect switch.
9. Verify the following actions during the VFD start-up self
test:
• The display shows SELF and all LEDs are illuminated for 5 to 6 seconds.
• The display reads a 0 after the diagnosis is
complete.
• If Err is displayed a fault has been detected.
Perform manual reset by establishing a reset
through the small hole under the VFD Keypad. If
this does not correct the fault contact your Carrier
representative.
• If AR with a counting down number is displayed
wait for the number to count to 0 and the display
should then revert to a 0. If the counter starts over
at 30 contact Carrier representative.
Configure VFD Parameters — The VFD controller must have
job specific parameters set as defined by the component nameplates and labels. The parameters come preset by the factory,
but must be verified prior to start-up by accessing the PROGRAM MODE of the VFD controller keypad. For information
on how to access the VFD keypad see page 58.
Press the PROGRAM softkey to access the parameter
screen to modify or view the following job specific parameters:.
VFD
PARAMETER
P.004
P.006
P.028
H.000
H.001
H.002
H.021
H.022
TITLE
Maximum
Speed
Password
Speed
Display
Scaling
Motor
Voltage
Frequency
Motor
Amps
Line
Voltage
Over
Frequency
Limit
DESCRIPTION
STARTER TYPE
(2 = SS/VFD)
MOTOR RATED
LINE VOLTAGE
MOTOR RATED
LOAD AMPS
MOTOR LOCKED
ROTOR TRIP
STARTER LRA RATING
MOTOR CURRENT
CT RATIO:1
3 GRND FAULT CT?
(1=NO)
FREQUENCY-60HZ
(NO=50)
SETTING
2
VFD Nameplate Voltage.
VFD Nameplate Chiller Rated Load
Amps
Compressor Nameplate
600 for VFD
part #19XVR0414XXX
700 for VFD
part #19XVR0500XXX
900 for VFD
part #19XVR0643XXX
163
120 (414A)
NO
NO for 50 Hz selection
YES for 60 Hz selection
6. Press to the SAVE softkey to save changes.
7. Press the EXIT softkey to and exit the ISM Configuration Screen.
VFD Enable Configuration — To access the parameters:
1. Press MENU .
2. Press SERVICE .
3. Select EQUIPMENT SERVICE.
4. Scroll down and select SETUP2.
5. Verify the following parameters:
VFD OPTION
VFD CURRENT LIMIT
ENABLED
COMPRESSOR NAMEPLATE AMPS
Configure Surge Parameters
1. Press MENU .
2. Press SERVICE .
3. Select EQUIPMENT SERVICE and OPTIONS to verify
the following:
SETTING
Line Frequency selected. Per
Compressor Nameplate.
107
60 for 60 Hz selection and
50 for 50 Hz selection
DESCRIPTION
SURGE/HGBP
DELTA T1
SURGE/HGBP
DELTA P1
SURGE/HGBP
DELTA T2
SURGE/HGBP
DELTA P2
Compressor nameplate voltage.
Line Frequency selected. Per
Compressor Nameplate.
Compressor nameplate amps.
SETTINGS
Surge parameter label
Surge parameter label
Surge parameter label
Surge parameter label
VFD CONTROL VERFICATION (Non-Running) — In order
to verify and, if necessary, tune the speed control signal of the
chiller controller to the VFD (ISM terminal J8 1-2 labeled
4-20 mA OUT VFD) and the speed feedback signal from the
VFD to the chiller controller (ISM terminal J6 1-2 labeled
VFD HZ), follow the steps below.
Set TARGET VFD SPEED to 0%.
1. Press MENU .
VFD nameplate voltage.
69 for 60 Hz selection and
57 for 50 Hz selection.
59
2. Press STATUS .
3. Press COMPRESS .
4. Press SELECT .
5. Set TARGET VFD SPEED to 0%.
Verify that the ACTUAL VFD SPEED shown on the VFD display is within 0 to 1 Hz.
1. Press the ENTER softkey on the VFD keypad until all
LEDs on the left side of the keypad are illuminated.
NOTE: The value displayed is the frequency at which the
VFD is being commanded to operate.
2. Adjust VFD parameter P.009 (Input Offset) if outside the
tolerance.
To confirm that the speed signal from the CVC/ICVC
corresponds to the value displayed at the VFD:
3. Verify that the actual speed signal feedback to the chiller
controller is 0% by accessing the COMPRESS screen.
4. Verify ACTUAL SPEED VFD is 0%-1% on CVC/ICVC.
5. Adjust VFD parameter r.002 (Analog Output Offset) if
outside the tolerance.
Set VFD TARGET VFD SPEED to 100%.
1. Press MENU .
2. Press STATUS .
3. Press COMPRESS .
4. Press SELECT .
5. Set TARGET VFD SPEED to 100%.
Verify that the ACTUAL VFD SPEED shown on the VFD display corresponds to the 50 Hz or 60 Hz setting.
1. Check the ACTUAL VFD SPEED configuration (50 Hz
or 60 Hz) on the ISM_CONF screen.
2. Confirm that the VFD displays the configured line frequency within ± 1 Hz.
3. Adjust parameter P.010 (Input Gain) if outside the
tolerance.
4. Release the TARGET VFD SPEED so that it can operate
in automatic mode. (Refer to Override Operations section
on page 16.)
VFD CONTROL VERIFICATION (Running)
Preparation
1. Disconnect power to the VFD. Verify that the branch disconnects or other local disconnects are open and properly
tagged out.
2. Connect a voltmeter and ampmeter to the line side of the
VFD. Locate meters safely away from the power cables.
3. Reconnect power to the VFD.
4. Measure the voltage on the line side of the drive.
5. Verify it is within 10% of the chiller nameplate voltage.
6. Set up the CVC/ICVC temperature controller per the requirements of the job.
7. Start the chiller and verify the rotation of the compressor
just as it starts.
8. Allow the chiller to load up. Verify that the chiller loads
up smoothly.
NOTE: One or two surges may be counted during the first
minute of operation.
Verify That Actual VFD Speed is 100% (±2%)
1. Set the VFD speed to 100%.
2. Verify that the ACTUAL VFD SPEED is 100% (± 2%).
3. If outside the tolerance, adjust r.003 (Output Analog
Gain).
4. Leave running for the next test.
ISM Current Calibration Check
1. With the target VFD speed at 100%, load the chiller so
that the CVC/ICVC default display shows 75% to 100%
under the display title AMPS %. A higher load is
preferred.
2. Measure the incoming current with a separate amp meter.
3. Calculate the line side error ratio using the following
equation:
Amp Meter current – Ave. ISM current
Amp Meter current
4. If the Line Side Error Ratio is greater than ± 0.02 adjust
the CVC/ICVC reading by adjusting the ISM CT
ratio.
5. Shut down the chiller.
Change CT Ratio
1. New CT Ratio = Present CT Ratio multiplied by (1+ Line
Side Error Ratio).
To access the ISM_CONF screen:
2. Press ENTER .
3. Press SERVICE .
4. Enter the password 1111.
5. Select ISM (STARTER) CONFIG DATA.
6. Enter password 4444.
7. Select ISM_CONF.
8. Change present CT ratio to new ratio using calculation
above.
9. Press to the SAVE softkey to save changes.
10. Press the EXIT softkey to exit the ISM_CONF screen.
11. Repeat ISM Current Calibration Check.
VFD Current Control Calibration Check
1. With the target VFD speed at 100%, load the chiller so
that the CVC/ICVC default display shows 75% to 100%
under the display title AMPS %. A higher load is
preferred.
2. Access the current on the keypad of the VFD. Determine
the Load Side Current Ratio, using the equation below.
Load Side Current Ratio =
VFD Actual Load Amps
Motor Nameplate Amps
Next, access the VFD Load Factor on the Capacity Control screen. Calculate the Load Side Error Ratio using the
equation below:
Load Side
VFD Load Factor – Load Side Current Ratio
Error Ratio =
Load Side Current Ratio
3. If the load side error ratio is greater than ± 0.02, adjust the
VFD load factor by changing the VFD current limit on
the Setup 2 screen.
a. The new VFD current limit = old VFD current
limit multiplied by (1+ Load Side Error Ratio).
b. Recheck the VFD Current Control Calibration.
c. Release the Speed Control by accessing the TARGET VFD SPEED control.
Press MENU .
Press STATUS .
Press COMPRESS .
(Refer to Override Operations section on page 16.)
60
Calculate Minimum Load — To calculate the minimum load
conditions, estimate the temperature difference the cooler will
have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated
pressure and temperature for the particular refrigerant used.
Suction Temperature:
43 F (6.1 C) = 38 psig (262 kPa) saturated
refrigerant pressure (HFC-134a)
Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated
refrigerant pressure (HFC-134a)
Minimum Load ∆T1 (at 20% Load): 2 F (1.1 C)
Minimum Load ∆P1:
71 – 38 = 33 psid (490 – 262 = 228 kPad)
Protecting the VFD Configuration
1. Select parameter P.051 from the VFD keypad.
2. Press the ENTER softkey to access the parameter. A
zero will be displayed.
3. Use the ↑ arrow key to increment the value to 26. This is
the password number.
4. Press the ENTER softkey to save the value. P.051 will
by displayed.
NOTE: Parameter programming is disabled when the
PASSWORD LED is on and enabled when the PASSWORD LED is off.
5. Select parameter P.006 from the VFD Keypad.
6. Press the ENTER softkey to access the parameter.
7. Use the ↑ arrow key to increment the value to 107. This
is the password number to restrict displaying the remaining P, and all of the H and r parameters.
8. Press the ENTER softkey to save the value.
Modify Minimum and Maximum Load Points (∆T1/P1; ∆T2/
P2) If Necessary — These pairs of chiller load points, located
on the OPTIONS screen, determine when to limit guide vane
travel or open the hot gas bypass valve when surge prevention
is needed. These points should be set based on individual
chiller operating conditions.
A label that lists the configuration values of the controls is
located on the inside of the unit’s control panel. These values
are based upon the original selection of the chiller. Jobsite conditions may require a slight modification to these parameters.
If after configuring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed by the operator.
An example of such a configuration is shown below.
Refrigerant: HCFC-134a
Estimated Minimum Load Conditions:
44 F (6.7 C) LCW
45.5 F (7.5 C) ECW
43 F (6.1 C) Suction Temperature
70 F (21.1 C) Condensing Temperature
Estimated Maximum Load Conditions:
44 F (6.7 C) LCW
54 F (12.2 C) ECW
42 F (5.6 C) Suction Temperature
98 F (36.7 C) Condensing Temperature
Calculate Maximum Load — To calculate the maximum load
points, use the design load condition data. If the chiller full load
cooler temperature difference is more than 15 F (8.3 C), estimate the refrigerant suction and condensing temperatures at
this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.
Suction Temperature:
42 F (5.6 C) = 37 psig (255 kPa) saturated
refrigerant pressure (HFC-134a)
Condensing Temperature:
98 F (36.7 C) = 120 psig (1827 kPa) saturated
refrigerant pressure (HFC-134a)
Maximum Load ∆T2:
54 – 44 = 10º F (12.2 – 6.7 = 5.5º C)
Maximum Load ∆P2:
120 – 37 = 83 psid (827 – 255 = 572 kPad)
To avoid unnecessary surge prevention, add about 10 psid
(70 kPad) to ∆P2 from these conditions:
∆T2 = 10º F (5.5º C)
∆P2 = 93 psid (642 kPad)
Again, to avoid unnecessary surge prevention, add 20 psid
(140 kPad) at ∆P1 from these conditions:
∆T1 = 2 F (1.1 C)
∆P1 = 53 psid (368 kPad)
If surge prevention occurs too soon or too late:
LOAD
At low loads
(<50%)
SURGE PREVENTION SURGE PREVENTION
OCCURS TOO SOON
OCCURS TOO LATE
Increase P1 by
Decrease P1 by
2 psid (14 kPad)
2 psid (14 kPad)
At high loads Increase P2 by
2 psid (14 kPad)
(>50%)
Decrease P2 by
2 psid (14 kPad)
The differential pressure (∆P) and temperature (∆T) can be
monitored during chiller operation by viewing ACTIVE
DELTA P and ACTIVE DELTA T (HEAT_EX screen). Comparing SURGE/HGBP DELTA T to ACTIVE DELTA T will determine when the SURGE PREVENTION function will occur.
The smaller the difference between the SURGE/HGBP DELTA
T and the ACTIVE DELTA T values, the closer to surge
prevention.
Units with VFD — On units with VFD further adjustments can
be made if response to surge prevention or protection is not
functioning as desired. VFD GAIN and VFD INCREASE STEP
can be adjusted to allow for more aggressive changes in speed
when surge prevention or protection is active.
CONFIGURE DIFFUSER CONTROL IF NECESSARY — If the compressor is equipped with a variable diffuser, (size 5 compressor) access the SETUP2 screen. Scroll to
DIFFUSER CONTROL and press the ENABLE softkey.
Compare the diffuser and guide vane values (GUIDE VANE
25% LOAD PT, GUIDE VANE 50% LOAD PT, GUIDE VANE
75% LOAD PT, DIFFUSER 25% LOAD POINT, DIFFUSER
50% LOAD POINT, DIFFUSER 75% LOAD POINT) to the
values located on the label inside the control panel. See
Fig. 12.
Compressors with variable diffuser control have actuators
tested and stamped with the milliamp (mA) value that results in
100% actuator rotation. This value is configured on the
SETUP2 screen. It is labeled DIFFUSER FULL SPAN mA.
MODIFY EQUIPMENT CONFIGURATION IF NECESSARY — The EQUIPMENT SERVICE table has screens to
select, view, or modify parameters. Carrier’s certified drawings
have the configuration values required for the jobsite. Modify
these values only if requested.
SERVICE Screen Modifications — Change the values on
these screens according to specific job data. See the certified
drawings for the correct values. Modifications can include:
• chilled water reset
• entering chilled water control (Enable/Disable)
• 4 to 20 mA demand limit
• auto restart option (Enable/Disable)
• remote contact option (Enable/Disable)
61
Owner-Modified CCN Tables — The following EQUIPMENT CONFIGURATION screens are described for reference only.
OCCDEFCS — The OCCDEFCS screen contains the Local
and CCN time schedules, which can be modified here or on the
SCHEDULE screen as described previously.
HOLIDAYS — From the HOLIDAYS screen, the days of the
year that holidays are in effect can be configured. See the holiday paragraphs in the Controls section for more details.
BRODEF — The BRODEF screen defines the start and end of
daylight savings time. Enter the dates for the start and end of
daylight savings if required for your location. BRODEF also
activates the Broadcast function which enables the holiday
periods that are defined on the CVC/ICVC to take effect.
Other Tables — The CONSUME, NET_OPT, and RUNTIME screens contain parameters used with a CCN system.
See the applicable CCN manual for more information on these
screens. These tables can only be defined from a CCN Building Supervisor.
COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION
(Optional with ICVC inputs available) — Calibration can be
checked by comparing the pressure readings from the
transducer to an accurate refrigeration gage reading. These
readings can be viewed or calibrated from the HEAT_EX
screen on the CVC/ICVC. The transducer can be checked and
calibrated at 2 pressure points. These calibration points are
0 psig (0 kPa) and between 25 and 250 psig (173 and
1724 kPa). To calibrate these transducers:
1. Shut down the compressor, cooler, and condenser pumps.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its Schrader
fitting for cooler or condenser transducer calibration. For
oil pressure or flow device calibration keep transducer in
place.
NOTE: If the cooler or condenser vessels are at 0 psig
(0 kPa) or are open to atmospheric pressure, the transducers can be calibrated for zero without removing the transducer from the vessel.
3. Access the HEAT_EX screen and view the particular
transducer reading (the EVAPORATOR PRESSURE or
CONDENSER PRESSURE parameter on the HEAT_EX
screen). To calibrate oil pressure or waterside flow device, view the particular reading (CHILLED WATER
DELTA P and CONDENSER WATER DELTA P on the
HEAT_EX screen and OIL PUMP DELTA P on the
COMPRESS screen). It should read 0 psi (0 kPa). If the
reading is not 0 psi (0 kPa), but within ±5 psi (35 kPa),
the value may be set to zero by pressing the SELECT
softkey while the appropriate transducer parameter is
highlighted on the CVC/ICVC screen. Then press the
ENTER softkey. The value will now go to zero. No high
end calibration is necessary for OIL PUMP DELTA P or
flow devices.
If the transducer value is not within the calibration range,
the transducer returns to the original reading. If the pressure is within the allowed range (noted above), check the
voltage ratio of the transducer. To obtain the voltage ratio,
divide the voltage (dc) input from the transducer by the
supply voltage signal (displayed in CONTROL TEST
menu in the CCM PRESSURE TRANSDUCERS
screen) or measure across the positive (+ red) and negative (– black) leads of the transducer. For example, the
condenser transducer voltage input is measured at CCM
terminals J2-4 and J2-5. The voltage ratio must be between 0.80 and 0.11 for the software to allow calibration.
Rotate the waterside flow pressure device from the inlet
nozzle to the outlet nozzle and repeat this step. If rotating
the waterside flow device does not allow calibration then
pressurize the transducer until the ratio is within range.
Then attempt calibration again.
4. A high pressure point can also be calibrated between 25
and 250 psig (172.4 and 1723.7 kPa) by attaching a regulated 250 psig (1724 kPa) pressure (usually from a nitrogen cylinder). The high pressure point can be calibrated
by accessing the appropriate transducer parameter on the
HEAT_EX screen, highlighting the parameter, pressing
the SELECT softkey, and then using the INCREASE
or DECREASE softkeys to adjust the value to the exact
pressure on the refrigerant gage. Press the ENTER softkey to finish the calibration. Pressures at high altitude locations must be compensated for, so the chiller temperature/pressure relationship is correct.
The PIC II does not allow calibration if the transducer is too
far out of calibration. In this case, a new transducer must be
installed and recalibrated.
Perform a Control Test — Check the safety controls
status by performing an automated control test. Access the
CONTROL TEST table and select a test to be performed function (Table 9).
The Automated Control Test checks all outputs and inputs
for function. In order to successfully proceed with the controls
test, the compressor should be off, no alarms showing, and voltage should be within ±10% of rating plate value. The compressor can be put in OFF mode by pressing the STOP push-button
on the CVC/ICVC. Each test asks the operator to confirm the
operation is occurring and whether or not to continue. If an error occurs, the operator can try to address the problem as the
test is being done or note the problem and proceed to the next
test.
NOTE: Enter guide vane calibration to calibrate guide
input on CCM (Plug J4 upper terminal 9 and 10).
NOTE: If during the control test the guide vanes do not open,
verify the low pressure alarm is not active. (An active low
pressure alarm causes the guide vanes to close.)
NOTE: The oil pump test will not energize the oil pump if
cooler pressure is below –5 psig (–35 kPa).
When the control test is finished or the EXIT softkey is
pressed, the test stops, and the CONTROL TEST menu displays. If a specific automated test procedure is not completed,
access the particular control test to test the function when ready.
The CONTROL TEST menu is described in the table below.
CCM Temperature Thermistors
CCM Pressure Transducers
Pump
Discrete outputs
Guide Vane
Diffuser Actuator*
Pumpdown/Lockout
Terminate Lockout
Guide Vane Calibration
Check of all thermistors.
Check of all transducers.
Checks operation of pump outputs;
pumps are activated. Also tests associated inputs such as flow or pressure.
Activation of all on/off outputs individually.
Check of the guide vane operation.
Check of the diffuser actuator.
Pumpdown prevents the low refrigerant
alarm during evacuation so refrigerant
can be removed form the unit. Also locks
the compressor off and starts the water
pumps.
To charge refrigerant and enable the
chiller to run after pumpdown lockout.
Calibrates guide vane input on CCM.
*Diffuser tests function only on size 4 and 5 compressor with diffuser control
enabled.
NOTE: During any of the tests, an out-of-range reading will have an asterisk
(*) next to the reading and a message will be displayed if you have diffuser
control enabled.
62
Check Optional Pumpout System Controls
and Compressor — Controls include an on/off switch,
High Altitude Locations — Because the chiller is initially calibrated at sea level, it is necessary to recalibrate the
pressure transducers if the chiller has been moved to a high altitude location. See the calibration procedure in the Troubleshooting Guide section.
a 3-amp fuse, the compressor overloads, an internal thermostat,
a compressor contactor, and a refrigerant high pressure cutout.
The high pressure cutout is factory set to open at 161 psig
(1110 kPa) and reset at 130 psig (896 kPa). Ensure the watercooled condenser has been connected. Loosen the compressor
holddown bolts to allow free spring travel. Open the compressor suction and discharge the service valves. Ensure oil is visible in the compressor sight glass. Add oil if necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 67 and
75, for details on the transfer of refrigerant, oil specifications,
etc.
Charge Refrigerant into Chiller
The transfer, addition, or removal of refrigerant in spring
isolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.
Table 9 — Control Test Menu Functions
TESTS TO BE
PERFORMED
1. CCM Thermistors
2. CCM Pressure
Transducers
3. Pumps
4. Discrete Outputs
5. Guide Vane Actuator
6. Diffuser Actuator
7. Pumpdown Lockout
DEVICES TESTED
Always operate the condenser and chilled water pumps
during charging operations to prevent freeze-ups.
Entering Chilled Water
Evaporator Refrigerant Temperature (ICVC only)
Leaving Chilled Water
Entering Condenser Water
Leaving Condenser Water
Remote Reset Sensor
Comp Discharge Temp
Oil Sump Temp
Comp Motor Winding Temp
Space Temperature 1
Space Temperature 2
Evaporator Pressure
Condenser Pressure
Oil Pump Delta P
Condenser Water Delta P
Transducer Voltage Ref
Chilled Water — Confirm pressure
Condenser Water — Confirm
Delta P
Oil Heater Relay
Hot Gas Bypass Relay
Tower Fan Relay Low
Tower Fan Relay High
Alarm Relay
Shunt Trip Relay
Open/Close
Open/Close
When using pumpdown/lockout,
observe freeze up precautions when
removing charge:
The standard 19XR chiller is shipped with the refrigerant
already charged in the vessels. However, the 19XR may be ordered with a nitrogen holding charge of 15 psig (103 kPa).
Evacuate the nitrogen from the entire chiller, and charge the
chiller from refrigerant cylinders.
CHILLER EQUALIZATION WITHOUT A PUMPOUT
UNIT
When equalizing refrigerant pressure on the 19XR chiller
after service work or during the initial chiller start-up, do
not use the discharge isolation valve to equalize. Either the
motor cooling isolation valve or the charging hose (connected between the pumpout valves on top of the cooler
and condenser) should be used as the equalization valve.
To equalize the pressure differential on a refrigerant isolated
19XR chiller, use the terminate lockout function of the CONTROL TEST on the SERVICE menu. This helps to turn on
pumps and advises the operator on proper procedures.
The following steps describe how to equalize refrigerant
pressure in an isolated 19XR chiller without a pumpout unit.
1. Access terminate lockout function on the CONTROL
TEST screen.
2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.
Instructs operator which valves to
close and when.
Starts chilled water and condenser
water pumps and confirms flows.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
pumpout procedures
3. Slowly open the refrigerant cooling isolation valve. The
chiller cooler and condenser pressures will gradually
equalize. This process takes approximately 15 minutes.
4. Once the pressures have equalized, the cooler isolation
valve, the condenser isolation valve, and the hot gas isolation valve may now be opened. Refer to Fig. 29 and 30,
for the location of the valves.
Turns pumps off after pumpdown.
8 Terminate Lockout
Locks out compressor.
Starts pumps and monitors flows.
Instructs operator which valves to
open and when.
Monitors
Evaporator pressure
Condenser pressure
Evaporator temperature during
charging process
Whenever turning the discharge isolation valve, be sure to
reattach the valve locking device. This prevents the valve
from opening or closing during service work or during
chiller operation.
Terminates compressor lockout.
63
Table 10 — Refrigerant (HFC-134a) Charge
CHILLER EQUALIZATION WITH PUMPOUT UNIT —
The following steps describe how to equalize refrigerant pressure on an isolated 19XR chiller using the pumpout unit.
1. Access the terminate lockout function on the CONTROL
TEST screen.
2. IMPORTANT: Turn on the chilled water and condenser water pumps to prevent freezing.
COOLER
CODE
10
11
12
15
16
17
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
3. Open valve 4 on the pumpout unit and open valves 1a and
1b on the chiller cooler and condenser, Fig. 29 and 30.
Slowly open valve 2 on the pumpout unit to equalize the
pressure. This process takes approximately 15 minutes.
4. Once the pressures have equalized, the discharge isolation valve, cooler isolation valve, optional hot gas bypass
isolation valve, and the refrigerant isolation valve can be
opened. Close valves 1a and 1b, and all pumpout unit
valves.
Whenever turning the discharge isolation valve, be sure to
reattach the valve locking device. This prevents the valve
from opening or closing during service work or during
chiller operation.
The full refrigerant charge on the 19XR will vary with chiller components and design conditions, as indicated on the job
data specifications. An approximate charge may be determined
by adding the condenser charge to the cooler charge as listed in
Table 10.
Always operate the condenser and chilled water pumps
whenever charging, transferring, or removing refrigerant
from the chiller.
REFRIGERANT
CHARGE
lb
kg
290
132
310
141
330
150
320
145
340
154
370
168
345
157
385
175
435
197
350
159
420
190
490
222
400
181
480
218
550
250
560
254
630
286
690
313
640
290
720
327
790
358
750
340
840
381
900
408
870
395
940
426
980
445
940
426
980
445
1020
463
1020
463
1060
481
1090
494
1220
553
1340
608
1440
653
1365
619
1505
683
1625
737
1500
680
1620
735
1730
785
1690
766
1820
825
1940
880
CONDENSER
CODE
10
11
12
15
16
17
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
REFRIGERANT
CHARGE
lb
kg
200
91
200
91
200
91
250
113
250
113
250
113
225
102
225
102
225
102
260
118
260
118
260
118
310
141
310
141
310
141
280
127
280
127
280
127
330
150
330
150
330
150
400
181
400
181
400
181
490
222
490
222
490
222
420
190
420
190
420
190
510
231
510
231
510
231
780
354
780
354
780
354
925
420
925
420
925
420
720
327
720
327
720
327
860
390
860
390
860
390
INITIAL START-UP
Use the CONTROL TEST terminate lockout function to
monitor conditions and start the pumps.
If the chiller has been shipped with a holding charge, the
refrigerant is added through the pumpout charging connection
(Fig. 29 and 30, valve 1b). First evacuate the nitrogen holding
charge from the chiller vessels. Charge the refrigerant as a gas
until the system pressure exceeds 35 psig (141 kPa) for
HFC-134a. After the chiller is beyond this pressure the refrigerant should be charged as a liquid until all the recommended
refrigerant charge has been added. The charging valve (Fig. 29
and 30, valve 7) can be used to charge liquid to the cooler if the
cooler isolation valve (11) is present and is closed. Do not
charge liquid through the linear float to the condenser.
TRIMMING REFRIGERANT CHARGE — The 19XR is
shipped with the correct charge for the design duty of the chiller. Trimming the charge can best be accomplished when the
design load is available. To trim the charge, check the temperature difference between the leaving chilled water temperature
and cooler refrigerant temperature at full load design conditions. If necessary, add or remove refrigerant to bring the
temperature difference to design conditions or minimum
differential.
Table 10 lists the 19XR chiller refrigerant charges for each
cooler and condenser code. Total refrigerant charge is the sum
of the cooler and condenser charge.
Preparation — Before starting the chiller, verify:
1. Power is on to the main starter, oil pump relay, tower fan
starter, oil heater relay, and the chiller control panel.
2. Cooling tower water is at proper level and at-or-below
design entering temperature.
3. Chiller is charged with refrigerant and all refrigerant and
oil valves are in their proper operating positions.
4. Oil is at the proper level in the reservoir sight glasses.
5. Oil reservoir temperature is above 140 F (60 C) or above
refrigerant temperature plus 50° F (28° C).
6. Valves in the evaporator and condenser water circuits are
open.
NOTE: If the pumps are not automatic, ensure water is
circulating properly.
Do not permit water or brine that is warmer than 110 F
(43 C) to flow through the cooler or condenser. Refrigerant
overpressure may discharge through the relief valves and
result in the loss of refrigerant charge.
7. Access the CONTROL TEST screen. Scroll down on the
TERMINATE LOCKOUT option. Press the SELECT (to
enable the chiller to start) and answer YES to reset unit to
operating mode. The chiller is locked out at the factory in
order to prevent accidental start-up.
64
Dry Run to Test Start-Up Sequence
For electro-mechanical starters.
1. Disengage the main motor disconnect (CB1) on the starter front panel. This should only disconnect the motor
power. Power to the controls, oil pump, and starter control circuit should still be energized.
2. Observe the default screen on the CVC/ICVC: the status
message in the upper left-hand corner reads, “Manually
Stopped,” Press the CCN or LOCAL softkey to start.
If the chiller controls do not go into a start mode (“Unoccupied Mode” is displayed) go to the SCHEDULE screen
and override the schedule or change the occupied
time. Press the LOCAL softkey to begin the start-up
sequences.
3. View the STARTUP display screen and verify the chilled
water and condenser water pumps have energized.
4. Verify the oil pump has started and is pressurizing the
lubrication system. After the oil pump has run about
11 seconds, the starter energizes (COMPRESSOR START
CONTACT is closed) and goes through its start-up
sequence.
5. Check the main contactor (1M) for proper operation.
6. The PIC II eventually shows an alarm for motors amps
not sensed. Reset this alarm and continue with the initial
start-up.
For Benshaw Inc. solid-state starters:
1. Close the main motor disconnect (CB1). Voltage will be
applied to the compressor motor but the SCRs will not
fire (compressor motor will not rotate). Enter MENU 4 in
the Benshaw RediStart MICRO™ Menu structure at the
Benshaw display (see Input Service Configurations,
Change The Benshaw RediStart MICRO Software Configuration page 57). Select Dry Run Mode and scroll to
YES.
2. Follow steps 2 through 4 for the electro-mechanical starters. When the Ramp Time is set for less than 10 seconds
COMPRESSOR RUN CONTACT will close.
3. The PIC II eventually shows an alarm for motors amps
not sensed. Reset this alarm and enter MENU 4 in the
Benshaw display. Select Dry Run Mode and scroll to NO.
Continue with the initial start-up.
Fig. 33 — Correct Motor Rotation
Do not check motor rotation during coastdown. Rotation
may have reversed during equalization of vessel pressures.
Check Oil Pressure and Compressor Stop
1. When the motor is at full speed, note the differential oil
pressure reading on the CVC/ICVC default screen. It
should be between 18 and 30 psid (124 to 206 kPad).
2. Press the Stop button and listen for any unusual sounds
from the compressor as it coasts to a stop.
To Prevent Accidental Start-Up — A chiller STOP
override setting may be entered to prevent accidental start-up
during service or whenever necessary. Access the MAINSTAT
screen and using the NEXT or PREVIOUS softkeys, highlight the CHILLER START/STOP parameter. Override the current START value by pressing the SELECT softkey. Press the
STOP softkey followed by the ENTER softkey. The word
SUPVSR! displays on the CVC/ICVC indicating the override
is in place.
To restart the chiller the STOP override setting must be removed. Access the MAINSTAT screen and using NEXT or
PREVIOUS softkeys highlight CHILLER START/STOP. The
3 softkeys that appear represent 3 choices:
• START — forces the chiller ON
• STOP — forces the chiller OFF
• RELEASE — puts the chiller under remote or schedule
control.
To return the chiller to normal control, press the
RELEASE softkey followed by the ENTER softkey. For
more information, see Local Start-Up, page 46.
The default CVC/ICVC screen message line indicates
which command is in effect.
Check Motor Rotation
1. Engage the oil pump circuit breaker (CB3) located inside
the right hand side of the starter panel.
2. Then engage the control power circuit breaker (CB2) located in the same section of the starter cabinet.
3. Finally close the main motor disconnect (CB1) on the
front of the starter panel.
4. The ISM mounted in the electro-mechanical starters
checks for proper phase rotation as soon as power is
applied to the starter and the PIC II controls power up.
Solid-state starters have phase protection and do not permit a start if the phase rotation is not correct.
5. An alarm message will appear on the CVC/ICVC if the
phase rotation is incorrect. If this occurs reverse any 2 of
the 3 incoming power leads to the starter and reapply
power. The motor is now ready for a rotation check.
6. After the default screen status message states ‘Ready to
Start’ press the LOCAL softkey. The PIC II control performs start-up checks.
7. When the starter is energized and the motor begins to
turn, check for clockwise motor rotation (Fig. 33).
Check Chiller Operating Condition — Check
to
be sure that chiller temperatures, pressures, water flows, and
oil and refrigerant levels indicate the system is functioning
properly.
Instruct the Customer Operator — Ensure the operator(s) understand all operating and maintenance procedures.
Point out the various chiller parts and explain their function as
part of the complete system.
COOLER-CONDENSER — Float chamber, relief valves, refrigerant charging valve, temperature sensor locations, pressure
transducer locations, Schrader fittings, waterboxes and tubes,
and vents and drains.
65
OPTIONAL PUMPOUT STORAGE TANK AND PUMPOUT SYSTEM — Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices.
MOTOR COMPRESSOR ASSEMBLY — Guide vane actuator, transmission, motor cooling system, oil cooling system,
temperature and pressure sensors, oil sight glasses, integral oil
pump, isolatable oil filter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.
MOTOR COMPRESSOR LUBRICATION SYSTEM —
Oil pump, cooler filter, oil heater, oil charge and specification,
operating and shutdown oil level, temperature and pressure,
and oil charging connections.
CONTROL SYSTEM — CCN and LOCAL start, reset,
menu, softkey functions, CVC/ICVC operation, occupancy
schedule, set points, safety controls, and auxiliary and optional
controls.
AUXILIARY EQUIPMENT — Starters and disconnects,
separate electrical sources, pumps, and cooling tower.
DESCRIBE CHILLER CYCLES — Refrigerant, motor
cooling, lubrication, and oil reclaim.
REVIEW MAINTENANCE — Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of
water treatment and tube cleaning, and importance of maintaining a leak-free chiller.
SAFETY DEVICES AND PROCEDURES — Electrical disconnects, relief device inspection, and handling refrigerant.
CHECK OPERATOR KNOWLEDGE — Start, stop, and
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
REVIEW THE START-UP OPERATION, AND MAINTENANCE MANUAL.
3.
4.
5.
6.
7.
8.
OPERATING INSTRUCTIONS
Operator Duties
temperature reads more than 180 F (83 C) with the oil
pump running, stop the chiller and determine the cause of
the high temperature. Do not restart the chiller until
corrected.
The oil level should be visible anywhere in one of the two
sight glasses. Foaming oil is acceptable as long as the oil
pressure and temperature are within limits.
The oil pressure should be between 18 and 30 psid (124
to 207 kPad) differential, as seen on the CVC/ICVC default screen. Typically the reading will be 18 to 25 psid
(124 to 172 kPad) at initial start-up.
The moisture indicator sight glass on the refrigerant
motor cooling line should indicate refrigerant flow and a
dry condition.
The condenser pressure and temperature varies with the
chiller design conditions. Typically the pressure will
range between 60 and 135 psig (390 to 950 kPa) with a
corresponding temperature range of 60 to 105 F (15 to
41 C). The condenser entering water temperature should
be controlled below the specified design entering
water temperature to save on compressor kilowatt
requirements.
Cooler pressure and temperature also will vary with the
design conditions. Typical pressure range will be between
60 and 80 psig (410 and 550 kPa), with temperature ranging between 34 and 45 F (1 and 8 C).
The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even though
the building load is small. The active electrical demand
setting can be overridden to limit the compressor IkW, or
the pulldown rate can be decreased to avoid a high
demand charge for the short period of high demand operation. Pulldown rate can be based on load rate or temperature rate and is accessed on the EQUIPMENT SERVICE screen, RAMP_DEM table (Table 2, Example 21).
To Stop the Chiller
1. Become familiar with the chiller and related equipment
before operating the chiller.
2. Prepare the system for start-up, start and stop the chiller,
and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document any
abnormal readings.
4. Inspect the equipment, make routine adjustments, and
perform a Control Test. Maintain the proper oil and refrigerant levels.
5. Protect the system from damage during shutdown periods.
6. Maintain the set point, time schedules, and other PIC
functions.
1. The occupancy schedule starts and stops the chiller automatically once the time schedule is configured.
2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed.
The compressor will then follow the normal shutdown
sequence as described in the Shutdown Sequence, StartUp/Shutdown/Recycle Sequence section, page 46. The
chiller will not restart until the CCN or LOCAL softkey is pressed. The chiller is now in the OFF control
mode.
IMPORTANT: Do not attempt to stop the chiller by opening
an isolating knife switch. High intensity arcing may occur.
Prepare the Chiller for Start-Up — Follow the steps
described in the Initial Start-Up section, page 64.
Do not restart the chiller until the problem is diagnosed
and corrected.
To Start the Chiller
After Limited Shutdown — No special preparations
1. Start the water pumps, if they are not automatic.
2. On the CVC/ICVC default screen, press the LOCAL or
CCN softkey to start the system. If the chiller is in the
OCCUPIED mode and the start timers have expired, the
start sequence will start. Follow the procedure described
in the Start-Up/Shutdown/Recycle Sequence section,
page 46.
should be necessary. Follow the regular preliminary checks and
starting procedures.
Preparation for Extended Shutdown — The refrigerant should be transferred into the pumpout storage tank (if
supplied; see Pumpout and Refrigerant Transfer Procedures) to
reduce chiller pressure and the possibility of leaks. Maintain a
holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant or
nitrogen to prevent air from leaking into the chiller.
If freezing temperatures are likely to occur in the chiller area, drain the chilled water, condenser water, and the pumpout
condenser water circuits to avoid freeze-up. Keep the waterbox
drains open.
Check the Running System — After the compressor starts, the operator should monitor the CVC/ICVC display
and observe the parameters for normal operating conditions:
1. The oil reservoir temperature should be above 120 F
(49 C) during shutdown.
2. The bearing oil temperature accessed on the COMPRESS
table should be 120 to 165 F (49 to 74 C). If the bearing
66
tank is supplied, the refrigerant can be isolated in the storage
tank. The following procedures describe how to transfer refrigerant from vessel to vessel and perform chiller evacuations.
Leave the oil charge in the chiller with the oil heater and
controls energized to maintain the minimum oil reservoir
temperature.
After Extended Shutdown — Ensure 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 and inspect the Schrader fittings on the waterside flow devices for fouling, if necessary.
Check the cooler pressure on the CVC/ICVC default screen
and compare it to the original holding charge that was left in
the chiller. If (after adjusting for ambient temperature changes)
any loss in pressure is indicated, check for refrigerant leaks.
See Check Chiller Tightness section, page 48.
Recharge the chiller by transferring refrigerant from the
pumpout storage tank (if supplied). Follow the Pumpout and
Refrigerant Transfer Procedures section, below. Observe
freeze-up precautions.
Carefully make all regular preliminary and running system
checks. Perform a Control Test before start-up. If the compressor oil level appears abnormally high, the oil may have
absorbed refrigerant. Ensure that the oil temperature is above
140 F (60 C) or above the cooler refrigerant temperature plus
50° F (27° C).
Always run the chiller cooler and condenser water pumps
and always charge or transfer refrigerant as a gas when the
chiller pressure is less than 30 psig (207 kPa). Below these
pressures, liquid refrigerant flashes into gas, resulting in
extremely low temperatures in the cooler/condenser tubes
and possibly causing tube freeze-up.
During transfer of refrigerant into and out of the optional
storage tank, carefully monitor the storage tank level gage.
Do not fill the tank more than 90% of capacity to allow for
refrigerant expansion. Overfilling may result in damage to
the tank or personal injury.
Cold Weather Operation — When the entering condenser water temperature drops very low, the operator should
automatically cycle the cooling tower fans off to keep the temperature up. Piping may also be arranged to bypass the cooling
tower. The PIC II controls have a low limit tower fan output
that can be used to assist in this control (terminal 11 and 12 on
ISM).
Do not mix refrigerants from chillers that use different
compressor oils. Compressor damage can result.
Operating the Optional Pumpout Unit
1. Be sure that the suction and the discharge service valves
on the optional pumpout compressor are open (backseated) during operation. Rotate the valve stem fully
counterclockwise to open. Front-seating the valve closes
the refrigerant line and opens the gage port to compressor
pressure.
2. Ensure that the compressor hold-down bolts have been
loosened to allow free spring travel.
3. Open the refrigerant inlet valve on the pumpout
compressor.
4. Oil should be visible in the pumpout unit compressor
sight glass under all operating conditions and during
shutdown. If oil is low, add oil as described under
Optional Pumpout System Maintenance section, page 75.
The pumpout unit control wiring schematic is detailed in
Fig. 35.
TO READ REFRIGERANT PRESSURES during pumpout or
leak testing:
1. The CVC/ICVC display on the chiller control panel is
suitable for determining refrigerant-side pressures and
low (soft) vacuum. To assure the desired range and accuracy when measuring evacuation and dehydration, use a
quality vacuum indicator or manometer. This can be
placed on the Schrader connections on each vessel (Fig.
9) by removing the pressure transducer.
2. To determine pumpout storage tank pressure, a 30 in.
-0-400 psi (-101-0-2769 kPa) gage is attached to the storage tank.
3. Refer to Fig. 29, 30, and 36 for valve locations and
numbers.
Manual Guide Vane Operation — It is possible to
manually operate the guide vanes in order to check control
operation or to control the guide vanes in an emergency. Manual operation is possible by overriding the target guide vane
position. Access the COMPRESS screen on the CVC/ICVC
and scroll down to highlight TARGET GUIDE VANE POS. To
control the position, use the INCREASE or DECREASE
softkey to adjust to the percentage of guide vane opening that is
desired. Zero percent is fully closed; 100% is fully open. To
release the guide vanes to automatic control, press the
RELEASE softkey.
NOTE: Manual control overrides the configured pulldown rate
during start-up and permits the guide vanes to open at a faster
rate. Motor current above the electrical demand setting, capacity overrides, and chilled water temperature below the control
point override the manual target and close the guide vanes. For
descriptions of capacity overrides and set points, see the Controls section.
Refrigeration Log — A refrigeration log (as shown in
Fig. 34), is a convenient checklist for routine inspection and
maintenance and provides a continuous record of chiller performance. It is also an aid when scheduling routine maintenance and diagnosing chiller problems.
Keep a record of the chiller pressures, temperatures, and liquid
levels on a sheet similar to the one in Fig. 34. Automatic
recording of PIC II data is possible by using CCN devices such
as the Data Collection module and a Building Supervisor.
Contact a Carrier representative for more information.
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
Transfer, addition, or removal of refrigerant in springisolated chillers may place severe stress on external piping
if springs have not been blocked in both up and down
directions.
Preparation — The 19XR may come equipped with an
optional pumpout storage tank, pumpout system, or pumpout
compressor. The refrigerant can be pumped for service work to
either the chiller compressor vessel or chiller condenser vessel
by using the optional pumpout system. If a pumpout storage
67
68
Press.
Temp
Refrigerant
In
Water
Out
GPM
Pressure
COOLER
In
Out
Temp
MACHINE MODEL NO.
Press.
Temp
Refrigerant
In
Out
GPM
Pressure
Water
CONDENSER
In
Out
Temp
MACHINE SERIAL NO.
BEARING
TEMP
Fig. 34 — Refrigeration Log
REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts.
TIME
DATE
Plant
Press.
Diff.
Temp
(reservoir)
Oil
Level
COMPRESSOR
Amperage
(or vane
position)
Motor
FLA
REFRIGERANT TYPE
REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE
OPERATOR
INITIALS
DATE
REMARKS
the CONTROL TEST table to turn on the water
pumps and monitor pressures.
If the chilled water and condenser water pumps are not
controlled by the PIC II, these pumps must be started and
stopped manually at the appropriate times during the refrigerant transfer procedure.
b. Close pumpout unit valves 2, 4, 5, 8, and 10, and
close chiller charging valve 7; open chiller isolation valves 11, 12, 13, and 14 (if present).
c. Open pumpout unit/storage tank valves 3 and 6,
open chiller valves 1a and 1b.
C
FU
HP
OL
T’STAT
—
—
—
—
—
LEGEND
Contactor
Fuse, 3 Amps
High-Pressure Cutout
Compressor Overload
Internal Thermostat
VALVE
CONDITION
Compressor Terminal
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C C
C C C
Follow Steps d and e carefully to prevent damage from
freeze-up.
Contactor Terminal
Overload Terminal
d. Slowly open valve 5 to increase chiller pressure to
68 psig 35 psig (141 kPa) for HFC-134a. Feed
refrigerant slowly to prevent freeze up.
e. Open valve 5 fully after the pressure rises above
the freeze point of the refrigerant. Open liquid line
valves 7 and 10 until refrigerant pressure
equalizes.
Pumpout Unit Terminal
*Bimetal thermal protector imbedded in motor winding.
Fig. 35 — 19XR Pumpout Unit Wiring Schematic
OIL RETURN
LINE
CONNECTION
VALVE
CONDITION
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C
C
2. Transfer the remaining refrigerant.
a. Close valve 5 and open valve 4.
VALVE
CONDITION
CONDENSER
WATER
CONNECTIONS
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C
C
b. Turn off the chiller water pumps using the CVC/
ICVC (or manually, if necessary).
c. Turn off the pumpout condenser water, and turn on
the pumpout compressor to push liquid out of the
storage tank.
d. Close liquid line valve 7.
e. Turn off the pumpout compressor.
f. Close valves 3 and 4.
g. Open valves 2 and 5.
REFRIGERANT
INLET VALVE
VALVE
Fig. 36 — Optional Pumpout Unit
CONDITION
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C C
C C
h. Turn on the pumpout condenser water.
i. Run the pumpout compressor until the pumpout
storage tank pressure reaches 5 psig (34 kPa)
(18 in. Hg [40 kPa absolute] if repairing the tank).
j. Turn off the pumpout compressor.
k. Close valves 1a, 1b, 2, 5, 6, and 10.
Chillers with Storage Tanks — If the chiller has isolation valves, leave them open for the following procedures.
The letter “C” describes a closed valve. See Fig. 17, 18, 29,
and 30.
TRANSFER REFRIGERANT FROM PUMPOUT STORAGE TANK TO CHILLER
1. Equalize refrigerant pressure.
a. Use the PIC II terminate lockout function on the
PUMPDOWN LOCKOUT screen, accessed from
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C C C C C
l. Turn off pumpout condenser water.
69
Chillers with Isolation Valves
TRANSFER REFRIGERANT FROM CHILLER TO PUMPOUT STORAGE TANK
1. Equalize refrigerant pressure.
a. Valve positions:
VALVE
CONDITION
TRANSFER ALL REFRIGERANT TO CHILLER CONDENSER VESSEL — For chillers with isolation valves,
refrigerant can be stored in one chiller vessel or the other without the need for an external storage tank.
1. Push refrigerant into the chiller condenser.
a. Valve positions:
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
C C
C C
b. Slowly open valve 5. When the pressures are
equalized, open liquid line valve 7 to allow liquid
refrigerant to drain by gravity into the pumpout
storage tank.
VALVE
CONDITION
VALVE
C
C
2. Transfer the remaining liquid.
a. Turn off the pumpout condenser water. Place the
valves in the following positions:
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C C
CONDITION
C
b. Run the pumpout compressor for approximately
30 minutes; then close valve 10.
VALVE
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C C
CONDITION
C C
c. Turn off the pumpout compressor.
3. Remove any remaining refrigerant.
a. Turn on the chiller water pumps using the PUMPDOWN LOCKOUT screen, accessed from the
CONTROL TEST table. Turn on the pumps manually, if they are not controlled by the PIC II.
b. Turn on the pumpout condenser water.
c. Place valves in the following positions:
VALVE
CONDITION
VALVE
C
4
C
5
8 11 12 13 14
C
C
C
C
3
4
C
5
8 11 12 13 14
C
C
C
C
C
C
b. Turn on the pumpout condenser water.
c. Run the pumpout compressor until the chiller
cooler vessel pressure reaches 18 in. Hg vac
(40 kPa abs.). Monitor pressures on the CVC/
ICVC and on refrigerant gages.
d. Close valve 1a.
e. Turn off the pumpout compressor.
f. Close valves 1b, 3, and 4.
C C
d. Run the pumpout compressor until the chiller pressure reaches 30 psig (207 kPa) for HFC-134a.
Then, shut off the pumpout compressor. Warm
condenser water will boil off any entrapped liquid
refrigerant and the chiller pressure will rise.
e. When the pressure rises to 40 psig (276 kPa) for
HFC-134a, turn on the pumpout compressor until
the pressure again reaches 30 psig (207 kPa), and
then turn off the pumpout compressor. Repeat this
process until the pressure no longer rises. Then,
turn on the pumpout compressor and pump until
the pressure reaches18 in. Hg. (40 kPa absolute).
f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.
VALVE
1a 1b 2
CONDITION
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
3
C
b. Using the PIC II controls, turn off the chiller water
pumps and pumpout condenser water. If the chiller
water pumps are not controlled through the PIC II,
turn them off manually.
c. Turn on the pumpout compressor to push the liquid
refrigerant out of the chiller cooler vessel.
d. When all liquid refrigerant has been pushed into
the chiller condenser vessel, close chiller isolation
valve 11.
e. Access the PUMPDOWN LOCKOUT screen on
the PIC II CONTROL TEST table to turn on the
chiller water pumps. If the chiller water pumps
are not controlled by the PIC II, turn them on
manually.
f. Turn off the pumpout compressor.
2. Evacuate the refrigerant gas from chiller cooler vessel.
a. Close pumpout compressor valves 2 and 5, and
open valves 3 and 4.
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
C
1a 1b 2
CONDITION
VALVE
1a 1b 2
CONDITION C
C
C
3
4
5
8 11 12 13 14
C
C
C
C
C
C
C
C
g. Turn off the pumpout condenser water.
h. Proceed to the PUMPDOWN/LOCKOUT function
accessed from the CONTROL TEST table to turn
off the chiller water pumps and lock out the chiller
compressor. Turn off the chiller water pumps manually if they are not controlled by the PIC II.
TRANSFER ALL REFRIGERANT TO CHILLER
COOLER VESSEL
1. Push the refrigerant into the chiller cooler vessel.
a. Valve positions:
1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C C C C C
g. Turn off the pumpout condenser water and continue to use the PIC II PUMPDOWN LOCKOUT
screen functions, which lock out the chiller compressor for operation.
4. Establish a vacuum for service.
To conserve refrigerant, operate the pumpout compressor
until the chiller pressure is reduced to 18 in. Hg vac., ref
30 in. bar. (40 kPa abs.) following Step 3e.
VALVE
CONDITION
1a 1b 2
C
3
4
5
8 11 12 13 14
C
C
C
C
C
b. Turn off the chiller water pumps (either through
the PIC II controls or manually, if necessary) and
the pumpout condenser water.
c. Turn on the pumpout compressor to push the
refrigerant out of the chiller condenser.
d. When all liquid refrigerant is out of the chiller condenser, close the cooler isolation valve 11.
e. Turn off the pumpout compressor.
70
GENERAL MAINTENANCE
2. Evacuate the refrigerant gas from the chiller condenser
vessel.
a. Access the PUMPDOWN LOCKOUT function
accessed from the CVC/ICVC CONTROL TEST
table to turn on the chiller water pumps. Turn the
chiller water pumps on manually if they are not
controlled by the PIC II.
b. Close pumpout unit valves 3 and 4; open valves 2
and 5.
VALVE
1a 1b 2
CONDITION
3
4
C
C
5
Refrigerant Properties — The standard refrigerant for
the 19XR chiller is HFC-134a. At normal atmospheric pressure, HFC-134a will boil at –14 F (–25 C) and must, therefore,
be kept in pressurized containers or storage tanks. The refrigerant is practically odorless when mixed with air and is noncombustible at atmospheric pressure. Read the Material Safety
Data Sheet and the latest ASHRAE Safety Guide for Mechanical Refrigeration to learn more about safe handling of this
refrigerant.
8 11 12 13 14
C
C
C
C
C
c. Turn on the pumpout condenser water.
d. Run the pumpout compressor until the chiller
condenser pressure reaches 18 in. Hg vac (40 kPa
abs.). Monitor pressure at the CVC/ICVC and at
refrigerant gages.
e. Close valve 1b.
f. Turn off the pumpout compressor.
g. Close valves 1a, 2, and 5.
VALVE
1a 1b 2
CONDITION C
C
C
3
4
5
8 11 12 13 14
C
C
C
C
C
C
C
HFC-134a will dissolve oil and some nonmetallic materials, dry the skin, and, in heavy concentrations, may displace enough oxygen to cause asphyxiation. When
handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.
Adding Refrigerant — Follow the procedures described in Trim Refrigerant Charge section, page 72.
C
Always use the compressor pumpdown function in the
Control Test table to turn on the cooler pump and lock out
the compressor when transferring refrigerant. Liquid refrigerant may flash into a gas and cause possible freeze-up
when the chiller pressure is below 30 psig (207 kPa) for
HFC-134a.
h. Turn off the pumpout condenser water.
i. Proceed to the PUMPDOWN LOCKOUT test
from the CVC/ICVC CONTROL TEST table to
turn off the chiller water pumps and lock out the
chiller compressor. Turn off the chiller water
pumps manually if they are not controlled by the
PIC II.
RETURN CHILLER TO NORMAL OPERATING
CONDITIONS
1. Ensure vessel that was opened has been evacuated.
2. Access the TERMINATE LOCKOUT function CVC/
ICVC from the CONTROL TEST table to view vessel
pressures and turn on chiller water pumps. If the chiller
water pumps are not controlled by the PIC II, turn them
on manually.
3. Open valves 1a, 1b, and 3.
VALVE
1a 1b 2
3
C
CONDITION
4
5
8 11 12 13 14
C
C
C
C
C
C
Removing Refrigerant — If the optional pumpout system is used, the 19XR refrigerant charge may be transferred to
a pumpout storage tank or to the chiller condenser or cooler
vessels. Follow the procedures in the Pumpout and Refrigerant
Transfer Procedures section when transferring refrigerant from
one vessel to another.
Adjusting the Refrigerant Charge — If the addition or removal of refrigerant is required to improve chiller performance, follow the procedures given under the Trim Refrigerant Charge section, page 72.
Refrigerant Leak Testing — Because HFC-134a is
above atmospheric pressure at room temperature, leak testing
can be performed with refrigerant in the chiller. Use an electronic halide leak detector, soap bubble solution, or ultrasonic
leak detector. Ensure that the room is well ventilated and free
from concentration of refrigerant to keep false readings to a
minimum. Before making any necessary repairs to a leak,
transfer all refrigerant from the leaking vessel.
C
4. Slowly open valve 5, gradually increasing pressure in the
evacuated vessel to 35 psig (141 kPa). Feed refrigerant
slowly to prevent tube freeze up.
5. Leak test to ensure vessel integrity.
6. Open valve 5 fully.
VALVE
1a 1b 2
3
C
CONDITION
4
5
C
Leak Rate — It is recommended by ASHRAE that chillers
8 11 12 13 14
C
C
C
C
be taken off line immediately and repaired if the refrigerant
leak rate for the entire chiller is more than 10% of the operating
refrigerant charge per year.
In addition, Carrier recommends that leaks totalling less
than the above rate but more than a rate of 0.1% of the total
charge per year should be repaired during annual maintenance
or whenever the refrigerant is transferred for other service
work.
C
7. Open valve 11 to equalize the liquid refrigerant level between the vessels.
8. Close valves 1a, 1b, 3, and 5.
9. Open isolation valves 12, 13, and 14 (if present).
VALVE
1a 1b 2
CONDITION C
C
C
3
4
5
8 11 12 13 14
C
C
C
C
Test After Service, Repair, or Major Leak — If
all the refrigerant has been lost or if the chiller has been opened
for service, the chiller or the affected vessels must be pressure
tested and leak tested. Refer to the Leak Test Chiller section to
perform a leak test.
10. Proceed to the TERMINATE LOCKOUT screen (accessed from the CONTROL TEST table) to turn off the water
pumps and enable the chiller compressor for start-up. If
the chiller water pumps are not controlled by the PIC II,
turn them off manually.
71
HFC-134a should not be mixed with air or oxygen and
pressurized for leak testing. In general, this refrigerant
should not be present with high concentrations of air or
oxygen above atmospheric pressures, because the mixture
can undergo combustion.
TESTING WITH REFRIGERANT TRACER — Use an environmentally acceptable refrigerant as a tracer for leak test
procedures. Use dry nitrogen to raise the machine pressure to
leak testing levels.
TESTING WITHOUT REFRIGERANT TRACER — Another method of leak testing is to pressurize with nitrogen only
and to use a soap bubble solution or an ultrasonic leak detector
to determine if leaks are present.
TO PRESSURIZE WITH DRY NITROGEN
NOTE: Pressurizing with dry nitrogen for leak testing should
not be done if the full refrigerant charge is in the vessel
because purging the nitrogen is very difficult.
1. Connect a copper tube from the pressure regulator on the
cylinder to the refrigerant charging valve. Never apply
full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the
regulating valve when the pressure reaches test level. Do
not exceed 140 psig (965 kPa).
5. Close the charging valve on the chiller. Remove the copper tube if it is no longer required.
Fig. 37 —Guide Vane Actuator Linkage
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a and b, page 70.
WEEKLY MAINTENANCE
Check the Lubrication System — Mark the oil level on the reservoir sight glass, and observe the level each week
while the chiller is shut down.
If the level goes below the lower sight glass, check the oil
reclaim system for proper operation. If additional oil is required, add it through the oil drain charging valve (Fig. 2). A
pump is required when adding oil against refrigerant pressure.
The oil charge for the 19XR compressor depends on the compressor Frame size:
• Frame 2 compressor — 5 gal (18.9 L)
• Frame 3 compressor — 8 gal (30 L)
• Frame 4 compressor — 10 gal (37.8 L)
• Frame 5 compressor — 18 gal (67.8 L)
The added oil must meet Carrier specifications for the
19XR. Refer to Changing Oil Filter and Oil Changes section
on page 73. Any additional oil that is added should be logged
by noting the amount and date. Any oil that is added due to oil
loss that is not related to service will eventually return to the
sump. It must be removed when the level is high.
An oil heater is controlled by the PIC II to maintain oil temperature (see the Controls section) when the compressor is off.
The CVC/ICVC COMPRESS screen displays whether the
heater is energized or not. The heater is energized if the OIL
HEATER RELAY parameter reads ON. If the PIC II shows that
the heater is energized and if the sump is still not heating up,
the power to the oil heater may be off or the oil level may be
too low. Check the oil level, the oil heater contactor voltage,
and oil heater resistance.
The PIC II does not permit compressor start-up if the oil
temperature is too low. The PIC II continues with start-up only
after the temperature is within allowable limits.
Repair the Leak, Retest, and Apply Standing
Vacuum Test — After pressurizing the chiller, test for
leaks with an electronic halide leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the chiller back to atmospheric pressure, repair any leaks found, and retest.
After retesting and finding no leaks, apply a standing vacuum test. Then dehydrate the chiller. Refer to the Standing Vacuum Test and Chiller Dehydration section (pages 50 and 53) in
the Before Initial Start-Up section.
Checking Guide Vane Linkage — When the chiller
is off, the guide vanes are closed and the actuator mechanism is
in the position shown in Fig. 37. If slack develops in the drive
chain, do the following to eliminate backlash:
1. With the chiller shut down and the actuator fully closed,
remove the chain guard and loosen the actuator bracket
hold-down bolts.
2. Loosen guide vane sprocket adjusting bolts.
3. Pry bracket upwards to remove slack, then retighten the
bracket hold-down bolts.
4. Retighten the guide vane sprocket adjusting bolts. Ensure
that the guide vane shaft is rotated fully in the clockwise
direction in order close it fully.
Trim Refrigerant Charge — If, to obtain optimal chiller performance, it becomes necessary to adjust the refrigerant
charge, operate the chiller at design load and then add or remove refrigerant slowly until the difference between the leaving chilled water temperature and the cooler refrigerant temperature reaches design conditions or becomes a minimum. Do
not overcharge.
Refrigerant may be added either through the storage tank or
directly into the chiller as described in the Charge Refrigerant
into Chiller section.
72
SCHEDULED MAINTENANCE
10. Remove the hose from the charging valve, open the isolation valves to the filter housing, and turn on the power to
the pump and the motor.
Establish a regular maintenance schedule based on your actual chiller requirements such as chiller load, run hours, and
water quality. The time intervals listed in this section are
offered as guides to service only.
Oil Specification — If oil is added, it must meet the following Carrier specifications:
Oil Type for units using R-134a . . . . . . . . . . . . . . . . . . Inhibited
polyolester-based synthetic
compressor oil formatted for
use with HFC, gear-driven,
hermetic compressors.
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
The polyolester-based oil (P/N: PP23BZ103) may be
ordered from your local Carrier representative.
Service Ontime — The CVC/ICVC will display a SERVICE ONTIME value on the MAINSTAT screen. This value
should be reset to zero by the service person or the operator
each time major service work is completed so that the time
between service can be viewed and tracked.
Inspect the Control Panel — Maintenance consists of
general cleaning and tightening of connections. Vacuum the
cabinet to eliminate dust build-up. If the chiller control malfunctions, refer to the Troubleshooting Guide section for control checks and adjustments.
Oil Changes — Carrier recommends changing the oil after the first year of operation and every five years thereafter as
a minimum in addition to a yearly oil analysis. However, if a
continuous oil monitoring system is functioning and a yearly
oil analysis is performed, the time between oil changes can be
extended.
TO CHANGE THE OIL
1. Transfer the refrigerant into the chiller condenser vessel
(for isolatable vessels) or to a pumpout storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 5 psig (34 kPa) or less, drain
the oil reservoir by opening the oil charging valve
(Fig. 2). Slowly open the valve against refrigerant
pressure.
5. Change the oil filter at this time. See Changing Oil Filter
section.
6. Change the refrigerant filter at this time, see the next section, Refrigerant Filter.
7. Charge the chiller with oil. Charge until the oil level is
equal to the oil level marked in Step 2. Turn on the power
to the oil heater and let the PIC II warm it up to at least
140 F (60 C). Operate the oil pump manually, using the
Control Test function, for 2 minutes. For shutdown conditions, the oil level should be full in the lower sight glass.
If the oil level is above 1/2 full in the upper sight glass, remove the excess oil. The oil level should now be equal to
the amount shown in Step 2.
Ensure power to the control center is off when cleaning and
tightening connections inside the control panel.
Check Safety and Operating Controls Monthly —
To ensure chiller protection, the automated Control Test
should be performed at least once per month. See Table 3
for safety control settings. See Table 9 for Control Test
functions.
Changing Oil Filter — Change the oil filter on a
yearly basis or when the chiller is opened for repairs. The
19XR has an isolatable oil filter so that the filter may be
changed with the refrigerant remaining in the chiller. Use
the following procedure:
1. Ensure the compressor is off and the disconnect for the
compressor is open.
2. Disconnect the power to the oil pump.
3. Close the oil filter isolation valves located behind power
panel on top of oil pump assembly.
4. Connect an oil charging hose from the oil charging valve
(Fig. 2) and place the other end in a clean container suitable for used oil. The oil drained from the filter housing
should be used as an oil sample and sent to a laboratory
for proper analysis. Do not contaminate this sample.
5. Slowly open the charging valve to drain the oil from the
housing.
Refrigerant Filter — A refrigerant filter/drier, located on
the refrigerant cooling line to the motor, should be changed
once a year or more often if filter condition indicates a need for
more frequent replacement. Change the filter by closing the filter isolation valves (Fig. 4) and slowly opening the flare fittings
with a wrench and back-up wrench to relieve the pressure. A
moisture indicator sight glass is located beyond this filter to indicate the volume and moisture in the refrigerant. If the moisture indicator indicates moisture, locate the source of water immediately by performing a thorough leak check.
The oil filter housing is at a high pressure. Relieve this
pressure slowly.
6. Once all oil has been drained, place some rags or absorbent material under the oil filter housing to catch any
drips once the filter is opened. Remove the 4 bolts from
the end of the filter housing and remove the filter cover.
7. Remove the filter retainer by unscrewing the retainer nut.
The filter may now be removed and disposed of properly.
8. Replace the old filter with a new filter. Install the filter retainer and tighten down the retainer nut. Install the filter
cover and tighten the 4 bolts.
9. Evacuate the filter housing by placing a vacuum pump on
the charging valve. Follow the normal evacuation procedures. Shut the charging valve when done and reconnect
the valve so that new oil can be pumped into the filter
housing. Fill with the same amount that was removed;
then close the charging valve.
Oil Reclaim Filter — The oil reclaim system has a
strainer on the eductor suction line, a strainer on the discharge
pressure line, and a filter on the cooler scavenging line.
Replace the filter once per year or more often if filter condition
indicates a need for more frequent replacement. Change the filter by closing the filter isolation valves and slowly opening the
flare fitting with a wrench and back-up wrench to relieve the
pressure. Change the strainers once every 5 years or whenever
refrigerant is evacuated from the cooler.
73
Inspect Refrigerant Float System — Perform this
Compressor Bearing and Gear Maintenance —
inspection every 5 years or when the condenser is opened for
service.
1. Transfer the refrigerant into the cooler vessel or into a
pumpout storage tank.
2. Remove the float access cover.
3. Clean the chamber and valve assembly thoroughly. Be
sure the valve moves freely. Ensure that all openings are
free of obstructions.
4. Examine the cover gasket and replace if necessary.
See Fig. 38 for a view of the float valve design. For linear
float valve designs, inspect the orientation of the float slide
pin. It must be pointed toward the bubbler tube for proper
operation.
The key to good bearing and gear maintenance is proper
lubrication. Use the proper grade of oil, maintained at recommended level, temperature, and pressure. Inspect the
lubrication system regularly and thoroughly.
To inspect the bearings, a complete compressor teardown is
required. Only a trained service technician should remove and
examine the bearings. The cover plate on older compressor
bases was used for factory-test purposes and is not usable
for bearing or gear inspection. The bearings and gears should
be examined on a scheduled basis for signs of wear. The
frequency of examination is determined by the hours of chiller
operation, load conditions during operation, and the condition
of the oil and the lubrication system. Excessive bearing wear
can sometimes be detected through increased vibration or
increased bearing temperature. If either symptom appears, contact an experienced and responsible service organization for
assistance.
Inspect Relief Valves and Piping — The relief valves
on this chiller protect the system against the potentially dangerous effects of overpressure. To ensure against damage to the
equipment and possible injury to personnel, these devices must
be kept in peak operating condition.
As a minimum, the following maintenance is required.
1. At least once a year, disconnect the vent piping at the
valve outlet and carefully inspect the valve body and
mechanism for any evidence of internal corrosion or rust,
dirt, scale, leakage, etc.
2. If corrosion or foreign material is found, do not attempt to
repair or recondition. Replace the valve.
3. If the chiller is installed in a corrosive atmosphere or the
relief valves are vented into a corrosive atmosphere, inspect the relief valves at more frequent intervals.
Inspect the Heat Exchanger Tubes and Flow
Devices
COOLER AND FLOW DEVICES — Inspect and clean the
cooler tubes at the end of the first operating season. Because
these tubes have internal ridges, a rotary-type tube cleaning
system is needed to fully clean the tubes. Inspect the tubes’
condition to determine the scheduled frequency for future
cleaning and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering and
leaving chilled water temperature sensors and flow devices for
signs of corrosion or scale. Replace a sensor or Schrader fitting
if corroded or remove any scale if found.
CONDENSER AND FLOW DEVICES — Since this water
circuit is usually an open-type system, the tubes may be subject
to contamination and scale. Clean the condenser tubes with a
rotary tube cleaning system at least once per year and more often if the water is contaminated. Inspect the entering and leaving condenser water sensors and flow devices for signs of corrosion or scale. Replace the sensor or Schrader fitting if corroded or remove any scale if found.
Higher than normal condenser pressures, together with the
inability to reach full refrigeration load, usually indicate dirty
tubes or air in the chiller. If the refrigeration log indicates a rise
above normal condenser pressures, check the condenser refrigerant temperature against the leaving condenser water temperature. If this reading is more than what the design difference is
supposed to be, the condenser tubes may be dirty or water flow
may be incorrect. Because HFC-134a is a high-pressure refrigerant, air usually does not enter the chiller.
During the tube cleaning process, use brushes specially designed to avoid scraping and scratching the tube wall. Contact
your Carrier representative to obtain these brushes. Do not use
wire brushes.
Hard scale may require chemical treatment for its prevention or removal. Consult a water treatment specialist for
proper treatment.
1
2
3
4
5
6
7
8
—
—
—
—
—
—
—
—
LEGEND
Refrigerant Inlet from FLASC Chamber
Linear Float Assembly
Float Screen
Bubble Line
Float Cover
Bubble Line Connection
Refrigerant Outlet to Cooler
Gasket
Water Leaks — The refrigerant moisture indicator on the
refrigerant motor cooling line (Fig. 2) indicates whether there
is water leakage during chiller operation. Water leaks should be
repaired immediately.
The chiller must be dehydrated after repair of water leaks.
See Chiller Dehydration section, page 53.
Fig. 38 — 19XR Float Valve Design
74
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.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows:
ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Carrier Part Number . . . . . . . . . . . . . . . . . . . . . . . . PP23BZ103
The total oil charge, 4.5 pints (2.6 L), consists of 3.5 pints
(2.0 L) for the compressor and one additional pint (0.6 L) for
the oil separator.
Oil should be visible in one of the compressor sight glasses
during both operation and at shutdown. Always check the oil
level before operating the compressor. Before adding or changing oil, relieve the refrigerant pressure as follows:
1. Attach a pressure gage to the gage port of either compressor service valve (Fig. 36).
2. Close the suction service valve and open the discharge
line to the storage tank or the chiller.
3. Operate the compressor until the crankcase pressure
drops to 2 psig (13 kPa).
4. Stop the compressor and isolate the system by closing the
discharge service valve.
5. Slowly remove the oil return line connection (Fig. 36).
Add oil as required.
6. Replace the connection and reopen the compressor service valves.
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
(Fig. 39) — The optional pumpout system high-pressure
switch opens at 161 psig (1110 kPa) and closes at 130 psig
(896 kPa). Check the switch setting by operating the pumpout
compressor and slowly throttling the pumpout condenser
water.
Ordering Replacement Chiller Parts — When
ordering Carrier specified parts, the following information
must accompany an order:
• chiller model number and serial number
• name, quantity, and part number of the part required
• delivery address and method of shipment.
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the potential of tube damage due to corrosion, scaling, erosion, and
algae. Carrier assumes no responsibility for chiller damage
resulting from untreated or improperly treated water.
Inspect the Starting Equipment — Before working
on any starter, shut off the chiller, open and tag all disconnects
supplying power to the starter.
The disconnect on the starter front panel does not deenergize all internal circuits. 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 eight transducers: the 2 oil differential pressure transducers, the condenser pressure transducer, the cooler
pressure transducer, and the waterside pressure transducers
(consisting of 4 flow devices: 2 cooler, 2 condenser).
Note the evaporator and condenser pressure readings on the
HEAT_EX screen on the CVC/ICVC (EVAPORATOR PRESSURE and CONDENSER PRESSURE). Attach an accurate set
of refrigeration gages to the cooler and condenser Schrader fittings. Compare the two readings. If there is a difference in
readings, the transducer can be calibrated as described in the
Troubleshooting Guide section. Oil differential pressure (OIL
PUMP DELTA P on the COMPRESS screen) should be zero
whenever the compressor is off.
Optional Pumpout System Maintenance — For
pumpout unit compressor maintenance details, refer to the
06D, 07D Installation, Start-Up, and Service Instructions.
Fig. 39 — Optional Pumpout System Controls
75
TROUBLESHOOTING GUIDE
VOLTAGE DROP — The voltage drop across any energized
sensor can be measured with a digital voltmeter while the control is energized. Table 12A or 12B lists the relationship between temperature and sensor voltage drop (volts dc measured
across the energized sensor). Exercise care when measuring
voltage to prevent damage to the sensor leads, connector plugs,
and modules. Sensors should also be checked at the sensor
plugs. Check the sensor wire at the sensor for 5 vdc if the control is powered on.
Overview — The PIC II has many features to help the operator and technician troubleshoot a 19XR chiller.
• The CVC/ICVC shows the chiller’s actual operating conditions and can be viewed while the unit is running.
• The CVC/ICVC default screen freezes when an alarm
occurs. The freeze enables the operator to view the
chiller conditions at the time of alarm. The STATUS
screens continue to show current information. Once all
alarms have been cleared (by correcting the problems
and pressing the RESET softkey), the CVC/ICVC
default screen returns to normal operation.
• The CONTROL ALGORITHM STATUS screens (which
include the CAPACITY, OVERRIDE, LL_MAINT,
ISM_HIST,
LOADSHED,
WSMDEFME,
and
OCCDEFCM screens) display information that helps to
diagnose problems with chilled water temperature
control, chilled water temperature control overrides, hot
gas bypass, surge algorithm status, and time schedule
operation.
• The control test feature facilitates the proper operation
and test of temperature sensors, pressure transducers, the
guide vane actuator, oil pump, water pumps, tower control, and other on/off outputs while the compressor is
stopped. It also has the ability to lock off the compressor
and turn on water pumps for pumpout operation. The
CVC/ICVC shows the temperatures and pressures
required during these operations.
• From other SERVICE tables, the operator/technician can
access configured items, such as chilled water resets,
override set points, etc.
• If an operating fault is detected, an alarm message is generated and displayed on the CVC/ICVC default screen.
A more detailed message — along with a diagnostic
message — is also stored into the ALARM HISTORY
table.
Relieve all refrigerant pressure or drain the water before
replacing the temperature sensors.
CHECK SENSOR ACCURACY — Place the sensor in a
medium of known temperature and compare that temperature
to the measured reading. The thermometer used to 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. 9 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 — For servicing convenience, there are 2 sensors each on the bearing and motor
temperature sensors. If one of the sensors is damaged, the other
can be used by simply moving a wire. The number 2 terminal
in the sensor terminal box is the common line. To use the second sensor, move the wire from the number 1 position to the
number 3 position.
Checking Pressure Transducers
UNITS EQUIPPED WITH CVC — There are 8 pressure
transducers on 19XR chillers. They determine cooler, condenser, oil pressure, and cooler and condenser flow. The cooler and
condenser transducers are also used by the PIC II to determine
the refrigerant temperatures. The oil supply pressure transducer
value and the oil transmission sump pressure transducer value
difference is calculated by the CCM. The CVC module then
displays the differential pressure. In effect, the CVC reads only
one input for oil pressure for a total of 5 pressure inputs: cooler
pressure, condenser pressure, oil differential pressure, cooler
waterside differential pressure, and condenser waterside differential pressure. See the Check Pressure Transducers section
(page 75) under Scheduled Maintenance.
UNITS EQUIPPED WITH ICVC — There are 6 factoryinstalled pressure transducers, with inputs available for both
cooler and The ICVC software will display a default reading of
26 psi during start-up and operation. An additional transducer,
factory installed in the bottom of the cooler barrel, will read as
EVAPORATOR SACTURATION TEMP on the HEAT_EX
DISPLAY screen. This provides additional protection against a
loss of water flow condition.
These pressure transducers can be calibrated if necessary. It
is not usually necessary to calibrate at initial start-up.
However, at high altitude locations, it is necessary to calibrate
the transducers to ensure the proper refrigerant temperature/
pressure relationship. Each transducer is supplied with 5 vdc
power from the CCM. If the power supply fails, a transducer
voltage reference alarm occurs. If the transducer reading is
suspected of being faulty, check the supply voltage. It should
be 5 vdc ±.5 v displayed in CONTROL TEST under CCM
Pressure Transducers. If the supply voltage is correct, the transducer should be recalibrated or replaced.
Checking Display Messages — The first area to
check when troubleshooting the 19XR is the CVC/ICVC display. If the alarm light is flashing, check the primary and secondary message lines on the CVC/ICVC default screen
(Fig. 14). These messages will indicate where the fault is occurring. These messages contain the alarm message with a
specified code. This code or state appears with each alarm and
alert message. The ALARM HISTORY table on the CVC/
ICVC SERVICE menu also contains an alarm message to further expand on the alarm. For a complete list of possible alarm
messages, see Table 11. If the alarm light starts to flash while
accessing a menu screen, press the EXIT softkey to return to
the default screen to read the alarm message. The STATUS
screen can also be accessed to determine where an alarm exists.
Checking Temperature Sensors — All temperature
sensors are thermistor-type sensors. This means that the resistance of the sensor varies with temperature. All sensors have
the same resistance characteristics. If the controls are on, determine sensor temperature by measuring voltage drop; if the controls are powered off, determine sensor temperature by measuring resistance. Compare the readings to the values listed in
Table 12A or 12B.
RESISTANCE CHECK — Turn off the control power and,
from the module, disconnect the terminal plug of the sensor in
question. With a digital ohmmeter, measure sensor resistance
between receptacles as designated by the wiring diagram. The
resistance and corresponding temperature are listed in
Table 12A or 12B. Check the resistance of both wires to
ground. This resistance should be infinite.
76
Control Test — The Control Test feature can check all the
TRANSDUCER REPLACEMENT — Since the transducers
are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel when replacing the transducers. Disconnect the transducer wiring. Do not pull on the 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.
thermistor temperature sensors, pressure transducers, pumps
and their associated flow devices, the guide vane actuator, and
other control outputs such as hot gas bypass. The tests can help
to determine whether a switch is defective or a pump relay is
not operating, as well as other useful troubleshooting issues.
During pumpdown operations, the pumps are energized to prevent freeze-up and the vessel pressures and temperatures are
displayed. The Pumpdown/Lockout feature prevents compressor start-up when there is no refrigerant in the chiller or if the
vessels are isolated. The Terminate Lockout feature ends the
Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
Be sure to use a back-up wrench on the Schrader fitting
whenever removing a transducer, since the Schrader fitting
may back out with the transducer, causing a large leak and
possible injury to personnel.
LEGEND TO TABLES 11A-11J
CCM — Chiller Control Module
CVC — Chiller Visual Controller
CHW — Chilled Water
International Chiller Visual
ICVC —
Control
ISM — Integrated Starter Module
PIC II — Product Integrated Controls II
VFD — Variable Frequency Drive
Control Algorithms Checkout Procedure — One
of the tables on the CVC/ICVC SERVICE menu is CONTROL ALGORITHM STATUS. The maintenance screens
may be viewed from the CONTROL ALGORITHM STATUS
table to see how a particular control algorithm is operating.
These maintenance screens are very useful in helping to determine how the control temperature is calculated and guide
vane positioned and for observing the reactions from load
changes, control point overrides, hot gas bypass, surge prevention, etc. The tables are:
CAPACITY
Capacity
Control
OVERRIDE
Override
Status
Surge/
HGBP
Status
HEAT_EX
LL_MAINT
OCCDEFCM
WSMDEFME
LEAD/LAG
Status
Time
Schedules
Status
Water
System
Manager
Status
This table shows all values used
to calculate the chilled water/brine
control point.
Details of all chilled water control
override values.
The surge and hot gas bypass
control algorithm status is viewed
from this screen. All
values dealing with this control
are displayed.
Indicates LEAD/LAG operation
status.
The Local and CCN occupied
schedules are displayed here to
help the operator quickly determine whether the schedule is in
the “occupied” mode or not.
The water system manager is a
CCN module that can turn on the
chiller and change the chilled
water control point. This screen
indicates the
status of this system.
77
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE
MANUALLY STOPPED — PRESS
TERMINATE PUMPDOWN MODE
SECONDARY MESSAGE
CCN OR LOCAL TO START
TO SELECT CCN OR LOCAL
SHUTDOWN IN PROGRESS
SHUTDOWN IN PROGRESS
COMPRESSOR UNLOADING
COMPRESSOR DEENERGIZED
ICE BUILD
OPERATION COMPLETE
PROBABLE CAUSE/REMEDY
PIC II in OFF mode, press CCN or LOCAL softkey to start unit.
Enter the CONTROL TEST table and select TERMINATE LOCKOUT to
unlock compressor.
Chiller unloading before shutdown due to soft/stop feature.
Chiller compressor is being commanded to stop. Water pumps are
deenergized within one minute.
Chiller shutdown from Ice Build operation.
B. READY TO START
PRIMARY MESSAGE
READY TO START IN XX MIN
SECONDARY MESSAGE
UNOCCUPIED MODE
READY TO START IN XX MIN
READY TO START IN XX MIN
REMOTE CONTACTS OPEN
STOP COMMAND IN EFFECT
READY TO START IN XX MIN
READY TO START IN XX MIN
OCCUPIED MODE
REMOTE CONTACTS CLOSED
READY TO START IN XX MIN
START COMMAND IN EFFECT
READY TO START IN XX MIN
READY TO START
RECYCLE RESTART PENDING
UNOCCUPIED MODE
READY TO START
READY TO START
REMOTE CONTACTS OPEN
STOP COMMAND IN EFFECT
READY TO START
READY TO START
READY TO START
OCCUPIED MODE
REMOTE CONTACTS CLOSED
START COMMAND IN EFFECT
STARTUP INHIBITED
LOADSHED IN EFFECT
PROBABLE CAUSE/REMEDY
Time schedule for PIC II is unoccupied. Chillers will start only when
occupied.
Remote contacts are open. Close contacts to start.
Chiller START/STOP on MAINSTAT manually forced to stop. Release
point to start.
Chiller timer counting down. Unit ready to start.
Chiller timer counting down. Unit ready to start. Remote contact enabled
and closed.
Chiller START/STOP on MAINSTAT manually forced to start. Release
value to start under normal control.
Chiller in recycle mode.
Time schedule for PIC II is unoccupied. Chiller will start when occupied.
Make sure the time and date are correct. Change values in TIME AND
DATE screen.
Remote contacts have stopped the chiller. Close contacts to start.
Chiller START/STOP on MAINSTAT manually forced to stop. Release
point to start.
Chiller timers complete, unit start will commence.
Chiller timer counting down. Unit ready for start.
Chiller START/STOP on MAINSTAT has been manually forced to start.
Chiller will start regardless of time schedule or remote contact status.
CCN loadshed module commanding chiller to stop.
C. IN RECYCLE SHUTDOWN
PRIMARY MESSAGE
RECYCLE RESTART PENDING
SECONDARY MESSAGE
OCCUPIED MODE
RECYCLE RESTART PENDING
REMOTE CONTACT CLOSED
RECYCLE RESTART PENDING
START COMMAND IN EFFECT
RECYCLE RESTART PENDING
ICE BUILD MODE
78
PROBABLE CAUSE/REMEDY
Unit in recycle mode, chilled water temperature is not sufficiently
above set point to start.
Unit in recycle mode, chilled water temperature is not sufficiently
above set point to start.
Chiller START/STOP on MAINSTAT manually forced to start, chilled
water temperature is not sufficiently above set point to start.
Chiller in ICE BUILD mode. Chilled fluid temperature is satisfied for
ICE BUILD conditions.
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
PRIMARY
MESSAGE
PRESTART
ALERT
PRESTART
ALERT
SECONDARY
MESSAGE
STARTS LIMIT
EXCEEDED
HIGH BEARING
TEMPERATURE
ALARM MESSAGE
PRIMARY CAUSE
100->Excessive compressor
starts (8 in 12 hours)
101->Comp Thrust Bearing
Temp [VALUE] exceeded
limit of [LIMIT]*.
102
PRESTART
ALERT
HIGH MOTOR
TEMPERATURE
102->Comp Motor Winding Temp
[VALUE] exceeded limit
of [LIMIT]*.
103
PRESTART
ALERT
HIGH DISCHARGE
TEMP
103->Comp Discharge Temp
[VALUE] exceeded limit of
[LIMIT]*.
104
PRESTART
ALERT
LOW REFRIGERANT
TEMP
105
PRESTART
ALERT
PRESTART
ALERT
LOW OIL
TEMPERATURE
HIGH CONDENSER
PRESSURE
107
PRESTART
ALERT
LOW LINE
VOLTAGE
108
PRESTART
ALERT
HIGH LINE
VOLTAGE
109
PRESTART
ALERT
GUIDE VANE
CALIBRATION
104->Evaporator Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.
105->Oil Sump Temp [VALUE]
exceeded limit of [LIMIT]*.
106->Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
107->Average Line Voltage
[VALUE] exceeded limit of
[LIMIT]*.
108->Average Line Voltage
[VALUE] exceeded limit of
[LIMIT]*.
109->Actual Guide Vane
Pos Calibration Required
Before Start-Up
STATE
100
101
106
ADDITIONAL CAUSE/REMEDY
Depress the RESET softkey if additional start is
required. Reassess start-up requirements.
Check oil heater for proper operation.
Check for low oil level, partially closed coil supply
valves, clogged oil filters, etc.
Check the sensor wiring and accuracy.
Check configurable range in SETUP1 screen.
Check motor sensors for wiring and accuracy.
Check motor cooling line for proper operation, or
restrictions.
Check for excessive starts within a short time span.
Check configurable range in SETUP1 screen.
Allow discharge sensor to cool.
Check for sensor wiring and accuracy.
Check for excessive starts.
Check configurable range in SETUP1 screen.
Check transducer wiring and accuracy.
Check for low chilled fluid supply temperatures.
Check refrigerant charge.
Check oil heater contactor/relay and power.
Check oil level and oil pump operation.
Check transducer wiring and accuracy.
Check for high condenser water temperatures.
Check voltage supply. Check voltage transformers.
Consult power utility if voltage is low.
Check voltage supply.
Check power transformers.
Consult power utility if voltage is high.
Calibrate guide vane actuator in Control Test.
*[LIMIT] is shown on the CVC/ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.
[VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
E. START-UP IN PROGRESS
PRIMARY MESSAGE
SECONDARY MESSAGE
CAUSE/REMEDY
STARTUP IN PROGRESS
STARTUP IN PROGRESS
STARTUP IN PROGRESS
OCCUPIED MODE
REMOTE CONTACT CLOSED
START COMMAND IN EFFECT
AUTORESTART IN PROGRESS
AUTORESTART IN PROGRESS
OCCUPIED MODE
REMOTE CONTACT CLOSED
AUTORESTART IN PROGRESS
START COMMAND IN EFFECT
Chiller is starting. Time schedule is occupied.
Chiller is starting. Remote contacts are enabled and closed.
Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to
start.
Chiller is starting after power failure. Time schedule is occupied.
Chiller is starting after power failure. Remote contacts are enabled and
closed.
Chiller is starting after power failure. Chiller START/STOP on MAINSTAT
manually forced to start.
F. NORMAL RUN
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
RUNNING — TEMP CONTROL
SECONDARY MESSAGE
4-20 mA SIGNAL
REMOTE TEMP SENSOR
CHW TEMP DIFFERENCE
LEAVING CHILLED WATER
ENTERING CHILLED WATER
TEMPERATURE RAMP LOADING
BY DEMAND RAMP LOADING
BY LOCAL DEMAND SETPOINT
BY 4-20 mA SIGNAL
BY CCN SIGNAL
BY LOADSHED/REDLINE
HOT GAS BYPASS
RUNNING — DEMAND LIMITED
RUNNING —TEMP CONTROL
BY LOCAL SIGNAL
ICE BUILD MODE
79
CAUSE/REMEDY
Auto chilled water reset active based on external input.
Auto chilled water reset active based on external input.
Auto chilled water reset active based on cooler ∆T.
Default method of temperature control.
Entering Chilled Water (ECW) control enabled in TEMP_CTL screen
Ramp Loading in effect. Use RAMP_DEM screen to modify.
Ramp Loading in effect. Use RAMP_DEM screen to modify.
Demand limit set point is less than actual demand.
Demand limit is active based on external auto demand limit option.
Demand limit is active based on control limit signal from CCN.
Demand limit is active based on LOADSHED screen set-up.
Hot gas bypass option is energized. See stall prevention in the control
section.
Active demand limit manually overridden on MAINSTAT table.
Chiller is running under Ice Build temperature control.
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
G. NORMAL RUN WITH OVERRIDES
STATE
120
121
122
123
124
125
PRIMARY
MESSAGE
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
RUN CAPACITY
LIMITED
SECONDARY
MESSAGE
HIGH CONDENSER
PRESSURE
HIGH MOTOR
TEMPERATURE
ALARM MESSAGE
PRIMARY CAUSE
120->Condenser Pressure
[VALUE] exceeded limit of [LIMIT]*.
121->Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.
ADDITIONAL
CAUSE/REMEDY
Check for high condenser water temperatures.
Check setting in SETUP1.
Check motor cooling lines.
Check for closed valves.
Check setting in SETUP1.
LOW EVAP
122->Evaporator Refrig Temp
Check refrigerant charge.
REFRIG TEMP
[VALUE] exceeded limit of [LIMIT]*. Check for low entering cooler temperatures.
HIGH COMPRESSOR 123->Surge Prevention Override:
Check for high condenser water temperatures or
LIFT
Lift Too High For Compressor.
low suction temperature.
MANUAL GUIDE
124->Run Capacity Limited:
Target guide vane point has been forced in
VANE TARGET
Manual Guide Vane Target.
MAINSTAT screen. Release force to continue
normal operation.
LOW DISCHARGE
No messages.
Check oil charge.
SUPERHEAT
Check refrigerant charge.
*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,
alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault condition.
H. OUT-OF-RANGE SENSOR ALARMS
STATE
260
261
262
263
264
265
266
267
268
269
270
271
273
PRIMARY
MESSAGE
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SENSOR
FAULT
SECONDARY
MESSAGE
LEAVING CHILLED
WATER
ENTERING CHILLED
WATER
CONDENSER
PRESSURE
EVAPORATOR
PRESSURE
COMPRESSOR
BEARING TEMP
COMPRESSOR
MOTOR TEMP
COMP DISCHARGE
TEMP
OIL SUMP TEMP
COMP OIL
PRESS DIFF
CHILLED WATER
FLOW
COND WATER
FLOW
VFD SPEED SENSOR
OUT OF RANGE
VFD SPEED OUT OF
RANGE
ALARM MESSAGE
PRIMARY CAUSE
260->Sensor Fault:
Leaving Chilled Water
261->Sensor Fault:
Entering Chilled Water
262->Sensor Fault:
Condenser Pressure
263->Sensor Fault:
Evaporator Pressure
264->Sensor Fault:
Comp Thrust Bearing Temp
265->Sensor Fault:
Comp Motor Winding Temp
266->Sensor Fault:
Comp Discharge Temp
267->Sensor Fault:
Oil Sump Temp
268->Sensor Fault:
Oil Pump Delta P
269->Sensor Fault:
Chilled Water Delta P
270->Sensor Fault:
Cond Water Delta P
271->Sensor Fault:
Check Actual VFD Speed Sensor
273->Sensor Fault:
Check Actual VFD Speed Sensor
80
ADDITIONAL
CAUSE/REMEDY
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor wiring.
Check sensor wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor wiring and accuracy.
Check sensor wiring and accuracy.
Check sensor wiring and accuracy.
Check voltage input on terminals J6-1 and J6-2 on
the ISM module. Check wiring.
Check VFD feedback 0-5 vac. Calibrate VFD
speed reference signal.
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECT LIMIT FAULTS
PRIMARY
MESSAGE
PROTECTIVE
LIMIT
SECONDARY
MESSAGE
1M CONTACT
FAULT
201
PROTECTIVE
LIMIT
2M CONTACT
FAULT
202
PROTECTIVE
LIMIT
MOTOR AMPS
NOT SENSED
203
FAILURE TO
START
EXCESS
ACCELERATION
TIME
204
FAILURE TO
STOP
1M/2M CONTACT
FAULT
205
FAILURE TO
STOP
MOTOR AMPS
WHEN STOPPED
206
PROTECTIVE
LIMIT
STARTER
FAULT
207
PROTECTIVE
LIMIT
HIGH CONDENSER
PRESSURE
208
PROTECTIVE
LIMIT
EXCESSIVE
MOTOR AMPS
209
PROTECTIVE
LIMIT
LINE PHASE
LOSS
210
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
LINE VOLTAGE
DROPOUT
HIGH LINE
VOLTAGE
208->Compressor Motor
Amps [VALUE] exceeded
limit of [LIMIT]*.
209->Line Phase Loss;
Check ISM Fault History to
Identify Phase
210->Single Cycle Line
Voltage Dropout
211->High Average Line
Voltage [VALUE]
212
PROTECTIVE
LIMIT
LOW LINE
VOLTAGE
212->Low Average Line
Voltage [VALUE]
213
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
STARTER MODULE
RESET
POWER LOSS
215
PROTECTIVE
LIMIT
LINE CURRENT
IMBALANCE
216
PROTECTIVE
LIMIT
LINE VOLTAGE
IMBALANCE
217
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
MOTOR OVERLOAD
TRIP
MOTOR LOCKED
ROTOR TRIP
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
STARTER LOCK
ROTOR TRIP
GROUND FAULT
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
PHASE REVERSAL
TRIP
LINE FREQUENCY
TRIP
PROTECTIVE
LIMIT
STARTER MODULE
FAILURE
213->Starter Module PowerOn Reset When Running
214->Power Loss:
Check transformers to ISM.
Check voltage supply
Check distribution bus.
Consult power company.
215->Line Current
Check upstream equipment.
Imbalance; Check ISM Fault
History to Identify Phase
216->Line Voltage
Check upstream equipment.
Imbalance; Check ISM Fault
History to Identify Phase
217->Motor Overload Trip;
Check ISM configuration.
Check ISM configurations
218->Motor Locked Rotor
Check ISM configuration.
Amps exceeded; Check
Motor & ISM Config
219->Starter Locked Rotor
Check ISM configuration.
Amps Rating exceeded
220->Ground Fault Trip;
Check Motor and Current
Transformers
221->Phase Reversal Trip;
Check Power Supply
222->Line Frequency —
[VALUE] exceeded limit of
[LIMIT]. Check Power
Supply.
223->Starter Module
Hardware Failure
STATE
200
211
214
218
219
220
221
222
223
ALARM MESSAGE
PRIMARY CAUSE
200->1M Aux Contact Fault;
Check 1M Contactor and
Aux
201->2M Aux Contact Fault;
Check 2M Contactor and
Aux
202->Motor Amps Not
Sensed — Average Line
Current [VALUE]
203->Motor Acceleration
Fault — Average Line
Current [VALUE]
204->1M/2M Aux Contact
Stop Fault; Check 1M/2M
Contactors and Aux
205->Motor Amps When
Stopped — Average Line
Current [VALUE]
206->Starter Fault Cutout;
Check Optional Starter
Contacts
207->High Cond Pressure
cutout. [VALUE] exceeded
limit of [LIMIT]*.
81
ADDITIONAL
CAUSE/REMEDY
Check for wiring of current transformers to the ISM.
Check main circuit breaker for trip.
Check to be sure that the inlet guide vanes are closed
at start-up.
Check starter for proper operation.
Reduce unit pressure if possible.
For Benshaw Inc. RediStart MICRO™ starters, view
fault code at RediStart MICRO display. Press FAULT
RESET to clear faults.
Check for high condenser water temperatures, low
water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.
If [VALUE] is less than Limit then check the
1CR Starting Circuit.
Check motor current for proper calibration.
Check inlet guide vane actuator.
Check transformers to ISM.
Check power distribution bus.
Consult power company.
Check transformers to ISM.
Check distribution bus.
Consult power company.
Check transformers to ISM.
Check distribution bus.
Consult power company.
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECT LIMIT FAULTS (cont)
PRIMARY
MESSAGE
PROTECTIVE
LIMIT
SECONDARY
MESSAGE
OIL PRESS
SENSOR FAULT
ALARM MESSAGE
PRIMARY CAUSE
227->Oil Pump Delta P
[VALUE] exceeded limit of
[LIMIT]*.
228
PROTECTIVE
LIMIT
LOW OIL
PRESSURE
228->Oil Pump Delta P
[VALUE] exceeded limit of
[LIMIT].*
229
PROTECTIVE
LIMIT
LOW CHILLED
WATER FLOW
229->Low Chilled Water
Flow; Check Delta P Config
& Calibration
230
PROTECTIVE
LIMIT
LOW CONDENSER
WATER FLOW
230->Low Condenser Water
Flow; Check Delta P Config
& Calibration
231
PROTECTIVE
LIMIT
HIGH DISCHARGE
TEMP
231->Comp Discharge
Temp [VALUE] exceeded
limit of [LIMIT].*
232
PROTECTIVE
LIMIT
LOW REFRIGERANT
TEMP
232->Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
233
PROTECTIVE
LIMIT
HIGH MOTOR
TEMPERATURE
233->Comp Motor Winding
Temp [VALUE] exceeded
limit of [LIMIT]*.
234
PROTECTIVE
LIMIT
HIGH BEARING
TEMPERATURE
234->Comp Thrust Bearing
Temp [VALUE] exceeded
limit of [LIMIT]*.
235
PROTECTIVE
LIMIT
HIGH CONDENSER
PRESSURE
235->Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.
236
PROTECTIVE
LIMIT
CCN OVERRIDE
STOP
236->CCN Override Stop
while in LOCAL run mode
237
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
SPARE SAFETY
DEVICE
EXCESSIVE
COMPR SURGE
237->Spare Safety Device
239
PROTECTIVE
LIMIT
TRANSDUCER
VOLTAGE FAULT
240
PROTECTIVE
LIMIT
LOW DISCHARGE
SUPERHEAT
241
LOSS OF
COMMUNICATION
LOSS OF
COMMUNICATION
POTENTIAL
FREEZE-UP
WITH STARTER
MODULE
WITH CCM
MODULE
EVAP PRESS/TEMP
TOO LOW
244
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
245
PROTECTIVE
LIMIT
VFD SPEED
OUT OF RANGE
STATE
227
238
242
243
238->Compressor Surge:
Check condenser water
temp and flow
239->Transducer Voltage
Ref [VALUE] exceeded limit
of [LIMIT]*.
240->Check for Oil in
Refrigerant or Overcharge
of Refrigerant
241->Loss of Communication With Starter.
242->Loss of Communication With CCM.
243->Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
244->Condenser Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.
245->Actual VFD Speed
[VALUE] exceeded limit of
[LIMIT]*.
82
ADDITIONAL
CAUSE/REMEDY
Check transducer wiring and accuracy.
Check power supply to pump.
Check pump operation.
Check transducer calibration.
Check transducer wiring and accuracy.
Check power supply to pump.
Check pump operation.
Check oil level.
Check for partially closed service valves.
Check oil filters.
Check for foaming oil at start-up.
Check transducer calibration.
Perform pump control test.
Check transducer accuracy and wiring.
Check water valves.
Check transducer calibration.
Perform pump control test.
Check transducer accuracy and wiring.
Check water valves.
Check transducer calibration.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for proper condenser flow and temperature.
Check for proper inlet guide vane and diffuser
actuator operation.
Check for fouled tubes or noncondensables in the
system.
Check for proper refrigerant charge.
Check float operation.
Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
Check motor sensors wiring and accuracy.
Check motor cooling line for proper operation, or
restrictions.
Check for excessive starts within a short time span.
Check oil heater for proper operation.
Check for low oil level, partially closed oil supply
valves, clogged oil filters, etc.
Check the sensor wiring and accuracy.
Check for high condenser water temperatures, low
water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.
CCN has signaled the chiller to stop. Reset and
restart when ready. If the signal was sent by the
CVC/ICVC, release the stop signal on the STATUS01
table.
Spare safety input has tripped or factory installed
jumper is not present.
Check condenser flow and temperatures.
Check surge protection configuration.
Check wiring to ISM.
Check wiring to CCM.
Check for proper refrigerant charge.
Check float operation.
Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
I. CHILLER PROTECT LIMIT FAULTS (cont)
PRIMARY
MESSAGE
PROTECTIVE
LIMIT
SECONDARY
MESSAGE
INVALID DIFFUSER
CONFIG
247
PROTECTIVE
LIMIT
DIFFUSER POSITION
FAULT
248
PROTECTIVE
LIMIT
SPARE TEMPERATURE
#1
249
PROTECTIVE
LIMIT
SPARE TEMPERATURE
#2
250
PROTECTIVE
LIMIT
REFRIGERANT LEAK
SENSOR
251
PROTECTIVE
LIMIT
PROTECTIVE
LIMIT
ISM CONFIG
CONFLICT
ISM CONFIG
CONFLICT
PROTECTIVE
LIMIT
GUIDE VANE
CALIBRATION
STATE
246
252
253
ALARM MESSAGE
PRIMARY CAUSE
246->Diffuser Control Invalid
Configuration:
Check SETUP2 Entries.
247->Diffuser Position Fault:
Check Guide Vane and Diffuser
Actuators
ADDITIONAL
CAUSE/REMEDY
Check diffuser/guide vane schedule.
Check rotating stall transducer wiring and
accuracy.
Check diffuser schedule.
Check for proper operation of diffuser actuator
and inlet guide vane actuator.
Check diffuser coupling.
Check inlet guide vane operation.
Check inlet guide vane calibration.
Check diffuser/inlet guide vane schedule.
Check diffuser mechanical set-up for proper
orientation.
If not using variable diffuser, check that the
option has not been enabled.
248->Spare Temperature #1
[VALUE] exceeded limit of
[LIMIT]*.
249->Spare Temperature #2
[VALUE] exceeded limit of
[LIMIT]*.
250->Refrigerant Leak Sensor
[VALUE] exceeded Limit of
[LIMIT]*.
251->ISM Config Conflict (ISM
Uploaded); Verify to Reset Alarm
252->ISM Config Conflict (ISM
Downloaded); Verify to Reset
Alarm
253->Guide Vane Fault [VALUE].
Check Calibration.
The refrigerant leak detector’s output wired to
J5-5 and J5-6 on the CCM module has
reached the alarm limit.
Check leak detector and for leaks.
Confirm valid settings in ISM_CONF screen.
Confirm valid settings in ISM_CONF screen.
Enter Control Test and execute Guide Vane
Calibration. Check guide vane feedback (terminals J4-9 and J4-10) on the CCM module.
*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,
alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
J. CHILLER ALERTS
140
PRIMARY
MESSAGE
SENSOR ALERT
SECONDARY
MESSAGE
LEAVING COND
WATER TEMP
141
SENSOR ALERT
ENTERING COND
WATER TEMP
142
LOW OIL PRESSURE
ALERT
CHECK OIL FILTER
143
AUTORESTART
PENDING
AUTORESTART
PENDING
LINE PHASE
LOSS
LINE VOLTAGE
DROP OUT
143->Line Phase Loss
AUTORESTART
PENDING
AUTORESTART
PENDING
AUTORESTART
PENDING
AUTORESTART
PENDING
HIGH LINE
VOLTAGE
LOW LINE
VOLTAGE
STARTER MODULE
RESET
POWER LOSS
145>Line Overvoltage —
Average Line Volt [VALUE]
146->Line Undervoltage —
Average Line Volt [VALUE]
147->Starter Module PowerOn Reset When Running
148->Control Power-Loss
When Running
STATE
144
145
146
147
148
ALARM MESSAGE
PRIMARY CAUSE
140->Sensor Fault:
Check Leaving Cond Water
Sensor
141->Sensor Fault:
Check Entering Cond Water
Sensor
142->Low Oil Pressure Alert.
Check Oil Filter.
144->Single Cycle Line
Voltage Dropout
83
ADDITIONAL
CAUSE/REMEDY
Check sensor resistance or voltage drop.
Check for proper wiring.
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for partially or closed shut-off valves.
Check oil filter.
Check oil pump and power supply.
Check oil level.
Check for foaming oil at start-up.
Check transducer wiring and accuracy.
Power loss has been detected in any phase.
Chiller automatically restarting.
A drop in line voltage has been detected within
2 voltage cycles. Chiller automatically restarting if
Autorestart option is enabled.
Check line power.
Check line power.
ISM has detected a hardware fault and has reset.
Chiller automatically restarting.
Check control power.
Table 11 — CVC/ICVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
J. CHILLER ALERTS (cont)
149
PRIMARY
MESSAGE
SENSOR ALERT
SECONDARY
MESSAGE
HIGH DISCHARGE
TEMP
150
SENSOR ALERT
HIGH BEARING
TEMPERATURE
151
CONDENSER
PRESSURE ALERT
PUMP RELAY
ENERGIZED
152
RECYCLE
ALERT
EXCESSIVE RECYCLE
STARTS
153
no message:
ALERT only
no message;
ALERT only
154
POTENTIAL
FREEZE-UP
COND PRESS/TEMP
TOO LOW
155
OPTION SENSOR
FAULT
REMOTE RESET
SENSOR
156
OPTION SENSOR
FAULT
AUTO CHILLED
WATER RESET
157
OPTION SENSOR
FAULT
AUTO DEMAND
LIMIT INPUT
158
SENSOR ALERT
SPARE TEMPERATURE
#1
159
SENSOR ALERT
SPARE TEMPERATURE
#2
160
DIFFUSER
ALERT
DIFFUSER
POSITION
STATE
ALARM MESSAGE
PRIMARY CAUSE
149->Comp Discharge Temp
[VALUE] exceeded limit of
[LIMIT]*.
ADDITIONAL
CAUSE/REMEDY
Check sensor resistance or voltage drop.
Check for proper wiring.
Check for proper condenser flow and
temperature.
Check for high lift or low load.
Check for proper inlet guide vane and diffuser
actuator operation (Size 5 compressor Only).
Check for fouled tubes or noncondensables in
the refrigerant system.
Check sensor resistance or voltage drop.
150->Comp Thrust Bearing
Temp [VALUE] exceeded limit Check for proper wiring.
Check for partially closed service valves.
of [LIMIT]*.
Check oil cooler TXV.
Check oil filter.
Check oil level.
151->High Condenser
Check sensor wiring and accuracy.
Pressure [VALUE]: Pump
Check condenser flow and fluid
Energized to Reduce
temperature.
Pressure.
Check for fouled tubes. This alarm is not
caused by the High Pressure Switch.
152->Excessive recycle starts. Chiller load is too low to keep compressor on
line and there has been more than
5 starts in 4 hours. Increase chiller load,
adjust hot gas bypass, increase RECYCLE
RESTART DELTA T from SETUP1 Screen.
153->Lead/Lag Disabled:
Illegal chiller address configuration in Lead/
Duplicate Chiller Address;
Lag screen. Both chillers require a different
Check Configuration
address.
154->Condenser freeze up
The condenser pressure transducer is readprevention
ing a pressure that could freeze the condenser tubes.
Check for condenser refrigerant leaks.
Check fluid temperature.
Check sensor wiring and accuracy.
Place the chiller in PUMPDOWN mode if the
vessel is evacuated.
155->Sensor Fault/Option
Check sensor resistance or voltage drop.
Disabled:
Check for proper wiring.
Remote Reset Sensor
156->Sensor Fault/Option
Check sensor resistance or voltage drop.
Disabled:
Check for proper wiring.
Auto Chilled Water Reset
157->Sensor Fault/Option
Check sensor resistance or voltage drop.
Disabled:
Check for proper wiring.
Auto Demand Limit Input
158->Spare Temperature #1
Check sensor resistance or voltage drop.
[VALUE] exceeded limit of
Check for proper wiring.
[LIMIT].*
159->Spare Temperature #2
Check sensor resistance or voltage drop.
[VALUE] exceeded limit of
Check for proper wiring.
[LIMIT].*
160->Diffuser Position Alert;
Check diffuser configuration in SETUP2
Check Diffuser Configuration. screen.
*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,
alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
84
Table 12A — Thermistor Temperature (F) vs. Resistance/Voltage Drop
TEMPERATURE
(F)
–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
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
PIC II
RESISTANCE
VOLTAGE
(Ohms)
DROP (V)
4.700
98,010
4.690
94,707
4.680
91,522
4.670
88,449
4.659
85,486
4.648
82,627
4.637
79,871
4.625
77,212
4.613
74,648
4.601
72,175
4.588
69,790
4.576
67,490
4.562
65,272
4.549
63,133
4.535
61,070
4.521
59,081
4.507
57,162
4.492
55,311
4.477
53,526
4.461
51,804
4.446
50,143
4.429
48,541
4.413
46,996
4.396
45,505
4.379
44,066
4.361
42,679
4.344
41,339
4.325
40,047
4.307
38,800
4.288
37,596
4.269
36,435
4.249
35,313
4.229
34,231
4.209
33,185
4.188
32,176
4.167
31,202
4.145
30,260
4.123
29,351
4.101
28,473
4.079
27,624
3.056
26,804
4.033
26,011
4.009
25,245
3.985
24,505
3.960
23,789
3.936
23,096
3.911
22,427
3.886
21,779
3.861
21,153
3.835
20,547
3.808
19,960
3.782
19,393
3.755
18,843
3.727
18,311
3.700
17,796
3.672
17,297
3.644
16,814
3.617
16,346
3.588
15,892
3.559
15,453
3.530
15,027
3.501
14,614
3.471
14,214
3.442
13,826
3.412
13,449
3.382
13,084
3.353
12,730
3.322
12,387
3.291
12,053
3.260
11,730
3.229
11,416
3.198
11,112
3.167
10,816
3.135
10,529
3.104
10,250
3.074
9,979
3.042
9,717
3.010
9,461
2.978
9,213
3.946
8,973
2.914
8,739
2.882
8,511
2.850
8,291
2.819
8,076
2.788
7,868
TEMPERATURE
(F)
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
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
PIC II
RESISTANCE
VOLTAGE
(Ohms)
DROP (V)
2.756
7,665
2.724
7,468
2.692
7,277
2.660
7,091
2.628
6,911
2.596
6,735
2.565
6,564
2.533
6,399
2.503
6,238
2.472
6,081
2.440
5,929
2.409
5,781
2.378
5,637
2.347
5,497
2.317
5,361
2.287
5,229
2.256
5,101
2.227
4,976
2.197
4,855
2.167
4,737
2.137
4,622
2.108
4,511
2.079
4,403
2.050
4,298
2.021
4,196
1.993
4,096
1.965
4,000
1.937
3,906
1.989
3,814
1.881
3,726
1.854
3,640
1.827
3,556
1.800
3,474
1.773
3,395
1.747
3,318
1.721
3,243
1.695
3,170
1.670
3,099
1.644
3,031
1.619
2,964
1.595
2,898
1.570
2,835
1.546
2,773
1.523
2,713
1.499
2,655
1.476
2,597
1.453
2,542
1.430
2,488
1.408
2,436
1.386
2,385
1.364
2,335
1.343
2,286
1.321
2,239
1.300
2,192
1.279
2,147
1.259
2,103
1.239
2,060
1.219
2,018
1.200
1,977
1.180
1,937
1.161
1,898
1.143
1,860
1.124
1,822
1.106
1,786
1.088
1,750
1.070
1,715
1.053
1,680
1.036
1,647
1.019
1,614
1.002
1,582
0.986
1,550
0.969
1,519
0.953
1,489
0.938
1,459
0.922
1,430
0.907
1,401
0.893
1,373
0.878
1,345
0.864
1,318
0.849
1,291
0.835
1,265
0.821
1,240
0.808
1,214
0.795
1,190
0.782
1,165
85
TEMPERATURE
(F)
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
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
PIC II
RESISTANCE
VOLTAGE
(Ohms)
DROP (V)
0.769
1,141
0.756
1,118
0.744
1,095
0.731
1,072
0.719
1,050
0.707
1,029
0.696
1,007
0.684
986
0.673
965
0.662
945
0.651
925
0.640
906
0.630
887
0.619
868
0.609
850
0.599
832
0.589
815
0.579
798
0.570
782
0.561
765
0.551
750
0.542
734
0.533
719
0.524
705
0.516
690
0.508
677
0.499
663
0.491
650
0.484
638
0.476
626
0.468
614
0.460
602
0.453
591
0.445
581
0.438
570
0.431
561
0.424
551
0.418
542
0.411
533
0.404
524
0.398
516
0.392
508
0.385
501
0.379
494
0.373
487
0.367
480
0.361
473
0.356
467
0.350
461
0.344
456
0.339
450
0.333
445
0.328
439
0.323
434
0.318
429
0.313
424
0.308
419
0.304
415
0.299
410
0.294
405
0.290
401
0.285
396
0.281
391
0.277
386
0.272
382
0.268
377
0.264
372
0.260
367
0.256
361
0.252
356
0.248
350
0.245
344
0.241
338
0.237
332
0.234
325
0.230
318
0.227
311
0.224
304
0.220
297
0.217
289
0.214
282
Table 12B — Thermistor Temperature (C) vs. Resistance/Voltage Drop
TEMPERATURE
(C)
–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
PIC II
VOLTAGE DROP (V)
4.722
4.706
4.688
4.670
4.650
4.630
4.608
4.586
4.562
4.538
4.512
4.486
4.458
4.429
4.399
4.368
4.336
4.303
4.269
4.233
4.196
4.158
4.119
4.079
4.037
3.994
3.951
3.906
3.861
3.814
3.765
3.716
3.667
3.617
3.565
3.512
3.459
3.406
3.353
3.298
3.242
3.185
3.129
3.074
3.016
2.959
2.901
2.844
2.788
2.730
2.672
2.615
2.559
2.503
2.447
2.391
2.335
2.280
2.227
2.173
2.120
2.067
2.015
1.965
1.914
1.865
1.816
1.768
1.721
1.675
1.629
RESISTANCE
(Ohms)
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
TEMPERATURE
(C)
38
39
40
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
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
86
PIC II
VOLTAGE DROP (V)
1.585
1.542
1.499
1.457
1.417
1.377
1.338
1.300
1.263
1.227
1.192
1.158
1.124
1.091
1.060
1.029
0.999
0.969
0.941
0.913
0.887
0.861
0.835
0.811
0.787
0.764
0.741
0.719
0.698
0.677
0.657
0.638
0.619
0.601
0.583
0.566
0.549
0.533
0.518
0.503
0.488
0.474
0.460
0.447
0.434
0.422
0.410
0.398
0.387
0.376
0.365
0.355
0.344
0.335
0.325
0.316
0.308
0.299
0.291
0.283
0.275
0.267
0.260
0.253
0.246
0.239
0.233
0.227
0.221
0.215
RESISTANCE
(Ohms)
2 888
2 773
2 663
2 559
2 459
2 363
2 272
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
Control Modules
Notes on Module Operation
1. The chiller operator monitors and modifies configurations in the microprocessor by using the 4 softkeys and
the CVC/ICVC. Communications between the CVC/
ICVC and the CCM is accomplished through the SIO
(Sensor Input/Output) bus, which is a phone cable. The
communication between the CCM and ISM is accomplished through the sensor bus, which is a 3-wire cable.
2. If a green LED is on continuously, check the communication wiring. If a green LED is off, check the red LED
operation. If the red LED is normal, check the module
address switches (SW1) (Fig. 40 and 41). Confirm all
switches are in OFF position.
All system operating intelligence resides in the CVC/
ICVC. Some safety shutdown logic resides in the ISM in
case communications are lost between the ISM and CVC/
ICVC. Outputs are controlled by the CCM and ISM as
well.
3. Power is supplied to the modules within the control panel
via 24-vac power sources.
The transformers are located within the power panel, with
the exception of the ISM, which operates from a 115-vac
power source and has its own 24-vac transformer located
in the module.
In the power panel, T1 supplies power to the compressor
oil heater, oil pump, and optional hot gas bypass, and T2
supplies power to both the CVC/ICVC and CCM.
Power is connected to Plug J1 on each module.
Turn controller power off before servicing controls. This
ensures safety and prevents damage to the controller.
The CVC/ICVC, CCM, and ISM modules perform continuous diagnostic evaluations of the hardware to determine its
condition. Proper operation of all modules is indicated by
LEDs (light-emitting diodes) located on the circuit board of the
CVC/ICVC, CCM, and ISM.
There is one green LED located on the CCM and ISM
boards respectively, and one red LED located on the CVC/
ICVC, CCM, and ISM boards respectively.
RED LED (Labeled as STAT) — If the red LED:
• blinks continuously at a 2-second interval, the module is
operating properly
• is lit continuously, there is a problem that requires
replacing the module
• is off continuously, the power should be checked
• blinks 3 times per second, a software error has been discovered and the module must be replaced
If there is no input power, check the fuses and circuit breaker. If the fuse is good, check for a shorted secondary of the
transformer or, if power is present to the module, replace the
module.
GREED LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the controller and the network modules and should blink continuously.
MODULE PART NUMBER
SOFTWARE PART NUMBER
CCN INTERFACE
CONNECTION
DATALINK OR
DATAPORT MODULE (OPTION)
CVC/ICVC
BACK OF CVC
J7 SIO
J1 POWER/
CCN
J8 SERVICE
SW1
Fig. 40 — Rear of CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller)
87
Chiller Control Module (CCM) (Fig. 41)
7. The CVC/ICVC now automatically attaches to the local
network device.
8. Access the MAINSTAT table and highlight the TOTAL
COMPRESSOR STARTS parameter. Press the SELECT
softkey. Increase or decrease the value to match the starts
value recorded in Step 3. Press the ENTER softkey
when you reach the correct value. Now, move the highlight bar to the COMPRESSOR ONTIME parameter.
Press the SELECT softkey. Increase or decrease the run
hours value to match the value recorded in Step 2. Press
the ENTER softkey when the correct value is reached.
9. Complete the CVC/ICVC installation. Following the instructions in the Input Service Configurations section,
page 55, input all the proper configurations such as the
time, date, etc. Check the pressure transducer calibrations. PSIO installation is now complete.
INPUTS — Each input channel has 2 or 3 terminals. Refer to
individual chiller wiring diagrams for the correct terminal
numbers for your application.
OUTPUTS — Output is 24 vac. There are 2 terminals per output. Refer to the chiller wiring diagram for your specific application for the correct terminal numbers.
Integrated Starter Module (Fig. 42)
INPUTS — Inputs on strips J3 through J6 are analog inputs
and J2 is discrete (on/off) input. The specific application of the
chiller determines which terminals are used. Refer to the individual chiller wiring diagram for the correct terminal numbers
for your application.
OUTPUTS — Outputs are 115-277 vac and wired to strip J9.
There are 2 terminals per output.
Replacing Defective Processor Modules —
Solid-State Starters — Troubleshooting information pertaining to the Benshaw, Inc., solid-state starter may be found
in the following paragraphs and in the Carrier RediStart
MICRO™ Instruction Manual supplied by the starter vendor.
Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables found
in the Benshaw manual.
The module replacement part number is printed on a small
label on the rear of the CVC/ICVC module. The chiller model
and serial numbers are printed on the chiller nameplate located
on an exterior corner post. The proper software is factoryinstalled by Carrier in the replacement module. When ordering
a replacement chiller visual control (CVC/ICVC) module,
specify the complete replacement part number, full chiller
model number, and chiller serial number. The installer must
configure the new module to the original chiller data. Follow
the procedures described in the Software Configuration section
on page 55.
1. Motor terminals or starter output lugs or wire should
not be touched without disconnecting the incoming
power supply. The silicon control rectifiers (SCRs)
although technically turned off still have AC mains
potential on the output of the starter.
2. Power is present on all yellow wiring throughout the
system even though the main circuit breaker in the
unit is off.
Electrical shock can cause personal injury. Disconnect all
electrical power before servicing.
INSTALLATION
1. Verify the existing CVC/ICVC module is defective by using the procedure described in the Troubleshooting Guide
section, page 76, and the Control Modules section,
page 87. Do not select the ATTACH TO NETWORK
DEVICE table if the CVC/ICVC indicates a communication failure.
2. Data regarding the CVC/ICVC configuration should have
been recorded and saved. This data must be reconfigured
into the new CVC/ICVC. If this data is not available, follow the procedures described in the Software Configuration section.
If a CCN Building Supervisor or Service Tool is available, the module configuration should have already been
uploaded into memory. When the new module is installed, the configuration can be downloaded from the
computer.
Any communication wires from other chillers or CCN
modules should be disconnected to prevent the new
CVC/ICVC module from uploading incorrect run hours
into memory.
3. To install this module, record values for the TOTAL
COMPRESSOR STARTS and the COMPRESSOR
ONTIME from the MAINSTAT screen on the CVC/
ICVC.
4. Power off the controls.
5. Remove the old CVC/ICVC.
6. Install the new CVC/ICVC module. Turn the control
power back on.
With power off:
• Inspect for physical damage and signs of arcing, overheating, etc.
• Verify the wiring to the starter is correct.
• Verify all connections in the starter are tight.
• Check the control transformer fuses.
TESTING SILICON CONTROL RECTIFIERS IN THE
BENSHAW, INC., SOLID-STATE STARTERS — If an SCR
is suspected of being defective, use the following procedure as
part of a general troubleshooting guide.
1. Verify power is applied.
2. Verify the state of each SCR light-emitting diode (LED)
on the micropower card.
NOTE: All LEDs should be lit. If any red or green side of
these LEDs is not lit, the line voltage is not present or one
or more SCRs has failed.
3. Check incoming power. If voltage is not present check
the incoming line. If voltage is present, proceed to Steps 4
through 11.
NOTE: If after completing Steps 4 - 11 all measurements
are within specified limits, the SCRs are functioning normally. If after completing Steps 4 - 11 resistance measurements are outside the specified limits, the motor leads on
the starter power lugs T1 through T6 should be removed
and the steps repeated. This will identify if abnormal resistance measurements are being influenced by the motor
windings.
4. Remove power from the starter unit.
88
J11
DISCRETE
OUTPUTS
SW1
J12
DISCRETE
OUTPUTS
J1
24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2
V/I INPUTS
J5
COMM
STAT
THERMISTORS
J4
PRESSURE
J2
DIFF PRESSURE
J3
Fig. 41 — Chiller Control Module (CCM)
STAT
COM
G + G +
- G + 1
J7
-
J9
1
1
J8
CBA
4-20 MA OUT
SPARE VFD
COMM
TRIP
ALARM
HI
FAN
LO
FAN
COND
PUMP
EVAP SHUNT TRANS
PUMP TRIP
1CR
DISCONNECT POWER BEFORE SERVICING
HIGH VOLTAGE
WARNING
DISCRETE CONTROL CONTACTS
WARNING
HIGH VOLTAGE
00001328
DISCONNECT POWER BEFORE SERVICING
ISM 19XR04012201 9925
CEPL13025901 PCB05
CEPP130173-03-04-01
INTERGRATED STARTER MODULE
R
INTEGRATEDSTARTERMODULE
CONTACT INPUTS
115 VAC
LL1 LL2
FUSE
1A
SPAR ICE REM STRT 1M 2M
SFTY BLD STRT FLT AUX AUX
LINE VOLTAGES
L2
L3
L1
GROUND
FAULTS VFD
1/4 2/5 3/6 HZ
LINE CURRENTS
IL1
IL2
IL3
J5
1A
1
J1
J4
J2
1 + C + C + C + C + C + C
J6
J3-1
J3-2
J3-3
1
+
Fig. 42 — Integrated Starter Module (ISM)
89
-
+
-
+
-
1 + G + G + G1 + G
5. Using quarter-turn increments, alternating between
clamping bolts, apply the appropriate number of whole
turns referencing the table in Fig. 43.
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
MEASURE
BETWEEN
T1 and T6
T2 and T4
T3 and T5
6.
7.
8.
9.
10.
SCR PAIRS
BEING
CHECKED
3 and 6
2 and 5
1 and 4
RECORDED
VALUE
Care must be taken to prevent nut rotation while tightening
the bolts. If the nut rotates while tightening the bolt, SCR
replacement must be started over.
If all measured values are greater than 5K ohms, proceed
to Step 10. If any values are less than 5K ohms, one or
more of the SCRs in that pair is shorted.
Remove both SCRs in the pair (See SCR Removal/
Installation).
Using an ohmmeter, measure the resistance (anode to
cathode) of each SCR to determine which device has
failed.
NOTE: Both SCRs may be defective, but typically, only
one is shorted. If both SCRs provide acceptable resistance
measurements, proceed to Step 10.
Replace the defective SCR(s).
Retest the “pair” for resistance values indicated above.
On the right side of the firing card, measure the resistance
between the red and white gate/cathode leads for each
SCR (1 through 6). A measurement between 5 and
50 ohms is normal. Abnormally high values may indicate
a failed gate for that SCR.
6. Reconnect the red (cathode) wire from the SCR and the
white (anode-gate) wire to the appropriate location on the
firing card (i.e., SCR1 wires to firing card terminal
G1-white wire, and K1-red wire).
7. Reconnect all other wiring and bus work.
8. Return starter to normal operation.
NUT
CLAMPING
BOLT
A
ALUMINUM
HEATSINK
LOOSEN
AND
TIGHTEN
BOLTS
FROM
THIS END
ROLL PIN
SCR
If any red or white SCR gate leads are removed from the
firing card or an SCR, care must be taken to ensure the
leads are replaced EXACTLY as they were (white wires to
gates, and red wires to cathodes on both the firing card and
SCR), or damage to the starter and/or motor may result.
11. Replace the SCRs and retest the pair.
SCR REMOVAL/INSTALLATION — Refer to Fig. 43.
1. Remove the SCR by loosening the clamping bolts on
each side of the SCR,
2. After the SCR has been removed and the bus work is
loose, apply a thin coat of either silicon based thermal
joint compound or a joint compound for aluminum or
copper wire connections to the contact surfaces of the replacement SCR. This allows for improved heat dissipation and electrical conductivity.
3. Place the SCR between the roll pins on the heatsink
assemblies so the roll pins fit into the small holes in each
side of the SCR.
NOTE: Ensure the SCR is installed so the cathode side is
the side from which the red wire extends. The heatsink is
labeled to show the correct orientation.
4. Hand tighten the bolts until the SCR contacts the
heatsink.
SCR PART
NUMBER
BISCR
CLAMP
SIZE
6601218
1030
6601818
1030
8801230
1035
8801830
1035
15001850
2040
15001850
2050
220012100
330018500
A
BOLT
NO. OF
DIMENSION
LENGTH
TURNS
(in.)
(in.)
2.75
3.0
11/2
(70 mm)
(76 mm)
2.75
3.0
11/2
(70 mm)
(76 mm)
2.75
3.5
13/4
(70 mm)
(89 mm)
3.0
2.75
13/4
(89 mm)
(70 mm)
4.00
4.0
23/4
(102 mm)
(102 mm)
5.0
4.00
23/4
(127 mm)
(102 mm)
Consult Benshaw Representative
Consult Benshaw Representative
Fig. 43 — SCR Installation
Physical Data — Tables 13A-20 and Fig. 44-57 provide
additional information on component weights, compressor fits
and clearances, physical and electrical data, and wiring schematics for the operator’s convenience during troubleshooting.
90
Table 13A — Heat Exchanger Data (English)
NUMBER OF TUBES
CODE
10
11
12
15
16
17
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
5A
5B
5C
55
56
57
5F
5G
5H
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
ENGLISH
Dry (Rigging) Weight (lb)
Cooler
Condenser
Cooler
Only
142
161
180
142
161
180
200
240
282
200
240
280
200
240
280
324
364
400
324
364
400
431
485
519
225
241
258
431
485
519
225
241
258
557
599
633
557
599
633
644
726
790
644
726
790
829
901
976
829
901
976
180
200
225
180
200
225
218
266
315
218
267
315
218
267
315
370
417
463
370
417
463
509
556
602
—
—
—
509
556
602
—
—
—
648
695
741
648
695
741
781
870
956
781
870
956
990
1080
1170
990
1080
1170
2,742
2,812
2,883
3,003
3,089
3,176
3,442
3,590
3,746
4,137
4,319
4,511
4,409
4,617
4,835
5,898
6,080
6,244
6,353
6,561
6,748
7,015
7,262
7,417
6,426
6,499
6,577
7,559
7,839
8,016
6,879
6,962
7,050
8,270
8,462
8,617
8,943
9,161
9,338
12,395
12,821
13,153
13,293
13,780
14,159
16,156
16,530
16,919
17,296
17,723
18,169
Condenser
Only
2,704
2,772
2,857
2,984
3,068
3,173
3,523
3,690
3,854
3,694
3,899
4,100
4,606
4,840
5,069
6,054
6,259
6,465
6,617
6,851
7,085
7,285
7,490
7,683
—
—
—
7,980
8,214
8,434
—
—
—
8,286
8,483
8,676
9,204
9,428
9,648
13,139
13,568
13,969
14,211
14,702
15,160
15,746
16,176
16,606
17,001
17,492
17,984
NOTES:
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight
includes suction elbow, control panel, and distribution piping.
Weight does not include compressor.
Chiller Charge
Refrigerant Weight (lb)
Water Volume (gal)
Cooler
Condenser
Cooler
Condenser
290
200
34
42
310
200
37
45
330
200
40
49
320
250
39
48
340
250
43
52
370
250
47
57
345
225
48
48
385
225
55
55
435
225
62
63
350
260
55
55
420
260
64
65
490
260
72
74
400
310
61
62
480
310
70
72
550
310
80
83
560
280
89
96
630
280
97
106
690
280
105
114
640
330
98
106
720
330
108
117
790
330
116
127
750
400
115
128
840
400
126
137
900
400
133
136
500
—
106
—
520
—
109
—
550
—
112
—
870
490
127
142
940
490
139
152
980
490
147
162
550
—
116
—
570
—
120
—
600
—
124
—
940
420
144
159
980
420
153
168
1020
420
160
177
1020
510
160
176
1060
510
169
187
1090
510
177
197
1220
780
224
209
1340
780
243
229
1440
780
257
248
1365
925
245
234
1505
925
266
257
1625
925
283
278
1500
720
285
264
1620
720
302
284
1730
720
319
304
1690
860
313
295
1820
860
331
318
1940
860
351
341
2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic
grooves. Weight includes the float valve, discharge elbow, and
distribution piping. Weight does not include unit-mounted starter,
isolation valves, and pumpout unit.
91
Table 13B — Heat Exchanger Data (SI)
NUMBER OF TUBES
CODE
10
11
12
15
16
17
20
21
22
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
5A
5B
5C
55
56
57
5F
5G
5H
60
61
62
65
66
67
70
71
72
75
76
77
80
81
82
85
86
87
SI
Dry (Rigging) Weight (kg)
Cooler
Condenser
Cooler
Only
142
161
180
142
161
180
200
240
282
200
240
280
200
240
280
324
364
400
324
364
400
431
485
519
225
241
258
431
485
519
225
241
258
557
599
633
557
599
633
644
726
790
644
726
790
829
901
976
829
901
976
180
200
225
180
200
225
218
266
315
218
267
315
218
267
315
370
417
463
370
417
463
509
556
602
—
—
—
509
556
602
—
—
—
648
695
741
648
695
741
781
870
956
781
870
956
990
1080
1170
990
1080
1170
1244
1275
1307
1362
1401
1440
1561
1628
1699
1876
1958
2046
2000
2094
2193
2675
2757
2832
2881
2976
3060
3181
3293
3364
2915
2949
2984
3428
3555
3635
3121
3159
3199
3751
3838
3908
4056
4155
4235
5622
5814
5965
6028
6259
6421
7326
7496
7673
7844
8037
8240
Condenser
Only
1226
1257
1296
1353
1391
1439
1598
1673
1748
1675
1768
1859
2089
2195
2300
2745
2839
2932
3001
3107
3213
3304
3397
3484
—
—
—
3619
3725
3825
—
—
—
3758
3847
3935
4174
4276
4376
5959
6153
6335
6445
6667
6875
7141
7336
7531
7710
7933
8156
NOTES:
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,
1034 psig, nozzle-in-head waterbox with victaulic grooves.
Weight includes suction elbow, control panel, and distribution piping. Weight does not include compressor.
Chiller Charge
Refrigerant Weight (kg)
Water Volume (L)
Cooler
Condenser
Cooler
Condenser
132
91
129
158
141
91
140
170
150
91
152
185
145
113
149
183
154
113
163
198
168
113
178
216
157
102
183
181
175
102
207
210
197
102
234
239
159
118
208
210
190
118
242
246
222
118
271
282
181
141
232
233
218
141
266
273
249
141
301
314
254
127
338
365
286
127
368
400
313
127
396
433
290
150
372
403
327
150
407
442
358
150
438
481
340
181
435
483
381
181
477
518
408
181
502
552
227
—
401
—
236
—
412
—
250
—
424
—
395
222
481
536
426
222
527
575
446
222
557
613
250
—
439
—
259
—
454
—
273
—
464
—
426
190
546
601
444
190
578
636
462
190
604
669
462
231
605
668
481
231
641
707
494
231
671
745
553
354
848
791
608
354
919
867
653
354
974
937
619
420
927
885
683
420
1009
971
737
420
1072
1052
680
327
1080
1000
735
327
1143
1075
785
327
1208
1150
766
390
1183
1118
825
390
1254
1205
880
390
1329
1291
2. Condenser data: based on a condenser with standard wall tubing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic
grooves. Weight includes the float valve, discharge elbow, and
distribution piping. Weight does not include unit-mounted starter,
isolation valves, and pumpout unit.
92
Table 14 — 19XR Additional Data for Marine Waterboxes*
HEAT EXCHANGER
FRAME, PASS
FRAME 2, 1 AND 2 PASS
FRAME 2, 2 PASS
FRAME 3, 1 AND 2 PASS
FRAME 3, 2 PASS
FRAME 4, 1 AND 3 PASS
FRAME 4, 2 PASS
FRAME 5, 1 AND 3 PASS
FRAME 5, 2 PASS
FRAME 6, 1 AND 3 PASS
FRAME 6, 2 PASS
FRAME 7, 1 AND 3 PASS
FRAME 7, 2 PASS
FRAME 8, 1 AND 3 PASS
FRAME 8, 2 PASS
FRAME 2, 1 AND 3 PASS
FRAME 2, 2 PASS
FRAME 3, 1 AND 3 PASS
FRAME 3, 2 PASS
FRAME 4, 1 AND 3 PASS
FRAME 4, 2 PASS
FRAME 5, 1 AND 3 PASS
FRAME 5, 2 PASS
FRAME 6, 1 AND 3 PASS
FRAME 6, 2 PASS
FRAME 7, 1 AND 3 PASS
FRAME 7, 2 PASS
FRAME 8, 1 AND 3 PASS
FRAME 8, 2 PASS
Psig
150
150
150
150
150
150
150
150
150
150
150
150
150
150
300
300
300
300
300
300
300
300
300
300
300
300
300
300
ENGLISH
Rigging Weight
(lb)
730
365
730
365
1060
530
1240
620
1500
750
2010
740
1855
585
860
430
860
430
1210
600
1380
690
1650
825
3100
1830
2745
1475
Water Volume
(gal)
84
42
84
42
123
61
139
69
162
81
326
163
406
203
84
42
84
42
123
61
139
69
162
81
326
163
405
203
kPa
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
1034
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
2068
SI
Rigging Weight
(kg)
331
166
331
166
481
240
562
281
680
340
912
336
841
265
390
195
390
195
549
272
626
313
748
374
1406
830
1245
766
Water Volume
(L)
318
159
317
159
465
231
526
263
612
306
1234
617
1537
768
318
159
317
159
465
231
526
263
612
306
1234
617
1533
768
*Add to heat exchanger data for total weights or volumes.
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame size.
2. For the total weight of a vessel with a marine waterbox, add these values to the heat
exchanger weights (or volumes).
Table 15 — Compressor Weights
COMPONENT
SUCTION ELBOW
DISCHARGE ELBOW
TRANSMISSION*
SUCTION HOUSING
IMPELLER SHROUD
COMPRESSOR BASE
DIFFUSER
OIL PUMP
MISCELLANEOUS
TOTAL WEIGHT
(Less Motor and Elbows)
FRAME 2
COMPRESSOR
WEIGHT
FRAME 3
COMPRESSOR
WEIGHT
lb
50
60
320
300
35
1260
35
125
100
kg
23
27
145
136
16
571
16
57
45
lb
54
46
730
350
80
1050
70
150
135
kg
24
21
331
159
36
476
32
68
61
2300
1043
2660
1207
*Transmission weight does not include rotor, shaft, and gear.
93
FRAME 4
COMPRESSOR
WEIGHT (Without
Split Ring Diffuser)
lb
kg
175
79
157
71
656
298
446
202
126
57
1589
721
130
59
150
68
144
65
3712
1684
FRAME 4
COMPRESSOR
WEIGHT (With
Split Ring Diffuser)
lb
kg
175
79
157
71
656
298
810
367
200
91
2022
917
130
59
150
68
200
91
4548
2063
FRAME 5
COMPRESSOR
WEIGHT
lb
400
325
1000
1200
250
3695
300
185
220
kg
181
147
454
544
113
1676
136
84
100
6850
3107
Table 16 — 19XR Motor Weights Standard and High Efficiency Motors
MOTOR
SIZE
BD
BE
BF
BG
BH
CD
CE
CL
CM
CN
CP
CQ
DB
DC
DD
DE
DF
DG
DH
DJ
EH
EJ
EK
EL
EM
EN
EP
Stator Weight*
(lb)
60 Hz
50 Hz
1030
1030
1070
1070
1120
1120
1175
1175
1175
1175
1286
1358
1305
1377
1324
1435
1347
1455
1358
1467
1401
1479
1455
1479
1665
1725
1681
1737
1977
2069
2018
2089
2100
2139
2187
2153
2203
2207
2228
2305
3060
3120
3105
3250
3180
3250
3180
3370
3270
3370
3270
3520
3340
3520
ENGLISH
Rotor Weight†
(lb)
60 Hz
50 Hz
240
240
250
250
265
265
290
290
290
290
258
273
265
281
280
296
303
303
316
316
329
316
329
316
361
391
391
404
536
596
550
550
575
567
599
599
604
604
614
614
701
751
716
751
716
768
737
801
737
801
801
851
830
851
End Bell
Cover
(lb)
185
185
185
185
185
274
274
274
274
274
274
274
236
236
318
318
318
318
318
318
414
414
414
414
414
414
414
Stator Weight*
(kg)
60 Hz
50 Hz
467
467
485
485
508
508
533
533
533
533
583
616
592
625
600
651
611
660
616
665
635
671
660
671
755
782
762
788
897
938
915
948
952
970
992
977
999
1001
1011
1046
1388
1415
1408
1474
1442
1474
1442
1529
1483
1529
1483
1597
1515
1597
*Stator weight includes stator and shell.
†Rotor weight includes rotor and shaft.
NOTE: When different voltage motors have different weights the largest weight is given.
94
SI
Rotor Weight†
(kg)
60 Hz
50 Hz
109
109
113
113
120
120
132
132
132
132
117
124
120
127
127
134
137
137
143
143
149
143
149
152
164
177
177
183
243
248
249
248
261
257
272
272
274
274
279
279
318
341
325
341
325
348
334
363
334
363
363
386
376
386
End Bell
Cover
(kg)
84
84
84
84
84
125
125
125
125
125
125
125
107
107
144
144
144
144
144
144
188
188
188
188
188
188
188
Table 17A — 19XR Waterbox Cover Weights — English (lb)
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
FRAME 1
Standard
Flanged
Nozzles
177
204
185
218
180
196
136
136
248
301
255
324
253
288
175
175
FRAME 2
Standard
Flanged
Nozzles
320
350
320
350
300
340
300
300
411
486
411
518
433
468
400
400
FRAME 3
Standard
Flanged
Nozzles
320
350
320
350
300
340
300
300
411
486
411
518
433
468
400
400
FRAME 4
Standard
Flanged
Nozzles
148
185
202
256
473
489
317
317
593
668
594
700
621
656
569
569
FRAME 5
Standard
Flanged
Nozzles
168
229
224
298
629
655
393
393
764
839
761
878
795
838
713
713
FRAME 6
Standard
Flanged
Nozzles
187
223
257
330
817
843
503
503
959
1035
923
1074
980
1031
913
913
FRAME 7 COOLER
Standard
Flanged
Nozzles
329
441
426
541
1202
1239
789
789
1636
1801
1585
1825
1660
1741
1451
1451
FRAME 7 CONDENSER
Standard
Flanged
Nozzles
329
441
426
541
1113
1171
703
703
1472
1633
1410
1644
1496
1613
1440
1440
FRAME 8 COOLER
Standard
Flanged
Nozzles
417
494
531
685
1568
1626
1339
1339
2265
2429
2170
2499
2273
2436
1923
1923
FRAME 8 CONDENSER
Standard
Flanged
Nozzles
417
494
531
685
1438
1497
898
898
1860
2015
1735
2044
1883
1995
1635
1635
LEGEND
NIH
— Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.
RIG MACHINE COMPONENTS — Refer to instructions
below, Fig. 6-9, and Carrier Certified Prints for machine component disassembly.
Do not attempt to disconnect flanges while the machine is
under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.
IMPORTANT: Only a qualified service technician should
perform this operation.
Before rigging the compressor, disconnect all wires entering the power panel.
95
Table 17B — 19XR Waterbox Cover Weights — SI (kg)
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
HEAT
EXCHANGER
WATERBOX
DESCRIPTION
COOLER/
CONDENSER
NIH, 1 Pass Cover, 150 psig
NIH, 2 Pass Cover, 150 psig
NIH, 3 Pass Cover, 150 psig
NIH/MWB End Cover, 150 psig
NIH, 1 Pass Cover, 300 psig
NIH, 2 Pass Cover, 300 psig
NIH, 3 Pass Cover, 300 psig
NIH/MWB End Cover, 300 psig
FRAME 1
Standard
Flanged
Nozzles
80
93
84
99
82
89
62
62
112
137
116
147
115
131
79
79
FRAME 2
Standard
Flanged
Nozzles
145
159
145
159
136
154
136
136
186
220
186
235
196
212
181
181
FRAME 3
Standard
Flanged
Nozzles
145
159
145
159
140
154
136
136
186
220
186
235
196
212
181
181
FRAME 4
Standard
Flanged
Nozzles
67
84
92
116
214
222
144
144
269
303
269
317
282
298
258
258
FRAME 5
Standard
Flanged
Nozzles
76
104
107
135
285
297
178
178
347
381
345
398
361
380
323
323
FRAME 6
Standard
Flanged
Nozzles
85
101
117
150
371
382
228
228
435
470
419
487
445
468
414
414
FRAME 7 COOLER
Standard
Flanged
Nozzles
149
200
193
245
545
562
357
358
742
817
719
828
753
790
658
658
FRAME 7 CONDENSER
Standard
Flanged
Nozzles
149
200
193
245
505
531
319
319
668
741
640
746
679
732
653
653
FRAME 8 COOLER
Standard
Flanged
Nozzles
189
224
241
311
711
738
607
607
1027
1102
984
1134
1031
1105
872
872
FRAME 8 CONDENSER
Standard
Flanged
Nozzles
189
224
241
311
652
679
407
407
844
914
787
927
854
905
742
742
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.
96
Table 20 — Motor Voltage Code
Table 18 — Optional Pumpout System
Electrical Data
MOTOR
CODE
1
4
5
6
CONDENSER
UNIT
19EA47-748
19EA42-748
19EA44-748
19EA46-748
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
Code
60
61
62
63
64
65
66
67
68
69
50
51
52
53
54
55
LRA
23.0
63.5
57.5
28.8
LEGEND
LRA — Locked Rotor Amps
RLA — Rated Load Amps
Table 19 — Additional Miscellaneous Weights
ITEM
CONTROL CABINET
UNIT-MOUNTED STARTER
OPTIONAL ISOLATION VALVES
UNIT MOUNTED VFD
Lb
30
500
115
1000
Kg
14
227
52
454
VFD — Variable Frequency Drive
97
MOTOR VOLTAGE CODE
Volts
200
230
380
416
460
575
2400
3300
4160
6900
230
346
400
3000
3300
6300
Frequency
60
60
60
60
60
60
60
60
60
60
50
50
50
50
50
50
COMPRESSOR, TRANSMISSION AREA
Compressor Assembly Torques
ITEM
1*
2
3
4
5*
6*
7*
DESCRIPTION
Oil Heater Retaining Nut
Bull Gear Retaining Bolt
Demister Bolts
Impeller Retaining Bolt
Motor Terminals (Low Voltage)
Guide Vane Shaft Seal Nut
Motor Terminals (High Voltage)
— Insulator
— Packing Nut
— Brass Jam Nut
TORQUE
ft.-lb
N•m
20
28
80-85
108-115
15-19
20-26
44-46
60-62
50
68
25
34
2-4
5
10
2.7-5.4
6.8
13.6
LEGEND
N•m — Newton meters
*Not shown.
NOTES:
1. All clearances for cylindrical surfaces are diametrical.
2. Dimensions are with rotor in thrust position.
3. Dimensions shown are in inches.
4. Impeller spacing should be performed in accordance with most
recent Carrier Service Bulletin on impeller spacing.
VIEW A
LOW SPEED SHAFT THRUST DISK
Fig. 44 — Compressor Fits and Clearances
98
VIEW B — HIGH SPEED SHAFT
19XR COMPRESSOR CLEARANCES
ITEM
A
B
C
D
E
F
G
221-299
.0050
.0040
.0050
.0040
.0115
.0055
.0190
.0040
–.002
–.0005
.0050
.0040
—*
COMPRESSOR CODE
321-389
421-489
.0050
.0055
.0040
.0043
.0050
.0053
.0040
.0043
.0115
.0100
.0080
.0050
.022
.027
.012
.017
–.0020
–.0029
–.0005
–.0014
.0050
.0048
.0040
.0038
—*
—*
*Depends on impeller size, contact your Carrier Service Representative for more information.
NOTE: All clearances for cylindrical surfaces are diametrical.
Fig. 44 — Compressor Fits and Clearances (cont)
99
521-599
.0069
.0059
.0065
.0055
.0010
.0060
.0350
.0250
–.0019
–.0005
.0062
.0052
—*
100
Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter
101
Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter (cont)
102
C
CB
CP
CT
DS
FU
GRD
HPR
ISM
L
—
—
—
—
—
—
—
—
—
—
LL
M
OP
PFCC
RES
S
ST
TB
TC
VL
LEGEND
—
—
—
—
—
—
—
—
—
—
Control Power Supply
Contactor
Oil Pump
Power Factor Correction Capacitor
Resistor
Contactor
Shunt Trip
Terminal Block
Transition Contactor
Wire Label
PRIMARY
H1-H3
H1-H4
416
480
400
460
380
440
H1-H5
600
575
550
500
SECONDARY
X1-X2
X1-X3
X1-X4
99
120
130
95
115
125
91
110
120
85
100
110
3. Current transformer
•amps nameplate ratio
•amps effective ratio with primary turns
•polarity marking
Be sure to connect per polarity markings.
4. “S” - “2M” contactors are electrically and mechanically interlocked.
5. Live capacitor unit. Deenergize starter. Wait one (1) minute and ground
terminals before servicing.
6. All control wiring 14 gage red except as noted.
H1-H2
240
230
220
208
NOTES:
1. Remote device.
2. Transformer connected for 480 v primary 120 v secondary. For other
voltages see chart:
Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter (cont)
Contactor
Circuit Breaker
Control Power
Current Transformer
Disconnect Switch
Fuse
Ground
High Pressure Relay
Integrated Starter Module
Main Supply Power
103
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
**
ISM
L
LVG
N.O.
PRESS
REQM’T
TEMP
TB
Fig. 46A — Electronic PIC II Control Panel Wiring Schematic For CVC (Frame 2, 3, 4 Compressor)
AUX
BRG
C
CB
CCM
CCN
COMP’R
COND
CVC
DISCH
DL/DP
ENT
EVAP
EXT
FR
GND
G.V.
HGBP
HT EXCH
LEGEND
Auxiliary
Bearing
Contactor
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Compressor
Condenser
Chiller Visual Controller
Discharge
Datalink or Dataport
Entering
Evaporator
External
Frame
Ground
Guide Vane
Hot Gas Bypass
Heat Exchanger
—
—
—
—
—
—
—
—
Denotes Component Terminal
Wire Splice
Denotes Conductor
Male/Female Connector
Option Wiring
Denotes Motor Starter Panel Conn.
Denotes Power Panel Terminal
Denotes Oil Pump Terminal
LEGEND (cont)
Integrated Starter Module
Main Supply Power
Leaving
Normally Open
Pressure
Requirement
Temperature
Terminal Board
Denotes Control Panel Terminal
104
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
**
ISM
L
LVG
N.O.
PRESS
REQM’T
TEMP
TB
Fig. 46B — Electronic PIC II Control Panel Wiring Schematic For ICVC (Frame 2, 3, 4 Compressor)
AUX
BRG
C
CB
CCM
CCN
COMP’R
COND
DISCH
DL/DP
ENT
EVAP
EXT
FR
GND
G.V.
HGBP
HT EXCH
ICVC
LEGEND
Auxiliary
Bearing
Contactor
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Compressor
Condenser
Discharge
Datalink or Dataport
Entering
Evaporator
External
Frame
Ground
Guide Vane
Hot Gas Bypass
Heat Exchanger
International Chiller Visual Controller
—
—
—
—
—
—
—
—
Denotes Component Terminal
Wire Splice
Denotes Conductor
Male/Female Connector
Option Wiring
Denotes Motor Starter Panel Conn.
Denotes Power Panel Terminal
Denotes Oil Pump Terminal
LEGEND (cont)
Integrated Starter Module
Main Supply Power
Leaving
Normally Open
Pressure
Requirement
Temperature
Terminal Board
Denotes Control Panel Terminal
105
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Auxiliary
Bearing
Contactor
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Compressor
Condenser
Chiller Visual Controller
Discharge
Datalink or Dataport
Entering
Evaporator
External
Frame
Ground
Guide Vane
Hot Gas Bypass
Heat Exchanger
**
—
—
—
—
—
—
—
—
Denotes Motor Starter Panel Conn.
Denotes Component Terminal
Wire Splice
Denotes Conductor Male/Female Connector
Option Wiring
Denotes Power Panel Terminal
Denotes Oil Pump Terminal
LEGEND (cont)
Integrated Starter Module
Main Supply Power
Leaving
Normally Open
Pressure
Requirement
Temperature
Terminal Board
Denotes Control Panel Terminal
Fig. 47A — Electronic PIC II Control Panel Wiring Schematic For CVC (Frame 4 with Split Ring Diffuser and Frame 5 Compressor)
AUX
BRG
C
CB
CCM
CCN
COMP’R
COND
CVC
DISCH
DL/DP
ENT
EVAP
EXT
FR
GND
G.V.
HGBP
HT EXCH
ISM
L
LVG
N.O.
PRESS
REQM’T
TEMP
TB
106
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Auxiliary
Bearing
Contactor
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Compressor
Condenser
Discharge
Datalink or Dataport
Entering
Evaporator
External
Frame
Ground
Guide Vane
Hot Gas Bypass
Heat Exchanger
International Chiller Visual Controller
Integrated Starter Module
**
L
LVG
N.O.
PRESS
REQM’T
TEMP
TB
—
—
—
—
—
—
—
Denotes Motor Starter Panel Conn.
Denotes Component Terminal
Wire Splice
Denotes Conductor Male/Female Connector
Option Wiring
Denotes Power Panel Terminal
Denotes Oil Pump Terminal
LEGEND (cont)
Main Supply Power
Leaving
Normally Open
Pressure
Requirement
Temperature
Terminal Board
Denotes Control Panel Terminal
Fig. 47B — Electronic PIC II Control Panel Wiring Schematic For ICVC (Frame 4 with Split Ring Diffuser and Frame 5 Compressor)
AUX
BRG
C
CB
CCM
CCN
COMP’R
COND
DISCH
DL/DP
ENT
EVAP
EXT
FR
GND
G.V.
HGBP
HT EXCH
ICVC
ISM
107
AUX
C
CB
CCM
COMM
COMPR
DISCH
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Chiller Control Module
Communication
Compressor
Discharge
FR
G
GRD
GVA
HGBP
HT EXCH
ISM
—
—
—
—
—
—
—
Frame
Ground
Ground
Guide Vane Actuator
Hot Gas Bypass
Heat Exchanger
Integrated Starter Module
—
—
—
—
—
—
Main Supply Power
Normally Open
Pressure
Requirement
Transformer
Terminal Board
LEGEND
*
**
Option Wiring
Denotes Conductor Male/Female Connector
Wire Splice
Denotes Power Panel Terminal
Denotes Mach. Control Panel Conn.
Denotes Motor Starter Panel Conn.
Denotes Component Terminal
Denotes Oil Pump Terminal
Fig. 48 — Power Panel Wiring Schematic
L
N.O.
PRESS
REQM’T
T
TB
LEGEND
AUX
C
CB
CT
DS
FU
G
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Current Transformer
Disconnect Switch
Fuse
Ground
HPR
ISM
L
LL
M
RES
S
TB
—
—
—
—
—
—
—
—
High Pressure Relay
Integrated Starter Module
Main Supply Power
Control Power Supply
Contactor
Resistor
Contactor
Terminal Block
NOTES:
1. Power factor correction capacitors (when required) are connected ahead of all current
transformers for proper calibration and sensing by the ISM and IQDP4130.
2. For phase to phase ground fault protection refer to Fig. 51.
3. For metering information refer to Fig. 52.
Fig. 49 — Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP
108
LEGEND
AUX
C
CB
CT
DS
FU
G
—
—
—
—
—
—
—
Auxiliary
Contactor
Circuit Breaker
Current Transformer
Disconnect Switch
Fuse
Ground
HPR
ISM
L
LL
M
RES
S
TB
—
—
—
—
—
—
—
—
High Pressure Relay
Integrated Starter Module
Main Supply Power
Control Power Supply
Contactor
Resistor
Contactor
Terminal Block
NOTES:
1. Power factor correction capacitors (when required) are connected ahead of all current
transformers for proper calibration and sensing by the ISM and IQDP4130.
2. For metering option see Fig. 52.
Fig. 50 — Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP
109
CT
ISM
VFD
LEGEND
— Current Transformer
— Integrated Starter Module
— Variable Frequency Drive
Represents Twisted Wire
To Door
Fig. 51 — Ground Fault Phase Current Option
AM
CT
L
VM
—
—
—
—
LEGEND
Ammeter
Current Transformer
Main Power Supply
Voltmeter
Represents Twisted Wire
To Door
Fig. 52 — Separate Metering Option
110
Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)
111
LEGEND
AUX
BR
CB
COND
CPU
CVC/
ICVC
CT
EVAP
FU
GND
—
—
—
—
—
—
Auxiliary
Bridge Rectifier
Circuit Breaker
Condenser
Central Processing Unit
Chiller Visual Controller
—
—
—
—
Current Transformer
Evaporator
Fuse
Ground
L
LL
M
O/L
PFCC
—
—
—
—
—
RLA
SCR
ST
TB
—
—
—
—
Main Supply Power
Control Power Supply
Contactor
Overload Reset
Power Factor
Correction Capacitor
Rated Load Amps
Silicone Controller Rectifier
Shunt Trip
Terminal Block
NOTES:
1 LED status with power applied and prior to run command.
Wire Node Symbol
may have terminal block
Benshaw supplied
terminal block
PC Board Terminals
Twisted Pair
Twisted Shielded Pair
Terminal Strip
Shield Wire
Power Connection
Field Wiring
"ON"
"OFF"
5
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1.
Transformer connections per transformer nameplate connection diagram.
MOVs are used on power stack assemblies for system voltages of 200 through 460 vac (as shown).
Resistor/capacitor networks (DVDTs) are used on power stack assemblies in place of MOVs for a system
voltage of 575 vac (not shown).
K3 relay shown in deenergized state. K3 contact will close when power is supplied. K3 contact will open
on stop command or system fault.
CT1-CT3 are sized per Chart 2.
6
Optional.
2
3
4
Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)
112
113
Fig. 54 — Typical Across-the-Line Starter Wiring Schematic (Medium Voltage)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
AUX
C
CB
COMM
COND
CPT
CR
CT
DS
EVAP
FU
G
GFCT
HPR
ISM
L
LL
LVG
M
MTR
PRESS
PT
ST
STAT
TB
TRANS
VFD
VL
LEGEND
Auxiliary
Contactor
Circuit Breaker
Communication
Condenser
Control Power
Transformer
Control Relay
Current Transformer
Disconnect Switch
Evaporator
Fuse
Ground
Ground Fault Current
Transformer
High Pressure Relay
Integrated Starter
Module
Main Power Supply
Control Power Supply
Leaving
Contactor
Motor
Pressure
Power Transformer
Shunt Trip
Status
Terminal Block
Transition
Variable Frequency
Drive
Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
(supplied by others)
Field Installed
Control Wiring
(supplied by others)
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
114
Fig. 55 — Typical Primary Reactor Starter Wiring Schematic (Medium Voltage)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
AUX
C
CB
COMM
COND
CPT
CR
CT
DS
EVAP
FU
G
GFCT
HPR
ISM
L
LL
LVG
M
MTR
PRESS
PT
ST
STAT
TB
TRANS
VFD
VL
LEGEND
Auxiliary
Contactor
Circuit Breaker
Communication
Condenser
Control Power
Transformer
Control Relay
Current Transformer
Disconnect Switch
Evaporator
Fuse
Ground
Ground Fault Current
Transformer
High Pressure Relay
Integrated Starter
Module
Main Power Supply
Control Power Supply
Leaving
Contactor
Motor
Pressure
Power Transformer
Shunt Trip
Status
Terminal Block
Transition
Variable Frequency
Drive
Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
(supplied by others)
Field Installed
Control Wiring
(supplied by others)
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
Fig. 56 — Typical Autotransformer Starter Wiring Schematic (Medium Voltage)
1A
115
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
AUX
C
CB
COMM
COND
CPT
CR
CT
DISCH
DS
EVAP
FU
GFCT
HPR
ISM
L
LL
MTR
PRESS
PT
ST
STAT
TB
TC
TRANS
VFD
VL
LEGEND
Auxiliary
Contactor
Circuit Breaker
Communication
Condenser
Control Power
Transformer
Control Relay
Current Transformer
Discharge
Disconnect Switch
Evaporator
Fuse
Ground Fault Current
Transformer
High Pressure Relay
Integrated Starter
Module
Main Power Supply
Control Power Supply
Motor
Pressure
Power Transformer
Shunt Trip
Status
Terminal Block
Transition Clear
Transition
Variable Frequency
Drive
Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
(supplied by others)
Field Installed
Control Wiring
(supplied by others)
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
116
Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic
117
Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
118
Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
119
Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
120
Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
121
Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
LEGEND FOR FIG. 57
AUX
CB
CCM
CCN
COMM
CT
CVC
DP/DL
DS
FD
FR
FU
G
GV
HGBP
HPR
HPS
HX
ICVC
IGBT
IGV
ISM
J
LEM
MAB
RC
RMI
ST
T
TB
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Auxiliary
Circuit Breaker
Chiller Control Module
Carrier Comfort Network
Communications
Current Transformer
Chiller Visual Controller
Data Port/Data Link
Disconnect Switch
Fused Disconnect
Fan Relay
Fuse
Chassis Ground
Guide Vane
Hot Gas Bypass
High Discharge Pressure Relay
High Pressure Switch
Heat Exchanger
International Chiller Visual Controller
Insulated Gate Bipolar Transistor
Inlet Guide Vane
Integrated Starter Module
Junction
Current Detector
Module Adapter Board
Regulator Controller
Remote Metering Interface
Shunt Trip
Transformer
Terminal Block
VFD
1C
1M
2C
3C
—
—
—
—
—
Variable Frequency Drive
Compressor Oil Heater Contactor
Start Contactor
Oil Pump Contactor
Hot Gas Bypass Relay
Field Control Wiring
Field Power Wiring
Factory Wiring
Pressure Switch
Shielded Cable
Chassis Ground
Twisted Pair Wiring
Male/Female Connector
Terminal Block Connection
Wire Splice or Junction
Cam Switch
Component Terminal
Thermistor
+
Compr Oil Pump Terminal
Cartridge Fuse
Earth Ground
Resistor
Light
Temperature Switch
Common Potential
Dry Contact
VFD Terminal
Current Transformer, Polarized
(Direction Determined by •)
Transformer
Transducer
IGBT
Fusible Link
Diode
Potentiometer
Silicone Control Rectifier
122
INDEX
Motor and Lubricating Oil Cooling Cycle, 7
Motor-Compressor, 5
Motor Rotation (Check), 65
Notes on Module Operation, 87
Oil Changes, 73
Oil Charge, 55
Oil Cooler, 36
Oil Pressure and Compressor Stop (Check), 65
Oil Reclaim Filter, 73
Oil Reclaim System, 8
Oil Specification, 73
Oil Sump Temperature Control, 36
Open Oil Circuit Valves, 48
Operating Instructions, 66
Operating the Optional Pumpout Unit, 67
Operator Duties, 66
Optional Pumpout Compressor Water Piping (Check), 53
Optional Pumpout System Controls and
Compressor (Check), 63
Optional Pumpout System Maintenance, 75
Ordering Replacement Chiller Parts, 75
Overview (Troubleshooting Guide), 76
Perform a Control Test, 62
Physical Data, 90
PIC II System Components, 11
PIC II System Functions, 33
Power Up the Controls and Check the Oil Heater, 55
Preparation (Initial Start-Up), 64
Preparation (Pumpout and Refrigerant Transfer
Procedures), 67
Prepare the Chiller for Start-Up, 66
Pressure Transducers (Check), 75, 76
Prevent Accidental Start-Up, 65
Pumpout and Refrigerant Transfer Procedures, 67
Ramp Loading, 36
Refrigerant Filter, 73
Refrigerant Float System (Inspect), 74
Refrigerant Leak Detector, 37
Refrigerant Leak Testing, 71
Refrigerant Properties, 71
Refrigerant (Removing), 71
Refrigerant Tracer, 48
Refrigeration Cycle, 7
Refrigeration Log, 67
Relief Valves (Check), 53
Relief Valves and Piping (Inspect), 74
Remote Reset of Alarms, 37
Remote Start/Stop Controls, 36
Repair the Leak, Retest, and
Apply Standing Vacuum Test, 72
Replacing Defective Processor Modules, 88
Running System (Check), 66
Safety and Operating Controls (Check Monthly), 73
Safety Considerations, 1
Safety Controls, 34
Safety Shutdown, 47
Scheduled Maintenance, 73
Service Configurations (Input), 55
Service Ontime, 73
Service Operation, 45
Shipping Packaging (Remove), 48
Shunt Trip (Option), 35
Shutdown Sequence, 47
Software Configuration, 55
Solid-State Starters, 88
Spare Safety Inputs, 36
Standing Vacuum Test, 50
Starter (Check), 54
Starting Equipment, 9
Starting Equipment (Inspect), 75
Abbreviations and Explanations, 4
Adding Refrigerant, 71
Adjusting the Refrigerant Charge, 71
After Extended Shutdown, 67
After Limited Shutdown, 66
Alarm (Trip) Output Contacts, 37
Attach to Network Device Control, 44
Automatic Soft Stop Amps Threshold, 47
Auto. Restart After Power Failure, 38
Before Initial Start-Up, 48
Capacity Override, 36
Carrier Comfort Network Interface, 54
Changing Oil Filter, 73
Charge Refrigerant Into Chiller, 63
Chilled Water Recycle Mode, 47
Chiller Control Module (CCM), 88
Chiller Dehydration, 53
Chiller Familiarization, 5
Chiller Information Nameplate, 5
Chiller Operating Condition (Check), 65
Chiller Tightness (Check), 48
Chillers with Isolation Valves, 70
Chillers with Storage Tanks, 69
Cold Weather Operation, 67
Compressor Bearing and Gear Maintenance, 74
Condenser, 5
Condenser Freeze Prevention, 38
Condenser Pump Control, 37
Control Algorithms Checkout Procedure, 77
Control Panel, 5
Control Modules, 87
Control Test, 77
Controls, 10
CVC/ICVC Operation and Menus, 15
Cooler, 5
Default Screen Freeze, 35
Definitions (Controls), 10
Demand Limit Control Option, 39
Design Set Points, (Input), 55
Details (Lubrication Cycle), 8
Display Messages (Check), 76
Dry Run to Test Start-Up Sequence, 65
Equipment Required, 48
Evaporator Freeze Protection, 38
Extended Shutdown (Preparation for), 66
Factory-Mounted Starter or Variable Frequency Drive, 7
General (Controls), 11
General Maintenance, 71
Guide Vane Linkage (Check), 72
Heat Exchanger Tubes and Flow Devices (Inspect), 74
High Altitude Locations, 63
High Discharge Temperature Control, 36
Ice Build Control, 43
Initial Start-Up, 64
Initial Start-Up Checklist for 19XR,XRV Hermetic
Centrifugal Liquid Chiller, CL-1
Inspect the Control Panel, 73
Instruct the Customer Operator, 65
Integrated Starter Module (ISM), 88
Introduction, 4
Job Data Required, 48
Kilowatt Output, 37
Lead/Lag Control, 40
Leak Rate, 71
Leak Test Chiller, 50
Local Occupied Schedule (Input), 55
Local Start-Up, 46
Lubrication Cycle, 8
Lubrication System (Check), 72
Manual Guide Vane Operation, 67
123
INDEX (cont)
Start-Up/Shutdown/Recycle Sequence, 46
Start the Chiller, 66
Stop the Chiller, 66
Storage Vessel, 7
Summary (Lubrication Cycle), 8
Surge Prevention Algorithm (Fixed Speed Chiller), 39
Surge Prevention Algorithm with VFD, 40
Surge Protection (Fixed Speed Chillers), 40
Surge Protection VFD Units, 40
System Components, 5
Temperature Sensors (Check), 76
Test After Service, Repair, or Major Leak, 71
Tighten All Gasketed Joints and Guide Vane Packing, 48
Tower Fan Relay Low and High, 38
Trim Refrigerant Charge, 72
Troubleshooting Guide, 76
Unit-Mounted Solid-State Starter, 9
Unit-Mounted VFD, 10
Unit-Mounted Wye-Delta Starter, 10
Using the Optional Storage Tank and Pumpout
System, 48
VFD Cooling Cycle, 8
Water/Brine Reset, 38
Water Leaks, 74
Water Piping (Inspect), 53
Water Treatment, 75
Weekly Maintenance, 72
Wiring (Inspect), 53
Copyright 2001 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 211
Catalog No. 531-982
Printed in U.S.A.
Form 19XR-5SS
Pg 124
6-01
Replaces: 19XR-4SS
Book 2
Tab 5a
INITIAL START-UP CHECKLIST
FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME
JOB NO.
ADDRESS
MODEL
CITY
STATE
ZIP
S/N
DESIGN CONDITIONS:
TONS
BRINE
FLOW
RATE
TEMPERATURE
IN
TEMPERATURE PRESSURE
OUT
DROP
PASS
COOLER
CONDENSER
COMPRESSOR:
STARTER:
OIL PUMP:
SUCTION
TEMPERATURE
CONDENSER
TEMPERATURE
******
******
Volts
Mfg
Volts
RLA
Type
RLA
U
OLTA
S/N
OLTA
U
CONTROL/OIL HEATER:
REFRIGERANT: Type:
Volts
CARRIER OBLIGATIONS:
Assemble... . . . . . . . . . . . . . . . .
Leak Test . . . . . . . . . . . . . . . . . . .
Dehydrate . . . . . . . . . . . . . . . . . .
Charging . . . . . . . . . . . . . . . . . . .
Operating Instructions
115
230
Charge
Yes
Yes
Yes
Yes
U
U
U
U
U
U
U
U
No
No
No
No
Hrs.
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS
JOB DATA REQUIRED:
No
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . Yes
2. Machine Assembly, Wiring and Piping Diagrams . . . . . . Yes
No
3. Starting Equipment Details and Wiring Diagrams. . . . . . Yes
No
4. Applicable Design Data (see above) . . . . . . . . . . . . . . . . Yes
No
5. Diagrams and Instructions for Special Controls . . . . . . . Yes
No
U
U
U
U
U
U
U
U
U
U
INITIAL MACHINE PRESSURE:
YES
NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD:
3/4
1/2 Top sight glass
1/4
ADD OIL: Yes
U
No
U
Amount:
3/4
1/2 Bottom sight glass
1/4
RECORD PRESSURE DROPS:
CHARGE REFRIGERANT:
Book
Tab
Cooler
Initial Charge
Condenser
Final Charge After Trim
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
2
PC 211
Catalog No. 531-982
Printed in U.S.A.
Form 19XR-5SS
Pg CL-1
6-01
Replaces: 19XR-4SS
5a
INSPECT WIRING AND RECORD ELECTRICAL DATA:
RATINGS:
Motor(s) Amps
Motor Voltage
Line Voltages: Motor
Oil Pump Voltage
Oil Pump
Starter LRA Rating
Controls/Oil Heater
FIELD-INSTALLED STARTERS ONLY:
Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state
starters; disconnect leads to motor and megger the leads.
“PHASE TO PHASE”
MEGGER MOTOR
T1-T2
T1-T3
“PHASE TO GROUND”
T2-T3
T1-G
T2-G
T3-G
10-Second Readings:
60-Second Readings:
Polarization Ratio:
STARTER:
Electro-Mechanical
U
Motor Load Current Transformer Ratio
Solid-State Overloads
Yes
No
U
Solid-State
U
U
Manufacturer
Serial Number
:
CONTROLS: SAFETY, OPERATING, ETC.
Perform Controls Test (Yes/No)
PIC II CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY Yes
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
RUN MACHINE:
Do these safeties shut down machine?
Condenser Water Flow
Chilled Water Flow
Pump Interlocks
Yes
Yes
Yes
U
U
U
No
No
No
U
U
U
INITIAL START:
Line Up All Valves in Accordance With Instruction Manual:
Start Water Pumps and Establish Water Flow
Oil Level OK and Oil Temperature OK
Check Oil Pump Rotation-Pressure
Check Compressor Motor Rotation (Motor End Sight Glass) and Record:
Clockwise
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?
Yes*
U
No
U
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:
A: Trim charge and record under Charge Refrigerant Into Chiller section on page 63.
B: Complete any remaining control calibration and record under Controls section (pages 10-45).
C: For unit mounted VFD complete pages 58-61.
D: Take at least two sets of operational log readings and record.
E: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.
Hours
F: Give operating instructions to owner’s operating personnel.
Hours Given:
G: Call your Carrier factory representative to report chiller start-up.
SIGNATURES:
CARRIER
TECHNICIAN
CUSTOMER
REPRESENTATIVE
DATE
DATE
CL-2
19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET
DESCRIPTION
Base Demand Limit
ECW Setpoint
LCW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
CVC/ICVC
Number:
CVC/ICVC
Identification: BUS:
Software
RANGE
40 to 100
10 to 120
15 to 120
15 to 60
55 to 105
UNITS
%
DEG F
DEG F
DEG F
DEG F
DEFAULT
100
60.0
50.0
40.0
75
VALUE
Version
Controller
ADDRESS:
CL-3
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag
M T W T F S
S H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S
Day Flag
M T W T F S
S H
Occupied
Time
Unoccupied
Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S
Day Flag
M T W T F S
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
CL-4
S H
Occupied
Time
Unoccupied
Time
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -
19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET
DESCRIPTION
Starter Type
(0=Full, 1=Red, 2=SS/VFD)
Motor Rated Line Voltage
Volt Transformer Ratio: 1
Overvoltage Threshold
Undervoltage Threshold
Over/Under Volt Time
Voltage% Imbalance
Voltage Imbalance Time
Motor Rated Load Amps
Motor Locked Rotor Trip
Locked Rotor Start Delay
Starter LRA Rating
Motor Current CT Ratio: 1
Current% Imbalance
Current Imbalance Time
Grnd Fault CT’s?
Ground Fault CT Ratio: 1
Ground Fault Current
Ground Fault Start Delay
Ground Fault Persistence
Single Cycle Dropout
Frequency-60 Hz? (No=50)
Line Frequency Faulting
RANGE
UNITS
0 to 2
200 to 13200
1 to 35
105 to 115
85 to 95
1 to 10
1 to 10
1 to 10
10 to 5000
100 to 60000
1 to 10
100 to 60000
3 to 1000
5 to 40
1 to 10
0/1
150
1 to 25
1 to 20
1 to 10
0/1
0/1
0/1
DEFAULT
1
VOLTS
%
%
SEC
%
SEC
AMPS
AMPS
cycles
AMPS
%
SEC
NO/YES
AMPS
cycles
cycles
DSABLE/ENABLE
NO/YES
DSABLE/ENABLE
CL-5
460
1
115
85
5
10
5
200
1000
5
2000
100
15
5
YES
150
15
10
5
DSABLE
YES
DSABLE
VALUE
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET
DESCRIPTION
Auto Restart Option
Remote Contacts Option
Soft Stop Amps Threshold
Surge/Hot Gas Bypass
Surge Limit/HGBP Option
Select: Surge=0, HGBP=1
Min. Load Point (T1, P1)
Surge/HGBP Delta T1
Surge/HGBP Delta P1
Full Load Point (T2, P2)
Surge/HGBP Delta T2
Surge/HGBP Delta P2
Surge/HGBP Deadband
Surge Protection
Surge Delta% Amps
Surge Time Period
Ice Build Control
Ice Build Option
Ice Build Termination
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle
RANGE
0/1
0/1
40 to 100
UNITS
DSABLE/ENABLE
DSABLE/ENABLE
%
0/1
DEFAULT
DSABLE
DSABLE
100
0
0.5 to 20
30 to 170
ˆF
PSI
1.5
50
0.5 to 20
50 to 170
0.5 to 3
ˆF
PSI
ˆF
10
85
1
5 to 20
7 to 10
%
MIN
10
8
0/1
DSABLE/ENABLE
DSABLE
0 to 2
0
0/1
DSABLE/ENABLE
DSABLE
Refrigerant Leak Option
Refrigerant Leak Alarm mA
0/1
4 to 20
DSABLE/ENABLE
mA
DSABLE
20
Head Pressure Reference
Delta P at 0% (4 mA)
Delta P at 100% (20 mA)
Minimum Output
20 to 60
20 to 60
0 to 100
psi
psi
%
25
35
0
CL-6
VALUE
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -
19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET
DESCRIPTION
Comp Motor Temp Override
Cond Press Override
Comp Discharge Alert
Comp Thrust Brg Alert
RANGE
150 to 200
90 to 165
125 to 200
165 to 185
UNITS
DEG F
PSI
DEG F
DEG F
DEFAULT
200
125
200
175
Chilled Medium
Chilled Water Deadband
Evap Refrig Trippoint
Refrig Override Delta T
Condenser Freeze Point
0/1
.5 to 2.0
0.0 to 40.0
2.0 to 5.0
–20 to 35
WATER/BRINE
ˆF
DEG F
ˆF
DEG F
WATER
1.0
33
3
34
Evap Flow Delta P Cutout
Cond Flow Delta P Cutout
Water Flow Verify Time
Oil Press Verify Time
Recycle Control
Restart Delta T
Shutdown Delta T
0.5 to 50.0
0.5 to 50.0
0.5 to 5
15 to 300
PSI
PSI
MIN
SEC
5.0
5.0
5
40
2.0 to 10.0
0.5 to 4.0
DEG F
DEG F
5
1
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable
Spare Temp #1 Limit
Spare Temp #2 Enable
Spare Temp #2 Limit
0 to 4
–40 to 245
0 to 4
–40 to 245
DEG F
DEG F
CL-7
0
245
0
245
VALUE
19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET
DESCRIPTION
Capacity Control
Proportional Inc Band
Proportional DEC Band
Proportional ECW Gain
STATUS
UNITS
DEFAULT
2 to 10
2 to 10
1 to 3
Guide Vane Travel Limit
30 to 100
%
80
Diffuser Control
Diffuser Option
Guide Vane 25% Load Pt
Diffuser 25% Load Point
Guide Vane 50% Load Pt
Diffuser 50% Load Point
Guide Vane 75% Load Pt
Diffuser 75% Load Point
Diffuser Full Span mA
0 to 1
0 to 78
0 to 100
0 to 78
0 to 100
0 to 78
0 to 100
15 to 22
DSABLE/ENABLE
%
%
%
%
%
%
mA
DSABLE
25
0
50
0
50
0
18
VFD Speed Control
VFD Option
VFD Gain
VFD Increase Step
VFD Minimum Speed
VFD Maximum Speed
VFD Current Limit
0/1
0.1 to 1.5
1 to 5
65 to 100
90 to 100
0 to 99999
DSABLE/ENABLE
DSABLE
0.75
2
70
100
250
6.5
6.0
2.0
%
%
%
Amp
CL-8
VALUE
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -
19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET
DESCRIPTION
Lead Lag Control
LEAD/LAG: Configuration
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
Load Balance Option
Common Sensor Option
LAG% Capacity
LAG Address
LAG START Timer
LAG STOP Timer
PRESTART FAULT Timer
STANDBY Chiller Option
STANDBY% Capacity
STANDBY Address
RANGE
UNITS
0 to 3
0/1
0/1
25 to 75
1 to 236
2 to 60
2 to 60
2 to 30
0/1
25 to 75
1 to 236
DEFAULT
0
DSABLE/ENABLE
DSABLE/ENABLE
%
MIN
MIN
MIN
DSABLE/ENABLE
%
CL-9
DSABLE
DSABLE
50
92
10
10
5
DSABLE
50
93
VALUE
19XR, XRV PIC II RAMP_DEM TABLE CONFIGURATION SHEET
DESCRIPTION
Pulldown Ramp Type:
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source
Select: Amps=0, kW=1
Motor Load Ramp% Min
Demand Limit Prop Band
Demand Limit At 20 mA
20 mA Demand Limit Opt
Motor Rated Kilowatts
Demand Watts Interval
RANGE
UNITS
DEFAULT
0/1
1
0/1
0
5 to 20
3 to 15
40 to 100
0/1
50 to 9999
5 to 60
%
%
DSABLE/ENABLE
kW
MIN
VALUE
10
10
40
DSABLE
145
15
19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET
DESCRIPTION
Control Point
ECW Control Option
Temp Pulldown Deg/Min
RANGE
UNITS
DEFAULT
0/1
2 to 10
DSABLE/ENABLE
ˆF
DSABLE
3
–30 to 30
ˆF
10
Temperature Reset
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
–40 to 245
–40 to 245
–30 to 30
DEG F
DEG F
ˆF
85
65
10
0 to 15
0 to 15
–30 to 30
ˆF
ˆF
ˆF
10
0
5
Select/Enable Reset Type
0 to 3
0
CL-10
VALUE
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -
BROADCAST (BRODEF) CONFIGURATION SHEET
DESCRIPTION
Time Broadcast Enable
Daylight Savings
Start Month
Start Day of Week
Start Week
Start Time
Start Advance
Stop Month
Stop Day of Week
Stop Week
Stop Time
Stop Back
RANGE
DSABLE/ENABLE
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
1 to 12
1 to 7
1 to 5
00:00 to 24:00
0 to 360
CL-11
UNITS
HH:MM
MIN
MIN
DEFAULT
DSABLE
4
7
3
02:00
60
10
7
3
02:00
60
VALUE
UNIT-MOUNTED VFD CONFIGURATION SHEET
DESCRIPTION
Maximum Speed
Speed Display Scaling
Motor Voltage
Frequency
Motor Amps
Line Voltage
Over Frequency Limit
PARAMETER
P.004
P.028
H.000
H.001
H.002
H.021
H.022
RANGE
15 to H.022
10 to 999
100 to 690
30 to 200
Power Module Dependent
300 to 565
30 to 210
*Variable by job — refer to component nameplates and labels.
CL-12
DEFAULT
*
*
*
*
*
*
*
COMMENTS
Job Sheet; 60 for 60 Hz and 50 for 50 Hz
Job Sheet; 60 for 60 Hz and 50 for 50 Hz
Selected line voltage
60 Hz = 60, 50 Hz = 50
Selected motor 100% amps
Selected line voltage
60 Hz = 69, 50 Hz = 57
CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -
CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
PRIMARY MESSAGE:
DATE:
SECONDARY MESSAGE:
COMPRESSOR ONTIME:
CCN
LOCAL
RESET
CL-13
TIME:
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS %
COMMUNICATION MESSAGE
MENU
CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
PRIMARY MESSAGE:
DATE:
SECONDARY MESSAGE:
COMPRESSOR ONTIME:
TIME:
CHW IN
CHW OUT
EVAP REF
CDW IN
CDW OUT
COND REF
OILPRESS
OIL TEMP
AMPS %
COMMUNICATION MESSAGE
CCN
LOCAL
RESET
CL-14
MENU
Book
Tab
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
2
PC 211
Catalog No. 531-982
Printed in U.S.A.
Form 19XR-5SS
Pg CL-16
6-01
Replaces: 19XR-4SS
5a
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE
CUT ALONG DOTTED LINE
Copyright 2001 Carrier Corporation