Carrier Refrigerator 19XL User Manual
19XL  
Hermetic Centrifugal Liquid Chillers  
50/60 Hz  
With HCFC-22 and HFC-134a  
Start-Up, Operation, and Maintenance Instructions  
SAFETY CONSIDERATIONS  
Centrifugal liquid chillers are designed to provide  
safe and reliable service when operated within design  
specifications. When operating this equipment, use good  
judgment and safety precautions to avoid damage to  
equipment and property or injury to personnel.  
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.  
Be sure you understand and follow the procedures and  
safety precautions contained in the chiller instructions  
as well as those listed in this guide.  
CHECK THE REFRIGERANT TYPE before adding refrigerant to  
the chiller. The introduction of the wrong refrigerant can cause dam-  
age or malfunction to this chiller.  
Operation of this equipment with refrigerants other than those  
cited herein should comply with ANSI/ASHRAE-15 (latest edi-  
tion). Contact Carrier for further information on use of this chiller  
with other refrigerants.  
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 Heat-  
ing, Refrigeration, and Air Conditioning Engineers). The accumu-  
lation 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 avail-  
able for breathing. Product causes eye and skin irritation. Decom-  
position products are hazardous.  
DO NOTATTEMPT 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 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 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 USE air for leak testing. Use only refrigerant or dry  
nitrogen.  
DO NOT VALVE OFF any safety device.  
BE SURE that all pressure relief devices are properly installed and  
functioning before operating any chiller.  
DO NOT 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 com-  
ponents are light, use mechanical equipment when there is a risk of  
slipping or losing your balance.  
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 quali-  
fied electrician.  
DO NOT WORK ON electrical components, including control pan-  
els, 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.  
BE AWARE that certain automatic start arrangements CAN EN-  
GAGE 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 require-  
ments 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.  
LOCK OPENAND TAG electrical circuits during servicing. IF WORK  
IS INTERRUPTED, confirm that all circuits are deenergized be-  
fore 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, IMME-  
DIATELY FLUSH EYES with water and consult a physician.  
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 cor-  
rosion, rust, leaks, or damage.  
PROVIDE A DRAIN connection in the vent line near each pres-  
sure relief device to prevent a build-up of condensate or rain  
water.  
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.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book 2  
PC 211  
Catalog No. 531-971  
Printed in U.S.A.  
Form 19XL-4SS  
Pg 1  
7-96  
Replaces: 19XL-3SS  
Tab 5a  
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CONTENTS (cont)  
Page  
Page  
Check Optional Pumpout Compressor  
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
Check Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . 47  
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47  
Carrier Comfort Network Interface . . . . . . . . . . . 48  
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48  
• MECHANICAL-TYPE STARTERS  
• BENSHAW, INC. SOLID-STATE STARTER  
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Power Up the Controls and  
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . 50  
• SOFTWARE VERSION  
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 56-58  
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56  
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . 56  
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 56  
Check the Running System . . . . . . . . . . . . . . . . . . 56  
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . 57  
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 57  
After Extended Shutdown . . . . . . . . . . . . . . . . . . . 57  
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . 57  
Manual Guide Vane Operation . . . . . . . . . . . . . . . 57  
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
Set Up Chiller Control Configuration . . . . . . . . . 50  
Input the Design Set Points . . . . . . . . . . . . . . . . . . 50  
Input the Local Occupied Schedule  
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
Selecting Refrigerant Type . . . . . . . . . . . . . . . . . . . 50  
• TO CONFIRM REFRIGERANT TYPE  
• TO CHANGE REFRIGERANT TYPE  
Input Service Configurations . . . . . . . . . . . . . . . . 50  
• PASSWORD  
PUMPOUT AND REFRIGERANT  
TRANSFER PROCEDURES . . . . . . . . . . . . . . . . 59-61  
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
Operating the Optional Pumpout  
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
• TO READ REFRIGERANT PRESSURES  
Chillers with Pumpout Storage Tanks . . . . . . . . 59  
• TRANSFER REFRIGERANT FROM  
STORAGE TANK TO CHILLER  
• TRANSFER THE REFRIGERANT FROM  
CHILLER TO STORAGE TANK  
Chillers with Isolation Valves . . . . . . . . . . . . . . . . 60  
• TRANSFER ALL REFRIGERANT TO  
CHILLER CONDENSER VESSEL  
• INPUT TIME AND DATE  
• CHANGE LID CONFIGURATION  
IF NECESSARY  
• MODIFY CONTROLLER IDENTIFICATION  
IF NECESSARY  
• INPUT EQUIPMENT SERVICE PARAMETERS  
IF NECESSARY  
• MODIFY EQUIPMENT CONFIGURATION  
IF NECESSARY  
• CHECK VOLTAGE SUPPLY  
• PERFORM AN AUTOMATED CONTROL TEST  
Check Optional Pumpout System  
Controls and Compressor . . . . . . . . . . . . . . . . . . . 52  
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . 53  
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . 53  
• 19XL CHILLER EQUALIZATION WITHOUT  
PUMPOUT UNIT  
• TRANSFER ALL REFRIGERANT TO CHILLER  
COOLER/COMPRESSOR VESSEL  
• RETURN REFRIGERANT TO NORMAL  
OPERATING CONDITIONS  
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . 61,62  
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . 61  
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . 61  
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 61  
Adjusting the Refrigerant Charge . . . . . . . . . . . . 61  
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . 61  
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61  
Test After Service, Repair, or Major Leak . . . . . 61  
• REFRIGERANT TRACER  
• 19XL CHILLER EQUALIZATION WITH  
PUMPOUT UNIT  
• TRIMMING REFRIGERANT CHARGE  
• TO PRESSURIZE WITH DRY NITROGEN  
Repair the Leak, Retest, and Apply  
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 55,56  
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Manual Operation of the Guide Vanes . . . . . . . . 55  
Dry Run to Test Start-Up Sequence . . . . . . . . . . 55  
Check Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
• IF ROTATION IS PROPER  
• IF THE MOTOR ROTATION IS NOT  
CLOCKWISE  
• NOTES ON SOLID-STATE STARTERS  
(Benshaw, Inc.)  
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . 62  
Checking Guide Vane Linkage . . . . . . . . . . . . . . . 62  
• CHECKING THE AUXILIARY SWITCH ON  
GUIDE VANE ACTUATOR  
Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . 62  
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . 62  
Check the Lubrication System . . . . . . . . . . . . . . . 62  
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . 63-65  
Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Inspect the Control Center . . . . . . . . . . . . . . . . . . . 63  
Check Safety and Operating Controls  
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
• TO CHANGE THE OIL  
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Oil Reclaim Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Inspect Refrigerant Float System . . . . . . . . . . . . 64  
Inspect Relief Valves and Piping . . . . . . . . . . . . . 64  
Compressor Bearing and Gear  
Check Oil Pressure and Compressor Stop . . . . 56  
Calibrate Motor Current . . . . . . . . . . . . . . . . . . . . . 56  
To Prevent Accidental Start-Up . . . . . . . . . . . . . . 56  
Check Chiller Operating Condition . . . . . . . . . . . 56  
Instruct the Customer Operator . . . . . . . . . . . . . . 56  
• COOLER-CONDENSER  
• OPTIONAL STORAGE TANK AND  
PUMPOUT SYSTEM  
• MOTOR COMPRESSOR ASSEMBLY  
• MOTOR COMPRESSOR LUBRICATION SYSTEM  
• CONTROL SYSTEM  
• AUXILIARY EQUIPMENT  
• DESCRIBE CHILLER CYCLES  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64  
Inspect the Heat Exchanger Tubes . . . . . . . . . . . 64  
• COOLER  
• REVIEW MAINTENANCE  
• SAFETY DEVICES AND PROCEDURES  
• CHECK OPERATOR KNOWLEDGE  
• REVIEW THE START-UP, OPERATION,  
AND MAINTENANCE MANUAL  
• CONDENSER  
3
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CONTENTS (cont)  
Page  
Page  
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64  
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78  
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
Inspect the Starting Equipment . . . . . . . . . . . . . . 65  
Check Pressure Transducers . . . . . . . . . . . . . . . . 65  
Optional Pumpout System Maintenance . . . . . . 65  
• OPTIONAL PUMPOUT COMPRESSOR OIL  
CHARGE  
• RED LED  
• GREEN LEDs  
Notes on Module Operation . . . . . . . . . . . . . . . . . . 78  
Processor Module (PSIO) . . . . . . . . . . . . . . . . . . . . 79  
• INPUTS  
• OUTPUTS  
• OPTIONAL PUMPOUT SAFETY CONTROL  
SETTINGS  
Ordering Replacement Chiller Parts . . . . . . . . . . 65  
Starter Management Module (SMM) . . . . . . . . . . 79  
• INPUTS  
• OUTPUTS  
Options Modules (8-Input) . . . . . . . . . . . . . . . . . . . 79  
Replacing Defective Processor Modules . . . . . . 80  
• INSTALLATION  
Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . 81  
• TESTING SILICON CONTROL RECTIFIERS  
IN BENSHAW, INC. SOLID-STATE STARTERS  
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85  
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 66-97  
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Checking the Display Messages . . . . . . . . . . . . . 66  
Checking Temperature Sensors . . . . . . . . . . . . . . 66  
• RESISTANCE CHECK  
• VOLTAGE DROP  
• CHECK SENSOR ACCURACY  
• DUAL TEMPERATURE SENSORS  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98,99  
INITIAL START-UP CHECKLIST FOR  
19XL HERMETIC CENTRIFUGAL  
Checking Pressure Transducers . . . . . . . . . . . . . 66  
• TRANSDUCER REPLACEMENT  
Control Algorithms Checkout Procedure . . . . . 67  
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . CL-1-CL-12  
INTRODUCTION  
ABBREVIATIONS AND EXPLANATIONS  
Frequently used abbreviations in this manual include:  
Prior to initial start-up of the 19XL unit, those involved in  
the start-up, operation, and maintenance should be thor-  
oughly familiar with these instructions and other necessary  
job data. This book is outlined so that you may become  
familiar with the control system before performing start-up  
procedures. Procedures in this manual are arranged in the  
sequence required for proper chiller start-up and operation.  
CCN — Carrier Comfort Network  
CCW — Counterclockwise  
CW  
— Clockwise  
ECW — Entering Chilled Water  
ECDW — Entering Condenser Water  
EMS — Energy Management System  
HGBP — Hot Gas Bypass  
I/O  
LCD  
LCDW — Leaving Condenser Water  
LCW — Leaving Chilled Water  
LED — Light-Emitting Diode  
LID — Local Interface Device  
OLTA — Overload Trip Amps  
PIC — Product Integrated Control  
— Input/Output  
— Liquid Crystal Display  
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 mod-  
ule 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. Cir-  
cuit boards can easily be damaged. Always hold boards  
by the edges and avoid touching components and  
connections.  
This equipment uses, and can radiate, radio frequency  
energy. If not installed and used in accordance with  
the instruction manual, it may cause interference to  
radio communications. It has been tested and found to  
comply with the limits for a Class A computing device  
pursuant to Subpart J of Part 15 of FCC (Federal Com-  
munication Commission) Rules, which are designed to  
provide reasonable protection against such interference  
when operated in a commercial environment. Operation  
of this equipment in a residential area is likely to cause  
interference, in which case the user, at his own expense,  
will be required to take whatever measures may be re-  
quired to correct the interference.  
PSIO — Processor Sensor Input/Output Module  
RLA  
SCR  
SI  
— Rated Load Amps  
— Silicon Control Rectifier  
— International System of Units  
SMM — Starter Management Module  
TXV — Thermostatic Expansion Valve  
The 19XL chillers use HCFC-22 and HFC-134a refrig-  
erant. When referencing refrigerant charges in this manual,  
the HCFC-22 charge will be listed first and the HFC-134a  
value will be shown next to it in brackets [ ].  
Words printed in all capital letters and italics represent val-  
ues that may be viewed on the LID.  
The PSIO software version number of your 19XL unit will  
be located on the front cover.  
Always store and transport replacement or defective boards  
in anti-static shipping bag.  
4
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valves, a magnetically coupled dial-type refrigerant level  
CHILLER FAMILIARIZATION  
(Fig. 1, 2A, and 2B)  
1
gage, a one-inch FPT drain valve, and a ⁄2-in. male flare  
vapor connection for the pumpout unit. A 30-in.-0-400 psi  
(–101-0-2750 kPa) gage also is supplied with each unit.  
Chiller Information Plate — The information plate  
is located on the right side of the chiller control center  
panel.  
NOTE: If a storage vessel is not used at the jobsite, factory-  
installed isolation valves on the chiller may be used to iso-  
late the chiller charge in either the cooler or condenser.  
An optional pumpout compressor 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.  
As the compressor suction reduces the pressure in the cooler,  
the remaining refrigerant boils at a fairly low temperature  
(typically 38 to 42 F [3 to 6 C]). The energy required for  
boiling is obtained from the water flowing through the cooler  
tubes. With heat energy removed, the water becomes cold  
enough for use in an air conditioning circuit or process liq-  
uid cooling.  
After taking heat from the water, the refrigerant vapor  
is compressed. Compression adds still more heat energy  
and the refrigerant is quite warm (typically 98 to 102 F  
[37 to 40 C]) when it is discharged from the compressor into  
the condenser.  
Fig. 1 — 19XL Identification  
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.  
System Components — The components include the  
cooler and condenser heat exchangers in separate vessels,  
motor-compressor, lubrication package, control center, and  
motor starter. All connections from pressure vessels have ex-  
ternal threads to enable each component to be pressure tested  
with a threaded pipe cap during factory assembly.  
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.  
Cooler — This vessel (also known as the evaporator) is  
located underneath the compressor. The cooler is main-  
tained at lower temperature/pressure so that evaporating  
refrigerant can remove heat from water flowing through its  
internal tubes.  
Condenser — The condenser operates at a higher  
temperature/pressure than the cooler, and has water flowing  
through its internal tubes in order to remove heat from the  
refrigerant.  
MOTOR/OIL REFRIGERATION  
COOLING CYCLE  
Motor-Compressor — This component maintains sys-  
tem temperature/pressure differences and moves the heat  
carrying refrigerant from the cooler to the condenser.  
The motor and the lubricating oil are cooled by liquid  
refrigerant taken from the bottom of the condenser vessel  
(Fig. 3). Flow of refrigerant is maintained by the pressure  
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 motor cooling and oil cooling systems.  
Control Center — The control center is the user inter-  
face for controlling the chiller. It regulates the chiller’s  
capacity as required to maintain proper leaving chilled water  
temperature. The control center:  
Flow to the motor flows through an orifice and into the  
motor. There is also another orifice and a solenoid valve which  
will open if additional motor cooling is required. Once past  
the orifice, the refrigerant is directed over the motor by a  
spray nozzle. The refrigerant collects in the bottom of the  
motor casing and then is drained back into the cooler through  
the motor refrigerant drain line. A back pressure valve or an  
orifice in this line maintains a higher pressure in the motor  
shell than in the cooler/oil sump. The motor is protected by  
a temperature sensor imbedded in the stator windings. Higher  
motor temperatures (above 125 F [51 C]) energize a sole-  
noid to provide additional motor cooling. A further increase  
in temperature past the motor override set point will over-  
ride the temperature capacity control to hold, and if the  
motor temperature rises 10° F (5.5° C) above this set point,  
will close the inlet guide vanes. If the temperature rises above  
the safety limit, the compressor will shut down.  
• 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 micro-  
processor control  
• provides access to other CCN (Carrier Comfort Network)  
devices  
Factory-Mounted Starter (Optional) — The starter  
allows the proper start and disconnect of electrical energy  
for the compressor-motor, oil pump, oil heater, and control  
panels.  
Storage Vessel (Optional) — There are 2 sizes  
of storage vessels available. The vessels have double relief  
5
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LEGEND  
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—
—
—
—
—
—
—
—
—
Unit-Mounted Starter  
Refrigerant Filter Drier  
3
Rigging Guide Bolt  
Refrigerant Moisture Indicator  
Motor Sight Glass  
Refrigerant Motor Drain  
Oil Filter Access Cover  
Refrigerant Oil Cooler  
Oil Level Sight Glasses  
Guide Vane Actuator  
Typical Flange Connection  
Control Center  
ASME Nameplate, Cooler  
Take-Apart, Rabbet Fit Connector  
(Lower)  
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
—
—
—
—
—
—
—
—
—
—
—
—
Refrigerant Charging Valve  
Cooler Refrigerant Isolation Valve  
Cooler Pressure Schrader Fittings  
Oil Drain/Charging Valve  
Power Panel  
Retro-Fit, Rig-in-Place Beams  
Typical Waterbox Drain Port  
Take-Apart, Shell Leveling Feet  
Cooler Return-End Waterbox Cover  
ASME Nameplate, Condenser  
Condenser Return-End Waterbox Cover  
Take-Apart, Rabbet Fit Connector  
(Upper)  
27  
28  
—
—
Protective Truck Holddown Lugs  
Refrigerant Cooling Isolation Valve  
(Hidden)  
19XL FRONT VIEW  
LEGEND  
29  
30  
31  
32  
33  
34  
35  
—
—
—
—
—
—
—
Pumpdown System Connection  
Cooler Relief Valves  
Chiller Identification Nameplate  
Cooler Pressure Transducer  
Suction Elbow  
Transmission Vent Line  
Discharge Pressure Switch and  
Discharge Pressure Transducer  
Condenser Isolation Valve  
Low-Voltage Access Door, Starter  
Medium-Voltage Access Door, Starter  
Amp/Volt Gages  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
—
—
—
—
—
—
—
—
—
—
—
Refrigerant Supply Sump  
Condenser Pressure Transducer  
Liquid Seal Float Chamber  
ASME Nameplate, Float Chamber  
Condenser Relief Valves  
Condenser In/Out Temperature Sensors  
Cooler In/Out Temperature Sensors  
19XL REAR VIEW  
Fig. 2A — Typical 19XL Components — Design I  
6
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LEGEND  
1
2
—
—
—
—
—
—
—
—
—
—
—
—
Unit-Mounted Starter  
Refrigerant Filter Drier  
Rigging Guide Bolt  
11  
4
5
6
7
8
9
10  
3
4
Motor Sight Glass  
24  
23  
5
Refrigerant Moisture Indicator  
Refrigerant Oil Cooler  
Oil Filter Access Cover  
Oil Level Sight Glasses  
Guide Vane Actuator  
Typical Flange Connection  
Control Center  
6
7
12  
13  
8
22  
9
10  
11  
12  
Cooler Pressure Schrader Fitting  
(Hidden)  
13  
14  
15  
—
—
—
ASME Nameplate, Cooler  
Cooler  
Take-Apart Rabbet Fit Connector  
(Lower)  
16  
17  
18  
19  
20  
21  
22  
23  
—
—
—
—
—
—
—
—
Refrigerant Charging Valve  
Oil Drain/Charging Valve  
Power Panel  
Cooler Waterbox Cover  
Cooler In/Out Temperature Sensors  
Condenser In/Out Temperature Sensors  
Condenser Waterbox Cover  
Take-Apart Rabbet Fit Connector  
(Upper)  
21  
14  
15  
20  
19 18 17  
16  
19XL FRONT VIEW  
24  
—
Refrigerant Cooling Isolation Valve  
(Hidden)  
25  
26  
27  
28  
29  
30  
LEGEND  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
—
—
—
—
—
—
—
—
—
—
—
—
Cooler Relief Valve  
Chiller Identification Plate  
Suction Elbow  
31  
32  
Transmission Vent Line  
Condenser Relief Valves  
Low Voltage Access Door, Starter  
Medium Voltage Access Door, Starter  
Amp/Volt Gages  
Condenser Isolation Valve  
Linear Float Valve Chamber  
Condenser Pressure Transducer  
Discharge Pressure Switch and  
Discharge Pressure Transducer  
Cooler Refrigerant Isolation Valve  
Condenser Return End Waterbox Cover  
Typical Waterbox Drain Port  
Cooler Return End Waterbox Cover  
Cooler Pressure Transducer  
Pumpdown Valve  
42  
41  
40  
39  
37  
38  
39  
40  
41  
42  
—
—
—
—
—
—
38  
37  
36 35  
34 33 15  
19XL REAR VIEW  
Fig. 2B — Typical 19XL Components — Design II  
7
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Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles  
Refrigerant that flows to the oil cooling system is reg-  
when the compressor is shut down. The oil level should be  
visible in at least one of the 2 sight glasses during operation.  
Oil sump temperature is displayed on the LID default  
screen. Oil sump temperature ranges during compressor  
operation between 100 to 120 F (37 to 49 C) [120 to 140 F  
(49 to 60 C)].  
ulated by a thermostatic expansion valve. There is always  
a minimum flow bypassing the TXV, which flows through  
an orifice. The TXV valve regulates flow into the oil/  
refrigerant plate and frame-type heat exchanger. The bulb  
for the expansion valve controls oil temperature to the bear-  
ings. The refrigerant leaving the heat exchanger then returns  
to the cooler.  
The oil pump suction is fed from the oil reservoir. An  
oil pressure relief valve maintains 18 to 25 psid (124 to  
172 kPad) differential pressure in the system at the pump  
discharge. This differential pressure can be read directly from  
the Local Interface Device (LID) default screen. The oil pump  
discharges oil to the oil filter assembly. This filter can be  
valved closed to permit removal of the filter without drain-  
ing the entire oil system (see Maintenance sections, pages  
61 to 65, for details). The oil is then piped to the oil cooler.  
This heat exchanger uses refrigerant from the condenser as  
the coolant. The refrigerant cools the oil to a temperature  
between 100 and 120 F (37 to 49 C).  
LUBRICATION CYCLE  
Summary — The oil pump, oil filter, and oil cooler make  
up a package located partially in the transmission casting of  
the compressor-motor assembly. The oil is pumped into a  
filter assembly to remove foreign particles, and is then forced  
into an oil cooler heat exchanger where the oil is cooled to  
proper operational temperatures. After the oil cooler, part of  
the flow is directed to the gears and the high speed shaft  
bearings; the remaining flow is directed to the motor shaft  
bearings. Oil drains into the transmission oil sump to com-  
plete the cycle (Fig. 4).  
As the oil leaves the oil cooler, it passes the oil pressure  
transducer and the thermal bulb for the refrigerant expan-  
sion valve on the oil cooler. The oil is then divided, with a  
portion flowing to the thrust bearing, forward pinion bear-  
ing, and gear spray. The balance then lubricates the motor  
shaft bearings and the rear pinion bearing. The oil temper-  
ature is measured as the oil leaves the thrust and forward  
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  
8
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Fig. 4 — Lubrication System  
journal bearings within the bearing housing. The oil then drains  
casing will vent this refrigerant into the suction of the com-  
pressor. Oil entrained in the refrigerant is eliminated by the  
demister filter.  
into the oil reservoir at the base of the compressor. The PIC  
(Product Integrated Control) measures the temperature of the  
oil in the sump and maintains the temperature during shut-  
down (see Oil Sump Temperature Control section, page 32).  
This temperature is read on the LID default screen.  
DURING NORMAL CHILLER OPERATION, oil is  
entrained with the refrigerant. As the compressor pulls  
the refrigerant into the guide vane housing to be com-  
pressed, the oil will normally drop out at this point and  
fall to the bottom of the housing where it accumulates. Us-  
ing discharge gas pressure to power an eductor, the oil is  
vacuumed from the housing by the eductor and is dis-  
charged into the oil reservoir. Oil and refrigerant are also  
recovered from the top of the cooler refrigerant level and are  
discharged into the guide vane housing. The oil will drop to  
the bottom of the guide vane housing and be recovered by  
the eductor system.  
During the chiller start-up, the PIC will energize the oil  
pump and provide 15 seconds of prelubrication to the bear-  
ings after pressure is verified before starting the compressor.  
During shutdown, the oil pump will run for 60 seconds to  
post-lubricate after the compressor shuts down. The oil pump  
can also be energized for testing purposes in the Control Test.  
Ramp loading can slow the rate of guide vane opening  
to minimize oil foaming at start-up. If the guide vanes  
open quickly, the sudden drop in suction pressure can cause  
any refrigerant in the oil to flash. The resulting oil foam  
cannot be pumped efficiently; therefore, oil pressure falls  
off and lubrication is poor. If oil pressure falls below  
15 psid (103 kPad) differential, the PIC will shut down the  
compressor.  
DURING LIGHT LOAD CONDITIONS, the suction gas into  
the compressor does not have enough velocity to return oil,  
which is floating in the cooler back to the compressor. In  
addition, the eductor may not have enough power to pull the  
oil from the guide vane housing back into the oil reservoir  
due to extremely low pressure at the guide vanes. Two so-  
lenoids, located on the oil reclaim piping, are operated so  
that the eductor can pull oil and refrigerant directly from the  
cooler and discharge the mixture into the oil reservoir. The  
oil reclaim solenoids are operated by an auxiliary contact  
integral to the guide vane actuator. This switchover of the  
solenoids occurs when the guide vanes are opened beyond  
30 degrees from the closed position.  
Oil Reclaim System — The oil reclaim system oper-  
ates to return oil back to the oil reservoir by recovering it  
from 2 areas on the chiller. The primary area of recovery is  
from the guide vane housing. Oil also is recovered, along  
with refrigerant, from the cooler.  
Any refrigerant that enters the oil reservoir/transmission  
area is flashed into gas. The demister line at the top of the  
9
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STARTING EQUIPMENT  
The 19XL requires a motor starter to operate the centrif-  
ugal hermetic compressor motor, the oil pump, and various  
auxiliary equipment. The starter serves as the main field  
wiring interface for the contractor.  
Three types of starters are available from Carrier Cor-  
poration: solid-state, wye-delta, and across-the-line starters.  
See Carrier Specification Z-375 for specific starter require-  
ments. All starters must meet these specifications in order  
to properly start and satisfy mechanical safety requirements.  
Starters may be supplied as separate, free-standing units, or  
may be mounted directly on the chiller (unit mounted) for  
low-voltage units only.  
Inside the starter are 3 separate circuit breakers. Circuit  
breaker CB1 is the compressor motor circuit breaker. The  
disconnect switch on the starter front cover is connected to  
this breaker. Circuit breaker CB1 supplies power to the com-  
pressor motor.  
LEGEND  
1
2
—
—
—
—
—
—
—
—
—
—
—
—
—
Field Wiring Terminal Strips (TB2 and TB3)  
Circuit Breaker 1, 2, 3, 4  
Overload Unit  
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 break-  
ers inside the starter must be turned off to disconnect  
power to the oil pump, PIC controls, and oil heater.  
3
4
Solid-State Controller  
5
Silicon Controlled Rectifier (SCR) LED (One of 6)  
Starter Fault and Run LEDs  
Voltmeter (Optional)  
6
7
8
Ammeter (Optional)  
Circuit breaker CB2 supplies power to the control center,  
oil heater, and portions of the starter controls. Circuit breaker  
CB3 supplies power to oil pump. Both of these circuit break-  
ers are wired in parallel with CB1 so that power is supplied  
to them if the CB1 disconnect is open.  
9
SCR (One of 6)  
10  
11  
12  
13  
Voltage LED  
Starter Management Module (SMM)  
Pilot Relays (PR1 to PR5)  
Starter Access Door  
Fig. 5 — Benshaw, Inc. Solid-State Starter,  
Internal View  
All starters are shipped with a Carrier control module called  
the Starter Management Module (SMM). This module  
controls and monitors all aspects of the starter. See the Con-  
trols section on page 11 for additional SMM information.  
All starter replacement parts are supplied by the starter  
manufacturer.  
Unit-Mounted Solid-State Starter (Optional)  
— The 19XL may be equipped with a solid-state, reduced-  
voltage starter (Fig. 5 and 6). This starter provides on-off  
control of the compressor motor as its primary function.  
Using this type of starter reduces the peak starting torque,  
reduces the motor inrush current, and decreases mechanical  
shock. This is summed up by the phrase ‘‘soft starting.’’  
Two varieties of solid-state starters are available as a 19XL  
option (factory supplied and installed). When a unit-mounted,  
optional, solid-state starter is purchased with the 19XL, a  
Benshaw, Inc. solid-state starter will be shipped with the unit.  
See Fig. 5. The solid-state starter’s manufacturer name will  
be located inside the starter access door. See Fig. 6.  
These starters operate by reducing the starting voltage. The  
starting torque of a motor at full voltage is typically 125%  
to 175% of the running torque. When the voltage and the  
current are reduced at start-up, the starting torque is reduced  
as well. The object is to reduce the starting voltage to just  
the voltage necessary to develop the torque required to get  
the motor moving. The voltage and current are then ramped  
up in a desired period of time. The voltage is reduced through  
the use of silicon controlled rectifiers (SCR). Once full volt-  
age is reached, a bypass contactor is energized to bypass the  
SCRs.  
Fig. 6 — Typical Starter External View  
(Solid-State Starter Shown)  
There are a number of LEDs (light-emitting diodes) that  
are useful in troubleshooting and starter check-out on  
Benshaw, Inc. solid-state starters. These are used to  
indicate:  
• voltage to the SCRs  
• SCR control voltage  
• power indication  
• proper phasing for rotation  
• start circuit energized  
When voltage is supplied to the solid-state circuitry, the  
heat sinks within the starter are at line voltage. Do not  
touch the heat sinks while voltage is present or serious  
injury will result.  
10  
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• overtemperature  
• ground fault  
• current unbalance  
• run state  
These LEDs are further explained in the Check Starter and  
Troubleshooting Guide section, page 66.  
The memory of the PSIO and LID modules are volatile.  
If the battery in a module is removed or damaged, all  
programming will be lost.  
General — The 19XL hermetic centrifugal liquid chiller  
contains a microprocessor-based control center that moni-  
tors and controls all operations of the chiller. The micro-  
processor control system matches the cooling capacity of the  
chiller to the cooling load while providing state-of-the-art  
chiller protection. The system controls cooling load within  
the set point plus the deadband by sensing the leaving chilled  
water or brine temperature, and regulating the inlet guide  
vane via a mechanically linked actuator motor. The guide  
vane is a variable flow prewhirl assembly that controls the  
refrigeration effect in the cooler by regulating the amount of  
refrigerant vapor flow into the compressor. An increase in  
guide vane opening increases capacity. A decrease in guide  
vane opening decreases capacity. Chiller protection is pro-  
vided by the processor which monitors the digital and ana-  
log inputs and executes capacity overrides or safety shutdowns,  
if required.  
Unit-Mounted Wye-Delta Starter (Optional) — The  
19XL chiller may be equipped with a wye-delta starter mounted  
on the unit (Fig. 7). This starter is intended for use with low-  
voltage motors (under 600 v). It reduces the starting current  
inrush by connecting each phase of the motor windings into  
a wye configuration. This occurs during the starting period  
when the motor is accelerating up to speed. After a time de-  
lay, once the motor is up to speed, the starter automatically  
connects the phase windings into a delta configuration.  
1
2
3
4
5
6
7
17  
PIC System Components — The Product Integrated  
Control (PIC) is the control system on the chiller. See  
Table 1. The PIC controls the operation of the chiller by moni-  
toring all operating conditions. The PIC can diagnose a prob-  
lem 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 aux-  
iliary equipment such as pumps and cooling tower fans to  
turn them on only when required. It continually checks all  
safeties to prevent any unsafe operating condition. It also  
regulates the oil heater while the compressor is off, and the  
hot gas bypass valve, if installed.  
The PIC can be interfaced with the Carrier Comfort Net-  
work (CCN) if desired. It can communicate with other PIC-  
equipped chillers and other CCN devices.  
The PIC consists of 3 modules housed inside the 3 major  
components. The component names and the control voltage  
contained in each component are listed below (also see  
Table 1):  
8
16  
15  
14  
13 12  
11  
LEGEND  
10  
9
1
2
—
—
Pilot Relays  
SMM Power Circuit Breaker and Voltage Calibration  
Potentiometer  
3
4
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Transistor Resistor Fault Protector (TRFP)  
Transformer (T2)  
5
Control Power Circuit Breaker  
Oil Pump Circuit Breaker  
6
7
Main Circuit Breaker Disconnect  
Voltmeter (Optional)  
• control center — all extra low-voltage wiring (24 v or less)  
• power panel — 230 or 115 v control voltage (per job  
requirement)  
— up to 600 v for oil pump power  
• starter cabinet — chiller power wiring (per job  
requirement)  
8
9
Ammeter (Optional)  
10  
11  
12  
13  
14  
15  
16  
17  
Current Transformers (T1, T2, T3)  
Phase Monitor Relay (Optional)  
Overload Unit  
Starter Management Module  
Starter Access Door  
Control Transformer Secondary Circuit Breaker  
Signal Resistor  
Field Wiring Terminal Strip (TB6)  
Table 1 — Major PIC Components and  
Panel Locations*  
Fig. 7 — Wye-Delta Starter, Internal View  
PANEL  
PIC COMPONENT  
LOCATION  
CONTROLS  
Processor Sensor Input/Output Module  
(PSIO)  
Definitions  
Control Center  
ANALOG SIGNAL — An analog signal varies in propor-  
tion to the monitored source. It quantifies values between  
operating limits. (Example: A temperature sensor is an ana-  
log device because its resistance changes in proportion to  
the temperature, generating many values.)  
Starter Management Module (SMM)  
Local Interface Device (LID)  
6-Pack Relay Board  
Starter Cabinet  
Control Center  
Control Center  
Control Center  
Power Panel  
Power Panel  
Power Panel  
Power Panel  
8-Input Modules (Optional)  
Oil Heater Contactor (1C)  
DIGITAL SIGNAL — A digital (discrete) signalis a 2-position  
representation of the value of a monitored source. (Ex-  
ample: A switch is a digital device because it only indicates  
whether a value is above or below a set point or boundary  
by generating an on/off, high/low, or open/closed signal.)  
VOLATILE MEMORY — Volatile memory is memory in-  
capable of being sustained if power is lost and subsequently  
restored.  
Oil Pump Contactor (2C)  
Hot Gas Bypass Relay (3C) (Optional)  
Control Transformers (T1-T4)  
Control and Oil Heater Voltage Selector (S1) Power Panel  
Temperature Sensors  
Pressure Transducers  
See Fig. 8  
See Fig. 8  
*See Fig. 5, 6, and Fig. 8-12.  
11  
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Fig. 8 — 19XL Controls and Sensor Locations  
Fig. 9 — Control Sensors  
(Temperature)  
LEGEND  
1
2
3
4
5
6
—
—
—
—
—
—
LID  
PSIO  
8-Input Module (One of 2 Available)  
5-Volt Transducer Power Supply  
6-Pack Relay Board  
Fig. 10 — Control Sensors  
(Pressure Transducer, Typical)  
Circuit Breakers (4)  
Fig. 11 — Control Center (Front View),  
with Options Module  
12  
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PROCESSOR MODULE (PSIO) — The PSIO is the brain  
of the PIC (Fig. 11). This module contains all the operating  
software needed to control the chiller. The 19XL uses 3 pres-  
sure transducers and 8 thermistors to sense pressures and tem-  
peratures. These are connected to the PSIO module. The PSIO  
also provides outputs to the guide vane actuator, oil pump,  
oil heater, hot gas bypass (optional), motor cooling solenoid,  
and alarm contact. The PSIO communicates with the LID,  
the SMM, and the optional 8-input modules for user inter-  
face and starter management.  
8-INPUT MODULES — One optional module is factory in-  
stalled in the control center panel when ordered (Fig. 11).  
There can be up to 2 of these modules per chiller with  
8 spare inputs each. They are used whenever chilled water  
reset, demand reset, or reading a spare sensor is required.  
The sensors or 4 to 20 mA signals are field-installed.  
The spare temperature sensors must have the same  
temperature/resistance curve as the other temperature sen-  
sors on this unit. These sensors are 5,000 ohm at 75 F  
(25 C).  
STARTER MANAGEMENT MODULE (SMM) — This mod-  
ule is located within the starter cabinet. This module ini-  
tiates PSIO commands for starter functions such as start/  
stop of the compressor, start/stop of the condenser and chilled  
water pumps, start/stop of the tower fan, spare alarm con-  
tacts, and the shunt trip. The SMM monitors starter inputs  
such as flow switches, line voltage, remote start contact, spare  
safety, condenser high pressure, oil pump interlock, motor  
current signal, starter 1M and run contacts, and kW trans-  
ducer input (optional). The SMM contains logic capable of  
safely shutting down the machine if communications with  
the PSIO are lost.  
OIL HEATER CONTACTOR (1C) — This contactor is lo-  
cated in the power panel (Fig. 12) and operates the heater at  
either 115 or 230 v. It is controlled by the PIC to maintain  
oil temperature during chiller shutdown.  
OIL PUMP CONTACTOR (2C) — This contactor is located  
in the power panel (Fig. 12). It operates all 200 to 575-v oil  
pumps. The PIC energizes the contactor to turn on the oil  
pump as necessary.  
HOT GAS BYPASS CONTACTOR RELAY (3C) (Op-  
tional) — This relay, located in the power panel, (Item 5,  
Fig. 12) controls the opening of the hot gas bypass valve.  
The PIC energizes the relay during low load, high lift  
conditions.  
LOCAL INTERFACE DEVICE (LID) — The LID is mounted  
to the control center and allows the operator to interface with  
the PSIO or other CCN devices (Fig. 11). It is the input cen-  
ter for all local chiller set points, schedules, set-up func-  
tions, and options. The LID has a STOP button, an alarm  
light, 4 buttons for logic inputs, and a display. The function  
of the 4 buttons or ‘‘softkeys’’are menu driven and are shown  
on the display directly above the key.  
CONTROL TRANSFORMERS (T1-T4) — These trans-  
formers convert incoming control voltage to either 21 vac  
power for the PSIO module and options modules, or 24 vac  
power for 3 power panel contactor relays, 3 control solenoid  
valves, and the guide vane actuator. They are located in the  
power panel. See Fig. 12.  
6-PACK RELAY BOARD — This device is a cluster of  
6 pilot relays located in the control center (Fig. 11). It is  
energized by the PSIO for the oil pump, oil heater, alarm,  
optional hot gas bypass relay, and motor cooling solenoid.  
CONTROLAND OIL HEATER VOLTAGE SELECTOR (S1)  
— It is possible to use either 115 v or 230 v incoming con-  
trol power in the power panel. The switch is set to the volt-  
age used at the jobsite.  
LEGEND  
1
—
T2 — 24 vac Power Transformer for Hot Gas Bypass Relay,  
4
5
6
7
8
—
—
—
—
—
T1 — 24 vac, Control Center Transformer  
3C Hot Gas Bypass Relay Location  
Oil Pump Terminal Block  
Oil Pump Relay, Oil Heater Relay, Motor Cooling Solenoid,  
Oil Reclaim Solenoid  
2
3
—
—
Oil Pressure Switch  
T4 — 24 vac, Optional 8-Input Module Transformer  
Factory Terminal Connections  
T3 — 24 vac Guide Vane Actuator Transformer  
Fig. 12 — Power Panel with Options  
13  
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ALARMS AND ALERTS — Alarm (*) and alert (!) status  
are indicated on the Status tables. An alarm (*) will shut down  
the compressor. An alert (!) notifies the operator that an un-  
usual condition has occurred. The chiller will continue to  
operate when an alert is shown.  
Alarms are indicated when the control center alarm light  
(!) flashes. The primary alarm message is viewed on the de-  
fault screen and an additional, secondary, message and  
troubleshooting information are sent to the Alarm History  
table.  
LID Operation and Menus (Fig. 13-19)  
GENERAL  
• The LID display will automatically revert to the default  
screen after 15 minutes if no softkey activity takes place  
and if the chiller is not in the Pumpdown mode  
(Fig. 13).  
• When not in the default screen, the upper right-hand cor-  
ner of the LID always displays the name of the screen that  
you have entered (Fig. 14).  
• The LID may be configured in English or SI units, through  
the LID configuration screen.  
• Local Operation — By pressing the LOCAL softkey, the  
PIC is now in the LOCAL operation mode. The control  
will accept changes to set points and configurations from  
the LID only. The PIC will use the Local Time Schedule  
to determine chiller start and stop times.  
When an alarm is detected, the LID default screen will  
freeze (stop updating) at the time of alarm. The freeze en-  
ables the operator to view the chiller conditions at the time  
of alarm. The Status tables will show the updated informa-  
tion. Once all alarms have been cleared (by pressing the  
RESET softkey), the default LID screen will return to nor-  
mal operation.  
• CCN Operation — By pressing the CCN softkey, the PIC  
MENU STRUCTURE — To perform any of the operations  
described below, the PIC must be powered up and have suc-  
cessfully completed its self test. The self test takes place  
automatically, after power-up.  
is now in the CCN operation mode, and the control will  
accept modifications from any CCN interface or module  
(with the proper authority), as well as the LID. The PIC  
will use the CCN time schedule to determine start and stop  
times.  
• Press QUIT to leave the selected decision or field with-  
out saving any changes.  
• 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.  
Fig. 13 — LID Default Screen  
• Press PREVIOUS to scroll the cursor bar up in order to  
highlight a point or to view points above the current screen.  
• Press SELECT to view the next screen level (high-  
lighted with the cursor bar), or to override (if allowable)  
the highlighted point value.  
Fig. 14 — LID Service Screen  
14  
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• Press EXIT to return to the previous screen level.  
4. On the Point Status table press NEXT or  
PREVIOUS until desired point is displayed on the screen.  
• Press INCREASE or DECREASE to change the high-  
lighted point value.  
OVERRIDE OPERATIONS  
To Override a Value or Status  
1. On the Point Status table press NEXT or  
PREVIOUto hghighhe desred pon.  
TO VIEW POINT STATUS (Fig. 15) — Point Status is the  
actual value of all of the temperatures, pressures, relays, and  
actuators sensed and controlled by the PIC.  
1. On the Menu screen, press STATUS to view the list of  
Point Status tables.  
2. Press SELECT to select thhighlightd point. Then:  
For Discrete Points — Press START or STOP to se-  
lect the desired state.  
2. Press NEXT or PREVIOUS to highlight the desired  
status table. The list of tables is:  
• Status01 — Status of control points and sensors  
• Status02 — Status of relays and contacts  
• Status03 — Status of both optional 8-input modules and  
sensors  
For Analog Points  
—
Press INCREASE or  
DECREASE to select the desired value.  
3. Press SELECT to view the Point Status table desired.  
3. Press ENTER to register new value.  
NOTE: When overriding or changing metric values, it is  
necessary to hold the softkey down for a few seconds in or-  
der to see a value change, especially on kilopascal  
values.  
To Remove an Override  
1. On the Point Status table press NEXT or  
PREVIOUS to highlight the desired point.  
2. Press SELECT to access the highlighted point.  
Fig. 15 − Example of Point Status Screen  
(Status01)  
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3. Press RELEASE to remove the override and return the  
point to the PIC’s automatic control.  
4. Press NEXT or PREVIOUS to highlight the de-  
sired period or override that you wish to change.  
5. Press SELECT to access the highlighted period or  
ov
Override Indication— An override value is indicated by  
‘‘SUPVSR,’’‘‘SERVC,’’or ‘‘BEST’’flashing next to the point  
value on the Status table.  
TIME SCHEDULE OPERATION (Fig. 16)  
1. On the Menu screen, press SCHEDULE .  
a. Press INCREASE or DECREASE to change the  
6.  
time values. Override values are in one-hour incre-  
ments, up to 4 hours.  
2. Press NEXT or PREVIOUS to highlight the de-  
sired schedule.  
PSIO Software Version 08 and lower:  
OCCPC01S — LOCAL Time Schedule  
OCCPC02S — CCN Time Schedule  
b. Press ENABLE to select days in the day-of-week  
fields. Press DISABLE to eliminate days from the  
period.  
PSIO Software Version 09 and higher:  
OCCPC01S — LOCAL Time Schedule  
OCCPC02S — ICE BUILD Time Schedule  
OCCPC03-99S — CCN Time Schedule (Actual  
number is defined in  
Config table.)  
7. Press ENTER to register the values and to move  
ho
3. Press SELECT to access and view the time schedule.  
8. Pr
9. Either return to Step 4 to select another period or  
override, or press EXIT again to leave the current time  
sc
10. Holiday Designation (HOLIDEF table) may be found in  
the Service Operation section, page 38. You must assign  
the month, day, and duration for the holiday. The Broad-  
cast function in the Brodefs table also must be enabled  
for holiday periods to function.  
Fig. 16 — Example of Time Schedule  
Operation Screen  
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TO VIEW AND CHANGE SET POINTS (Fig. 19)  
3. Press NEXT or PREVIOUS to highlight the desired  
set point entry.  
1. To view the Set Point table, at the Menu screen press  
SETPOINT .  
4. Press SELECT to modify the highlighted set point.  
2. There are 4 set points on this screen: Base Demand Limit;  
LCW Set Point (leaving chilled water set point); ECW  
Set Point (entering chilled water set point); and ICE BUILD  
set point (PSIO Software Version 09 and higher only).  
Only one of the chilled water set points can be active at  
one time, and the type of set point is activated in the Serv-  
ice menu. ICE BUILD is also activated and configured in  
the Service menu.  
5. Press INCREASE or DECREASE to change the se-  
lected set point value.  
6. Press ENTER to save the changes and return to the  
previous screen.  
SERVICE OPERATION — To view the menu-driven pro-  
grams available for Service Operation, see Service Opera-  
tion section, page 38. For examples of LID display screens,  
see Table 2.  
Fig. 19 — Example of Set Point Screen  
20  
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Table 2 — LID Screens  
NOTES:  
1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points  
below or above the current screen.  
2. The LID may be configured in English or SI units, as required, through the LID configuration screen.  
3. Data appearing in the Reference Point Names column is used for CCN operations only.  
4. All options associated with ICE BUILD, Lead/Lag, CCN Occupancy Configuration, and Soft Stopping are only available on PSIO Software  
Version 9 and higher.  
EXAMPLE 1 — STATUS01 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press STATUS (STATUS01 will be highlighted).  
3. Press SELECT .  
REFERENCE POINT NAME  
(ALARM HISTORY)  
DESCRIPTION  
RANGE  
UNITS  
Control Mode  
Run Status  
Reset, Off, Local, CCN  
MODE  
Timeout, Recycle, Startup,  
Ramping, Running, Demand, Override,  
Shutdown, Abnormal, Pumpdown  
No/Yes  
STATUS  
Occupied ?  
Alarm State  
OCC  
ALM  
CHIL  
DLM  
Normal/Alarm  
*Chiller Start/Stop  
Base Demand Limit  
*Active Demand Limit  
Compressor Motor Load  
Current  
Stop/Start  
S
S
40-100  
%
40-100  
%
DEM LIM  
0-999  
%
%
CA  
CA  
CA  
L
P
A
0-999  
Amps  
0-999  
AMPS  
*Target Guide Vane Pos  
Actual Guide Vane Pos  
Water/Brine: Setpoint  
0-100  
%
%
GV TRG  
GV ACT  
SP  
LCW STPT  
ECW  
LCW  
0-100  
10-120 (–12.2-48.9)  
10-120 (–12.2-48.9)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–6.7-420 (–46-2896)  
–40-245 (–40-118)  
–6.7-420 (–46-2896)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–6.7-420 (–46-2896)  
–6.7-420 (–46-2896)  
0-999  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
PSI (kPa)  
DEG F (DEG C)  
PSI (kPa)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
PSI (kPa)  
PSID (kPad)  
%
*
Control Point  
Entering Chilled Water  
Leaving Chilled Water  
Entering Condenser Water  
Leaving Condenser Water  
Evaporator Refrig Temp  
Evaporator Pressure  
Condenser Refrig Temp  
Condenser Pressure  
Discharge Temperature  
Bearing Temperature  
Motor Winding Temp  
Oil Sump Temperature  
Oil Pressure Transducer  
Oil Pressure  
ECDW  
LCDW  
ERT  
ERP  
CRT  
CRP  
CMPD  
MTRB  
MTRW  
OILT  
OILP  
OILPD  
Line Voltage: Percent  
Actual  
V
V
P
A
0-9999  
VOLTS  
*Remote Contacts Input  
Total Compressor Starts  
Starts in 12 Hours  
Compressor Ontime  
*Service Ontime  
*Compressor Motor kW  
Off/On  
REMCON  
0-65535  
c
starts  
0-8  
STARTS  
0-500000.0  
HOURS  
HOURS  
kW  
c
S
hrs  
HRS  
0-32767  
0-9999  
CKW  
NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations for BEST programming  
language, data transfer, and overriding.  
21  
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Table 2 — LID Screens (cont)  
EXAMPLE 2 — STATUS02 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press STATUS .  
3. Scroll down to highlight STATUS02.  
4. Press SELECT .  
POINT TYPE  
UNITS  
REFERENCE POINT NAME  
(ALARM HISTORY)  
DESCRIPTION  
INPUT  
OUTPUT  
Hot Gas Bypass Relay  
*Chilled Water Pump  
Chilled Water Flow  
X
X
OFF/ON  
HGBR  
OFF/ON  
CHWP  
X
X
NO/YES  
EVFL  
*Condenser Water Pump  
Condenser Water Flow  
Compressor Start Relay  
Compressor Start Contact  
Compressor Run Contact  
Starter Fault Contact  
Pressure Trip Contact  
Single Cycle Dropout  
Oil Pump Relay  
Oil Heater Relay  
Motor Cooling Relay  
*Tower Fan Relay  
Compr. Shunt Trip Relay  
Alarm Relay  
Spare Prot Limit Input  
X
X
OFF/ON  
CDP  
NO/YES  
CDFL  
OFF/ON  
CMPR  
X
X
X
X
X
OPEN/CLOSED  
OPEN/CLOSED  
OPEN/CLOSED  
OPEN/CLOSED  
NORMAL/ALARM  
OFF/ON  
1CR AUX  
RUN AUX  
STR FLT  
PRS TRIP  
V1 CYCLE  
OILR  
X
X
X
X
X
X
OFF/ON  
OILH  
OFF/ON  
MTRC  
OFF/ON  
TFR  
OFF/ON  
TRIPR  
NORMAL/ALARM  
ALARM/NORMAL  
ALM  
X
SPR PL  
NOTE: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations from the LID only.  
EXAMPLE 3 — STATUS03 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press STATUS .  
3. Scroll down to highlight STATUS03.  
4. Press SELECT .  
REFERENCE POINT NAME  
(ALARM HISTORY)  
DESCRIPTION  
RANGE  
UNITS  
OPTIONS BOARD 1  
*Demand Limit 4-20 mA  
*Temp Reset 4-20 mA  
4-20  
4-20  
mA  
mA  
DEM OPT  
RES OPT  
CHWS  
*Common CHWS Sensor  
*Common CHWR Sensor  
*Remote Reset Sensor  
*Temp Sensor — Spare 1  
*Temp Sensor — Spare 2  
*Temp Sensor — Spare 3  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
CHWR  
R
RESET  
SPARE1  
SPARE2  
SPARE3  
OPTIONS BOARD 2  
*4-20 mA — Spare 1  
4-20  
mA  
SPARE1  
SPARE2  
SPARE4  
SPARE5  
SPARE6  
SPARE7  
SPARE8  
SPARE9  
M
M
*4-20 mA — Spare 2  
4-20  
mA  
*Temp Sensor — Spare 4  
*Temp Sensor — Spare 5  
*Temp Sensor — Spare 6  
*Temp Sensor — Spare 7  
*Temp Sensor — Spare 8  
*Temp Sensor — Spare 9  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
NOTE: All values shall be variables available for read operation to a CCN network. Descriptions shown with (*) support write operations for BEST  
programming language, data transfer, and overriding.  
EXAMPLE 4 — SETPOINT DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press SETPOINT .  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
Base Demand Limit  
LCW Setpoint  
40-100  
%
DLM  
100  
20-120 (–6.7-48.9)  
20-120 (–6.7-48.9)  
20- 60 (–6.7-15.6)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
lcw sp  
ecw sp  
ice sp  
50.0 (10.0)  
60.0 (15.6)  
40.0 ( 4.4)  
ECW Setpoint  
ICE BUILD Setpoint  
22  
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Table 2 — LID Screens (cont)  
EXAMPLE 5 — CONFIGURATION (CONFIG) DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight EQUIPMENT CONFIGURATION.  
4. Press SELECT .  
5. Scroll down to highlight CONFIG.  
6. Press SELECT .  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
RESET TYPE 1  
Degrees Reset at 20 mA  
–30-30 (–17-17)  
DEG F (DEG C)  
deg 20ma  
10⌬(6⌬)  
RESET TYPE 2  
Remote Temp (No Reset)  
Remote Temp (Full Reset)  
Degrees Reset  
–40-245 (–40-118)  
–40-245 (–40-118)  
–30-30 (–17-17)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
res rt1  
res rt2  
res rt  
85 (29)  
65 (18)  
10⌬(6⌬)  
RESET TYPE 3  
CHW Delta T (No Reset)  
CHW Delta T (Full Reset)  
Degrees Reset  
0-15 (0-8)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
restd  
restd  
1
2
10⌬(6⌬)  
0⌬(0⌬)  
5⌬(3⌬)  
0-15 (0-8)  
–30-30 (–17-17)  
deg chw  
Select/Enable Reset Type  
0-3  
res sel  
0
ECW CONTROL OPTION  
Demand Limit At 20 mA  
20 mA Demand Limit Option  
DISABLE/ENABLE  
40-100  
DISABLE/ENABLE  
ecw opt  
dem 20ma  
dem sel  
DISABLE  
40  
DISABLE  
%
Auto Restart Option  
DISABLE/ENABLE  
DISABLE/ENABLE  
astart  
DISABLE  
DISABLE  
Remote Contacts Option  
r
contact  
Temp Pulldown Deg/Min  
Load Pulldown %/Min  
Select Ramp Type:  
2-10  
5-20  
0/1  
tmp ramp  
kw ramp  
ramp opt  
3
10  
1
Temp = 0, Load = 1  
Loadshed Group Number  
Loadshed Demand Delta  
Maximum Loadshed Time  
0-99  
0-60  
0-120  
ldsgrp  
ldsdelta  
maxldstm  
0
20  
60  
%
MIN  
CCN Occupancy Config:  
Schedule Number  
Broadcast Option  
3-99  
occpcxxe  
occbrcst  
3
DISABLE/ENABLE  
DISABLE  
ICE BUILD Option  
DISABLE/ENABLE  
ibopt  
DISABLE  
ICE BUILD TERMINATION  
0 =Temp, 1 =Contacts, 2 =Both  
0-2  
ibterm  
0
ICE BUILD Recycle Option  
DISABLE/ENABLE  
ibrecyc  
DISABLE  
NOTE: ⌬ = delta degrees.  
EXAMPLE 6 — LEAD/LAG CONFIGURATION DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press SERVICE .  
3. Scroll down to highlight EQUIPMENT CONFIGURATION.  
4. Press SELECT .  
5. Scroll down to highlight Lead/Lag.  
6. Press SELECT .  
LEAD/LAG CONFIGURATION SCREEN  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
LEAD/LAG SELECT  
DISABLE =0, LEAD =1,  
LAG =2, STANDBY =3  
Load Balance Option  
Common Sensor Option  
0-3  
leadlag  
0
DISABLE/ENABLE  
DISABLE/ENABLE  
loadbal  
commsens  
DISABLE  
DISABLE  
LAG Percent Capacity  
LAG Address  
25-75  
%
lag per  
lag add  
lagstart  
50  
1-236  
92  
LAG START Timer  
2-60  
MIN  
MIN  
MIN  
10  
LAG STOP Timer  
2-60  
lagstop  
10  
PRESTART FAULT Timer  
STANDBY Chiller Option  
STANDBY Percent Capacity  
STANDBY Address  
0-30  
preflt  
5
DISABLE/ENABLE  
25-75  
stndopt  
DISABLE  
%
stnd per  
stnd add  
50  
93  
1-236  
NOTE: The Lead/Lag Configuration table is available on PSIO Software Version 09 and higher.  
23  
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Table 2 — LID Screens (cont)  
EXAMPLE 7 — SERVICE1 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight EQUIPMENT SERVICE.  
4. Press SELECT .  
5. Scroll down to highlight SERVICE1.  
6. Press SELECT .  
DESCRIPTION  
Motor Temp Override  
Cond Press Override  
CONFIGURABLE RANGE  
UNITS  
DEG F (DEG C)  
PSI (kPa)  
REFERENCE POINT NAME  
mt over  
DEFAULT VALUE  
200 (93)  
150-200 (66-93)  
150-245 (1034-1689)  
[90-200 (620-1379)]  
2-5 (1-3)  
Water/Brine  
8-40 (–13.3-4)  
cp over  
195 (1345) [125 (862)]  
Refrig Override Delta T  
Chilled Medium  
Brine Refrig Trippoint  
DEG F (DEG C)  
ref over  
medium  
br trip  
3⌬ (1.6⌬)  
WATER  
33 (1)  
DEG F (DEG C)  
Compr Discharge Alert  
Bearing Temp Alert  
125-200 (52-93)  
175-185 (79-85)  
DEG F (DEG C)  
DEG F (DEG C)  
cd alert  
tb alert  
200 (93)  
175 (79)  
Water Flow Verify Time  
Oil Press Verify Time  
0.5-5  
15-300  
MIN  
SEC  
wflow  
oilpr  
t
5
15  
t
Water/Brine Deadband  
Recycle Restart Delta T  
Recycle Shutdown Delta T  
0.5-2.0 (0.3-1.1)  
2.0-10.0 (1.1-5.6)  
0.5-4.0 (0.27-2.2)  
DEG F (DEG C)  
DEG F (DEG C)  
⌬DEG F (⌬DEG C)  
cw db  
1.0 (0.6)  
5 (2.8)  
1.0 (0.6)  
rcyc dt  
rcycs dt  
Surge Limit/HGBP Option  
Select: Surge=0, HGBP=1  
Surge/HGBP Delta T1  
0/1  
srg hgbp  
0
0.5-15 (0.3-8.3)  
50-170 (345-1172)  
[30-170 (207-1172)]  
DEG F (DEG C)  
PSI (kPA)  
hgb dt1  
hgb dp1  
1.5 (0.8)  
Surge/HGBP Delta P1  
75 (517) [50 (345)]  
Min. Load Points (T1/P1)  
Surge/HGBP Delta T2  
0.5-15 (0.3-8.3)  
50-170 (345-1172)  
[30-170 (207-1172)]  
DEG F (DEG C)  
PSI (kPa)  
hgb dt2  
hgb dp2  
10 (5.6)  
Surge/HGBP Delta P2  
170 (1172) [85 (586)]  
Full Load Points (T2/P2)  
Surge/HGBP Deadband  
1-3 (0.6-1.6)  
DEG F (DEG C)  
hgb dp  
1 (0.6)  
Surge Delta Percent Amps  
Surge Time Period  
10-50  
1-5  
%
MIN  
surge  
surge  
a
t
25  
2
Demand Limit Source  
Select: Amps=0, Load=1  
Amps Correction Factor  
Motor Rated Load Amps  
Motor Rated Line Voltage  
Meter Rated Line kW  
0/1  
dem src  
0
1-8  
corfact  
3
1-9999  
1-9999  
1-9999  
AMPS  
VOLTS  
kW  
a
v
fs  
fs  
200  
460  
600  
kw fs  
Line Frequency  
Select: 0=60 Hz, 1=50 Hz  
0/1  
HZ  
freq  
0
Compr Starter Type  
REDUCE/FULL  
–20-35 (–28.9-1.7)  
40-100  
starter  
REDUCE  
34 (1)  
100  
Condenser Freeze Point  
Soft Stop Amps Threshold  
DEG F (DEG C)  
%
cdfreeze  
softstop  
NOTES:  
1. Condenser Freeze Point and Softstop Amps Threshold are only selectable/readable on PSIO Software Versions 09 and higher.  
2. Values in [ ] indicate HFC-134a values.  
3. ⌬ = delta degrees.  
24  
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Table 2 — LID Screens (cont)  
EXAMPLE 8 — SERVICE2 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight EQUIPMENT SERVICE.  
4. Press SELECT .  
5. Scroll down to highlight SERVICE2.  
6. Press SELECT .  
DESCRIPTION  
OPTIONS BOARD 1  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
20 mA POWER CONFIGURATION  
External = 0, Internal = 1  
RESET 20 mA Power Source  
DEMAND 20 mA Power Source  
0,1  
0,1  
res 20 ma  
0
0
dem 20 ma  
SPARE ALERT ENABLE  
Disable = 0, Low = 1, High = 2  
Temp = Alert Threshold  
CHWS Temp Enable  
CHWS Temp Alert  
CHWR Temp Enable  
CHWR Temp Alert  
Reset Temp Enable  
Reset Temp Alert  
Spare Temp 1 Enable  
Spare Temp 1 Alert  
Spare Temp 2 Enable  
Spare Temp 2 Alert  
Spare Temp 3 Enable  
Spare Temp 3 Alert  
0-2  
chws en  
chws al  
chwr en  
chwr al  
rres en  
rres al  
spr1 en  
spr1 al  
spr2 en  
spr2 al  
spr3 en  
spr3 al  
0
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
245 (118)  
0-2  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
245 (118)  
OPTIONS BOARD 2  
20 mA POWER CONFIGURATION  
External = 0, Internal = 1  
SPARE 1 20 mA Power Source  
SPARE 2 20 mA Power Source  
0,1  
0,1  
sp1 20 ma  
sp2 20 ma  
0
0
SPARE ALERT ENABLE  
Disable = 0, Low = 1, High = 2  
Temp = Alert Threshold  
Spare Temp 4 Enable  
Spare Temp 4 Alert  
Spare Temp 5 Enable  
Spare Temp 5 Alert  
Spare Temp 6 Enable  
Spare Temp 6 Alert  
Spare Temp 7 Enable  
Spare Temp 7 Alert  
Spare Temp 8 Enable  
Spare Temp 8 Alert  
Spare Temp 9 Enable  
Spare Temp 9 Alert  
0-2  
spr4 en  
spr4 al  
spr5 en  
spr5 al  
spr6 en  
spr6 al  
spr7 en  
spr7 al  
spr8 en  
spr8 al  
spr9 en  
spr9 al  
0
–40-245 (–40-118)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
245 (118)  
0-2  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
0-2  
245 (118)  
0
–40-245 (–0-118)  
0-2  
245 (118)  
0
–40-245 (–40-118)  
245 (118)  
NOTE: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp Alert’’ threshold for each point listed. If the  
‘‘Enable’’ is set to 1, a value above the ‘‘Temp Alert’’ threshold shall generate an alert message. If the ‘‘Enable’’ is set to 2, a value below the ‘‘Temp  
Alert’’ threshold shall generate an alert message. If the ‘‘Enable’’ is set to 0, alert generation is disabled.  
EXAMPLE 9 — SERVICE3 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press SERVICE .  
3. Scroll down to highlight EQUIPMENT SERVICE.  
4. Press SELECT .  
5. Scroll down to highlight SERVICE3.  
DESCRIPTION  
CONFIGURABLE RANGE  
UNITS  
REFERENCE POINT NAME  
DEFAULT VALUE  
Proportional Inc Band  
Proportional Dec Band  
Proportional ECW Gain  
Guide Vane Travel Limit  
2-10  
2-10  
1-3  
gv inc  
gv de  
gv ecw  
gv lim  
6.5  
6.0  
2.0  
50  
30-100  
%
25  
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Table 2 — LID Screens (cont)  
EXAMPLE 10 — MAINTENANCE (MAINT01) DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight ALGORITHM STATUS.  
4. Press SELECT .  
5. Scroll down to highlight MAINT01.  
DESCRIPTION  
RANGE/STATUS  
UNITS  
REFERENCE POINT NAME  
CAPACITY CONTROL  
Control Point  
Leaving Chilled Water  
Entering Chilled Water  
Control Point Error  
ECW Delta T  
ECW Reset  
LCW Reset  
Total Error + Resets  
Guide Vane Delta  
10-120 (–12.2-48.9)  
–40-245 (–40-118)  
–40-245 (–40-118)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–99-99 (–55-55)  
–2-2  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
DEG F (DEG C)  
%
ctrlpt  
LCW  
ECW  
cperr  
ecwdt  
ecwres  
lcwres  
error  
gvd  
Target Guide Vane Pos  
Actual Guide Vane Pos  
Proportional Inc Band  
Proportional Dec Band  
Proportional ECW Gain  
Water/Brine Deadband  
0-100  
0-100  
2-10  
2-10  
%
%
GV  
GV  
gv inc  
gv dec  
gv ecw  
cwdb  
TRG  
ACT  
1-3  
0.5-2 (0.3-1.1)  
DEG F (DEG C)  
NOTE: Overriding is not supported on this maintenance screen. Active overrides show the associated point in alert (*). Only values with capital letter  
reference point names are variables available for read operation.  
EXAMPLE 11 — MAINTENANCE (MAINT02) DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press SERVICE .  
3. Scroll down to highlight CONTROL ALGORITHM STATUS.  
4. Press SELECT .  
5. Scroll down to highlight MAINT02.  
6. Press SELECT .  
DESCRIPTION  
RANGE/STATUS  
UNITS  
REFERENCE POINT NAME  
OVERRIDE/ALERT STATUS  
MOTOR WINDING TEMP  
Override Threshold  
–40-245 (–40-118)  
150-200 (66-93)  
DEG F (DEG C)  
DEG F (DEG C)  
MTRW  
mt over  
CONDENSER PRESSURE  
Override Threshold  
–6.7-420 (–42-2896)  
90-245 (621-1689)  
PSI (kPa)  
PSI (kPa)  
CRP  
cp over  
EVAPORATOR REFRIG TEMP  
Override Threshold  
–40-245 (–40-118)  
2-45 (1-7.2)  
DEG F (DEG C)  
DEG F (DEG C)  
ERT  
rt over  
DISCHARGE TEMPERATURE  
Alert Threshold  
–40-245 (–40-118)  
125-200 (52-93)  
DEG F (DEG C)  
DEG F (DEG C)  
CMPD  
cd alert  
BEARING TEMPERATURE  
Alert Threshold  
–40-245 (–40-118)  
175-185 (79-85)  
DEG F (DEG C)  
DEG F (DEG C)  
MTRB  
tb alert  
NOTE: Overriding is not supported on this maintenance screen. Active overrides show the associated point in alert (*). Only values with capital letter  
reference point names are variables available for read operation.  
26  
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Table 2 — LID Screens (cont)  
EXAMPLE 12 — MAINTENANCE (MAINT03) DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
2. Press SERVICE .  
.
3. Scroll down to highlight CONTROL ALGORITHM STATUS.  
4. Press SELECT .  
5. Scroll down to highlight MAINT03.  
6. Press SELECT .  
DESCRIPTION  
SURGE/HGBP ACTIVE ?  
Active Delta P  
RANGE/STATUS  
NO/YES  
UNITS  
PSI (kPa)  
REFERENCE POINT NAME  
0-200 (0-1379)  
dp  
a
Active Delta T  
Calculated Delta T  
0-200 (0-111)  
0-200 (0-111)  
DEG F (DEG C)  
DEG F (DEG C)  
dt  
dt  
a
c
Surge Protection Counts  
0-12  
spc  
NOTE: Override is not supported on this maintenance screen. Only values with capital letter reference point names are variables available for read  
operation.  
EXAMPLE 13 — MAINTENANCE (MAINT04 DISPLAY SCREEN  
To access this display from the LID default screen:  
1. Press MENU  
.
2. Press SERVICE .  
3. Scroll down to highlight CONTROL ALGORITHM STATUS.  
4. Press SELECT .  
5. Scroll down to highlight MAINT04.  
6. Press SELECT .  
DESCRIPTION  
RANGE/STATUS  
UNITS  
REFERENCE POINT NAME  
LEAD/LAG: Configuration  
Current Mode  
DISABLE,LEAD,LAG,STANDBY, INVALID  
DISABLE,LEAD,LAG,STANDBY, CONFIG  
leadlag  
llmode  
Load Balance Option  
LAG Start Time  
DISABLE/ENABLE  
loadbal  
lagstart  
lagstop  
preflt  
pull dt  
pull sat  
0-60  
MIN  
MIN  
MIN  
LAG Stop Time  
0-60  
0-30  
Prestart Fault Time  
Pulldown: Delta T/Min  
Satisfied?  
2-10 F/min (1.1-5.5 C/min)  
No/Yes  
⌬ DEG F/min  
(⌬ DEG C/min)  
LEAD CHILLER in Control  
No/Yes  
leadctrl  
LAG CHILLER: Mode  
Run Status  
Reset,Off,Local,CCN  
lagmode  
lagstat  
Timeout,Recycle,Startup,Ramping,Running  
Demand,Override,Shutdown,Abnormal,Pumpdown  
Stop,Start,Retain  
Start/Stop  
Recovery Start Request  
lag  
s
s
s
No/Yes  
lag rec  
stdmode  
stdstat  
STANDBY CHILLER: Mode  
Reset,Off,Local,CCN  
Run Status  
Timeout,Recycle,Startup,Ramping,Running  
Demand,Override,Shutdown,Abnormal,Pumpdown  
Stop,Start,Retain  
Start/Stop  
std  
s
Recovery Start Request  
NOTES:  
No/Yes  
std rec  
1. Only values with capital letter reference point names are variables available for read operation. Forcing is not supported on this maintenance  
screen.  
2. The MAINT04 screen is available on PSIO Software Version 09 and higher.  
3. ⌬ = delta degrees.  
27  
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DEMAND LIMITING — The PIC will respond to the  
ACTIVE DEMAND LIMIT set point by limiting the open-  
ing of the guide vanes. It will compare the set point  
to either COMPRESSOR MOTOR LOAD or COMPRES-  
SOR MOTOR CURRENT (percentage), depending on how  
the control is configured for the DEMAND LIMIT SOURCE  
which is accessed on the SERVICE1 table. The default set-  
ting is current limiting.  
PIC System Functions  
NOTE: Throughout this manual, words printed in capital let-  
ters and italics represent values that may be viewed on the  
LID. See Table 2 for examples of LID screens. Point names  
are listed in the Description column. An overview of LID  
operation and menus is given in Fig. 13-19.  
CAPACITY CONTROL — The PIC controls the chiller  
capacity by modulating the inlet guide vanes in response to  
chilled water temperature changes away from the CON-  
TROL POINT. The CONTROL POINT may be changed by  
a CCN network device, or is determined by the PIC adding  
any active chilled water reset to the ECW (Entering Chilled  
Water) SET POINT or LCW SET POINT. The PIC uses the  
PROPORTIONAL INC (Increase) BAND, PROPORTIONAL  
DEC (Decrease) BAND, and the PROPORTIONAL ECW GAIN  
to determine how fast or slow to respond. CONTROL POINT  
may be viewed/overridden on the Status table, Status01  
selection.  
CHILLER TIMERS — The PIC maintains 2 runtime clocks,  
known as COMPRESSOR ONTIME and SERVICE ON-  
TIME. COMPRESSOR ONTIME indicates the total life-  
time compressor run hours. This timer can register up  
to 500,000 hours before the clock turns back to zero. The  
SERVICE ONTIME is a resettable timer that can be used to  
indicate the hours since the last service visit or any other  
reason. The time can be changed through the LID to  
whatever value is desired. This timer can register up to  
32,767 hours before it rolls over to zero.  
The chiller also maintains a start-to-start timer and a stop-  
to-start timer. These timers limit how soon the chiller can be  
started. See the Start-Up/Shutdown/Recycle Sequence sec-  
tion, page 39, for operational information.  
ENTERING CHILLED WATER CONTROL — If this op-  
tion is enabled, the PIC uses ENTERING CHILLED WATER  
temperature to modulate the vanes instead of LEAV-  
ING CHILLED WATER temperature. ENTERING CHILLED  
WATER control option may be viewed/modified on the Equip-  
ment Configuration table, Config table.  
OCCUPANCYSCHEDULE — This schedule determines when  
the chiller is either occupied or unoccupied.  
DEADBAND — This is the tolerance on the chilled water/  
brine temperature CONTROL POINT. If the water temper-  
ature goes outside of the DEADBAND, the PIC opens or closes  
the guide vanes in response until it is within tolerance. The  
PIC may be configured with a 0.5 to 2 F (0.3 to 1.1 C) dead-  
band. DEADBAND may be viewed or modified on the Equip-  
ment Service1 table.  
For example, a 1° F (0.6° C) deadband setting controls  
the water temperature within ±0.5° F (0.3° C) of the con-  
trol 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.  
Each schedule consists of from one to 8 occupied/unoccupied  
time periods, set by the operator. These time periods can be  
enabled to be in effect, or not in effect, on each day of the  
week and for holidays. The day begins with 0000 hours and  
ends with 2400 hours. The chiller is in OCCUPIED mode  
unless an unoccupied time period is in effect.  
The chiller will shut down when the schedule goes to UN-  
OCCUPIED. These schedules can be set up to follow the  
building schedule or to be 100% OCCUPIED if the operator  
wishes. The schedules also can be bypassed by forcing the  
Start/Stop command on the PIC Status screen to start. The  
schedules also can be overridden to keep the unit in an OC-  
CUPIED mode for up to 4 hours, on a one-time basis.  
Figure 18 shows a schedule for a typical office building  
time schedule, with a 3-hour, off-peak cool down period  
from midnight to 3 a.m., following a weekend shutdown.  
Example: Holiday periods are unoccupied 24 hours per day.  
The building operates Monday through Friday, 7:00 a.m. to  
6:00 p.m., with a Saturday schedule of 6:00 a.m. to  
1:00 p.m., and includes the Monday midnight to 3:00 a.m.  
weekend cool-down schedule.  
PROPORTIONAL BANDSAND 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 tempera-  
ture is moving from CONTROL POINT.  
The proportional band can be viewed/modified on the LID.  
There are two response modes, one for temperature re-  
sponse above the control point, the other for response below  
the control point.  
The first type is called PROPORTIONAL INC BAND, and  
it can slow or quicken vane response to chilled water/  
brine temperature above DEADBAND. It can be adjusted  
from a setting of 2 to 10; the default setting is 6.5. PRO-  
PORTIONAL DEC BAND can slow or quicken vane re-  
sponse to chilled water temperature below deadband plus control  
point. It can be adjusted on the LID from a setting of 2 to 10,  
and the default setting is 6.0. Increasing either of these set-  
tings will cause the vanes to respond slower than at a lower  
setting.  
NOTE: This schedule is for illustration only, and is not in-  
tended to be a recommended schedule for chiller operation.  
PSIO Software Version 08 and Lower — Whenever the chiller  
is in the LOCAL mode, the chiller will start when the  
Occupancy Schedule 01 indicates OCCUPIED. When in the  
CCN mode, Occupancy Schedule 02 is used.  
PSIO Software Version 09 and Higher — The Local Time  
Schedule is still the Occupancy Schedule 01. The Ice Build  
Time Schedule is Schedule 02 and the CCN Default Time  
Schedule is Schedule 03. The CCN schedule number is de-  
fined on the Config table in the Equipment Configuration  
table on page 23. The schedule number can change to any  
value from 03 to 99. If this schedule number is changed on  
the Config table, the operator must use the Attach to Net-  
work Device table to upload the new number into the Sched-  
ule screen. See Fig. 17.  
The PROPORTIONAL ECW GAIN can be adjusted at the LID  
display from a setting of 1.0 to 3.0, with a default setting of  
2.0. Increase this setting to increase guide vane response to  
a change in entering chilled water temperature. The propor-  
tional bands and gain may be viewed/modified on the Equip-  
ment Service3 table.  
28  
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To give a better warning as to the operating condition of  
the chiller, the operator also can define alert limits on vari-  
ous monitored inputs. Safety contact and alert limits are  
defined in Table 3. Alarm and alert messages are listed in the  
Troubleshooting Guide section, page 66.  
Safety Controls — The PIC monitors all safety control  
inputs, and if required, shuts down the chiller or limits the  
guide vanes to protect the chiller from possible damage from  
any of the following conditions:  
• high bearing temperature  
SHUNT TRIP — The shunt trip function of the PIC is a safety  
trip. The shunt trip is wired from an output on the SMM to  
a shunt trip-equipped motor circuit breaker. If the PIC tries  
to shut down the compressor through normal shutdown pro-  
cedure but is unsuccessful for 30 seconds, the shunt trip out-  
put is energized and causes the circuit breaker to trip off. If  
ground fault protection has been applied to the starter, the  
ground fault trip will also energize the shunt trip to trip the  
circuit breaker.  
• high motor winding temperature  
• high discharge temperature  
• low oil pressure  
• low cooler refrigerant temperature/pressure  
• condenser high pressure or low pressure  
• inadequate water/brine cooler and condenser flow  
• high, low, or loss of voltage  
• excessive motor acceleration time  
• excessive starter transition time  
• lack of motor current signal  
Default Screen Freeze — Whenever an alarm  
occurs, the LID default screen will freeze displaying the  
condition of the chiller at the time of alarm. Knowledge of  
the operating state of the chiller at the time an alarm occurs  
is useful when troubleshooting. Current chiller information  
can be viewed on the Status tables. Once all existing alarms  
• excessive motor amps  
• excessive compressor surge  
• temperature and transducer faults  
Starter faults or optional protective devices within the starter  
can shut down the chiller. These devices are dependent on  
what has been purchased as options.  
are cleared (by pressing the RESET softkey), the default  
LID will return to normal operation.  
Motor Cooling Control — Motor temperature is  
reduced by refrigerant entering the motor shell and evap-  
orating. The refrigerant is regulated by the motor cooling  
relay. This relay will energize when the compressor is run-  
ning and motor temperature is above 125 F (51.7 C). The  
relay will close when motor temperature is below 100 F  
(37.8 C). Note that there is always a minimum flow of  
refrigerant when the compressor is operating for motor cool-  
ing; the relay only controls additional refrigerant to the  
motor.  
If compressor motor overload occurs, check the motor  
for grounded or open phases before attempting a  
restart.  
If the controller initiates a safety shutdown, it displays  
the fault on the LID display with a primary and a secondary  
message, and energizes an alarm relay in the starter and blinks  
the alarm light on the control center. The alarm is stored in  
memory and can be viewed in the PIC alarm table along with  
a message for troubleshooting.  
29  
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Table 3 — Protective Safety Limits and Control Settings  
MONITORED PARAMETER  
LIMIT  
APPLICABLE COMMENTS  
TEMPERATURE SENSORS  
OUT OF RANGE  
–40 to 245 F (–40 to 118.3 C)  
Must be outside range for 2 seconds  
Must be outside range for 2 seconds.  
Ratio = Input Voltage ÷ Voltage  
Reference  
PRESSURE TRANSDUCERS  
OUT OF RANGE  
0.08 to 0.98 Voltage Ratio  
COMPRESSOR DISCHARGE  
TEMPERATURE  
Ͼ220 F (104.4 C)  
Preset, alert setting configurable  
MOTOR WINDING TEMPERATURE  
BEARING TEMPERATURE  
Ͼ220 F (104.4 C)  
Ͼ185 F (85 C)  
Preset, alert setting configurable  
Preset, alert setting configurable  
Preset, configure chilled medium for  
water (Service1 table)  
Ͻ33 F (for water chilling) (0.6° C)  
EVAPORATOR REFRIGERANT  
TEMPERATURE  
Configure chilled medium for brine  
(Service1 table). Adjust brine refrigerant  
trippoint for proper cutout  
ϽBrine Refrigerant Trippoint (set point adjustable  
from 0 to 40 F [–18 to 4 C] for brine chilling)  
TRANSDUCER VOLTAGE  
Ͻ4.5 vdc Ͼ 5.5 vdc  
Preset  
Ͼ263 ± 7 psig (1813 ± 48 kPa),  
reset at 180 ± 10 (1241 ± 69 kPa)  
CONDENSER PRESSURE — SWITCH  
Preset  
Ͼ260 psig (1793 kPa) for HCFC-22;  
215 psig (1482 kPa) for HFC-134a  
— CONTROL  
Preset  
OIL PRESSURE — SWITCH  
Cutout Ͻ11 psid (76 kPad) ± 1.5 psid (10.3 kPad)  
Cut-in Ͼ16.5 psid (114 kPad) ± 4 psid (27.5 kPad)  
Preset, no calibration needed  
Preset  
Cutout Ͻ15 psid (103 kPad)  
Alert Ͻ18 psid (124 kPad)  
— CONTROL  
Preset, based on transformed line volt-  
age to 24 vac rated-input to the Starter  
Management Module. Also monitored at  
PSIO power input.  
LINE VOLTAGE — HIGH  
— LOW  
Ͼ110% for one minute  
Ͻ90% for one minute or р85% for 3 seconds  
Ͻ50% for one cycle  
— SINGLE-CYCLE  
Ͼ110% for 30 seconds  
Preset  
Preset  
Preset  
COMPRESSOR MOTOR LOAD  
Ͻ10% with compressor running  
Ͼ10% with compressor off  
For chillers with reduced voltage me-  
chanical and solid-state starters  
STARTER ACCELERATION TIME  
(Determined by inrush current  
going below 100% compressor  
motor load)  
Ͼ45 seconds  
For chillers with full voltage starters  
(Configured on Service1 table)  
Ͼ10 seconds  
Ͼ75 seconds  
STARTER TRANSITION  
Reduced voltage starters only  
Energizes condenser pump relay if condenser  
refrigerant temperature or condenser entering  
water temperature is below the configured con-  
denser freeze point temperature. Deenergizes  
when the temperature is 5 F (3 C) above con-  
denser freeze point temperature.  
CONDENSER FREEZE POINT config-  
ured in Service01 table with a default  
setting of 34 F (1 C).  
CONDENSER FREEZE  
PROTECTION  
Flow Switches (Field Supplied)  
Operate water pumps with chiller off. Manually  
reduce water flow and observe switch for proper  
cutout. Safety shutdown occurs when cutout time  
exceeds 3 seconds.  
CUT-OUT  
SETTING  
ADJUSTMENT  
SCREW  
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on the LID Equipment Configuration table, Config table (see  
Table 2). Motor load is the default type.  
Ramp Loading Control — The ramp loading control  
slows down the rate at which the compressor loads up. This  
control can prevent the compressor from loading up during  
the short period of time when the chiller is started, and the  
chilled water loop has to be brought down to normal design  
conditions. This helps reduce electrical demand charges by  
slowly bringing the chilled water to control point. However,  
the total power draw during this period remains almost  
unchanged.  
Capacity Override (Table 4) — Capacity overrides  
can prevent some safety shutdowns caused by exceeding  
motor amperage limit, refrigerant low temperature safety limit,  
motor high temperature safety limit, and condenser high pres-  
sure limit. In all cases there are 2 stages of compressor vane  
control.  
1. The vanes are held from opening further, and the status  
line on the LID indicates the reason for the override.  
2. The vanes are closed until condition decreases below the  
first step set point, and then the vanes are released to nor-  
mal capacity control.  
There are 2 methods of ramp loading with the PIC. Ramp  
loading can be based on chilled water temperature or on mo-  
tor load.  
1. Temperature ramp loading limits the rate at which either  
leaving chilled water or entering chilled water temper-  
ature decreases by an operator-configured rate. The low-  
est temperature ramp table will be used the first time the  
chiller is started (at commissioning). The lowest tem-  
perature ramp rate will also be used if chiller power has  
been off for 3 hours or more (even if the motor ramp load  
is selected).  
2. Motor load ramp loading limits the rate at which the  
compressor motor current or compressor motor load  
increases by an operator-configured rate.  
The TEMP (Temperature) PULLDOWN, LOAD PULL  
DOWN, and SELECT RAMP TYPE may be viewed/modified  
Whenever the motor current demand limit set point is reached,  
it activates a capacity override, again with a 2-step process.  
Exceeding 110% of the rated load amps for more than  
30 seconds will initiate a safety shutdown.  
The compressor high lift (surge prevention) set point will  
cause a capacity override as well. When the surge preven-  
tion set point is reached, the controller normally will only  
hold the guide vanes from opening. If so equipped, the hot  
gas bypass valve will open instead of holding the vanes.  
Table 4 — Capacity Overrides  
SECOND  
STAGE  
OVERRIDE  
FIRST STAGE SET POINT  
TERMINATION  
OVERRIDE  
CAPACITY  
CONTROL  
SET POINT  
View/Modify  
on  
LID Screen  
Default Value  
Configurable Range  
Value  
Value  
ϾOverride  
Set Point  
+ 4 psig  
HCFC-22  
HFC-134a  
HCFC-22  
150 to 245 psig  
HFC-134a  
HIGH  
CONDENSER  
PRESSURE  
Equipment  
Service1  
ϽOverride  
Set Point  
Ͼ195 psig  
(1345 kPa)  
125 psig  
(862 kPa)  
90 to 200 psig  
(1034 to 1689 kPa) (620 to 1379 kPa)  
(28 kPa)  
ϾOverride  
Set Point  
+10° F  
HIGH MOTOR  
TEMPERATURE  
Equipment  
Service1  
ϽOverride  
Set Point  
Ͼ200 F (93.3 C)  
150 to 200 F (66 to 93 C)  
(6° C)  
LOW  
REFRIGERANT  
TEMPERATURE  
(Refrigerant  
рTrippoint  
+ Override  
⌬T –1° F  
(0.56° C)  
ϾTrippoint  
+ Override  
⌬T +2° F  
(1.2° C)  
Equipment  
Service1  
Ͻ3° F (1.6° C)  
(Above Trippoint)  
2° to 5° F  
(1° to 3° C)  
Override Delta  
Temperature)  
HCFC-22  
Minimum:  
HFC-134a  
HCFC-22  
HFC-134a  
Minimum:  
T1 — 1.5° F  
(0.8° C)  
P1 — 50 psid  
(345 kPad)  
Maximum:  
T2 — 10° F  
(5.6° C)  
T1 — 1.5° F  
(0.8° C)  
0.5° to 15° F  
(0.3° to 8.3° C)  
50 to 170 psid  
0.5° to 15° F  
(0.3° to 8.3° C)  
30 to 170 psid  
Within  
Lift Limits  
Plus Surge/  
HGBP  
HIGH  
COMPRESSOR  
LIFT  
P1 — 75 psid  
(517 kPad)  
Maximum:  
T2 — 10° F  
(5.6° C)  
P2 — 170 psid P2 — 85 psid  
(1172 kPad) (586 kPad)  
Equipment  
Service1  
None  
None  
(345 to 1172 kPad) (207 to 1172 kPad)  
(Surge  
Deadband  
Setting  
Prevention)  
0.5° to 15° F  
(0.3° to 8.3° C)  
50 to 170 psid  
0.5° to 15° F  
(0.3° to 8.3° C)  
30 to 170 psid  
(345 to 1172 kPad) (207 to 1172 kPad)  
MANUAL  
GUIDE VANE  
TARGET  
Control  
Algorithm  
Maint01  
Release of  
Manual  
Control  
Automatic  
0 to 100%  
MOTOR LOAD —  
ACTIVE  
DEMAND LIMIT  
2% Lower  
Than  
Set Point  
у5% of  
Set Point  
Status01  
100%  
40 to 100%  
31  
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3 times every 12 hours. If more than 8 starts in 12 hours  
occur, then an Excessive Starts alarm is displayed, prevent-  
ing the chiller from starting. The operator must reset the alarm  
at the LID in order to override the starts counter and start  
the chiller. If Automatic Restart After a Power Failure is not  
activated when a power failure occurs, and the remote con-  
tact is closed, the chiller will indicate an alarm because of  
the loss of voltage.  
High Discharge Temperature Control — If the  
discharge temperature increases above 160 F (71.1 C)  
(PSIO Software Version 09 and higher) or 180 F (82 C) (PSIO  
Software Version 08 or lower), the guide vanes are propor-  
tionally 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 con-  
trols will bring the chiller into the recycle mode.  
The contacts for Remote Start are wired into the starter at  
terminal strip TB5, terminals 8A and 8B. See the certified  
drawings for further details on contact ratings. The contacts  
must be dry (no power).  
Oil Sump Temperature Control — The oil sump tem-  
perature control is regulated by the PIC which uses the oil  
heater relay when the chiller is shut down.  
As part of the pre-start checks executed by the controls,  
oil sump temperature is compared against evaporator refrig-  
erant temperature. If the difference between these 2 tem-  
peratures 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.  
Spare Safety Inputs — Normally closed (NC) digital  
inputs for additional field-supplied safeties may be wired to  
the spare protective limits input channel in place of the factory-  
installed jumper. (Wire multiple inputs in series.) The open-  
ing of any contact will result in a safety shutdown and LID  
display. Refer to the certified drawings for safety contact  
ratings.  
Analog temperature sensors may also be added to the  
options modules, if installed. These may be programmed to  
cause an alert on the CCN network, but will not shut the  
chiller down.  
PSIO SOFTWARE VERSION 08 AND LOWER — The oil  
heater relay is energized whenever the chiller compressor is  
off, and the oil sump temperature is less than 140 F (60 C)  
or sump temperature is less than the cooler refrigerant tem-  
perature plus 60° F (33.3° C). The heater is then turned  
off when the oil sump temperature is: 1) more than  
160 F (71.1 C); or 2) the sump temperature is more than  
145 F (62.8 C) and more than the cooler refrigerant tem-  
perature plus 65° F (36.1° C). The heater is always off dur-  
ing start-up or when the compressor is running.  
SPARE ALARM CONTACTS — Two spare sets of alarm  
contacts are provided within the starter. The contact ratings  
are provided in the certified drawings. The contacts are  
located on terminal strip TB6, terminals 5A and 5B, and  
terminals 5C and 5D.  
PSIO SOFTWARE VERSION 09 AND HIGHER — The oil  
heater relay is energized whenever the chiller compressor is  
off and the oil sump temperature is less than 150 F (65.6 C)  
or the oil sump temperature is less than the cooler refrig-  
erant temperature plus 70° F (39° C). The oil heater is turned  
off when the oil sump temperature is either 1) more than  
160 F (71.1 C); or 2) the oil sump temperature is more than  
155 F (68.3 C) and more than the cooler refrigerant tem-  
perature plus 75° F (41.6° C). The oil heater is always off  
during start-up or when the compressor is running.  
When a power failure to the PSIO module has occurred  
for more than 3 hours (i.e., initial start-up), the oil sump is  
heated to 100° F (56° C) above the evaporator refrigerant  
temperature or 190 F (88 C), whichever is lower. Once this  
temperature is reached, the oil pump will be energized for  
1 to 2 minutes or until the oil sump temperature cools to  
below 145 F (63 C). The normal heating algorithm is now  
followed once ramp loading has been completed.  
Condenser Pump Control — The chiller will moni-  
tor the CONDENSER PRESSURE and may turn on this pump  
if the pressure becomes too high whenever the compressor  
is shut down. CONDENSER PRESSURE OVERRIDE is used  
to determine this pressure point. This value is found on the  
Equipment Service1 LID table and has a default value  
(Table 4). If the CONDENSER PRESSURE is greater than  
or equal to the CONDENSER PRESSURE OVERRIDE, and  
the ENTERING CONDENSER WATER TEMP (Temper-  
ature) is less than 115 F (46 C), then the condenser pump  
will energize to try to decrease the pressure. The pump will  
turn off when the condenser pressure is less than the  
pressure override less 5 psi (34 kPa), or the CONDENSER  
REFRIG (Refrigerant) TEMP is within 3° F (2° C) of the  
ENTERING CONDENSER WATER temperature.  
Condenser Freeze Prevention — This control  
algorithm helps prevent condenser tube freeze-up by ener-  
gizing the condenser pump relay. If the pump is controlled  
by the PIC, starting the pump will help prevent the water in  
the condenser from freezing. Condenser freeze prevention  
can occur whenever the chiller is not running except when  
it is either actively in pumpdown or in Pumpdown Lockout  
with the freeze prevention disabled (refer to Control Test table,  
Pumpdown/Terminate Lockout tables).  
When the CONDENSER REFRIG TEMP is less than  
or equal to the CONDENSER FREEZE POINT, or the  
ENTERING CONDENSER WATER temperature is less than  
or equal to the CONDENSER FREEZE POINT, then the  
CONDENSER WATER PUMP shall be energized until the  
CONDENSER REFRIG TEMP is greater than the CON-  
DENSER FREEZE POINT plus 5° F (2.7° C). An alarm will  
be generated if the chiller is in PUMPDOWN mode and the  
pump is energized. An alert will be generated if the chiller  
is not in PUMPDOWN mode and the pump is energized. If  
in recycle shutdown, the mode shall transition to a non-  
recycle shutdown.  
After a 3-hour power failure, the oil temperature must rise  
to the higher oil temperature. The controls will delay the start  
of the compressor until this temperature is met.  
Oil Cooler — The oil must be cooled when the compres-  
sor is running. This is accomplished through a small, plate-  
type heat exchanger located behind the oil pump. The heat  
exchanger uses liquid condenser refrigerant as the cooling  
liquid. Arefrigerant thermostatic expansion valve (TXV) regu-  
lates refrigerant flow to control oil temperature entering the  
bearings. There is always a flow of refrigerant bypassing the  
thermostatic TXV. The bulb for the expansion valve is strapped  
to the oil supply line leaving the heat exchanger and the valve  
is set to maintain 110 F (43 C).  
NOTE: The TXV is not adjustable. Oil sump temperature  
may be at a lower temperature.  
Remote Start/Stop Controls — A remote device, such  
as a time clock which uses a set of contacts, may be used to  
start and stop the chiller. However, the device should not be  
programmed to start and stop the chiller in excess of 2 or  
32  
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RESET TYPE 1—Reset Type 1 requires an optional 8-input  
module. It is an automatic chilled water temperature reset  
based on a 4 to 20 mA input signal. This type permits up to  
± 30° F (± 16° C) of automatic reset to the chilled water or  
brine temperature set point, based on the input from a 4 to  
20 mA signal. This signal is hardwired into the number one  
8-input module.  
If the 4-20 mAsignal is externally powered from the 8-input  
module, the signal is wired to terminals J1-5(+) and J1-6(–).  
If the signal is to be internally powered by the 8-input mod-  
ule (for example, when using variable resistance), the signal  
is wired to J1-7(+) and J1-6(–). The PIC must now be con-  
figured on the Service2 table to ensure that the appropriate  
power source is identified.  
Tower Fan Relay — Low condenser water tempera-  
ture can cause the chiller to shut down on low refrigerant  
temperature. The tower fan relay, located in the starter, is  
controlled by the PIC to energize and deenergize as the pres-  
sure differential between cooler and condenser vessels changes  
in order to prevent low condenser water temperature and to  
maximize chiller efficiency. The tower fan relay can only  
accomplish this if the relay has been added to the cooling  
tower temperature controller. The TOWER FAN RELAY is  
turned on whenever the CONDENSER WATER PUMP is  
running, flow is verified, and the difference between cooler  
and condenser pressure is more than 45 psid (310 kPad)  
[30 psid (207 kPad)] or entering condenser water temper-  
ature is greater than 85 F (29 C). The TOWER FAN RELAY  
is deenergized when the condenser pump is off, flow is lost,  
the evaporator refrigerant temperature is less than the over-  
ride temperature, or the differential pressure is less than  
40 psid (279 kPad) [28 psid (193 kPad)] and entering con-  
densing water is less than 80 F (27 C).  
RESET TYPE 2—Reset Type requires an optional 8-input  
module. It is an automatic chilled water temperature reset  
based on a remote temperature sensor input. This reset type  
permits ± 30° F (± 16° C) of automatic reset to the set point  
based on a temperature sensor wired to the number one 8-input  
module (see wiring diagrams or certified drawings). The tem-  
perature sensor must be wired to terminal J1-19 and J1-20.  
To configure Reset Type 2, enter the temperature of the  
remote sensor at the point where no temperature reset will  
occur. Next, enter the temperature at which the full amount  
of reset will occur. Then, enter the maximum amount of re-  
set required to operate the chiller. Reset Type 2 can now be  
activated.  
IMPORTANT: A field-supplied water temperature con-  
trol system for condenser water should be installed.  
The system should maintain the leaving condenser wa-  
ter temperature at a temperature that is 20° F (11° C)  
above the leaving chilled water temperature.  
RESET TYPE 3—Reset Type 3 is an automatic chilled  
water temperature reset based on cooler temperature differ-  
ence. This type of reset will add ± 30° F (± 16° C) based on  
the temperature difference between entering and leaving chilled  
water temperature. This is the only type of reset available  
without the need of the number one 8-input module. No wir-  
ing is required for this type as it already uses the cooler  
water sensors. To configure Reset Type 3, enter the chilled  
water temperature difference (the difference between enter-  
ing and leaving chilled water) at which no temperature reset  
occurs. This chilled water temperature difference is usually  
the full design load temperature difference. The difference in  
chilled water temperature at which the full amount of  
reset will occur is now entered on the next input line. Next,  
the amount of reset is entered. Reset Type 3 can now be  
activated.  
The tower-fan relay control is not a substitute for a con-  
denser water temperature control. When used with a  
Water Temperature Control system, the tower fan relay  
control can be used to help prevent low condenser wa-  
ter temperatures.  
Auto. Restart After Power Failure — This option  
may be enabled or disabled, and may be viewed/modified in  
the Config table of Equipment Configuration. If enabled, the  
chiller will start up automatically after a single cycle drop-  
out, low, high, or loss of voltage has occurred, and the power  
is within ±10% of normal. The 15- and 3-minute inhibit tim-  
ers are ignored during this type of start-up.  
When power is restored after the power failure, and if the  
compressor had been running, the oil pump will be ener-  
gized for one minute prior to the evaporator pump ener-  
gizing. Auto restart will then continue like a normal  
start-up.  
If power to the PSIO module has been off for more than  
3 hours, the oil heat algorithm, discussed in the Oil Sump  
Temperature Control section on page 32, will take effect be-  
fore the compressor can start. Refrigerant normally migrates  
into the oil when the oil heater is left off for extended pe-  
riods of time. The PIC operates the oil pump for 1 to 2 min-  
utes to ensure that the oil is free of excess refrigerant. Once  
this algorithm is completed, the RESTART of the chiller will  
continue.  
Demand Limit Control, Option — (Requires  
Optional 8-Input Module) — The demand limit may  
be externally controlled with a 4 to 20 mA signal from an  
energy management system (EMS). The option is set up on  
the Config table. When enabled, the control is set for 100%  
demand with 4 mA and an operator configured minimum de-  
mand set point at 20 mA.  
The Demand Reset input from an energy management  
system is hardwired into the number one, 8-input module.  
The signal may be internally powered by the module or  
externally powered. If the signal is externally powered, the  
signal is wired to terminals J1-1 (+) and J1-2 (–). If the sig-  
nal is internally powered, the signal is wired to terminals  
J1-3 (+) and J1-2 (–). When enabled, the control is set for  
100% demand with 4 mA and an operator configured mini-  
mum demand set point at 20 mA.  
Water/Brine Reset — Three types of chilled water or  
brine reset are available and can be viewed or modified on  
the Equipment Configuration table Config selection.  
The LID default screen status message indicates when  
the chilled water reset is active. The Control Point tempera-  
ture on the Status01 table indicates the chiller’s current reset  
temperature.  
To activate a reset type, input all configuration informa-  
tion for that reset type in the Config table. Then input the  
reset type number in the SELECT/ENABLE RESET TYPE  
input line.  
Surge Prevention Algorithm — This is an operator  
configurable feature which can determine if lift conditions  
are too high for the compressor and then take corrective  
action. Lift is defined as the difference between the pressure  
at the impeller eye and the impeller discharge. The maxi-  
mum lift that a particular impeller can perform varies with  
the gas flow across the impeller and the size of the impeller.  
33  
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The algorithm first determines if corrective action is nec-  
essary. This is done by checking 2 sets of operator con-  
figured data points, which are the MINIMUM and the  
MAXIMUM Load Points, (T1/P1;T2/P2). These points have  
default settings for each type of refrigerant, HCFC-22 or  
HFC-134a, as defined on the Service1 table, or on Table 4.  
These settings and the algorithm function are graphically  
displayed in Fig. 20 and 21. The two sets of load points on  
this graph (default settings are shown) describe a line which  
the algorithm uses to determine the maximum lift of the com-  
pressor. Whenever the actual differential pressure between  
the cooler and condenser, and the temperature difference  
between the entering and leaving chilled water are above the  
line on the graph (as defined by the MINIMUM and MAXI-  
MUM Load Points) the algorithm will go into a corrective  
action mode. If the actual values are below the line, the  
algorithm takes no action. Modification of the default set points  
of the MINIMUM and MAXIMUM load points is described  
in the Input Service Configuration section on page 50.  
LEGEND  
Corrective action can be taken by making one of 2 choices.  
If a hot gas bypass line is present, and the hot gas is con-  
figured on the Service1 table, then the hot gas bypass valve  
can be energized. If a hot gas bypass if not present, then  
the action taken is to hold the guide vanes. See Table 4 —  
Capacity Overrides. Both of these corrective actions will  
reduce the lift experienced by the compressor and help to  
prevent a surge condition. Surge is a condition when the  
lift becomes so high that the gas flow across the impeller  
reverses. This condition can eventually cause chiller dam-  
age. The surge prevention algorithm is intended to notify the  
operator that chiller operating conditions are marginal, and  
to take action to help prevent chiller damage such as low-  
ering entering condenser water temperature.  
ECW  
HGBP  
LCW  
—
—
—
Entering Chilled Water  
Hot Gas Bypass  
Leaving Chilled Water  
⌬P = (Condenser Psi) — (Cooler Psi)  
⌬T = (ECW) − (LCW)  
Fig. 20 — 19XL Hot Gas Bypass/Surge  
Prevention  
Surge Protection — Surging of the compressor can be  
determined by the PIC through operator configured settings.  
Surge will cause amperage fluctuations of the compressor  
motor. The PIC monitors these amperage swings, and if the  
swing is greater than the configurable setting in one sec-  
ond, then one surge count has occurred. The SURGE DELTA  
PERCENT AMPS setting is displayed and configured on the  
Service1 screen. It has a default setting of 25% amps, SURGE  
PROTECTION COUNTS can be monitored on the Maint03  
table.  
Asurge protection shutdown of the chiller will occur when-  
ever the surge protection counter reaches 12 counts with-  
in an operator specified time, known as the SURGE TIME  
PERIOD. The SURGE TIME PERIOD is displayed and  
configured on the Service1 screen. It has a default of  
2 minutes.  
LEGEND  
Lead/Lag Control  
NOTE: Lead/lag control is only available on chillers with  
PSIO Software Version 09 or higher.  
ECW  
HGBP  
LCW  
—
—
—
Entering Chilled Water  
Hot Gas Bypass  
Leaving Chilled Water  
⌬P = (Condenser kPa)  
⌬T = (ECW) — (LCW)  
—
(Cooler kPa)  
Lead/lag is a control system process that automatically starts  
and stops a lag or second chiller in a 2-chiller water system.  
Refer to Fig. 16 and 17 for menu, table, and screen selection  
information. On chillers that have PSIO software with Lead/  
Lag capability, it is possible to utilize the PIC controls to  
perform the lead/lag function on 2 chillers. A third chiller  
can be added to the lead/lag system as a standby chiller to  
start up in case the lead or lag chiller in the system has shut  
down during an alarm condition and additional cooling is  
required.  
Fig. 21 — 19XL with Default Metric Settings  
Lead/Lag System Requirements:  
• all chillers must have PSIO software capable of perform-  
ing the lead/lag function  
NOTE: Lead/lag configuration is viewed and edited under  
Lead/Lag in the Equipment Configuration table (located in  
the Service menu). Lead/lag status during chiller operation  
is viewed in the MAINT04 table in the Control Algorithm  
Status table. See Table 2.  
• water pumps MUST be energized from the PIC controls  
• water flows should be constant  
• CCN Time Schedules for all chillers must be identical  
34  
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Operation Features:  
• 2 chiller lead/lag  
If the address assignments placed into the LAG  
ADDRESS and STANDBY ADDRESS values conflict, the lead/  
lag will be disabled and an alert (!) message will  
occur. For example, if the LAG ADDRESS matches the lead  
chiller’s address, the lead/lag will be disabled and  
an alert (!) message will occur. The lead/lag maintenance  
screen (MAINT04) will display the message ‘INVALID  
CONFIG’ in the LEAD/LAG CONFIGURATION and  
CURRENT MODE fields.  
• addition of a third chiller for backup  
• manual rotation of lead chiller  
• load balancing if configured  
• staggered restart of the chillers after a power failure  
• chillers may be piped in parallel or in series chilled water  
flow  
COMMON POINT SENSOR INSTALLATION — Lead/  
lag operation does not require a common chilled water point  
sensor. Common point sensors can be added to the 8-input  
option module, if desired. Refer to the certified drawings for  
termination of sensor leads.  
The lead chiller responds to normal start/stop controls such  
as occupancy schedule, forced start/stop, and remote start  
contact inputs. After completing start up and ramp loading,  
the PIC evaluates the need for additional capacity. If addi-  
tional capacity is needed, the PIC initiates the start up of the  
chiller configured at the LAG ADDRESS. If the lag chiller is  
faulted (in alarm) or is in the OFF or LOCAL modes, then  
the chiller at the STANDBY ADDRESS (if configured) is  
requested to start. After the second chiller is started and is  
running, the lead chiller shall monitor conditions and evalu-  
ate whether the capacity has reduced enough for the lead  
chiller to sustain the system alone. If the capacity is reduced  
enough for the lead chiller to sustain the CONTROL POINT  
temperatures alone, then the operating lag chiller is stopped.  
If the lead chiller is stopped in CCN mode for any reason  
other than an alarm (*) condition, then the lag and standby  
chillers are stopped. If the configured lead chiller stops for  
and alarm condition, then the configured lag chiller takes the  
lead chiller’s place as the lead chiller and the standby chiller  
serves as the lag chiller.  
If the configured lead chiller does not complete the start-  
up before the PRESTART FAULT TIMER (user configured  
value) elapses, then the lag chiller shall be started and the  
lead chiller will shut down. The lead chiller then monitors  
the start request from the acting lead chiller to start. ThePRE-  
START FAULT TIMER is initiated at the time of a start  
request. The PRESTART FAULT TIMER’s function is to  
provide a timeout in the event that there is a prestart alert  
condition preventing the chiller from starting in a timely man-  
ner. The timer is configured under Lead/Lag, found in the  
Equipment Configuration table of the Service menu.  
NOTE: If the common point sensor option is chosen on a  
chilled water system, both chillers should have their own 8-input  
option module and common point sensor installed. Each chiller  
will use its own common point sensor for control, when that  
chiller is designated as the lead chiller. The PIC cannot read  
the value of common point sensors installed on other chill-  
ers in the chilled water system.  
When installing chillers in series, a common point sensor  
should be used. If a common point sensor is not used, the  
leaving chilled water sensor of the upstream chiller must be  
moved into the leaving chilled water pipe of the downstream  
chiller.  
If return chilled water control is required on chillers piped  
in series, the common point return chilled water sensor should  
be installed. If this sensor is not installed, the return chilled  
water sensor of the downstream chiller must be relocated to  
the return chilled water pipe of the upstream chiller.  
To properly control the common supply point temperature  
sensor when chillers are piped in parallel, the water flow through  
the shutdown chillers must be isolated so that no water by-  
pass around the operating chiller occurs. The common point  
sensor option must not be used if water bypass around the  
operating chiller is occurring.  
CHILLER COMMUNICATION WIRING — Refer to the  
chiller’s Installation Instructions or to the Carrier Comfort  
Network Interface section on page 48 of this manual for  
information on chiller communication wiring.  
If the lag chiller does not achieve start-up before the  
PRESTART FAULT TIMER elapses, then the lag chiller shall  
be stopped and the standby chiller will be requested to start,  
if configured and ready.  
LEAD/LAG OPERATION — The PIC control provides the  
ability to operate 2 chillers in the LEAD/LAG mode. It also  
provides the additional ability to start a designated standby  
chiller when either the lead or lag chiller is faulted and  
capacity requirements are not met. The lead/lag option op-  
erates in CCN mode only. If any other chiller configured for  
lead/lag is set to the LOCAL or OFF modes, it will be un-  
available for lead/lag operation.  
Standby Chiller Configuration and Operation — The con-  
figured standby chiller is identified as such by having the  
LEAD/LAG SELECT configured to the value of ‘‘3.’’ The  
standby chiller can only operate as a replacement for the  
lag chiller if one of the other two chillers is in an alarm (*)  
condition (as shown on the LID panel). If both lead and lag  
chillers are in an alarm (*) condition, the standby chiller shall  
default to operate in CCN mode based on its configured  
Occupancy Schedule and remote contacts input.  
NOTE: Lead/lag configuration is viewed and edited in Lead/  
Lag, under the Equipment Configuration table of the Service  
menu. Lead/lag status during chiller operation is viewed in  
the MAINT04 table in the Control Algorithm Status  
table.  
Lag Chiller Start-Up Requirements — Before the lag chiller  
can be started, the following conditions must be met:  
1. Lead chiller ramp loading must be complete.  
2. Lead chiller CHILLED WATER temperature must be greater  
than the CONTROL POINT plus 1/2 the WATER/BRINE  
DEADBAND.  
Lead/Lag Chiller Configuration and Operation — The con-  
figured lead chiller is identified when the LEAD/LAG  
SELECT value for that chiller is configured to the value of  
‘‘1.’’The configured lag chiller is identified when the LEAD/  
LAG SELECT for that chiller is configured to the value of  
‘‘2.’’ The standby chiller is configured to a value of ‘‘3.’’ A  
value of ‘‘0’’ disables the lead/lag in that chiller.  
To configure the LAG ADDRESS value on the LEAD/  
LAG Configuration table, always use the address of the other  
chiller on the system for this value. Using this address will  
make it easier to rotate the lead and lag chillers.  
NOTE: The chilled water temperature sensor may be the  
leaving chilled water sensor, the return water sensor, the  
common supply water sensor, or the common return  
water sensor, depending on which options are configured  
and enabled.  
3. Lead chiller ACTIVE DEMAND LIMIT value must be greater  
than 95% of full load amps.  
35  
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4. Lead chiller temperature pulldown rate of the CHILLED  
WATER temperature is less than 0.5° F (0.27° C) per  
minute.  
is disabled, the ACTIVE DEMAND LIMIT and the CON-  
TROL POINT are forced to the same value as the lead  
chiller.  
5. The lag chiller status indicates it is in CCN mode and is  
not faulted. If the current lag chiller is in an alarm con-  
dition, then the standby chiller becomes the active lag chiller,  
if it is configured and available.  
6. The configured LAG START TIMER entry has elapsed.  
The LAG START TIMER shall be started when the lead  
chiller ramp loading is completed. TheLAG START TIMER  
entry is accessed by selecting Lead/Lag from the Equip-  
ment Configuration table of the Service menu.  
AUTO. RESTART AFTER POWER FAILURE — When  
an auto. restart condition occurs, each chiller may have a  
delay added to the start-up sequence, depending on its lead/  
lag configuration. The lead chiller does not have a delay. The  
lag chiller has a 45-second delay. The standby chiller has a  
90-second delay. The delay time is added after the chiller  
water flow verification. The PIC controls ensure that the guide  
vanes are closed. After the guide vane position is confirmed,  
the delay for lag and standby chiller occurs prior to ener-  
gizing the oil pump. The normal start-up sequence then  
continues. The auto. restart delay sequence occurs whether  
the chiller is in CCN or LOCAL mode and is intended to  
stagger the compressor motors from being energized simul-  
taneously. This will help reduce the inrush demands on the  
building power system.  
When all of the above requirements have been met, the  
lag chiller is forced to a START mode. The PIC control then  
monitors the lag chiller for a successful start. If the lag chiller  
fails to start, the standby chiller, if configured, is started.  
Lag Chiller Shutdown Requirements — The following con-  
ditions must be met in order for the lag chiller to be stopped.  
Ice Build Control  
1. Lead chiller COMPRESSOR MOTOR LOAD value is less  
than the lead chiller percent capacity plus 15%.  
IMPORTANT: The Ice Build control option is only avail-  
able on chillers with PSIO Software Version 09 and  
higher.  
NOTE: Lead chiller percent capacity = 100 – LAG PER-  
CENT CAPACITY  
The LAG PERCENT CAPACITY value is configured on  
Ice build control automatically sets the chilled WATER/  
BRINE CONTROL POINT of the chiller to a temperature  
where an ice building operation for thermal storage can be  
accomplished.  
The PIC can be configured for ice build operation. Con-  
figuration of ice build control is accomplished through  
entries in the Config table, Ice Build Setpoint table, and the  
Ice Build Time Schedule table. Figures 16 and 17 show how  
to access each entry.  
The Ice Build Time Schedule defines the period during  
which ice build is active if the ice build option is  
ENABLED. If the Ice Build Time Schedule overlaps other  
schedules defining time, then the Ice Build Time Schedule  
shall take priority. During the ice build period, the WATER/  
BRINE CONTROL POINT is set to the ICE BUILD SET POINT  
for temperature control. The ICE BUILD RECYCLE  
OPTION and ICE BUILD TERMINATION entries from a  
screen in the Config (configuration) table provide options  
for chiller recycle and termination of ice build cycle, respec-  
tively. Termination of ice build can result from the ENTER-  
ING CHILLED WATER/BRINE temperature being less than  
the ICE BUILD SET POINT, opening of the REMOTE CON-  
TACT inputs from an ice level indicator, or reaching the end  
of the Ice Build Time Schedule.  
the Lead/Lag Configuration screen.  
2. The lead chiller chilled water temperature is less than  
1
the CONTROL POINT plus ⁄2 of the WATER/BRINE  
DEADBAND.  
3. The configured LAG STOP TIMER entry has elapsed.  
The LAG STOP TIMER is started when the CHILLED  
WATER TEMPERATURE is less than the CHILLED  
1
WATER CONTROL POINT plus  
⁄2  
of the WATER/  
BRINE DEADBAND and the lead chiller COMPRESSOR  
MOTOR LOAD is less than the lead chiller percent  
capacity plus 15%. The timer is ignored if the chilled  
water temperature reaches 3° F (1.67° C) below theCON-  
TROL POINT and the lead chiller COMPRESSOR  
MOTOR LOAD value is less than the lead chiller percent  
capacity plus 15%.  
FAULTED CHILLER OPERATION — If the lead chiller  
shuts down on an alarm (*) condition, it stops communica-  
tion to the lag and standby chillers. After 30 seconds, the lag  
chiller will now become the acting lead chiller and will start  
and stop the standby chiller, if necessary.  
If the lag chiller faults when the lead chiller is also faulted,  
the standby chiller reverts to a stand-alone CCN mode of  
operation.  
If the lead chiller is in an alarm (*) condition (as shown  
on the LID panel), the RESET softkey is pressed to clear  
ICE BUILD INITIATION — The Ice Build Time Schedule  
provides the means for activating ice build. The ice build  
time table is named OCCPC02S.  
If the Ice Build Time Schedule is OCCUPIED and the ICE  
BUILD OPTION is ENABLED, then ice build is active and  
the following events automatically take place (unless over-  
ridden by a higher authority CCN device):  
1. Force CHILLER START/STOP to START.  
2. Force WATER/BRINE CONTROL POINT to the ICE BUILD  
SET POINT.  
the alarm, and the chiller is placed in the CCN mode, the  
lead chiller will now communicate and monitor the RUN  
STATUS of the lag and standby chillers. If both the lag and  
standby chillers are running, the lead chiller will not attempt  
to start and will not assume the role of lead chiller until  
either the lag or standby chiller shuts down. If only one chiller  
is running, the lead chiller will wait for a start request from  
the operating chiller. When the configured lead chiller starts,  
it assumes its role as lead chiller.  
3. Remove any force (Auto) on the ACTIVE DEMAND LIMIT.  
LOAD BALANCING — When the LOAD BALANCE  
OPTION is enabled, the lead chiller will set the ACTIVE  
DEMAND LIMIT in the lag chiller to the lead chiller’s COM-  
PRESSOR MOTOR LOAD value. This value has limits of  
40% to 100%. When setting the lag chiller ACTIVE  
DEMAND LIMIT, the CONTROL POINT will be modi-  
fied to a value of 3° F (1.67° C) less than the lead chiller’s  
CONTROL POINT value. If the LOAD BALANCE OPTION  
NOTE: Items 1-3 (shown above) shall not occur if the chiller  
is configured and operating as a lag or standby chiller for  
lead/lag and is actively controlled by a lead chiller. The lead  
chiller communicates the ICE BUILD SET POINT, desired  
CHILLER START/STOP state, and ACTIVE DEMAND LIMIT  
to the lag or standby chiller as required for ice build, if con-  
figured to do so.  
36  
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START-UP/RECYCLE OPERATION — If the chiller is not  
running when ice build activates, then the PIC checks the  
following parameters, based on the ICE BUILD TERMINA-  
TION value, to avoid starting the compressor unnecessarily:  
• if ICE BUILD TERMINATION is set to the temperature  
only option (zero) and the ENTERING CHILLED WATER  
temperature is less than or equal to the ICE BUILD SET  
POINT;  
• if ICE BUILD TERMINATION is set to the contacts only  
option (1) and the remote contacts are open;  
• if the ICE BUILD TERMINATION is set to the both tem-  
perature and contacts option (2) and ENTERING CHILLED  
WATER temperature is less than or equal to the ICE BUILD  
SET POINT and remote contacts are open.  
NOTE: Overriding the CHILLER START/STOP, WATER/  
BRINE CONTROL POINT, and ACTIVE DEMAND LIMIT  
variables by CCN devices (with a priority less than 4)  
during the ice build period is not possible. However, over-  
riding can be accomplished with CCN during two chiller lead/  
lag.  
RETURN TO NON-ICE BUILD OPERATIONS — Upon  
termination of ice build, the chiller shall return to normal  
temperature control and start/stop schedule operation. If  
the CHILLER START/STOP or WATER/BRINE CONTROL  
POINT has been forced (with a priority less than 4), prior to  
entering ice build operation, then chiller START/STOP and  
WATER/BRINE CONTROL POINT forces will be removed.  
Attach to Network Device Control — On the Serv-  
ice menu, one of the selections is ATTACH TO NETWORK  
DEVICE. This table serves the following purposes:  
• to upload new parameters when switching the controller  
to HFC-134a refrigerant.  
• to upload the Occupancy Schedule Number (if changed)  
for OCCPC03S software (version 09 and later), as defined  
in the Service01 table  
• to attach the LID to any CCN device, if the chiller has  
been connected to a CCN Network. This may include other  
PIC controlled chillers.  
• to change to a new PSIO or LID module or upgrade  
software.  
The ICE BUILD RECYCLE OPTION determines whether  
or not the PIC will go into a RECYCLE mode. If the ICE  
BUILD RECYCLE OPTION is set to DSABLE (disable) when  
the ice build terminates, the PIC will revert back to normal  
temperature control duty. If the ICE BUILD RECYCLE  
OPTION is set to ENABLE, when ice build terminates, the  
PIC will go into an ICE BUILD RECYCLE mode and the  
chilled water pump relay will remain energized to keep the  
chilled water flowing. If the entering CHILLED WATER/  
BRINE TEMPERATURE increases above the ICE BUILD SET  
POINT plus the RECYCLE RESTART DELTA T value, the  
compressor will restart and control the CHILLED WATER/  
BRINE TEMPERATURE to the ICE BUILD SET POINT.  
Figure 22 illustrates the ATTACH TO NETWORK  
DEVICE table. The Local description is always the PSIO  
module address of the chiller the LID is mounted on. When-  
ever the controller identification of the PSIO is changed, this  
change is reflected on the bus and address for the LOCAL  
DEVICE of the ATTACH TO DEVICE screen automat-  
ically. See Fig. 17.  
TEMPERATURE CONTROL DURING ICE BUILD  
—During ice build, the capacity control algorithm uses the  
WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to con-  
trol the LEAVING CHILLED WATER temperature. The ECW  
OPTION and any temperature reset option are ignored dur-  
ing ice build. The 20 mA DEMAND LIMIT OPTION is also  
ignored during ice build.  
Whenever the ATTACH TO NETWORK DEVICE table  
is entered, no information can be read from the LID on any  
device until you attach one of the devices listed on the  
display. The LID erases information about the module to which  
it was attached to make room for information on another de-  
vice. Therefore, a CCN module must be attached when this  
screen is entered. To attach a device, highlight it using the  
TERMINATION OF ICE BUILD — Ice build termination  
occurs under the following conditions:  
1. Ice Build Time Schedule — When the Ice Build Time  
Schedule transitions to UNOCCUPIED, ice build opera-  
tion shall terminate.  
2. ECW TEMPERATURE — Termination of compressor  
operation, based on temperature, shall occur if the  
ICE BUILD TERMINATION is set to the ice build  
termination temperature option (0) and the ENTERING  
CHILLED WATER TEMPERATURE is less than the  
ICE BUILD SET POINT. If the ICE BUILD RECYCLE  
SELECT softkey and then press the ATTACH softkey. The  
message, ‘‘UPLOADING TABLES, PLEASE WAIT’’ dis-  
plays. The LID then uploads the highlighted device or  
module. If the module address cannot be found, the mes-  
sage, ‘‘COMMUNICATION FAILURE’’ appears. The LID  
then reverts to the ATTACH TO DEVICE screen. Try  
another device or check the address of the device that  
would not attach. The upload process time for each CCN  
module is different. In general, the uploading process takes  
3 to 5 minutes. Before leaving the ATTACH TO NET-  
WORK DEVICE screen, select the LOCAL device. Other-  
wise, the LID will be unable to display information on the  
local chiller.  
OPTION is set to ENABLE , a recycle shutdown occurs  
and recycle start-up shall be based onLEAVING CHILLED  
WATER temperature being greater than the WATER/  
BRINE CONTROL POINT plus RECYCLE RESTART  
DELTA T.  
3. Remote Contacts/Ice Level Input — Termination of  
compressor operation occurs when ICE BUILD TERMI-  
NATION is set to the contacts only option (1) and the  
remote contacts are open. In this case, the contacts are  
provided for ice level termination control. The remote con-  
tacts can still be opened and closed to start and stop the  
chiller when the Ice Build Time Schedule is UNOCCU-  
PIED. The contacts are used to stop the ICE BUILD mode  
when the Ice Build Time Schedule is OCCUPIED.  
CHANGING REFRIGERANT TYPES — To select refrig-  
erant type, go to the Control Test table. Whenever the  
refrigerant type is changed, the ATTACH TO NETWORK  
DEVICE table must be used. After changing the refrigerant  
type in the Control Test table, move to the ATTACH TO NET-  
WORK DEVICE table. Make sure the highlight bar is  
4. ECW TEMPERATURE and Remote Contacts — Termi-  
nation of compressor operation shall occur when ICE  
BUILD TERMINATION is set to both the temperature and  
contacts (2) option and the previously described condi-  
tions for ENTERING CHILLED WATER temperature and  
remote contacts have occurred.  
located on the LOCAL selection. Press the ATTACH soft-  
key. The information in the PSIO module will now be up-  
loaded. The default screen will appear. The new refrigerant  
type change for the controller is complete.  
37  
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ATTACHING TO OTHER CCN MODULES — If the chiller  
PSIO has been connected to a CCN Network or other PIC  
controlled chillers through CCN wiring, the LID can be used  
to view or change parameters on the other controllers. Other  
PIC chillers can be viewed and set points changed (if the  
other unit is in CCN control), if desired from this particular  
LID module.  
If the password is entered incorrectly, an error message is  
displayed. If this occurs, return to Step 1 and try logging  
on again.  
To view the other devices, move to the ATTACH TO  
NETWORK DEVICE table. Move the highlight bar to any  
device number. Press the SELECT softkey to change the  
NOTE: The initial factory set password is 1-1-1-1.  
TO LOG OFF — Access the Log Out of Device table of the  
Service menu in order to password-protect the Service menu.  
The LID will automatically sign off and password-protect  
itself if a key is not pressed for 15 minutes. The LID default  
screen is then displayed.  
bus number and address of the module to be viewed. Press  
EXIT softkey to move back to the ATTACH TO NET-  
WORK DEVICE table. If the module number is not valid,  
the ‘‘COMMUNICATION FAILURE’’ message will show  
and a new address number should be entered or the wiring  
checked. If the model is communicating properly, the ‘‘UP-  
LOAD IN PROGRESS’’message will flash and the new mod-  
ule can now be viewed.  
Whenever there is a question regarding which module on  
the LID is currently being shown, check the device name  
descriptor on the upper left hand corner of the LID screen.  
See Fig. 22.  
When the CCN device has been viewed, the ATTACH TO  
NETWORK DEVICE table should now be used to  
attach to the PIC that is on the chiller. Move to the  
ATTACH TO NETWORK DEVICE table and press the  
ATTACH softkey to upload the LOCAL device. The PSIO  
for the 19XL will now be uploaded.  
HOLIDAY SCHEDULING (Fig. 23) — The time schedules  
may be configured for special operation during a holiday  
period. When modifying a time period, the ‘‘H’’ at the end  
of the days of the week field signifies that the period is ap-  
plicable to a holiday. (See Fig. 18.)  
The Broadcast function must be activated for the holidays  
configured in the Holidef tables to work properly. Access  
the Brodefs table in the Equipment Configuration table and  
answer ‘‘Yes’’ to the activated function. However, when the  
chiller is connected to a CCN Network, only one chiller or  
CCN device can be configured to be the broadcast device.  
The controller that is configured to be the broadcaster is the  
device responsible for transmitting holiday, time, and daylight-  
savings dates throughout the network.  
NOTE: The LID will not automatically reattach to the PSIO  
module on the chiller. Press the ATTACH softkey to attach  
to LOCAL DEVICE and view the chiller PSIO.  
To view or change the holiday periods for up to 18 dif-  
ferent holidays, perform the following operation:  
1. At the Menu screen, press SERVICE to access the Serv-  
ice menu.  
2. If not logged on, follow the instructions for To Log On  
or To Log Off. Once logged on, press NEXT un-  
til Equipment Configuration is highlighted.  
Fig. 22 — Example of Attach to Network  
Device Screen  
3. Once Equipment Configuration is highlighted, press  
SELECT to access.  
Service Operation — An overview of the menu-  
driven programs available for Service Operation is shown in  
Fig. 17.  
TO LOG ON  
1. On the Menu screen, press SERVICE . The keys now  
correspond to the numerals 1, 2, 3, 4.  
2. Press the four digits of your password, one at a time. An  
asterisk (*) appears as you enter each digit.  
4. Press NEXT until Holidef is highlighted. This is  
the Hoday Deniton abe.  
5. Press SELECT to enter the Data Table Select screen.  
This scren lists 18 holiday tbles.  
The menu bar (Next-Previous-Select-Exit) is displayed  
to indicate that you have successfully logged on.  
38  
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START-UP/SHUTDOWN/RECYCLE  
SEQUENCE (Fig. 24)  
6. Press NEXT to highlight the holiday table that you  
wish to view or change. Each table is one holiday pe-  
riod, starting on a specific date, and lasting up to 99 days.  
Local Start-Up — Local start-up (or a manual start-up)  
is initiated by pressing the LOCAL menu softkey which is  
on the default LID screen. Local start-up can proceed when  
Time Schedule 01 is in OCCUPIED mode, and after the in-  
ternal 15-minute start-to-start and the 3-minute stop-to-start  
inhibit timers have expired (on PSIO software Version 08  
and lower or a 1-minute stop-to-start timer on PSIO Soft-  
ware Version 09 and higher).  
The chiller start/stop status point on the Status01 table may  
be overridden to start, regardless of the time schedule, in  
order to locally start the unit. Also, the remote contacts may  
be enabled through the LID and closed to initiate a start-up.  
7. Press SELECT to access the holiday table. The Con-  
figuration Select table now shows the holiday start month  
and day, and how many days the holiday period will last.  
Whenever the chiller is in LOCAL control mode, the PIC  
will wait for Time Schedule 01 to become occupied and the  
remote contacts to close, if enabled. The PIC will then per-  
form a series of pre-start checks to verify that all pre-start  
alerts and safeties are within the limits shown in Table 3.  
The run status line on the LID now reads ‘‘Starting.’’ If the  
checks are successful, the chilled water/brine pump relay will  
be energized. Five seconds later, the condenser pump relay  
is energized. Thirty seconds later the PIC monitors the chilled  
water and condenser water flow switches, and waits until the  
WATER FLOW VERIFY TIME (operator configured, default  
5 minutes) to confirm flow. After flow is verified, the chilled  
water/brine temperature is compared to CONTROL POINT  
plus DEADBAND. If the temperature is less than or equal to  
this value, the PIC will turn off the condenser pump relay  
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 se-  
lected value.  
11. Press ENTER to save the changes.  
12. Press EXIT to return to the previous menu.  
A
—
START INITIATED — Prestart checks made; evaporator  
pump started  
B
C
—
—
Condenser water pump started (5 seconds after A)  
Water flows verified (30 seconds to 5 minutes maximum  
after B). Chilled water temperatures checked against con-  
trol point. Guide vanes checked for closure. Oil pump started;  
tower fan control enabled.  
D
E
—
—
Oil pressure verified (30 seconds minimum, 300 seconds  
maximum after C)  
Compressor motor starts, compressor ontime and serv-  
ice ontime start, 15-minute inhibit timer starts (10 seconds  
after D), total compressor starts advances by one, number  
of starts over a 12-hour period advances by one  
SHUTDOWN INITIATED — Compressor motor stops, com-  
pressor ontime and service ontime stops, 3-minute inhibit  
timer starts on PSIO Software Version 08 and lower and  
1-minute inhibit timer starts for PSIO Software Version 09  
and higher.  
F
—
G
—
—
Oil pump and evaporator pumps deenergized (60 seconds  
after F). Condenser pump and tower fan control may con-  
tinue to operate if condenser pressure is high. Evaporator  
pump may continue if in RECYCLE mode.  
Restart permitted (both inhibit timers expired) (minimum of  
15 minutes after E; [minimum of 3 minutes after F on PSIO  
Software Version 08 and lower] [minimum of 1 minute after  
F on PSIO Software Version 09 and higher]  
O/A  
Fig. 24 — Control Sequence  
Fig. 23 — Example of Holiday Period Screen  
39  
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and go into a RECYCLE mode. If the water/brine tempera-  
ture is high enough, the start-up sequence continues on to  
check the guide vane position. If the guide vanes are more  
than 6% open, the start-up waits until the PIC closes the vanes.  
If the vanes are closed, and the oil pump pressure is less  
than 3 psid (21 kPad), the oil pump relay will then be en-  
ergized. The PIC then waits until the OIL PRESS (Pressure)  
VERIFY TIME (operator configured, default 15 seconds) for  
oil pressure to reach 18 psid (124 kPad). After oil pressure  
is verified, the PIC waits 15 seconds, and then the compres-  
sor start relay (1CR) is energized to start the compressor.  
Compressor ontime and service ontime timers start and the  
compressor starts counter and the number of starts over a  
12-hour period counter are advanced by one.  
Failure to verify any of the requirements up to this point  
will result in the PIC aborting the start and displaying the  
applicable pre-start mode of failure on the LID default screen.  
A pre-start failure does not advance the starts in 12 hours  
counter. Any failure, after the 1CR relay has energized, re-  
sults in a safety shutdown, energizes the alarm light, and dis-  
plays the applicable shutdown status on the LID display.  
If the STOP button is pressed, the guide vanes close to a  
preset amperage percent or until the guide vane is less than  
2% open. The compressor will then shut off.  
If the chiller enters an alarm state or if the compressor  
enters a RECYCLE mode, the compressor will be de-  
energized immediately.  
To activate SOFT STOP AMPS THRESHOLD, view  
the bottom of Service1 table. Set the SOFT STOP AMPS  
THRESHOLD value to the percentage amps at which the  
motor will shut down. The default setting is 100% amps (no  
Soft Stop).  
When the SOFT STOP AMPS THRESHOLD is being  
applied, a status message ‘‘SHUTDOWN IN PROGRESS,  
COMPRESSOR UNLOADING’’ is shown.  
Chilled Water Recycle Mode — The chiller may cycle  
off and wait until the load increases to restart again when  
the compressor is running in a lightly loaded condition. This  
cycling of the chiller is normal and is known as recycle. A  
recycle shutdown is initiated when any of the following con-  
ditions are true:  
• when in LCW control, the difference between the LEAV-  
ING CHILLED WATER temperature and ENTERING  
CHILLED WATER temperature is less than the RECYCLE  
SHUTDOWN DELTA T (found in the Service1 table) and  
the LEAVING CHILLED WATER TEMP is below the  
CONTROL POINT, and the CONTROL POINT has not  
increased in the last 5 minutes.  
• when ECW CONTROL OPTION is enabled, the difference  
between the ENTERING CHILLED WATER temperature  
and the LEAVING CHILLED WATER temperature is less  
than the RECYCLE SHUTDOWN DELTA T (found in the  
Service1 table) and the ENTERING CHILLED WATER  
TEMPERATURE is below the CONTROL POINT, and the  
CONTROL POINT has not increased in the last 5 minutes.  
Shutdown Sequence — Shutdown of the chiller can  
occur if any of the following events happen:  
• the STOP button is pressed for at least one second (the  
alarm light will blink once to confirm stop command)  
• recycle condition is present (see Chilled Water Recycle Mode  
section)  
• time schedule has gone into UNOCCUPIED mode (chiller  
protective limit has been reached and chiller is in alarm)  
• the start/stop status is overridden to stop from the CCN  
network or the LID  
When a stop signal occurs, the shutdown sequence first  
stops the compressor by deactivating the start relay. A status  
message of ‘‘SHUTDOWN IN PROGRESS, COMPRES-  
SOR DEENERGIZED’’is displayed. Compressor ontime and  
service ontime stop. The guide vanes are then brought to the  
closed position. The oil pump relay and the chilled water/  
brine pump relay are shut down 60 seconds after the com-  
pressor stops. The condenser water pump will be shut down  
when the CONDENSER REFRIGERANT TEMP is less than  
the CONDENSER PRESSURE OVERRIDE minus 5 psi  
(34 kPa) or is less than or equal to the ENTERING  
CONDENSER WATER TEMP plus 3° F (2° C). The stop-  
to-start timer will now begin to count down. If the start-to-  
start timer is still greater than the value of the start-to-stop  
timer, then this time is now displayed on the LID.  
• when the LEAVING CHILLED WATER temperature is within  
3° F (2° C) of the BRINE REFRIG TRIPPOINT  
When the chiller is in RECYCLE mode, the chilled water  
pump relay remains energized so that the chilled water tem-  
perature can be monitored for increasing load. The recycle  
control uses RECYCLE RESTART DELTA T to check when  
the compressor should be restarted. This is an operator-  
configured function which defaults to 5° F (3° C). This value  
is viewed/modified on the Service1 table. The compressor  
will restart when:  
• in LCW CONTROL the LEAVING CHILLED WATER tem-  
perature is greater than the CONTROL POINT plus the  
RECYCLE RESTART DELTA T; or  
Certain conditions during shutdown will change this  
sequence:  
• in ECW CONTROL, the ENTERING CHILLED WATER  
temperature is greater than the CONTROL POINT plus the  
RECYCLE RESTART DELTA T  
• if the COMPRESSOR MOTOR LOAD is greater than 10%  
after shutdown, or the starter contacts remain energized,  
the oil pump and chilled water pump remain energized and  
the alarm is displayed  
Once these conditions are met, the compressor will ini-  
tiate a start-up, with a normal start-up sequence.  
An alert condition may be generated if 5 or more  
RECYCLE STARTUPs occur in less than 4 hours. This  
excessive recycling can reduce chiller life. Compressor re-  
cycling due to extremely low loads should be reduced. To  
reduce compressor recycling, use the time schedule to shut  
the chiller down during low load operation or increase the  
chiller load by running the fan systems. If the hot gas bypass  
is installed, adjust the values to ensure that hot gas is ener-  
gized during light load conditions. Increase the RECYCLE  
RESTART DELTA T on the Service1 table to lengthen the  
time between restarts.  
• if the ENTERING CONDENSER WATER temperature is  
greater than 115 F (46 C) at shutdown, the condenser pump  
will be deenergized after the 1CR compressor start relay  
• if the chiller shuts down due to low refrigerant tempera-  
ture, the chilled water pump will stay running until the  
LEAVING CHILLED WATER is greater than CONTROL  
POINT, plus 5° F (3° C)  
Automatic Soft Stop Amps Threshold (PSIO Soft-  
ware Version 09 and Higher) — The SOFT STOP  
AMPS THRESHOLD closes the guide vanes of the com-  
pressor automatically when a non-recycle, non-alarm stop  
signal occurs before the compressor motor is deenergized.  
The chiller should not be operated below design mini-  
mum load without a hot gas bypass installed on the  
chiller.  
40  
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Safety Shutdown — A safety shutdown is identical to  
a manual shutdown with the exception that the LID will dis-  
play the reason for the shutdown, the alarm light will blink  
continuously, and the spare alarm contacts will be ener-  
Using the Optional Storage Tank and Pumpout  
System — Refer to Pumpout and Refrigerant Transfer  
Procedures section, page 59 for: pumpout system prepara-  
tion, refrigerant transfer, and chiller evacuation.  
gized. A safety shutdown requires that the RESET softkey  
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.  
be pressed in order to clear the alarm. If the alarm is still  
present, the alarm light will continue to blink. Once the alarm  
is cleared, the operator must press the CCN or  
LOCAL softkeys to restart the chiller.  
Open Oil Circuit Valves — Check that the oil filter  
isolation valves (Fig. 4) are open by removing the valve cap  
and checking the valve stem.  
Do not reset starter loads or any other starter safety for  
30 seconds after the compressor has stopped. Voltage  
output to the compressor start signal is maintained for  
10 seconds to determine starter fault.  
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 guide vane shaft packing to ensure a leak-  
tight chiller.  
BEFORE INITIAL START-UP  
Job Data Required  
Check Chiller Tightness — Figure 26 outlines the  
proper sequence and procedures for leak testing.  
• list of applicable design temperatures and pressures (pro-  
duct data submittal)  
• chiller certified prints  
• starting equipment details and wiring diagrams  
• diagrams and instructions for special controls or options  
• 19XL Installation Instructions  
19XL chillers are shipped with the refrigerant contained  
in the condenser shell and the oil charge shipped in the  
compressor. The cooler will have a 15 psig (103 kPa)  
refrigerant charge. Units may be ordered with the refrigerant  
shipped separately, along with a 15 psig (103 kPa) nitrogen-  
holding charge in each vessel. To determine if there are any  
leaks, the chiller should be charged with refrigerant. Use an  
electronic leak detector to check all flanges and solder joints  
after the chiller is pressurized. If any leaks are detected, fol-  
low the leak test procedure.  
• pumpout unit instructions  
Equipment Required  
• mechanic’s tools (refrigeration)  
• digital volt-ohmmeter (DVM)  
• clamp-on ammeter  
• electronic leak detector  
• absolute pressure manometer or wet-bulb vacuum indica-  
tor (Fig. 25)  
• 500 v insulation tester (megohmmeter) for compressor  
motors with nameplate voltage of 600 v or less, or a  
5000-v insulation tester for compressor motor rated above  
600 v  
If the chiller is spring isolated, keep all springs blocked in  
both directions in order to prevent possible piping stress and  
damage during the transfer of refrigerant from vessel to  
vessel during the leak test process, or any time refrigerant is  
transferred. Adjust the springs when the refrigerant is in  
operating condition, and when the water circuits are full.  
Refrigerant Tracer — Carrier recommends the use of  
an environmentally acceptable refrigerant tracer for leak test-  
ing with an electronic detector or halide torch.  
Ultrasonic leak detectors also can be used if the chiller is  
under pressure.  
Do not use air or oxygen as a means of pressurizing the  
chiller. Some mixtures of HCFC-22 or HFC-134a and  
air can undergo combustion.  
Leak Test Chiller — Due to regulations regarding  
refrigerant emissions and the difficulties associated with sepa-  
rating contaminants from refrigerant, Carrier recommends  
the following leak test procedures. See Fig. 26 for an outline  
of the leak test procedures. Refer to Fig. 27 and 28 during  
pumpout procedures and Tables 5A, B, C, and D for refrig-  
erant pressure/temperature values.  
1. If the pressure readings are normal for chiller  
condition:  
a. Evacuate the holding charge from the vessels, if present.  
b. Raise the chiller pressure, if necessary, by adding re-  
frigerant until pressure is at equivalent saturated pres-  
sure for the surrounding temperature. Follow the pumpout  
Fig. 25 — Typical Wet-Bulb Type  
Vacuum Indicator  
41  
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procedures in the Transfer Refrigerant from Storage  
Tank to Chiller section, Steps 1a-e, page 59.  
6. If no leak is found after a retest:  
a. Transfer the refrigerant to the storage tank and  
perform a standing vacuum test as outlined in the  
Standing Vacuum Test section, this page.  
b. If the chiller fails this test, check for large leaks  
(Step 2b).  
Never charge liquid refrigerant into the chiller if  
the pressure in the chiller is less than 68 psig  
(469 kPa) for HCFC-22 and 35 psig (241 kPa) for  
HFC-134a. Charge as a gas only, with the cooler  
and condenser pumps running, until this pressure  
is reached, using PUMPDOWN LOCKOUT and  
TERMINATE LOCKOUT mode on the PIC. Flash-  
ing of liquid refrigerant at low pressures can cause  
tube freezeup and considerable damage.  
c. Dehydrate the chiller if it passes the standing vacuum  
test. Follow the procedure in the Chiller Dehydration  
section. Charge chiller with refrigerant (see Pumpout  
and Refrigerant Transfer Procedures, Transfer Refrig-  
erant from Storage Tank to Chiller section, Steps 1a-e  
or page 59).  
7. If a leak is found, pump the refrigerant back into the stor-  
age tank, or if isolation valves are present, pump into the  
non-leaking vessel (see Pumpout and Refrigerant Trans-  
fer procedures section).  
8. Transfer the refrigerant until chiller pressure is at  
18 in. Hg (40 kPa absolute).  
9. Repair the leak and repeat the procedure, beginning from  
Step 2h to ensure a leaktight repair. (If chiller is opened  
to the atmosphere for an extended period, evacuate it be-  
fore repeating leak test.)  
c. Leak test chiller as outlined in Steps 3-9.  
2. If the pressure readings are abnormal for chiller  
condition:  
a. Prepare to leak test chillers shipped with refrigerant  
(Step 2h).  
b. Check for large leaks by connecting a nitrogen bottle  
and raising the pressure to 30 psig (207 kPa). Soap  
test all joints. If the test pressure holds for 30 minutes,  
prepare the test for small leaks (Steps 2g-h).  
Standing Vacuum Test — When performing the stand-  
ing vacuum test, or chiller dehydration, use a manometer or  
a wet bulb indicator. Dial gages cannot indicate the small  
amount of acceptable leakage during a short period of time.  
1. Attach an absolute pressure manometer or wet bulb in-  
dicator to the chiller.  
2. Evacuate the vessel (see Pumpout and Refrigerant Trans-  
fer Procedures section, page 59) to at least 18 in. Hg vac,  
ref 30-in. bar (41 kPa), using a vacuum pump or the  
pumpout unit.  
3. Valve off the pump to hold the vacuum and record the  
manometer or indicator reading.  
c. Plainly mark any leaks which are found.  
d. Release the pressure in the system.  
e. Repair all leaks.  
f. Retest the joints that were repaired.  
g. After successfully completing the test for large leaks,  
remove as much nitrogen, air, and moisture as pos-  
sible, given the fact that small leaks may be present in  
the system. This can be accomplished by following  
the dehydration procedure, outlined in the Chiller  
Dehydration section, page 47.  
h. Slowly raise the system pressure to a maximum of  
210 psig (1448 kPa) but no less than 68 psig (469 kPa)  
for HCFC-22, 35 psig (241 kPa) for HFC-134a by add-  
ing refrigerant. Proceed with the test for small leaks  
(Steps 3-9).  
4. a. If the leakage rate is less than 0.05 in. Hg (.17 kPa) in  
24 hours, the chiller is sufficiently tight.  
b. If the leakage rate exceeds 0.05 in. Hg (.17 kPa) in  
24 hours, repressurize the vessel and test for leaks. If  
refrigerant is available in the other vessel, pressurize  
by following Steps 2-10 of Return Refrigerant To  
Normal Operating Conditions section, page 61. If not,  
use nitrogen and a refrigerant tracer. Raise the vessel  
pressure in increments until the leak is detected. If  
refrigerant is used, the maximum gas pressure is  
approximately 120 psig (827 kPa) for HCFC-22,  
70 psig (483 kPa) for HFC-134a at normal ambient  
temperature. If nitrogen is used, limit the leak test pres-  
sure to 230 psig (1585 kPa) maximum.  
3. Check the chiller carefully with an electronic leak detec-  
tor, halide torch, or soap bubble solution.  
4. Leak Determination — If an electronic leak detector  
indicates a leak, use a soap bubble solution, if possible,  
to confirm. Total all leak rates for the entire chiller. Leak-  
age at rates greater than 1 lb/year (0.45 kg/year) for the  
entire chiller must be repaired. Note total chiller leak rate  
on the start-up report.  
5. If no leak is found during initial start-up procedures, com-  
plete the transfer of refrigerant gas from the storage tank  
to the chiller (see Pumpout and Refrigerant Transfer Pro-  
cedures, Transfer Refrigerant from Storage Tank to Chiller  
section, Step 1e, page 59). Retest.  
5. Repair leak, retest, and proceed with dehydration.  
43  
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Table 5A — HCFC-22 Pressure — Temperature (F)  
PRESSURE (psi)  
PRESSURE (psi)  
PRESSURE (psi)  
TEMPERATURE  
(F)  
TEMPERATURE  
(F)  
TEMPERATURE  
(F)  
Absolute  
Gage  
Absolute  
Gage  
Absolute  
Gage  
−50  
−48  
−46  
−44  
−42  
11.67  
12.34  
13.00  
13.71  
14.45  
6.154*  
4.829*  
3.445*  
2.002*  
0.498*  
30  
32  
34  
36  
38  
69.59  
72.17  
74.82  
77.54  
80.34  
54.90  
57.47  
60.12  
62.84  
65.64  
110  
112  
114  
116  
118  
241.04  
247.50  
254.08  
260.79  
267.63  
226.35  
232.80  
239.38  
246.10  
252.94  
−40  
−38  
−36  
−34  
−32  
15.22  
16.02  
16.86  
17.73  
18.63  
0.526  
1.328  
2.163  
3.032  
3.937  
40  
42  
44  
46  
48  
83.21  
86.15  
89.18  
92.28  
95.46  
68.51  
71.46  
74.48  
77.58  
80.77  
120  
122  
124  
126  
128  
274.60  
281.71  
288.95  
296.33  
303.84  
259.91  
267.01  
274.25  
281.63  
289.14  
−30  
−28  
−26  
−24  
−22  
19.57  
20.55  
21.56  
22.62  
23.71  
4.877  
5.853  
6.868  
7.921  
9.015  
50  
52  
54  
56  
58  
98.73  
102.07  
105.50  
109.02  
112.62  
84.03  
87.38  
90.81  
94.32  
97.93  
130  
132  
134  
136  
138  
311.50  
319.29  
327.23  
335.32  
343.56  
296.80  
304.60  
312.54  
320.63  
328.86  
−20  
−18  
−16  
−14  
−12  
24.85  
26.02  
27.24  
28.50  
29.81  
10.15  
11.32  
12.54  
13.81  
15.11  
60  
62  
64  
66  
68  
116.31  
120.09  
123.96  
127.92  
131.97  
101.62  
105.39  
109.26  
113.22  
117.28  
140  
142  
144  
146  
148  
150  
152  
154  
156  
158  
160  
351.94  
360.48  
369.17  
378.02  
387.03  
396.19  
405.52  
415.02  
424.68  
434.52  
444.53  
337.25  
345.79  
354.48  
363.32  
372.33  
381.50  
390.83  
400.32  
409.99  
419.82  
420.83  
−10  
−8  
−6  
−4  
−2  
31.16  
32.56  
34.01  
35.51  
37.06  
16.47  
17.87  
19.32  
20.81  
22.36  
70  
72  
74  
76  
78  
136.12  
140.37  
144.71  
149.15  
153.69  
121.43  
125.67  
130.01  
134.45  
138.99  
0
2
4
6
8
38.66  
40.31  
42.01  
43.78  
45.59  
23.96  
25.61  
27.32  
29.08  
30.90  
80  
82  
84  
86  
88  
158.33  
163.07  
167.92  
172.87  
177.93  
143.63  
148.37  
153.22  
158.17  
163.23  
*Inches of mercury below one atmosphere.  
10  
12  
14  
16  
18  
47.46  
49.40  
51.39  
53.44  
55.55  
32.77  
34.70  
36.69  
38.74  
40.86  
90  
92  
94  
96  
98  
183.09  
188.37  
193.76  
199.26  
204.87  
168.40  
173.67  
179.06  
184.56  
190.18  
20  
22  
24  
26  
28  
57.73  
59.97  
62.27  
64.64  
67.08  
43.03  
45.27  
47.58  
49.95  
52.39  
100  
102  
104  
106  
108  
210.60  
216.45  
222.42  
228.50  
234.71  
195.91  
201.76  
207.72  
213.81  
220.02  
Table 5B — HCFC-22 Pressure — Temperature (C)  
PRESSURE (kPa)  
PRESSURE (kPa)  
PRESSURE (kPa)  
TEMPERATURE  
(C)  
TEMPERATURE  
(C)  
TEMPERATURE  
(C)  
Absolute  
Gage  
Absolute  
Gage  
Absolute  
Gage  
−18  
−17  
−16  
−15  
264  
274  
284  
296  
163  
173  
183  
195  
12  
13  
14  
15  
723  
744  
766  
789  
622  
643  
665  
688  
42  
43  
44  
45  
1610  
1650  
1690  
1730  
1510  
1550  
1590  
1630  
−14  
−13  
−12  
−11  
−10  
307  
318  
330  
342  
354  
206  
217  
229  
241  
253  
16  
17  
18  
19  
20  
812  
836  
860  
885  
910  
711  
735  
759  
784  
809  
46  
47  
48  
49  
50  
1770  
1810  
1850  
1900  
1940  
1670  
1710  
1750  
1800  
1840  
−9  
−8  
−7  
−6  
−5  
367  
380  
393  
407  
421  
266  
279  
292  
306  
320  
21  
22  
23  
24  
25  
936  
962  
835  
861  
888  
919  
939  
51  
52  
53  
54  
55  
1980  
2030  
2080  
2130  
2170  
1890  
1930  
1980  
2030  
2070  
989  
1020  
1040  
−4  
−3  
−2  
−1  
0
436  
451  
466  
482  
498  
335  
350  
365  
381  
397  
26  
27  
28  
29  
30  
1070  
1100  
1130  
1160  
1190  
969  
1000  
1030  
1060  
1090  
56  
57  
58  
59  
60  
2220  
2270  
2320  
2370  
2430  
2120  
2170  
2220  
2270  
2330  
1
2
3
4
5
514  
531  
548  
566  
584  
413  
430  
447  
465  
483  
31  
32  
33  
34  
35  
1220  
1260  
1290  
1320  
1360  
1120  
1160  
1190  
1220  
1260  
61  
62  
63  
64  
65  
2480  
2530  
2590  
2640  
2700  
2380  
2430  
2490  
2540  
2600  
6
7
602  
621  
641  
660  
681  
701  
501  
520  
540  
559  
580  
600  
36  
37  
38  
39  
40  
41  
1390  
1420  
1460  
1500  
1530  
1570  
1290  
1320  
1360  
1400  
1430  
1470  
66  
67  
68  
69  
70  
2760  
2820  
2870  
2930  
3000  
2660  
2720  
2770  
2830  
2900  
8
9
10  
11  
44  
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Table 5C — HFC-134a Pressure — Temperature (F)  
TEMPERATURE  
(F)  
PRESSURE  
(psig)  
TEMPERATURE  
(F)  
PRESSURE  
(psig)  
TEMPERATURE  
(F)  
PRESSURE  
(psig)  
0
2
4
6
8
6.50  
7.52  
60  
62  
64  
66  
68  
57.46  
60.06  
62.73  
65.47  
68.29  
120  
122  
124  
126  
128  
171.17  
176.45  
181.83  
187.32  
192.93  
8.60  
9.66  
10.79  
10  
12  
14  
16  
18  
11.96  
13.17  
14.42  
15.72  
17.06  
70  
72  
74  
76  
78  
71.18  
74.14  
77.18  
80.30  
83.49  
130  
132  
134  
136  
138  
140  
198.66  
204.50  
210.47  
216.55  
222.76  
229.09  
20  
22  
24  
26  
28  
18.45  
19.88  
21.37  
22.90  
24.48  
80  
82  
84  
86  
88  
86.17  
90.13  
93.57  
97.09  
100.70  
30  
32  
34  
36  
38  
26.11  
27.80  
29.53  
31.32  
33.17  
90  
92  
94  
96  
98  
104.40  
108.18  
112.06  
116.02  
120.08  
40  
42  
44  
46  
48  
35.08  
37.04  
39.06  
41.14  
43.28  
100  
102  
104  
106  
108  
124.23  
128.47  
132.81  
137.25  
141.79  
50  
52  
54  
56  
58  
45.48  
47.74  
50.07  
52.47  
54.93  
110  
112  
114  
116  
118  
146.43  
151.17  
156.01  
160.96  
166.01  
Table 5D — HFC-134a Pressure — Temperature (C)  
TEMPERATURE  
(C)  
PRESSURE  
GAGE (kPa)  
TEMPERATURE  
(C)  
PRESSURE  
GAGE (kPa)  
TEMPERATURE  
(C)  
PRESSURE  
GAGE (kPa)  
−18.0  
−16.7  
−15.6  
−14.4  
−13.3  
44.8  
51.9  
59.3  
66.6  
74.4  
10.0  
11.1  
12.2  
13.3  
14.4  
314.0  
329.0  
345.0  
362.0  
379.0  
43.3  
44.4  
45.6  
46.7  
47.8  
1010.0  
1042.0  
1076.0  
1110.0  
1145.0  
−12.2  
−11.1  
−10.0  
−8.9  
82.5  
90.8  
15.6  
16.7  
17.8  
18.9  
20.0  
396.0  
414.0  
433.0  
451.0  
471.0  
48.9  
50.0  
51.1  
52.2  
53.3  
1180.0  
1217.0  
1254.0  
1292.0  
1330.0  
99.4  
108.0  
118.0  
−7.8  
−6.7  
−5.6  
−4.4  
−3.3  
−2.2  
127.0  
137.0  
147.0  
158.0  
169.0  
21.1  
22.2  
23.3  
24.4  
25.6  
491.0  
511.0  
532.0  
554.0  
576.0  
54.4  
55.6  
56.7  
57.8  
58.9  
60.0  
1370.0  
1410.0  
1451.0  
1493.0  
1536.0  
1580.0  
−1.1  
0.0  
1.1  
2.2  
3.3  
180.0  
192.0  
204.0  
216.0  
229.0  
26.7  
27.8  
28.9  
30.0  
31.1  
598.0  
621.0  
645.0  
669.0  
694.0  
4.4  
5.0  
5.6  
6.1  
6.7  
242.0  
248.0  
255.0  
261.0  
269.0  
32.2  
33.3  
34.4  
35.6  
36.7  
720.0  
746.0  
773.0  
800.0  
828.0  
7.2  
7.8  
8.3  
8.9  
9.4  
276.0  
284.0  
290.0  
298.0  
305.0  
37.8  
38.9  
40.0  
41.1  
42.2  
857.0  
886.0  
916.0  
946.0  
978.0  
45  
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Fig. 27 — Typical Optional Pumpout System Piping Schematic  
with Storage Tank  
Fig. 28 — Typical Optional Pumpout System Piping Schematic  
without Storage Tank  
46  
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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.  
Inspect Water Piping — Refer to piping diagrams pro-  
vided in the certified drawings, and the piping instructions  
in the 19XL Installation Instructions manual. Inspect the  
piping to the cooler and condenser. Be sure that flow direc-  
tions 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 pres-  
sure drop across cooler and across condenser.  
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.  
Water must be within design limits, clean, and treated  
to ensure proper chiller performance and reduce the  
potential of tubing damage due to corrosion, scaling, or  
erosion. Carrier assumes no responsibility for chiller dam-  
age resulting from untreated or improperly treated  
water.  
Dehydration is readily accomplished at room tempera-  
tures. Use of a cold trap (Fig. 29) may substantially reduce  
the time required to complete the dehydration. The higher  
the room temperature, the faster dehydration takes place. At  
low room temperatures, a very deep vacuum is required for  
boiling off any moisture. If low ambient temperatures are  
involved, contact a qualified service representative for the  
dehydration techniques required.  
Check Optional Pumpout Compressor Water Pip-  
Perform dehydration as follows:  
ing — If the optional storage tank and/or pumpout system  
are installed, check to ensure the pumpout condenser water  
has been piped in. Check for field-supplied shutoff valves  
and controls as specified in the job data. Check for refrig-  
erant leaks on field-installed piping. See Fig. 27 and 28.  
1. Connect a high capacity vacuum pump (5 cfm  
[.002 m3/s] or larger is recommended) to the refrigerant  
charging valve (Fig. 2A or 2B). Tubing from the pump to  
the chiller should be as short and as large a diameter as  
possible to provide least resistance to gas flow.  
Check Relief Devices — Be sure that relief devices  
have been piped to the outdoors in compliance with the lat-  
est 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.  
2. Use an absolute pressure manometer or a wet bulb vacuum  
indicator to measure the vacuum. Open the shutoff valve  
to the vacuum indicator only when taking a reading. Leave  
the valve open for 3 minutes to allow the indicator vacuum  
to equalize with the chiller vacuum.  
3. Open all isolation valves (if present), if the entire chiller  
is to be dehydrated.  
4. With the chiller ambient temperature at 60 F (15.6 C) or  
higher, operate the vacuum pump until the manometer reads  
29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (–100.61 kPa)  
or a vacuum indicator reads 35 F (1.7 C). Operate the  
pump an additional 2 hours.  
19XL relief valves are set to relieve at the 300 psig  
(2068 kPa) chiller design pressure.  
Inspect Wiring  
Do not apply greater vacuum than 29.82 in. Hg vac  
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb  
vacuum indicator. At this temperature/pressure, isolated  
pockets of moisture can turn into ice. The slow rate of  
evaporation (sublimination) of ice at these low temperatures/  
pressures greatly increases dehydration time.  
Do not check voltage supply without proper equipment  
and precautions. Serious injury may result. Follow power  
company recommendations.  
5. Valve off the vacuum pump, stop the pump, and record  
the instrument reading.  
6. After a 2-hour wait, take another instrument reading. If  
the reading has not changed, dehydration is complete. If  
the reading indicates vacuum loss, repeat Steps 4 and 5.  
7. If the reading continues to change after several attempts,  
perform a leak test up to the maximum 230 psig  
(1585 kPa) pressure. Locate and repair the leak, and re-  
peat dehydration.  
Do not apply any kind of test voltage, even for a rota-  
tion check, if the chiller is under a dehydration vacuum.  
Insulation breakdown and serious damage may result.  
1. Examine wiring for conformance to job wiring dia-  
grams and to all applicable electrical codes.  
2. On low-voltage compressors (600 v or less) connect  
voltmeter across the power wires to the compressor  
starter and measure the voltage. Compare this reading  
with the voltage rating on the compressor and starter  
nameplates.  
3. Compare the ampere rating on the starter nameplate with  
the compressor nameplate. The overload trip amps must  
be 108% to 120% of the rated load amps.  
4. The starter for a centrifugal compressor motor must con-  
tain the components and terminals required for PIC  
refrigeration control. Check certified drawings.  
5. Check the voltage to the following components and  
compare to the nameplate values: oil pump contact,  
pumpout compressor starter, and power panel.  
Fig. 29 — Dehydration Cold Trap  
47  
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6. Be sure that fused disconnects or circuit breakers have  
been supplied for the oil pump, power panel, and  
pumpout unit.  
7. Check that all electrical equipment and controls are prop-  
erly grounded in accordance with job drawings, certi-  
fied drawings, and all applicable electrical codes.  
8. Make sure that the customer’s contractor has verified  
proper operation of the pumps, cooling tower fans, and  
associated auxiliary equipment. This includes ensuring  
that motors are properly lubricated and have proper elec-  
trical supply and proper rotation.  
9. For field-installed starters only, test the chiller compres-  
sor 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.) Factory-  
mounted starters do not require a megohm test.  
To attach the CCN communication bus wiring, refer to  
the certified drawings and wiring diagrams. The wire is in-  
serted into the CCN communications plug (COMM1) on the  
PSIO module. This plug also is referred to as J5.  
NOTE: Conductors and drain wire must be 20 AWG  
(American Wire Gage) minimum stranded, tinned copper.  
Individual conductors must be insulated with PVC, PVC/  
nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester  
100% foil shield and an outer jacket of PVC, PVC/nylon,  
chrome vinyl or Teflon with a minimum operating tempera-  
ture range of –20 C to 60 C is required. See table below for  
cables that meet the requirements.  
MANUFACTURER  
Alpha  
CABLE NO.  
2413 or 5463  
A22503  
American  
Belden  
a. Open the starter main disconnect switch and follow  
lockout/tagout rules.  
8772  
Columbia  
02525  
When connecting the CCN communication bus to a sys-  
tem element, a color code system for the entire network is  
recommended to simplify installation and checkout. The fol-  
lowing 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.  
PSIO MODULE  
COMM 1 PLUG (J5)  
PIN NO.  
SIGNAL  
TYPE  
CCN BUS CONDUCTOR  
INSULATION COLOR  
b. With the tester connected to the motor leads, take  
10-second and 60-second megohm readings as  
follows:  
+
Ground  
–
RED  
1
2
3
WHITE  
BLACK  
6-Lead Motor — Tie all 6 leads together and test be-  
tween the lead group and ground. Next tie leads in  
pairs, 1 and 4, 2 and 5, and 3 and 6. Test between  
each pair while grounding the third pair.  
3-Lead Motor — Tie terminals 1, 2, and 3 together  
and test between the group and ground.  
Check Starter  
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.  
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.  
If the readings on a field-installed starter are unsat-  
isfactory, repeat the test at the motor with the power  
leads disconnected. Satisfactory readings in this sec-  
ond test indicate the fault is in the power leads.  
Use the instruction and service manual supplied by the  
starter manufacturer to verify that the starter has been in-  
stalled correctly.  
NOTE: Unit-mounted starters do not have to be meg-  
ohm tested.  
10. Tighten up all wiring connections to the plugs on the  
SMM, 8-input, and PSIO modules.  
11. Ensure that the voltage selector switch inside the power  
panel is switched to the incoming voltage rating.  
12. On chillers with free-standing starters, inspect the power  
panel to ensure that the contractor has fed the wires into  
the bottom of the panel. Wiring into the top of the panel  
can cause debris to fall into the contactors. Clean and  
inspect the contactors if this has occurred.  
The main disconnect on the starter front panel may not  
deenergize all internal circuits. Open all internal and re-  
mote disconnects before servicing the starter.  
Whenever a starter safety trip device activates, wait at least  
30 seconds before resetting the safety. The microprocessor  
maintains its output to the 1CR relay for 10 seconds to de-  
termine the fault mode of failure.  
MECHANICAL-TYPE STARTERS  
1. Check all field wiring connections for tightness, clear-  
ance from moving parts, and correct connection.  
Carrier Comfort Network Interface — The Carrier  
Comfort Network (CCN) communication bus wiring is sup-  
plied 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 sig-  
nal ground pins must be wired to signal ground pins.  
2. Check the contactor(s) to be sure they move freely. Check  
the mechanical interlock between contactors to ensure that  
1S and 2M contactors cannot be closed at the same time.  
Check all other electro-mechanical devices, e.g., relays,  
timers, for free movement. If the devices do not move  
freely, contact the starter manufacturer for replacement  
components.  
48  
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3. Some dashpot-type magnetic overload relays must be filled  
with oil on the jobsite. If the starter is equipped with de-  
vices of this type, remove the fluid cups from these mag-  
netic overload relays.Add dashpot oil to cups per instructions  
supplied with the starter. The oil is usually shipped in a  
small container attached to the starter frame near the re-  
lays. Use only dashpot oil supplied with the starter. Do  
not substitute.  
Factory-filled dashpot overload relays need no oil at start-up  
and solid-state overload relays do not have oil.  
4. Reapply starter control power (not main chiller power) to  
check electrical functions. When using a reduced-voltage  
starter (such as a wye-delta type) check the transition timer  
for proper setting. The factory setting is 30 seconds  
(± 5 seconds), timed closing. The timer is adjustable in a  
range between 0 and 60 seconds and settings other than  
the nominal 30 seconds may be chosen as needed (typi-  
cally 20 to 30 seconds are used).  
When the timer has been set, check that the starter (with  
relay 1CR closed) goes through a complete and proper  
start cycle.  
LEGEND  
1
2
—
—
Phase Voltage Indicator  
Starter Fault and Run LEDs (5)  
• Overtemp  
• Ground Fault  
• Current Unbalance (CUB)  
While Stopped  
BENSHAW, INC. SOLID-STATE STARTER  
This equipment is at line voltage when AC power is  
connected. Pressing the STOP button does not remove  
voltage. Use caution when adjusting the potentiometers  
on the equipment.  
• Current Unbalance  
• Run (Start Initiated)  
Starting Torque Potentiometer  
Ramp Up Potentiometer  
Phase Correct LED  
3
4
5
6
7
—
—
—
—
—
Relay On LED  
Power +15 and Auxiliary (Starter  
in RUN State) LEDs (Hidden)  
SCR Indicator LEDs (Hidden)  
Reset Button  
1. Check that all wiring connections are properly termi-  
nated to the starter.  
2. Verify that the ground wire to the starter is installed prop-  
erly and is of sufficient size.  
8
9
—
—
Fig. 30 — Benshaw, Inc. Solid-State Starter  
Power Stack  
3. Verify that the motors are properly grounded to the starter.  
4. Check that all of the relays are properly seated in their  
sockets.  
5. Verify that the proper ac input voltage is brought into the  
starter per the certified drawings.  
6. Verify the initial factory settings of the starting torque and  
ramp potentiometers are set per the note on the schematic  
for the starters.  
NOTE: The potentiometers are located at the lower left  
hand corner on the circuit board mounted in front of the  
starter power stack (Fig. 30 and 31).  
The starting torque potentiometer should be set so that  
when the PIC calls for the motor to start, the rotor should  
just start to turn. The nominal dial position for a 60 Hz  
motor is approximately the 11:30 position. The nominal  
dial position for a 50 Hz motor is approximately in the  
9:30 position because the board is turned on its side, so  
that the 9:00 o’clock position is located where the  
6:00 o’clock position would normally be located. The ramp  
potentiometer should be set so that the motor is up to full  
speed in 15 to 20 seconds, the bypass contactors have  
energized, and the auxiliary LCD is energized.  
NOTE: Adjustments:  
Starting torque — 0% to 100% rated motor torque.  
Ramp time to full motor voltage — 0.5 seconds to  
60 seconds.  
Fig. 31 — Ramp Up and Starting Torque  
Potentiometers  
7. Proceed to apply power to the starter.  
8. The Power +15 and Phase Correct LEDs should be on. If  
not, see the starter Troubleshooting Guide section.  
49  
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Oil Charge — The 19XL compressor holds approxi-  
mately 8 gal. (30 L) of oil. The chiller will be shipped with  
oil in the compressor. When the sump is full, the oil level  
should be no higher than the middle of the upper sight glass  
and minimum level is the bottom of the lower sight glass  
(Fig. 2A or 2B). If oil is added, it must meet Carrier’s speci-  
fication for centrifugal compressor usage as described in the  
Oil Specification section on page 63. Charge the oil through  
the oil charging valve, located near the bottom of the trans-  
mission housing (Fig. 2Aor Fig. 2B). The oil must be pumped  
from the oil container through the charging valve due to higher  
refrigerant pressure. The pumping device must be able to lift  
from 0 to 200 psig (0 to 1380 kPa) or above unit pressure.  
Oil should only be charged or removed when the chiller is  
shut down.  
Input the Local Occupied Schedule (OCCPC01S)  
— Access the schedule OCCPC01S screen on the LID  
and set up the occupied time schedule per the customer’s  
requirements. If no schedule is available, the default is fac-  
tory set for 24 hours occupied 7 days per week including  
holidays.  
For more information about how to set up a time sched-  
ule, see the Controls section, page 11.  
The CCN Occupied Schedule should be configured if a  
CCN system is being installed or if a secondary time sched-  
ule is needed.  
NOTE: The default CCN Occupied Schedule is OCCPC03S  
for Software Version 09 and above; the default is OCCPC02S  
for Software Version 08 and below.  
Power Up the Controls and Check the Oil Heater  
Selecting Refrigerant Type — The 19XL control must  
be configured for the refrigerant being used, either HCFC-22  
or HFC-134a.  
— Ensure that an oil level is visible in the compressor  
before energizing controls. A circuit breaker in the starter  
energizes the oil heater and the control circuit. When first  
powered, the LID should display the default screen within a  
short period of time.  
The oil heater is energized by powering the control cir-  
cuit. This should be done several hours before start-up to  
minimize oil-refrigerant migration. The oil heater is con-  
trolled by the PIC and is powered through a contactor in the  
power panel. Starters contain a separate circuit breaker to  
power the heater and the control circuit. This set up allows  
the heater to energize when the main motor circuit breaker  
is off for service work or extended shutdowns. The oil heater  
relay status can be viewed on the Status02 table on the LID.  
Oil sump temperature can be viewed on the LID default screen.  
When the Time/Date is configured for the first time or if  
power is lost for more than 3 hours, the oil heat algorithm  
will take effect before the compressor can start. See the Oil  
Sump Temperature Control section on page 32 for addi-  
tional information. The oil pump will then energize for 1 to  
2 minutes to bring the oil temperature to normal operating  
temperature. A LOW OIL TEMPERATURE alert will show  
on the default LID screen if the operator has the controls set  
to start.  
SOFTWARE VERSION — The software version will  
always be labeled on the PSIO module, and on the back  
side of the LID module. On both the Controller ID and LID  
ID display screens, the software version number will also  
appear.  
TO CONFIRM REFRIGERANT TYPE — Confirm that the  
correct refrigerant type is indicated by entering the Controls  
Test tables on the Service menu, Fig. 17. Select REFRIG-  
ERANT TYPE. The screen will display the current refrig-  
erant setting. Press EXIT softkey to leave the screen with-  
out changes.  
TO CHANGE REFRIGERANT TYPE — Enter the Con-  
trols Test tables on the Service Menu. See Fig. 17. Select  
REFRIGERANT TYPE. The screen will display the current  
refrigerant setting. Press YES softkey to change the cur-  
rent setting. Next, move to the ATTACH TO NETWORK  
DEVICE screen on the Service menu and the ATTACH TO  
LOCAL DEVICE to upload the new refrigerant tables.  
Input Service Configurations — The following con-  
figurations require the LID screen to be in the Service por-  
tion of the menu.  
• password  
• input time and date  
• LID configuration  
• controller identification  
• service parameters  
• equipment configuration  
• automated control test  
Set Up Chiller Control Configuration  
PASSWORD — When accessing the Service tables, a pass-  
word must be entered. All LIDs are initially set for a pass-  
word of 1-1-1-1. This password may be changed in the LID  
configuration screen, if desired.  
Do not operate the chiller before the control configu-  
rations 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.  
INPUT TIME AND DATE — Access the Time and Date  
table on the Service menu. Input the present time of day,  
date, and day of the week. ‘‘Holiday Today’’ should only be  
configured to ‘‘Yes’’ if the present day is a holiday.  
As configuration of the 19XL unit is performed, write down  
all configuration settings. A log, such as the one shown on  
pages CL-1 to CL-2, provides a convenient list for configu-  
ration values.  
CHANGE LID CONFIGURATION IF NECESSARY — The  
LID Configuration screen is used to view or modify the LID  
CCN address, change to English or SI units, and to change  
the password. If there is more than one chiller at the jobsite,  
change the LID address on each chiller so that each chiller  
has its own address. Note and record the new address. Change  
the screen to SI units as required, and change the password  
if desired.  
Input the Design Set Points — Access the LID set  
point screen and view/modify the base demand limit set point,  
and either the LCW set point or the ECW set point. The PIC  
can control a set point to either the leaving or entering chilled  
water. This control method is set in the Equipment Configu-  
ration table, Config table.  
50  
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MODIFY CONTROLLER IDENTIFICATION IF NECES-  
SARY — The controller identification screen is used to change  
the PSIO module address. Change this address for each chiller  
if there is more than one chiller at the jobsite. Write the new  
address on the PSIO module for future reference.  
Change the LID address if there is more than one chiller  
on the jobsite. Access the LID configuration screen to view  
or modify this address.  
estimate the refrigerant suction and condensing tempera-  
tures at this difference. Use the proper saturated pressure and  
temperature for the particular refrigerant used.  
Suction Temperature:  
42 F (5.6 C) = 71.5 psig (521 kPa) saturated  
refrigerant pressure (HCFC-22)  
Condensing Temperature:  
98 F (36.7 C) = 190 psig (1310 kPa) saturated  
INPUT EQUIPMENT SERVICE PARAMETERS IF NEC-  
ESSARY — The Equipment Service table has three service  
tables: Service1, Service2, and Service3.  
refrigerant pressure (HCFC-22)  
Maximum Load ⌬T2:  
Configure SERVICE1 Table — Access Service1 table to  
modify/view the following to jobsite parameters:  
54 – 44 = 10° F (12.2 – 6.7 = 5.5° C)  
Maximum Load ⌬P2:  
190 – 71.5 = 118.5 psid (1310 – 521 = 789 kPad)  
Chilled Medium  
Water or Brine?  
To avoid unnecessary surge prevention, add about 10 psid  
Brine Refrigerant Trippoint  
Usually 3° F (1.7° C) below  
design refrigerant temperature  
(70 kPad) to ⌬P2 from these conditions:  
Surge Limiting or Hot Gas  
Bypass (HGBP) Option  
Is HGBP installed?  
⌬T2 = 10° F (5.5° C)  
⌬P2 = 130 psid (900 kPad)  
Minimum Load Points  
(T1/P1)  
Per job data —  
See Modify Load Points section  
Maximum Load Points  
(T2/P2)  
Per job data —  
Calculate Minimum Load — To calculate minimum load con-  
ditions, estimate the temperature difference that the cooler  
will have at 10% load, then estimate what the suction and  
condensing temperatures will be at this point. Use the proper  
saturated pressure and temperature for the particular refrig-  
erant used.  
See Modify Load Points section  
Amps Correction Factor  
Motor Rated Load Amps  
Motor Rated Line Voltage  
Motor Rated Line kW  
See Table 6  
Per job data  
Per job data  
Per job data  
(if kW meter installed)  
Suction Temperature:  
43 F (6.1 C) = 73 psig (503 kPa) saturated  
refrigerant pressure (HCFC-22)  
Line Frequency  
50 or 60 Hz  
Compressor Starter Type  
Reduced voltage or full?  
NOTE: Other values are left at the default values. These may be changed  
by the operator as required. Service2 and Service3 tables can be modi-  
fied by the owner/operator as required.  
Condensing Temperature:  
70 F (21.1 C) = 121 psig (834 kPa) saturated  
refrigerant pressure (HCFC-22)  
Minimum Load ⌬T1:  
Modify Minimum and Maximum Load Points (⌬T1/P1;  
⌬ T2/P2) If Necessary —These pairs of chiller load points,  
located on the Service1 table, determine when to limit guide  
vane travel or to open the hot gas bypass valve when surge  
prevention is needed. These points should be set based on  
individual chiller operating conditions.  
If, after configuring a value for these points, surge pre-  
vention is operating too soon or too late for conditions, these  
parameters should be changed by the operator.  
45.5 – 44 = 1.5° F (7.5 – 6.7 = 0.8° C)  
Minimum Load ⌬P1:  
121 – 73 = 45 psid (834 – 503 = 331 kPad)  
Again, to avoid unnecessary surge prevention, add 10 psid  
(70 kPad) at ⌬P1 from these conditions:  
⌬T1 = 1.5 F (0.8 C)  
⌬P1 = 60 psid (410 kPad)  
Example of configuration: Chiller operating parameters  
Refrigerant used: HCFC-22  
If surge prevention occurs too soon or too late:  
Estimated Minimum Load Conditions:  
44 F (6.7 C) LCW  
SURGE PREVENTION  
OCCURS TOO SOON  
SURGE PREVENTION  
OCCURS TOO LATE  
LOAD  
45.5 F (7.5 C) ECW  
At low  
loads  
(Ͻ50%)  
Increase P1 by  
10 psid (70 kPad)  
Decrease P1 by  
10 psid (70 kPad)  
43 F (6.1 C) Suction Temperature  
70 F (21.1 C) Condensing Temperature  
At high  
loads  
(Ͼ50%)  
Increase P2 by  
10 psid (70 kPad)  
Decrease P2 by  
10 psid (70 kPad)  
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  
Modify Amp Correction Factors — To modify the amp cor-  
rection factor, use the values listed in Table 6. Enter the  
appropriate amp correction factor in the Service1 table of  
Equipment Service.  
Calculate Maximum Load — To calculate maximum load  
points, use design load condition data. If the chiller full load  
cooler temperature difference is more than 15° F (8.3 C),  
51  
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Table 6 — Amps Correction Factors  
for 19XL Motors  
to the incoming power to the starter. Use a voltmeter to check  
incoming power at the starter power leads. If the readings  
are not equal, an adjustment can be made to the 24-v input  
to the SMM at the potentiometer located in the low-voltage  
section to equalize the two readings.  
MOTOR CODE  
VOLT/  
Hz  
CB CC CD CE CL CM CN CP CQ CR  
200/60  
208/60  
220/60  
230/60  
4
5
3
5
5
5
4
6
3
5
2
4
6
8
2
4
3
4
2
3
2
2
3
5
3
4
1
2
2
2
1
2
2
2
1
2
2
2
1
2
PERFORM AN AUTOMATED CONTROL TEST — Check  
the safety controls status by performing an automated con-  
trols test. Access the Control Test table and select the  
Automated Tests function (Table 8).  
240/60  
360/60  
380/60  
400/60  
5
4
7
7
6
2
4
5
4
4
6
8
4
2
4
4
3
2
4
4
8
2
5
5
2
1
3
3
2
1
2
2
2
1
2
3
2
1
2
4
The Automated Control Test will check all outputs and  
inputs for function. It will also set the refrigerant type. The  
compressor must be in the OFF mode in order to operate the  
controls test and the 24-v input to the SMM must be in range  
(per line voltage percent on Status01 table). The OFF mode  
is caused by pressing the STOP pushbutton on the LID. Each  
test will ask the operator to confirm that the operation is oc-  
curring, and whether or not to continue. If an error occurs,  
the operator has the choice to try to address the problem as  
the test is being done, or to note the problem and proceed to  
the next test.  
440/60  
460/60  
480/60  
550/60  
3
5
7
4
3
4
5
2
2
3
4
3
2
2
3
2
1
2
3
1
1
2
3
2
1
2
3
3
1
2
3
2
3
5
7
2
4
6
8
2
575/60  
600/60  
3300/60  
2400/60  
4
8
4
4
4
5
4
4
4
6
4
3
2
4
1
3
2
3
2
2
3
4
3
3
4
6
3
2
3
5
3
2
3
4
2
3
3
4
2
3
4160/60  
220/50  
230/50  
240/50  
4
3
4
5
4
1
2
3
3
2
2
5
3
2
3
4
2
2
2
3
3
3
4
5
2
2
3
3
2
1
2
3
3
1
1
2
3
1
1
2
NOTE: If during the Control Test the guide vanes do not  
open, check to see that the low pressure alarm is not active.  
(This will cause the guide vanes to close).  
NOTE: The oil pump test will not energize the oil pump if  
cooler pressure is below –5 psig (–35 kPa).  
320/50  
346/50  
360/50  
380/50  
2
4
5
5
2
4
5
2
2
3
4
3
2
3
4
3
1
3
4
3
1
2
2
2
1
1
2
4
1
2
2
2
3
3
8
2
3
4
8
2
400/50  
415/50  
3000/50  
3300/50  
6
8
3
4
4
5
2
3
4
5
2
3
5
6
3
3
4
5
2
3
3
4
3
4
6
7
1
2
4
5
2
2
3
4
1
1
3
4
2
2
When the test is finished, or the EXIT softkey is pressed,  
the test will be stopped and the Control Test menu will be  
displayed. If a specific automated test procedure is not  
completed, access the particular control test to test the func-  
tion when ready. The Control Test menu is described as  
follows:  
MODIFY EQUIPMENT CONFIGURATION IF NECES-  
SARY — The Equipment Configuration table has tables to  
select and view or modify. Carrier’s certified drawings will  
have the configuration values required for the jobsite. Modify  
these tables only if requested.  
Automated Tests  
As described above, a complete  
control test.  
PSIO Thermistors  
Check of all PSIO thermistors only.  
Config Table Modifications — Change the values in this table  
per job data. See certified drawings for values. Modifica-  
tions include:  
Options Thermistors  
Check of all options boards  
thermistors.  
Transducers  
Guide Vane Actuator  
Pumps  
Check of all transducers.  
Check of the guide vane operation.  
• chilled water reset  
Check operation of pump outputs,  
either all pumps can be activated,  
or individual pumps. The test will  
also test the associated input such  
as flow or pressure.  
• entering chilled water control (Enable/Disable)  
• 4-20 mA demand limit  
• auto. restart option (Enable/Disable)  
• remote contact option (Enable/Disable)  
Discrete Outputs  
Activation of all on/off outputs or  
individually.  
Owner-Modified CCN Tables— The following tables are de-  
scribed for reference only.  
Pumpdown/Lockout  
Pumpdown prevents the low refrig-  
erant alarm during evacuation so  
refrigerant can be removed from  
the unit, locks the compressor off,  
and starts the water pumps.  
Occdef Table Modifications — The Occdef tables contain  
the Local and CCN time schedules, which can be modified  
here, or in the Schedule screen as described previously.  
Holidef Table Modifications — The Holidef tables configure  
the days of the year that holidays are in effect. See the holi-  
day paragraphs in the Controls section for more  
details.  
Terminate Lockout  
Refrigerant Type*  
To charge refrigerant and enable  
the chiller to run after pumpdown  
lockout.  
Sets type of refrigerant used:  
HCFC-22 or HFC-134a.  
Brodefs Table Modifications — The Brodefs table defines  
the outside-air temperature sensor and humidity sensor if one  
is to be installed. It will define the start and end of day-  
light savings time. Enter the dates for the start and end of  
daylight savings if required for the location. Brodefs also  
will activate the Broadcast function which enables the holi-  
day periods that are defined on the LID.  
Other Tables — The Alarmdef, Cons-def, and Runt-def con-  
tain tables for use with a CCN system. See the applicable  
CCN manual for more information on these tables.  
These tables can only be defined through a CCN Building  
Supervisor.  
*Make sure to Attach to Local Device after changing refrigerant type.  
Refer to Selecting Refrigerant Type section on page 50.  
Check Optional Pumpout System Controls and  
Compressor — Controls include an on/off switch, a 3-amp  
fuse, the compressor overloads, an internal thermostat, a com-  
pressor contactor, and a refrigerant high pressure cutout. The  
high pressure cutout is factory set to open at 220 ± 5 psig  
(1250 ± 34 kPa), and automatically reset at 185 + 0,  
−7 psig (1280 +0,–48 kPa) with HCFC-22. HFC-134a units  
open at 161 psig (1110 kPa) and reset at 130 psig (896 kPa).  
Check that the water-cooled condenser has been connected.  
CHECK VOLTAGE SUPPLY — Access the Status 01 screen  
and read the actual line voltage. This reading should be equal  
52  
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Loosen the compressor holddown bolts to allow free spring  
travel. Open the compressor suction and discharge service  
valves. Check that oil is visible in the compressor sight glass.  
Add oil if necessary.  
Table 7 — Control Test Menu Functions  
TESTS TO BE  
PERFORMED  
DEVICES TESTED  
1. Automated Tests*  
Operates the second through  
seventh tests  
See Pumpout and Refrigerant Transfer Procedures and  
Optional Pumpout System Maintenance sections, pages 59  
and 65, for details on transfer of refrigerant, oil specifica-  
tions, etc.  
2. PSIO Thermistors  
Entering chilled water  
Leaving chilled water  
Entering condenser water  
Leaving condenser water  
Discharge temperature  
Bearing temperature  
High Altitude Locations — Recalibration of the pres-  
sure transducers will be necessary as the chiller was initially  
calibrated at sea level. Please see the calibration procedure  
in the Troubleshooting Guide section.  
Motor winding temperature  
Oil sump temperature  
3. Options Thermistors Common chilled water supply  
sensor  
Common chilled water return sensor  
Remote reset sensor  
Temperature sensor — Spare 1  
Charge Refrigerant into Chiller  
Spare 2  
Spare 3  
Spare 4  
Spare 5  
Spare 6  
Spare 7  
Spare 8  
Spare 9  
The transfer, addition, or removal of refrigerant in spring  
isolated chillers may place severe stress on external pip-  
ing if springs have not been blocked in both up and down  
directions.  
4. Transducers  
Evaporator pressure  
Condenser pressure  
Oil pressure differential  
Oil pump pressure  
The standard 19XL chiller will have the refrigerant  
already charged in the vessels. The 19XL may be ordered  
with a nitrogen holding charge of 15 psig (103 kPa). Evacu-  
ate the entire chiller, and charge chiller from refrigerant  
cylinders.  
5. Guide Vane Actuator Open  
Close  
6. Pumps  
All pumps or individual pumps may  
be activated:  
Oil pump — Confirm pressure  
Chilled water pump — Confirm flow  
Condenser water pump — Confirm  
flow  
19XL CHILLER EQUALIZATION WITHOUT PUMP-  
OUT UNIT  
7. Discrete Outputs  
All outputs or individual outputs may  
be energized:  
When equalizing refrigerant pressure on the 19XL chiller  
after service work or during the initial chiller start-up,  
do not use the discharge isolation valve to equalize. The  
motor cooling isolation valve or charging hose (con-  
nected between pumpout valves on top of cooler and  
condenser) is to be used as the equalization valve.  
Hot gas bypass relay  
Oil heater relay  
Motor cooling relay  
Tower fan relay  
Alarm relay  
Shunt trip relay  
8. Pumpdown/Lockout When using pumpdown/lockout,  
observe freeze up precautions when  
removing charge:  
To equalize the pressure differential on a refrigerant  
isolated 19XL chiller, use the TERMINATE LOCKOUT  
function of the Control Test in the SERVICE menu. This  
will help to turn on pumps and advise the proper procedure.  
The following procedure describes how to equalize refrig-  
erant pressure on an isolated 19XL chiller without a pump-  
out unit:  
Instructs operator as to 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  
1. Access TERMINATE LOCKOUT function on the Con-  
trol Test.  
2. Turn on the chilled water and condenser water pumps to  
ensure against freezing.  
procedures  
Turns pumps off after pumpdown  
Locks out compressor  
9. Terminate Lockout  
Starts pumps and monitors flows  
3. Slowly open the refrigerant cooling isolation valve.  
The chiller cooler and condenser pressures will grad-  
ually equalize. This process will take approximately  
15 minutes.  
4. Once the pressures have equalized, the cooler isolation  
valve, the condenser isolation valve, and the hot gas by-  
pass isolation valve may now be opened. Refer to Fig. 27  
and 28, valves 11, 12, and 14.  
Instructs operator as to which values  
to open and when  
Monitors — Evaporator pressure  
Condenser pressure  
Evaporator temperature  
during charging process  
Terminates compressor lockout  
10. Refrigerant Type  
Sets refrigerant type used:  
HCFC-22 or HFC-134a.  
NOTE: Be sure to ATTACH TO  
LOCAL DEVICE after changing  
refrigerant type.  
Whenever turning the discharge isolation valve, be  
sure to reattach the valve locking device. This will  
prevent the valve from opening or closing during serv-  
ice work or during chiller operation.  
See Attach to Network Device  
Control section, page 37.  
*During any of the tests that are not automated, an out-of-range read-  
ing will have an asterisk (*) next to the reading and a message will  
be displayed.  
53  
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19XL CHILLER EQUALIZATION WITH PUMPOUT  
UNIT — The following procedure describes how to equal-  
ize refrigerant pressure on an isolated 19XL chiller using the  
pumpout unit.  
1. Access the TERMINATE LOCKOUT mode in the Con-  
trol Test.  
vessels. Charge the refrigerant as a gas until the system pres-  
sure exceeds 68 psig (469 kPa); [35 psig (141 kPa)]. After  
the chiller is beyond this pressure the refrigerant should be  
charged as a liquid until all of the recommended refrigerant  
charge has been added.  
TRIMMING REFRIGERANT CHARGE — The 19XL is  
shipped with the correct charge for the design duty of the  
chiller. Trimming the charge can be best accomplished when  
design load is available. To trim, check the temperature  
difference between leaving chilled water temperature and  
cooler refrigerant temperature at full load design conditions.  
If necessary, add or remove refrigerant to bring the tempera-  
ture difference to design conditions or minimum differential.  
2. Turn on the chilled water and condenser water pumps to  
prevent possible freezing.  
3. Open valve 4 on the pumpout unit and open valves 1a  
and 1b on the chiller cooler and condenser, Fig. 27 and  
28. Slowly open valve 2 on the pumpout unit to equalize  
the pressure. This process will take approximately  
15 minutes.  
4. Once the pressures have equalized, the discharge isola-  
tion 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.  
Table 8 — Refrigerant Charges*  
19XL TOTAL REFRIGERANT CHARGE  
Design II  
COOLER  
SIZE  
Design I  
Chiller  
Chiller  
HCFC-22  
lb kg  
HFC-134a  
lb  
kg  
lb  
kg  
Whenever turning the discharge isolation valve, be  
sure to reattach the valve locking device. This will  
prevent the valve from opening or closing during serv-  
ice work or during chiller operation.  
40  
41  
42  
1420  
1490  
1550  
640  
680  
700  
1100  
1150  
1250  
499  
522  
568  
900  
950  
1000  
409  
431  
454  
43  
50  
51  
1600  
1850  
1900  
730  
840  
860  
1350  
1500  
1600  
613  
681  
726  
1050  
1100  
1200  
477  
499  
545  
The full refrigerant charge on the 19XL will vary with  
chiller components and design conditions, indicated on the  
job data specifications. An approximate charge may be found  
by adding the condenser charge to the cooler charge listed in  
Table 8.  
Always operate the condenser and chilled water pumps  
during charging operations to prevent freeze-ups. Use the  
Control Test Terminate Lockout to monitor conditions and  
start the pumps.  
If the chiller has been shipped with a holding charge, the  
refrigerant will be added through the refrigerant charging valve  
(Fig. 27 and 28, valve 7) or to the pumpout charging con-  
nection. First evacuate the nitrogen holding charge from the  
52  
53  
55  
1980  
2050  
—
900  
930  
—
1750  
1850  
1900  
795  
840  
863  
1300  
1350  
1550  
590  
613  
704  
56  
57  
58  
—
—
—
—
—
—
2200  
2500  
2700  
999  
1135  
1226  
1650  
1750  
1900  
749  
795  
863  
*Design I chillers use HCFC-22. Design II chillers use either HCFC-22  
or HFC-134a.  
NOTES:  
1. The size of the cooler determines refrigerant charge for the entire  
chiller.  
2. Design I chillers have float chambers.  
3. Design II chillers have linear floats.  
54  
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controls do not go into start mode, go to the Schedule  
screen and override the schedule or change the oc-  
cupied time. Press the LOCAL softkey to begin the start-  
up sequences.  
INITIAL START-UP  
Preparation — Before starting the chiller, check that the:  
1. Power is on to the main starter, oil pump relay, tower fan  
starter, oil heater relay, and the chiller control  
center.  
2. Cooling tower water is at proper level, and at or below  
design entering temperature.  
3. Check that chilled water and condenser water pumps  
energize.  
4. Check that the oil pump starts and pressurizes the lubri-  
cation system. After the oil pump has run about 11 sec-  
onds, the starter will be energized and go through its start-up  
sequence.  
3. Chiller is charged with refrigerant and all refrigerant and  
oil valves are in their proper operating position.  
4. Oil is at the proper level in the reservoir sight glasses.  
5. Check the main contactor for proper operation.  
5. Oil reservoir temperature is above 140 F (60 C) or re-  
frigerant temperature plus 50° F (28° C).  
6. Valves in the evaporator and condenser water circuits are  
open.  
6. The PIC will eventually show an alarm for motor amps  
not sensed. Reset this alarm and continue with the initial  
start-up.  
Check Rotation  
1. Engage the main motor disconnect on the front of the starter  
panel. The motor is now ready for rotation check.  
NOTE: If pumps are not automatic, make sure water is  
circulating properly.  
7. Solid-state starter checks: The Power +15 and the Phase  
Correct LEDs must be lit before the starter will energize.  
If the Power +15 LED is not on, incoming voltage is not  
present or is incorrect. If the Phase Correct LED is not  
lit, rotate any 2 incoming phases to correct the phasing.  
2. After the default screen Status message states ‘‘Ready  
for Start’’press the LOCAL softkey; start-up checks will  
be made by the control.  
3. When the starter is energized and the motor begins to turn.  
Check for clockwise rotation (Fig. 32).  
IF ROTATION IS PROPER, allow the compressor to come  
up to speed.  
Do not permit water or brine that is warmer than  
110 F (43 C) to flow through the cooler or con-  
denser. Refrigerant overpressure may discharge through  
the relief devices and result in the loss of refrigerant  
charge.  
IF THE MOTOR ROTATION IS NOT CLOCKWISE  
(as viewed through the sight glass), reverse any 2 of the 3  
incoming power leads to the starter and recheck rotation.  
NOTE: Solid-state starters have phase protection and will  
not allow a start if the phase is not correct. Instead, a Starter  
Fault message will occur if this happens.  
8. Press RELEASE to automate the chiller start/stop value  
on the Status01 table to enable the chiller to start. The  
initial factory setting of this value is overridden to stop in  
order to prevent accidental start-up.  
Do not check motor rotation during coastdown. Rota-  
tion may have reversed during equalization of vessel  
pressures.  
Manual Operation of the Guide Vanes — Manual  
operation of the guide vanes is helpful to establish a steady  
motor current for calibration of the motor amps value.  
In order to manually operate the guide vanes, it is nec-  
essary to override the TARGET GUIDE VANE POSITION  
value which is accessed on the Status01 table. Manual con-  
trol is indicated by the word ‘‘SUPVSR!’’ flashing after the  
target value position. Manual control is also indicated on the  
default screen on the run status line.  
1. Access the Status01 table and look at the target guide vane  
position (Fig. 16). If the compressor is off, the value will  
read zero.  
2. Move the highlight bar to the TARGET GUIDE VANE  
POSITION line and press the SELECT softkey.  
3. Press ENTER to override the automatic target. The screen  
will now read a value of zero, and the word  
‘‘SUPVSR!’’ will flash.  
4. Press the SELECT softkey, and then press  
RELEASE softkey to release the vanes to AUTO-  
MATIC mode. After a few seconds the ‘‘SUPVSR!’’ will  
disappear.  
Fig. 32 — Correct Motor Rotation  
Dry Run to Test Start-Up Sequence  
1. Disengage the main motor disconnect on the starter front  
panel. This should only disconnect the motor power. Power  
to the controls, oil pump, and starter control circuit should  
still be energized.  
2. Look at the default screen on the LID: the Status mes-  
sage in the upper left-hand corner will read, ‘‘Manually  
Stopped.’’ Press CCN or Local to start. If the chiller  
NOTES ON SOLID-STATE STARTERS (Benshaw, Inc.)  
1. When the compressor is energized to start by the 1CR  
relay, confirm that the Relay On LED is lit on the starter  
SCR control board. The compressor motor should start to  
turn immediately when this light comes on. If not, adjust  
the start torque potentiometer in a clockwise direction.  
55  
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2. Observe that all 6-gate LEDs are lit on the starter SCR  
control board.  
3. The factory setting should bring the motor to full voltage  
in 15 to 30 seconds. If the setting is not correct, adjust the  
ramp potentiometer counterclockwise for a shorter time,  
clockwise for a longer time. (See Fig. 5 for starter com-  
ponent placement.)  
MOTOR COMPRESSOR ASSEMBLY — Guide vane  
actuator, transmission, motor cooling system, oil cool-  
ing 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.  
Check Oil Pressure and Compressor Stop  
1. When the motor is up to full speed, note the differential  
oil pressure reading on the LID default screen. It should  
be between 18 and 30 psid (124 to 206 kPad).  
2. Press the Stop button and listen for any unusual sounds  
from the compressor as it coasts to a stop.  
CONTROL SYSTEM — CCN and Local start, reset, menu,  
softkey functions, LID operation, occupancy schedule, set  
points, safety controls, and auxiliary and optional controls.  
AUXILIARY EQUIPMENT — Starters and disconnects, sepa-  
rate electrical sources, pumps, and cooling tower.  
Calibrate Motor Current  
DESCRIBE CHILLER CYCLES — Refrigerant, motor cool-  
ing, lubrication, and oil reclaim.  
1. Make sure that the compressor motor rated load amps in  
the Service1 table has been configured. Place an ammeter  
on the line that passes through the motor load current trans-  
fer on the motor side of the power factor correction ca-  
pacitors (if provided).  
2. Start the compressor and establish a steady motor current  
value between 70% and 100% RLA by manually over-  
riding the guide vane target value on the LID and setting  
the chilled water set point to a low value. Do not exceed  
105% of the nameplate RLA.  
3. When a steady motor current value in the desired range  
is met, compare the compressor motor amps value on the  
Status01 table to the actual amps shown on the ammeter  
on the starter. Adjust the amps value on the LID to  
the actual value seen at the starter if there is a difference.  
REVIEW MAINTENANCE — Scheduled, routine, and ex-  
tended shutdowns, importance of a log sheet, importance of  
water treatment and tube cleaning, and importance of main-  
taining a leak-free chiller.  
SAFETY DEVICES AND PROCEDURES — Electrical dis-  
connects, relief device inspection, and handling refrigerant.  
CHECK OPERATOR KNOWLEDGE — Start, stop, and shut-  
down procedures; safety and operating controls; refrigerant  
and oil charging; and job safety.  
REVIEW THE START-UP, OPERATION, AND MAINTE-  
NANCE MANUAL  
Highlight the amps value then press SELECT .  
OPERATING INSTRUCTIONS  
Operator Duties  
1. Become familiar with refrigeration chiller and related equip-  
ment before operating the chiller.  
2. Prepare the system for start-up, start and stop the chiller,  
and place the system in a shutdown condition.  
3. Maintain a log of operating conditions and document any  
abnormal readings.  
4. Inspect the equipment, make routine adjustments, and per-  
form a Control Test. Maintain the proper oil and refrig-  
erant levels.  
5. Protect the system from damage during shutdown  
periods.  
Press INCREASE or DECREASE to bring the value  
to that indicated on the ammeter. Press ENTER when  
equal.  
4. Make sure that the target guide vane position is released  
into AUTOMATIC mode.  
To Prevent Accidental Start-Up — The PIC can be  
set up so that start-up of the unit is more difficult than just  
pressing the LOCAL or CCN softkeys during chiller serv-  
ice or when necessary. By accessing the Status01 table, and  
highlighting the chiller Start/Stop line, the value can be over-  
ridden to stop by pressing SELECT and then the  
STOP and ENTER softkeys. ‘‘SUPVSR’’ will appear  
after the value. When attempting to restart, remember to  
release the override. The default chiller message line will  
also state that the Start/Stop has been set to ‘‘Start’’or ‘‘Stop’’  
when the value is overridden.  
6. Maintain the set point, time schedules, and other PIC  
functions.  
Prepare the Chiller for Start-Up — Follow the steps  
described in the Initial Start-Up section, page 55.  
Check Chiller Operating Condition — Check to  
be sure that chiller temperatures, pressures, water flows, and  
oil and refrigerant levels indicate that the system is func-  
tioning properly.  
To Start the Chiller  
1. Start the water pumps, if they are not automatic.  
2. On the LID default screen, press the LOCAL or  
CCN softkey to start the system. If the chiller is in  
Instruct the Customer Operator — Check to be sure  
that the operator(s) understand all operating and main-  
tenance procedures. Point out the various chiller parts and  
explain their function as part of the complete system.  
the OCCUPIED mode, and the start timers have expired,  
the start sequence will start. Follow the procedure de-  
scribed in the Start-Up/Shutdown/Recycle section,  
page 39.  
COOLER-CONDENSER — Float chamber, relief devices,  
refrigerant charging valve, temperature sensor locations, pres-  
sure transducer locations, Schrader fittings, waterboxes and  
tubes, and vents and drains.  
Check the Running System — After the compres-  
sor starts, the operator should monitor the LID display and  
observe the parameters for normal operating conditions:  
OPTIONAL STORAGE TANK AND PUMPOUT SYS-  
TEM — Transfer valves and pumpout system, refrigerant  
charging and pumpdown procedure, and relief devices.  
1. The oil reservoir temperature should be above 140 F  
(60 C) during shutdown, and above 100 F (38 C) during  
compressor operation.  
56  
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2. The bearing oil temperature accessed on the Status01 table  
should be 120 to 165 F (49 to 74 C). If the bearing  
temperature reads more than 180 F (83 C) with the oil  
pump running, stop the chiller and determine the cause  
of the high temperature. Do not restart the chiller until  
corrected.  
of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant to prevent air  
from leaking into the chiller.  
If freezing temperatures are likely to occur in the chiller  
area, drain the chilled water, condenser water, and the  
pumpout condenser water circuits to avoid freeze-up. Keep  
the waterbox drains open.  
3. The oil level should be visible anywhere in one of the  
two sight glasses. Foaming of the oil is acceptable as  
long as the oil pressure and temperature are within  
limits.  
4. The oil pressure should be between 18 and 30 psid  
(124 to 207 kPad), as seen on the LID default screen.  
Typically the reading will be 18 to 25 psid (124 to  
172 kPad) at initial start-up.  
Leave the oil charge in the chiller with the oil heater  
and controls energized to maintain the minimum oil reser-  
voir temperature.  
After Extended Shutdown — Be sure that the water  
system drains are closed. It may be advisable to flush the  
water circuits to remove any soft rust which may have formed.  
This is a good time to brush the tubes if necessary.  
Check the cooler pressure on the LID default screen, and  
compare to the original holding charge that was left in the  
chiller. If (after adjusting for ambient temperature changes)  
any loss in pressure is indicated, check for refrigerant leaks.  
See Check Chiller Tightness section, page 41.  
Recharge the chiller by transferring refrigerant from the  
storage tank (if supplied). Follow the Pumpout and Refrig-  
erant Transfer Procedures section, page 59. Observe freeze-up  
precautions.  
Carefully make all regular preliminary and running sys-  
tem checks. Perform a Control Test before start-up. If the  
compressor oil level appears abnormally high, the oil may  
have absorbed refrigerant. Make sure that the oil tempera-  
ture is above 140 F (60 C) or cooler refrigerant temperature  
plus 50° F (27° C).  
5. The moisture indicator sight glass on the refrigerant  
motor cooling line should indicate refrigerant flow and a  
dry condition.  
6. The condenser pressure and temperature varies with  
the chiller design conditions. Typically the pressure  
will range between 100 and 210 psig (690 to 1450 kPa)  
with a corresponding temperature range of 60 to 105 F  
(15 to 41 C). The condenser entering water temperature  
should be controlled below the specified design entering  
water temperature to save on compressor kilowatt  
requirements.  
7. Cooler pressure and temperature also will vary with the  
design conditions. Typical pressure range will be be-  
tween 60 and 80 psig (410 and 550 kPa), with temper-  
ature ranging between 34 and 45 F (1 and 8 C).  
8. The compressor may operate at full capacity for a short  
time after the pulldown ramping has ended, even though  
the building load is small. The active electrical demand  
setting can be overridden to limit the compressor IkW,  
or the pulldown rate can be decreased to avoid a high  
demand charge for the short period of high demand  
operation. Pulldown rate can be based on load rate or  
temperature rate. It is accessed on the Equipment Con-  
figuration, Config table (Table 2, Example 5).  
Cold Weather Operation — When the entering con-  
denser water drops very low, the operator should auto-  
matically cycle the cooling tower fans off to keep the  
temperature up. Piping may also be arranged to bypass the  
cooling tower. The PIC controls have a low limit tower fan  
relay (PR3) that can be used to assist in this control.  
Manual Guide Vane Operation — Manual opera-  
tion of the guide vanes in order to check control operation  
or control of the guide vanes in an emergency operation is  
possible by overriding the target guide vane position.  
Access the Status01 table on the LID and highlight  
TARGET GUIDE VANE POSITION. To control the position,  
enter a percentage of guide vane opening that is desired.  
Zero percent is fully closed, 100% is fully open. To re-  
lease the guide vanes to AUTOMATIC mode, press the  
To Stop the Chiller  
1. The occupancy schedule will start and stop the chiller  
automatically once the time schedule is set up.  
2. By pressing the STOP button for one second, the alarm  
light will blink once to confirm that the button has been  
pressed, then the compressor will follow the normal shut-  
down sequence as described in the Controls section. The  
RELEASE softkey.  
chiller will not restart until the CCN or LOCAL soft-  
key is pressed. The chiller is now in the OFF mode.  
NOTE: Manual control will increase the guide vanes and  
override the pulldown rate during start-up. Motor current above  
the electrical demand setting, capacity overrides, and chilled  
water below control point will override the manual target  
and close the guide vanes. For descriptions of capacity over-  
rides and set points, see the Controls section.  
If the chiller fails to stop, in addition to action that  
the PIC will initiate, the operator should close the guide  
vanes by overriding the guide vane target to zero to re-  
duce chiller load; then by opening the main disconnect.  
Do not attempt to stop the chiller by opening an isolating  
knife switch. High intensity arcing may occur. Do not re-  
start the chiller until the problem is diagnosed and  
corrected.  
Refrigeration Log — A refrigeration log, such as  
the one shown in Fig. 33, provides a convenient check-  
list for routine inspection and maintenance and provides a  
continuous record of chiller performance. It is an aid in  
scheduling routine maintenance and in diagnosing chiller  
problems.  
Keep a record of the chiller pressures, temperatures, and  
liquid levels on a sheet similar to that shown. Automatic  
recording of PIC data is possible through the use of CCN  
devices such as the Data Collection module and a Building  
Supervisor. Contact your Carrier representative for more  
information.  
After Limited Shutdown — No special preparations  
should be necessary. Follow the regular preliminary checks  
and starting procedures.  
Extended Shutdown — The refrigerant should be trans-  
ferred into the storage vessel (if supplied; see Pumpout and  
Refrigerant Transfer Procedures) in order to reduce chiller  
pressure and possibility of leaks. Maintain a holding charge  
57  
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PUMPOUT AND REFRIGERANT TRANSFER  
PROCEDURES  
Preparation — The 19XL may come equipped with  
an optional storage tank or pumpout system, or a pump-  
out compressor. The refrigerant can be pumped for service  
work to either the cooler/compressor vessel or the condenser  
vessel by using the optional pumpout system. If a storage  
tank is supplied, the refrigerant can be isolated in the  
external storage tank. The following procedures describe how  
to transfer refrigerant from vessel to vessel and perform chiller  
evacuations.  
Operating the Optional Pumpout Compressor  
1. Be sure that the suction and the discharge service valves  
on the optional pumpout compressor are open (back-  
seated) during operation. Rotate the valve stem fully coun-  
terclockwise to open. Frontseating the valve closes the  
refrigerant line and opens the gage port to compressor  
pressure.  
LEGEND  
C
—
—
—
—
—
Contactor  
Fuse, 3 Amps  
High-Pressure Cutout  
Compressor Overload  
Internal Thermostat  
FU  
HP  
OL  
T’STAT  
2. Make sure that the compressor holddown bolts have been  
loosened to allow free spring travel.  
3. Open the refrigerant inlet valve on the pumpout  
compressor.  
Compressor Terminal  
Contactor Terminal  
Overload Terminal  
4. Oil should be visible in the pumpout compressor sight  
glass under all operating conditions and during shut-  
down. If oil is low, add oil as described under Optional  
Pumpout System Maintenance section, page 65. The  
pumpout unit control wiring schematic is detailed in  
Fig. 34.  
Pumpout Unit Terminal  
*Bimetal thermal protector imbedded in motor winding.  
Fig. 34 — 19XL Pumpout Unit  
Wiring Schematic  
TO READ REFRIGERANT PRESSURES during pumpout  
or leak testing:  
VENT VALVE 8  
OIL RETURN  
LINE  
CONNECTION  
1. The LID display on the chiller control center is suitable  
for determining refrigerant-side pressures and low (soft)  
vacuum. For evacuation or dehydration measurement, use  
a quality vacuum indicator or manometer to ensure the  
desired range and accuracy. This can be placed on the  
Schrader connections on each vessel by removing the pres-  
sure transducer.  
2. To determine storage tank pressure, a 30 in.-0-400 psi  
(-101-0-2760 kPa) gage is attached to the vessel.  
3. Refer to Fig. 27, 28, and 35 for valve locations and  
numbers.  
PUMPOUT  
STARTER  
PANEL  
Transfer, addition, or removal of refrigerant in spring-  
isolated chillers may place severe stress on external pip-  
ing if springs have not been blocked in both up and down  
directions.  
CONDENSER  
WATER  
CONNECTIONS  
REFRIGERANT  
INLET VALVE  
Chillers with Pumpout Storage Tanks — If the  
chiller has isolation valves, leave them open for the follow-  
ing procedures. The letter ‘‘C’’ describes a closed valve. See  
Fig. 16, 17, 27, and 28.  
Fig. 35 — Optional Pumpout Unit  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
TRANSFER REFRIGERANT FROM STORAGE TANK TO  
CHILLER  
CONDITION  
C
C
C
C
C
C
1. Equalize refrigerant pressure.  
d. Gradually crack open valve 5 to increase chiller pres-  
sure to 68 psig (469 kPa), [35 psig (141 kPa)]. Slowly  
feed refrigerant to prevent freeze up.  
e. Open valve 5 fully after the pressure rises above the  
freeze point of the refrigerant. Open liquid line valves  
7 and 10 until refrigerant pressure equalizes.  
a. Use the Control Test Terminate Lockout to turn on  
water pumps and monitor pressures.  
b. Close pumpout unit/storage tank valves 2, 4, 5, 8, and  
10 and close chiller charging valve 7; open chiller iso-  
lation valves 11, 12, 13, and 14 (if present).  
c. Open pumpout unit/storage tank valves 3 and 6, open  
chiller valves 1a and 1b.  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
CONDITION  
C
C
C
59  
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2. Transfer remaining refrigerant.  
a. Close valve 5 and open valve 4.  
then shut off the pumpout compressor. Warm con-  
denser water will boil off any entrapped liquid refrig-  
erant and chiller pressure will rise.  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
e. When the pressure rises to 70 psig (483 kPa) [40 psig  
(276 kPa)], turn on the pumpout compressor until the  
pressure again reaches 65 psig (448 kPa) [30 psig  
(207 kPa)], and then turn off the compressor. Repeat  
this process until the pressure no longer rises, then  
turn on the pumpout compressor and pump out until  
the pressure reaches 18 in. Hg (40 kPa absolute).  
CONDITION  
C
C
C
b. Turn off the chiller water pumps through the LID.  
c. Turn off the pumpout condenser water, and turn on the  
pumpout compressor to push liquid out of the storage  
tank.  
d. Close liquid line valve 7.  
e. Turn off the pumpout compressor.  
f. Close valves 3 and 4.  
f. Close valves 1a, 1b, 3, 4, 6, and 7.  
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
g. Open valves 2 and 5.  
g. Turn off the pumpout condenser water and continue  
with the Control Test for Pumpdown, which will lock  
out the chiller compressor for operation.  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
CONDITION  
C
C
C
C
4. Establish vacuum for service.  
h. Turn on pumpout condenser water.  
a. In order to conserve refrigerant, operate the pump-  
out compressor until the chiller pressure is reduced to  
18 in. Hg vac, ref 30 in. bar. (40 kPa abs.) following  
Step 3e.  
i. Run the pumpout compressor until the storage tank  
pressure reaches 5 psig (34 kPa) (18 in. Hg [40 kPa  
absolute] if repairing the tank).  
j. Turn off the pumpout compressor.  
k. Close valves 1a, 1b, 2, 5, 6, and 10.  
Chillers with Isolation Valves  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
TRANSFER ALL REFRIGERANT TO CHILLER CON-  
DENSER VESSEL — For chillers with isolation valves, re-  
frigerant can be transferred from one chiller vessel to another  
without the need for an external storage tank and valve 7  
stays closed. See Fig. 27, 28, and 35 for valve locations.  
1. Push refrigerant into chiller condenser.  
a. Valve positions:  
CONDITION  
C
C
C
C
C
C
C
C
C
C
l. Turn off pumpout condenser water.  
TRANSFER THE REFRIGERANT FROM CHILLER TO  
STORAGE TANK  
1. Equalize refrigerant pressure.  
a. Valve positions:  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
CONDITION  
C
C
C
C
C
C
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
CONDITION  
C
C
C
C
C
C
b. Turn off chiller water pumps and pumpout unit con-  
denser water.  
c. Turn on pumpout compressor to push liquid out of the  
cooler/compressor.  
d. When all liquid has been pushed into the condenser,  
close cooler isolation valve 11.  
e. Access the Control Test, Pumpdown table on the LID  
display to turn on the chiller water pumps.  
b. Slowly open valve 5 and liquid line valves 7 and 10  
to allow liquid refrigerant to drain by gravity into the  
pumpout storage tank.  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
CONDITION  
C
C
C
2. Transfer the remaining liquid.  
f. Turn off the pumpout compressor.  
a. Turn off pumpout condenser water. Place valves in the  
following positions:  
2. Evacuate gas from cooler/compressor vessel.  
a. Close pumpout valves 2 and 5, and open valves 3  
and 4.  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11  
2
13 14  
CONDITION  
C
C
C
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
b. Run the pumpout compressor for approximately30 min-  
utes; then, close valve 10.  
CONDITION  
C
C
C
C
C
C
C
b. Turn on pumpout condenser water.  
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
c. Run pumpout until the compressor reaches 18 in. Hg  
vac (40 kPa abs.). Monitor pressures on the LID and  
on refrigerant gages.  
CONDITION  
C
C
C
C
c. Turn off the pumpout compressor.  
3. Remove any remaining refrigerant.  
d. Close valve 1a.  
e. Turn off pumpout compressor.  
f. Close valves 1b, 3, and 4.  
a. Turn on chiller water pumps using the Control Test  
Pumpdown.  
b. Turn on pumpout condenser water.  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
c. Place valves in the following positions:  
CONDITION  
C
C
C
C
C
C
C
C
C
C
C
VALVE  
1a 1b  
2
3
4
5
6
7
8
10 11 12 13 14  
g. Turn off pumpout condenser water.  
CONDITION  
C
C
C
C
h. Proceed to Pumpdown test on the LID to turn off chiller  
water pumps and lock out chiller compressor.  
d. Run the pumpout compressor until the chiller pres-  
sure reaches 65 psig (448 kPa) [30 psig (207 kPa)],  
60  
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TRANSFER ALL REFRIGERANT TO CHILLER  
COOLER/COMPRESSOR VESSEL  
GENERAL MAINTENANCE  
Refrigerant Properties — HCFC-22 or HFC-134a  
is the standard refrigerant in the 19XL. At normal atmo-  
spheric pressure, HCFC-22 will boil at –41 F (–40 C) and  
HFC-134a will boil at –14 F (–25 C) and must, therefore, be  
kept in pressurized containers or storage tanks. The refrig-  
erants are practically odorless when mixed with air. Both  
refrigerants are non-combustible at atmospheric pressure. Read  
the Material Safety Data Sheet and the latest ASHRAE Safety  
Guide for Mechanical Refrigeration to learn more about safe  
handling of these refrigerants.  
1. Push refrigerant into the chiller cooler vessel.  
a. Valve positions:  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
CONDITION  
C
C
C
C
C
C
b. Turn off chiller water pumps and pumpout condenser  
water.  
c. Turn on pumpout compressor to push refrigerant out  
of the condenser.  
d. When all liquid is out of the condenser, close cooler  
isolation valve 11.  
e. Turn off the pumpout compressor.  
2. Evacuate gas from the chiller condenser vessel.  
HCFC-22 and HFC-134a will dissolve oil and some  
non-metallic materials, dry the skin, and, in heavy con-  
centrations, may displace enough oxygen to cause  
asphyxiation. When handling this refrigerant, protect the  
hands and eyes and avoid breathing fumes.  
a. Access the Control Test Pumpdown table on the LID  
display to turn on the chiller water pumps.  
b. Close pumpout valves 3 and 4; open valves 2 and 5.  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
Adding Refrigerant — Follow the procedures de-  
scribed in Trimming Refrigerant Charge section, page 54.  
CONDITION  
C
C
C
C
C
C
C
c. Turn on pumpout condenser water.  
d. Run the pumpout compressor until the chiller com-  
pressor reaches 18 in. Hg vac (40 kPa abs.). Monitor  
pressure at the LID and refrigerant gages.  
e. Close valve 1b.  
f. Turn off pumpout compressor.  
g. Close valves 1a, 2, and 5.  
Always use the compressor Pumpdown function in the  
Control Test table to turn on the evaporator pump and  
lock out the compressor when transferring refrigerant.  
Liquid refrigerant may flash into a gas and cause pos-  
sible freeze-up when the chiller pressure is below  
65 psig (448 kPa) [30 psig (207 kPa)].  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
CONDITION  
C
C
C
C
C
C
C
C
C
C
C
Removing Refrigerant — If the optional pumpout unit  
is used, the 19XL refrigerant charge may be transferred to a  
pumpout storage tank or to the chiller condenser or cooler  
vessels. Follow procedures in the Pumpout and Refrigerant  
Transfer Procedures section when removing refrigerant from  
the pumpout storage tank to the chiller vessel.  
h. Turn off pumpout condenser water.  
i. Proceed to the Pumpdown test on the LID to turn off  
chiller water pumps and lockout chiller compressor.  
RETURN REFRIGERANT TO NORMAL OPERATING  
CONDITIONS  
1. Be sure that the chiller vessel that was opened has been  
evacuated.  
2. Access the Control Test Terminate Lockout table to view  
vessel pressures and turn on chiller water pumps.  
Adjusting the Refrigerant Charge — If the addi-  
tion or removal of refrigerant is required for improved chiller  
performance, follow the procedures given under the Trim  
Refrigerant Charge section, page 62.  
3. Open valves 1a, 1b, and 3.  
Refrigerant Leak Testing — Because HCFC-22 and  
HFC-134a are above atmospheric pressure at room tempera-  
ture, leak testing can be performed with refrigerant in the  
chiller. Use an electronic, halide leak detector, soap bubble  
solution, or ultra-sonic leak detector. Be sure that the room  
is well ventilated and free from concentration of refrigerant  
to keep false readings to a minimum. Before making any  
necessary repairs to a leak, transfer all refrigerant from the  
leaking vessel.  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
CONDITION  
C
C
C
C
C
C
C
C
4. Crack open valve 5, gradually increasing pressure in the  
evacuated vessel to 68 psig (469 kPa) [35 psig (141 kPa)].  
Feed refrigerant slowly to prevent tube freeze up.  
5. Leak test to ensure vessel integrity.  
6. Open valve 5 fully.  
Leak Rate — ASHRAE recommends that chillers should  
be immediately taken off line and repaired if the refrigerant  
leakage rate for the entire chiller is more than 10% of the  
operating refrigerant charge per year.  
Additionally, Carrier recommends that leaks totalling less  
than the above rate but more than a rate of 1 lb (0.5 kg)  
per year should be repaired during annual maintenance or  
whenever the refrigerant is pumped over for other service  
work.  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
CONDITION  
C
C
C
C
C
C
C
7. Open valve 11 to equalize the liquid refrigerant level  
between vessels.  
8. Close valves 1a, 1b, 3, and 5.  
9. Open isolation valves 11, 12, 13, and 14 (if present).  
VALVE  
1a 1b  
2
3
4
5
8
11 12 13 14  
CONDITION  
C
C
C
C
C
C
C
Test After Service, Repair, or Major Leak — If  
all refrigerant has been lost or if the chiller has been opened  
for service, the chiller or the affected vessels must be pres-  
sured and leak tested. Refer to the Leak Test Chiller section  
to perform a leak test.  
10. Proceed to Terminate Pumpdown Lockout test to turn  
off water pumps and enable the chiller compressor for  
start-up.  
61  
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HCFC-22 and HFC-134a should not be mixed with  
air or oxygen and pressurized for leak testing. In gen-  
eral, neither refrigerant should not be allowed to be pre-  
sent with high concentrations of air or oxygen above  
atmospheric pressures, as the mixture can undergo  
combustion.  
REFRIGERANT TRACER — Use an environmentally  
acceptable refrigerant as a tracer for leak test procedures.  
TO PRESSURIZE WITH DRY NITROGEN — Another  
method of leak testing is to pressurize with nitrogen only  
and use a soap bubble solution or an ultrasonic leak detector  
to determine if leaks are present. This should only be done  
if all refrigerant has been evacuated from the vessel.  
1. Connect a copper tube from the pressure regulator on the  
cylinder to the refrigerant charging valve. Never apply  
full cylinder pressure to the pressurizing line. Follow the  
listed sequence.  
2. Open the charging valve fully.  
3. Slowly open the cylinder regulating valve.  
4. Observe the pressure gage on the chiller and close the  
regulating valve when the pressure reaches test level. Do  
not exceed 140 psig (965 kPa).  
Fig. 36 — Guide Vane Actuator Linkage  
5. Close the charging valve on the chiller. Remove the cop-  
per tube if no longer required.  
Refrigerant may be added either through the storage tank  
or directly into the chiller as described in the Charge  
Refrigerant into Chiller section.  
To remove any excess refrigerant, follow the procedure in  
Transfer Refrigerant from Chiller to Storage Tank section,  
Steps 1a and b, page 60.  
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, and then dehydrate the chiller. Refer to the Standing  
Vacuum Test and Chiller Dehydration in the Before Initial  
Start-Up section, pages 43 and 47.  
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.  
Checking Guide Vane Linkage — When the chiller  
is off, the guide vanes are closed and the actuator mecha-  
nism is in the position shown in Fig. 36. If slack develops in  
the drive chain, backlash can be eliminated as follows:  
1. With the machine shut down and the actuator fully closed,  
remove the chain guard and loosen the actuator bracket  
holddown bolts.  
2. Loosen guide vane sprocket adjusting bolts.  
3. Pry bracket upwards to remove slack, then retighten the  
bracket holddown bolts.  
If the level goes below the lower sight glass, the oil  
reclaim system will need to be checked for proper operation.  
If additional oil is required, add it through the oil drain  
charging valve (Fig. 2A or Fig. 2B). A pump is required for  
adding oil against refrigerant pressure. The oil charge is  
approximately 8 gallons (30 L). The added oil must meet  
Carrier specifications for the 19XL. Refer to Changing Oil  
Filter and Oil Changes sections on page 63. Any additional  
oil that is added should be logged by noting the amount and  
date. Any oil that is added due to oil loss that is not related  
to service will eventually return to the sump. It must be  
removed when the level is high.  
A 1200-watt oil heater is controlled by the PIC to main-  
tain oil temperature (see the Controls section) when the  
compressor is off. The LID Status02 table displays whether  
the heater is energized or not. If the PIC shows that the heater  
is energized, but the sump is not heating up, the power to the  
oil heater may be off or the oil level may be too low. Check  
the oil level, the oil heater contactor voltage, and oil heater  
resistance.  
4. Retighten the guide vane sprocket adjusting bolts. Make  
sure that the guide vane shaft is rotated fully in the clock-  
wise direction in order for it to be fully closed.  
CHECKING THEAUXILIARY SWITCH ON GUIDE VANE  
ACTUATOR — The auxiliary switch used to activate the oil  
reclaim system solenoids should move to the OPEN posi-  
tion when the actuator is 70 degrees open. (At this point the  
guide vanes should be 30 degrees open.)  
Trim Refrigerant Charge — If it becomes necessary  
to adjust the refrigerant charge to obtain optimum chiller per-  
formance, operate the chiller at design load and then add or  
remove refrigerant slowly until the difference between leav-  
ing chilled water temperature and the cooler refrigerant tem-  
perature reaches design conditions or becomes a minimum.  
Do not overcharge.  
The PIC will not permit compressor start-up if the oil  
temperature is too low. The control will continue with start-up  
only after the temperature is within limits.  
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10. Remove the hose from the charging valve, open the iso-  
lation valves to the filter housing, and turn on the power  
to the pump and the motor.  
SCHEDULED MAINTENANCE  
Establish a regular maintenance schedule based on the  
actual chiller requirements such as chiller load, run hours,  
and water quality. The time intervals listed in this section are  
offered as guides to service only.  
Oil Specification — The 19XL compressor holds ap-  
proximately 11.7 gal. (44.3 L) of oil. If oil is added, it must  
meet the following Carrier specifications:  
Service Ontime — The LID will display a SERVICE  
ONTIME value on the Status01 table. This value should be  
reset to zero by the service person or the operator each time  
major service work is completed so that time between serv-  
ice can be viewed.  
• Oil type for HCFC-22 Chillers only . . . . . . . . . . . Alkyl-  
benzene-based synthetic compressor oil  
specifically formatted for use in  
HCFC-22 gear-driven machines  
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 86  
• Oil Type for units using R-134a . . . . . . . . . . . . Inhibited  
polyolester-based synthetic compressor  
oil formatted for use with HFC, gear-  
driven, hermetic compressors.  
Inspect the Control Center — Maintenance is lim-  
ited to general cleaning and tightening of connections. Vacuum  
the cabinet to eliminate dust build-up. In the event of chiller  
control malfunctions, refer to the Troubleshooting Guide sec-  
tion for control checks and adjustments.  
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 68  
The alkyl-benzene type oil (part number PP23BZ101) or  
the polyolester-based oil (part number PP23BZ103) may be  
ordered from your local Carrier representative.  
Be sure power to the control center is off when  
cleaning and tightening connections inside the control  
center.  
Oil Changes — Carrier recommends changing the oil  
after the first year of operation and every 3 years thereafter  
as a minimum in addition to a yearly oil analysis. However,  
if a continuous oil monitoring system is functioning and a  
yearly oil analysis is performed, time between oil changes  
can be extended.  
Check Safety and Operating Controls Monthly  
— To ensure chiller protection, the Control Test Automated  
Test should be done at least once per month. See  
Table 3 for safety control settings. See Table 7 for Control  
Test functions.  
TO CHANGE THE OIL  
1. Transfer the refrigerant into the condenser (for isolatable  
vessels) or a storage tank.  
2. Mark the existing oil level.  
3. Open the control and oil heater circuit breaker.  
4. When the chiller pressure is 5 psi (34 kPa) or less, drain  
the oil reservoir by opening the oil charging valve  
(Fig. 2A or Fig. 2B). Slowly open the valve against  
refrigerant pressure.  
5. Change the oil filter at this time. See Changing Oil Filter  
section.  
Changing Oil Filter — Change the oil filter on a yearly  
basis or when the chiller is opened for repairs. The 19XL  
has an isolatable oil filter so that the filter may be changed  
with the refrigerant remaining in the chiller. Use the follow-  
ing procedure:  
1. Make sure that the compressor is off, and the disconnect  
for the compressor is open.  
2. Disconnect the power to the oil pump.  
3. Close the oil filter isolation valves (Fig. 4).  
4. Connect an oil charging hose from the oil charging valve  
(Fig. 4), and place the other end in a clean container  
suitable for used oil. The oil drained from the filter hous-  
ing should be used as an oil sample to be sent to a labo-  
ratory for proper analysis. Do not contaminate this sample.  
5. Slowly open the charging valve to drain the oil from the  
housing.  
6. Change the refrigerant filter at this time; see the next sec-  
tion, Refrigerant Filter.  
7. Charge the chiller with oil. Charge until the oil level is  
equal to the oil level marked in Step 2. Turn on the  
power to the oil heater and let the PIC warm it up to at  
least 140 F (60 C). Operate the oil pump manually, through  
the Control Test, for 2 minutes. The oil level should be  
full in the lower sight glass for shutdown conditions. If  
1
the oil level is above ⁄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.  
The oil filter housing is at a high pressure. Relieve  
this pressure slowly.  
Refrigerant Filter — A refrigerant filter drier, located  
on the refrigerant cooling line to the motor (Fig. 2A or 2B),  
should be changed once a year, or more often if filter  
condition indicates a need for more frequent replacement.  
Change the filter with the chiller pressure at 0 psig (0 kPa)  
by transferring the refrigerant to the condenser vessel, (if iso-  
lation valves are present), or a storage tank. A moisture  
indicator sight glass is located beyond this filter to indicate  
the volume and moisture in the refrigerant. If the moisture  
indicator (dry-eye) indicates moisture, locate the source of  
water immediately by performing a thorough leak check.  
6. Once all oil has been drained, place some rags or ab-  
sorbent 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 fil-  
ter cover and tighten the 4 bolts.  
Oil Reclaim Filters — The oil reclaim system has a  
strainer on the eductor suction line and a filter on the cooler  
scavaging line. Replace these filters once per year, or more  
often if filter condition indicates a need for more frequent  
replacement. Change these filters by transferring the refrig-  
erant charge to a storage vessel or the condenser.  
9. Evacuate the filter housing by placing a vacuum pump  
on the charging valve. Follow the normal evacuation pro-  
cedures. Shut the charging valve when done, and recon-  
nect 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.  
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Inspect Refrigerant Float System — Perform  
inspection every 5 years or when the condenser is opened  
for service. Transfer the refrigerant into the cooler vessel or  
into a storage tank. Remove the float access cover. Clean the  
chamber and valve assembly thoroughly. Be sure that the  
valve moves freely. Make sure that all openings are free of  
obstructions. Examine the cover gasket and replace if nec-  
essary. See Fig. 37 for views of both float valve designs. On  
the linear float valve design, inspect orientation of the float  
slide pin. It must be pointed toward the bubbler tube for proper  
operation.  
Compressor Bearing and Gear Mainten-  
ance — 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 com-  
pressor 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 symp-  
tom appears, contact an experienced and responsible service  
organization for assistance.  
Inspect the Heat Exchanger Tubes  
COOLER — Inspect and clean the cooler tubes at the end of  
the first operating season. Because these tubes have internal  
ridges, a rotary-type tube cleaning system is necessary to fully  
clean the tubes. Upon inspection, the tube condition will  
determine the scheduled frequency for cleaning, and will  
indicate whether water treatment is adequate in the chilled  
water/brine circuit. Inspect the entering and leaving chilled  
water temperature sensors for signs of corrosion or scale.  
Replace the sensor if corroded or remove any scale if found.  
CONDENSER — Since this water circuit is usually an open-  
type system, the tubes may be subject to contamination and  
scale. Clean the condenser tubes with a rotary tube clean-  
ing system at least once per year, and more often if the water  
is contaminated. Inspect the entering and leaving condenser  
water sensors for signs of corrosion or scale. Replace the  
sensor if corroded or remove any scale if found.  
Higher than normal condenser pressures, together with the  
inability to reach full refrigeration load, usually indicate dirty  
tubes or air in the chiller. If the refrigeration log indicates a  
rise above normal condenser pressures, check the condenser  
refrigerant temperature against the leaving condenser water  
temperature. If this reading is more than what the design  
difference is supposed to be, then the condenser tubes may  
be dirty, or water flow may be incorrect. Because HCFC-22  
and HFC134-a are high-pressure refrigerants, air usually does  
not enter the chiller, rather, the refrigerant leaks out.  
During the tube cleaning process, use brushes especially  
designed to avoid scraping and scratching the tube wall. Con-  
tact your Carrier representative to obtain these brushes. Do  
not use wire brushes.  
Fig. 37 — 19XL Float Valve Designs  
Inspect Relief Valves and Piping — The relief valves  
on this chiller protect the system against the potentially dan-  
gerous effects of overpressure. To ensure against damage  
to the equipment and possible injury to personnel, these  
devices must be kept in peak operating condition.  
Hard scale may require chemical treatment for its pre-  
vention or removal. Consult a water treatment specialist  
for proper treatment.  
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.  
Water Leaks — Water is indicated during chiller opera-  
tion by the refrigerant moisture indicator (Fig. 2A or 2B) on  
the refrigerant motor cooling line. Water leaks should be re-  
paired immediately.  
2. If corrosion or foreign material is found, do not attempt  
to repair or recondition. Replace the valve.  
3. If the chiller is installed in a corrosive atmosphere or the  
relief valves are vented into a corrosive atmosphere, make  
valve inspections at more frequent intervals.  
Chiller must be dehydrated after repair of water leaks.  
See Chiller Dehydration section, page 47.  
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Oil should be visible in one of the compressor sight glasses  
both during operation and at shutdown. Always check the  
oil level before operating the compressor. Before adding or  
changing oil, relieve the refrigerant pressure as follows:  
Water Treatment — Untreated or improperly treated wa-  
ter may result in corrosion, scaling, erosion, or algae. The  
services of a qualified water treatment specialist should be  
obtained to develop and monitor a treatment program.  
1. Attach a pressure gage to the gage port of either com-  
pressor service valve (Fig. 35).  
2. Close the suction service valve and open the discharge  
line to the storage tank or the chiller.  
3. Operate the compressor until the crankcase pressure drops  
to 2 psig (13 kPa).  
4. Stop the compressor and isolate the system by closing  
the discharge service valve.  
Water must be within design flow limits, clean, and treated  
to ensure proper chiller performance and reduce the  
potential of tubing damage due to corrosion, scaling, ero-  
sion, and algae. Carrier assumes no responsibility for  
chiller damage resulting from untreated or improperly  
treated water.  
5. Slowly remove the oil return line connection (Fig. 35).  
Add oil as required.  
6. Replace the connection and reopen the compressor serv-  
ice valves.  
Inspect the Starting Equipment — Before work-  
ing on any starter, shut off the chiller, and open all discon-  
nects supplying power to the starter.  
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS  
(Fig. 38) — The optional pumpout system high-pressure switch  
should open at 220 ± 5 psig (1517 ± 34 kPa) and should  
reset automatically on pressure drop to 190 psig (1310 kPa)  
for HCFC-22 chillers. For chillers using HFC-134a, the  
switch opens at 161 psig (1110 kPa) and closes at 130 psig  
(896 kPa). Check the switch setting by operating the  
pumpout compressor and slowly throttling the pumpout  
condenser water.  
The disconnect on the starter front panel does not de-  
energize all internal circuits. Open all internal and re-  
mote 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 silver-  
plated contacts. Follow the starter manufacturer’s instruc-  
tions for contact replacement, lubrication, spare parts order-  
ing, 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, over-  
heating, malfunctioning, or failures.  
Check Pressure Transducers — Once a year, the  
pressure transducers should be checked against a pressure  
gage reading. Check all three transducers: oil pressure, con-  
denser pressure, cooler pressure.  
Note the evaporator and condenser pressure readings  
on the Status01 table on the LID. Attach an accurate set of  
refrigeration gages to the cooler and condenser Schrader  
fittings. Compare the two readings. If there is a difference in  
readings, the transducer can be calibrated, as described in  
the Troubleshooting Guide section.  
Fig. 38 — Optional Pumpout System  
Controls  
Optional Pumpout System Maintenance —  
For compressor maintenance details, refer to the 06D, 07D  
Installation, Start-Up, and Service Instructions.  
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.  
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —  
The pumpout compressor uses oil with the same specifi-  
cations as the centrifugal compressor oil. For more details  
on oil selection, see Oil Specification section, page 63.  
The total oil charge, 4.5 pints (2.6 L), consists of  
3.5 pints (2.0 L) for the compressor and one additional pint  
(0.6 L) for the oil separator.  
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at the sensor plugs. Check the sensor wire at the sensor for  
5 vdc if the control is powered.  
TROUBLESHOOTING GUIDE  
Overview — The PIC has many features to aid the  
operator and the technician in troubleshooting a 19XL  
chiller.  
Relieve all refrigerant pressure or drain the water prior  
to replacing the temperature sensors.  
• By using the LID display, the chiller actual operating con-  
ditions can be viewed while the unit is running.  
• When an alarm occurs, the default LID screen will freeze  
at the time of alarm. The freeze enables the operator to  
view the chiller conditions at the time of alarm. The Status  
tables will still show the current information. Once all alarms  
have been cleared, the default LID screens will return to  
normal operation.  
CHECK SENSOR ACCURACY — Place the sensor in a  
medium of a known temperature and compare that temper-  
ature to the measured reading. The thermometer used to  
determine the temperature of the medium should be of lab-  
oratory quality with 0.5° F (.25° C) graduations. The sensor  
in question should be accurate to within 2° F (1.2° C).  
• The Control Algorithm Status tables will display various  
screens of information in order to diagnose problems with  
chilled water temperature control, chilled water temper-  
ature control overrides, hot gas bypass, surge algorithm  
status, and time schedule operation.  
• The Control Test feature allows proper operation and test-  
ing of temperature sensors, pressure transducers, the guide  
vane actuator, oil pump, water pumps, tower control, and  
other on/off outputs while the compressor is stopped. It  
also has the ability to lock off the compressor and turn  
on water pumps for pumpout operation. The display will  
show the required temperatures and pressures during these  
operations.  
• Other Service menu tables can access configured items,  
such as chilled water resets, override set points, etc.  
• If an operating fault is detected, an alarm message is gen-  
erated and displayed on the LID default screen. A more  
detailed message — along with a diagnostic message —  
also is stored into the Alarm History table.  
See Fig. 8 for sensor locations. The sensors are immersed  
directly in the refrigerant or water circuits. The wiring at each  
sensor is easily disconnected by unlatching the connector.  
These connectors allow only one-way connection to the  
sensor. When installing a new sensor, apply a pipe sealant or  
thread sealant to the sensor threads.  
DUAL TEMPERATURE SENSORS — There are 2 sensors  
each on the bearing and motor temperature sensors for  
servicing convenience. In case one of the dual sensors is  
damaged, the other one can be used by moving a wire.  
The number 2 terminal in the sensor terminal box is the  
common line. To use the second sensor, move the wire from  
the number 1 position to the number 3 position.  
Checking Pressure Transducers — There are 3  
pressure transducers on the 19XL. These determine cooler,  
condenser, and oil pressure. The cooler and condenser trans-  
ducers also are used by the PIC to determine the refrigerant  
temperatures. All 3 can be calibrated if necessary. It is not  
usually necessary to calibrate at initial start-up. However, at  
high altitude locations, calibration of the transducer will be  
necessary to ensure the proper refrigerant temperature/  
pressure relationship. Each transducer is supplied with  
5 vdc power from a power supply. If the power supply fails,  
a transducer voltage reference alarm will occur. If the trans-  
ducer reading is suspected of being faulty, check the supply  
voltage. It should be 5 vdc ± .5 v. If the supply voltage is  
correct, the transducer should be recalibrated or replaced.  
Checking the Display Messages — The first area  
to check when troubleshooting the 19XL is the LID display.  
If the alarm light is flashing, check the primary and second-  
ary message lines on the LID default screen (Fig. 13). These  
messages will indicate where the fault is occurring. The Alarm  
History table on the LID Service menu will also carry an  
alarm message to further expand on this alarm. For a com-  
plete listing of messages, see Table 9. If the alarm light  
starts to flash while accessing a menu screen, depress  
IMPORTANT: Whenever the oil pressure or the cooler  
pressure transducer is calibrated, the other sensor should  
be calibrated to prevent problems with oil differential  
pressure readings.  
EXIT to return to the Default screen to read the failure  
message. The compressor will not run with an alarm con-  
dition existing, unless the alarm type is an unauthorized start  
or a failure to shut down.  
Calibration can be checked by comparing the pressure  
readings from the transducer against an accurate refrig-  
eration gage. These readings are all viewed or calibrated from  
the Status01 table on the LID. The transducer can be checked  
and calibrated at 2 pressure points. These calibration points  
are 0 psig (0 kPa) and between 240 and 260 psig (1655 to  
1793 kPa). To calibrate these transducers:  
Checking Temperature Sensors — All tempera-  
ture sensors are of the thermistor type. This means that the  
resistance of the sensor varies with temperature. All sensors  
have the same resistance characteristics. Determine sensor  
temperature by measuring voltage drop if the controls are  
powered, or resistance if the controls are powered off. Com-  
pare the readings to the values listed in Tables 10A or 10B.  
1. Shut down the compressor.  
2. Disconnect the transducer in question from its Schrader  
fitting.  
RESISTANCE CHECK — Turn off the control power and  
disconnect the terminal plug of the sensor in question from  
the module. Measure sensor resistance between recep-  
tacles designated by the wiring diagram with a digital ohm-  
meter. The resistance and corresponding temperature is listed  
in Tables 10A or 10B. Check the resistance of both wires to  
ground. This resistance should be infinite.  
NOTE: If the cooler or condenser vessels are at 0 psig  
(0 kPa) or are open to atmospheric pressure, the trans-  
ducers can be calibrated for zero without removing the  
transducer from the vessel.  
VOLTAGE DROP — Using a digital voltmeter, the voltage  
drop across any energized sensor can be measured while  
the control is energized. Tables 10A or 10B lists the relation-  
ship 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  
3. Access the Status01 table, and view the particular trans-  
ducer reading; it should read 0 psi (0 kPa). If the reading  
is not 0 psi (0 kPa), but within ± 5 psi (35 kPa), the value  
may be zeroed by pressing the SELECT softkey while  
the highlight bar is located on the transducer, and then by  
pressing the ENTER . The value will now go to zero.  
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If the transducer value is not within the calibration range,  
the transducer will return to the original reading. If  
the LID pressure value is within the allowed range (noted  
above), check the voltage ratio of the transducer. To ob-  
tain the voltage ratio, divide the voltage (dc) input from  
the transducer by the supply voltage signal, measured at  
the PSIO terminals J7-J34 and J7-J35. For example, the  
condenser transducer voltage input is measured at PSIO  
terminals J7-1 and J7-2. The voltage ratio must be be-  
tween 0.80 vdc and 0.11 vdc for the software to allow  
calibration. Pressurize the transducer until the ratio is within  
range. Then attempt calibration again.  
Control Algorithms Checkout Procedure — The  
Control Algorithm Status table is in the LID Service menu.  
The ControlAlgorithm Status table contains maintenance tables  
that may be viewed in order to see how the particular control  
algorithm is operating. The tables are:  
MAINT01  
Capacity  
Control  
This table shows all values that  
are used to calculate the chilled  
water/brine control point.  
MAINT02  
MAINT03  
Override  
Status  
Details of all chilled water control  
override values are viewed here.  
Surge/  
HGBP  
Status  
The surge and hot gas bypass  
control algorithm status is viewed  
from this screen. All values deal-  
ing with this control are displayed.  
4. A high pressure point can also be calibrated between  
240 and 260 psig (1655 and 1793 kPa) by attaching a  
regulated 250 psig (1724 kPa) pressure (usually from a  
nitrogen cylinder). The high pressure point can be cali-  
brated by accessing the transducer on the Status01 screen,  
MAINT04  
(PSIO  
LEAD/LAG This screen indicates LEAD/LAG  
Status  
operation status.  
Software  
Version 09  
and Higher)  
highlighting the transducer, pressing the SELECT soft-  
key, and then increasing or decreasing the value to the  
exact pressure on the refrigerant gage. Press ENTER  
to finish. High altitude locations must compensate the  
pressure so that the temperature/pressure relationship is  
correct.  
OCCDEFM  
Time  
The Local and CCN occupied  
Schedules schedules are displayed here in  
Status  
a manner that the operator can  
quickly determine whether the  
schedule is in the OCCUPIED  
mode or not.  
WSMDEFME Water  
System  
The water system manager is a  
CCN module which can turn on  
the chiller and change the chilled  
water control point. This screen  
indicates the status of this system.  
If the transducer reading returns to the previous value and  
the pressure is within the allowed range, check the volt-  
age ratio of the transducer. Refer to Step 3 above. The  
voltage ratio for this high pressure calibration must be  
between 0.585 and 0.634 vdc to allow calibration. Change  
the pressure at the transducer until the ratio is within the  
acceptable range. Then attempt calibrate to the new pres-  
sure input.  
Manager  
Status  
These maintenance tables are very useful in determining  
how the control temperature is calculated, the position of the  
guide vane, reaction from load changes, control point over-  
rides, hot gas bypass reaction, surge prevention, etc.  
The PIC will not allow calibration if the transducer is too  
far out of calibration. A new transducer must be installed  
and re-calibrated.  
Control Test — The Control Test feature can check all  
of the thermistor temperature sensors, including those on  
the Options modules, pressure transducers, pumps and their  
associated flow switches, the guide vane actuator, and other  
control outputs, such as hot gas bypass. The tests can help  
to determine whether a switch is defective, or a pump relay  
is not operating, among other useful troubleshooting tests.  
During pumpdown operations, the pumps are energized to  
prevent freeze-up and the vessel pressures and temperatures  
are displayed. The lockout feature will prevent start-up of  
the compressor when no refrigerant is present in the chiller,  
or if the vessels are isolated. The lockout is then terminated  
by the operator by using the Terminate Lockout function  
after the pumpdown procedure is reversed and refrigerant  
is added.  
TRANSDUCER REPLACEMENT — Since the transduc-  
ers are mounted on Schrader-type fittings, there is no need  
to remove refrigerant from the vessel. Disconnect the trans-  
ducer wiring by pulling up on the locking tab while pulling  
up on the weather-tight connecting plug from the end of the  
transducer. Do not pull on the transducer wires. Unscrew  
the transducer from the Schrader fitting. When installing a  
new transducer, do not use pipe sealer, which can plug the  
sensor. Put the plug connector back on the sensor and snap  
into place. Check for refrigerant leaks.  
Make sure to use a backup wrench on the Schrader fit-  
ting whenever removing a transducer.  
67  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides  
A. SHUTDOWN WITH ON/OFF/RESET-OFF  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
PROBABLE CAUSE/REMEDY  
PIC in OFF mode, press the CCN or local softkey  
to start unit.  
MANUALLY STOPPED — PRESS  
TERMINATE PUMPDOWN MODE  
SHUTDOWN IN PROGRESS  
CCN OR LOCAL TO START  
Enter the Control Test table and select Terminate  
Lockout to unlock compressor.  
TO SELECT CCN OR LOCAL  
COMPRESSOR UNLOADING  
Chiller unloading before shutdown due to Soft  
Stop feature.  
Chiller compressor is being commanded to stop.  
Water pumps are deenergized within one minute.  
SHUTDOWN IN PROGRESS  
ICE BUILD  
COMPRESSOR DEENERGIZED  
OPERATION COMPLETE  
Chiller shutdown from Ice Build operation.  
B. TIMING OUT OR TIMED OUT  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
PROBABLE CAUSE/REMEDY  
Time schedule for PIC is unoccupied. Chillers will  
start only when occupied.  
READY TO START IN XX MIN  
UNOCCUPIED MODE  
Remote contacts have stopped chiller. Close con-  
tacts to start.  
READY TO START IN XX MIN  
REMOTE CONTACTS OPEN  
Chiller START/STOP on Status01 manually forced  
to stop. Release value to start.  
READY TO START IN XX MIN  
READY TO START IN XX MIN  
STOP COMMAND IN EFFECT  
RECYCLE RESTART PENDING  
Chiller in recycle mode.  
Time schedule for PIC is UNOCCUPIED. Chiller  
will start when occupied. Make sure the time and  
date have been set on the Service menu.  
READY TO START  
UNOCCUPIED MODE  
Remote contacts have stopped chiller. Close con-  
tacts to start.  
READY TO START  
READY TO START  
REMOTE CONTACTS OPEN  
STOP COMMAND IN EFFECT  
Chiller START/STOP on Status01 manually forced  
to stop. Release value to start.  
READY TO START IN XX MIN  
READY TO START IN XX MIN  
READY TO START  
REMOTE CONTACTS CLOSED  
OCCUPIED MODE  
Chiller timer counting down unit. Ready for start.  
Chiller timer counting down unit. Ready for start.  
Chiller timers complete, unit start will commence.  
Chiller timers complete, unit start will commence.  
REMOTE CONTACTS CLOSED  
OCCUPIED MODE  
READY TO START  
CCN loadshed module commanding chiller to  
stop.  
STARTUP INHIBITED  
LOADSHED IN EFFECT  
Chiller START/STOP on Status01 has been  
manually forced to start. Chiller will start regard-  
less of time schedule or remote contact status.  
READY TO START IN XX MIN  
START COMMAND IN EFFECT  
LEGEND  
1CR AUX  
—
—
—
—
—
—
—
—
—
—
—
Compressor Start Contact  
Compressor Current  
Carrier Comfort Network  
Condenser Water Flow  
Chiller Start/Stop  
ECW  
ERT  
—
—
Entering Chilled Water  
Evaporator Refrigerant  
Temperature  
PSIO  
—
Processor Sensor  
Input/Output Module  
Rated Load Amps  
Compressor Run Contact  
Spare Protective Limit Input  
Starter Management  
Module  
CA  
P
RLA  
—
—
—
—
CCN  
RUN AUX  
SPR PL  
SMM  
EVFL  
GV TRG  
LID  
MTRB  
MTRW  
OILPD  
OILT  
—
—
—
—
—
—
—
—
Chilled Water Flow  
CDFL  
CHIL  
Target Guide Vane Position  
Local Interface Device  
Bearing Temperature  
Motor Winding Temperature  
Oil Pressure  
S
S
CHW  
CHWS  
CHWR  
CMPD  
CRP  
Chilled Water  
Chilled Water Supply  
Chiller Water Return  
Discharge Temperature  
Condenser Pressure  
Condenser Refrigerant  
Temperature  
STR FLT  
TXV  
—
—
Starter Fault  
Thermostatic Expansion  
Valve  
Line Voltage: Percent  
Voltage Reference  
Oil Sump Temperature  
Product Integrated Control  
V
V
P
REF  
—
—
PIC  
CRT  
68  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
C. IN RECYCLE SHUTDOWN  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
PROBABLE CAUSE/REMEDY  
Unit in recycle mode, chilled water temperature is not  
high enough to start.  
RECYCLE RESTART PENDING  
OCCUPIED MODE  
Unit in recycle mode, chilled water temperature is not  
high enough to start.  
RECYCLE RESTART PENDING  
RECYCLE RESTART PENDING  
RECYCLE RESTART PENDING  
REMOTE CONTACT CLOSED  
START COMMAND IN EFFECT  
ICE BUILD MODE  
Chiller START/STOP on Status01 manually forced to  
start, chilled water temperature is not high enough to  
start.  
Chiller in ICE BUILD mode. Chilled Water/Brine Tem-  
perature is satisfied for Ice Build Setpoint temperature.  
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  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Depress the RESET softkey if addi-  
tional start is required. Reassess  
start-up requirements.  
STARTS EXCESSIVE Compressor  
Starts (8 in 12 hours)  
STARTS LIMIT EXCEEDED  
Check motor cooling line for proper  
operation. Check for excessive  
starts within a short time span.  
MTRW [VALUE]* exceeded limit of  
[LIMIT]*. Check motor temperature.  
PRESTART ALERT  
PRESTART ALERT  
PRESTART ALERT  
HIGH MOTOR TEMPERATURE  
Check oil heater for proper opera-  
tion, check for low oil level, partially  
closed oil supply valves, etc. Check  
sensor accuracy.  
MTRB [VALUE]* exceeded limit of  
HIGH BEARING TEMPERATURE [LIMIT]*. Check thrust bearing  
temperature.  
Check sensor accuracy. Allow dis-  
charge temperature to cool. Check  
for excessive starts.  
CMPD [VALUE]* exceeded limit of  
HIGH DISCHARGE TEMP  
[LIMIT]*. Check discharge temperature.  
Check transducer accuracy. Check  
for low chilled water/brine supply  
temperature.  
ERT [VALUE]* exceeded limit of  
LOW REFRIGERANT TEMP  
PRESTART ALERT  
PRESTART ALERT  
[LIMIT]*. Check refrigerant temperature.  
OILT [VALUE]* exceeded limit of  
LOW OIL TEMPERATURE  
Check oil heater power, oil heater  
relay. Check oil level.  
[LIMIT]*. Check oil temperature.  
Check voltage supply. Check volt-  
age transformers. Consult power  
utility if voltage is low. Adjust voltage  
potentiometer in starter for SMM  
voltage input.  
V
P [VALUE]* exceeded limit of  
PRESTART ALERT  
LOW LINE VOLTAGE  
HIGH LINE VOLTAGE  
[LIMIT]*. Check voltage suppy.  
Check voltage supply. Check volt-  
age transformers. Consult power  
utility if voltage is low. Adjust voltage  
potentiometer in starter for SMM  
voltage input.  
V
P [VALUE]* exceeded limit of  
PRESTART ALERT  
PRESTART ALERT  
[LIMIT]*. Check voltage supply.  
CRP [VALUE]* exceeded limit of  
HIGH CONDENSER PRESSURE [LIMIT]*. Check condenser water and  
transducer.  
Check for high condenser water  
temperature. Check transducer  
accuracy.  
*[LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is  
the actual temperature, pressure, voltage, etc., at which the control tripped.  
E. NORMAL OR AUTO.-RESTART  
PRIMARY MESSAGE  
STARTUP IN PROGRESS  
STARTUP IN PROGRESS  
SECONDARY MESSAGE  
OCCUPIED MODE  
PROBABLE CAUSE/REMEDY  
Chiller starting. Time schedule is occupied.  
Chiller starting. Remote contacts are closed.  
REMOTE CONTACT CLOSED  
Chiller starting. Chiller START/STOP on Status01 manu-  
ally forced to start.  
STARTUP IN PROGRESS  
START COMMAND IN EFFECT  
AUTORESTART IN PROGRESS  
AUTORESTART IN PROGRESS  
OCCUPIED MODE  
Chiller starting. Time schedule is occupied.  
Chiller starting. Remote contacts are closed.  
REMOTE CONTACT CLOSED  
Chiller starting. Chiller START/STOP on Status01 manu-  
ally forced to start.  
AUTORESTART IN PROGRESS  
START COMMAND IN EFFECT  
NOTE: See Legend on page 68.  
69  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
F. START-UP FAILURES: This is an alarm condition. A manual reset is required to clear.  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Check for closed oil supply valves. Check  
oil filter. Check for low oil temperature.  
Check transducer accuracy.  
OILPD [VALUE] exceeded limit of  
[LIMIT]*. Check oil pump system.  
FAILURE TO START LOW OIL PRESSURE  
Check for excessive refrigerant in oil sump.  
Run oil pump manually for 5 minutes.  
Check transducer calibration. Check cooler  
pressure transducer calibration. Check  
wiring. Replace transducer if necessary.  
OILPD [VALUE] exceeded limit of  
[LIMIT]*. Check oil pressure sensor.  
FAILURE TO START OIL PRESS SENSOR FAULT  
LOW CHILLED WATER  
FLOW  
EVFL Evap Flow Fault: Check water  
pump/flow switch.  
Check wiring to flow switch. Check through  
Control Test for proper switch operation.  
FAILURE TO START  
LOW CONDENSER  
FAILURE TO START  
CDFL Cond. Flow Fault: Check water  
pump/flow switch.  
Check wiring to flow switch. Check through  
Control Test for proper switch operation.  
WATER FLOW  
A starter protective device has faulted.  
Check starter for ground fault, voltage trip,  
temperature trip, etc.  
STR FLT Starter Fault: Check Starter  
for Fault Source.  
FAILURE TO START STARTER FAULT  
STR FLT Starter Overload Trip:  
Check amps calibration/reset overload.  
FAILURE TO START STARTER OVERLOAD TRIP  
Reset overloads before restart.  
Check voltage supply. Check transformers  
for supply. Check with utility if voltage  
supply is erratic. Monitor must be installed  
to confirm consistent, single-cycle drop-  
outs. Check low oil pressure switch.  
V
P Single-Cycle Dropout Detected:  
FAILURE TO START LINE VOLTAGE DROPOUT  
Check voltage supply.  
Check the high-pressure switch. Check for  
proper condenser pressures and con-  
denser waterflow. Check for fouled tubes.  
Check the 2C aux contact and the oil  
pressure switch in the power panel. This  
alarm is not caused by the transducer.  
High Condenser Pressure [OPEN]*:  
Check switch, oil pressure contact, and  
water temperature/flow.  
HIGH CONDENSER  
FAILURE TO START  
PRESSURE  
Check water flow in condenser. Check for  
fouled tubes. Transducer should be  
checked for accuracy. This alarm is not  
caused by the high pressure switch.  
High Condenser Pressure [VALUE]*:  
Check switch, water flow, and  
transducer.  
Check that guide vanes are closed at  
start-up. Check starter for proper operation.  
Reduce unit pressure if possible.  
EXCESS ACCELERATION  
TIME  
CA P Excess Acceleration:  
Check guide vane closure at start-up.  
FAILURE TO START  
STARTER TRANSITION  
FAULT  
RUN AUX Starter Transition Fault:  
Check 1CR/1M/Interlock mechanism.  
Check starter for proper operation.  
Run contact failed to close.  
FAILURE TO START  
1CR AUX Starter Contact Fault:  
Check 1CR/1M aux. contacts.  
Check starter for proper operation.  
Start contact failed to close.  
FAILURE TO START 1CR AUX CONTACT FAULT  
FAILURE TO START MOTOR AMPS NOT SENSED  
Check for proper motor amps signal to  
SMM. Check wiring from SMM to current  
transformer. Check main motor circuit  
breaker for trip.  
CA P Motor Amps Not Sensed:  
Check motor load signal.  
Pressures at transducers indicate another  
refrigerant type in Control Test. Make sure  
to access the ATTACH TO NETWORK  
DEVICE table after changing refrigerant  
type.  
Current Refrigerant Properties  
Abnormal —  
Check Selection of refrigerant type  
CHECK REFRIGERANT  
TYPE  
FAILURE TO START  
The oil pressure differential switch is open  
when the compressor tried to START.  
Check the switch for proper operation.  
Also, check the oil pump interlock (2C aux)  
in the power panel and the high condenser  
pressure switch.  
Low Oil Pressure [LIMIT]*:  
Check oil pressure switch/pump  
and 2C aux.  
FAILURE TO START LOW OIL PRESSURE  
*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or  
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is  
open.  
NOTE: See Legend on page 68.  
70  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
G. COMPRESSOR JUMPSTART AND REFRIGERANT PROTECTION  
PRIMARY MESSAGE  
SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Compressor is running with more than  
10% RLA and control is trying to shut it  
down. Throw power off to compressor if  
unable to stop. Determine cause before  
repowering.  
UNAUTHORIZED  
OPERATION  
UNIT SHOULD BE  
STOPPED  
CA P Emergency: Compressor  
running without control authorization.  
Determine cause. If pumping refrigerant  
out of chiller, stop operation and go over  
pumpout procedures.  
EVAP PRESS/TEMP  
TOO LOW  
ERT Emergency: Freeze-up  
prevention.  
POTENTIAL FREEZE-UP  
FAILURE TO STOP  
Starter and run and start contacts are  
energized while control tried to shut  
down. Disconnect power to starter.  
RUN AUX Emergency: DISCON-  
NECT POWER.  
DISCONNECT POWER  
LOSS OF  
COMMUNCIATION  
Loss of Communication with Starter:  
Check chiller.  
Check wiring from PSIO to SMM. Check  
SMM module troubleshooting procedures.  
WITH STARTER  
STARTER CONTACT  
FAULT  
ABNORMAL 1CR OR  
RUN AUX  
1CR AUX Starter Contact Fault:  
Check 1CR/1M aux. contacts.  
Starter run and start contacts energized  
while chiller was off. Disconnect power.  
The condenser pressure transducer is  
reading a pressure that could freeze the  
water in the condenser tubes. Check for  
condenser refrigerant leaks, bad trans-  
ducers, or transferred refrigerant. Place  
the unit in Pumpdown mode to eliminate  
ALARM if vessel is evacuated.  
CRT [VALUE] exceeded limit of  
[LIMIT]* Emergency: Freeze-up  
prevention.  
COND PRESS/TEMP  
TOO LOW  
POTENTIAL FREEZE UP  
*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or  
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.  
H. NORMAL RUN WITH RESET, TEMPERATURE, OR DEMAND  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
4-20MA SIGNAL  
PROBABLE CAUSE/REMEDY  
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  
REMOTE SENSOR CONTROL  
CHW TEMP DIFFERENCE  
LEAVING CHILLED WATER  
ENTERING CHILLED WATER  
TEMPERATURE RAMP LOADING  
BY DEMAND RAMP LOADING  
BY LOCAL DEMAND SETPOINT  
BY 4-20MA SIGNAL  
Reset program active based upon Config table setup.  
Default method of temperature control.  
ECW control activated on Config table.  
Ramp loading in effect. Use Service1 table to modify.  
Ramp loading in effect. Use Service1 table to modify.  
Demand limit setpoint is Ͻ actual demand.  
BY CCN SIGNAL  
Demand limit is active based on Config table setup.  
BY LOADSHED/REDLINE  
Hot Gas Bypass is energized. See surge prevention  
in the control section.  
RUNNING — TEMP CONTROL  
HOT GAS BYPASS  
Active demand limit manually overridden or Status01  
table.  
RUNNING — DEMAND LIMITED  
RUNNING — TEMP CONTROL  
NOTE: See Legend on page 68.  
BY LOCAL SIGNAL  
ICE BUILD MODE  
Chiller is running under Ice Build temperature control.  
71  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
RUN CAPACITY  
LIMITED  
CRP [VALUE]* exceeded limit of  
[LIMIT]*. Condenser pressure override.  
HIGH CONDENSER PRESSURE  
RUN CAPACITY  
LIMITED  
MTRW [VALUE]* exceeded limit of  
[LIMIT]*. Motor temperature override.  
HIGH MOTOR TEMPERATURE  
LOW EVAP REFRIG TEMP  
HIGH COMPRESSOR LIFT  
MANUAL GUIDE VANE TARGET  
See Capacity Overrides, Table 4.  
Correct operating condition, modify  
setpoint, or release override.  
RUN CAPACITY  
LIMITED  
ERT [VALUE]* exceeded limit of  
[LIMIT]*. Check refrigerant charge level.  
RUN CAPACITY  
LIMITED  
Surge Prevention Override; lift too high  
for compressor.  
RUN CAPACITY  
LIMITED  
GV TRG Run Capacity Limited:  
Manual guide vane target.  
*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or  
alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped.  
J. OUT-OF-RANGE SENSOR FAILURES  
PRIMARY MESSAGE  
SENSOR FAULT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Sensor Fault: Check leaving CHW  
sensor.  
LEAVING CHW TEMPERATURE  
Sensor Fault: Check entering CHW  
sensor.  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
SENSOR FAULT  
ENTERING CHW TEMPERATURE  
CONDENSER PRESSURE  
EVAPORATOR PRESSURE  
BEARING TEMPERATURE  
MOTOR WINDING TEMP  
Sensor Fault: Check condenser  
pressure transducer.  
Sensor Fault: Check evaporator  
pressure transducer.  
See sensor test procedure and  
check sensors for proper operation  
and wiring.  
Sensor Fault: Check bearing  
temperature sensor.  
Sensor Fault: Check motor temperature  
sensor.  
Sensor Fault: Check discharge  
temperature sensor.  
DISCHARGE TEMPERATURE  
OIL SUMP TEMPERATURE  
OIL PRESSURE TRANSDUCER  
Sensor Fault: Check oil sump  
temperature sensor.  
Sensor Fault: Check oil pressure  
transducer.  
NOTE: See Legend on page 68.  
72  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
K. CHILLER PROTECT LIMIT FAULTS  
Excessive numbers of the same fault can lead to severe  
chiller damage. Seek service expertise.  
PRIMARY MESSAGE SECONDARY MESSAGE ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Check discharge temperature immediately. Check sen-  
sor for accuracy; check for proper condenser flow and  
temperature; check oil reservoir temperature. Check  
condenser for fouled tubes or air in chiller. Check for  
proper guide vane actuator operation.  
Check for proper amount of refrigerant charge; check  
for proper water flow and temperatures. Check for  
proper guide vane actuator operation.  
Check motor temperature immediately. Check sensor  
for accuracy. Check for proper condenser flow and  
temperature. Check motor cooling system for restric-  
tions. Check motor cooling solenoid for proper opera-  
tion. Check refrigerant filter.  
HIGH DISCHARGE  
TEMP  
CMPD [VALUE] exceeded limit of  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
[LIMIT]*. Check discharge temperature.  
LOW REFRIGERANT  
TEMP  
ERT [VALUE] exceeded limit of [LIMIT]*.  
Check evap pump and flow switch.  
MTRW [VALUE] exceeded limit of  
[LIMIT]*. Check motor cooling and  
solenoid.  
HIGH MOTOR  
TEMPERATURE  
Check for throttled oil supply isolation valves. Valves  
should be wide open. Check oil cooler thermal expan-  
sion valve. Check sensor accuracy. Check journal and  
thrust bearings. Check refrigerant filter. Check for ex-  
cessive oil sump level.  
HIGH BEARING  
TEMPERATURE  
MTRB [VALUE] exceeded limit of  
[LIMIT]*. Check oil cooling control.  
PROTECTIVE LIMIT  
Check power to oil pump and oil level. Check for dirty  
filters or oil foaming at start-up. Check for thermal  
overload cutout. Reduce ramp load rate if foaming  
noted.  
NOTE: This alarm is not related to pressure switch  
problems.  
OILPD [VALUE] exceeded limit of  
[LIMIT]*. Check oil pump and  
transducer.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
LOW OIL PRESSURE  
NO MOTOR CURRENT  
Check the oil pressure switch for proper operation.  
Check oil pump for proper pressure. Check for exces-  
sive refrigerant in oil system.  
Check wiring: Check torque setting on solid-state  
starter. Check for main circuit breaker trip. Check  
power supply to PSIO module.  
Low Oil Pressure [OPEN]*. Check oil  
pressure switch/pump and 2C aux.  
CA P Loss of Motor Current: Check  
sensor.  
V
P Power Loss: Check voltage  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
POWER LOSS  
supply.  
Check 24-vdc input sensor on the SMM; adjust potenti-  
ometer if necessary. Check transformers to SMM.  
Check power to PSIO module. Check distribution bus.  
Consult power company.  
V
P [VALUE] exceeded limit of  
LOW LINE VOLTAGE  
HIGH LINE VOLTAGE  
[LIMIT]*. Check voltage supply.  
V
P [VALUE] exceeded limit of  
[LIMIT]*. Check voltage supply.  
LOW CHILLED  
WATER FLOW  
LOW CONDENSER  
WATER FLOW  
EVFL Flow Fault: Check evap pump/flow  
switch.  
CDFL Flow Fault: Check cond pump/  
flow switch.  
Perform pumps Control Test and verify proper switch  
operation. Check all water valves and pump operation.  
Check the high-pressure switch. Check for proper con-  
denser pressures and condenser waterflow. Check for  
fouled tubes. Check the 2C aux. contact and the oil  
pressure switch in the power panel. This alarm is not  
caused by the transducer.  
High Cond Pressure [OPEN]*. Check  
switch, oil pressure contact, and water  
temp/flow.  
HIGH CONDENSER  
PRESSURE  
PROTECTIVE LIMIT  
Check water flow in condenser. Check for fouled  
tubes. Transducer should be checked for accuracy.  
This alarm is not caused by the high pressure switch.  
High Cond Pressure [VALUE]: Check  
switch, water flow, and transducer.  
1CR AUX CONTACT  
FAULT  
RUN AUX CONTACT  
FAULT  
1CR AUX Starter Contact Fault: Check 1CR auxiliary contact opened while chiller was run-  
1CR/1M aux contacts. ning. Check starter for proper operation.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
RUN AUX Starter Contact Fault Check Run auxiliary contact opened while chiller was running.  
1CR/1M aux contacts.  
Check starter for proper operation.  
CCN has signaled chiller to stop. Reset and restart  
when ready. If the signal was sent by the LID, release  
the Stop signal on STATUS01 table.  
Spare safety input has tripped or factory-installed  
jumper not present.  
CHIL  
S
S CCN Override Stop while  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
CCN OVERRIDE STOP  
in LOCAL run mode.  
SPARE SAFETY  
DEVICE  
SRP PL Spare Safety Fault: Check  
contacts.  
CA P [VALUE] exceeded limit of  
[LIMIT]*. High Amps; Check guide vane  
drive.  
EXCESSIVE MOTOR  
AMPS  
Check motor current for proper calibration. Check  
guide vane drive and actuator for proper operation.  
EXCESSIVE COMPR  
SURGE  
Compressor Surge: Check condenser  
water temp and flow.  
STR FLT Starter Fault: Check starter  
for fault source.  
Check condenser flow and temperatures. Check con-  
figuration of surge protection.  
Check starter for possible ground fault, reverse rota-  
tion, voltage trip, etc.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
STARTER FAULT  
Reset overloads and reset alarm. Check motor current  
calibration or overload calibration (do not field-calibrate  
overloads).  
STARTER OVERLOAD  
TRIP  
STR FLT Starter Overload Trip: Check  
amps calibration/reset overload.  
PROTECTIVE LIMIT  
PROTECTIVE LIMIT  
V
REF [VALUE] exceeded limit of  
TRANSDUCER  
VOLTAGE FAULT  
Check transformer power (5 vdc) supply to trans-  
ducers. Power must be 4.5 to 5.5 vdc.  
[LIMIT]*. Check transducer power  
supply.  
*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or alarm  
condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped. [OPEN] indicates that an input circuit is open.  
NOTE: See Legend on page 68.  
73  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
L. CHILLER ALERTS  
PRIMARY MESSAGE  
RECYCLE ALERT  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Check that guide vanes are closing.  
High Amps at Recycle: Check guide vane Check motor amps correction cali-  
drive.  
HIGH AMPS AT SHUTDOWN  
bration is correct. Check actuator for  
proper operation.  
LEAVING COND WATER  
TEMP  
Sensor Fault: Check leaving condenser  
water sensor.  
SENSOR FAULT ALERT  
SENSOR FAULT ALERT  
Check sensor. See sensor test  
procedure.  
ENTERING COND WATER  
TEMP  
Sensor Fault: Check entering condenser  
water sensor.  
LOW OIL PRESSURE  
ALERT  
Check oil filter. Check for improper  
oil level or temperature.  
CHECK OIL FILTER  
Low Oil Pressure Alert: Check oil  
AUTORESTART PENDING POWER LOSS  
V
V
P Power Loss: Check voltage supply.  
P [VALUE]* exceeded limit of  
AUTORESTART PENDING LOW LINE VOLTAGE  
Check power supply if there are ex-  
cessive compressor starts occurring.  
[LIMIT].* Check voltage supply.  
V
P [VALUE]* exceeded limit of  
AUTORESTART PENDING HIGH LINE VOLTAGE  
[LIMIT].* Check voltage supply.  
Discharge temperature exceeded  
the alert threshold. Check entering  
condenser water temperature.  
CMPD [VALUE]* exceeded limit of  
SENSOR ALERT  
SENSOR ALERT  
HIGH DISCHARGE TEMP  
[LIMIT].* Check discharge temperature.  
Thrust bearing temperature ex-  
ceeded the alert threshold. Check  
for closed valves, improper oil level  
or temperatures.  
MTRB [VALUE]* exceeded limit of  
[LIMIT]*. Check thrust bearing  
temperature.  
HIGH BEARING  
TEMPERATURE  
CRP High Condenser Pressure  
[LIMIT]*. Pump energized to reduce  
pressure.  
CONDENSER PRESSURE  
ALERT  
Check ambient conditions. Check  
condenser pressure for accuracy.  
PUMP RELAY ENERGIZED  
The chiller load is too small to keep  
the chiller on line and there have  
been more than 5 restarts in 4  
hours. Increase chiller load, adjust  
hot gas bypass, increase RECYCLE  
RESTART DELTA T.  
EXCESSIVE RECYCLE  
STARTS  
RECYCLE ALERT  
Excessive recycle starts.  
*[LIMIT] is shown on the LID as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or  
alarm condition. [VALUE] is the actual temperature, pressure, voltage, etc., at which the control tripped.  
M. SPARE SENSOR ALERT MESSAGES  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
ALARM MESSAGE/PRIMARY CAUSE  
ADDITIONAL CAUSE/REMEDY  
Sensor Fault:  
SPARE SENSOR ALERT COMMON CHWS SENSOR  
SPARE SENSOR ALERT COMMON CHWR SENSOR  
SPARE SENSOR ALERT REMOTE RESET SENSOR  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 1  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 2  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 3  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 4  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 5  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 6  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 7  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 8  
SPARE SENSOR ALERT TEMP SENSOR — SPARE 9  
NOTE: See Legend on page 68.  
Check common CHWS sensor.  
Sensor Fault:  
Check common CHWR sensor.  
Sensor Fault:  
Check remote reset temperature sensor.  
Sensor Fault:  
Check temperature sensor — Spare 1.  
Sensor Fault:  
Check temperature sensor — Spare 2.  
Sensor Fault:  
Check temperature sensor — Spare 3.  
Check alert temperature set points  
on Equipment Service, SERVICE2  
LID table. Check sensor for accu-  
racy if reading is not accurate.  
Sensor Fault:  
Check temperature sensor — Spare 4.  
Sensor Fault:  
Check temperature sensor — Spare 5.  
Sensor Fault:  
Check temperature sensor — Spare 6.  
Sensor Fault:  
Check temperature sensor — Spare 7.  
Sensor Fault:  
Check temperature sensor — Spare 8.  
Sensor Fault:  
Check temperature sensor — Spare 9.  
74  
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Table 9 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages  
with Troubleshooting Guides (cont)  
N. OTHER PROBLEMS/MALFUNCTIONS  
DESCRIPTION/MALFUNCTION  
PROBABLE CAUSE/REMEDY  
Chilled water set point set too high. Access set point on LID and verify.  
Capacity override or excessive cooling load (chiller at design capacity).  
Check LID status messages. Check for outside air infiltration into  
conditioned space.  
Condenser temperature too high. Check for proper flow, examine cooling  
tower operation, check for air or water leaks, check for fouled tubes.  
Refrigerant level low. Check for leaks, add refrigerant, and trim charge.  
Chilled Water/Brine Temperature  
Too High (Machine Running)  
Liquid bypass in waterbox. Examine division plates and gaskets for  
leaks.  
Guide vanes fail to open. Use Control Test to check operation.  
Chilled water control point too high. Access control algorithm status  
and check chilled water control operation.  
Guide vanes fail to open fully. Be sure that the guide vane target is  
released. Check guide vane linkage. Check limit switch in actuator.  
Check that sensor is in the proper terminals.  
Chilled water set point set too low. Access set point on LID and verify.  
Chilled water control point too low. Access control algorithm status and  
check chilled water control for proper resets.  
Chilled Water/Brine Temperature Too Low  
(Machine Running)  
High discharge temperature keeps guide vanes open.  
Guide vanes fail to close. Be sure that guide vane target is released.  
Check chilled water sensor accuracy. Check guide vane linkage. Check  
actuator operation.  
Deadband too narrow. Configure LID for a larger deadband.  
Proportional bands too narrow. Either INC or DEC proportional bands  
should be increased.  
Chilled Water Temperature Fluctuates.  
Vanes Hunt  
Loose guide vane drive. Adjust chain drive.  
Defective vane actuator. Check through Control Test.  
Defective temperature sensor. Check sensor accuracy.  
Low Oil Sump Temperature While Running  
(Less than 100 F [38 C])  
Check for proper oil level (not enough oil). Check for proper refrigerant  
level (too much refrigerant).  
Check for proper communications wiring on PSIO module. Check that  
the COMM1 communications wires from the LID are terminated to the  
COMM1 PSIO connection.  
At Power Up, Default Screen Does Not Appear,  
‘‘Tables Loading’’ Message Continually Appears  
Check that PSIO communication plugs are connected correctly. Check  
SMM communication plug. Check for proper SMM power supply. See  
Control Modules section on page 78.  
SMM Communications Failure  
High Oil Temperature While Running  
Blank LID Screen  
Check for proper oil level (too much oil). Check that TXV valve is  
operating properly.  
Increase contrast potentiometer. See Fig. 40. Check red LED on LID for  
proper operation, (power supply). If LED is blinking, but green LED’s are  
not, replace LID module, (memory failure)  
LID is not properly addressed to the PSIO. Make sure that ‘‘Attach to  
Network Device,’’ ‘‘Local Device’’ is set to read the PSIO address. Check  
LED’s on PSIO. Is red LED operating properly? Are green LED’s  
blinking? See control module troubleshooting section.  
‘‘Communications Failure’’ Highlighted Message  
At Bottom of LID Screen  
Press the ‘‘Stop’’ pushbutton. The PIC must be in the OFF mode for the  
controls test to operate. Clear all alarms. Check line voltage percent on  
Status01 screen. The percent must be within 90% to 110%. Check  
voltage input to SMM, calibrate starter voltage potentiometer for  
accuracy.  
Controls Test Disabled  
Low pressure alarm is active. Put chiller into pumpdown mode or  
equalize pressure. Check guide vane actuator wiring.  
Vanes Will Not Open In Control Test  
Oil Pump Does Not Run  
Check oil pump voltage supply. Cooler vessel pressure under vacuum.  
Pressurize vessel. Check temperature overload cutout switch.  
NOTE: See Legend on page 68.  
75  
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Table 10A — Thermistor Temperature (F) vs Resistance/Voltage Drop  
TEMPERATURE VOLTAGE RESISTANCE  
TEMPERATURE VOLTAGE RESISTANCE  
TEMPERATURE VOLTAGE RESISTANCE  
(F)  
DROP (V)  
(Ohms)  
(F)  
DROP (V)  
(Ohms)  
(F)  
DROP (V)  
(Ohms)  
−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
4.821  
4.818  
4.814  
4.806  
4.800  
4.793  
4.786  
4.779  
4.772  
4.764  
4.757  
4.749  
4.740  
4.734  
4.724  
4.715  
4.705  
4.696  
4.688  
4.676  
4.666  
4.657  
4.648  
4.636  
4.624  
4.613  
4.602  
4.592  
4.579  
4.567  
4.554  
4.540  
4.527  
4.514  
4.501  
4.487  
4.472  
4.457  
4.442  
4.427  
4.413  
4.397  
4.381  
4.366  
4.348  
4.330  
4.313  
4.295  
4.278  
4.258  
4.241  
4.223  
4.202  
4.184  
4.165  
4.145  
4.125  
4.103  
4.082  
4.059  
4.037  
4.017  
3.994  
3.968  
3.948  
3.927  
3.902  
3.878  
3.854  
3.828  
3.805  
3.781  
3.757  
3.729  
3.705  
3.679  
3.653  
3.627  
3.600  
3.575  
3.547  
3.520  
3.493  
3.464  
98,010  
94,707  
91,522  
88,449  
85,486  
82,627  
79,871  
77,212  
74,648  
72,175  
69,790  
67,490  
65,272  
63,133  
61,070  
59,081  
57,162  
55,311  
53,526  
51,804  
50,143  
48,541  
46,996  
45,505  
44,066  
42,679  
41,339  
40,047  
38,800  
37,596  
36,435  
35,313  
34,231  
33,185  
32,176  
31,202  
30,260  
29,351  
28,473  
27,624  
26,804  
26,011  
25,245  
24,505  
23,789  
23,096  
22,427  
21,779  
21,153  
20,547  
19,960  
19,393  
18,843  
18,311  
17,796  
17,297  
16,814  
16,346  
15,892  
15,453  
15,027  
14,614  
14,214  
13,826  
13,449  
13,084  
12,730  
12,387  
12,053  
11,730  
11,416  
11,112  
10,816  
10,529  
10,250  
9,979  
59  
60  
3.437  
3.409  
3.382  
3.353  
3.323  
3.295  
3.267  
3.238  
3.210  
3.181  
3.152  
3.123  
3.093  
3.064  
3.034  
3.005  
2.977  
2.947  
2.917  
2.884  
2.857  
2.827  
2.797  
2.766  
2.738  
2.708  
2.679  
2.650  
2.622  
2.593  
2.563  
2.533  
2.505  
2.476  
2.447  
2.417  
2.388  
2.360  
2.332  
2.305  
2.277  
2.251  
2.217  
2.189  
2.162  
2.136  
2.107  
2.080  
2.053  
2.028  
2.001  
1.973  
1.946  
1.919  
1.897  
1.870  
1.846  
1.822  
1.792  
1.771  
1.748  
1.724  
1.702  
1.676  
1.653  
1.630  
1.607  
1.585  
1.562  
1.538  
1.517  
1.496  
1.474  
1.453  
1.431  
1.408  
1.389  
1.369  
1.348  
1.327  
1.308  
1.291  
1.289  
1.269  
7,868  
7,665  
7,468  
7,277  
7,091  
6,911  
6,735  
6,564  
6,399  
6,238  
6,081  
5,929  
5,781  
5,637  
5,497  
5,361  
5,229  
5,101  
4,976  
4,855  
4,737  
4,622  
4,511  
4,403  
4,298  
4,196  
4,096  
4,000  
3,906  
3,814  
3,726  
3,640  
3,556  
3,474  
3,395  
3,318  
3,243  
3,170  
3,099  
3,031  
2,964  
2,898  
2,835  
2,773  
2,713  
2,655  
2,597  
2,542  
2,488  
2,436  
2,385  
2,335  
2,286  
2,239  
2,192  
2,147  
2,103  
2,060  
2,018  
1,977  
1,937  
1,898  
1,860  
1,822  
1,786  
1,750  
1,715  
1,680  
1,647  
1,614  
1,582  
1,550  
1,519  
1,489  
1,459  
1,430  
1,401  
1,373  
1,345  
1,318  
1,291  
1,265  
1,240  
1,214  
143  
144  
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  
1.250  
1.230  
1.211  
1.192  
1.173  
1.155  
1.136  
1.118  
1.100  
1.082  
1.064  
1.047  
1.029  
1.012  
0.995  
0.978  
0.962  
0.945  
0.929  
0.914  
0.898  
0.883  
0.868  
0.853  
0.838  
0.824  
0.810  
0.797  
0.783  
0.770  
0.758  
0.745  
0.734  
0.722  
0.710  
0.700  
0.689  
0.678  
0.668  
0.659  
0.649  
0.640  
0.632  
0.623  
0.615  
0.607  
0.600  
0.592  
0.585  
0.579  
0.572  
0.566  
0.560  
0.554  
0.548  
0.542  
0.537  
0.531  
0.526  
0.520  
0.515  
0.510  
0.505  
0.499  
0.494  
0.488  
0.483  
0.477  
0.471  
0.465  
0.459  
0.453  
0.446  
0.439  
0.432  
0.425  
0.417  
0.409  
0.401  
0.393  
0.384  
0.375  
0.366  
1,190  
1,165  
1,141  
1,118  
1,095  
1,072  
1,050  
1,029  
1,007  
986  
965  
945  
925  
906  
887  
868  
850  
832  
815  
798  
782  
765  
750  
734  
719  
705  
690  
677  
663  
650  
638  
626  
614  
602  
591  
581  
570  
561  
551  
542  
533  
524  
516  
508  
501  
494  
487  
480  
473  
467  
461  
456  
450  
445  
439  
434  
429  
424  
419  
415  
410  
405  
401  
396  
391  
386  
382  
377  
372  
367  
361  
356  
350  
344  
338  
332  
325  
318  
311  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
1
85  
2
86  
3
87  
4
88  
5
89  
6
90  
7
91  
8
92  
9
93  
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  
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  
9,717  
9,461  
9,213  
8,973  
304  
297  
289  
282  
8,739  
8,511  
8,291  
8,076  
76  
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Table 10B — Thermistor Temperature (C) vs Resistance/Voltage Drop  
TEMPERATURE VOLTAGE RESISTANCE  
TEMPERATURE VOLTAGE RESISTANCE  
TEMPERATURE VOLTAGE RESISTANCE  
(C)  
DROP (V)  
(Ohms)  
(C)  
DROP (V)  
(Ohms)  
(C)  
DROP (V)  
(Ohms)  
−40  
−39  
−38  
−37  
−36  
−35  
−34  
−33  
−32  
−31  
−30  
−29  
−28  
−27  
−26  
−25  
−24  
−23  
−22  
−21  
−20  
−19  
−18  
−17  
−16  
−15  
−14  
−13  
−12  
−11  
−10  
−9  
4.896  
4.889  
4.882  
4.874  
4.866  
4.857  
4.848  
4.838  
4.828  
4.817  
4.806  
4.794  
4.782  
4.769  
4.755  
4.740  
4.725  
4.710  
4.693  
4.676  
4.657  
4.639  
4.619  
4.598  
4.577  
4.554  
4.531  
4.507  
4.482  
4.456  
4.428  
4.400  
4.371  
4.341  
4.310  
4.278  
4.245  
4.211  
4.176  
4.140  
4.103  
4.065  
4.026  
3.986  
3.945  
3.903  
3.860  
3.816  
3.771  
3.726  
3.680  
3.633  
3.585  
3.537  
3.487  
3.438  
3.387  
3.337  
168 230  
157 440  
147 410  
138 090  
129 410  
121 330  
113 810  
106 880  
100 260  
94 165  
88 480  
83 170  
78 125  
73 580  
69 250  
65 205  
61 420  
57 875  
54 555  
51 450  
48 536  
45 807  
43 247  
40 845  
38 592  
38 476  
34 489  
32 621  
30 866  
29 216  
27 633  
26 202  
24 827  
23 532  
22 313  
21 163  
20 079  
19 058  
18 094  
17 184  
16 325  
15 515  
14 749  
14 026  
13 342  
12 696  
12 085  
11 506  
10 959  
10 441  
9 949  
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  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
3.285  
3.234  
3.181  
3.129  
3.076  
3.023  
2.970  
2.917  
2.864  
2.810  
2.757  
2.704  
2.651  
2.598  
2.545  
2.493  
2.441  
2.389  
2.337  
2.286  
2.236  
2.186  
2.137  
2.087  
2.039  
1.991  
1.944  
1.898  
1.852  
1.807  
1.763  
1.719  
1.677  
1.635  
1.594  
1.553  
1.513  
1.474  
1,436  
1.399  
1.363  
1.327  
1.291  
1.258  
1.225  
1.192  
1.160  
1.129  
1.099  
1.069  
1.040  
1.012  
0.984  
0.949  
0.920  
0.892  
0.865  
0.838  
6 840  
6 536  
6 246  
5 971  
5 710  
5 461  
5 225  
5 000  
4 786  
4 583  
4 389  
4 204  
4 028  
3 861  
3 701  
3 549  
3 404  
3 266  
3 134  
3 008  
2 888  
2 773  
2 663  
2 559  
2 459  
2 363  
2 272  
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  
76  
77  
0.813  
0.789  
0.765  
0.743  
0.722  
0.702  
0.683  
0.665  
0.648  
0.632  
0.617  
0.603  
0.590  
0.577  
0.566  
0.555  
0.545  
0.535  
0.525  
0.515  
0.506  
0.496  
0.486  
0.476  
0.466  
0.454  
0.442  
0.429  
0.416  
0.401  
0.386  
0.370  
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  
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  
−8  
−7  
−6  
−5  
−4  
−3  
−2  
−1  
0
1
2
3
4
5
6
7
8
9
10  
938  
11  
9 485  
906  
12  
9 044  
876  
13  
8 627  
836  
14  
8 231  
805  
15  
7 855  
775  
16  
7 499  
747  
17  
7 161  
719  
77  
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red LED is normal, check the module address switches  
(Fig. 39-43). Proper addresses are:  
Control Modules  
ADDRESS  
MODULE  
Turn controller power off before servicing controls. This  
ensures safety and prevents damage to controller.  
S1  
S2  
SMM (Starter Management Module)  
8-input Options Module 1  
3
6
7
2
4
2
8-input Options Module 2  
The Processor module (PSIO), 8-input (Options) mod-  
ules, Starter Management Module (SMM), and the Local  
Interface Device (LID) module perform continuous di-  
agnostic evaluations of the hardware to determine its con-  
dition. See Fig. 39-43. Proper operation of all modules is  
indicated by LEDs (light-emitting diodes) located on the  
side of the LID, and on the top horizontal surface of the  
PSIO, SMM, and 8-input modules.  
If all modules indicate communications failure, check com-  
munications plug on the PSIO module for proper seating.  
Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk;  
Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connec-  
tion is assured and the condition persists, replace the PSIO  
module.  
If only one 8-input module or SMM indicates commu-  
nication failure, check the communications plug on that  
module. If a good connection is assured and the condi-  
tion persists, replace the module.  
All system operating intelligence rests in the PSIO mod-  
ule. Some safety shutdown logic resides in the SMM in  
case communications are lost between the 2 modules. The  
PSIO monitors conditions using input ports on the PSIO,  
the SMM, and the 8-input modules. Outputs are con-  
trolled by the PSIO and SMM as well.  
RED LED — If the LED is blinking continuously at a  
2-second rate, it is indicating proper operation. If it is lit  
continuously it indicates a problem requiring replacement  
of the module. Off continuously indicates that the power  
should be checked. If the red LED blinks 3 times per sec-  
ond, a software error has been discovered and the module  
must be replaced. If there is no input power, check fuses and  
the circuit breaker. If fuse is good, check for shorted sec-  
ondary of transformer, or if power is present to the module,  
replace the module.  
3. Power is supplied to modules within the control panel via  
21-vac power sources.  
GREEN LEDs — There are one or 2 green LEDs on each  
type of module. These LEDs indicate communication status  
between different parts of the controller and the network mod-  
ules as follows:  
The transformers are located within the power panel, with  
the exception of the SMM, which operates from a  
24-vac power source and has its own 24-vac transformer  
located within the starter.  
LID Module  
Within the power panel, T1 supplies power to the LID,  
the PSIO, and the 5-vac power supply for the transduc-  
ers. The other 21-vac transformer is T4, which supplies  
power to both 8-input modules (if present). T4 is capable  
of supplying power to two modules; if additional mod-  
ules are added, another power supply will be required.  
Upper LED — Communication with CCN network, if present;  
blinks when communication occurs.  
Lower LED — Communication with PSIO module; must  
blink every 5 to 8 seconds when the LID default screen is  
displayed.  
Power is connected to Terminals 1 and 2 of the power  
input connection on each module.  
PSIO Module  
Green LED Closest to Communications Connection — Com-  
munication with SMM and 8-input module; must blink  
continuously.  
Other Green LED — Communication with LID; must blink  
every 3 to 5 seconds.  
8-Input Modules and SMM  
Green LED — Communication with PSIO module; will blink  
continuously.  
Notes on Module Operation  
1. The chiller operator monitors and modifies configura-  
tions in the microprocessor through the 4 softkeys and  
the LID. Communication with the LID and the PSIO is  
accomplished through the CCN bus. The communication  
between the PSIO, SMM, and both 8-input modules is  
accomplished through the sensor bus, which is a 3-wire  
cable.  
On sensor bus terminal strips, Terminal 1 of PSIO mod-  
ule is connected to Terminal 1 of each of the other  
modules. Terminals 2 and 3 are connected in the same  
manner. See Fig. 39-43. If a Terminal 2 wire is connected  
to Terminal 1, the system does not work.  
2. If a green LED is solid on, check communication wiring.  
If a green LED is off, check the red LED operation. If the  
Fig. 39 — PSIO Module Address Selector Switch  
Locations and LED Locations  
78  
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Starter Management Module (SMM) (Fig. 42)  
INPUTS — Inputs on strips J2 and J3 are a mix of analog  
and discrete (on/off) inputs. Application of the chiller de-  
termines which terminals are used. Always refer to the  
individual unit wiring diagram for terminal numbers.  
OUTPUTS — Outputs are 24 vdc and wired to strip J1. There  
are 2 terminals used per output.  
NOTE: Address switches on this module can be at any position.  
Addresses are only changed through the LID screen or CCN.  
Fig. 40 — LID Module (Rear View) and  
LED Locations  
Processor Module (PSIO) (Fig. 41)  
INPUTS — Each input channel has 3 terminals; only 2 of  
the terminals are used. Application of chiller determines which  
terminals are normally used. Always refer to individual unit  
wiring for terminal numbers.  
OUTPUTS — Output is 20 vdc. There are 3 terminals per  
output, only 2 of which are used, depending on the appli-  
cation. Refer to the unit wiring diagram.  
NOTE: SMM address switches should be set as follows:  
S1 set at 3; S2 set at 2.  
Fig. 42 — Starter Management Module  
(SMM)  
Options Modules (8-Input) — The options modules  
are optional additions to the PIC, and are used to add tem-  
perature reset inputs, spare sensor inputs, and demand limit  
inputs. Each option module contains 8 inputs, each input meant  
for a specific duty. See the wiring diagram for exact module  
wire terminations. Inputs for each of the options modules  
available include the following:  
OPTIONS MODULE 1  
4 to 20 mA Auto. Demand Reset  
4 to 20 mA Auto. Chilled Water Reset  
Common Chilled Water Supply Temperature  
Common Chilled Water Return Temperature  
Remote Temperature Reset Sensor  
Spare Temperature 1  
Spare Temperature 2  
Spare Temperature 3  
OPTIONS MODULE 2  
4 to 20 mA Spare 1  
4 to 20 mA Spare 2  
Spare Temperature 4  
Spare Temperature 5  
Spare Temperature 6  
Spare Temperature 7  
Spare Temperature 8  
Spare Temperature 9  
NOTE: Address switches on this module can be at any position.  
Addresses are only changed through the LID screen or CCN.  
Fig. 41 — Processor (PSIO) Module  
79  
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Terminal block connections are provided on the options  
modules. All sensor inputs are field wired and installed.  
Options module number 1 can be factory or field-installed.  
Options module 2 is shipped separately and must be field  
installed. For installation, refer to the unit or field wiring  
diagrams. Be sure to address the module for the proper mod-  
ule number (Fig. 43) and to configure the chiller for each  
feature being used.  
INSTALLATION  
1. Verify that the existing PSIO module is defective by us-  
ing the procedure described in the Troubleshooting Guide  
section, page 66, and Control Modules section, page 78.  
Do not select the Attach to Network Device table if the  
LID displays communication failure.  
2. Data regarding the PSIO configuration should have been  
recorded and saved. This data will have to be recon-  
figured into the LID. If this data is not available, follow  
the procedures described in the Set Up Chiller Control  
Configuration section.  
If a CCN Building Supervisor or Service Tool is present,  
the module configuration should have already been  
uploaded into memory; then, when the new module is  
installed, the configuration can be downloaded from the  
computer.  
Any communication wires from other chillers or CCN  
modules should be disconnected to prevent the new PSIO  
module from uploading incorrect run hours into memory.  
3. To install this module, first record the TOTAL COM-  
PRESSOR STARTS and the COMPRESSOR ONTIME  
from the Status01 table screen on the LID.  
4. Power off the controls.  
5. Remove the old PSIO. DO NOT install the new PSIO at  
this time.  
6. Turn on the control power. When the LID screen re-  
appears, press the MENU softkey, then press the  
SERVICE softkey. Enter the password, if applicable.  
Move the highlight bar down to the ATTACH TO NET-  
WORK DEVICE line. Press the SELECT softkey.  
Now, press the ATTACH softkey. The LID will dis-  
play ‘‘UPLOADING TABLES, PLEASE WAIT’’ and  
then display ‘‘COMMUNICATIONS FAILURE.’’Press  
the EXIT softkey.  
7. Turn the control power off.  
8. Install the new PSIO module. Turn the control power  
back on.  
9. The LID will now automatically upload the new PSIO  
module.  
SWITCH  
SETTING  
OPTIONS  
OPTIONS  
MODULE 1  
MODULE 2  
S1  
S2  
6
4
7
2
Fig. 43 — Options Module  
10. Access the Status01 table and move the highlight bar  
down to the TOTAL COMPRESSOR STARTS line. Press  
the SELECT softkey. Increase the value to indicate  
the correct starts value recorded in Step 2. Press the  
ENTER softkey when you reach the correct value. Now,  
move the highlight bar to the COMPRESSOR ON-  
TIME line. Press the SELECT softkey. Increase the run  
hours value to the value recorded in Step 2. Press the  
ENTER softkey when the correct value is reached.  
Replacing Defective Processor Modules — The  
replacement part number is printed in a small label on front  
of the PSIO module. The model and serial numbers are printed  
on the unit nameplate located on an exterior corner post.  
The proper software is factory-installed by Carrier in the  
replacement module. When ordering a replacement proces-  
sor module (PSIO), specify complete replacement part  
number, full unit model number, and serial number. This new  
unit requires reconfiguration to the original chiller data by  
the installer. Follow the procedures described in the Set Up  
Chiller Control Configuration section on page 50.  
11. Complete the PSIO installation. Following the instruc-  
tions in the Start-up, Operation, and Maintenance manual,  
input all the proper configurations such as time, date,  
etc. Re-calibrate the motor amps and check the pres-  
sure transducer calibrations. PSIO installation is now  
complete.  
Electrical shock can cause personal injury. Disconnect  
all electrical power before servicing.  
80  
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Solid-State Starters — Troubleshooting guides and in-  
formation pertaining to the operation of the solid-state starter  
may be found in Fig. 44-46 and Table 11.  
Attempt to solve the problem by using the following  
preliminary checks before consulting the troubleshooting  
table.  
When the power is off:  
• Inspect for physical damage and signs of arcing, overheat-  
ing, etc.  
• Is the wiring to the starter correct?  
• Are all connections in the starter tight?  
• Is the current feedback resistor properly adjusted and  
installed?  
• Is a heater coil installed in each leg of the motor?  
• Is the control transformer fuse blown?  
• Is the motor connected to the starter?  
TESTING SILICON CONTROL RECTIFIERS IN  
BENSHAW, INC. SOLID-STATE STARTERS — If a sili-  
con control rectifier (SCR) is suspected of being defective,  
use the following procedure as part of a general trouble-  
shooting guide.  
LEGEND  
SCR  
—
Silicon Control Rectifier  
Fig. 44 — Typical Benshaw, Inc. Solid-State  
Starter (internal View)  
IMPORTANT: Before performing the SCR check be-  
low, remove power from the starter and disconnect the  
motor terminals T1, T2, and T3.  
Resistance should normally be between 8 and 20 ohms  
average. Excessively high or low resistance may be  
indicative of a defective logic card. Replace and retest.  
1. Connect ohmmeter across terminals L1 and T1. Resis-  
tance reading should be greater than 50,000 ohms.  
2. If reading is less than 50,000 ohms, remove connecting  
bus heatsink between SCR3 and SCR6 and check anode  
to cathode of SCR3 and SCR6 separately to determine  
which device is defective. See Fig. 44. Replace defective  
device and retest controller.  
6. Repeat Step 5 for SCR leads 2 through 6. Care should  
be taken to ensure that the gate and cathode wires are  
replaced exactly as they were: white wire to gate  
(G1 through G6); red wire to cathode (K1 through K6).  
Damage to the starter may result if wires are  
reversed.  
3. Repeat Steps 1 and 2 across terminals L2 and T2 for SCRs  
2 and 5.  
4. Repeat Steps 1 and 2 across terminals L3 and T3 for SCRs  
1 and 4.  
If the problem is still not resolved, consult the starter manu-  
facturer for servicing.  
If the SCRs tested were not defective but the problem  
still persists, refer to the following Steps 5 and 6.  
5. Disconnect the SCR1 from the white gate and red cath-  
ode wires on the AK control logic card. With an ohm-  
meter set on Rx1, check between white and red wires.  
81  
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LEGEND  
SCR  
—
Silicon Control Rectifier  
*See test procedure described in Testing SCRs in Solid-State Starters section on page 81.  
Fig. 45 — Solid-State Starter, General Operation Troubleshooting Guide (Typical)  
82  
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Fig. 46 — Solid-State Starter, Starter Fault (Motor Will Not Start)  
Troubleshooting Guide (Typical)  
83  
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Table 11 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide  
PROBLEM  
PROBABLE CAUSES  
AREA OF CORRECTION  
AK board phase correct not  
on.  
1. L1 and L3 switch phases  
reversed.  
1. Switch incoming phases L1 and L3 at top of CD1 or CB1.  
2. Missing phase voltage.  
3. Improper line voltage.  
2. Check for missing phase voltage.  
3. Verify proper line voltage applied against synchronizing transformer  
voltage.  
AK board relay not on.  
Ribbon cable not properly  
seated.  
Check ribbon cable for proper seating. Replace board if necessary.  
AK board power  
+15 vdc not on.  
1. Improper line voltage.  
1. Make sure proper line voltage is present at primary synchronizing  
transformer.  
2. Transformer malfunction.  
2. Check synchronizing transformer secondary voltage as follows: On  
the BC board, measure from TB11-1 to TB11-2 and TB11-1 to  
TB11-3. Both readings should be within 30 to 36 vac. On the BC  
board, measure from TB11-1 to TB11-4 and TB11-2 to TB11-4. Both  
readings should be within 18 to 24 vac. Replace synchronizing  
transformer if voltages are not within the specified tolerances.  
1L boards LEDs not on.  
1. A short exists between line  
and load terminals.  
1. Remove power and check resistance with ohmmeter.  
Locate and remove stray wire strands if required.  
2. An SCR is shorted in the  
phase assembly.  
2. Remove power. Use ohmmeter to measure the resistance or each  
SCR phase assembly from anode to cathode. The reading should  
be 50,000 ohm or greater. If not, replace phase assembly.  
BC board over-temperature  
LED (L3) on prior to run  
command.  
1. Temperature switch not  
functioning properly.  
1. Disconnect power and check for continuity between TB11-10 and  
TB11-11. If no continuity exists, the overtemperature switch is not  
functioning properly. Replace defective switch if necessary.  
2. BC board not functioning  
properly.  
2. Make sure BC board is functioning properly. Replace board if  
necessary.  
BC board LEDs on prior to run BC board not functioning  
Board not functioning properly. Replace board, if necessary.  
command.  
properly.  
BC board LEDs not on after  
run command but before  
starter reaches full voltage.  
1. Phase assembly malfunction. 1. Remove power and check SCRs. Ohmmeter reading of each SCR  
gate to cathode resistance at terminals is 8 to 20 ohm. If not,  
replace the phase assembly.  
2. BC board not functioning  
properly.  
2. Replace board, if necessary.  
1L board LEDs remain on after Imbalance between phases  
Check for loose SCR gate lead or open SCR gate. Replace phase  
starter reaches full voltage.  
exists in motor terminal voltages. assembly, if necessary.  
BC board run LED (L5) not lit. BC board not functioning  
Measure 24 vdc at TB11-8 to TB11-4. If voltage is present, replace  
board. If not present, replace relay 1CR.  
properly.  
AK board power applied, run  
AK board not functioning  
Replace board.  
command given, starter at full properly.  
voltage, but aux LED not lit.  
1L boards LEDs lit.  
Motor terminal voltage phase  
imbalance exists.  
Check motor terminal voltages for imbalance between phases. If an  
imbalance exists, check for loose SCR gate or open SCR gate.  
Replace phase assembly, if necessary.  
BC board LED L4 and L5  
not lit.  
BC board not functioning  
properly.  
Replace board.  
BC board LED L3 lit.  
1. FU5 and FU6 fuses not  
functioning properly.  
1. Check fuses FU5 and FU6. Replace if necessary.  
2. Phase assembly not  
functioning properly.  
2. Verify that bypass is pulling in by measuring the voltage drop  
across the contacts. The reading should be 50 mV or less.  
Replace phase assembly, if necessary.  
3. Fan not functioning properly.  
3. Verify fan operation on each phase for 200 amp units. Replace  
fan, if necessary.  
BC board L2 lit.  
SCR phases not functioning  
properly.  
Measure resistance from anode to cathode for each SCR phase  
assembly. Replace shorted phase, if necessary.  
BC board L1 lit.  
Motor lead grounded.  
Megger motor to test for motor lead going to ground.  
Start command given.  
Motor does not begin rotation.  
Turn ‘Starting Torque’ potentiometer RV2 clockwise until motor  
rotation begins.  
Motor does not reach full  
speed within 25 seconds.  
Ramp up setting is not correct.  
Turn ‘Ramp’ potentiometer RV1 counterclockwise. Restart motor  
and verify that motor reaches full speed within 25 seconds.  
115 vac missing from LL1  
and LL2.  
1. CB2 is not on.  
1. Verify CB2 is on.  
2. Fuse no. 4 (FU4) blown.  
1. CB4 is not on.  
2. Check FU4 for continuity. Replace, if necessary.  
1. Verify CB4 is on.  
SMM not responding.  
2. Potentiometer RV1 needs  
adjustment.  
2. Adjust potentiometer RV1 for 24 vac at SMM terminals J3-23 and  
J3-24.  
LEGEND  
AK  
—
—
—
—
—
—
—
Vendor Board Designation  
L1, L3  
LL1, LL2  
RV1  
—
—
—
—
—
—
Terminal Board  
BC  
CB  
CD  
CR  
FU  
Vendor Board Designation  
Circuit Breaker  
Control Power Terminals  
Line Voltage Signal Calibration  
Silicon Control Rectifier  
Starter Management Module  
Terminal Board  
Disconnect Switch  
Control Relay  
SCR  
SMM  
TB  
Fuse  
LED  
Light-Emitting Diode  
84  
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clearances, physical and electrical data, and wiring sche-  
matics for operator convenience during troubleshooting.  
Physical Data — Tables 12-17 and Fig. 47-51 pro-  
vide additional information regarding compressor fits and  
Table 12 — Heat Exchanger Data  
COOLER  
RIGGING WEIGHTS  
Dry Wt.  
Design II  
VESSEL CHARGE  
Refrigerant  
Design II  
HCFC-22 HFC-134a  
HEAT  
EXCHANGER  
CODE  
NUMBER  
Volume  
VESSEL  
Design I  
HCFC-22  
OF TUBES  
of Water  
Design I  
Lb Kg  
Lb  
Kg  
Lb  
1020  
1090  
1150  
1200  
1450  
1500  
1580  
1650  
—
Kg  
Lb  
Kg  
341  
363  
408  
454  
522  
568  
636  
681  
640  
776  
913  
1003  
Lb  
550  
Kg  
Gal  
L
40  
41  
42  
43  
50  
51  
52  
53  
55  
56  
57  
58  
201  
227  
257  
290  
314  
355  
400  
445  
201  
227  
257  
290  
5000  
5150  
5325  
5500  
6625  
6850  
7100  
7375  
—
2275  
2350  
2425  
2500  
3000  
3100  
3225  
3350  
—
5340  
5485  
5655  
5845  
7020  
7255  
7510  
7770  
8510  
8845  
9205  
9575  
2422  
2488  
2565  
2651  
3184  
3291  
3406  
3524  
3860  
4012  
4175  
4343  
463  
494  
522  
544  
658  
680  
717  
748  
—
750  
250  
272  
295  
318  
341  
386  
431  
454  
481  
527  
572  
640  
53  
58  
201  
220  
242  
269  
299  
329  
363  
394  
395  
438  
486  
531  
800  
600  
900  
650  
64  
1000  
1150  
1250  
1400  
1500  
1410  
1710  
2010  
2210  
700  
71  
750  
79  
850  
87  
COOLER  
950  
96  
1000  
1060  
1160  
1260  
1410  
104  
104  
115  
128  
140  
—
—
—
—
—
—
—
—
—
—
—
—
CONDENSER  
RIGGING WEIGHTS  
Dry Wt.  
VESSEL CHARGE  
Design II  
HEAT  
Refrigerant  
NUMBER  
Volume  
VESSEL  
EXCHANGER  
CODE  
OF TUBES  
of Water  
Design I  
Design II  
Design I  
Lb  
Lb  
5050  
5200  
5375  
5575  
7050  
7275  
7500  
7775  
—
Kg  
2100  
2350  
2450  
2525  
3200  
3300  
3400  
3525  
—
Lb  
Kg  
Kg  
181  
181  
181  
181  
181  
181  
181  
181  
—
Lb  
Kg  
Gal  
L
40  
41  
42  
43  
50  
51  
52  
53  
55  
56  
57  
58  
218  
246  
279  
315  
347  
387  
432  
484  
218  
246  
279  
315  
4855  
5010  
5180  
5370  
6750  
6960  
7200  
7475  
8345  
8635  
8980  
9370  
2202  
2272  
2350  
2436  
3062  
3157  
3266  
3391  
3785  
3917  
4073  
4250  
400  
400  
400  
400  
400  
400  
400  
400  
—
350  
350  
350  
350  
350  
350  
350  
350  
490  
490  
490  
490  
159  
159  
159  
159  
159  
159  
159  
159  
222  
222  
222  
222  
56  
62  
212  
235  
257  
284  
318  
348  
382  
416  
423  
466  
513  
565  
68  
75  
84  
92  
CONDENSER  
101  
110  
112  
123  
135  
149  
–
—
—
—
—
—
—
—
—
—
—
—
NOTES:  
1. Design I chillers are equipped with a float box, and chiller weight is based on a 150 psi (1034 kPa)  
waterbox with 2 pass arrangement.  
2. Design II chillers are equipped with a linear float, and chiller weight is based on a 300 psi (2068 kPa)  
waterbox with 1 pass arrangement.  
3. Total refrigerant charge is equal to the cooler charge added to the condenser charge.  
Table 13 — Additional Data for Marine Waterboxes*  
ENGLISH  
SI  
HEAT EXCHANGER  
FRAME, PASS  
Rigging Wt  
(lb)  
Water Volume  
(gal)  
Rigging Wt  
(kg)  
Water Volume  
(L)  
Cooler  
Condenser  
660  
Cooler  
Condenser  
Cooler  
Condenser  
300  
Cooler  
261  
Condenser  
193  
FRAME 4, 2 PASS  
1115  
2030  
1220  
2240  
69  
138  
88  
51  
101  
64  
506  
922  
FRAME 4, 1 & 3 PASS  
FRAME 5, 2 PASS  
1160  
527  
524  
384  
935  
554  
424  
331  
243  
FRAME 5, 1 & 3 PASS  
1705  
175  
128  
1017  
774  
663  
486  
*Add to heat exchanger weights and volumes for total weight or volume.  
85  
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Table 14 — Waterbox Cover Weights*  
ENGLISH (lb)  
FRAME 4,  
FRAME 4,  
STANDARD  
FLANGED  
NOZZLES  
FRAME 5,  
STANDARD  
NOZZLES  
FRAME 5,  
FLANGED  
HEAT  
EXCHANGER  
WATERBOX  
DESCRIPTION  
150 psig 300 psig 150 psig 300 psig 150 psig 300 psig 150 psig 300 psig  
NIH, 1 PASS COVER  
NIH, 2 PASS COVER  
NIH, 3 PASS COVER  
NIH, PLAIN END COVER  
MWB COVER  
284  
285  
292  
243  
CS  
414  
411  
433  
292  
621  
482  
446  
435  
466  
271  
474  
359  
324  
341  
309  
243  
CS  
491  
523  
469  
292  
621  
482  
523  
547  
502  
271  
474  
359  
412  
410  
423  
304  
CS  
578  
573  
602  
426  
766  
471  
472  
469  
493  
379  
590  
428  
452  
466  
440  
304  
CS  
655  
685  
638  
426  
766  
471  
549  
541  
549  
379  
590  
428  
COOLERS  
PLAIN END COVER  
NIH, 1 PASS COVER  
NIH, 2 PASS COVER  
NIH, 3 PASS COVER  
NIH, PLAIN END COVER  
MWB COVER  
CS  
CS  
CS  
CS  
306  
288  
319  
226  
CS  
346  
344  
336  
226  
CS  
373  
368  
407  
271  
CS  
413  
428  
419  
271  
CS  
CONDENSERS  
PLAIN END COVER  
CS  
CS  
CS  
CS  
SI (kg)  
FRAME 4,  
STANDARD  
NOZZLES  
FRAME 5,  
STANDARD  
NOZZLES  
FRAME 4,  
FLANGED  
FRAME 5,  
FLANGED  
HEAT  
EXCHANGER  
WATERBOX  
DESCRIPTION  
1034 kPa 2068 kPa 1034 kPa 2068 kPa 1034 kPa 2068 kPa 1034 kPa 2068 kPa  
NIH, 1 PASS COVER  
NIH, 2 PASS COVER  
NIH, 3 PASS COVER  
NIH, PLAIN END COVER  
MWB COVER  
129  
129  
133  
110  
CS  
188  
187  
197  
133  
282  
219  
202  
197  
212  
123  
215  
163  
147  
155  
140  
110  
CS  
223  
237  
213  
133  
282  
219  
237  
248  
228  
123  
215  
163  
187  
186  
192  
138  
CS  
262  
260  
273  
193  
348  
214  
214  
213  
224  
172  
268  
194  
205  
212  
200  
138  
CS  
297  
311  
290  
193  
348  
214  
249  
246  
249  
172  
268  
194  
COOLERS  
PLAIN END COVER  
NIH, 1 PASS COVER  
NIH, 2 PASS COVER  
NIH, 3 PASS COVER  
NIH, PLAIN END COVER  
MWB COVER  
CS  
CS  
CS  
CS  
139  
131  
145  
103  
CS  
157  
156  
153  
103  
CS  
169  
167  
185  
123  
CS  
188  
194  
190  
123  
CS  
CONDENSERS  
PLAIN END COVER  
CS  
CS  
CS  
CS  
LEGEND  
*These weights are for reference only. To determine frame size, see Fig. 1.  
NIH  
MWB  
CS  
—
—
—
Nozzle-in-Head  
Marine Waterbox  
Contact Syracuse  
NOTE: For Design I chillers, the 150 psig (1034 kPa) standard waterbox cover weights (NIH, 2-pass  
cover) have been included in the heat exchanger weights shown in Table 12. Design II chillers are  
equipped with a linear float, and chiller weight is based on a 300 psig (2066 kPa) waterbox with 1-pass  
arrangement.  
86  
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Table 15 — Compressor/Motor Weights  
ENGLISH  
SI  
Stator Weight  
(kg)  
60 Hz  
MOTOR  
SIZE  
Stator Weight  
(lb)  
Rotor Weight  
(lb)  
Rotor Weight  
(kg)  
Compressor  
Weight  
(lb)  
End Bell Compressor  
End Bell  
Cover  
(lb)  
Cover  
(lb)  
Weight  
(kg)  
60 Hz  
1135  
1143  
1153  
1162  
1202  
1225  
1276  
1289  
1306  
1335  
50 Hz  
1147  
1150  
1213  
1227  
1283  
1308  
1341  
1356  
1363  
1384  
60 Hz  
171  
197  
234  
237  
246  
254  
263  
266  
273  
282  
50 Hz  
233  
239  
252  
255  
270  
275  
279  
284  
287  
294  
50 Hz  
520  
522  
551  
557  
582  
594  
609  
616  
619  
628  
60 Hz  
78  
50 Hz  
106  
109  
114  
116  
123  
125  
127  
129  
130  
133  
CB  
CC  
CD  
CE  
CL  
CM  
CN  
CP  
CQ  
CR  
2660  
2660  
2660  
2660  
2660  
2660  
2660  
2660  
2660  
2660  
250  
250  
250  
250  
250  
250  
250  
250  
250  
250  
1208  
1208  
1208  
1208  
1208  
1208  
1208  
1208  
1208  
1208  
515  
518  
523  
528  
546  
556  
579  
585  
593  
606  
114  
114  
114  
114  
114  
114  
114  
114  
114  
114  
90  
106  
108  
112  
115  
119  
121  
124  
128  
NOTE: For medium voltage motors add 85 lbs (39 kg) to above for 60 Hz motors and 145 lbs (66 kg)  
for 50 Hz motors. Total compressor/motor weight is the sum of the compressor, stator, rotor, and end  
bell cover weight. Compressor weight includes suction and discharge elbow weights.  
Table 16 — Compressor Weights  
Table 17 — Optional Pumpout System  
Electrical Data  
WEIGHT  
COMPONENT  
Lb  
MOTOR  
CODE  
CONDENSER  
UNIT  
MAX  
RLA  
Kg  
25  
VOLTS-PH-Hz  
LRA  
SUCTION ELBOW  
DISCHARGE ELBOW  
TRANSMISSION  
SUCTION HOUSING  
IMPELLER SHROUD  
COMPRESSOR BASE  
DIFFUSER  
55  
50  
1
4
5
6
19EA47-748  
19EA42-748  
19EA44-748  
19EA46-748  
575-3-60  
200/208-3-60  
230-3-60  
3.8  
10.9  
9.5  
23.0  
63.5  
57.5  
28.8  
23  
331  
159  
36  
730  
350  
80  
400/460-3-50/60  
4.7  
1050  
70  
476  
32  
LEGEND  
LRA  
RLA  
—
—
Locked Rotor Amps  
Rated Load Amps  
OIL PUMP  
150  
135  
68  
MISCELLANEOUS  
61  
TOTAL WEIGHT  
(Less Motor)  
2660  
1207  
87  
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NOTES:  
1. Dimensions are in inches with rotor in the thrust position.  
2. All clearances listed are new chiller tolerances.  
3. All radial clearances are diametrical.  
NOTE: Radial clearances shown are diametrical.  
Fig. 47 — Compressor Fits and Clearances  
88  
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COMPRESSOR ASSEMBLY TORQUES  
TORQUE  
ITEM  
DESCRIPTION  
ft-lb  
10  
N•m  
14  
1*  
2
Oil Heater Grommet Nut  
Impeller Retaining Bolt  
Bull Gear Retaining Bolt  
Motor Terminals (Low Voltage)  
Demister Bolts  
44-46  
80-85  
50  
60-62  
108-115  
68  
3
4
5
15-19  
25  
20-26  
34  
6*  
7*  
Guide Vane Shaft Seal Nut  
Motor Terminals (High Voltage)  
— Insulator  
— Packing Nut  
— Brass Jam Nut  
2-4  
5
10  
2.7-5.4  
6.8  
13.6  
LEGEND  
N•m  
—
Newton Meters  
*Not shown.  
*‘‘Z’’ clearance is determined by a combination of impeller diameter and shroud size. The  
table lists ‘‘Z’’ clearances for each compressor code. Figure 1 shows the location (on the  
chiller information plate) of the compressor code for each chiller.  
COMPRESSOR  
CODE  
‘‘Z’’  
(in.)  
‘‘Z’’  
(mm)  
COMPRESSOR  
CODE  
‘‘Z’’  
(in.)  
‘‘Z’’  
(mm)  
COMPRESSOR  
CODE  
‘‘Z’’  
(in.)  
‘‘Z’’  
(mm)  
516-517  
518-519  
526-527  
528-529  
536-537  
538-539  
.015  
.025  
.015  
.025  
.015  
.025  
0.381  
0.635  
0.381  
0.635  
0.381  
0.635  
546-547  
548-549  
556-557  
558-559  
566-567  
568-569  
.015  
.025  
.015  
.025  
.015  
.025  
0.381  
0.635  
0.381  
0.635  
0.381  
0.635  
203-204  
223-274  
283-307  
321-377  
381-397  
410-469  
470-499  
.025  
.015  
.025  
.015  
.025  
.015  
.025  
0.635  
0.381  
0.635  
0.381  
0.635  
0.381  
0.635  
Fig. 47 — Compressor Fits and Clearances (cont)  
89  
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LEGEND  
BRG  
C
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Bearing  
NO  
—
—
Normally Open  
Contact  
PSIO  
Processor Sensor Input/  
Output Module  
CB  
Circuit Breaker  
Clear  
Common  
Communication Connector  
External  
Guide Vane  
Hot Gas Bypass  
Internal  
CLR  
COM  
COMM  
EXT  
G.V.  
HGBP  
INT  
J
RBPL  
S
SMM  
SOL  
TB  
—
—
—
—
—
Relay Board Plug  
Compressor Motor Start Contactor  
Starter Management Module  
Solenoid  
Terminal Board  
Carrier Factory Wiring  
Optional (Factory or Field-Installed)  
Wiring  
Thermistor  
Module Connector  
Relay Designation  
Local Interface Device  
Milliampere  
K
LID  
MA  
t*  
NC  
Normally Closed  
Fig. 48 — Electronic PIC Controls Wiring Schematic  
(For 19XL with No Backlight or with Fluorescent Backlight)  
90  
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Fig. 48 — Electronic PIC Controls Wiring Schematic  
(For 19XL with No Backlight or with Fluorescent Backlight) (cont)  
91  
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LEGEND  
BRG  
C
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Bearing  
NO  
—
—
Normally Open  
Contact  
PSIO  
Processor Sensor Input/  
Output Module  
CB  
Circuit Breaker  
Clear  
Common  
Communication Connector  
External  
Guide Vane  
Hot Gas Bypass  
Internal  
CLR  
COM  
COMM  
EXT  
G.V.  
HGBP  
INT  
J
RBPL  
S
SMM  
SOL  
TB  
—
—
—
—
—
Relay Board Plug  
Compressor Motor Start Contactor  
Starter Management Module  
Solenoid  
Terminal Board  
Carrier Factory Wiring  
Optional (Factory or Field-Installed)  
Wiring  
Thermistor  
Module Connector  
Relay Designation  
Local Interface Device  
Milliampere  
K
LID  
MA  
t*  
NC  
Normally Closed  
Fig. 49 — Electronic PIC Controls Wiring Schematic  
(For 19XL with Halogen Backlight)  
92  
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Fig. 49 — Electronic PIC Controls Wiring Schematic  
(For 19XL with Halogen Backlight) (cont)  
93  
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LEGEND  
1M  
—
—
—
—
—
—
—
—
—
—
Main Starter Contactor  
Contactor  
PR  
—
—
—
—
—
—
Pilot Relay  
C
PWR  
RLA  
SMM  
TB  
Power  
CB  
CR  
COMM  
J
Circuit Board  
Rated Load Amps  
Starter Management Module  
Terminal Board  
Variable Number  
Starter Cabinet Wiring  
Field Wiring  
Control Relay  
Communications Connector  
Connector  
X
N.C.  
N.O.  
OL  
Normally Closed  
Normally Open  
Overload  
Carrier Factory Wiring  
OS  
3-Phase Current Power Source  
*All starters, including across-the-line starters, require 2 separate contacts for the START AUX  
DRY contact and RUN AUX DRY contact, as shown above.  
Fig. 50 — Chiller Power Panel, Starter Assembly,  
and Motor Wiring Schematic  
94  
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Fig. 50 — Chiller Power Panel, Starter Assembly,  
and Motor Wiring Schematic (cont)  
95  
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96  
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97  
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INDEX  
Abbreviations and Explanations, 4  
Adding Refrigerant, 61  
Oil Changes, 63  
Oil Charge, 50  
Adjusting the Refrigerant Charge, 61  
After Extended Shutdown, 57  
After Limited Shutdown, 57  
Attach to Network Device Control, 37  
Automatic Soft-Stop Amps Threshold, 40  
Auto. Restart After Power Failure, 33  
Before Initial Start-Up, 41  
Calibrate Motor Current, 56  
Capacity Override, 31  
Oil Cooler, 32  
Oil Pressure and Compressor Stop (Check), 56  
Oil Reclaim Filters, 63  
Oil Reclaim System, 9  
Oil Specification, 63  
Oil Sump Temperature Control, 32  
Open Oil Circuit Valves, 41  
Operating Instructions, 56  
Operating the Optional Pumpout Compressor, 59  
Operator Duties, 56  
Optional Pumpout System Maintenance, 65  
Options Modules, 79  
Ordering Replacement Chiller Parts, 65  
Overview (Troubleshooting Guide), 66  
Physical Data, 85  
PIC System Components, 11  
PIC System Functions, 28  
Power Up the Controls and Check the Oil Heater, 50  
Pumpout Compressor Water Piping (Check), 47  
Pumpout System Controls and Compressor (Check), 52  
Preparation (Initial Start-Up), 55  
Preparation (Pumpout and Refrigerant Transfer  
Procedures), 59  
Carrier Comfort Network Interface, 48  
Changing Oil Filter, 63  
Charge Refrigerant Into Chiller, 53  
Chilled Water Recycle Mode, 40  
Chiller Dehydration, 47  
Chiller Familiarization, 5  
Chiller Information Plate, 5  
Chiller Operating Condition (Check), 56  
Chiller Tightness (Check), 41  
Chillers with Isolation Valves, 60  
Chillers with Pumpout Storage Tanks, 59  
Cold Weather Operation, 57  
Compressor Bearing and Gear Maintenance, 64  
Condenser, 5  
Condenser Freeze Prevention, 32  
Condenser Pump Control, 32  
Control Algorithms Checkout Procedure, 67  
Control Center, 5, 63  
Prepare the Chiller for Start-Up, 56  
Pressure Transducers (Check), 65, 66  
Prevent Accidential Start-Up, 56  
Processor Module, 79  
Control Modules, 78  
Pumpout and Refrigerant Transfer Procedures, 59  
Ramp Loading Control, 31  
Control Test, 67  
Controls, 11  
Refrigerant Filter, 63  
Cooler, 5  
Refrigerant Float System (Inpsect), 64  
Refrigerant Leak Testing, 61  
Refrigerant Properties, 61  
Default Screen Freeze, 29  
Definitions (Controls), 11  
Demand Limit Control, Option, 33  
Design Set Points, (Input), 50  
Details (Lubrication Cycle), 8  
Display Messages (Check), 66  
Dry Run to Test Start-Up Sequence, 55  
Equipment Required, 41  
Refrigerant (Removing), 61  
Refrigerant Tracer, 41  
Refrigeration Cycle, 5  
Refrigeration Log, 57  
Relief Devices (Check), 47  
Relief Valves and Piping (Inspect), 64  
Remote Start/Stop Controls, 32  
Repair the Leak, Retest, and Apply Standing  
Vacuum Test, 62  
Replacing Defective Processor Modules, 80  
Rotation (Check), 55  
Running System (Check), 56  
Safety and Operating Controls (Check Monthly), 63  
Safety Considerations, 1  
Safety Controls, 29  
Safety Shutdown, 41  
Extended Shutdown, 57  
Factory-Mounted Starter, 5  
General (Controls), 11  
General Maintenance, 61  
Guide Vane Linkage (Check), 62  
Heat Exchanger Tubes (Inspect), 64  
High Altitude Locations, 53  
High Discharge Temperature Control, 32  
Ice Build Control, 36  
Initial Start-Up, 55  
Instruct the Customer Operator, 56  
Introduction, 4  
Scheduled Maintenance, 63  
Selecting Refrigerant Type, 50  
Service Configuration (Input), 50  
Service Ontime, 63  
Job Data Required, 41  
Lead/Lag Control, 34  
Leak Rate, 61  
Service Operation, 38  
Leak Test Chiller, 41  
Set Up Chiller Control Configuration, 50  
Shipping Packaging (Remove), 41  
Shutdown Sequence, 40  
LID Operation and Menus, 14  
Local Occupied Schedule (Input), 50  
Local Start-Up, 39  
Solid-State Starters, 81  
Lubrication Cycle, 8  
Spare Safety Inputs, 32  
Lubrication System (Check), 62  
Manual Guide Vane Operation, 57  
Manual Operation of the Guide Vanes, 55  
Motor-Compressor, 5  
Standing Vacuum Test, 43  
Starter (Check), 48  
Starter Management Module, 79  
Starting Equipment, 10, 65  
Motor Cooling Control, 29  
Motor/Oil Refrigeration Cooling Cycle, 5  
Notes on Module Operation, 78  
Start-Up/Shutdown/Recycle Sequence, 39  
Start the Chiller, 56  
Stop the Chiller, 57  
98  
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INDEX (cont)  
Troubleshooting Guide, 66  
Storage Vessel, 5  
Summary (Lubrication Cycle), 8  
Surge Prevention Algorithm, 33  
Surge Protection, 34  
Unit Mounted Solid-State Starter, 10  
Unit Mounted Wye-Delta Starter, 11  
Using the Optional Storage Tank and Pumpout  
System, 41  
System Components, 5  
Temperature Sensors (Check), 66  
Test After Service, Repair, or Major Leak, 61  
Tighten All Gasketed Joints and Guide Vane Shaft  
Packing, 41  
Water/Brine Reset, 33  
Water Leaks, 64  
Water Piping (Inspect), 47  
Water Treatment, 65  
Tower Fan Relay, 33  
Trim Refrigerant Charge, 62  
Weekly Maintenance, 62  
Wiring (Inspect), 47  
99  
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Copyright 1996 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book 2  
PC 211  
Catalog No. 531-971  
Printed in U.S.A.  
Form 19XL-4SS  
Pg 100  
7-96  
Replaces: 19XL-3SS  
Tab 5a  
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