Carrier Refrigerator XRV User Manual
19XR,XRV  
Hermetic Centrifugal Liquid Chillers  
50/60 Hz  
With PIC II Controls and HFC-134a  
Start-Up, Operation, and Maintenance Instructions  
SAFETY CONSIDERATIONS  
Centrifugal liquid chillers are designed to provide safe and  
reliable service when operated within design specifica-  
tions. When operating this equipment, use good judgment  
and safety precautions to avoid damage to equipment and  
property or injury to personnel.  
soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY  
FLUSH EYES with water and consult a physician.  
NEVER APPLY an open flame or live steam to a refrigerant cylinder.  
Dangerous over pressure can result. When it is necessary to heat  
refrigerant, use only warm (110 F [43 C]) water.  
Be sure you understand and follow the procedures and  
safety precautions contained in the chiller instructions as  
well as those listed in this guide.  
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to  
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is  
emptied, evacuate remaining gas pressure, loosen the collar and  
unscrew and discard the valve stem. DO NOT INCINERATE.  
CHECK THE REFRIGERANT TYPE before adding refrigerant to  
the chiller. The introduction of the wrong refrigerant can cause 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 edition).  
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 accor-  
dance with the latest edition of ANSI/ASHRAE 15 (American  
National Standards Institute/American Society of Heating, Refrigera-  
tion, and Air Conditioning Engineers). The accumulation of refriger-  
ant 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 irregular-  
ities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier  
than air and reduces the amount of oxygen available for breathing.  
Product causes eye and skin irritation. Decomposition products are  
hazardous.  
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for  
any purpose. Oxygen gas reacts violently with oil, grease, and other  
common substances.  
NEVER EXCEED specified test pressures, VERIFY the allowable  
test pressure by checking the instruction literature and the design pres-  
sures on the equipment nameplate.  
DO NOT USE air for leak testing. Use only refrigerant or dry  
nitrogen.  
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while  
chiller is under pressure or while chiller is running. Be sure pressure is  
at 0 psig (0 kPa) before breaking any refrigerant connection.  
CAREFULLY INSPECT all relief devices, rupture discs, and other  
relief devices AT LEAST ONCE A YEAR. If chiller operates in a  
corrosive atmosphere, inspect the devices at more frequent intervals.  
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief  
device when corrosion or build-up of foreign material (rust, dirt, scale,  
etc.) is found within the valve body or mechanism. Replace the  
device.  
DO NOT install relief devices in series or backwards.  
USE CARE when working near or in line with a compressed spring.  
Sudden release of the spring can cause it and objects in its path to act  
as projectiles.  
DO NOT 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.  
RISK OF INJURY OR DEATH by electrocution. High voltage is  
present on motor leads even though the motor is not running when a  
solid-state or inside-delta mechanical starter is used. Open the power  
supply disconnect before touching motor leads or terminals.  
DO NOT climb over a chiller. Use platform, catwalk, or staging. Fol-  
low safe practices when using ladders.  
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or  
move inspection covers or other heavy components. Even if compo-  
nents are light, use mechanical equipment when there is a risk of slip-  
ping or losing your balance.  
BE AWARE that certain automatic start arrangements CAN  
ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the  
disconnect ahead of the starter, tower fans, or pumps.  
USE only repair or replacement parts that meet the code requirements  
of the original equipment.  
DO NOT VENT OR DRAIN waterboxes containing industrial brines,  
liquid, gases, or semisolids without the permission of your process  
control group.  
DO NOT LOOSEN waterbox cover bolts until the waterbox has been  
completely drained.  
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or  
other items have been removed before rotating any shafts.  
DO NOT LOOSEN a packing gland nut before checking that the nut  
has a positive thread engagement.  
PERIODICALLY INSPECT all valves, fittings, and piping for corro-  
sion, rust, leaks, or damage.  
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until  
all refrigerant (liquid and vapor) has been removed from chiller.  
Traces of vapor should be displaced with dry air or nitrogen and the  
work area should be well ventilated. Refrigerant in contact with an  
open flame produces toxic gases.  
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the  
entire assembly.  
DO NOT work on high-voltage equipment unless you are a qualified  
electrician.  
DO NOT WORK ON electrical components, including control 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.  
LOCK OPEN AND TAG electrical circuits during servicing. IF  
WORK IS INTERRUPTED, confirm that all circuits are deenergized  
before resuming work.  
AVOID SPILLING liquid refrigerant on skin or getting it into the  
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with  
PROVIDE A DRAIN connection in the vent line near each pressure  
relief device to prevent a build-up of condensate or rain water.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 211 Catalog No. 531-982 Printed in U.S.A. Form 19XR-5SS Pg 1 6-01 Replaces: 19XR-4SS  
Book 2  
Tab 5a  
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CONTENTS (cont)  
Page  
Page  
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
• MOTOR COMPRESSOR LUBRICATION  
SYSTEM  
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
Check Optional Pumpout Compressor  
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54  
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54  
• MECHANICAL STARTER  
• CONTROL SYSTEM  
• AUXILIARY EQUIPMENT  
• DESCRIBE CHILLER CYCLES  
• REVIEW MAINTENANCE  
• SAFETY DEVICES AND PROCEDURES  
• CHECK OPERATOR KNOWLEDGE  
• REVIEW THE START-UP, OPERATION, AND  
MAINTENANCE MANUAL  
• BENSHAW, INC. RediStart MICRO™  
SOLID-STATE STARTER  
• VFD STARTER  
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67  
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66  
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66  
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66  
Preparation for Extended Shutdown . . . . . . . . . . . . 66  
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67  
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67  
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67  
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
PUMPOUT AND REFRIGERANT TRANSFER  
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71  
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67  
Operating the Optional Pumpout Unit . . . . . . . . . . . 67  
• TO READ REFRIGERANT PRESSURES  
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69  
• TRANSFER REFRIGERANT FROM  
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Power Up the Controls and  
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
• SOFTWARE VERSION  
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55  
Input the Local Occupied Schedule  
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55  
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55  
• PASSWORD  
• INPUT TIME AND DATE  
• CHANGE CVC/ICVC CONFIGURATION  
IF NECESSARY  
• TO CHANGE THE PASSWORD  
• TO CHANGE THE CVC/ICVC DISPLAY FROM  
ENGLISH TO METRIC UNITS  
• CHANGE LANGUAGE (ICVC ONLY)  
• MODIFY CONTROLLER IDENTIFICATION  
IF NECESSARY  
PUMPOUT STORAGE TANK TO CHILLER  
• TRANSFER REFRIGERANT FROM  
• INPUT EQUIPMENT SERVICE PARAMETERS  
IF NECESSARY  
• CHANGE THE BENSHAW, INC., RediStart  
MICRO SOFTWARE CONFIGURATION  
IF NECESSARY  
CHILLER TO PUMPOUT STORAGE TANK  
Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70  
• TRANSFER ALL REFRIGERANT TO  
CHILLER CONDENSER VESSEL  
• TRANSFER ALL REFRIGERANT TO  
CHILLER COOLER VESSEL  
• VERIFY VFD CONFIGURATION AND CHANGE  
PARAMETERS IF NECESSARY  
• VFD CHILLER FIELD SET UP AND VERIFICATION  
• VFD CONTROL VERIFICATION (Non-Running)  
• VFD CONTROL VERIFICATION (Running)  
• CONFIGURE DIFFUSER CONTROL IF  
NECESSARY  
• RETURN CHILLER TO NORMAL  
OPERATING CONDITIONS  
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72  
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71  
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71  
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71  
Test After Service, Repair, or Major Leak . . . . . . . . 71  
• TESTING WITH REFRIGERANT TRACER  
• MODIFY EQUIPMENT CONFIGURATION  
IF NECESSARY  
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62  
• COOLER CONDENSER PRESSURE TRANSDUCER  
AND WATERSIDE FLOW DEVICE CALIBRATION  
Check Optional Pumpout System  
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63  
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Charge Refrigerant Into Chiller. . . . . . . . . . . . . . . . . . 63  
• CHILLER EQUALIZATION WITHOUT A  
PUMPOUT UNIT  
• TESTING WITHOUT REFRIGERANT TRACER  
• TO PRESSURIZE WITH DRY NITROGEN  
Repair the Leak, Retest, and Apply  
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72  
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72  
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72  
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 72  
Check the Lubrication System . . . . . . . . . . . . . . . . . . 72  
• CHILLER EQUALIZATION WITH  
PUMPOUT UNIT  
• TRIMMING REFRIGERANT CHARGE  
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75  
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73  
Check Safety and Operating Controls  
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
• TO CHANGE THE OIL  
INITIAL START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66  
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64  
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65  
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
Check Oil Pressure and Compressor Stop . . . . . . 65  
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65  
Check Chiller Operating Condition . . . . . . . . . . . . . . 65  
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65  
• COOLER-CONDENSER  
Refrigerant Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74  
• OPTIONAL PUMPOUT STORAGE TANK AND  
PUMPOUT SYSTEM  
• MOTOR COMPRESSOR ASSEMBLY  
3
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CONTENTS (cont)  
Page  
Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74  
Compressor Bearing and Gear  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
Inspect the Heat Exchanger Tubes  
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
• COOLER AND FLOW DEVICES  
• CONDENSER AND FLOW DEVICES  
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75  
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75  
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75  
Optional Pumpout System Maintenance. . . . . . . . . 75  
• OPTIONAL PUMPOUT COMPRESSOR OIL  
CHARGE  
• OPTIONAL PUMPOUT SAFETY CONTROL  
SETTINGS  
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75  
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122  
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76  
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76  
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76  
• RESISTANCE CHECK  
• VOLTAGE DROP  
• CHECK SENSOR ACCURACY  
• DUAL TEMPERATURE SENSORS  
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76  
• UNITS EQUIPPED WITH CVC  
• UNITS EQUIPPED WITH ICVC  
• TRANSDUCER REPLACEMENT  
ABBREVIATIONS AND EXPLANATIONS  
Control Algorithms Checkout Procedure . . . . . . . . 77  
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77  
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87  
• RED LED (Labeled as STAT)  
Frequently used abbreviations in this manual include:  
• GREEN LED (Labeled as COM)  
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87  
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88  
• INPUTS  
• OUTPUTS  
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88  
• INPUTS  
• OUTPUTS  
Replacing Defective Processor Modules . . . . . . . . 88  
• INSTALLATION  
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88  
• TESTING SILICON CONTROL RECTIFIERS IN  
BENSHAW, INC. SOLID-STATE STARTERS  
• SCR REMOVAL/INSTALLATION  
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124  
INITIAL START-UP CHECKLIST FOR  
19XR, XRV HERMETIC CENTRIFUGAL  
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16  
Words printed in all capital letters or in italics may be  
viewed on the Chiller Visual Controller/International Chiller  
Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN,  
ALARM, etc.).  
Words printed in both all capital letters and italics can also  
be viewed on the CVC/ICVC and are parameters (e.g., CON-  
TROL MODE, COMPRESSOR START RELAY, ICE BUILD  
OPTION, etc.) with associated values (e.g., modes, tempera-  
INTRODUCTION  
Prior to initial start-up of the 19XR unit, those involved in  
the start-up, operation, and maintenance should be thoroughly  
familiar with these instructions and other necessary job data.  
This book is outlined to familiarize those involved in the start-  
up, operation and maintenance of the unit with the control sys-  
tem before performing start-up procedures. Procedures in this  
manual are arranged in the sequence required for proper chiller  
start-up and operation.  
4
Factory-installed additional components are referred to as  
options in this manual; factory-supplied but field-installed ad-  
ditional components are referred to as accessories.  
The chiller software part number of the 19XR unit is located  
on the back of the CVC/ICVC.  
through its internal tubes in order to remove heat from the  
refrigerant.  
Motor-Compressor — This component maintains sys-  
tem temperature and pressure differences and moves the heat-  
carrying refrigerant from the cooler to the condenser.  
Control Panel — The control panel is the user interface  
for controlling the chiller. It regulates the chiller’s capacity as  
required to maintain proper leaving chilled water temperature.  
The control panel:  
• registers cooler, condenser, and lubricating system  
pressures  
• shows chiller operating condition and alarm shutdown  
conditions  
CHILLER FAMILIARIZATION  
(Fig. 1 and 2)  
Chiller Information Nameplate — The information  
nameplate is located on the right side of the chiller control  
panel.  
System Components — The components include the  
cooler and condenser heat exchangers in separate vessels,  
motor-compressor, lubrication package, control panel, and mo-  
tor starter. All connections from pressure vessels have external  
threads to enable each component to be pressure tested with a  
threaded pipe cap during factory assembly.  
• records the total chiller operating hours  
• sequences chiller start, stop, and recycle under micropro-  
cessor control  
• displays status of motor starter  
• provides access to other CCN (Carrier Comfort Net-  
work) devices and energy management systems  
• Languages pre-installed at factory include: English, Chi-  
nese, Japanese, and Korean (ICVC only).  
• International language translator (ILT) is available for  
conversion of extended ASCII characters (ICVC only).  
Cooler — This vessel (also known as the evaporator) is lo-  
cated underneath the compressor. The cooler is maintained at  
lower temperature/pressure so evaporating refrigerant can re-  
move heat from water flowing through its internal tubes.  
Condenser — The condenser operates at  
a
higher  
temperature/pressure than the cooler and has water flowing  
19XRV 52 51 473 DG  
H
64  
–
19XR- — High Efficiency Hermetic  
Centrifugal Liquid Chiller  
19XRV — High Efficiency Hermetic  
Centrifugal Liquid Chiller with  
Variable Frequency Drive  
Unit-Mounted  
Special Order Indicator  
– — Standard  
S — Special Order  
Motor Voltage Code  
Code Volts-Phase-Hertz  
60 — 200-3-60  
61 — 230-3-60  
62 — 380-3-60  
63 — 416-3-60  
64 — 460-3-60  
65 — 575-3-60  
66 — 2400-3-60  
67 — 3300-3-60  
68 — 4160-3-60  
69 — 6900-3-60  
50 — 230-3-50  
51 — 346-3-50  
52 — 400-3-50  
53 — 3000-3-50  
54 — 3300-3-50  
55 — 6300-3-50  
Cooler Size  
10-12 (Frame 1 XR)  
15-17 (Frame 1 XR)  
20-22 (Frame 2 XR)  
30-32 (Frame 3 XR)  
35-37 (Frame 3 XR)  
40-42 (Frame 4 XR)  
45-47 (Frame 4 XR)  
50-52 (Frame 5 XR)  
5A (Frame 5 XR)  
55-57 (Frame 5 XR)  
5F (Frame 5 XR)  
5G (Frame 5 XR)  
5H (Frame 5 XR)  
60-62 (Frame 6 XR)  
65-67 (Frame 6 XR)  
70-72 (Frame 7 XR)  
75-77 (Frame 7 XR)  
80-82 (Frame 8 XR)  
85-87 (Frame 8 XR)  
5B (Frame 5 XR)  
5C (Frame 5 XR)  
Condenser Size  
10-12 (Frame 1 XR)  
15-17 (Frame 1 XR)  
20-22 (Frame 2 XR)  
30-32 (Frame 3 XR)  
35-37 (Frame 3 XR)  
40-42 (Frame 4 XR)  
45-47 (Frame 4 XR)  
50-52 (Frame 5 XR)  
55-57 (Frame 5 XR)  
60-62 (Frame 6 XR)  
65-67 (Frame 6 XR)  
70-72 (Frame 7 XR)  
75-77 (Frame 7 XR)  
80-82 (Frame 8 XR)  
85-87 (Frame 8 XR)  
Motor Efficiency Code  
H — High Efficiency  
S — Standard Efficiency  
Motor Code  
BD  
BE  
BF  
CD  
CE  
CL  
DB  
DC  
DD  
DE  
DF  
EH  
EJ  
EK  
EL  
EM  
BG CM  
BH  
CN  
CP  
CQ  
DG EN  
DH  
DJ  
EP  
Compressor Code  
(First Digit Indicates Compressor Frame Size)*  
*Second digit will be a letter (example 4G3)  
on units equipped with split ring diffuser.  
MODEL NUMBER NOMENCLATURE  
27 99  
Q
59843  
Unique Number  
Week of Year  
Year of Manufacture  
Place of Manufacture  
SERIAL NUMBER BREAKDOWN  
Fig. 1 — 19XR Identification  
5
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FRONT VIEW  
1
2
3
4
5
LEGEND  
17  
16  
6
1 — Guide Vane Actuator  
2 — Suction Elbow  
3 — Chiller Visual Controller/ International Chiller  
Visual Control (CVC/ICVC)  
4 — Chiller Identification Nameplate  
5 — Cooler, Auto Reset Relief Valves  
6 — Cooler Pressure Transducer  
7 — Condenser In/Out Temperature Thermistors  
8 — Condenser Waterflow Device (ICVC Inputs  
available)  
9 — Cooler In/Out Temperature Thermistors  
10 — Cooler Waterflow Device (ICVC Inputs avail-  
able)  
11 — Refrigerant Charging Valve  
12 — Typical Flange Connection  
13 — Oil Drain Charging Valve  
14 — Oil Level Sight Glasses  
15 — Refrigerant Oil Cooler (Hidden)  
16 — Auxiliary Power Panel  
17 — Compressor Motor Housing  
7
8
15  
14  
13  
12  
9
11  
10  
REAR VIEW  
19  
20 21  
22  
18  
LEGEND  
34  
18 — Condenser Auto. Reset Relief Valves  
19 — Compressor Motor Circuit Breaker  
20 — Solid-State Starter Control Display  
21 — Unit-Mounted Starter (Optional)  
Solid-State Starter Shown  
23  
22 — Motor Sight Glass  
23 — Cooler Return-End Waterbox Cover  
24 — ASME Nameplate (One Hidden)  
25 — Typical Waterbox Drain Port  
26 — Condenser Return-End Waterbox Cover  
27 — Refrigerant Moisture/Flow Indicator  
28 — Refrigerant Filter/Drier  
29 — Liquid Line Isolation Valve (Optional)  
30 — Linear Float Valve Chamber  
31 — Vessel Take-Apart Connector  
32 — Discharge Isolation Valve (Optional)  
33 — Pumpout Valve  
34 — Condenser Pressure Transducer  
24  
33  
32  
31  
30  
28 27  
26 25  
29  
24  
Fig. 2 — Typical 19XR Components  
6
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refrigerant is quite warm (typically 98 to 102 F [37 to 40 C])  
when it is discharged from the compressor into the condenser.  
Relatively cool (typically 65 to 90 F [18 to 32 C]) water  
flowing into the condenser tubes removes heat from the refrig-  
erant and the vapor condenses to liquid.  
The liquid refrigerant passes through orifices into the  
FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC  
chamber is at a lower pressure, part of the liquid refrigerant  
flashes to vapor, thereby cooling the remaining liquid. The  
FLASC vapor is recondensed on the tubes which are cooled by  
entering condenser water. The liquid drains into a float cham-  
ber between the FLASC chamber and cooler. Here a float valve  
forms a liquid seal to keep FLASC chamber vapor from enter-  
ing 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 liq-  
uid. The refrigerant is now at a temperature and pressure at  
which the cycle began.  
Factory-Mounted Starter or Variable Fre-  
quency Drive (Optional) — The starter allows for the  
proper start and disconnect of electrical energy for the com-  
pressor-motor, oil pump, oil heater, and control panel.  
Storage Vessel (Optional) — There are 2 sizes of  
storage vessels available. The vessels have double relief valves,  
a magnetically-coupled dial-type refrigerant level gage, a  
1
one-inch FPT drain valve, and a /2-in. male flare vapor con-  
nection for the pumpout unit.  
NOTE: If a storage vessel is not used at the jobsite, factory-  
installed isolation valves on the chiller may be used to isolate  
the chiller charge in either the cooler or condenser. An optional  
pumpout system is used to transfer refrigerant from vessel to  
vessel.  
REFRIGERATION CYCLE  
The compressor continuously draws refrigerant vapor from  
the cooler at a rate set by the amount of guide vane opening or  
compressor speed (19XRV only). As the compressor suction  
reduces the pressure in the cooler, the remaining refrigerant  
boils at a fairly low temperature (typically 38 to 42 F [3 to  
6 C]). The energy required for boiling is obtained from the wa-  
ter flowing through the cooler tubes. With heat energy re-  
moved, the water becomes cold enough to use in an air condi-  
tioning circuit or for process liquid cooling.  
MOTOR AND LUBRICATING OIL  
COOLING CYCLE  
The motor and the lubricating oil are cooled by liquid re-  
frigerant taken from the bottom of the condenser vessel  
(Fig. 3). Refrigerant flow is maintained by the pressure differ-  
ential that exists due to compressor operation. After the refrig-  
erant flows past an isolation valve, an in-line filter, and a sight  
glass/moisture indicator, the flow is split between the motor  
cooling and oil cooling systems.  
After taking heat from the water, the refrigerant vapor is  
compressed. Compression adds still more heat energy, and the  
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles  
7
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Flow to the motor cooling system passes through an orifice  
and into the motor. Once past the orifice, the refrigerant is  
directed over the motor by a spray nozzle. The refrigerant  
collects in the bottom of the motor casing and is then drained  
back into the cooler through the motor refrigerant drain line.  
An orifice (in the motor shell) maintains a higher pressure in  
the motor shell than in the cooler. The motor is protected by a  
temperature sensor imbedded in the stator windings. An  
increase in motor winding temperature past the motor override  
set point overrides the temperature capacity control to hold,  
and if the motor temperature rises 10° F (5.5° C) above this set  
point, closes the inlet guide vanes. If the temperature rises  
above the safety limit, the compressor shuts down.  
Refrigerant that flows to the oil cooling system is regulated  
by thermostatic expansion valves (TXVs). The TXVs regulate  
flow into the oil/refrigerant plate and frame-type heat exchang-  
er (the oil cooler in Fig. 3). The expansion valve bulbs control  
oil temperature to the bearings. The refrigerant leaving the oil  
cooler heat exchanger returns to the chiller cooler.  
cooler heat exchanger. The oil cooler uses refrigerant from the  
condenser as the coolant. The refrigerant cools the oil to a tem-  
perature between 120 and 140 F (49 to 60 C).  
As the oil leaves the oil cooler, it passes the oil pressure  
transducer and the thermal bulb for the refrigerant expansion  
valve on the oil cooler. The oil is then divided. Part of the oil  
flows to the thrust bearing, forward pinion bearing, and gear  
spray. The rest of the oil lubricates the motor shaft bearings and  
the rear pinion bearing. The oil temperature is measured in the  
bearing housing as it leaves the thrust and forward journal  
bearings. The oil then drains into the oil reservoir at the base of  
the compressor. The PIC II (Product Integrated Control II)  
measures the temperature of the oil in the sump and maintains  
the temperature during shutdown (see Oil Sump Temperature  
Control section, page 36). This temperature is read on the  
CVC/ICVC default screen.  
During the chiller start-up, the PIC II energizes the oil pump  
and provides 45 seconds of pre-lubrication to the bearings after  
pressure is verified before starting the compressor. During  
shutdown, the oil pump will run for 60 seconds to post-  
lubricate after the compressor shuts down. The oil pump can  
also be energized for testing purposes during a Control Test.  
Ramp loading can slow the rate of guide vane opening to  
minimize oil foaming at start-up. If the guide vanes open  
quickly, the sudden drop in suction pressure can cause any re-  
frigerant in the oil to flash. The resulting oil foam cannot be  
pumped efficiently; therefore, oil pressure falls off and lubrica-  
tion is poor. If oil pressure falls below 15 psid (103 kPad) dif-  
ferential, the PIC II will shut down the compressor.  
If the controls are subject to a power failure that lasts more  
than 3 hours, the oil pump will be energized periodically when  
the power is restored. This helps to eliminate refrigerant that  
has migrated to the oil sump during the power failure. The con-  
trols energize the pump for 60 seconds every 30 minutes until  
the chiller is started.  
VFD COOLING CYCLE  
The unit-mounted variable frequency drive (VFD) is cooled  
in a manner similar to the motor and lubricating oil cooling  
cycle (Fig. 3).  
If equipped with a unit-mounted VFD, the refrigerant line  
that feeds the motor cooling and oil cooler also feeds the heat  
exchanger on the unit-mounted VFD. Refrigerant is metered  
through a thermostatic expansion valve (TXV). To maintain  
proper operating temperature in the VFD, the TXV bulb is  
mounted to the heat exchanger to regulate the flow of refriger-  
ant. The refrigerant leaving the heat exchanger returns to the  
cooler.  
LUBRICATION CYCLE  
Summary — The oil pump, oil filter, and oil cooler make  
up a package located partially in the transmission casing of the  
compressor-motor assembly. The oil is pumped into a filter  
assembly to remove foreign particles and is then forced into an  
oil cooler heat exchanger where the oil is cooled to proper  
operational temperatures. After the oil cooler, part of the flow  
is directed to the gears and the high speed shaft bearings; the  
remaining flow is directed to the motor shaft bearings. Oil  
drains into the transmission oil sump to complete the cycle  
(Fig. 4).  
Oil Reclaim System — The oil reclaim system returns  
oil lost from the compressor housing back to the oil reservoir  
by recovering the oil from 2 areas on the chiller. The guide  
vane housing is the primary area of recovery. Oil is also recov-  
ered by skimming it from the operating refrigerant level in the  
cooler vessel.  
PRIMARY OIL RECOVERY MODE — Oil is normally re-  
covered through the guide vane housing on the chiller. This is  
possible because oil is normally entrained with refrigerant in  
the chiller. As the compressor pulls the refrigerant up from the  
cooler into the guide vane housing to be compressed, the oil  
normally drops out at this point and falls to the bottom of the  
guide vane housing where it accumulates. Using discharge gas  
pressure to power an eductor, the oil is drawn from the housing  
and is discharged into the oil reservoir.  
SECONDARY OIL RECOVERY METHOD — The sec-  
ondary method of oil recovery is significant under light load  
conditions, when the refrigerant going up to the compressor  
suction does not have enough velocity to bring oil along. Under  
these conditions, oil collects in a greater concentration at the  
top level of the refrigerant in the cooler. This oil and refrigerant  
mixture is skimmed from the side of the cooler and is then  
drawn up to the guide vane housing. There is a filter in this line.  
Because the guide vane housing pressure is much lower than  
the cooler pressure, the refrigerant boils off, leaving the oil be-  
hind to be collected by the primary oil recovery method.  
Details — Oil is charged into the lubrication system through  
a hand valve. Two sight glasses in the oil reservoir permit oil  
level observation. Normal oil level is between the middle of the  
upper sight glass and the top of the lower sight glass when the  
compressor is shut down. The oil level should be visible in at  
least one of the 2 sight glasses during operation. Oil sump tem-  
perature is displayed on the CVC/ICVC (Chiller Visual Con-  
troller/International Chiller Visual Controller) default screen.  
During compressor operation, the oil sump temperature ranges  
between 125 to 150 F (52 to 66 C).  
The oil pump suction is fed from the oil reservoir. An oil  
pressure relief valve maintains 18 to 25 psid (124 to172 kPad)  
differential pressure in the system at the pump discharge. This  
differential pressure can be read directly from the CVC/ICVC  
default screen. The oil pump discharges oil to the oil filter as-  
sembly. This filter can be closed to permit removal of the filter  
without draining the entire oil system (see Maintenance sec-  
tions, pages 71 to 75, for details). The oil is then piped to the oil  
8
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REAR MOTOR  
BEARING  
FWD MOTOR  
BEARING  
OIL SUPPLY TO  
FORWARD HIGH  
SPEED BEARING  
LABYRINTH  
GAS LINE  
MOTOR  
COOLING LINE  
ISOLATION  
VALVE  
OIL  
FILTER  
TXV BULB  
PRESSURE  
ISOLATION  
PUMP  
TRANSDUCER VALVE  
OIL  
HEATER  
SIGHT  
GLASS  
OIL  
COOLER  
OIL PUMP  
MOTOR  
EDUCTOR FILTER  
ISOLATION  
VALVE  
SIGHT GLASS  
OIL SKIMMER LINE  
Fig. 4 — Lubrication System  
solid-state starters. This module controls and monitors all as-  
pects of the starter. See the Controls section on page 10 for ad-  
ditional ISM information. All starter replacement parts are sup-  
plied by the starter manufacturer excluding the ISM (contact  
Carrier’s Replacement Component Division [RCD]).  
STARTING EQUIPMENT  
The 19XR requires a motor starter to operate the centrifugal  
hermetic compressor motor, the oil pump, and various auxilia-  
ry equipment. The starter is the main field wiring interface for  
the contractor.  
Unit-Mounted Solid-State Starter (Optional) —  
The 19XR chiller may be equipped with a solid-state, reduced-  
voltage starter (Fig. 5 and 6). This starter’s primary function is  
to provide on-off control of the compressor motor. This type of  
starter reduces the peak starting torque, reduces the motor in-  
rush current, and decreases mechanical shock. This capability  
is summed up by the phrase “soft starting.” The solid-state  
starter is available as a 19XR option (factory supplied and in-  
stalled). The solid-state starters manufacturer name is located  
inside the starter access door.  
A solid-state, reduced-voltage starter operates by reducing  
the starting voltage. The starting torque of a motor at full volt-  
age 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 re-  
quired to get the motor moving. The voltage is reduced by sili-  
con controlled rectifiers (SCRs). The voltage and current are  
then ramped up in a desired period of time. Once full voltage is  
reached, a bypass contactor is energized to bypass the SCRs.  
See Carrier Specification Z-415 for specific starter require-  
ments, Z-416 for free-standing VFD requirements and Z-417  
for unit-mounted VFD requirements. All starters must meet  
these specifications in order to properly start and satisfy me-  
chanical safety requirements. Starters may be supplied as sepa-  
rate, free-standing units or may be mounted directly on the  
chiller (unit mounted) for low voltage units only.  
Three separate circuit breakers are inside the starter. Circuit  
breaker CB1 is the compressor motor circuit breaker. The dis-  
connect switch on the starter front cover is connected to this  
breaker. Circuit breaker CB1 supplies power to the compressor  
motor.  
The main circuit breaker (CB1) on the front of the starter  
disconnects the main motor current only. Power is still  
energized for the other circuits. Two more circuit breakers  
inside the starter must be turned off to disconnect power to  
the oil pump, PIC II controls, and oil heater.  
Circuit breaker CB2 supplies power to the control panel, oil  
heater, and portions of the starter controls.  
Circuit breaker CB3 supplies power to the oil pump. Both  
CB2 and CB3 are wired in parallel with CB1 so that power is  
supplied to them if the CB1 disconnect is open.  
When voltage is supplied to the solid-state circuitry (CB1  
is closed), the heat sinks in the starter as well as the wires  
leading to the motor and the motor terminal are at line volt-  
age. Do not touch the heat sinks, power wiring, or motor  
terminals while voltage is present or serious injury will  
result.  
All starters must include a Carrier control module called the  
Integrated Starter Module (ISM), excluding the Benshaw  
9
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There is a display on the front of the Benshaw, Inc., solid-  
state starters that is useful for troubleshooting and starter  
checkout. The display indicates:  
• voltage to the SCRs  
• SCR control voltage  
• power indication  
• proper phasing for rotation  
• start circuit energized  
• over-temperature  
• ground fault  
• current unbalance  
• run state  
• software configuration  
The starter is further explained in the Check Starter and  
Troubleshooting Guide sections, pages 54 and 76.  
Unit-Mounted Wye-Delta Starter (Optional) —  
The 19XR chiller may be equipped with a wye-delta starter  
mounted on the unit. This starter is used with low-voltage mo-  
tors (under 600 v). It reduces the starting current inrush by con-  
necting each phase of the motor windings into a wye configu-  
ration. This occurs during the starting period when the motor is  
accelerating up to speed. Once the motor is up to speed, the  
starter automatically connects the phase windings into a delta  
configuration. Starter control, monitoring, and motor protec-  
tion is provided by Carrier’s Integrated Starter Module (ISM).  
Unit-Mounted VFD (Optional) — The 19XRV unit  
will be equipped with a variable frequency drive motor control-  
ler mounted on the unit. See Fig. 7 and 8. This VFD is used  
with low voltage motors between 380 and 480 VAC. It reduces  
the starting current inrush by controlling the voltage and fre-  
quency to the compressor motor. Once the motor has accelerat-  
ed to minimum speed the PIC II modulates the compressor  
speed and guide vane position to control chilled water tempera-  
ture. The VFD is further explained in the Controls section and  
Troubleshooting Guide section, pages 10 and 76.  
There is a separate display located on the unit-mounted  
VFD. Operational parameters and fault codes are displayed rel-  
ative to the drive. Refer to specific drive literature along with  
troubleshooting sections. The display is also the interface for  
entering specific chiller operational parameters. These parame-  
ters have been preprogrammed at the factory. An adhesive  
backed label on the inside of the drive has been provided for  
verification of the specific job parameters. See Initial Start-Up  
Checklist section for details.  
CONTROLS  
Definitions  
ANALOG SIGNAL — An analog signal varies in proportion  
10  
Forward  
Reverse  
AUTO  
MAN  
RUNNING  
SPEED  
REMOTE  
JOG  
AUTO  
VOLTS  
AMPS  
Hz  
RUN  
JOB  
PROGRAM  
FORWARD  
REVERSE  
Kw  
TORQUE  
ENTER  
PROGRAM  
Password  
Forward  
Reverse  
AUTO  
MAN  
SPEED  
RUNNING  
VOLTS  
AMPS  
Hz  
REMOTE  
JOG  
AUTO  
RUN  
JOB  
PRO-  
GRAM  
Kw  
TORQUE  
FORWARD  
REVERSE  
ENTER  
Password  
PROGRAM  
OPTIONAL  
METER  
PACKAGE  
MANUAL RESET  
Fig. 7 — Variable Frequency Drive (VFD)  
DC BUS BAR  
+
- MPOEIANSTUREMENT  
INTEGRATED  
STARTER  
MODULE  
(ISM)  
INITIAL DC BUS  
MEASUREMENT  
POINT  
+
DANGER  
HIGH VOLTAGE  
-
OIL PUMP  
DISCONNECT  
Forward  
AUTO  
MAN  
SPEED  
RUNNING  
Reverse  
VOLTS  
AMPS  
Hz  
REMOTE  
JOG  
AUTO  
CONTROL  
AND OIL  
RUN  
JOB  
PROGRAM  
Kw  
TORQUE  
FORWARD  
REVERSE  
ENTER  
Password  
PROGRAM  
LINE  
HEATER  
DISCONNECT  
VFD  
MODULE  
LOAD  
COOLING LINES  
COMPRESSOR  
MOTOR  
DISCONNECT  
TXV  
Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View  
General — The 19XR hermetic centrifugal liquid chiller  
contains a microprocessor-based control center that monitors  
and controls all operations of the chiller (see Fig. 9). The  
microprocessor control system matches the cooling capacity of  
the chiller to the cooling load while providing state-of-the-art  
chiller protection. The system controls cooling load within the  
set point plus the deadband by sensing the leaving chilled water  
or brine temperature and regulating the inlet guide vane via a  
mechanically linked actuator motor. The guide vane is a vari-  
able flow pre-whirl assembly that controls the refrigeration ef-  
fect in the cooler by regulating the amount of refrigerant vapor  
flow into the compressor. An increase in guide vane opening  
increases capacity. A decrease in guide vane opening decreases  
capacity. The microprocessor-based control center protects the  
chiller by monitoring the digital and analog inputs and execut-  
ing capacity overrides or safety shutdowns, if required.  
PIC II System Components — The chiller control  
system is called the PIC II (Product Integrated Control II). See  
Table 1. The PIC II controls the operation of the chiller by  
monitoring all operating conditions. The PIC II can diagnose a  
problem and let the operator know what the problem is and  
what to check. It promptly positions the guide vanes to main-  
tain leaving chilled water temperature. It can interface with  
auxiliary equipment such as pumps and cooling tower fans to  
turn them on when required. It continually checks all safeties to  
prevent any unsafe operating condition. It also regulates the oil  
heater while the compressor is off and regulates the hot gas by-  
pass valve, if installed. The PIC II controls provide critical pro-  
tection for the compressor motor and controls the motor starter.  
11  
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FITTING (HIDDEN)  
PANEL  
ACTUATOR CABLE  
PANEL  
CABLE  
WATER  
SENSOR  
CABLES  
WATER  
SENSOR  
CABLES  
COOLER  
PRESSURE  
TRANSDUCER  
CONNECTION  
CONDENSER  
SERVICE  
VALVE  
CONDENSER  
PRESSURE  
CABLE  
SCHRADER  
DISCHARGE  
ISOLATION  
VALVE  
COMPRESSOR  
MOTOR WINDING  
TEMPERATURE  
CABLE  
FITTING (HIDDEN)  
CONDENSER  
PRESSURE  
DISCHARGE  
ELBOW JOINTS  
(OPTIONAL)  
TRANSDUCER  
CONNECTION  
TOP VIEW  
COMPRESSOR DETAIL  
Fig. 9 — 19XR Controls and Sensor Locations  
12  
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The PIC II can interface with the Carrier Comfort Network  
(CCN) if desired. It can communicate with other PIC I or PIC  
II equipped chillers and other CCN devices.  
ground fault, remote start contact, spare safety, condenser high  
The PIC II consists of 3 modules housed inside 3 major  
components. The component names and corresponding control  
voltages are listed below (also see Table 1):  
• control panel  
— all extra low-voltage wiring (24 v or less)  
• power panel  
— 230 or 115 v control voltage (per job requirement)  
— up to 600 v for oil pump power  
• starter cabinet  
— chiller power wiring (per job requirement)  
Table 1 — Major PIC II Components and  
Panel Locations*  
*See Fig. 8-13.  
CHILLER VISUAL CONTROLLER (CVC) — The CVC is  
the “brain” of the PIC II. This module contains all the operating  
software needed to control the chiller. The CVC is mounted to  
the control panel (Fig. 12) and is the input center for all local  
chiller set points, schedules, configurable functions, and op-  
tions. The CVC has a stop button, an alarm light, four buttons  
for logic inputs, and a backlight display. The backlight will au-  
tomatically turn off after 15 minutes of non-use. The functions  
of the four buttons or “softkeys” are menu driven and are  
shown on the display directly above the softkeys.  
The viewing angle of the CVC can be adjusted for optimum  
viewing. Remove the 2 bolts connecting the control panel to  
the brackets attached to the cooler. Place them in one of the  
holes to pivot the control panel forward to backward to change  
the viewing angle. See Fig. 12. To change the contrast of the  
display, access the adjustment on the back of the CVC. See  
Fig. 12.  
INTERNATIONAL CHILLER VISUAL CONTROLLER  
(ICVC) — Incorporates all of the functions and operating soft-  
ware of the CVC with the added feature of 4 factory pro-  
grammed languages:  
English (default)  
Chinese  
Japanese  
Korean  
NOTE: Pressing any one of the four softkey buttons will acti-  
vate the backlight display without implementing a softkey  
function.  
INTEGRATED STARTER MODULE (ISM) — This mod-  
ule is located in the starter cabinet. This module initiates com-  
mands from the CVC/ICVC for starter functions such as start-  
ing and stopping the compressor, condenser, chilled water  
pumps, tower fan, spare alarm contacts, and the shunt trip. The  
ISM monitors starter inputs such as line voltage, motor current,  
13  
Fig. 12 — Control Panel  
Fig. 13 — Power Panel  
14  
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r re rmtn tCOeMPReESSORtrcrereTeIrME
CVC/ICVC Operation and Menus (Fig. 14-20)  
GENERAL  
PRIMARY STATUS  
MESSAGE  
DATE  
ON TIME  
SECONDARY  
STATUS  
MESSAGE  
• The CVC/ICVC display automatically reverts to the  
default screen after 15 minutes if no softkey activity  
takes place and if the chiller is not in the pumpdown  
mode (Fig. 14).  
• If a screen other than the default screen is displayed on  
the CVC/ICVC, the name of that screen is in the upper  
right corner (Fig. 15).  
RUNNING TEMP CONTROL  
LEAVING CHILLED WATER  
01-01-95 11:48  
28.8 HOURS  
CHW IN  
CHW OUT  
EVAP REF  
ALARM LIGHT  
55.1  
44.1  
40.7  
(ILLUMINATED  
CDW IN  
CDW OUT  
COND REF  
WHEN POWER ON)  
85.0  
95.0  
98.1  
BLINKS CONTINUOUSLY  
•
OIL PRESS  
OIL TEMP  
AMPS %  
ON FOR AN ALARM  
21.8  
CCN  
132.9  
93  
MENU  
BLINKS ONCE TO  
•
LOCAL  
RESET  
CONFIRM A STOP  
• The CVC/ICVC may be set to display either English or  
SI units. Use the CVC/ICVC configuration screen  
(accessed from the Service menu) to change the units.  
See the Service Operation section, page 45.  
STOP BUTTON  
HOLD FOR ONE  
•
SECOND TO STOP  
• Local Operation — The PIC II can be placed in local  
SOFT KEYS  
operating mode by pressing the  
softkey. The  
LOCAL  
MENU  
LINE  
EACH KEY'S FUNCTION IS  
PIC II then accepts commands from the CVC/ICVC only  
and uses the Local Time Schedule to determine chiller  
start and stop times.  
DEFINED BY THE MENU DESCRIPTION  
ON MENU LINE ABOVE  
Fig. 14 — CVC/ICVC Default Screen  
• CCN Operation — The PIC II can be placed in the CCN  
operating mode by pressing the  
softkey. The PIC  
CCN  
II then accepts modifications from any CCN interface or  
module (with the proper authority), as well as from the  
CVC/ICVC. The PIC II uses the CCN time schedule to  
determine start and stop times.  
ALARMS AND ALERTS — An alarm shuts down the com-  
pressor. An alert does not shut down the compressor, but it no-  
tifies the operator that an unusual condition has occurred. An  
alarm (*) or alert (!) is indicated on the STATUS screens on the  
far right field of the CVC/ICVC display screen.  
Alarms are indicated when the control center alarm light (!)  
flashes. The primary alarm message is displayed on the default  
screen. An additional, secondary message and troubleshooting  
information are sent to the ALARM HISTORY table.  
SERVICE  
19XR_II  
ALARM HISTORY  
CONTROL TEST  
CONTROL ALGORITHM STATUS  
EQUIPMENT CONFIGURATION  
ISM (STARTER) CONFIGURATION DATA  
EQUIPMENT SERVICE  
TIME AND DATE  
ATTACH TO NETWORK DEVICE  
LOG OUT OF DEVICE  
CVC CONFIGURATION  
When an alarm is detected, the CVC/ICVC 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 information.  
RESET  
Once all alarms have been cleared (by pressing the  
softkey), the default CVC/ICVC screen will return to normal  
operation.  
CVC/ICVC MENU ITEMS — To perform any of the opera-  
tions described below, the PIC II must be powered up and have  
successfully completed its self test. The self test takes place au-  
tomatically, after power-up.  
Fig. 15 — CVC/ICVC Service Screen  
Press the  
softkey to view the list of menu struc-  
MENU  
tures:  
,
,
,
and  
STATUS  
SCHEDULE  
SETPOINT  
.
SERVICE  
Press the softkey that corresponds to the menu structure to  
• The STATUS menu allows viewing and limited calibra-  
tion or modification of control points and sensors, relays  
and contacts, and the options board.  
• The SCHEDULE menu allows viewing and modification  
of the local and CCN time schedules and Ice Build time  
schedules.  
• The SETPOINT menu allows set point adjustments, such  
as the entering chilled water and leaving chilled water set  
points.  
• The SERVICE menu can be used to view or modify  
information on the Alarm History, Control Test, Control  
Algorithm Status, Equipment Configuration, ISM Starter  
Configuration data, Equipment Service, Time and Date,  
Attach to Network Device, Log Out of Network Device,  
and CVC/ICVC Configuration screens.  
be viewed:  
SERVICE  
,
, or  
STATUS SCHEDULE  
. To view or change parameters within any of these  
SETPOINT  
menu structures, use the  
and  
softkeys  
SELECT  
NEXT  
to scroll down to the desired item or table. Use the  
PREVIOUS  
softkey to select that item. The softkey choices that then appear  
depend on the selected table or menu. The softkey choices and  
their functions are described below.  
BASIC CVC/ICVC OPERATIONS (Using the Soft-  
keys) — To perform any of the operations described below,  
the PIC II must be powered up and have successfully complet-  
ed its self test.  
15  
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• Press  
to leave the selected decision or field with-  
QUIT  
2. Press  
or  
to highlight the desired  
PREVIOUS  
NEXT  
out saving any changes.  
status table. The list of tables is:  
•MAINSTAT — Overall chiller status  
•STARTUP — Status required to perform start-up of  
chiller  
•COMPRESS — Status of sensors related to the  
compressor  
•HEAT_EX — Status of sensors related to the heat  
exchangers  
• Press  
to leave the selected decision or field and  
ENTER  
save changes.  
•POWER — Status of motor input power  
•ISM_STAT — Status of motor starter  
•CVC_PSWD — Service menu password forcing  
access screen  
•ICVC_PSWD — Service menu password forcing  
access screen  
• Press  
to scroll the cursor bar down in order to  
NEXT  
highlight a point or to view more points below the cur-  
rent screen.  
3. Press  
to view the desired point status table.  
SELECT  
• Press  
to scroll the cursor bar up in order to  
PREVIOUS  
highlight a point or to view points above the current  
screen.  
4. On the point status table, press  
or  
PREVIOUS  
NEXT  
until the desired point is displayed on the screen.  
• Press  
to view the next screen level (high-  
SELECT  
lighted with the cursor bar), or to override (if allowable)  
the highlighted point value.  
POINT STATUS  
OFF  
19XR_II MAINSTAT  
Control Mode  
Run Status  
Ready  
0.0 Min  
NO  
Start Inhibit Timer  
Occupied?  
System Alert/Alarm  
Chiller Start/Stop  
Remote Start Contact  
Temperature Reset  
Control Point  
Chilled Water Temp  
Active Demand Limit  
Average Line Current  
NORMAL  
STOP  
Open  
0.0 F  
• Press  
to return to the previous screen level.  
EXIT  
44.0 F  
44.6 F  
100%  
0.0%  
• Press  
or  
to change the high-  
DECREASE  
INCREASE  
lighted point value.  
Fig. 16 — Example of Status Screen  
OVERRIDE OPERATIONS  
To Override a Value or Status  
1. From any point status screen, press  
or  
NEXT  
TO VIEW STATUS (Fig. 16) — The status table shows the  
actual value of overall chiller status such as CONTROL  
MODE, RUN STATUS, AUTO CHILLED WATER RESET,  
and REMOTE RESET SENSOR.  
to highlight the desired value.  
PREVIOUS  
1. On the menu screen, press  
point status tables.  
to view the list of  
STATUS  
2. Press  
to select the highlighted value. Then:  
SELECT  
16  
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•
DEFAULT SCREEN  
LOCAL RESET  
MENU  
(SOFTKEYS)  
CCN  
Start Chiller In CCN Control  
Start Chiller in Local Control  
Clear Alarms  
Access Main Menu  
SCHEDULE  
SETPOINT  
STATUS  
SERVICE  
1 1 1 1  
(ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)  
List the  
Status Tables  
List the Service Tables  
Display The Setpoint Table  
• MAINSTAT  
• STARTUP  
• COMPRESS  
• HEAT_EX  
• POWER  
• ISM_STAT  
• CVC_PSWD  
List the Schedules  
• Base Demand Limit  
• LCW Setpoint  
• ECW Setpoint  
• Ice Build Setpoint  
• Tower Fan High Setpoint  
Select a Status Table  
PREVIOUS  
Select the Setpoint  
SELECT  
SELECT  
EXIT  
EXIT  
NEXT  
SELECT  
QUIT  
PREVIOUS  
EXIT  
NEXT  
Modify the Setpoint  
Select a Modification Point  
PREVIOUS  
ENTER  
INCREASE  
DECREASE  
NEXT  
Modify a Discrete Point  
START  
ON  
ENTER  
STOP  
OFF  
RELEASE  
Modify an Analog Point  
INCREASE  
• OCCPC01S – LOCAL TIME SCHEDULE  
DECREASE  
ENTER  
ENTER  
RELEASE  
QUIT  
• OCCPC02S – ICE BUILD TIME SCHEDULE  
• OCCPC03S – CCN TIME SCHEDULE  
Modify Control Options  
DISABLE  
Select a Schedule  
ENABLE  
SELECT  
PREVIOUS  
EXIT  
NEXT  
1
2
3
4
5
6
7
8
Override  
Select a Time Period/Override  
SELECT  
ENTER  
ENTER  
PREVIOUS  
EXIT  
EXIT  
EXIT  
NEXT  
Modify a Schedule Time  
INCREASE DECREASE  
(ANALOG VALUES)  
(DISCRETE VALUES)  
Add/Eliminate a Day  
ENABLE  
DISABLE  
ALARM HISTORY  
CONTROL TEST  
CONTROL ALGORITHM STATUS  
EQUIPMENT CONFIGURATION  
ISM (STARTER) CONFIG DATA  
EQUIPMENT SERVICE  
TIME AND DATE  
ATTACH TO NETWORK DEVICE  
LOG OUT OF DEVICE  
CVC CONFIGURATION  
ICVC CONFIGURATION  
SELECT  
PREVIOUS  
EXIT  
NEXT  
SEE FIGURE 18  
Fig. 17 — 19XR Chiller Display Menu Structure (CVC/ICVC)  
17  
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SERVICE TABLE  
PREVIOUS  
ALARM HISTORY  
•
SELECT  
EXIT  
NEXT  
Display Alarm History  
(The table holds up to 25 alarms and  
alerts with the most recent alarm  
at the top of the screen.)  
CONTROL TEST  
List the Control Tests  
• CCM Thermistors  
• CCM Pressure Transducers  
• Pumps  
CONTROL ALGORITHM STATUS  
• Discrete Outputs  
• Guide Vane Actuator  
• Diffuser Actuator  
List the Control Algorithm Status Tables  
• CAPACITY (Capacity Control)  
• Pumpdown/Lockout  
• Terminate Lockout  
• Guide Vane Calibration  
• OVERRIDE (Override Status)  
• LL_MAINT (Lead Lag Status)  
• ISM_HIST (ISM Alarm History)  
• LOADSHED  
Select a Test  
• WSMDEFME (Water System Manager Control Status)  
• OCCDEFCM (Time Schedule Status)  
SELECT  
PREVIOUS  
EXIT  
NEXT  
Select a Table  
SELECT  
PREVIOUS  
EXIT  
NEXT  
OCCDEFM (Time Schedule Status)  
Data Select Table  
• CAPACITY (Capacity Control Algorithm)  
• OVERRIDE (Override Status)  
• LL_MAINT (LEADLAG Status)  
SELECT  
PREVIOUS  
EXIT  
NEXT  
• WSMDEFM2 (Water System Manager Control Status)  
OCCPC01S (Local Status)  
OCCPC02S (CCN, ICE BUILD Status)  
OCCPC03S (CCN Status)  
Maintenance Table Data  
EQUIPMENT CONFIGURATION  
List the Equipment Configuration Tables  
• NET_OPT  
• BRODEF  
• OCCEFCS  
• HOLIDAYS  
• CONSUME  
• RUNTIME  
Select a Table  
SELECT  
PREVIOUS  
EXIT  
NEXT  
Select a Parameter  
SELECT  
PREVIOUS  
EXIT  
NEXT  
ICVC CONFIGURATION  
Modify a Parameter  
INCREASE  
ENTER  
ENTER  
(ANALOG VALUES)  
(DISCRETE VALUES)  
DECREASE  
QUIT  
QUIT  
DISABLE  
ENABLE  
CONTINUED  
ON NEXT PAGE  
SELECT (USE ENTER) TO SCROLL DOWN  
LID LANGUAGE  
ENTER  
INCREASE  
DECREASE  
EXIT  
Fig. 18 — 19XR Service Menu Structure  
18  
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SERVICE MENU CONTINUED  
FROM PREVIOUS PAGE  
ISM (STARTER) CONFIG DATA  
EQUIPMENT SERVICE  
(ENTER A 4-DIGIT PASSWORD)  
(VALUES SHOWN AT FACTORY DEFAULT)  
4 4 4 4  
Service Tables:  
• OPTIONS  
• SETUP1  
Service Tables:  
• ISM (STARTER) CONFIG PASSWORD  
• ISM_CONF  
• SETUP2  
• LEADLAG  
• RAMP_DEM  
• TEMP_CTL  
Select a Service Table  
PREVIOUS  
SELECT  
EXIT  
EXIT  
NEXT  
Select a Service Table Parameter  
SELECT  
PREVIOUS  
NEXT  
Modify a Service Table Parameter  
INCREASE  
ENTER  
ENTER  
(ANALOG VALUES)  
(DISCRETE VALUES)  
DECREASE  
QUIT  
DISABLE  
QUIT  
ENABLE  
TIME AND DATE  
Display Time and Date Table:  
• To Modify — Current Time  
— Current Date  
— Day of Week  
— Holiday Today  
ATTACH TO NETWORK DEVICE  
EXIT  
(ANALOG VALUE)  
DECREASE  
ENTER  
INCREASE  
List Network Devices  
• Local  
• Device 6  
NO  
EXIT  
YES  
ENTER  
(DISCRETE VALUE)  
• Device 1 • Device 7  
• Device 2 • Device 8  
• Device 3 • Device 9  
• Device 4  
• Device 5  
Select a Device  
SELECT  
ENTER  
ATTACH  
EXIT  
PREVIOUS  
NEXT  
Modify Device Address  
INCREASE  
DECREASE  
• Use to attach CVC to another CCN network or device  
• Attach to "LOCAL" to enter this machine  
• To upload new tables  
LOG OUT OF DEVICE  
Default Screen  
LOCAL  
RESET  
MENU  
CCN  
CVC CONFIGURATION  
CVC Configuration Table  
INCREASE  
• To Modify — CVC CCN Address  
— English (U.S. IMP.) or S.I. Metric Units  
— Password  
DECREASE  
ENTER  
EXIT  
• To View — CVC Software Version  
(last 2 digits of part number  
indicate software version)  
LEGEND  
CCN — Carrier Comfort Network  
CVC — Chiller Visual Controller  
ICVC — International Chiller Visual Controller  
ISM — Integrated Starter Module  
PIC II — Product Integrated Control II  
Fig. 18 — 19XR Service Menu Structure (cont)  
19  
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For Discrete Points — Press  
or  
to se-  
OCCPC02S — ICE BUILD Time Schedule  
OCCPC03S — CCN Time Schedule  
START  
Press  
STOP  
lect the desired state.  
For Analog Points  
DECREASE  
—
or  
INCREASE  
3. Press  
to view the desired time schedule.  
SELECT  
NEXT  
to select the desired value.  
4. Press  
or  
to highlight the desired  
PREVIOUS  
3. Press  
to register the new value.  
ENTER  
period or override to change.  
NOTE: When overriding or changing metric values, it is nec-  
essary to hold down the softkey for a few seconds in order to  
see a value change, especially on kilopascal values.  
5. Press  
to access the highlighted period or  
SELECT  
override.  
To Remove an Override  
1. On the point status table press  
to highlight the desired value.  
or  
PREVIOUS  
NEXT  
6. a. Press  
or  
to change the  
DECREASE  
INCREASE  
time values. Override values are in one-hour  
increments, up to 4 hours.  
2. Press  
3. Press  
to access the highlighted value.  
SELECT  
b. Press  
to select days in the day-of-week  
ENABLE  
fields. Press  
to eliminate days from the  
DISABLE  
period.  
to remove the override and return the  
RELEASE  
point to the PIC II’s automatic control.  
Override Indication — An override value is indicated by  
“SUPVSR,” “SERVC,” or “BEST” flashing next to the point  
value on the STATUS table.  
TIME SCHEDULE OPERATION (Fig. 19)  
1. On the Menu screen, press  
.
SCHEDULE  
2. Press  
or  
to highlight the desired  
PREVIOUS  
NEXT  
schedule.  
OCCPC01S — LOCAL Time Schedule  
Fig. 19 — Example of Time Schedule  
Operation Screen  
20  
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7. Press  
to register the values and to move hori-  
2. There are 5 set points on this screen: BASE DEMAND  
LIMIT, LCW SETPOINT (leaving chilled water set  
point), ECW SETPOINT (entering chilled water set  
point), ICE BUILD SETPOINT, and TOWER FAN  
HIGH SETPOINT. Only one of the chilled water set  
points can be active at one time. The set point that is  
active is determined from the SERVICE menu. See the  
Service Operation section, page 45. The ice build (ICE  
BUILD) function is also activated and configured from  
the SERVICE menu.  
ENTER  
zontally (left to right) within a period.  
8. Press  
to leave the period or override.  
EXIT  
3. Press  
or  
to highlight the desired  
PREVIOUS  
NEXT  
set point entry.  
9. Either return to Step 4 to select another period or over-  
ride, or press  
again to leave the current time  
EXIT  
schedule screen and save the changes.  
4. Press  
to modify the highlighted set point.  
SELECT  
10. The Holiday Designation (HOLIDEF table) may be  
found in the Service Operation section, page 45. The  
month, day, and duration for the holiday must be  
assigned. The Broadcast function in the BRODEF  
table also must be enabled for holiday periods to  
function.  
5. Press  
or  
to change the select-  
DECREASE  
INCREASE  
ed set point value.  
TO VIEW AND CHANGE SET POINTS (Fig. 20)  
1. To view the SETPOINT table, from the MENU screen  
press  
.
SETPOINT  
6. Press  
to save the changes and return to the pre-  
ENTER  
vious screen.  
SETPOINT SELECT  
100%  
19XR_II  
SETPOINT  
SERVICE OPERATION — To view the menu-driven pro-  
grams available for Service Operation, see Service Operation  
section, page 45. For examples of CVC/ICVC display screens,  
see Table 2.  
Base Demand Limit  
Control Point  
LCW Setpoint  
ECW Setpoint  
ICE BUILD Setpoint  
Tower Fan High Setpoint  
50.0 F  
60.0 F  
40.0 F  
85.0 F  
Fig. 20 — Example of Set Point Screen  
21  
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Table 2 — CVC/ICVC Display Data  
6. Reference Point Names shown in these tables in all capital let-  
ters can be read by CCN and BS software. Of these capitalized  
names, those preceded by a dagger can also be changed (that  
1. Only 12 lines of information appear on the chiller display screen  
at any one time. Press the or softkey to  
highlight a point or to view items below or above the current  
screen. Press the softkey twice to page forward; press  
the softkey twice to page back.  
2. To access the information shown in Examples 10 through 22,  
enter your 4-digit password after pressing the soft-  
key. If no softkeys are pressed for 15 minutes, the CVC/ICVC  
automatically logs off (to prevent unrestricted access to PIC II  
controls) and reverts to the default screen. If this happens, you  
must re-enter your password to access the tables shown in  
Examples 10 through 22.  
3. Terms in the Description column of these tables are listed as they  
appear on the chiller display screen.  
4. The CVC/ICVC may be configured in English or Metric (SI) units  
using the CVC/ICVC CONFIGURATION screen. See the Service  
Operation section, page 45, for instructions on making this  
change.  
5. The items in the Reference Point Name column do not appear on  
the chiller display screen. They are data or variable names used  
in CCN or Building Supervisor (BS) software. They are listed in  
these tables as a convenience to the operator if it is necessary to  
cross reference CCN/BS documentation or use CCN/BS pro-  
grams. For more information, see the 19XR CCN literature.  
22  
Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
(
will be highlighted).  
STATUS MAINSTAT  
3. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Control Mode  
NOTE 1  
NOTE 2  
0-15  
NOTE 1  
MODE  
Run Status  
NOTE 2  
min  
STATUS  
Start Inhibit Timer  
Occupied?  
System Alert/Alarm  
*Chiller Start/Stop  
*Remote Start Contact  
Temperature Reset  
*Control Point  
T_START  
OCC  
0/1  
NO/YES  
NOTE 3  
STOP/START  
OPEN/CLOSE  
DEG F  
DEG F  
DEG F  
%
0-2  
SYS_ALM  
CHIL_S_S  
REMCON  
T_RESET  
LCW_STPT  
CHW_TMP  
DEM_LIM  
%_AMPS  
KW_P  
0/1  
0/1  
–30-30  
10-120  
–40-245  
40-100  
0-999  
0-999  
4-20  
Chilled Water Temp  
*Active Demand Limit  
Average Line Current  
Motor Percent Kilowatts  
Auto Demand Limit Input  
Auto Chilled Water Reset  
Remote Reset Sensor  
Total Compressor Starts  
Starts in 12 Hours  
Compressor Ontime  
*Service Ontime  
%
%
mA  
AUTODEM  
AUTORES  
R_RESET  
c_starts  
4-20  
mA  
–40-245  
0-99999  
0-8  
DEG F  
STARTS  
0-500000.0  
0-32767  
0-1  
HOURS  
HOURS  
OPEN/CLOSE  
mA  
c_hrs  
S_HRS  
Ice Build Contact  
Refrigerant Leak Sensor  
ICE_CON  
REF_LEAK  
0-20  
NOTES:  
1. Reset, Off, Local, CCN  
2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout  
3. Normal, Alert, Alarm  
4. All variables with capital letter point names are available for CCN read operation. Those shown with (*) support write operations for all CCN  
devices.  
EXAMPLE 3 — STARTUP DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press STATUS .  
3. Scroll down to highlight  
.
STARTUP  
4. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Actual Guide Vane Pos  
**Chilled Water Pump  
Chilled Water Flow  
0-100  
0-1  
%
GV_ACT  
CHWP  
OFF/ON  
0-1  
NO/YES  
CHW_FLOW  
CDP  
**Condenser Water Pump  
Condenser Water Flow  
Oil Pump Relay  
0-1  
OFF/ON  
0-1  
NO/YES  
CDW_FLOW  
OILR  
OILPD  
CMPR  
0-1  
OFF/ON  
**Oil Pump Delta P  
–6.7-200  
0-1  
^PSI  
Compressor Start Relay  
Compressor Start Contact  
Starter Trans Relay  
Compressor Run Contact  
**Tower Fan Relay Low  
**Tower Fan Relay High  
Starter Fault  
OFF/ON  
0-1  
OPEN/CLOSED  
OFF/ON  
CR_AUX  
CMPTRANS  
RUN_AUX  
TFR_LOW  
TFR_HIGH  
STR_FLT  
SAFETY  
TRIPR  
0-1  
0-1  
OPEN/CLOSED  
OFF/ON  
0-1  
0-1  
OFF/ON  
0-1  
ALARM/NORMAL  
ALARM/NORMAL  
OFF/ON  
Spare Safety Input  
0-1  
Shunt Trip Relay  
0-1  
ISM Fault Status  
0-255  
STRSTAT  
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write  
operations for the CVC/ICVC only.  
23  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 4 — COMPRESS DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
STATUS  
3. Scroll down to highlight COMPRESS .  
4. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Actual Guide Vane Pos  
0-100  
%
GV_ACT  
GV_DELTA  
GV_TRG  
OILT  
Guide Vane Delta  
0-100  
%
**Target Guide Vane Pos  
Oil Sump Temp  
**Oil Pump Delta P  
0-100  
%
–40-245  
–6.7-200  
–40-245  
–40-245  
–40-245  
–40-245  
–40-245  
0/1  
DEG F  
^PSI  
DEG F  
DEG F  
DEG F  
DEG F  
DEG F  
OFF/ON  
%
OILPD  
Comp Discharge Temp  
Comp Thrust Brg Temp  
Comp Motor Winding Temp  
Spare Temperature 1  
Spare Temperature 2  
Oil Heater Relay  
CMPD  
MTRB  
MTRW  
SPARE1  
SPARE2  
OILH  
Diffuser Actuator  
0-100  
DIFF_ACT  
VFD_OUT  
VFD_ACT  
SPC  
**Target VFD Speed  
**Actual VFD Speed  
Surge Protection Counts  
0-100  
%
%
0-110  
0-5  
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations  
for the CVC/ICVC only.  
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press STATUS .  
3. Scroll down to highlight  
.
HEAT_EX  
4. Press SELECT .  
DESCRIPTION  
**Chilled Water Delta P  
STATUS  
UNITS  
PSI  
POINT  
–6.7-420  
–40-245  
–40-245  
–6.7-420  
–20-20  
–40-245  
–6.7-420  
0-99  
CHW_PD  
Entering Chilled Water  
Leaving Chilled Water  
Chilled Water Delta T  
Chill Water Pulldown/Min  
Evaporator Refrig Temp  
**Evaporator Pressure  
Evaporator Approach  
**Condenser Water Delta P  
Entering Condenser Water  
Leaving Condenser Water  
Condenser Refrig Temp  
**Condenser Pressure  
Condenser Approach  
Hot Gas Bypass Relay  
Surge / HGBP Active?  
Active Delta P  
DEG F  
DEG F  
^F  
ECW  
LCW  
CHW_DT  
CHW_PULL  
ERT  
^F  
DEG F  
PSI  
ERP  
^F  
PSI  
EVAP_APP  
COND_PD  
ECDW  
LCDW  
CRT  
–6.7-420  
–40-245  
–40-245  
–40-245  
–6.7-420  
0-99  
DEG F  
DEG F  
DEG F  
PSI  
CRP  
^F  
COND_APP  
HGBR  
SHG_ACT  
dp_a  
0/1  
OFF/ON  
NO/YES  
PSI  
0/1  
0-200  
Active Delta T  
0-200  
DEG F  
DEG F  
%
dt_a  
Surge / HGBP Delta T  
Head Pressure Reference  
Evaporator Saturation Temp  
(ICVC only)  
0-200  
dt_c  
0-100  
hpr  
–40-245  
^F  
EST  
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations  
for the CVC/ICVC only.  
24  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 6 — POWER DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press STATUS .  
3. Scroll down to highlight POWER .  
4. Press  
.
SELECT  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Average Line Current  
Actual Line Current  
Average Line Voltage  
Actual Line Voltage  
Power Factor  
0-999  
%
%_AMPS  
AMP_A  
VOLT_P  
VOLT_A  
PF  
0-99999  
0-999  
AMPS  
%
0-99999  
0.0-1.0  
0-99999  
0-99999  
0-99999  
0-99999  
0-99999  
0-99999  
0-99999  
0-99999  
0-99999  
0-999  
VOLTS  
Motor Kilowatts  
kW  
KW_A  
**Motor Kilowatt-Hours  
Demand Kilowatts  
Line Current Phase 1  
Line Current Phase 2  
Line Current Phase 3  
Line Voltage Phase 1  
Line Voltage Phase 2  
Line Voltage Phase 3  
Ground Fault Phase 1  
Ground Fault Phase 2  
Ground Fault Phase 3  
Frequency  
kWH  
kWH  
AMPS  
AMPS  
AMPS  
VOLTS  
VOLTS  
VOLTS  
AMPS  
AMPS  
AMPS  
Hz  
KWH  
DEM_KWH  
AMPS_1  
AMPS_2  
AMPS_3  
VOLTS_1  
VOLTS_2  
VOLTS_3  
GF_1  
0-999  
GF_2  
0-999  
GF_3  
0-99  
FREQ  
I2T Sum Heat-Phase 1  
I2T Sum Heat-Phase 2  
I2T Sum Heat-Phase 3  
0-200  
%
HEAT1SUM  
HEAT2SUM  
HEAT3SUM  
0-200  
%
0-200  
%
NOTES:  
1. All variables with CAPITAL LETTER point names are available for CCN read operation.  
2. Those shown with (**) shall support write operations for CVC/ICVC only.  
EXAMPLE 7 — ISM_STAT DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press  
.
MENU  
2. Press STATUS .  
3. Scroll down to highlight  
4. Press SELECT .  
.
ISM_STAT  
DESCRIPTION  
STATUS  
UNITS  
POINT  
ISM Fault Status  
Single Cycle Dropout  
Phase Loss  
0-223  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
0-1  
ISMFLT  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
FALSE/TRUE  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
FALSE/TRUE  
CYCLE_1  
PH_LOSS  
OV_VOLT  
UN_VOLT  
AMP_UNB  
VOLT_UNB  
OVERLOAD  
LRATRIP  
Overvoltage  
Undervoltage  
Current Imbalance  
Voltage Imbalance  
Overload Trip  
Locked Rotor Trip  
Starter LRA Trip  
Ground Fault  
SLRATRIP  
GRND_FLT  
PH_REV  
Phase Reversal  
Frequency Out of Range  
ISM Power on Reset  
Phase 1 Fault  
FREQFLT  
ISM_POR  
PHASE_1  
PHASE_2  
PHASE_3  
START_OK  
1M_FLT  
Phase 2 Fault  
Phase 3 Fault  
1CR Start Complete  
1M Start/Run Fault  
2M Start/Run Fault  
Pressure Trip Contact  
Starter Fault  
2M_FLT  
PRS_RIP  
STRT_FLT  
NO_AMPS  
ACCELFLT  
HIGHAMPS  
STOP_OK  
1M2MSTOP  
AMPSTOP  
HARDWARE  
Motor Amps Not Sensed  
Starter Acceleration Fault  
High Motor Amps  
1CR Stop Complete  
1M/2M Stop Fault  
NORMAL/ALARM  
NORMAL/ALARM  
NORMAL/ALARM  
Motor Amps When Stopped  
Hardware Failure  
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.  
25  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 8 — CVC/ICVC_PSWD DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
STATUS  
CVC  
3. Scroll down to highlight  
.or  
ICVC  
4. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Disable Service Password  
**Remote Reset Option  
Reset Alarm?  
0-1  
0-1  
0-1  
0-1  
DSABLE/ENABLE  
DSABLE/ENABLE  
NO/YES  
PSWD_DIS  
RESETOPT  
REMRESET  
REM_CCN  
CCN Mode?  
NO/YES  
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations  
for the CVC/ICVC only.  
EXAMPLE 9 — SETPOINT DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press SETPOINT .  
3. Press  
.
SELECT  
DESCRIPTION  
STATUS  
UNITS  
POINT  
DEFAULT  
Base Demand Limit  
Control Point  
40-100  
%
DLM  
100  
ECW Setpoint  
15-120  
10-120  
15-60  
DEG F  
DEG F  
DEG F  
DEG F  
ecw_sp  
lcw_sp  
ice_sp  
tf2_sp  
60.0  
50.0  
40.0  
75  
LCW Setpoint  
Ice Build Setpoint  
Tower Fan High Setpoint  
55-105  
NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.  
EXAMPLE 10 — CAPACITY DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
SERVICE  
3. Scroll down to highlight CONTROL ALGORITHM STATUS .  
4. Press SELECT .  
5. Scroll down to highlight  
.
CAPACITY  
6. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Entering Chilled Water  
Leaving Chilled Water  
Capacity Control  
Control Point  
–40-245  
–40-245  
DEG F  
DEG F  
ECW  
LCW  
10-120  
–99-99  
–99-99  
–99-99  
–99-99  
–99-99  
–2-2  
0-100  
0-100  
0-100  
0-100  
0.1-1.5  
0-100  
0-100  
0-200  
DEG F  
^F  
^F  
^F  
^F  
^F  
%
ctrlpt  
cperr  
Control Point Error  
ECW Delta T  
ecwdt  
ECW Reset  
LCW Reset  
ecwres  
lcwres  
Total Error + Resets  
Guide Vane Delta  
Target Guide Vane Pos  
Actual Guide Vane Pos  
Target VFD Speed  
Actual VFD Speed  
VFD Gain  
error  
gvd  
%
GV_TRG  
GV_ACT  
VFD_IN  
VFD_ACT  
vfd_gain  
DEM_INH  
DMD_RAMP  
VFD_LF  
%
%
%
Demand Limit Inhibit  
Amps/kW Ramp  
VFD Load Factor  
%
%
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance  
screen.  
26  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 11 — OVERRIDE DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
SERVICE  
3. Scroll down to highlight CONTROL ALGORITHM STATUS .  
4. Press SELECT .  
5. Scroll down to highlight  
.
OVERRIDE  
6. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
Comp Motor Winding Temp  
Comp Motor Temp Override  
Condenser Pressure  
–40-245  
150-200  
0-420  
90-180  
–40-245  
2-45  
DEG F  
DEG F  
PSI  
MTRW  
mt_over  
CRP  
Cond Press Override  
Evaporator Refrig Temp  
Evap Ref Override Temp  
Comp Discharge Temp  
Comp Discharge Alert  
Comp Thrust Brg Temp  
Comp Thrust Brg Alert  
Actual Superheat  
PSI  
cp_over  
ERT  
DEG F  
DEG F  
DEG F  
DEG F  
DEG F  
DEG F  
^F  
rt_over  
CMPD  
–40-245  
125-200  
–40-245  
165-185  
–20-99  
6-99  
cd_alert  
MTRB  
tb_alert  
SUPRHEAT  
SUPR_REQ  
CRT  
Superheat Required  
Condenser Refrig Temp  
^F  
DEG F  
–40-245  
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance  
screens.  
EXAMPLE 12 — LL_MAINT DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
SERVICE  
3. Scroll down to highlight CONTROL ALGORITHM STATUS .  
4. Press SELECT .  
5. Scroll down to highlight  
LL_MAINT.  
6. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
LeadLag Control  
LEADLAG: Configuration  
Current Mode  
NOTE 1  
NOTE 2  
0/1  
leadlag  
llmode  
Load Balance Option  
LAG START Time  
LAG STOP Time  
Prestart Fault Time  
Pulldown: Delta T / Min  
Satisfied?  
DSABLE/ENABLE  
loadbal  
lagstart  
lagstop  
preflt  
2-60  
MIN  
2-60  
MIN  
2-30  
MIN  
x.xx  
^F  
pull_dt  
0/1  
NO/YES  
NO/YES  
pull_sat  
leadctrl  
lagmode  
lagstat  
LEAD CHILLER in Control  
LAG CHILLER: Mode  
Run Status  
0/1  
NOTE 3  
NOTE 4  
NOTE 5  
0/1  
Start/Stop  
lag_s_s  
lag_rec  
stdmode  
stdstat  
Std_s_s  
std_rec  
SPARE_1  
SPARE_2  
Recovery Start Request  
STANDBY CHILLER: Mode  
Run Status  
NO/YES  
NOTE 3  
NOTE 4  
NOTE 5  
0/1  
–40-245  
–40-245  
Start/Stop  
Recovery Start Request  
Spare Temperature 1  
Spare Temperature 2  
NO/YES  
DEG F  
DEG F  
NOTES:  
1. DISABLE, LEAD, LAG, STANDBY, INVALID  
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG  
3. Reset, Off, Local, CCN  
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout  
5. Stop, Start, Retain  
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.  
27  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 13 — ISM_HIST DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press  
.
2. Press  
.
3. Scroll down to highlight  
4. Press  
5. Scroll down to highlight  
6. Press  
.
.
.
.
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance  
28  
Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 15 — NET_OPT DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press SERVICE .  
3. Scroll down to highlight  
4. Press SELECT .  
.
EQUIPMENT CONFIGURATION  
5. Scroll down to highlight  
.
NET_OPT  
6. Press  
.
SELECT  
DESCRIPTION  
STATUS  
UNITS  
POINT  
DEFAULT  
Loadshed Function  
Group Number  
0-99  
0-60  
0-120  
ldsgrp  
ldsdelta  
maxldstm  
0
20  
60  
Demand Limit Decrease  
%
MIN  
Maximum Loadshed Time  
CCN Occupancy Config:  
Schedule Number  
3-99  
0-1  
occpcxxe  
occbrcst  
3
Broadcast Option  
DSABLE/ENABLE  
MIN  
DSABLE  
Alarm Configuration  
Re-Alarm Time  
0-1440  
0-1  
30  
Alarm Routing  
10000000  
NOTE: No variables are available for CCN read or write operation.  
EXAMPLE 16 — ISM_CONF DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press SERVICE .  
3. Scroll down to highlight ISM (STARTER) CONFIG DATA .  
4. Press  
.
SELECT  
5. Enter password (4444 Factory Default).  
6. Scroll down to highlight ISM_CONF .  
7. Press  
.
SELECT  
DESCRIPTION  
Starter Type  
STATUS  
0-2  
UNITS  
POINT  
starter  
DEFAULT  
1
(0 = Full, 1 = Red, 2 = SS/VFD)  
Motor Rated Line Voltage  
Volt Transformer Ratio:1  
Overvoltage Threshold  
Undervoltage Threshold  
Over/Under Volt Time  
Voltage % Imbalance  
Voltage Imbalance Time  
Motor Rated Load Amps  
Motor Locked Rotor Trip  
Locked Rotor Start Delay  
Starter LRA Rating  
Motor Current CT Ratio:1  
Current % Imbalance  
Current Imbalance Time  
Grnd Fault CT’s?  
Ground Fault CT Ratio:1  
Ground Fault Current  
Ground Fault Start Delay  
Ground Fault Persistence  
Single Cycle Dropout  
Frequency = 60 Hz? (No = 50)  
Line Frequency Faulting  
200-13200  
1-35  
105-115  
85-95  
1-10  
1-10  
1-10  
10-5000  
100-60000  
1-10  
VOLTS  
v_fs  
460  
1
vt_rat  
%
%
SEC  
%
SEC  
AMPS  
AMPS  
cycles  
AMPS  
overvolt  
undvolt  
uvuntime  
v_unbal  
v_time  
a_fs  
motor_lr  
lrdelay  
start_lr  
ct_turns  
c_unbal  
c_time  
gf_phase  
gf_ctr  
115  
85  
5
10  
5
200  
1000  
5
100-60000  
3-1000  
5-40  
2000  
100  
15  
%
1-10  
SEC  
NO/YES  
5
0-1  
YES  
150  
15  
150  
1-25  
AMPS  
gf_amps  
gf_delay  
gf_pers  
cycdrop  
freq  
1-20  
cycles  
10  
5
DSABLE  
YES  
DSABLE  
1-10  
cycles  
0/1  
DSABLE/ENABLE  
NO/YES  
0/1  
0/1  
DSABLE/ENABLE  
freq_en  
29  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 17 — OPTIONS DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
SERVICE  
3. Scroll down to highlight EQUIPMENT SERVICE .  
4. Press SELECT .  
5. Scroll down to highlight  
.
OPTIONS  
6. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
DEFAULT  
Auto Restart Option  
0/1  
DSABLE/ENABLE  
DSABLE/ENABLE  
%
start  
r_contact  
softstop  
DSABLE  
DSABLE  
100  
Remote Contacts Option  
0/1  
Soft Stop Amps Threshold  
40-100  
Surge / Hot Gas Bypass  
Surge Limit/HGBP Option  
Select: Surge=0, HGBP=1  
Min. Load Point (T1,P1)  
Surge/HGBP Delta T1  
Surge/HGBP Delta P1  
Full Load Point (T2,P2)  
Surge/HGBP Delta T2  
Surge/HGBP Delta P2  
Surge/HGBP Deadband  
0/1  
srg_hgbp  
0
0.5-20  
30-170  
^F  
hgb_dt1  
hgb_dp1  
1.5  
50  
PSI  
0.5-20  
50-170  
0.5-3  
^F  
PSI  
^F  
hbg_dt2  
hgb_dp2  
hbg_db  
10  
85  
1
Surge Protection  
Surge Delta% Amps  
Surge Time Period  
5-20  
7-10  
%
MIN  
surge_a  
surge_t  
10  
8
Ice Build Control  
Ice Build Option  
0/1  
0-2  
DSABLE/ENABLE  
ibopt  
DSABLE  
0
Ice Build Termination  
0=Temp, 1=Contacts, 2=Both  
Ice Build Recycle  
ibterm  
0/1  
DSABLE/ENABLE  
ibrecyc  
DSABLE  
Refrigerant Leak Option  
Refrigerant Leak Alarm mA  
Head Pressure Reference  
Delta P at 0% (4mA)  
Delta P at 100% (20mA)  
Minimum Output  
0/1  
DSABLE/ENABLE  
mA  
DSABLE  
20  
4-20  
REF_LEAK  
20-60  
20-60  
0-100  
PSI  
PSI  
%
HPDPO  
HPDP100  
HPDPMIN%  
25  
35  
0
NOTE: No variables are available for CCN read or write operation.  
EXAMPLE 18 — SETUP1 DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press SERVICE .  
3. Scroll down to highlight EQUIPMENT SERVICE .  
4. Press  
.
SELECT  
5. Scroll down to highlight  
.
SETUP1  
6. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
DEFAULT  
Comp Motor Temp Override  
150-200  
DEG F  
mt_over  
cp_over  
cd_alert  
tb_alert  
200  
125  
200  
175  
Cond Press Override  
90-165  
PSI  
Comp Discharge Alert  
Comp Thrust Brg Alert  
125-200  
165-185  
DEG F  
DEG F  
Chilled Medium  
0/1  
WATER/BRINE  
medium  
cw _db  
ert_trip  
ref_over  
cdfreeze  
WATER  
Chilled Water Deadband  
Evap Refrig Trippoint  
Refrig Override Delta T  
Condenser Freeze Point  
.5-2.0  
^F  
1.0  
33  
3
0.0-40.0  
2.0-5.0  
–20 - 35  
DEG F  
^F  
DEG F  
34  
Evap Flow Delta P Cutout  
Cond Flow Delta P Cutout  
Water Flow Verify Time  
Oil Pressure Verify Time  
Recycle Control  
0.5 - 50.0  
0.5 - 50.0  
0.5-5  
PSI  
evap_cut  
cond_cut  
wflow_t  
oilpr_t  
5.0  
5.0  
5
PSI  
MIN  
SEC  
15-300  
40  
Restart Delta T  
2.0-10.0  
0.5-4.0  
DEG F  
DEG F  
rcycr_dt  
rcycs_dt  
5
1
Shutdown Delta T  
SPARE ALERT/ALARM ENABLE  
Disable=0, Lo=1/3, Hi=2/4  
Spare Temp #1 Enable  
Spare Temp #1 Limit  
Spare Temp #2 Enable  
Spare Temp #2 Limit  
0-4  
sp1_en  
sp1_lim  
sp2_ en  
sp2_ lim  
0
–40-245  
0-4  
DEG F  
DEG F  
245  
0
–40-245  
245  
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 19 — SETUP2 DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press  
.
SERVICE  
3. Scroll down to highlight EQUIPMENT SERVICE .  
4. Press SELECT .  
5. Scroll down to highlight  
.
SETUP2  
6. Press SELECT .  
DESCRIPTION  
STATUS  
UNITS  
POINT  
DEFAULT  
Capacity Control  
Proportional Inc Band  
2-10  
2-10  
1-3  
gv_inc  
gv_dec  
gw_ecw  
6.5  
6.0  
2
Proportional DEC Band  
Proportional ECW Band  
Guide Vane Travel Limit  
30-100  
%
gv_lim  
80  
Diffuser Control  
Diffuser Option  
0-1  
DSABLE/ENABLE  
diff_opt  
gv_25  
df_25  
DSABLE  
Guide Vane 25% Load Pt  
Diffuser 25% Load Point  
Guide Vane 50% Load Pt  
Diffuser 50% Load Point  
Guide Vane 75% Load Pt  
Diffuser 75% Load Point  
Diffuser Full Span mA  
0-78  
%
%
25  
0
0-100  
0-78  
%
gv_50  
df_50  
50  
0
0-100  
0-78  
%
%
gv_75  
df_75  
diff_ma  
75  
0
0-100  
15-22  
%
mA  
18  
VFD Speed Control  
VFD Option  
0/1  
DSABLE/ENABLE  
vfd_opt  
vfd_gain  
vfd_step  
vfd_min  
vfd_max  
vfdlim_i  
DSABLE  
0.75  
2
VFD Gain  
0.1-1.5  
1-5  
VFD Increase Step  
VFD Minimum Speed  
VFD Maximum Speed  
VFD Current Limit  
%
65-100  
90-100  
0-99999  
%
70  
%
100  
250  
Amps  
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.  
EXAMPLE 20 — LEADLAG DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press MENU .  
2. Press SERVICE .  
3. Scroll down to highlight EQUIPMENT SERVICE .  
4. Press  
.
SELECT  
5. Scroll down to highlight LEADLAG  
6. Press SELECT .  
.
DESCRIPTION  
STATUS  
UNITS  
POINT  
DEFAULT  
Lead Lag Control  
LEAD/LAG: Configuration  
DSABLE=0, Lead=1  
LAG=2, STANDBY=3  
Load Balance Option  
Common Sensor Option  
LAG % Capacity  
0-3  
leadlag  
0
0/1  
0/1  
DSABLE/ENABLE  
DSABLE/ENABLE  
%
load/bal  
commsens  
lag_per  
lag_add  
lagstart  
lagstop  
preft  
stndopt  
stnd_per  
stnd_add  
DSABLE  
DSABLE  
25-75  
1-236  
2-60  
2-60  
2-30  
0/1  
50  
LAG Address  
92  
LAG START Timer  
MIN  
10  
LAG STOP Timer  
MIN  
10  
PRESTART FAULT Timer  
STANDBY Chiller Option  
STANDBY % Capacity  
STANDBY Address  
MIN  
5
DSABLE/ENABLE  
%
DSABLE  
25-75  
1-236  
50  
93  
NOTE: No variables are available for CCN read or write operation.  
31  
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Table 2 — CVC/ICVC Display Data (cont)  
EXAMPLE 21 — RAMP_DEM DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press  
.
2. Press  
.
3. Scroll down to highlight  
4. Press  
5. Scroll down to highlight  
6. Press  
.
.
.
.
NOTE: No variables are available for CCN read or write operation.  
EXAMPLE 22 — TEMP_CTL DISPLAY SCREEN  
To access this display from the CVC/ICVC default screen:  
1. Press  
.
2. Press  
.
3. Scroll down to highlight  
4. Press  
5. Scroll down to highlight  
6. Press  
.
.
.
.
32  
display screen. The TARGET VFD SPEED can be manually  
overridden by the operator from the COMPRESS screen. The  
VFD MINIMUM SPEED, MAXIMUM SPEED, VFD GAIN  
and INCREASE STEP can be viewed and modified in the  
SETUP2 display screen. TARGET and ACTUAL VFD SPEED  
can be viewed in the COMPRESS screen.  
ECW CONTROL OPTION — If this option is enabled, the  
PIC II uses the ENTERING CHILLED WATER temperature to  
modulate the vanes instead of the LEAVING CHILLED  
WATER temperature. The ECW CONTROL OPTION may be  
viewed on the TEMP_CTL screen, which is accessed from the  
EQUIPMENT SERVICE screen.  
CONTROL POINT DEADBAND — This is the tolerance  
range on the chilled water/brine temperature control point. If  
the water temperature goes outside the CHILLED WATER  
DEADBAND, the PIC II opens or closes the guide vanes until  
the temperature is within tolerance. The PIC II may be config-  
ured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED  
WATER DEADBAND may be viewed or modified on the  
SETUP1 screen, which is accessed from the EQUIPMENT  
SERVICE table.  
For example, a 1° F (0.6° C) deadband setting controls the  
water temperature within ±0.5° F (0.3° C) of the control point.  
This may cause frequent guide vane movement if the chilled  
water load fluctuates frequently. A value of 1° F (0.6° C) is the  
default setting.  
DIFFUSER CONTROL — On 19XR FRAME sizes 4 and  
5 compressors equipped with a variable discharge diffuser, the  
PIC II adjusts the diffuser actuator position (DIFFUSER  
ACTUATOR on the COMPRESS screen) to correspond to the  
actual guide vane position (ACTUAL GUIDE VANE POS on  
the COMPRESS screen).  
The diffuser control can be enabled or disabled from the  
SETUP2 screen. See Table 2, Example 19. In addition, the dif-  
fuser and guide vane load points may be viewed and modified  
from this screen. These points must be correct for the compres-  
sor size. The diffuser opening can be incremented from fully  
open to completely closed. A 0% setting is fully open; a 100%  
setting is completely closed. To obtain the proper settings for  
Diffuser Control, contact a Carrier Engineering representative.  
PROPORTIONAL BANDS AND GAIN — Proportional band  
is the rate at which the guide vane position is corrected in pro-  
portion to how far the chilled water/brine temperature is from  
the control point. Proportional gain determines how quickly the  
guide vanes react to how quickly the temperature is moving  
from the CONTROL POINT. The proportional bands and gain  
may be viewed or modified from the SETUP2 screen, which is  
accessed from the EQUIPMENT SERVICE table.  
PIC II System Functions  
NOTE: Words not part of paragraph headings and printed in all  
capital letters can be viewed on the CVC/ICVC (e.g., LOCAL,  
CCN, RUNNING, ALARM, etc.). Words printed both in all  
capital letters and italics can also be viewed on the CVC/ICVC  
and are parameters (CONTROL MODE, TARGET GUIDE  
VANE POS, etc.) with associated values (e.g., modes, tempera-  
tures, pressures, percentages, on, off, enable, disable, etc.).  
Words printed in all capital letters and in a box represent soft-  
keys on the CVC/ICVC (e.g.,  
and  
). See  
ENTER  
EXIT  
Table 2 for examples of the type of information that can appear  
on the CVC/ICVC screens. Figures 14-20 give an overview of  
CVC/ICVC operations and menus.  
CAPACITY CONTROL FIXED SPEED — The PIC II con-  
trols the chiller capacity by modulating the inlet guide vanes in  
response to chilled water temperature deviation from the CON-  
TROL POINT. The CONTROL POINT may be changed by a  
CCN network device or is determined by the PIC II adding any  
active chilled water reset to the SET POINT. The PIC II uses  
the PROPORTIONAL INC (Increase) BAND, PROPOR-  
TIONAL DEC (Decrease) BAND, and the PROPORTIONAL  
ECW (Entering Chilled Water) GAIN to determine how fast or  
slow to respond. CONTROL POINT may be viewed or over-  
ridden from the MAINSTAT screen.  
CAPACITY CONTROL VFD — The PIC II controls the  
machine capacity by modulating the motor speed and inlet  
guide vanes in response to chilled water temperature deviation  
from the CONTROL POINT. The controller will maintain the  
highest inlet guide vane setting at the lowest speed to maxi-  
mize efficiency while avoiding surge. The CONTROL POINT  
may be changed by a CCN network device or is determined by  
the PIC II adding any active chilled water reset to the to the  
SET POINT. CONTROL POINT may be viewed or overridden  
from the MAINSTAT screen. The PIC II uses the PROPOR-  
TIONAL INC (Increase) BAND, PROP DEC (Decrease)  
BAND, and the PROPORTIONAL ECW (Entering Chilled  
Water) GAIN to determine how fast or slow it takes the system  
to respond. The VFD GAIN allows for additional adjustment of  
the VFD response. At start-up, the inlet guide vanes (IGV)  
start in the closed position and the VFD ramps to its minimum  
speed setting.  
The PIC II controller then initiates the Capacity Control al-  
gorithm to maintain the chilled water temperature at the CON-  
TROL POINT. During operation when the CONTROL POINT  
is not met, the controller will establish a GUIDE VANE DELTA  
which will either affect a percentage change to the GUIDE  
VANES or the VFD TARGET SPEED. Any change that will be  
made to the IGV position or the VFD SPEED will depend on  
whether the GUIDE VANE DELTA is positive or negative, and  
the status of the Surge Control Algorithm. The Surge Control  
Algorithm determines if the chiller should operate in Normal  
Mode or Surge Prevention Mode. The logic for how the IGV’s  
and VFD SPEED will be affected by the GUIDE VANE DEL-  
TA and the Surge Control Algorithm can be seen below:  
The Proportional Band — There are two response modes, one  
for temperature response above the control point, the other for  
the response below the control point.  
The temperature response above the control point is called  
the PROPORTIONAL INC BAND, and it can slow or quicken  
guide vane response to chilled water/brine temperatures above  
the DEADBAND. The PROPORTIONAL INC BAND can be  
adjusted from a setting of 2 to 10; the default setting is 6.5.  
NORMAL  
CONTROL  
MODE  
SURGE  
PREVENTION  
MODE  
GUIDE VANE  
DELTA  
IGV  
1st  
2nd  
VFD  
2nd  
1st  
IGV  
2nd  
1st  
VFD  
1st  
—
The response below the control point is called the PRO-  
PORTIONAL DEC BAND, and it can slow or quicken the  
guide vane response to chilled water temperature below the  
deadband plus the control point. The PROPORTIONAL DEC  
BAND can be adjusted on the CVC/ICVC from a setting of 2 to  
10. The default setting is 6.0.  
NOTE: Increasing either of these settings causes the guide  
vanes to respond more slowly than they would at a lower  
setting.  
From +0.2 to +2.0  
From –0.2 to –2.0  
Normal Control mode occurs when ACTIVE DELTA T >  
SURGE/HGBP DELTA T.  
Surge Prevention Mode occurs when ACTIVE DELTA T  
≤ SURGE/HGBP DELTA T.  
The TARGET VFD SPEED, ACTUAL VFD SPEED and the  
VFD GAIN can be viewed and modified in the CAPACITY  
33  
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The PROPORTIONAL ECW GAIN can be adjusted on the  
CVC/ICVC display for values of 1, 2, or 3; the default setting  
is 2. Increase this setting to increase guide vane response to a  
change in entering chilled water temperature.  
DEMAND LIMITING — The PIC II responds to the ACTIVE  
DEMAND LIMIT set point by limiting the opening of the  
guide vanes. It compares the ACTIVE DEMAND LIMIT set  
point to the DEMAND LIMIT SOURCE (either the AVERAGE  
LINE CURRENT or the MOTOR KW). Depending on how the  
control is configured. DEMAND LIMIT SOURCE is on the  
RAMP_DEM screen. The default source is the compressor  
motor current.  
CHILLER TIMERS — The PIC II maintains 2 run time  
clocks, known as COMPRESSOR ONTIME and SERVICE  
ONTIME. COMPRESSOR ONTIME indicates the total life-  
time compressor run hours. This timer can register up to  
500,000 hours before the clock turns back to zero. The SER-  
VICE ONTIME is a reset table timer that can be used to indi-  
cate the hours since the last service visit or any other event.  
The time can be changed from the CVC/ICVC to whatever  
value is desired. This timer can register up to 32,767 hours  
before it rolls over to zero.  
The chiller also maintains a start-to-start timer and a stop-  
to-start timer. These timers limit how soon the chiller can be  
started. START INHIBIT TIMER is displayed on the MAIN-  
STAT screen. See the Start-Up/Shutdown/Recycle Sequence  
section, page 46, for more information on this topic.  
ICE BUILD mode, it uses Occupancy Schedule 02  
(OCCPC02S). When the chiller is in CCN mode, it uses  
Occupancy Schedule 03 (OCCPC03S).  
The CCN SCHEDULE NUMBER is configured on the  
NET_OPT display screen, accessed from the EQUIPMENT  
CONFIGURATION table. See Table 2, Example 15. SCHED-  
ULE NUMBER can be changed to any value from 03 to 99. If  
this number is changed on the NET_OPT screen, the operator  
must go to the ATTACH TO NETWORK DEVICE screen to  
upload the new number into the SCHEDULE screen. See  
Fig. 18.  
Safety Controls — The PIC II monitors all safety control  
inputs and, if required, shuts down the chiller or limits the  
guide vanes to protect the chiller from possible damage from  
any of the following conditions:  
• high bearing temperature  
• high motor winding temperature  
• high discharge temperature  
• low discharge superheat*  
• low oil pressure  
• low cooler refrigerant temperature/pressure  
• condenser high pressure or low pressure  
• inadequate water/brine cooler and condenser flow  
• high, low, or loss of voltage  
• ground fault  
• voltage imbalance  
• current imbalance  
OCCUPANCY SCHEDULE — The chiller schedule, de-  
scribed in the Time Schedule Operation section (page 20), de-  
termines when the chiller can run. Each schedule consists of  
from 1 to 8 occupied or unoccupied time periods, set by the op-  
erator. The chiller can be started and run during an occupied  
time period (when OCCUPIED? is set to YES on the MAIN-  
STAT display screen). It cannot be started or run during an un-  
occupied time period (when OCCUPIED? is set to NO on the  
MAINSTAT display screen). These time periods can be set for  
each day of the week and for holidays. The day begins with  
0000 hours and ends with 2400 hours. The default setting for  
OCCUPIED? is YES, unless an unoccupied time period is in  
effect.  
• excessive motor acceleration time  
• excessive starter transition time  
• lack of motor current signal  
• excessive motor amps  
• excessive compressor surge  
• temperature and transducer faults  
*Superheat is the difference between saturation temperature  
and sensible temperature. The high discharge temperature  
safety measures only sensible temperature.  
Starter faults or optional protective devices within the starter  
can shut down the chiller. The protective devices you have for  
your application depend on what options were purchased.  
These schedules can be set up to follow a building’s occu-  
pancy schedule, or the chiller can be set so to run 100% of the  
time, if the operator wishes. The schedules also can be by-  
passed by forcing the CHILLER START/STOP parameter on  
the MAINSTAT screen to START. For more information on  
forced starts, see Local Start-Up, page 46.  
The schedules also can be overridden to keep the chiller in  
an occupied state for up to 4 hours, on a one time basis. See the  
Time Schedule Operation section, page 20.  
Figure 19 shows a schedule for a typical office building  
with a 3-hour, off-peak, cool-down period from midnight to  
3 a.m., following a weekend shutdown. Holiday periods are in  
an unoccupied state 24 hours per day. The building operates  
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays  
from 6:00 a.m. to 1:00 p.m. This schedule also includes the  
Monday midnight to 3:00 a.m. weekend cool-down schedule.  
If compressor motor overload occurs, check the motor for  
grounded or open phases before attempting a restart.  
If the PIC II control initiates a safety shutdown, it displays  
the reason for the shutdown (the fault) on the CVC/ICVC dis-  
play screen along with a primary and secondary message, ener-  
gizes an alarm relay in the starter, and blinks the alarm light on  
the control panel. The alarm is stored in memory and can be  
viewed on the ALARM HISTORY and ISM_HIST screens on  
the CVC/ICVC, along with a message for troubleshooting. If  
the safety shutdown was also initiated by a fault detected in the  
motor starter, the conditions at the time of the fault will be  
stored in ISM_HIST.  
To give more precise information or warnings on the  
chiller’s operating condition, the operator can define alert lim-  
its on various monitored inputs. Safety contact and alert limits  
are defined in Table 3. Alarm and alert messages are listed in  
the Troubleshooting Guide section, page 76.  
NOTE: This schedule is for illustration only and is not  
intended to be a recommended schedule for chiller operation.  
Whenever the chiller is in the LOCAL mode, it uses Occu-  
pancy Schedule 01 (OCCPC01S). When the chiller is in the  
34  
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Table 3 — Protective Safety Limits and Control Settings  
Shunt Trip (Option) — The function of the shunt trip  
option on the PIC II is to act as a safety trip. The shunt trip is  
wired from an output on the ISM to a shunt trip equipped mo-  
tor circuit breaker. If the PIC II tries to shut down the compres-  
sor using a normal shutdown procedure but is unsuccessful for  
20 seconds, the shunt trip output is energized and causes the  
circuit breaker to trip off. If ground fault protection has been  
applied to the starter, the ground fault trip also energizes the  
shunt trip to trip the circuit breaker. Protective devices in the  
starter can also energize the shunt trip. The shunt trip feature  
can be tested using the Control Test feature.  
Default Screen Freeze — When the chiller is in an  
alarm state, the default CVC/ICVC display “freezes,” that is, it  
stops updating. The first line of the CVC/ICVC default screen  
displays a primary alarm message; the second line displays a  
secondary alarm message.  
The CVC/ICVC default screen freezes to enable the opera-  
tor to see the conditions of the chiller at the time of the alarm  
35  
As part of the pre-start checks executed by the controls, the  
oil sump temperature (OIL SUMP TEMP) is compared to the  
cooler refrigerant temperature (EVAPORATOR REFRIG  
TEMP). If the difference between these 2 temperatures is 50 F  
(27.8 C) or less, the start-up will be delayed until the oil tem-  
perature is 50 F (27.8 C) or more. Once this temperature is con-  
firmed, the start-up continues.  
The oil heater relay is energized whenever the chiller com-  
pressor is off and the oil sump temperature is less than 140 F  
(60.0 C) or the oil sump temperature is less than the cooler re-  
frigerant temperature plus 53° F (11.7° C). The oil heater is  
turned off when the oil sump temperature is either  
• more than 152 F (66.7 C), or  
• more than 142 F (61.1 C) and more than the cooler  
refrigerant temperature plus 55° F (12.8° C).  
The oil heater is always off during start-up or when the  
compressor is running.  
The oil pump is also energized during the time the oil is be-  
ing heated (for 60 seconds at the end of every 30 minutes).  
Ramp Loading — The ramp loading control slows down  
the rate at which the compressor loads up. This control can pre-  
vent the compressor from loading up during the short period of  
time when the chiller is started and the chilled water loop has to  
be brought down to CONTROL POINT. This helps reduce  
electrical demand charges by slowly bringing the chilled water  
to CONTROL POINT. The total power draw during this period  
remains almost unchanged.  
There are two methods of ramp loading with the PIC II.  
Ramp loading can be based on chilled water temperature or on  
motor load. Either method is selected from the RAMP__DEM  
screen.  
1. Temperature ramp loading (TEMP PULLDOWN DEG/  
MIN) limits the degrees per minute rate at which either  
leaving chilled water or entering chilled water tempera-  
ture decreases. This rate is configured by the operator on  
the TEMP_CTL screen. The lowest temperature ramp  
rate will also be used if chiller power has been off for  
3 hours or more (even if the motor ramp load is selected  
as the ramp loading method).  
2. Motor load ramp loading (LOAD PULLDOWN) limits  
the degrees per minute rate at which the compressor mo-  
tor current or compressor motor load increases. The  
LOAD PULLDOWN rate is configured by the operator  
on the RAMP_DEM screen in amps or kilowatts. The  
point name is MOTOR LOAD RAMP%/MIN.  
Oil Cooler — The oil must be cooled when the compres-  
sor is running. This is accomplished through a small, plate-type  
heat exchanger (also called the oil cooler) located behind the  
oil pump. The heat exchanger uses liquid condenser refrigerant  
as the cooling liquid. Refrigerant thermostatic expansion  
If kilowatts is selected for the DEMAND LIMIT SOURCE,  
the MOTOR RATED KILOWATTS must be entered (informa-  
tion found on the chiller Requisition form).  
The TEMP PULLDOWN DEG/MIN may be viewed or  
modified on the TEMP_CTL screen which is accessed from  
the EQUIPMENT SERVICE screen. PULLDOWN RAMP  
TYPE, DEMAND LIMIT SOURCE, and MOTOR LOAD  
RAMP %/MIN may be viewed or modified on the  
RAMP_DEM screen.  
Capacity Override (Table 4) — Capacity overrides can  
prevent some safety shutdowns caused by exceeding the motor  
amperage limit, refrigerant low temperature safety limit, motor  
high temperature safety limit, and condenser high pressure  
limit. In all cases there are 2 stages of compressor vane control.  
1. The vanes are prevented from opening further, and the  
status line on the CVC/ICVC indicates the reason for the  
override.  
2. The vanes are closed until the condition decreases to be-  
low the first step set point. Then the vanes are released to  
normal capacity control.  
Whenever the motor current demand limit set point  
(ACTIVE DEMAND LIMIT) is reached, it activates a capacity  
override, again, with a 2-step process. Exceeding 110% of the  
rated load amps for more than 30 seconds will initiate a safety  
shutdown.  
The compressor high lift (surge prevention) set point will  
cause a capacity override as well. When the surge prevention  
set point is reached, the controller normally will only prevent  
the guide vanes from opening. If so equipped, the hot gas by-  
pass valve will open instead of holding the vanes. See the  
Surge Prevention Algorithm section, page 39.  
High Discharge Temperature Control — If the  
discharge temperature increases above 160 F (71.1 C), the  
guide vanes are proportionally opened to increase gas flow  
through the compressor. If the leaving chilled water tempera-  
ture is then brought 5° F (2.8° C) below the control set point  
temperature, the PIC II will bring the chiller into the recycle  
mode.  
Oil Sump Temperature Control — The oil sump  
temperature control is regulated by the PIC II, which uses the  
oil heater relay when the chiller is shut down.  
36  
Table 4 — Capacity Overrides  
Alarm (Trip) Output Contacts — One set of alarm  
contacts is provided in the starter. The contact ratings are pro-  
vided in the certified drawings. The contacts are located on ter-  
minal strip J9, terminals 15 and 16.  
Refrigerant Leak Detector — An input is available  
on the CCM module [terminal J5-5 (–) and J5-6 (+)] for a  
refrigerant leak detector. Enabling REFRIGERANT LEAK  
OPTION (OPTIONS screen) will allow the PIC II controls to  
go into an alarm state at a user configured level (REFRIGER-  
ANT LEAK ALARM mA). The input is configured for 4 to  
20 mA by setting the DIP switch 1 on SW2 at the ON position,  
or configured for 1 to 5 vdc by setting switch 1 at the OFF posi-  
tion. The output of the refrigerant leak detector is displayed as  
REFRIGERANT LEAK SENSOR on the MAINSTAT screen.  
For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed  
and 5 vdc input represents 20 mA displayed.  
Kilowatt Output — An output is available on the CCM  
module [Terminal J8-1 (+) and J8-2 (–)] to represent the power  
consumption of the chiller. The 4 to 20 mA signal generated by  
the CCM module can be wired to the building automation or  
energy management system to monitor the chiller’s energy  
consumption. A 4 mA signal represents the chiller in an off  
37  
The TOWER FAN RELAY LOW and HIGH parameters are  
accessed from the STARTUP screen.  
Condenser Freeze Prevention — This control algo-  
rithm helps prevent condenser tube freeze-up by energizing the  
condenser pump relay. The PIC II controls the pump and, by  
starting it, helps to prevent the water in the condenser from  
freezing. The PIC II can perform this function whenever the  
chiller is not running except when it is either actively in pump-  
down or in pumpdown/lockout with the freeze prevention  
disabled.  
When the CONDENSER REFRIG TEMP is less than or  
equal to the CONDENSER FREEZE POINT, the CONDENS-  
ER WATER PUMP is energized until the CONDENSER RE-  
FRIG TEMP is greater than the CONDENSER FREEZE  
POINT plus 5° F (2.7° C) and the ENTERING CONDENSER  
WATER TEMPERATURE is less than or equal to the CON-  
DENSER FREEZE POINT. An alarm is generated if the chiller  
is in PUMPDOWN mode and the pump is energized. An alert  
is generated if the chiller is not in PUMPDOWN mode and the  
pump is energized. If the chiller is in RECYCLE SHUT-  
DOWN mode, the mode will transition to a non-recycle  
shutdown.  
Auto. Restart After Power Failure — This option  
may be enabled or disabled and may be viewed or modified on  
the OPTIONS screen, which is accessed from the EQUIP-  
MENT CONFIGURATION table. If the AUTO. RESTART  
OPTION is enabled, the chiller will start up automatically after a  
power failure has occurred (after a single cycle dropout; low,  
high, or loss of voltage; and the power is within ± 15% of nor-  
mal). The 15- and 5-minute inhibit timers are ignored during this  
type of start-up.  
When power is restored after the power failure and if the  
compressor had been running, the oil pump will energize for  
one minute before energizing the cooler pump. AUTO.  
RESTART will then continue like a normal start-up.  
Evaporator Freeze Protection (ICVC only) — A  
refrigerant temperature sensor is installed at the bottom of the  
cooler to provide redundant freeze protection. In place of the  
cooler and condenser water pressure transducer inputs on the  
CCM is a 4.3k ohm resister and a jumper lead. When the  
EVAPORATOR REFRIGERANT TEMPERATURE is less  
than the EVAP REFRIG TRIPPOINT plus the REFRIG  
OVERRIDE DELTA T (configurable from 2° to 5°), state 122  
will be displayed and a capacity override will occur. If the  
EVAPORATOR REFRIG TEMP is equal to or less than the  
EVAP Refrig TRIPPOINT, Protective Limit ALARM STATE  
232 will be displayed and the unit will shut down.  
If power to the CVC/ICVC module has been off for more  
than 3 hours or the timeclock has been set for the first time,  
start the compressor with the slowest temperature-based ramp  
load rate possible in order to minimize oil foaming.  
Tower Fan Relay Low and High — Low condenser  
water temperature can cause the chiller to shut down when re-  
frigerant temperature is low. The tower fan relays, located in  
the starter, are controlled by the PIC II to energize and deener-  
gize as the pressure differential between cooler and condenser  
vessels changes. This prevents low condenser water tempera-  
ture and maximizes chiller efficiency. The tower fan relay can  
only accomplish this if the relay has been added to the cooling  
tower temperature controller.  
The tower fan relay low is turned on whenever the condens-  
er water pump is running, flow is verified, and the difference  
between cooler and condenser pressure is more than 30 psid  
(207 kPad) for entering condenser water temperature greater  
than 65 F (18.3 C).  
The tower fan relay low is turned off when the condenser  
pump is off, flow is stopped, or the cooler refrigerant tempera-  
ture is less than the override temperature for ENTERING CON-  
DENSER WATER temperature less than 62 F (16.7 C), or the  
differential pressure is less than 25 psid (172.4 kPad) for enter-  
ing condenser water less than 80 F (27 C).  
The tower fan relay high is turned on whenever the  
condenser water pump is running, flow is verified and the dif-  
ference between cooler and condenser pressure is more than  
35 psid (241.3 kPa) for entering condenser water temperature  
greater than the TOWER FAN HIGH SETPOINT (SETPOINT  
menu, default 75 F [23.9 C]).  
The oil pump is energized occasionally during the time the  
oil is being brought up to proper temperature in order to elimi-  
nate refrigerant that has migrated to the oil sump during the  
power failure. The pump turns on for 60 seconds at the end of  
every 30-minute period until the chiller is started.  
Water/Brine Reset — Three types of chilled water or  
brine reset are available and can be viewed or modified on the  
TEMP_CTL screen, which is accessed from the EQUIPMENT  
SERVICE table.  
The CVC/ICVC default screen indicates when the chilled  
water reset is active. TEMPERATURE RESET on the MAIN-  
STAT screen indicates the amount of reset. The CONTROL  
POINT will be determined by adding the TEMPERATURE  
RESET to the SETPOINT.  
To activate a reset type, access the TEMP_CTL screen and  
input all configuration information for that reset type. Then, in-  
put the reset type number (1, 2, or 3) in the SELECT/ENABLE  
RESET TYPE input line.  
RESET TYPE 1: 4 to 20 mA (1 to 5 vdc) TEMPERATURE  
RESET — Reset Type 1 is an automatic chilled water temper-  
The tower fan relay high is turned off when the condenser  
pump is off, flow is stopped, or the cooler refrigerant tempera-  
ture is less than the override temperature and ENTERING  
CONDENSER WATER is less than 70 F (21.1 C), or the differ-  
ence between cooler and condenser pressure is less than  
28 Psid (193 kPa), or ENTERING CONDENSER WATER  
temperature is less than TOWER FAN HIGH SETPOINT  
minus 3 F (–16.1 C).  
38  
(see wiring diagrams or certified drawings). The temperature  
sensor must be wired to terminal J4-13 and J4-14. To configure  
Reset Type 2, enter the temperature of the remote sensor at the  
point where no temperature reset will occur (REMOTE TEMP  
–> NO RESET). Next, enter the temperature at which the full  
amount of reset will occur (REMOTE TEMP –> FULL  
RESET). Then, enter the maximum amount of reset required to  
operate the chiller (DEGREES RESET). Reset Type 2 can now  
be activated.  
RESET TYPE 3 — Reset Type 3 is an automatic chilled water  
temperature reset based on cooler temperature difference.  
Reset Type 3 adds ± 30° F (± 16° C) based on the temperature  
difference between the entering and leaving chilled water  
temperature.  
To configure Reset Type 3, enter the chilled water tempera-  
ture difference (the difference between entering and leaving  
chilled water) at which no temperature reset occurs (CHW  
DELTA T –> NO RESET). This chilled water temperature dif-  
ference is usually the full design load temperature difference.  
Next, enter the difference in chilled water temperature at which  
the full amount of reset occurs (CHW DELTA T –> FULL RE-  
SET). Finally, enter the amount of reset (DEGREES RESET).  
Reset Type 3 can now be activated.  
where the HOT GAS BYPASS/SURGE PREVENTION is off,  
the point must pass through the deadband region to the line  
determined by the configured values before the HOT GAS  
BYPASS/SURGE PREVENTION will be turned on. As the  
point moves from the region where the HOT GAS BYPASS/  
SURGE PREVENTION is on, the point must pass through the  
deadband region before the HOT GAS BYPASS/SURGE  
PREVENTION is turned off. Information on modifying the de-  
fault set points of the minimum and full load points may be  
found in the Input Service Configurations section, page 55.  
The state of the surge/hot gas bypass algorithm on the  
HEAT_EX DISPLAY SCREEN (Surge/HGBP Active?).  
Corrective action can be taken by making one of 2 choices.  
If a hot gas bypass line is present and the hot gas option is  
selected on the OPTIONS table (SURGE LIMIT/HGBP  
OPTION is set to 1), the hot gas bypass valve can be energized.  
If the hot gas bypass option is not selected (SURGE LIMIT/  
HGBP OPTION is set to 0), hold the guide vanes. See Table 4,  
Demand Limit Control Option — The demand limit  
control option (20 mA DEMAND LIMIT OPT) is externally  
controlled by a 4 to 20 mA or 1 to 5 vdc signal from an energy  
management system (EMS). The option is set up on the  
RAMP_DEM screen. When enabled, 4 mA is the 100% de-  
mand set point with an operator-configured minimum demand  
at a 20 mA set point (DEMAND LIMIT AT 20 mA).  
The auto. demand limit is hardwired to terminals J5-1 (–)  
and J5-2 (+) on the CCM. Switch setting number 1 on SW2  
will determine the type of input signal. With the switch set at  
the ON position the input is configured for an externally pow-  
ered 4 to 20 mA signal. With the switch in the OFF position the  
input is configured for an external 1 to 5 vdc signal.  
LEGEND  
ECW  
HGBP  
LCW  
—
—
—
Entering Chilled Water  
Hot Gas Bypass  
Leaving Chilled Water  
Surge Prevention Algorithm (Fixed Speed  
Chiller) — This is an operator-configurable feature that can  
determine if lift conditions are too high for the compressor and  
then take corrective action. Lift is defined as the difference be-  
tween the pressure at the impeller eye and at the impeller  
discharge. The maximum lift a particular impeller wheel can  
perform varies with the gas flow across the impeller and the  
size of the wheel.  
∆P = (Condenser Psi) – (Cooler Psi)  
∆T = (ECW) – (LCW)  
Fig. 21 — 19XR Hot Gas Bypass/Surge  
Prevention with Default English Settings  
A surge condition occurs when the lift becomes so high the  
gas flow across the impeller reverses. This condition can even-  
tually cause chiller damage. The surge prevention algorithm  
notifies the operator that chiller operating conditions are mar-  
ginal and to take action to help prevent chiller damage such as  
lowering entering condenser water temperature.  
The surge prevention algorithm first determines if correc-  
tive action is necessary. The algorithm checks 2 sets of opera-  
tor-configured data points, the minimum load points (MIN.  
LOAD POINT [T1,P1]) and the full load points (FULL LOAD  
POINT [T2,P2]). These points have default settings as defined  
on the OPTIONS screen or on Table 4.  
The surge prevention algorithm function and settings are  
graphically displayed in Fig. 21 and 22. The two sets of load  
points on the graph (default settings are shown) describe a line  
the algorithm uses to determine the maximum lift of the com-  
pressor. When the actual differential pressure between the cool-  
er and condenser and the temperature difference between the  
entering and leaving chilled water are above the line on the  
graph (as defined by the minimum and full load points), the al-  
gorithm goes into a corrective action mode. If the actual values  
are below the line and outside of the deadband region, the algo-  
rithm takes no action. When the point defined by the ACTIVE  
DELTA P and ACTIVE DELTA T, moves from the region  
LEGEND  
ECW  
HGBP  
LCW  
—
—
—
Entering Chilled Water  
Hot Gas Bypass  
Leaving Chilled Water  
∆P = (Condenser kPa) – (Cooler kPa)  
∆T = (ECW) – (LCW)  
Fig. 22 — 19XR Hot Gas Bypass/Surge  
Prevention with Default Metric Settings  
39  
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Capacity Overrides. Both of these corrective actions try to  
reduce the lift experienced by the compressor and help prevent  
a surge condition.  
parameter, and use the  
or  
softkey  
DECREASE  
INCREASE  
to adjust the amount of time. The default setting is 8 minutes.  
Access the display screen (COMPRESS) to monitor the  
surge count (SURGE PROTECTION COUNTS).  
Surge Prevention Algorithm with VFD — This is  
an operator configurable feature that can determine if lift con-  
ditions are too high for the compressor and then take corrective  
action. Lift is defined as the difference between the pressure at  
the impeller eye and at the impeller discharge. The maximum  
lift a particular impeller wheel can perform varies with the gas  
flow through the impeller and the diameter of the impeller.  
A surge condition occurs when the lift becomes so high the  
gas flow across the impeller reverses. This condition can even-  
tually cause chiller damage. When enabled, the Surge Preven-  
tion Algorithm will adjust either the inlet guide vane (IGV)  
position or compressor speed to maintain the compressor at a  
safe distance from surge while maintaining machine efficiency.  
If the surge condition degrades then the algorithm will move  
aggressively away from surge. This condition can be identified  
when the SURGE/HGBP ACTIVE? on the HEAT_EX display  
screen displays a YES.  
Surge Protection (Fixed Speed Chiller) — The  
PIC II monitors surge, which is a fluctuation in compressor  
motor amperage. Each time the fluctuation exceeds an  
operator-specified limit (SURGE DELTA % AMPS), the PIC II  
counts the surge. If more than 5 surges occur within an  
operator-specified time (SURGE TIME PERIOD), the PIC II  
initiates a surge protection shutdown of the chiller.  
The surge limit can be adjusted from the OPTIONS screen.  
Scroll down to the SURGE DELTA % AMPS parameter, and  
use the  
or  
softkey to adjust the  
INCREASE  
DECREASE  
percent of surge. The default setting is 10% amps.  
The surge time period can also be adjusted from the  
OPTIONS screen. Scroll to the SURGE TIME PERIOD  
parameter, and use the  
to adjust the amount of time. The default setting is 8 minutes.  
or  
softkey  
INCREASE  
DECREASE  
Access the display screen (COMPRESS) to monitor the  
The surge prevention algorithm first determines if correc-  
tive action is necessary. The algorithm checks two sets of  
operator-configured data points, the lower surge point (MIN.  
LOAD POINT [T1,P1]) and the upper surge point (FULL  
LOAD POINT [T2,P2]). The surge characteristics vary be-  
tween different chiller configurations and operating conditions.  
The surge characteristics are factory set based on the original  
selection with the values displayed inside the control panel of  
the chiller. Since operating conditions may affect the surge pre-  
vention algorithm, some field adjustments may be necessary.  
The surge prevention algorithm function and settings are  
graphically displayed on Fig. 21 and 22. The two sets of load  
points on the graph (default settings are shown) describe a line  
the algorithm uses to determine the maximum lift of the com-  
pressor for the particular maximum operating speed. When the  
actual differential pressure between the cooler and condenser  
and the temperature difference between the entering and leav-  
ing chilled water are above the line on the graph (as defined by  
the minimum and full load points), the algorithm operates in  
Surge Prevention mode. This is determined when the ACTIVE  
DELTA T is less than SURGE/HGBP DELTA T minus the  
deadband.  
surge count (SURGE PROTECTION COUNTS).  
HEAD PRESSURE REFERENCE OUTPUT (See  
Fig. 23) — The PIC II control outputs a 4 to 20 mA signal for  
the configurable Delta P (condenser pressure minus evaporator  
pressure) reference curve shown in Fig. 23. An output is avail-  
able on the ISM module [Terminal J8 (+), J8 (–) labeled spare].  
For chillers with Benshaw Inc. solid-state starters terminal strip  
labeled J8 (+), J8 (–) located next to the RediStart MICRO™  
input/output card is provided. The Delta P at 100% (chiller at  
maximum load condition default at 35 psi), DELTA P AT 0%  
(chiller at minimum load condition default at 25 psi) and MIN-  
IMUM OUTPUT points are configurable in the EQUIPMENT  
SERVICE-OPTIONS table. When configuring this output en-  
sure that minimum requirements for oil pressure and proper  
condenser FLASC orifice performance are maintained. The 4  
to 20 mA output can be used as a reference to control a  
tower bypass valve, tower speed control, or condenser pump  
speed control.  
Lead/Lag Control — The lead/lag control system auto-  
matically starts and stops a lag or second chiller in a 2-chiller  
water system. A third chiller can be added to the lead/lag sys-  
tem as a standby chiller to start up in case the lead or lag chiller  
in the system has shut down during an alarm condition and ad-  
ditional cooling is required. Refer to Fig. 17 and 18 for menu,  
table, and screen selection information.  
When in Surge Prevention mode, with a command to in-  
crease capacity, the VFD speed will increase until maximum  
VFD speed is reached. At VFD MAXIMUM SPEED, when Ca-  
pacity still needs to increase, the IGV’s open. When in Surge  
Prevention mode, with a command to decrease capacity only  
the IGVs will close.  
DELTA P  
AT 100%  
Surge Protection VFD Units — The PIC II monitors  
surge, which is detected as a fluctuation in compressor motor  
amperage. Each time the fluctuation exceeds an operator-  
specified limit (SURGE DELTA % AMPS), the PIC II registers  
a surge protection count. If more than 5 surges occur within an  
operator-specified time (SURGE TIME PERIOD), the PIC II  
initiates a surge protection shutdown of the chiller.  
MINIMUM  
REFERENCE  
DELTA P  
OUTPUT  
On VFD units, if a surge count is registered and if ACTUAL  
VFD SPEED is less than VFD MAXIMUM SPEED then motor  
speed will be increased by the configured VFD increase step.  
While the SURGE PROTECTION COUNTS are >0, a speed  
decrease will not be honored.  
DELTA P  
AT 0%  
The surge limit can be adjusted from the OPTIONS screen  
(see Table 2). Scroll down to the SURGE DELTA % AMPS  
parameter, and use the  
or  
softkey  
INCREASE  
DECREASE  
4 mA  
(0%)  
0 mA 2 mA  
20 mA  
(100%)  
to adjust the percent of surge. The default setting is 10% amps.  
4 T0 20 mA OUTPUT  
The surge time period can also be adjusted from the  
OPTIONS screen. Scroll to the SURGE TIME PERIOD  
Fig. 23 — Head Pressure Reference Output  
40  
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NOTE: The lead/lag function can be configured on the LEAD-  
LAG screen, which is accessed from the SERVICE menu and  
EQUIPMENT SERVICE table. See Table 2, Example 20.  
Lead/lag status during chiller operation can be viewed on the  
LL_MAINT display screen, which is accessed from the SER-  
VICE menu and CONTROL ALGORITHM STATUS table.  
See Table 2, Example 12.  
Lead/Lag System Requirements:  
• all chillers in the system must have software capable of  
performing the lead/lag function  
• water pumps MUST be energized from the PIC II  
controls  
• water flows should be constant  
• the CCN time schedules for all chillers must be identical  
Operation Features:  
• 2 chiller lead/lag  
• addition of a third chiller for backup  
• manual rotation of lead chiller  
• load balancing if configured  
• staggered restart of the chillers after a power failure  
• chillers may be piped in parallel or in series chilled water  
flow  
COMMON POINT SENSOR INSTALLATION — Lead/lag  
operation does not require a common chilled water point sen-  
sor. Common point sensors (Spare Temp #1 and #2) can be  
added to the CCM module, if desired. Spare Temp #1 and #2  
are wired to plug J4 terminals 25-26 and 27-28 (J4 lower,  
respectively).  
NOTE: If the common point sensor option is chosen on a  
chilled water system, each chiller should have its own common  
point sensor installed. Each chiller uses its own common point  
sensor for control when that chiller is designated as the lead  
chiller. The PIC II cannot read the value of common point sen-  
sors installed on the other chillers in the chilled water system.  
If leaving chilled water control (ECW CONTROL OPTION  
is set to 0 [DSABLE] TEMP_CTL screen) and a common  
point sensor is desired (COMMON SENSOR OPTION in  
LEADLAG screen selected as 1) then the sensor is wired in  
41  
Standby Chiller Configuration and Operation — A chiller is  
designated as a standby chiller when its LEADLAG: CONFIG-  
URATION value on the LEADLAG screen is set to “3.” The  
standby chiller can operate as a replacement for the lag chiller  
only if one of the other two chillers is in an alarm (*) condition  
(as shown on the CVC/ICVC panel). If both lead and lag chill-  
ers are in an alarm (*) condition, the standby chiller defaults to  
operate in CCN mode, based on its configured occupancy  
schedule and remote contacts input.  
NOTE: Lead chiller percent capacity = 115 – LAG % CAPAC-  
ITY. The LAG % CAPACITY parameter is on the LEADLAG  
screen, which is accessed from the EQUIPMENT SERVICE  
table on the SERVICE menu.  
FAULTED CHILLER OPERATION — If the lead chiller  
shuts down because of an alarm (*) condition, it stops commu-  
nicating to the lag and standby chillers. After 30 seconds, the  
lag chiller becomes the acting lead chiller and starts and stops  
the standby chiller, if necessary.  
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.  
If the lag chiller goes into alarm when the lead chiller is also  
in alarm, the standby chiller reverts to a stand-alone CCN  
mode of operation.  
2. Lead chilled water temperature must be greater than the  
CONTROL POINT temperature (see the MAINSTAT  
screen) plus 1/2 the CHILLED WATER DEADBAND  
temperature (see the SETUP1 screen).  
If the lead chiller is in an alarm (*) condition (as shown on  
the CVC/ICVC panel), press the  
softkey to clear the  
RESET  
alarm. The chiller is placed in CCN mode. The lead chiller  
communicates and monitors the RUN STATUS of the lag and  
standby chillers. If both the lag and standby chillers are run-  
ning, the lead chiller does not attempt to start and does not as-  
sume the role of lead chiller until either the lag or standby chill-  
er shuts down. If only one chiller is running, the lead chiller  
waits for a start request from the operating chiller. When the  
configured lead chiller starts, it assumes its role as lead chiller.  
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 wa-  
ter sensor, depending on which options are configured  
and enabled.  
3. Lead chiller ACTIVE DEMAND LIMIT (see the MAIN-  
STAT screen) value must be greater than 95% of full load  
amps.  
4. Lead chiller temperature pulldown rate (TEMP PULL-  
DOWN DEG/MIN on the TEMP_CTL screen) of the  
chilled water temperature is less than 0.5° F (0.27° C) per  
minute.  
If the lag chiller is the only chiller running when the lead  
chiller assumes its role as a lead chiller then the lag chiller will  
perform a RECOVERY START REQUEST (LL_MAINT  
screen). The lead chiller will start up when the following condi-  
tions are met.  
1. Lag chiller ramp loading must be complete.  
2. Lag CHILLED WATER TEMP (MAINSTAT screen) is  
5. The lag chiller status indicates it is in CCN mode and is  
not in an alarm condition. If the current lag chiller is in an  
alarm condition, the standby chiller becomes the active  
lag chiller, if it is configured and available.  
6. The configured LAG START TIMER entry has elapsed.  
The LAG START TIMER starts when the lead chiller ramp  
loading is completed. The LAG START TIMER entry is  
on the LEADLAG screen, which is accessed from the  
EQUIPMENT SERVICE table of the SERVICE menu.  
1
greater than CONTROL POINT plus /2 the CHILLED  
WATER DEADBAND temperature.  
3. Lag chiller ACTIVE DEMAND LIMIT value must be  
greater than 95% of full load amps.  
4. Lag chiller temperature pulldown rate (TEMP PULL-  
DOWN DEG/MIN) of the chilled water temperature is  
less than 0.5 F (0.27 C) per minute.  
5. The standby chiller is not running as a lag chiller.  
When all the above requirements have been met, the lag  
chiller is commanded to a STARTUP mode (SUPVSR flashing  
next to the point value on the STATUS table). The PIC II con-  
trol then monitors the lag chiller for a successful start. If the lag  
chiller fails to start, the standby chiller, if configured, is started.  
Lag Chiller Shutdown Requirements — The following condi-  
tions must be met in order for the lag chiller to be stopped.  
1. Lead chiller compressor motor average line current or  
load value (MOTOR PERCENT KILOWATTS on the  
MAINSTAT screen) is less than the lead chiller percent  
capacity.  
6. The configured LAG START TIMER has elapsed. The  
LAG START TIMER is started when ramp loading is  
completed.  
LOAD BALANCING — When the LOAD BALANCE  
OPTION (see LEADLAG screen) is enabled, the lead chiller  
sets the ACTIVE DEMAND LIMIT in the lag chiller to the lead  
chiller’s compressor motor load value MOTOR PERCENT  
KILOWATTS or AVERAGE LINE CURRENT on the MAIN-  
STAT screen). This value has limits of 40% to 100%. When the  
lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL  
POINT must be modified to a value of 3° F (1.67° C) less than  
the lead chiller’s CONTROL POINT value. If the LOAD BAL-  
ANCE OPTION is disabled, the ACTIVE DEMAND LIMIT  
and the CONTROL POINT are forced to the same value as the  
lead chiller.  
NOTE: Lead chiller percent capacity = 115 – LAG % CA-  
PACITY. The LAG % CAPACITY parameter is on the  
LEADLAG screen, which is accessed from the EQUIP-  
MENT SERVICE table on 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 con-  
figuration. The lead chiller does not have a delay. The lag chill-  
er has a 45-second delay. The standby chiller has a 90-second  
delay. The delay time is added after the chiller water flow is  
verified. The PIC II ensures the guide vanes are closed. After  
the guide vane position is confirmed, the delay for lag and  
standby chillers occurs prior to energizing the oil pump. The  
normal start-up sequence then continues. The auto. restart de-  
lay sequence occurs whether the chiller is in CCN or LOCAL  
mode and is intended to stagger the compressor motor starts.  
Preventing the motors from starting simultaneously helps re-  
duce the inrush demands on the building power system.  
2. The lead chiller chilled water temperature is less than the  
CONTROL POINT temperature (see the MAINSTAT  
screen) plus 1/2 the CHILLED WATER DEADBAND tem-  
perature (see the SETUP1 screen).  
3. The configured LAG STOP TIMER entry has elapsed.  
The LAG STOP TIMER starts when the lead chiller  
chilled water temperature is less than the chilled water  
CONTROL POINT plus 1/2 of the CHILLED WATER  
DEADBAND and the lead chiller compressor motor load  
(MOTOR PERCENT KILOWATT or AVERAGE LINE  
CURRENT on the MAINSTAT screen) is less than the  
lead chiller percent capacity.  
42  
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LIMIT to the lag or standby chiller as required for ice build, if  
Ice Build Control — The ice build control option auto-  
matically sets the CONTROL POINT of the chiller to a temper-  
ature that allows ice building for thermal storage.  
NOTE: For ice build control to operate properly, the PIC II  
must be in CCN mode.  
configured to do so.  
START-UP/RECYCLE OPERATION — If the chiller is not  
running when ice build activates, the PIC II checks the follow-  
ing conditions, based on the ICE BUILD TERMINATION  
value, to avoid starting the compressor unnecessarily:  
• if ICE BUILD TERMINATION is set to the TEMP option  
and the ENTERING CHILLED WATER temperature is  
less than or equal to the ICE BUILD SETPOINT;  
• if ICE BUILD TERMINATION is set to the CONTACTS  
option and the remote contacts are open;  
• if the ICE BUILD TERMINATION is set to the BOTH  
(temperature and contacts) option and the ENTERING  
CHILLED WATER temperature is less than or equal to  
the ICE BUILD SETPOINT and the remote contacts are  
open.  
NOTE: See Fig. 17 and 18 for more information on ice build-  
related menus.  
The PIC II can be configured for ice build operation.  
• From the SERVICE menu, access the EQUIPMENT  
SERVICE table. From there, select the OPTIONS screen  
to enable or disable the ICE BUILD OPTION. See  
Table 2, Example 17.  
• The ICE BUILD SETPOINT can be configured from the  
SETPOINT display, which is accessed from the PIC II  
main menu. See Table 2, Example 9.  
• The ice build schedule can be viewed or modified from  
the SCHEDULE table. From this table, select the ice  
build schedule (OCCPC02S) screen. See Fig. 19 and the  
section on Time Schedule Operation, page 20, for more  
information on modifying chiller schedules.  
The ice build time schedule defines the period(s) during  
which ice build is active if the ice build option is enabled. If the  
ice build time schedule overlaps other schedules, the ice build  
time schedule takes priority. During the ice build period, the  
CONTROL POINT is set to the ICE BUILD SETPOINT for  
temperature control. The ICE BUILD RECYCLE and ICE  
BUILD TERMINATION parameters, accessed from the  
OPTIONS screen, allow the chiller operator to recycle or ter-  
minate the ice build cycle. The ice build cycle can be config-  
ured to terminate if:  
The ICE BUILD RECYCLE on the OPTIONS screen deter-  
mines whether or not the chiller will go into an ice build RE-  
CYCLE mode.  
• If the ICE BUILD RECYCLE is set to DSABLE (dis-  
able), the PIC II reverts to normal temperature control  
when the ice build function terminates.  
• If the ICE BUILD RECYCLE is set to ENABLE, the PIC  
II goes into an ICE BUILD RECYCLE mode and the  
chilled water pump relay remains energized to keep the  
chilled water flowing when the ice build function termi-  
nates. If the temperature of the ENTERING CHILLED  
WATER increases above the ICE BUILD SETPOINT plus  
the RECYCLE RESTART DELTA T value, the compres-  
sor restarts and controls the chilled water/brine tempera-  
ture to the ICE BUILD SETPOINT.  
• the ENTERING CHILLED WATER temperature is less  
than the ICE BUILD SETPOINT. In this case, the opera-  
tor sets the ICE BUILD TERMINATION parameter to 0  
on the OPTIONS screen.  
• the REMOTE CONTACT inputs from an ice level indi-  
cator are opened. In this case, the operator sets the ICE  
BUILD TERMINATION parameter to 1 on the OPTIONS  
screen.  
TEMPERATURE CONTROL DURING ICE BUILD —  
During ice build, the capacity control algorithm shall use the  
CONTROL POINT minus 5 F (–2.8 C) for control of the  
LEAVING CHILLED WATER temperature. (See Table 2, ex-  
ample 10, the CAPACITY CONTROL parameter on the CA-  
PACITY screen.) The ECW CONTROL OPTION and any tem-  
perature reset option shall be ignored, if enabled, during ice  
build. The AUTO DEMAND LIMIT INPUT shall also be  
ignored if enabled during ice build.  
• ECW CONTROL OPTION and any temperature reset  
options (configured on TEMP_CTL screen).  
• 20 mA DEMAND LIMIT OPT (configured on  
RAMP_DEM screen).  
TERMINATION OF ICE BUILD — The ice build function  
terminates under the following conditions:  
1. Time Schedule — When the current time on the ice build  
time schedule (OCCPC02S) is not set as an ice build time  
period.  
2. Entering Chilled Water Temperature — Compressor  
operation terminates, based on temperature, if the ICE  
BUILD TERMINATION parameter is set to 0 (TEMP),  
the ENTERING CHILLED WATER temperature is less  
than the ICE BUILD SETPOINT, and the ICE BUILD  
RECYCLE is set to DSABLE. If the ICE BUILD RECY-  
CLE OPTION is set to ENABLE, a recycle shutdown oc-  
curs and recycle start-up depends on the LEAVING  
CHILLED WATER temperature being greater than the  
water/brine CONTROL POINT plus the RESTART  
DELTA T temperature.  
• the chilled water temperature is less than the ice build set  
point and the remote contact inputs from an ice level  
indicator are open. In this case, the operator sets the ICE  
BUILD TERMINATION parameter to 2 on the OPTIONS  
screen.  
• the end of the ice build time schedule has been reached.  
ICE BUILD INITIATION — The ice build time schedule  
(OCCPC02S) is the means for activating the ice build option.  
The ice build option is enabled if:  
• a day of the week and a time period on the ice build time  
schedule are enabled. The SCHEDULE screen shows an  
X in the day field and ON/OFF times are designated for  
the day(s),  
• and the ICE BUILD OPTION is enabled.  
The following events take place (unless overridden by a  
higher authority CCN device).  
• CHILLER START/STOP is forced to START.  
• The CONTROL POINT is forced to the ICE BUILD SET-  
POINT.  
• Any force (Auto) is removed from the ACTIVE  
DEMAND LIMIT.  
NOTE: A parameter’s value can be forced, that is, the value  
can be manually changed at the CVC/ICVC by an operator,  
changed from another CCN device, or changed by other algo-  
rithms in the PIC II control system.  
NOTE: The Ice Build steps do not occur if the chiller is config-  
ured and operating as a lag or standby chiller for lead/lag oper-  
ation and is actively being controlled by a lead chiller. The lead  
chiller communicates the ICE BUILD SET POINT, the desired  
CHILLER START/STOP state, and the ACTIVE DEMAND  
3. Remote Contacts/Ice Level Input — Compressor opera-  
tion terminates when the ICE BUILD TERMINATION  
parameter is set to 1 (CONTACTS) and the remote con-  
tacts are open and the ICE BUILD RECYCLE is set to  
DSABLE (0). In this case, the contacts provide ice level  
termination control. The contacts are used to stop the ice  
build function when a time period on the ice build sched-  
ule (OCCPC02S) is set for ice build operation. The re-  
mote contacts can still be opened and closed to start and  
43  
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stop the chiller when a specific time period on the ice  
build schedule is not set for ice build.  
4. Entering Chilled Water Temperature and ICE BUILD  
Contacts — Compressor operation terminates when the  
ICE BUILD TERMINATION parameter is set to  
2 (BOTH) and the conditions described above in items  
2 and 3 for entering chilled water temperature and remote  
contacts have occurred.  
NOTE: It is not possible to override the CHILLER START/  
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT  
variables from CCN devices (with a priority 4 or greater) dur-  
ing the ice build period. However, a CCN device can override  
these settings during 2-chiller lead/lag operation.  
Fig. 24 — Example of Attach to Network  
Device Screen  
module address cannot be found, the message “COMMUNI-  
CATION FAILURE” appears. The CVC/ICVC then reverts  
back to the ATTACH TO DEVICE screen. Try another device  
or check the address of the device that would not attach. The  
upload process time for each CCN module is different. In gen-  
eral, the uploading process takes 1 to 2 minutes. Before leaving  
the ATTACH TO NETWORK DEVICE screen, select the lo-  
cal device. Otherwise, the CVC/ICVC will be unable to display  
information on the local chiller.  
ATTACHING TO OTHER CCN MODULES — If the chill-  
er CVC/ICVC has been connected to a CCN Network or other  
PIC controlled chillers through CCN wiring, the CVC/ICVC  
can be used to view or change parameters on the other control-  
lers. Other PIC II chillers can be viewed and set points changed  
(if the other unit is in CCN control), if desired, from this partic-  
ular CVC/ICVC module.  
If the module number is not valid, the “COMMUNICA-  
TION FAILURE” message will show and a new address num-  
ber must be entered or the wiring checked. If the module is  
communicating properly, the “UPLOAD IN PROGRESS”  
message will flash and the new module can now be viewed.  
Whenever there is a question regarding which module on  
the CVC/ICVC is currently being shown, check the device  
name descriptor on the upper left hand corner of the CVC/  
ICVC screen. See Fig. 24.  
RETURN TO NON-ICE BUILD OPERATIONS — The ice  
build function forces the chiller to start, even if all other sched-  
ules indicate that the chiller should stop. When the ice build  
function terminates, the chiller returns to normal temperature  
control and start/stop schedule operation. The CHILLER  
START/STOP and CONTROL POINT return to normal opera-  
tion. If the CHILLER START/STOP or CONTROL POINT has  
been forced (with a device of less than 4 priority) before the ice  
build function started, when the ice build function ends, the  
previous forces (of less than 4 priority) are not automatically  
restored.  
Attach to Network Device Control — The Service  
menu includes the ATTACH TO NETWORK DEVICE  
screen. From this screen, the operator can:  
• enter the time schedule number (if changed) for  
OCCPC03S, as defined in the NET_OPT screen  
• attach the CVC/ICVC to any CCN device, if the chiller  
has been connected to a CCN network. This may include  
other PIC-controlled chillers.  
• upgrade software  
Figure 24 shows the ATTACH TO NETWORK DEVICE  
screen. The LOCAL parameter is always the CVC/ICVC mod-  
ule address of the chiller on which it is mounted. Whenever the  
controller identification of the CVC/ICVC changes, the change  
is reflected automatically in the BUS and ADDRESS columns  
for the local device. See Fig. 18. Default address for local de-  
vice is BUS 0 ADDRESS 1.  
When the ATTACH TO NETWORK DEVICE screen is ac-  
cessed, information can not be read from the CVC/ICVC on  
any device until one of the devices listed on that screen is at-  
tached. The CVC/ICVC erases information about the module  
to which it was attached to make room for information on an-  
other device. Therefore, a CCN module must be attached when  
this screen is entered.  
When the CCN device has been viewed, the ATTACH TO  
NETWORK DEVICE table should be used to attach to the PIC  
that is on the chiller. Move to the ATTACH TO NETWORK  
DEVICE table (LOCAL should be highlighted) and press the  
softkey to upload the LOCAL device. The CVC/  
ICVC for the 19XR will be uploaded and default screen will  
display.  
ATTACH  
NOTE: The CVC/ICVC will not automatically reattach to the  
local module on the chiller. Press the  
softkey to  
ATTACH  
attach to the LOCAL device and view the chiller operation.  
To attach any CCN device, highlight it using the  
SELECT  
softkey. The message “UP-  
softkey and press the  
ATTACH  
LOADING TABLES, PLEASE WAIT” displays. The CVC/  
ICVC then uploads the highlighted device or module. If the  
44  
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HOLIDAY SCHEDULING (Fig. 25) — The time schedules  
may be configured for special operation during a holiday peri-  
od. When modifying a time period, the “H” at the end of the  
days of the week field signifies that the period is applicable to a  
holiday. (See Fig. 19.)  
Service Operation — An overview of the tables and  
screens available for the SERVICE function is shown in  
Fig. 18.  
TO ACCESS THE SERVICE SCREENS — When the SER-  
VICE screens are accessed, a password must be entered.  
The broadcast function must be activated for the holidays  
configured on the HOLIDEF screen to work properly. Access  
the BRODEF screen from the EQUIPMENT CONFIGURA-  
TION table and select ENABLE to activate function. Note that  
when the chiller is connected to a CCN Network, only one  
chiller or CCN device can be configured as the broadcast de-  
vice. The controller that is configured as the broadcaster is the  
device responsible for transmitting holiday, time, and daylight-  
savings dates throughout the network.  
1. From the main MENU screen, press the  
SERVICE  
softkey. The softkeys now correspond to the numerals  
1, 2, 3, 4.  
2. Press the four digits of the password, one at a time. An  
asterisk (*) appears as each digit is entered  
To access the BRODEF screen, see the SERVICE menu  
structure, Fig. 18.  
To view or change the holiday periods for up to 18 different  
holidays, perform the following operation:  
NOTE: The initial factory-set password is 1-1-1-1. If the  
password is incorrect, an error message is displayed  
1. At the Menu screen, press  
vice menu.  
to access the Ser-  
SERVICE  
2. If not logged on, follow the instructions for Attach to Net-  
work Device or To Log Out. Once logged on, press  
until Equipment Configuration is highlighted.  
NEXT  
3. Once Equipment Configuration is highlighted, press  
to access.  
If this occurs, return to Step 1 and try to access the SER-  
VICE screens again. If the password is correct, the soft-  
key labels change to:  
SELECT  
4. Press  
until HOLIDAYS is highlighted. This is  
NEXT  
the Holiday Definition table.  
5. Press  
to enter the Data Table Select screen.  
SELECT  
This screen lists 18 holiday tables.  
6. Press  
to highlight the holiday table that is to be  
NEXT  
viewed or changed. Each table is one holiday period,  
starting on a specific date, and lasting up to 99 days.  
NOTE: The SERVICE screen password can be changed  
by entering the CVC/ICVC CONFIGURATION screen  
under SERVICE menu. The password is located at the  
bottom of the menu.  
The CVC/ICVC screen displays the following list of  
available SERVICE screens:  
• Alarm History  
• Control Test  
• Control Algorithm Status  
• Equipment Configuration  
• ISM (Starter) Config Data  
• Equipment Service  
• Time and Date  
7. Press  
to access the holiday table. The Config-  
SELECT  
uration Select table now shows the holiday start month  
and day, and how many days the holiday period will last.  
8. Press  
or  
to highlight the month,  
NEXT  
PREVIOUS  
day, or duration.  
9. Press  
to modify the month, day, or duration.  
SELECT  
10. Press  
or  
to change the  
DECREASE  
INCREASE  
selected value.  
11. Press  
12. Press  
to save the changes.  
ENTER  
to return to the previous menu.  
EXIT  
• Attach to Network Device  
• Log Out of Device  
• CVC/ICVC Configuration  
See Fig. 18 for additional screens and tables available from  
the SERVICE screens listed above. Use the  
return to the main MENU screen.  
softkey to  
EXIT  
NOTE: To prevent unauthorized persons from accessing the  
CVC/ICVC service screens, the CVC/ICVC automatically  
signs off and password-protects itself if a key has not been  
pressed for 15 minutes. The sequence is as follows. Fifteen  
minutes after the last key is pressed, the default screen dis-  
plays, the CVC/ICVC screen light goes out (analogous to a  
screen saver), and the CVC/ICVC logs out of the password-  
protected SERVICE menu. Other screen and menus, such as  
the STATUS screen can be accessed without the password by  
pressing the appropriate softkey.  
TO LOG OUT OF NETWORK DEVICE — To access this  
screen and log out of a network device, from the default CVC/  
ICVC screen, press the  
and  
softkeys.  
MENU  
Enter the password and, from the SERVICE menu, highlight  
LOG OUT OF NETWORK DEVICE and press the  
SERVICE  
SELECT  
softkey. The CVC/ICVC default screen will now be displayed.  
Fig. 25 — Example of Holiday Period Screen  
45  
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NOTE: Units equipped with ICVC are not available with fac-  
tory installed chilled water or condenser water flow devices  
(available as an accessory for use with the CCM Control  
board).  
If the water/brine temperature is high enough, the start-up  
sequence continues and checks the guide vane position. If the  
guide vanes are more than 4% open, the start-up waits until the  
PIC II closes the vanes. If the vanes are closed and the oil pump  
pressure is less than 4 psi (28 kPa), the oil pump relay energiz-  
es. The PIC II then waits until the oil pressure (OIL PRESS  
VERIFY TIME, operator-configured, default of 40 seconds)  
reaches a maximum of 18 psi (124 kPa). After oil pressure is  
verified, the PIC II waits 40 seconds, and the compressor start  
relay (1CR) energizes to start the compressor.  
START-UP/SHUTDOWN/  
RECYCLE SEQUENCE (Fig. 26)  
Local Start-Up — Local start-up (or a manual start-up) is  
initiated by pressing the  
menu softkey on the default  
LOCAL  
CVC/ICVC screen. Local start-up can proceed when the chiller  
schedule indicates that the current time and date have been  
established as a run time and date, and after the internal  
15-minute start-to-start and the 1-minute stop-to-start inhibit  
timers have expired. These timers are represented in the START  
INHIBIT TIMER and can be viewed on the MAINSTAT screen  
and DEFAULT screen. The timer must expire before the chiller  
will start. If the timers have not expired the RUN STATUS pa-  
rameter on the MAINSTAT screen now reads TIMEOUT.  
NOTE: The time schedule is said to be “occupied” if the  
OCCUPIED ? parameter on the MAINSTAT screen is set to  
YES. For more information on occupancy schedules, see the  
sections on Time Schedule Operation (page 20), Occupancy  
Schedule (page 34), and To Prevent Accidental Start-Up  
(page 65), and Fig. 19.  
Compressor ontime and service ontime timers start, and the  
compressor STARTS IN 12 HOURS counter and the number of  
starts over a 12-hour period counter advance by one.  
Failure to verify any of the requirements up to this point will  
result in the PIC II aborting the start and displaying the applica-  
ble pre-start mode of failure on the CVC/ICVC default screen.  
A pre-start failure does not advance the STARTS IN 12 HOURS  
counter. Any failure after the 1CR relay has energized results in  
a safety shutdown, advances the starts in 12 hours counter by  
one, and displays the applicable shutdown status on the CVC/  
ICVC display.  
If the OCCUPIED ? parameter on the MAINSTAT screen  
is set to NO, the chiller can be forced to start as follows. From  
the default CVC/ICVC screen, press the  
and  
MENU  
softkeys. Scroll to highlight MAINSTAT. Press the  
softkey. Scroll to highlight CHILLER START/STOP.  
STATUS  
SELECT  
Press the  
the chiller.  
softkey to override the schedule and start  
START  
NOTE: The chiller will continue to run until this forced start is  
released, regardless of the programmed schedule. To release  
the forced start, highlight CHILLER START/STOP from the  
MAINSTAT screen and press the  
action returns the chiller to the start and stop times established  
by the schedule.  
softkey. This  
RELEASE  
The chiller may also be started by overriding the time  
schedule. From the default screen, press the  
and  
MENU  
softkeys. Scroll down and select the current  
SCHEDULE  
schedule. Select OVERRIDE, and set the desired override  
time.  
Another condition for start-up must be met for chillers that  
have the REMOTE CONTACTS OPTION on the EQUIP-  
MENT SERVICE screen set to ENABLE. For these chillers,  
the REMOTE START CONTACT parameter on the MAIN-  
STAT screen must be CLOSED. From the CVC/ICVC default  
screen, press the  
highlight MAINSTAT and press the  
and  
softkeys. Scroll to  
MENU  
STATUS  
SELECT  
down the MAINSTAT screen to highlight REMOTE START  
CONTACT and press the softkey. Then, press the  
softkey. Scroll  
SELECT  
softkey. To end the override, select REMOTE CON-  
A
—
START INITIATED: Pre-start checks are made; evaporator pump  
started.  
CLOSE  
TACTS INPUT and press the  
B
C
—
—
Condenser water pump started (5 seconds after A).  
softkey.  
RELEASE  
Water flows verified (30 seconds to 5 minutes maximum after B).  
Chilled water temperatures checked against control point. Guide  
vanes checked for closure. Oil pump started; tower fan control  
enabled.  
Once local start-up begins, the PIC II performs a series of  
pre-start tests to verify that all pre-start alerts and safeties are  
within the limits shown in Table 4. The RUN STATUS parame-  
ter on the MAINSTAT screen line now reads PRESTART. If a  
test is not successful, the start-up is delayed or aborted. If the  
tests are successful, the chilled water/brine pump relay energiz-  
es, and the MAINSTAT screen line now reads STARTUP.  
D
E
—
—
Oil pressure verified (15 seconds minimum, 300 seconds maximum  
after C).  
Compressor motor starts; compressor ontime and service ontime  
start, 15-minute inhibit timer starts (10 seconds after D), total com-  
pressor starts advances by one, and the number of starts over a  
12-hour period advances by one.  
Five seconds later, the condenser pump relay energizes.  
Thirty seconds later the PIC II monitors the chilled water and  
condenser water flow devices and waits until the WATER  
FLOW VERIFY TIME (operator-configured, default 5 minutes)  
F
—
—
SHUTDOWN INITIATED — Compressor motor stops; compressor  
ontime and service ontime stop, and 1-minute inhibit timer starts.  
G
Oil pump and evaporator pumps deenergized (60 seconds after F).  
Condenser pump and tower fan control may continue to operate if  
condenser pressure is high. Evaporator pump may continue if in  
RECYCLE mode.  
expires to confirm flow. After flow is verified, the chilled water  
1
temperature is compared to CONTROL POINT plus  
/
O/A — Restart permitted (both inhibit timers expired: minimum of 15 minutes  
CHILLED WATER DEADBAND. If the temperature is les2s  
than or equal to this value, the PIC II turns off the condenser  
pump relay and goes into a RECYCLE mode.  
after E; minimum of 1 minute after F).  
Fig. 26 — Control Sequence  
46  
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Shutdown Sequence — Chiller shutdown begins if  
any of the following occurs:  
• the STOP button is pressed for at least one second (the  
alarm light blinks once to confirm the stop command)  
• a recycle condition is present (see Chilled Water Recycle  
Mode section)  
• the time schedule has gone into unoccupied mode  
• the chiller protective limit has been reached and chiller is  
in alarm  
• the start/stop status is overridden to stop from the CCN  
network or the CVC/ICVC  
When a stop signal occurs, the shutdown sequence first  
stops the compressor by deactivating the start relay (1CR). A  
status message of “SHUTDOWN IN PROGRESS, COM-  
PRESSOR DEENERGIZED” is displayed, and the compres-  
sor ontime and service ontime stop. The guide vanes are then  
brought to the closed position. The oil pump relay and the  
chilled water/brine pump relay shut down 60 seconds after the  
compressor stops. The condenser water pump shuts down at  
the same time if the ENTERING CONDENSER WATER tem-  
perature is greater than or equal to 115 F (46.1 C) and the  
CONDENSER REFRIG TEMP is greater than the CONDENS-  
ER FREEZE POINT plus 5 F (–15.0 C). The stop-to-start timer  
now begins to count down. If the start-to-start timer value is  
still greater than the value of the start-to-stop timer, then this  
time displays on the CVC/ICVC.  
Certain conditions that occur during shutdown can change  
this sequence.  
• If the AVERAGE LINE CURRENT is greater than 5%  
after shutdown, or the starter contacts remain energized,  
the oil pump and chilled water pump remain energized  
and the alarm is displayed.  
Chilled Water Recycle Mode — The chiller may  
cycle off and wait until the load increases to restart when the  
compressor is running in a lightly loaded condition. This cy-  
cling is normal and is known as “recycle.” A recycle shutdown  
is initiated when any of the following conditions are true:  
• the chiller is in LCW control, the difference between the  
LEAVING CHILLED WATER temperature and ENTER-  
ING CHILLED WATER temperature is less than the  
RECYCLE SHUTDOWN DELTA T (found in the  
SETUP1 table) the LEAVING CHILLED WATER tem-  
perature is 5° F (2.8° C) below the CONTROL POINT,  
the CONTROL POINT has not increased in the last  
5 minutes and ICE BUILD is not active.  
• the ECW CONTROL OPTION is enabled, the difference  
between the ENTERING CHILLED WATER temperature  
and the LEAVING CHILLED WATER temperature is less  
than the RECYCLE SHUTDOWN DELTA T (found in the  
SETUP1 table), the ENTERING CHILLED WATER tem-  
perature is 5° F (2.8° C) below the CONTROL POINT,  
and the CONTROL POINT has not increased in the last  
5 minutes.  
• the LEAVING CHILLED WATER temperature is within  
3° F (2° C) of the EVAP REFRIG TRIPPOINT.  
When the chiller is in RECYCLE mode, the chilled water  
pump relay remains energized so the chilled water temperature  
can be monitored for increasing load. The recycle control uses  
RESTART DELTA T to check when the compressor should be  
restarted. This is an operator-configured function which de-  
faults to 5° F (3° C). This value can be viewed or modified on  
the SETUP1 table. The compressor will restart when the chiller  
is:  
• in LCW CONTROL and the LEAVING CHILLED  
WATER temperature is greater than the CONTROL  
POINT plus the RECYCLE RESTART DELTA T.  
• in ECW CONTROL and the ENTERING CHILLED  
WATER temperature is greater than the CONTROL  
POINT plus the RECYCLE RESTART DELTA T.  
Once these conditions are met, the compressor initiates a  
start-up with a normal start-up sequence.  
An alert condition may be generated if 5 or more recycle  
start-ups occur in less than 4 hours. Excessive recycling can  
reduce chiller life; therefore, compressor recycling due to ex-  
tremely low loads should be reduced.  
To reduce compressor recycling, use the time schedule to  
shut the chiller down during known low load operation period,  
or increase the chiller load by running the fan systems. If the  
hot gas bypass is installed, adjust the values to ensure that hot  
gas is energized during light load conditions. Increase the  
RECYCLE RESTART DELTA T on the SETUP1 table to  
lengthen the time between restarts.  
• The condenser pump shuts down when the CON-  
DENSER PRESSURE is less than the COND PRESS  
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the  
CONDENSER REFRIG TEMP is less than or equal to the  
ENTERING CONDENSER WATER temperature plus  
3° F (–1.6° C).  
• If the chiller shuts down due to low refrigerant tempera-  
ture, the chilled water pump continues to run until the  
LEAVING CHILLED WATER temperature is greater than  
the CONTROL POINT temperature, plus 5° F (3° C).  
Automatic Soft Stop Amps Threshold — The soft  
stop amps threshold feature closes the guide vanes of the com-  
pressor automatically if a non-recycle, non-alarm stop signal  
occurs before the compressor motor is deenergized.  
If the STOP button is pressed, the guide vanes close to a  
preset amperage percent until the guide vane is less than 4%  
open or 4 minutes have passed. The compressor then shuts off.  
If the chiller enters an alarm state or if the compressor enters  
a RECYCLE mode, the compressor deenergizes immediately.  
To activate the soft stop amps threshold feature, scroll to the  
bottom of OPTIONS screen on the CVC/ICVC. Use the  
The chiller should not be operated below design minimum  
load without a hot gas bypass installed.  
Safety Shutdown — A safety shutdown is identical to  
a manual shutdown with the exception that, during a safety  
shutdown, the CVC/ICVC displays the reason for the shut-  
down, the alarm light blinks continuously, and the spare alarm  
contacts are energized.  
or  
softkey to set the SOFT STOP  
INCREASE  
DECREASE  
AMPS THRESHOLD parameter to the percent of amps at  
which the motor will shut down. The default setting is 100%  
amps (no soft stop). The range is 40 to 100%.  
When the soft stop amps threshold feature is being applied,  
a status message, “SHUTDOWN IN PROGRESS, COM-  
PRESSOR UNLOADING” displays on the CVC/ICVC.  
The soft stop amps threshold function can be terminated and  
the compressor motor deenergized immediately by depressing  
the STOP button twice.  
After a safety shutdown, the  
softkey must be  
RESET  
pressed to clear the alarm. If the alarm condition is still present,  
the alarm light continues to blink. Once the alarm is cleared,  
the operator must press the  
start the chiller.  
or  
softkeys to re-  
LOCAL  
CCN  
47  
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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 pressur-  
ized. If any leaks are detected, follow the leak test procedure.  
If the chiller is spring isolated, keep all springs blocked in  
both directions to prevent possible piping stress and damage  
during the transfer of refrigerant from vessel to vessel during  
the leak test process, or any time refrigerant is being trans-  
ferred. Adjust the springs when the refrigerant is in operating  
condition and the water circuits are full.  
BEFORE INITIAL START-UP  
Job Data Required  
• list of applicable design temperatures and pressures  
(product data submittal)  
• chiller certified prints  
• starting equipment details and wiring diagrams  
• diagrams and instructions for special controls or options  
• 19XR Installation Instructions  
• pumpout unit instructions  
Equipment Required  
Refrigerant Tracer — Carrier recommends the use of an  
environmentally acceptable refrigerant tracer for leak testing  
with an electronic detector or halide torch.  
Ultrasonic leak detectors can also be used if the chiller is  
under pressure.  
• mechanic’s tools (refrigeration)  
• digital volt-ohmmeter (DVM)  
• clamp-on ammeter  
• electronic leak detector  
• absolute pressure manometer or wet-bulb vacuum indi-  
cator (Fig. 27)  
• 500-v insulation tester (megohmmeter) for compressor  
motors with nameplate voltage of 600 v or less, or a  
5000-v insulation tester for compressor motor rated  
above 600 v  
Do not use air or oxygen as a means of pressurizing  
the chiller. Mixtures of HFC-134a and air can undergo  
combustion.  
Using the Optional Storage Tank and Pump-  
out System — Refer to Chillers with Storage Tanks sec-  
tion, page 69 for pumpout system preparation, refrigerant  
transfer, and chiller evacuation.  
Remove Shipping Packaging — Remove any pack-  
aging material from the control center, power panel, guide vane  
actuator, motor cooling and oil reclaim solenoids, motor and  
bearing temperature sensor covers, and the factory-mounted  
starter.  
Open Oil Circuit Valves — Check to ensure the oil fil-  
ter isolation valves (Fig. 4) are open by removing the valve cap  
and checking the valve stem.  
Tighten All Gasketed Joints and Guide Vane  
Shaft Packing — Gaskets and packing normally relax by  
the time the chiller arrives at the jobsite. Tighten all gasketed  
joints and the guide vane shaft packing to ensure a leak-tight  
chiller.  
Check Chiller Tightness — Figure 28 outlines the  
proper sequence and procedures for leak testing.  
Fig. 27 — Typical Wet-Bulb Type  
The 19XR chillers are shipped with the refrigerant con-  
tained in the condenser shell and the oil charge in the compres-  
sor. The cooler is shipped with a 15 psig (103 kPa) refrigerant  
charge. Units may be ordered with the refrigerant shipped sepa-  
rately, along with a 15 psig (103 kPa) nitrogen-holding charge  
in each vessel.  
Vacuum Indicator  
48  
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5. If no leak is found during the initial start-up procedures,  
complete the transfer of refrigerant gas from the pumpout  
storage tank to the chiller (see Transfer Refrigerant from  
Pumpout Storage Tank to Chiller section, page 69). Re-  
test for leaks.  
Leak Test Chiller — Due to regulations regarding refrig-  
erant emissions and the difficulties associated with separating  
contaminants from the refrigerant, Carrier recommends the  
following leak test procedure. See Fig. 28 for an outline of the  
leak test procedure. Refer to Fig. 29 and 30 during pumpout  
procedures and Tables 5A and 5B for refrigerant pressure/  
temperature values.  
6. If no leak is found after a retest:  
a. Transfer the refrigerant to the pumpout storage  
tank and perform a standing vacuum test as out-  
lined in the Standing Vacuum Test section, below.  
1. If the pressure readings are normal for the chiller  
condition:  
a. Evacuate the holding charge from the vessels, if  
present.  
b. If the chiller fails the standing vacuum test, check  
for large leaks (Step 2b).  
b. Raise the chiller pressure, if necessary, by adding  
refrigerant until pressure is at the equivalent satu-  
rated pressure for the surrounding temperature.  
Follow the pumpout procedures in the Transfer  
Refrigerant from Pumpout Storage Tank to Chiller  
section, Steps 1a - e, page 69.  
c. If the chiller passes the standing vacuum test,  
dehydrate the chiller. Follow the procedure in  
the Chiller Dehydration section. Charge the chiller  
with refrigerant (see Transfer Refrigerant from  
Pumpout Storage Tank to Chiller section,  
page 69).  
7. If a leak is found after a retest, pump the refrigerant back  
into the pumpout storage tank or, if isolation valves are  
present, pump the refrigerant into the non-leaking  
vessel (see Pumpout and Refrigerant Transfer procedures  
section).  
8. Transfer the refrigerant until the chiller pressure is at  
18 in. Hg (40 kPa absolute).  
9. Repair the leak and repeat the procedure, beginning from  
Step 2h, to ensure a leak-tight repair. (If the chiller is  
opened to the atmosphere for an extended period, evacu-  
ate it before repeating the leak test.)  
Never charge liquid refrigerant into the chiller if the pres-  
sure in the chiller is less than 35 psig (241 kPa) for  
HFC-134a. Charge as a gas only, with the cooler and con-  
denser pumps running, until this pressure is reached, using  
PUMPDOWN LOCKOUT and TERMINATE LOCK-  
OUT mode on the PIC II. Flashing of liquid refrigerant at  
low pressures can cause tube freeze-up and considerable  
damage.  
c. Leak test chiller as outlined in Steps 3 - 9.  
2. If the pressure readings are abnormal for the chiller  
condition:  
Standing Vacuum Test — When performing the  
standing vacuum test or chiller dehydration, use a manometer  
or a wet bulb indicator. Dial gages cannot indicate the small  
amount of acceptable leakage during a short period of time.  
1. Attach an absolute pressure manometer or wet bulb indi-  
cator to the chiller.  
2. Evacuate the vessel (see Pumpout and Refrigerant Trans-  
fer Procedures section, page 67) to at least 18 in. Hg vac,  
ref 30-in. bar (41 kPa), using a vacuum pump or the  
pump out unit.  
3. Valve off the pump to hold the vacuum and record the  
manometer or indicator reading.  
a. Prepare to leak test chillers shipped with refriger-  
ant (Step 2h).  
b. Check for large leaks by connecting a nitrogen bottle  
and raising the pressure to 30 psig (207 kPa). Soap  
test all joints. If the test pressure holds for 30 minutes,  
prepare the test for small leaks (Steps 2g - h).  
c. Plainly mark any leaks that are found.  
d. Release the pressure in the system.  
e. Repair all leaks.  
4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in  
24 hours, the chiller is sufficiently tight.  
f. Retest the joints that were repaired.  
g. After successfully completing the test for large  
leaks, remove as much nitrogen, air, and moisture  
as possible, given the fact that small leaks may be  
present in the system. This can be accomplished by  
following the dehydration procedure, outlined in  
the Chiller Dehydration section, page 53.  
h. Slowly raise the system pressure to a maximum of  
160 psig (1103 kPa) but no less than 35 psig  
(241 kPa) for HFC-134a by adding refrigerant.  
Proceed with the test for small leaks (Steps 3-9).  
b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in  
24 hours, repressurize the vessel and test for leaks.  
If refrigerant is available in the other vessel, pressur-  
ize by following Steps 2-10 of Return Chiller To  
Normal Operating Conditions section, page 71. If  
not, use nitrogen and a refrigerant tracer. Raise the  
vessel pressure in increments until the leak is  
detected. If refrigerant is used, the maximum gas  
pressure is approximately 70 psig (483 kPa) for  
HFC-134a at normal ambient temperature. If nitro-  
gen is used, limit the leak test pressure 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 indi-  
cates a leak, use a soap bubble solution, if possible, to  
confirm. Total all leak rates for the entire chiller. Leakage  
at rates greater than 1 lb./year (0.45 kg/year) for the entire  
chiller must be repaired. Note the total chiller leak rate on  
the start-up report.  
5. Repair the leak, retest, and proceed with dehydration.  
50  
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Fig. 29 — Typical Optional Pumpout System Piping Schematic with Storage Tank  
Fig. 30 — Typical Optional Pumpout System Piping Schematic without Storage Tank  
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Table 5A — HFC-134a Pressure —  
Table 5B — HFC-134a Pressure —  
Temperature (F)  
Temperature (C)  
TEMPERATURE,  
PRESSURE  
(psig)  
TEMPERATURE,  
PRESSURE  
F
C
(kPa)  
0
2
4
6
8
6.50  
7.52  
–18.0  
–16.7  
–15.6  
–14.4  
–13.3  
44.8  
51.9  
59.3  
66.6  
74.4  
8.60  
9.66  
10.79  
10  
12  
14  
16  
18  
11.96  
13.17  
14.42  
15.72  
17.06  
–12.2  
–11.1  
–10.0  
–8.9  
82.5  
90.8  
99.4  
108.0  
118.0  
–7.8  
20  
22  
24  
26  
28  
18.45  
19.88  
21.37  
22.90  
24.48  
–6.7  
–5.6  
–4.4  
–3.3  
–2.2  
127.0  
137.0  
147.0  
158.0  
169.0  
30  
32  
34  
36  
38  
26.11  
27.80  
29.53  
31.32  
33.17  
–1.1  
0.0  
1.1  
2.2  
3.3  
180.0  
192.0  
204.0  
216.0  
229.0  
40  
42  
44  
46  
48  
35.08  
37.04  
39.06  
41.14  
43.28  
4.4  
5.0  
5.6  
6.1  
6.7  
242.0  
248.0  
255.0  
261.0  
269.0  
50  
52  
54  
56  
58  
45.48  
47.74  
50.07  
52.47  
54.93  
7.2  
7.8  
8.3  
8.9  
9.4  
276.0  
284.0  
290.0  
298.0  
305.0  
60  
62  
64  
66  
68  
57.46  
60.06  
62.73  
65.47  
68.29  
10.0  
11.1  
12.2  
13.3  
14.4  
314.0  
329.0  
345.0  
362.0  
379.0  
70  
72  
74  
76  
78  
71.18  
74.14  
77.18  
80.30  
83.49  
15.6  
16.7  
17.8  
18.9  
20.0  
396.0  
414.0  
433.0  
451.0  
471.0  
80  
82  
84  
86  
88  
86.17  
90.13  
93.57  
97.09  
100.70  
21.1  
22.2  
23.3  
24.4  
25.6  
491.0  
511.0  
532.0  
554.0  
576.0  
90  
92  
94  
96  
98  
104.40  
108.18  
112.06  
116.02  
120.08  
26.7  
27.8  
28.9  
30.0  
31.1  
598.0  
621.0  
645.0  
669.0  
694.0  
100  
102  
104  
106  
108  
124.23  
128.47  
132.81  
137.25  
141.79  
32.2  
33.3  
34.4  
35.6  
36.7  
720.0  
746.0  
773.0  
800.0  
828.0  
110  
112  
114  
116  
118  
146.43  
151.17  
156.01  
160.96  
166.01  
37.8  
38.9  
40.0  
41.1  
42.2  
857.0  
886.0  
916.0  
946.0  
978.0  
120  
122  
124  
126  
128  
171.17  
176.45  
181.83  
187.32  
192.93  
43.3  
44.4  
45.6  
46.7  
47.8  
1010.0  
1042.0  
1076.0  
1110.0  
1145.0  
130  
132  
134  
136  
138  
140  
198.66  
204.50  
210.47  
216.55  
222.76  
229.09  
48.9  
50.0  
51.1  
52.2  
53.3  
54.4  
55.6  
56.7  
57.8  
58.9  
60.0  
1180.0  
1217.0  
1254.0  
1292.0  
1330.0  
1370.0  
1410.0  
1451.0  
1493.0  
1536.0  
1580.0  
52  
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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.  
Do not start or megohm-test the compressor motor or oil  
pump motor, even for a rotation check, if the chiller is  
under dehydration vacuum. Insulation breakdown and  
severe damage may result.  
Fig. 31 — Dehydration Cold Trap  
Inspect Water Piping — Refer to piping diagrams pro-  
vided in the certified drawings and the piping instructions in  
the 19XR Installation Instructions manual. Inspect the piping to  
the cooler and condenser. Be sure that the flow directions are  
correct and that all piping specifications have been met.  
Piping systems must be properly vented with no stress on  
waterbox nozzles and covers. Water flows through the cooler  
and condenser must meet job requirements. Measure the pres-  
sure drop across the cooler and the condenser.  
Inside-delta type starters must be disconnected by an isola-  
tion switch before placing the machine under a vacuum  
because one lead of each phase is live with respect to  
ground even though there is not a complete circuit to run  
the motor. To be safe, isolate any starter before evacuating  
the chiller if you are not sure if there are live leads to the  
hermetic motor.  
Dehydration can be done at room temperatures. Using a  
cold trap (Fig. 31) may substantially reduce the time required  
to complete the dehydration. The higher the room temperature,  
the faster dehydration takes place. At low room temperatures, a  
very deep vacuum is required to boil off any moisture. If low  
ambient temperatures are involved, contact a qualified service  
representative for the dehydration techniques required.  
Water must be within design limits, clean, and treated to  
ensure proper chiller performance and to reduce the poten-  
tial of tube damage due to corrosion, scaling, or erosion.  
Carrier assumes no responsibility for chiller damage result-  
ing from untreated or improperly treated water.  
Perform dehydration as follows:  
1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]  
or larger is recommended) to the refrigerant charging  
valve (Fig. 2). Tubing from the pump to the chiller should  
be as short in length and as large in diameter as possible to  
provide least resistance to gas flow.  
2. Use an absolute pressure manometer or a wet bulb vacu-  
um indicator to measure the vacuum. Open the shutoff  
valve to the vacuum indicator only when taking a read-  
ing. Leave the valve open for 3 minutes to allow the indi-  
cator vacuum to equalize with the chiller vacuum.  
3. If the entire chiller is to be dehydrated, open all isolation  
valves (if present).  
4. With the chiller ambient temperature at 60 F (15.6 C) or  
higher, operate the vacuum pump until the manometer  
reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)  
(–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C).  
Operate the pump an additional 2 hours.  
Check Optional Pumpout Compressor Water  
Piping — If the optional pumpout storage tank and/or  
pumpout system are installed, check to ensure the pumpout  
condenser water has been piped in. Check for field-supplied  
shutoff valves and controls as specified in the job data. Check  
for refrigerant leaks on field-installed piping. See Fig. 29  
and 30.  
Check Relief Valves — Be sure the relief valves have  
been piped to the outdoors in compliance with the latest edition  
of ANSI/ASHRAE Standard 15 and applicable local safety  
codes. Piping connections must allow for access to the valve  
mechanism for periodic inspection and leak testing.  
The 19XR relief valves are set to relieve at the 185 psig  
(1275 kPa) chiller design pressure.  
Inspect Wiring  
Do not apply a greater vacuum than 29.82 in. Hg vac  
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb  
vacuum indicator. At this temperature and pressure, iso-  
lated pockets of moisture can turn into ice. The slow rate  
of evaporation (sublimation) of ice at these low tempera-  
tures and pressures greatly increases dehydration time.  
Do not check the 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 160 psig  
(1103 kPa) pressure. Locate and repair the leak, and re-  
peat dehydration.  
Do not apply any kind of test voltage, even for a rotation  
check, if the chiller is under a dehydration vacuum. Insula-  
tion breakdown and serious damage may result.  
1. Examine the wiring for conformance to the job wiring di-  
agrams and all applicable electrical codes.  
53  
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2. On low-voltage compressors (600 v or less) connect a  
voltmeter across the power wires to the compressor start-  
er and measure the voltage. Compare this reading to the  
voltage rating on the compressor and starter nameplates.  
3. Compare the ampere rating on the starter nameplate to  
rating on the compressor nameplate. The overload trip  
amps must be 108% to 120% of the rated load amps.  
4. The starter for a centrifugal compressor motor must  
contain the components and terminals required for PIC II  
refrigeration control. Check the certified drawings.  
5. Check the voltage to the following components and  
compare it to the nameplate values: oil pump contact,  
pumpout compressor starter, and power panel.  
11. On chillers with free-standing starters, inspect the power  
panel to ensure that the contractor has fed the wires into  
the bottom of the panel. Wiring into the top of the panel  
can cause debris to fall into the contactors. Clean and in-  
spect the contactors if this has occurred.  
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 sys-  
tem element communication connector must be wired to the  
positive pins of the system element on either side of it. The  
negative pins must be wired to the negative pins. The signal  
ground pins must be wired to the signal ground pins. See instal-  
lation manual.  
6. Ensure that fused disconnects or circuit breakers have  
been supplied for the oil pump, power panel, and  
pumpout unit.  
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 –4 F to 140 F (–20 C to 60 C) is required. See  
table below for cables that meet the requirements.  
7. Ensure all electrical equipment and controls are properly  
grounded in accordance with job drawings, certified  
drawings, and all applicable electrical codes.  
8. Ensure the customer’s contractor has verified proper op-  
eration of the pumps, cooling tower fans, and associated  
auxiliary equipment. This includes ensuring motors are  
properly lubricated and have proper electrical supply and  
proper rotation.  
9. For field-installed starters only, test the chiller 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.  
MANUFACTURER  
Alpha  
CABLE NO.  
2413 or 5463  
A22503  
American  
Belden  
Columbia  
8772  
02525  
a. Open the starter main disconnect switch and follow  
lockout/tagout rules.  
When connecting the CCN communication bus to a system  
element, a color code system for the entire network is recom-  
mended to simplify installation and checkout. The following  
color code is recommended:  
If the motor starter is a solid-state starter, the motor leads  
must be disconnected from the starter before an insulation  
test is performed. The voltage generated from the tester can  
damage the starter solid-state components.  
CCN BUS  
CONDUCTOR  
INSULATION  
COLOR  
CCN TERMINAL  
CONNECTION  
SIGNAL TYPE  
b. With the tester connected to the motor leads, take  
10-second and 60-second megohm readings as  
follows:  
+
Ground  
–
Red  
White  
Black  
RED (+)  
WHITE (G)  
BLACK (–)  
6-Lead Motor — Tie all 6 leads together and test  
between the lead group and ground. Next tie the  
leads in pairs: 1 and 4, 2 and 5, and 3 and 6. Test  
between each pair while grounding the third pair.  
Check Starter  
3-Lead Motor — Tie terminals 1, 2, and 3 together  
and test between the group and ground.  
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.  
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.  
Use the instruction and service manual supplied by the start-  
er manufacturer to verify the starter has been installed correct-  
ly, to set up and calibrate the starter, and for complete trouble-  
shooting information.  
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 second test indicate the fault is in the power  
leads.  
NOTE: Unit-mounted starters do not have to be  
megohm tested.  
10. Tighten all wiring connections to the plugs on the ISM  
and CCM modules.  
The main disconnect on the starter front panel may not  
deenergize all internal circuits. Open all internal and  
remote disconnects before servicing the starter.  
54  
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MECHANICAL STARTER  
1. Check all field wiring connections for tightness, clear-  
ance from moving parts, and correct connection.  
2. Check the contactor(s) to ensure they move freely. Check  
the mechanical interlock between contactors to ensure  
that 1S and 2M contactors cannot be closed at the same  
time. Check all other electro-mechanical devices, such as  
relays, for free movement. If the devices do not move  
freely, contact the starter manufacturer for replacement  
components.  
powered, the CVC/ICVC should display the default screen  
within a short period of time.  
The oil heater is energized by powering the control circuit.  
This should be done several hours before start-up to minimize  
oil-refrigerant migration. The oil heater is controlled by the  
PIC II and is powered through a contactor in the power panel.  
Starters contain a separate circuit breaker to power the heater  
and the control circuit. This arrangement allows the heater to  
energize when the main motor circuit breaker is off for service  
work or extended shutdowns. The oil heater relay status (OIL  
HEATER RELAY) can be viewed on the COMPRESS table on  
the CVC/ICVC. Oil sump temperature can be viewed on the  
CVC/ICVC default screen.  
3. Reapply starter control power (not main chiller power) to  
check the electrical functions.  
Ensure the starter (with relay 1CR closed) goes through a  
complete and proper start cycle.  
SOFTWARE VERSION — The software part number is la-  
beled on the backside of the CVC/ICVC module. The software  
version also appears on the CVC/ICVC configuration screen as  
the last two digits of the software part number.  
BENSHAW, INC. RediStart MICRO™ SOLID-STATE  
STARTER  
Software Configuration  
This equipment is at line voltage when AC power is con-  
nected. Pressing the STOP button does not remove voltage.  
Do not operate the chiller before the control configurations  
have been checked and a Control Test has been  
satisfactorily completed. Protection by safety controls can-  
not be assumed until all control configurations have been  
confirmed.  
1. Ensure all wiring connections are properly terminated to  
the starter.  
2. Verify the ground wire to the starter is installed properly  
and is sufficient size.  
3. Verify the motors are properly grounded to the starter.  
4. Verify the proper ac input voltage is brought into the start-  
er according to the certified drawings.  
As the 19XR unit is configured, all configuration settings  
should be written down. A log, such as the one shown on pages  
CL-1 to CL-16, provides a list for configuration values.  
5. Apply power to the starter  
VFD STARTER  
1. Turn off unit, tag and lock disconnects and wait 5 minutes.  
2. Verify that the DC voltage is zero.  
3. Ensure there is adequate clearance around the drive.  
Input the Design Set Points — Access the CVC/  
ICVC set point screen and view/modify the base demand limit  
set point, and either the LCW set point or the ECW set point.  
The PIC II can control a set point to either the leaving or enter-  
ing chilled water. This control method is set in the EQUIP-  
MENT SERVICE (TEMP_CTL) table.  
4. Verify that the wiring to the terminal strip and power ter-  
minals is correct.  
5. Verify that wire size is within the terminal specification  
and the wires are secure.  
6. Inspect the field supplied branch circuit protection is  
properly rated and installed.  
Input the Local Occupied Schedule (OCCPC01S) —  
Access the schedule OCCPC01S screen on the CVC/ICVC  
and set up the occupied time schedule according to the custom-  
er’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 schedule,  
see the Controls section, page 10.  
The CCN Occupied Schedule (OCCPC03S) should be con-  
figured if a CCN system is being installed or if a secondary  
time schedule is needed.  
7. Verify that the system is properly grounded.  
8. Inspect all liquid cooling connections for leaks.  
Oil Charge — The oil charge for the 19XR compressor de-  
pends on the compressor Frame size:  
• Frame 2 compressor — 5 gal (18.9 L)  
• Frame 3 compressor — 8 gal (30 L)  
• Frame 4 compressor — 10 gal (37.8 L)  
• Frame 5 compressor — 18 gal (67.8 L)  
NOTE: The default CCN Occupied Schedule OCCPC03S is  
configured to be unoccupied.  
Input Service Configurations — The following con-  
figurations require the CVC/ICVC screen to be in the SER-  
VICE portion of the menu.  
The chiller is shipped with oil in the compressor. When the  
sump is full, the oil level should be no higher than the middle  
of the upper sight glass, and minimum level is the bottom  
of the lower sight glass (Fig. 2). If oil is added, it must meet  
Carrier’s specification for centrifugal compressor use as de-  
scribed in the Oil Specification section. Charge the oil through  
the oil charging valve located near the bottom of the transmis-  
sion housing (Fig. 2). The oil must be pumped from the oil  
container through the charging valve due to higher refrigerant  
pressure. The pumping device must be able to lift from 0 to  
200 psig (0 to 1380 kPa) or above unit pressure. Oil should  
only be charged or removed when the chiller is shut down.  
• password  
• input time and date  
• CVC/ICVC configuration  
• service parameters  
• equipment configuration  
• automated control test  
PASSWORD — When accessing the SERVICE tables, a pass-  
word must be entered. All CVC/ICVC are initially set for a  
password of 1-1-1-1.  
INPUT TIME AND DATE — Access the TIME AND DATE  
table on the SERVICE menu. Input the present time of day,  
date, and day of the week. The HOLIDAY TODAY parameter  
should only be configured to YES if the present day is a  
holiday.  
Power Up the Controls and Check the Oil  
Heater — Ensure that an oil level is visible in the compres-  
sor before energizing the controls. A circuit breaker in the start-  
er energizes the oil heater and the control circuit. When first  
55  
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NOTE: Because a schedule is integral to the chiller control  
sequence, the chiller will not start until the time and date have  
been set.  
CHANGE CVC/ICVC CONFIGURATION IF NECES-  
SARY — From the SERVICE table, access the CVC/ICVC  
CONFIGU-RATION screen. From there, view or modify the  
CVC/ICVC CCN address, change to English or SI units, and  
change the password. If there is more than one chiller at the  
jobsite, change the CVC/ICVC address on each chiller so that  
each chiller has its own address. Note and record the new  
address. Change the screen to SI units as required, and change  
the password if desired.  
TO CHANGE THE PASSWORD — The password may be  
changed from the CVC/ICVC CONFIGURATION screen.  
1. Press the  
current password and highlight CVC/ICVC CONFIGU-  
RATION. Press the softkey. Only the last  
and  
softkeys. Enter the  
5 entries on the CVC/ICVC CONFIG screen can be  
changed: BUS #, ADDRESS #, BAUD RATE, US IMP/  
METRIC, and PASSWORD.  
2. Use the  
softkey to scroll to PASSWORD. The  
first digit of the password is highlighted on the screen.  
3. To change the digit, press the  
or  
softkey. When the desired digit is seen,  
press the  
softkey.  
4. The next digit is highlighted. Change it, and the third and  
fourth digits in the same way the first was changed.  
5. After the last digit is changed, the CVC/ICVC goes to the  
BUS parameter. Press the  
softkey to leave that  
screen and return to the SERVICE menu.  
TO CHANGE THE CVC/ICVC DISPLAY FROM  
ENGLISH TO METRIC UNITS — By default, the CVC/  
ICVC displays information in English units. To change to met-  
ric units, access the CVC/ICVC CONFIGURATION screen:  
1. Press the  
and  
softkeys. Enter the  
password and highlight CVC/ICVC CONFIGURATION.  
Press the  
softkey.  
2. Use the  
softkey to scroll to US IMP/METRIC.  
3. Press the softkey that corresponds to the units desired for  
display on the CVC/ICVC (e.g., US or METRIC).  
CHANGE LANGUAGE (ICVC Only) — By default, the  
ICVC displays information in English. To change to another  
Language, access the ICVC CONFIGURATION screen:  
1. Press the  
and  
softkeys. Enter the  
password and highlight ICVC CONFIGURATION. Press  
the  
softkey.  
softkey to scroll to LID LANGUAGE.  
2. Use the  
3. Press the INCREASE or DECREASE softkey until the  
desired language is displayed. Press  
desired language.  
to confirm  
56  
CHANGE THE BENSHAW INC., RediStart MICRO™  
SOFTWARE CONFIGURATION IF NECESSARY — Ben-  
shaw starter configurations are checked and modified from the  
menus in the Benshaw Redistart MICRO Default Display. See  
Fig. 32 and Table 6 for default display and menu items. To ac-  
cess the menus to perform checks and modifications, the Ben-  
shaw starter must be powered up and its self-test must have  
been successfully completed. The self-test takes place automat-  
ically after power-up. Current transformer ratio configurations  
and hardware switch settings checks are performed in the  
MENU1 display screen. See Table 7 for menu structure and  
Table 8 for switch settings.  
To view other settings and troubleshooting guide consult the  
Benshaw RediStart MICRO instructional manual included in  
the starter.  
DISPLAY  
RediStart MICRO  
STOP  
READY  
I = OA  
V = 461V  
FAULT  
RESET  
SCROLL UP  
MENU  
ENTER  
SCROLL DOWN  
1. Press the  
softkey until the desired menu is se-  
MENU  
lected on the display.  
2. Press the softkey to access the displayed menu  
ENTER  
items (Table 6).  
MENU  
MENU ENTRY  
DATA ENTRY  
3. Use the or  
arrow keys to scroll between menu  
↓
↑
SELECTION  
items until the desired item is reached on the display.  
Fig. 32 — Benshaw RediStart  
4. Press the  
changed.  
softkey to access the value to be  
ENTER  
MICRO Default Display  
5. Use the  
or  
arrow keys to adjust the new displayed  
↑
↓
value. The  
key increases the value while the  
key  
↑
↓
Table 6 — Benshaw RediStart  
decreases the value. Holding the arrow key will progres-  
sively increase the rate of change. The value will stop  
changing when either the factory set minimum or maxi-  
mum value is reached. To make fine adjustments press  
and release the arrow key.  
MICRO Menu Structure  
MENU 3  
Event  
Recorder  
MENU 4  
Dry Run  
Mode  
MENU 1  
MENU 2  
Meter Setup  
Starter Setup  
Initial Current  
as % RLA  
Meter #1  
display  
Events 1-99  
Dry Run  
Mode  
6. When the correct value has been selected, press the  
key to store the new configuration. At this  
ENTER  
point, there are two options. The  
Max. Cur  
As% LRA  
Meter #2  
display  
key will return  
MENU  
Ramp Time  
(sec.)  
CT Ratio: 1  
the display to the main display. The or  
arrow keys  
↑
↓
will move the display to the next menu item. When fin-  
ished press the key to return to the main display.  
MENU  
Table 7 — Benshaw RediStart MICRO Menu Items*  
DESCRIPTION  
INITIAL CURRENT  
MAX. CURR AS % LRA  
RAMP TIME  
RANGE  
50-300  
30-70  
UNITS  
%
%
DEFAULT  
125  
55  
15  
5-30  
SEC  
CT RATIO  
2640-5760  
Enter Value from Table 8.  
*These values are not displayed in the ISM_CONFIG table.  
Table 8 — Benshaw RediStart MICRO Current Transformer DIP Switch Settings  
CURRENT TRANSFORMER CT1-CT3  
MIcro Power Card (BIPCMIPWR-C4)  
Overload Switch Settings  
Starter  
Frame Size  
(Amps)  
Motor  
RLA Range  
(Amps)  
CT  
Ratio  
SW1-1  
SW1-2  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
ON  
95- 135 Amps  
136- 200 Amps  
201- 231 Amps  
232- 300 Amps  
301- 340 Amps  
341- 480 Amps  
481- 580 Amps  
581- 600 Amps  
601- 740 Amps  
741- 855 Amps  
856-1250 Amps  
3900:1  
5760:1  
2640:1  
3900:1  
3900:1  
5760:1  
2640:1  
3900:1  
3900:1  
3900:1  
5760:1  
OFF  
OFF  
ON  
ON  
ON  
ON  
ON  
ON  
ON  
ON  
ON  
200 Amps  
300 Amps  
480 Amps  
600 Amps  
740 Amps  
1250 Amps  
ON  
ON  
ON  
ON  
LEGEND  
CT — Current Transformer  
57  
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VERIFY VFD CONFIGURATION AND CHANGE  
PARAMETERS IF NECESSARY  
Accessing Password Protected Parameters — Although the  
VFD controller has been preconfigured as the factory, the user  
will need to be able to access the parameters to verify the job  
specific parameters are correct, tune the controller or correct a  
problem. The two passwords protecting the VFD configuration  
are Parameter Set Display password and Program Disable  
password. The Parameter Set Display password restricts view-  
ing. P.nnn parameters above 007 and all H.nnn and R.nnn  
screens. The password can be accessed at parameter P.006 and  
will switch between enabled and disabled each time the pass-  
word 107 is entered. The Program Disable password restricts  
the changing of the drive parameter set. To enable or disable  
changes select parameter P.051 and enter the password 26.  
IMPORTANT: The VFD controller has been factory con-  
figured for use and communications to the Chiller Visual  
Controller/International Chiller Visual Controller (CVC/  
ICVC). Some parameters are specific to the chiller config-  
uration and will need to be verified prior to operation.  
Speed control and starting the drive have been disabled at  
the VFD keypad. All command functions must be initiated  
from the CVC/ICVC.  
Using the Keypad — The keypad display is used to monitor,  
view fault history and adjust the program of the VFD  
microprocessor. It operates in two modes: Monitor mode and  
Program mode:  
NOTE: Some of the parameters can be changed only when the  
drive is stopped.  
Use the and keys to:  
↑
↓
• Step through the drive parameter menus and error log  
when the keypad/display is in Program mode.  
• Increase or decrease a numeric value such as the refer-  
ence or parameter value.  
It is the operator’s responsibility to distribute access to the  
passwords. Carrier is not responsible for unauthorized  
access violations within the operator’s organization. Failure  
to observe this warning could result in bodily injury.  
• Hold down these keys to increase the scroll speed.  
Use the  
softkey to:  
ENTER  
See the Initial Start-Up Checklist section for VFD Job Specific  
Configuration table. For job specific parameters see inside of  
the VFD enclosure door, next to the keypad. Refer to the VFD  
Configuration table for the entire list of parameters.  
• Display a parameter or a selection value in Program  
mode.  
• Save a value.  
• Move through each monitor display item when in Moni-  
tor mode.  
Monitor Mode (Default Mode) — Specific drive conditions  
may be monitored on the keypad when in this mode. An LED  
will be illuminated next to the description of what is displayed  
Restoring the default parameter P.050 will require all the  
Carrier default parameters to be restored manually.  
on the keypad. Use the  
softkey to scroll through and  
ENTER  
monitor the following selections:  
VFD CHILLER FIELD SET UP AND VERIFICATION  
• All LEDs on — Speed request from the CVC/ICVC  
• Motor Speed  
Label Locations — Verify the following labels have been  
installed properly and match the chiller requisition:  
• Surge parameters — Located inside the control panel.  
• Chiller identification nameplate — Located on the right  
side of the control panel.  
• VFD Parameter — Located to the right of the VFD con-  
troller keypad on the VFD module.  
• VFD Nameplate — Located on the right side of the VFD  
as viewed from its front.  
• Output Frequency  
• Output Voltage  
• Output Current  
Program Mode — This mode displays and modifies the con-  
figuration parameters of the VFD microprocessor. Particular  
parameters, parameter numbers, and error log information can  
be displayed when in Program mode.  
• Record all nameplate information on the Reliance Con-  
figuration sheet.  
Press the  
softkey until the PROGRAM LED is  
PROGRAM  
illuminated to enter the Program mode.  
Drive Protection and Other Incoming Wiring  
1. Verify that the branch disconnects or other local discon-  
nects are open and properly tagged out.  
Use the and keys to move through the menus  
↑
↓
Press  
softkey to select the desired menu.  
ENTER  
Press  
and keys to move through following parameters.  
↑
↓
2. Verify that the branch circuit protection and AC input  
wiring to the VFD are in accordance with NEC/CEC  
(National Electrical Code/California Energy Commis-  
sion) and all other local codes.  
3. Verify that the fuses are per the field wiring diagram.  
4. Verify that the incoming source does not exceed 85 kA.  
5. Verify the power lugs in the VFD and branch protection  
are properly secured. Inspect the ground cable and ensure  
it is properly connected at the branch and to the ground  
lug in the VFD.  
6. Verify the conduit for the power wiring in securely con-  
nected to the VFD flanged cover and runs continuously to  
the branch protection.  
P.nnn  
— General Parameters  
U.nnn  
H.nnn  
R.nnn  
— Vector Control Parameters*  
— Volts/Hertz Control Parameters  
— RMI Remote Monitor Interface  
Parameters  
E.nnn  
— Error Log (See fault codes)  
*Vector control is not used in this configuration.  
Press softkey to select a parameter menu screen.  
ENTER  
Press and keys to adjust the selected parameter.  
↑
↓
Press the  
turns off to exit the program.  
softkey until the PROGRAM LED  
PROGRAM  
7. Verify that the incoming and outgoing wires have been  
properly connected inside of the reactor enclosure if a  
separate line reactor has been added to the chiller.  
8. Ensure the control and signal wires connected to the chill-  
er controller or the VFD are in separate conduit.  
Changing parameters may adversely affect chiller  
operation.  
58  
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VFD Cooling System Leak Inspection  
1. Check for leaks on the refrigerant cooling flange connec-  
tions to the VFD enclosure.  
2. Check for leaks on all tubing internal to the VFD enclo-  
sure, the tubing flair connection to the VFD module and  
the TXV valve.  
3. Verify that the VFD refrigerant cooling system TXV  
valve control bulb is securely inserted into the VFD drive  
module heat sink.  
Power Up Verification  
1. Inspect control wiring inside the VFD and verify the in-  
tegrity of the connections between the integrated starter  
module (ISM) and the VFD module.  
2. Close the control power switch in the VFD enclosure.  
3. Close the oil pump power switch inside the VFD  
enclosure.  
4. Verify the VFD disconnect switch is in the open position.  
5. Close and latch the doors of the VFD enclosure.  
6. Apply power to the VFD enclosure. Remove lock outs  
59  
2. Press  
3. Press  
4. Press  
.
.
.
5. Set TARGET VFD SPEED to 0%.  
Verify that the ACTUAL VFD SPEED shown on the VFD dis-  
play is within 0 to 1 Hz.  
1. Press the  
softkey on the VFD keypad until all  
LEDs on the left side of the keypad are illuminated.  
NOTE: The value displayed is the frequency at which the  
60  
Protecting the VFD Configuration  
1. Select parameter P.051 from the VFD keypad.  
61  
Owner-Modified CCN Tables — The following EQUIP-  
MENT CONFIGURATION screens are described for refer-  
ence only.  
OCCDEFCS — The OCCDEFCS screen contains the Local  
and CCN time schedules, which can be modified here or on the  
SCHEDULE screen as described previously.  
HOLIDAYS — From the HOLIDAYS screen, the days of the  
year that holidays are in effect can be configured. See the holi-  
day paragraphs in the Controls section for more details.  
COOLER CONDENSER PRESSURE TRANSDUCER  
AND WATERSIDE FLOW DEVICE CALIBRATION  
(Optional with ICVC inputs available) — Calibration can be  
checked by comparing the pressure readings from the  
transducer to an accurate refrigeration gage reading. These  
readings can be viewed or calibrated from the HEAT_EX  
screen on the CVC/ICVC. The transducer can be checked and  
BRODEF — The BRODEF screen defines the start and end of  
daylight savings time. Enter the dates for the start and end of  
daylight savings if required for your location. BRODEF also  
activates the Broadcast function which enables the holiday  
periods that are defined on the CVC/ICVC to take effect.  
Other Tables — The CONSUME, NET_OPT, and RUN-  
TIME screens contain parameters used with a CCN system.  
See the applicable CCN manual for more information on these  
screens. These tables can only be defined from a CCN Build-  
ing Supervisor.  
Perform a Control Test — Check the safety controls  
status by performing an automated control test. Access the  
CONTROL TEST table and select a test to be performed func-  
tion (Table 9).  
The Automated Control Test checks all outputs and inputs  
for function. In order to successfully proceed with the controls  
test, the compressor should be off, no alarms showing, and volt-  
age should be within ±10% of rating plate value. The compres-  
sor can be put in OFF mode by pressing the STOP push-button  
on the CVC/ICVC. Each test asks the operator to confirm the  
operation is occurring and whether or not to continue. If an er-  
ror occurs, the operator can try to address the problem as the  
test is being done or note the problem and proceed to the next  
test.  
NOTE: Enter guide vane calibration to calibrate guide  
input on CCM (Plug J4 upper terminal 9 and 10).  
NOTE: If during the control test the guide vanes do not open,  
verify the low pressure alarm is not active. (An active low  
pressure alarm causes the guide vanes to close.)  
NOTE: The oil pump test will not energize the oil pump if  
cooler pressure is below –5 psig (–35 kPa).  
When the control test is finished or the  
softkey is  
pressed, the test stops, and the CONTROL TEST menu dis-  
plays. If a specific automated test procedure is not completed,  
access the particular control test to test the function when ready.  
The CONTROL TEST menu is described in the table below.  
*Diffuser tests function only on size 4 and 5 compressor with diffuser control  
enabled.  
NOTE: During any of the tests, an out-of-range reading will have an asterisk  
(*) next to the reading and a message will be displayed if you have diffuser  
control enabled.  
62  
Check Optional Pumpout System Controls  
and Compressor — Controls include an on/off switch,  
a 3-amp fuse, the compressor overloads, an internal thermostat,  
a compressor contactor, and a refrigerant high pressure cutout.  
The high pressure cutout is factory set to open at 161 psig  
(1110 kPa) and reset at 130 psig (896 kPa). Ensure the water-  
cooled condenser has been connected. Loosen the compressor  
holddown bolts to allow free spring travel. Open the compres-  
sor suction and discharge the service valves. Ensure oil is visi-  
ble in the compressor sight glass. Add oil if necessary.  
See the Pumpout and Refrigerant Transfer Procedures and  
Optional Pumpout System Maintenance sections, pages 67 and  
75, for details on the transfer of refrigerant, oil specifications,  
etc.  
High Altitude Locations — Because the chiller is ini-  
tially calibrated at sea level, it is necessary to recalibrate the  
pressure transducers if the chiller has been moved to a high alti-  
tude location. See the calibration procedure in the Trouble-  
shooting Guide section.  
Charge Refrigerant into Chiller  
The transfer, addition, or removal of refrigerant in spring  
isolated chillers may place severe stress on external piping  
if springs have not been blocked in both up and down  
directions.  
Table 9 — Control Test Menu Functions  
TESTS TO BE  
PERFORMED  
DEVICES TESTED  
Always operate the condenser and chilled water pumps  
during charging operations to prevent freeze-ups.  
1. CCM Thermistors  
Entering Chilled Water  
Evaporator Refrigerant Tempera-  
ture (ICVC only)  
Leaving Chilled Water  
Entering Condenser Water  
Leaving Condenser Water  
Remote Reset Sensor  
Comp Discharge Temp  
Oil Sump Temp  
Comp Motor Winding Temp  
Space Temperature 1  
Space Temperature 2  
The standard 19XR chiller is shipped with the refrigerant  
already charged in the vessels. However, the 19XR may be or-  
dered with a nitrogen holding charge of 15 psig (103 kPa).  
Evacuate the nitrogen from the entire chiller, and charge the  
chiller from refrigerant cylinders.  
CHILLER EQUALIZATION WITHOUT A PUMPOUT  
UNIT  
2. CCM Pressure  
Transducers  
Evaporator Pressure  
Condenser Pressure  
Oil Pump Delta P  
Condenser Water Delta P  
Transducer Voltage Ref  
When equalizing refrigerant pressure on the 19XR chiller  
after service work or during the initial chiller start-up, do  
not use the discharge isolation valve to equalize. Either the  
motor cooling isolation valve or the charging hose (con-  
nected between the pumpout valves on top of the cooler  
and condenser) should be used as the equalization valve.  
3. Pumps  
Chilled Water — Confirm pressure  
Condenser Water — Confirm  
Delta P  
4. Discrete Outputs  
Oil Heater Relay  
Hot Gas Bypass Relay  
Tower Fan Relay Low  
Tower Fan Relay High  
Alarm Relay  
To equalize the pressure differential on a refrigerant isolated  
19XR chiller, use the terminate lockout function of the CON-  
TROL TEST on the SERVICE menu. This helps to turn on  
pumps and advises the operator on proper procedures.  
Shunt Trip Relay  
Open/Close  
Open/Close  
5. Guide Vane Actuator  
6. Diffuser Actuator  
The following steps describe how to equalize refrigerant  
pressure in an isolated 19XR chiller without a pumpout unit.  
1. Access terminate lockout function on the CONTROL  
TEST screen.  
7. Pumpdown Lockout  
When using pumpdown/lockout,  
observe freeze up precautions when  
removing charge:  
Instructs operator which valves to  
close and when.  
2.  
IMPORTANT: Turn on the chilled water and con-  
denser water pumps to prevent freezing.  
Starts chilled water and condenser  
water pumps and confirms flows.  
Monitors  
Evaporator pressure  
Condenser pressure  
Evaporator temperature during  
pumpout procedures  
3. Slowly open the refrigerant cooling isolation valve. The  
chiller cooler and condenser pressures will gradually  
equalize. This process takes approximately 15 minutes.  
Turns pumps off after pumpdown.  
4. Once the pressures have equalized, the cooler isolation  
valve, the condenser isolation valve, and the hot gas isola-  
tion valve may now be opened. Refer to Fig. 29 and 30,  
for the location of the valves.  
Locks out compressor.  
Starts pumps and monitors flows.  
8 Terminate Lockout  
Instructs operator which valves to  
open and when.  
Monitors  
Evaporator pressure  
Condenser pressure  
Evaporator temperature during  
charging process  
Whenever turning the discharge isolation valve, be sure to  
reattach the valve locking device. This prevents the valve  
from opening or closing during service work or during  
chiller operation.  
Terminates compressor lockout.  
63  
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CHILLER EQUALIZATION WITH PUMPOUT UNIT —  
The following steps describe how to equalize refrigerant pres-  
sure on an isolated 19XR chiller using the pumpout unit.  
1. Access the terminate lockout function on the CONTROL  
TEST screen.  
2.  
3. Open valve 4 on the pumpout unit and open valves 1a and  
1b on the chiller cooler and condenser, Fig. 29 and 30.  
Slowly open valve 2 on the pumpout unit to equalize the  
pressure. This process takes approximately 15 minutes.  
4. Once the pressures have equalized, the discharge 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.  
The full refrigerant charge on the 19XR will vary with chill-  
er components and design conditions, as indicated on the job  
data specifications. An approximate charge may be determined  
by adding the condenser charge to the cooler charge as listed in  
Table 10.  
Use the CONTROL TEST terminate lockout function to  
monitor conditions and start the pumps.  
If the chiller has been shipped with a holding charge, the  
refrigerant is added through the pumpout charging connection  
(Fig. 29 and 30, valve 1b). First evacuate the nitrogen holding  
charge from the chiller vessels. Charge the refrigerant as a gas  
until the system pressure exceeds 35 psig (141 kPa) for  
HFC-134a. After the chiller is beyond this pressure the refrig-  
erant should be charged as a liquid until all the recommended  
refrigerant charge has been added. The charging valve (Fig. 29  
and 30, valve 7) can be used to charge liquid to the cooler if the  
cooler isolation valve (11) is present and is closed. Do not  
charge liquid through the linear float to the condenser.  
64  
Dry Run to Test Start-Up Sequence  
For electro-mechanical starters.  
1. Disengage the main motor disconnect (CB1) on the start-  
er front panel. This should only disconnect the motor  
power. Power to the controls, oil pump, and starter con-  
trol circuit should still be energized.  
2. Observe the default screen on the CVC/ICVC: the status  
message in the upper left-hand corner reads, “Manually  
Stopped,” Press the  
or  
softkey to start.  
LOCAL  
CCN  
If the chiller controls do not go into a start mode (“Unoc-  
cupied Mode” is displayed) go to the SCHEDULE screen  
and override the schedule or change the occupied  
time. Press the  
sequences.  
softkey to begin the start-up  
LOCAL  
3. View the STARTUP display screen and verify the chilled  
water and condenser water pumps have energized.  
4. Verify the oil pump has started and is pressurizing the  
lubrication system. After the oil pump has run about  
11 seconds, the starter energizes (COMPRESSOR START  
CONTACT is closed) and goes through its start-up  
sequence.  
Fig. 33 — Correct Motor Rotation  
5. Check the main contactor (1M) for proper operation.  
Do not check motor rotation during coastdown. Rotation  
may have reversed during equalization of vessel pressures.  
6. The PIC II eventually shows an alarm for motors amps  
not sensed. Reset this alarm and continue with the initial  
start-up.  
Check Oil Pressure and Compressor Stop  
1. When the motor is at full speed, note the differential oil  
pressure reading on the CVC/ICVC default screen. It  
should be between 18 and 30 psid (124 to 206 kPad).  
2. Press the Stop button and listen for any unusual sounds  
from the compressor as it coasts to a stop.  
For Benshaw Inc. solid-state starters:  
1. Close the main motor disconnect (CB1). Voltage will be  
applied to the compressor motor but the SCRs will not  
fire (compressor motor will not rotate). Enter MENU 4 in  
the Benshaw RediStart MICRO™ Menu structure at the  
Benshaw display (see Input Service Configurations,  
Change The Benshaw RediStart MICRO Software Con-  
figuration page 57). Select Dry Run Mode and scroll to  
YES.  
2. Follow steps 2 through 4 for the electro-mechanical start-  
ers. When the Ramp Time is set for less than 10 seconds  
COMPRESSOR RUN CONTACT will close.  
3. The PIC II eventually shows an alarm for motors amps  
not sensed. Reset this alarm and enter MENU 4 in the  
Benshaw display. Select Dry Run Mode and scroll to NO.  
Continue with the initial start-up.  
To Prevent Accidental Start-Up — A chiller STOP  
override setting may be entered to prevent accidental start-up  
during service or whenever necessary. Access the MAINSTAT  
screen and using the  
or  
softkeys, high-  
NEXT  
PREVIOUS  
light the CHILLER START/STOP parameter. Override the cur-  
rent START value by pressing the  
softkey. Press the  
softkey. The word  
SELECT  
ENTER  
softkey followed by the  
STOP  
SUPVSR! displays on the CVC/ICVC indicating the override  
is in place.  
To restart the chiller the STOP override setting must be re-  
moved. Access the MAINSTAT screen and using  
PREVIOUS  
3 softkeys that appear represent 3 choices:  
or  
NEXT  
softkeys highlight CHILLER START/STOP. The  
Check Motor Rotation  
1. Engage the oil pump circuit breaker (CB3) located inside  
•
•
•
— forces the chiller ON  
— forces the chiller OFF  
START  
STOP  
the right hand side of the starter panel.  
2. Then engage the control power circuit breaker (CB2) lo-  
cated in the same section of the starter cabinet.  
3. Finally close the main motor disconnect (CB1) on the  
front of the starter panel.  
4. The ISM mounted in the electro-mechanical starters  
checks for proper phase rotation as soon as power is  
applied to the starter and the PIC II controls power up.  
Solid-state starters have phase protection and do not per-  
mit a start if the phase rotation is not correct.  
5. An alarm message will appear on the CVC/ICVC if the  
phase rotation is incorrect. If this occurs reverse any 2 of  
the 3 incoming power leads to the starter and reapply  
power. The motor is now ready for a rotation check.  
— puts the chiller under remote or schedule  
RELEASE  
control.  
To return the chiller to normal control, press the  
softkey followed by the softkey. For  
RELEASE  
ENTER  
more information, see Local Start-Up, page 46.  
The default CVC/ICVC screen message line indicates  
which command is in effect.  
Check Chiller Operating Condition — Check to  
be sure that chiller temperatures, pressures, water flows, and  
oil and refrigerant levels indicate the system is functioning  
properly.  
Instruct the Customer Operator — Ensure the op-  
erator(s) understand all operating and maintenance procedures.  
Point out the various chiller parts and explain their function as  
part of the complete system.  
COOLER-CONDENSER — Float chamber, relief valves, re-  
frigerant charging valve, temperature sensor locations, pressure  
transducer locations, Schrader fittings, waterboxes and tubes,  
and vents and drains.  
6. After the default screen status message states ‘Ready to  
Start’ press the  
softkey. The PIC II control per-  
LOCAL  
forms start-up checks.  
7. When the starter is energized and the motor begins to  
turn, check for clockwise motor rotation (Fig. 33).  
65  
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OPTIONAL PUMPOUT STORAGE TANK AND PUMP-  
OUT SYSTEM — Transfer valves and pumpout system, refrig-  
erant charging and pumpdown procedure, and relief devices.  
MOTOR COMPRESSOR ASSEMBLY — Guide vane actu-  
ator, transmission, motor cooling system, oil cooling system,  
temperature and pressure sensors, oil sight glasses, integral oil  
pump, isolatable oil filter, extra oil and motor temperature sen-  
sors, synthetic oil, and compressor serviceability.  
MOTOR COMPRESSOR LUBRICATION SYSTEM —  
Oil pump, cooler filter, oil heater, oil charge and specification,  
operating and shutdown oil level, temperature and pressure,  
and oil charging connections.  
CONTROL SYSTEM — CCN and LOCAL start, reset,  
menu, softkey functions, CVC/ICVC operation, occupancy  
schedule, set points, safety controls, and auxiliary and optional  
controls.  
AUXILIARY EQUIPMENT — Starters and disconnects,  
separate electrical sources, pumps, and cooling tower.  
DESCRIBE CHILLER CYCLES — Refrigerant, motor  
cooling, lubrication, and oil reclaim.  
REVIEW MAINTENANCE — Scheduled, routine, and ex-  
tended shutdowns, importance of a log sheet, importance of  
water treatment and tube cleaning, and importance of maintain-  
ing a leak-free chiller.  
SAFETY DEVICES AND PROCEDURES — Electrical dis-  
connects, relief device inspection, and handling refrigerant.  
temperature reads more than 180 F (83 C) with the oil  
pump running, stop the chiller and determine the cause of  
the high temperature. Do not restart the chiller until  
corrected.  
3. The oil level should be visible anywhere in one of the two  
sight glasses. Foaming oil is acceptable as long as the oil  
pressure and temperature are within limits.  
4. The oil pressure should be between 18 and 30 psid (124  
to 207 kPad) differential, as seen on the CVC/ICVC de-  
fault screen. Typically the reading will be 18 to 25 psid  
(124 to 172 kPad) at initial start-up.  
5. The moisture indicator sight glass on the refrigerant  
motor cooling line should indicate refrigerant flow and a  
dry condition.  
6. The condenser pressure and temperature varies with the  
chiller design conditions. Typically the pressure will  
range between 60 and 135 psig (390 to 950 kPa) with a  
corresponding temperature range of 60 to 105 F (15 to  
41 C). The condenser entering water temperature should  
be controlled below the specified design entering  
water temperature to save on compressor kilowatt  
requirements.  
7. Cooler pressure and temperature also will vary with the  
design conditions. Typical pressure range will be between  
60 and 80 psig (410 and 550 kPa), with temperature rang-  
ing 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 oper-  
ation. Pulldown rate can be based on load rate or temper-  
ature rate and is accessed on the EQUIPMENT SER-  
VICE screen, RAMP_DEM table (Table 2, Example 21).  
CHECK OPERATOR KNOWLEDGE — Start, stop, and  
shutdown procedures, safety and operating controls, refrigerant  
and oil charging, and job safety.  
REVIEW THE START-UP OPERATION, AND MAINTE-  
NANCE MANUAL.  
OPERATING INSTRUCTIONS  
Operator Duties  
1. Become familiar with the chiller and related equipment  
before operating the chiller.  
2. Prepare the system for start-up, start and stop the chiller,  
and place the system in a shutdown condition.  
3. Maintain a log of operating conditions and document any  
abnormal readings.  
To Stop the Chiller  
1. The occupancy schedule starts and stops the chiller auto-  
matically once the time schedule is configured.  
2. By pressing the STOP button for one second, the alarm  
light blinks once to confirm the button has been pressed.  
The compressor will then follow the normal shutdown  
sequence as described in the Shutdown Sequence, Start-  
Up/Shutdown/Recycle Sequence section, page 46. The  
4. Inspect the equipment, make routine adjustments, and  
perform a Control Test. Maintain the proper oil and re-  
frigerant levels.  
chiller will not restart until the  
or  
soft-  
CCN  
LOCAL  
key is pressed. The chiller is now in the OFF control  
mode.  
5. Protect the system from damage during shutdown periods.  
6. Maintain the set point, time schedules, and other PIC  
functions.  
IMPORTANT: Do not attempt to stop the chiller by opening  
an isolating knife switch. High intensity arcing may occur.  
Prepare the Chiller for Start-Up — Follow the steps  
Do not restart the chiller until the problem is diagnosed  
and corrected.  
described in the Initial Start-Up section, page 64.  
To Start the Chiller  
1. Start the water pumps, if they are not automatic.  
After Limited Shutdown — No special preparations  
should be necessary. Follow the regular preliminary checks and  
starting procedures.  
2. On the CVC/ICVC default screen, press the  
or  
LOCAL  
softkey to start the system. If the chiller is in the  
CCN  
Preparation for Extended Shutdown — The refrig-  
erant should be transferred into the pumpout storage tank (if  
supplied; see Pumpout and Refrigerant Transfer Procedures) to  
reduce chiller pressure and the possibility of leaks. Maintain a  
holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant or  
nitrogen to prevent air from leaking into the chiller.  
If freezing temperatures are likely to occur in the chiller ar-  
ea, drain the chilled water, condenser water, and the pumpout  
condenser water circuits to avoid freeze-up. Keep the waterbox  
drains open.  
OCCUPIED mode and the start timers have expired, the  
start sequence will start. Follow the procedure described  
in the Start-Up/Shutdown/Recycle Sequence section,  
page 46.  
Check the Running System — After the compres-  
sor starts, the operator should monitor the CVC/ICVC display  
and observe the parameters for normal operating conditions:  
1. The oil reservoir temperature should be above 120 F  
(49 C) during shutdown.  
2. The bearing oil temperature accessed on the COMPRESS  
table should be 120 to 165 F (49 to 74 C). If the bearing  
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Leave the oil charge in the chiller with the oil heater and  
controls energized to maintain the minimum oil reservoir  
temperature.  
tank is supplied, the refrigerant can be isolated in the storage  
tank. The following procedures describe how to transfer refrig-  
erant from vessel to vessel and perform chiller evacuations.  
After Extended Shutdown — Ensure the water sys-  
tem drains are closed. It may be advisable to flush the water  
circuits to remove any soft rust which may have formed. This  
is a good time to brush the tubes and inspect the Schrader fit-  
tings on the waterside flow devices for fouling, if necessary.  
Check the cooler pressure on the CVC/ICVC default screen  
and compare it to the original holding charge that was left in  
the chiller. If (after adjusting for ambient temperature changes)  
any loss in pressure is indicated, check for refrigerant leaks.  
See Check Chiller Tightness section, page 48.  
Always run the chiller cooler and condenser water pumps  
and always charge or transfer refrigerant as a gas when the  
chiller pressure is less than 30 psig (207 kPa). Below these  
pressures, liquid refrigerant flashes into gas, resulting in  
extremely low temperatures in the cooler/condenser tubes  
and possibly causing tube freeze-up.  
Recharge the chiller by transferring refrigerant from the  
pumpout storage tank (if supplied). Follow the Pumpout and  
Refrigerant Transfer Procedures section, below. Observe  
freeze-up precautions.  
Carefully make all regular preliminary and running system  
checks. Perform a Control Test before start-up. If the compres-  
sor oil level appears abnormally high, the oil may have  
absorbed refrigerant. Ensure that the oil temperature is above  
140 F (60 C) or above the cooler refrigerant temperature plus  
50° F (27° C).  
During transfer of refrigerant into and out of the optional  
storage tank, carefully monitor the storage tank level gage.  
Do not fill the tank more than 90% of capacity to allow for  
refrigerant expansion. Overfilling may result in damage to  
the tank or personal injury.  
Cold Weather Operation — When the entering con-  
denser water temperature drops very low, the operator should  
automatically cycle the cooling tower fans off to keep the tem-  
perature up. Piping may also be arranged to bypass the cooling  
tower. The PIC II controls have a low limit tower fan output  
that can be used to assist in this control (terminal 11 and 12 on  
ISM).  
Do not mix refrigerants from chillers that use different  
compressor oils. Compressor damage can result.  
Operating the Optional Pumpout Unit  
1. Be sure that the suction and the discharge service valves  
on the optional pumpout compressor are open (back-  
seated) during operation. Rotate the valve stem fully  
counterclockwise to open. Front-seating the valve closes  
the refrigerant line and opens the gage port to compressor  
pressure.  
2. Ensure that the compressor hold-down bolts have been  
loosened to allow free spring travel.  
3. Open the refrigerant inlet valve on the pumpout  
compressor.  
4. Oil should be visible in the pumpout unit compressor  
sight glass under all operating conditions and during  
shutdown. If oil is low, add oil as described under  
Optional Pumpout System Maintenance section, page 75.  
The pumpout unit control wiring schematic is detailed in  
Fig. 35.  
Manual Guide Vane Operation — It is possible to  
manually operate the guide vanes in order to check control  
operation or to control the guide vanes in an emergency. Manu-  
al operation is possible by overriding the target guide vane  
position. Access the COMPRESS screen on the CVC/ICVC  
and scroll down to highlight TARGET GUIDE VANE POS. To  
control the position, use the  
or  
DECREASE  
INCREASE  
softkey to adjust to the percentage of guide vane opening that is  
desired. Zero percent is fully closed; 100% is fully open. To  
release the guide vanes to automatic control, press the  
softkey.  
RELEASE  
NOTE: Manual control overrides the configured pulldown rate  
during start-up and permits the guide vanes to open at a faster  
rate. Motor current above the electrical demand setting, capac-  
ity overrides, and chilled water temperature below the control  
point override the manual target and close the guide vanes. For  
descriptions of capacity overrides and set points, see the Con-  
trols section.  
TO READ REFRIGERANT PRESSURES during pumpout or  
leak testing:  
1. The CVC/ICVC display on the chiller control panel is  
suitable for determining refrigerant-side pressures and  
low (soft) vacuum. To assure the desired range and accu-  
racy when measuring evacuation and dehydration, use a  
quality vacuum indicator or manometer. This can be  
placed on the Schrader connections on each vessel (Fig.  
9) by removing the pressure transducer.  
2. To determine pumpout storage tank pressure, a 30 in.  
-0-400 psi (-101-0-2769 kPa) gage is attached to the stor-  
age tank.  
Refrigeration Log — A refrigeration log (as shown in  
Fig. 34), is a convenient checklist for routine inspection and  
maintenance and provides a continuous record of chiller per-  
formance. It is also an aid when scheduling routine mainte-  
nance and diagnosing chiller problems.  
Keep a record of the chiller pressures, temperatures, and liquid  
levels on a sheet similar to the one in Fig. 34. Automatic  
recording of PIC II data is possible by using CCN devices such  
as the Data Collection module and a Building Supervisor.  
Contact a Carrier representative for more information.  
3. Refer to Fig. 29, 30, and 36 for valve locations and  
numbers.  
PUMPOUT AND REFRIGERANT  
TRANSFER PROCEDURES  
Transfer, addition, or removal of refrigerant in spring-  
isolated chillers may place severe stress on external piping  
if springs have not been blocked in both up and down  
directions.  
Preparation — The 19XR may come equipped with an  
optional pumpout storage tank, pumpout system, or pumpout  
compressor. The refrigerant can be pumped for service work to  
either the chiller compressor vessel or chiller condenser vessel  
by using the optional pumpout system. If a pumpout storage  
67  
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the CONTROL TEST table to turn on the water  
pumps and monitor pressures.  
If the chilled water and condenser water pumps are not  
controlled by the PIC II, these pumps must be started and  
stopped manually at the appropriate times during the refrig-  
erant transfer procedure.  
b. Close pumpout unit valves 2, 4, 5, 8, and 10, and  
close chiller charging valve 7; open chiller isola-  
tion valves 11, 12, 13, and 14 (if present).  
c. Open pumpout unit/storage tank valves 3 and 6,  
open chiller valves 1a and 1b.  
LEGEND  
VALVE  
1a 1b 2  
3
4
5
6
7
8 10 11 12 13 14  
C
— Contactor  
C
C C  
C C C  
CONDITION  
FU  
— Fuse, 3 Amps  
HP  
— High-Pressure Cutout  
— Compressor Overload  
OL  
T’STAT  
Internal Thermostat  
Compressor Terminal  
Contactor Terminal  
Overload Terminal  
—
Follow Steps d and e carefully to prevent damage from  
freeze-up.  
d. Slowly open valve 5 to increase chiller pressure to  
68 psig 35 psig (141 kPa) for HFC-134a. Feed  
refrigerant slowly to prevent freeze up.  
Pumpout Unit Terminal  
*Bimetal thermal protector imbedded in motor winding.  
e. Open valve 5 fully after the pressure rises above  
the freeze point of the refrigerant. Open liquid line  
Fig. 35 — 19XR Pumpout Unit Wiring Schematic  
valves  
7
and 10 until refrigerant pressure  
OIL RETURN  
LINE  
CONNECTION  
equalizes.  
VALVE  
1a 1b 2  
3
4
5
6
7
7
8 10 11 12 13 14  
C
C
C
CONDITION  
2. Transfer the remaining refrigerant.  
a. Close valve 5 and open valve 4.  
VALVE  
1a 1b 2  
3
4
5
6
8 10 11 12 13 14  
C
C
C
CONDITION  
b. Turn off the chiller water pumps using the CVC/  
ICVC (or manually, if necessary).  
c. Turn off the pumpout condenser water, and turn on  
the pumpout compressor to push liquid out of the  
storage tank.  
d. Close liquid line valve 7.  
e. Turn off the pumpout compressor.  
f. Close valves 3 and 4.  
CONDENSER  
REFRIGERANT  
WATER  
g. Open valves 2 and 5.  
INLET VALVE  
CONNECTIONS  
VALVE  
1a 1b 2  
3
4
5
6
7
8 10 11 12 13 14  
Fig. 36 — Optional Pumpout Unit  
C C  
C C  
CONDITION  
h. Turn on the pumpout condenser water.  
Chillers with Storage Tanks — If the chiller has iso-  
lation valves, leave them open for the following procedures.  
The letter “C” describes a closed valve. See Fig. 17, 18, 29,  
and 30.  
TRANSFER REFRIGERANT FROM PUMPOUT STOR-  
AGE TANK TO CHILLER  
i. Run the pumpout compressor until the pumpout  
storage tank pressure reaches 5 psig (34 kPa)  
(18 in. Hg [40 kPa absolute] if repairing the tank).  
j. Turn off the pumpout compressor.  
k. Close valves 1a, 1b, 2, 5, 6, and 10.  
1. Equalize refrigerant pressure.  
VALVE  
1a 1b 2  
3
4
5
6
7
8 10 11 12 13 14  
C C C C C C C C C C  
CONDITION  
a. Use the PIC II terminate lockout function on the  
PUMPDOWN LOCKOUT screen, accessed from  
l. Turn off pumpout condenser water.  
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TRANSFER REFRIGERANT FROM CHILLER TO PUMP-  
OUT STORAGE TANK  
1. Equalize refrigerant pressure.  
a. Valve positions:  
Chillers with Isolation Valves  
TRANSFER ALL REFRIGERANT TO CHILLER CON-  
DENSER VESSEL — For chillers with isolation valves,  
refrigerant can be stored in one chiller vessel or the other with-  
out the need for an external storage tank.  
1. Push refrigerant into the chiller condenser.  
a. Valve positions:  
b. Slowly open valve 5. When the pressures are  
equalized, open liquid line valve 7 to allow liquid  
refrigerant to drain by gravity into the pumpout  
storage tank.  
b. Using the PIC II controls, turn off the chiller water  
pumps and pumpout condenser water. If the chiller  
water pumps are not controlled through the PIC II,  
turn them off manually.  
c. Turn on the pumpout compressor to push the liquid  
refrigerant out of the chiller cooler vessel.  
2. Transfer the remaining liquid.  
a. Turn off the pumpout condenser water. Place the  
valves in the following positions:  
d. When all liquid refrigerant has been pushed into  
the chiller condenser vessel, close chiller isolation  
b. Run the pumpout compressor for approximately  
30 minutes; then close valve 10.  
c. Turn off the pumpout compressor.  
3. Remove any remaining refrigerant.  
a. Turn on the chiller water pumps using the PUMP-  
DOWN LOCKOUT screen, accessed from the  
CONTROL TEST table. Turn on the pumps manu-  
ally, if they are not controlled by the PIC II.  
b. Turn on the pumpout condenser water.  
c. Place valves in the following positions:  
d. Run the pumpout compressor until the chiller pres-  
sure reaches 30 psig (207 kPa) for HFC-134a.  
Then, shut off the pumpout compressor. Warm  
condenser water will boil off any entrapped liquid  
refrigerant and the chiller pressure will rise.  
e. When the pressure rises to 40 psig (276 kPa) for  
HFC-134a, turn on the pumpout compressor until  
the pressure again reaches 30 psig (207 kPa), and  
then turn off the pumpout compressor. Repeat this  
process until the pressure no longer rises. Then,  
turn on the pumpout compressor and pump until  
the pressure reaches18 in. Hg. (40 kPa absolute).  
f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.  
g. Turn off the pumpout condenser water and con-  
tinue to use the PIC II PUMPDOWN LOCKOUT  
screen functions, which lock out the chiller com-  
pressor for operation.  
4. Establish a vacuum for service.  
To conserve refrigerant, operate the pumpout compressor  
until the chiller pressure is reduced to 18 in. Hg vac., ref  
30 in. bar. (40 kPa abs.) following Step 3e.  
70  
2. Evacuate the refrigerant gas from the chiller condenser  
vessel.  
GENERAL MAINTENANCE  
Refrigerant Properties — The standard refrigerant for  
the 19XR chiller is HFC-134a. At normal atmospheric pres-  
sure, HFC-134a will boil at –14 F (–25 C) and must, therefore,  
be kept in pressurized containers or storage tanks. The refriger-  
ant is practically odorless when mixed with air and is noncom-  
bustible at atmospheric pressure. Read the Material Safety  
Data Sheet and the latest ASHRAE Safety Guide for Mechani-  
cal Refrigeration to learn more about safe handling of this  
refrigerant.  
a. Access the PUMPDOWN LOCKOUT function  
accessed from the CVC/ICVC CONTROL TEST  
table to turn on the chiller water pumps. Turn the  
chiller water pumps on manually if they are not  
controlled by the PIC II.  
b. Close pumpout unit valves 3 and 4; open valves 2  
and 5.  
c. Turn on the pumpout condenser water.  
d. Run the pumpout compressor until the chiller  
condenser pressure reaches 18 in. Hg vac (40 kPa  
abs.). Monitor pressure at the CVC/ICVC and at  
refrigerant gages.  
e. Close valve 1b.  
f. Turn off the pumpout compressor.  
g. Close valves 1a, 2, and 5.  
Adding Refrigerant — Follow the procedures de-  
scribed in Trim Refrigerant Charge section, page 72.  
h. Turn off the pumpout condenser water.  
i. Proceed to the PUMPDOWN LOCKOUT test  
from the CVC/ICVC CONTROL TEST table to  
turn off the chiller water pumps and lock out the  
chiller compressor. Turn off the chiller water  
pumps manually if they are not controlled by the  
PIC II.  
Removing Refrigerant — If the optional pumpout sys-  
tem is used, the 19XR refrigerant charge may be transferred to  
a pumpout storage tank or to the chiller condenser or cooler  
vessels. Follow the procedures in the Pumpout and Refrigerant  
Transfer Procedures section when transferring refrigerant from  
one vessel to another.  
RETURN CHILLER TO NORMAL OPERATING  
CONDITIONS  
1. Ensure vessel that was opened has been evacuated.  
2. Access the TERMINATE LOCKOUT function CVC/  
ICVC from the CONTROL TEST table to view vessel  
pressures and turn on chiller water pumps. If the chiller  
water pumps are not controlled by the PIC II, turn them  
on manually.  
Adjusting the Refrigerant Charge — If the addi-  
tion or removal of refrigerant is required to improve chiller per-  
formance, follow the procedures given under the Trim Refrig-  
3. Open valves 1a, 1b, and 3.  
4. Slowly open valve 5, gradually increasing pressure in the  
evacuated vessel to 35 psig (141 kPa). Feed refrigerant  
slowly to prevent tube freeze up.  
5. Leak test to ensure vessel integrity.  
6. Open valve 5 fully.  
7. Open valve 11 to equalize the liquid refrigerant level be-  
tween the vessels.  
8. Close valves 1a, 1b, 3, and 5.  
9. Open isolation valves 12, 13, and 14 (if present).  
10. Proceed to the TERMINATE LOCKOUT screen (access-  
ed from the CONTROL TEST table) to turn off the water  
pumps and enable the chiller compressor for start-up. If  
the chiller water pumps are not controlled by the PIC II,  
turn them off manually.  
71  
TESTING WITH REFRIGERANT TRACER — Use an en-  
vironmentally acceptable refrigerant as a tracer for leak test  
procedures. Use dry nitrogen to raise the machine pressure to  
leak testing levels.  
TESTING WITHOUT REFRIGERANT TRACER — An-  
other method of leak testing is to pressurize with nitrogen only  
and to use a soap bubble solution or an ultrasonic leak detector  
to determine if leaks are present.  
TO PRESSURIZE WITH DRY NITROGEN  
NOTE: Pressurizing with dry nitrogen for leak testing should  
not be done if the full refrigerant charge is in the vessel  
because purging the nitrogen is very difficult.  
1. Connect a copper tube from the pressure regulator on the  
cylinder to the refrigerant charging valve. Never apply  
full cylinder pressure to the pressurizing line. Follow the  
listed sequence.  
2. Open the charging valve fully.  
3. Slowly open the cylinder regulating valve.  
4. Observe the pressure gage on the chiller and close the  
regulating valve when the pressure reaches test level. Do  
not exceed 140 psig (965 kPa).  
5. Close the charging valve on the chiller. Remove the cop-  
per tube if it is no longer required.  
Repair the Leak, Retest, and Apply Standing  
Vacuum Test — After pressurizing the chiller, test for  
leaks with an electronic halide leak detector, soap bubble solu-  
tion, or an ultrasonic leak detector. Bring the chiller back to at-  
mospheric pressure, repair any leaks found, and retest.  
After retesting and finding no leaks, apply a standing vacu-  
um test. Then dehydrate the chiller. Refer to the Standing Vacu-  
um Test and Chiller Dehydration section (pages 50 and 53) in  
the Before Initial Start-Up section.  
Checking Guide Vane Linkage — When the chiller  
is off, the guide vanes are closed and the actuator mechanism is  
in the position shown in Fig. 37. If slack develops in the drive  
chain, do the following to eliminate backlash:  
1. With the chiller shut down and the actuator fully closed,  
remove the chain guard and loosen the actuator bracket  
hold-down bolts.  
2. Loosen guide vane sprocket adjusting bolts.  
3. Pry bracket upwards to remove slack, then retighten the  
bracket hold-down bolts.  
4. Retighten the guide vane sprocket adjusting bolts. Ensure  
that the guide vane shaft is rotated fully in the clockwise  
direction in order close it fully.  
Trim Refrigerant Charge — If, to obtain optimal chill-  
er performance, it becomes necessary to adjust the refrigerant  
charge, operate the chiller at design load and then add or re-  
move refrigerant slowly until the difference between the leav-  
ing chilled water temperature and the cooler refrigerant tem-  
perature reaches design conditions or becomes a minimum. Do  
not overcharge.  
Refrigerant may be added either through the storage tank or  
directly into the chiller as described in the Charge Refrigerant  
into Chiller section.  
72  
10. Remove the hose from the charging valve, open the isola-  
tion 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 your ac-  
tual chiller requirements such as chiller load, run hours, and  
water quality. The time intervals listed in this section are  
offered as guides to service only.  
Oil Specification — If oil is added, it must meet the fol-  
lowing Carrier specifications:  
Oil Type for units using R-134a . . . . . . . . . . . . . . . . . . Inhibited  
polyolester-based synthetic  
Service Ontime — The CVC/ICVC will display a SER-  
VICE ONTIME value on the MAINSTAT screen. This value  
should be reset to zero by the service person or the operator  
each time major service work is completed so that the time  
between service can be viewed and tracked.  
compressor oil formatted for  
use with HFC, gear-driven,  
hermetic compressors.  
Inspect the Control Panel — Maintenance consists of  
general cleaning and tightening of connections. Vacuum the  
cabinet to eliminate dust build-up. If the chiller control mal-  
functions, refer to the Troubleshooting Guide section for con-  
trol checks and adjustments.  
Check Safety and Operating Controls Monthly —  
To ensure chiller protection, the automated Control Test  
should be performed at least once per month. See Table 3  
for safety control settings. See Table 9 for Control Test  
functions.  
Changing Oil Filter — Change the oil filter on a  
yearly basis or when the chiller is opened for repairs. The  
19XR has an isolatable oil filter so that the filter may be  
changed with the refrigerant remaining in the chiller. Use  
the following procedure:  
1. Ensure the compressor is off and the disconnect for the  
compressor is open.  
2. Disconnect the power to the oil pump.  
3. Close the oil filter isolation valves located behind power  
panel on top of oil pump assembly.  
4. Connect an oil charging hose from the oil charging valve  
(Fig. 2) and place the other end in a clean container suit-  
able for used oil. The oil drained from the filter housing  
should be used as an oil sample and sent to a laboratory  
for proper analysis. Do not contaminate this sample.  
5. Slowly open the charging valve to drain the oil from the  
housing.  
6. Once all oil has been drained, place some rags or absor-  
bent 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 re-  
tainer and tighten down the retainer nut. Install the filter  
cover and tighten the 4 bolts.  
9. Evacuate the filter housing by placing a vacuum pump on  
the charging valve. Follow the normal evacuation proce-  
dures. Shut the charging valve when done and reconnect  
the valve so that new oil can be pumped into the filter  
housing. Fill with the same amount that was removed;  
then close the charging valve.  
73  
Inspect Refrigerant Float System — Perform this  
inspection every 5 years or when the condenser is opened for  
service.  
1. Transfer the refrigerant into the cooler vessel or into a  
pumpout storage tank.  
Compressor Bearing and Gear Maintenance —  
The key to good bearing and gear maintenance is proper  
lubrication. Use the proper grade of oil, maintained at rec-  
ommended level, temperature, and pressure. Inspect the  
lubrication system regularly and thoroughly.  
To inspect the bearings, a complete compressor teardown is  
required. Only a trained service technician should remove and  
examine the bearings. The cover plate on older compressor  
bases was used for factory-test purposes and is not usable  
for bearing or gear inspection. The bearings and gears should  
be examined on a scheduled basis for signs of wear. The  
frequency of examination is determined by the hours of chiller  
operation, load conditions during operation, and the condition  
of the oil and the lubrication system. Excessive bearing wear  
can sometimes be detected through increased vibration or  
increased bearing temperature. If either symptom appears, con-  
tact an experienced and responsible service organization for  
assistance.  
2. Remove the float access cover.  
3. Clean the chamber and valve assembly thoroughly. Be  
sure the valve moves freely. Ensure that all openings are  
free of obstructions.  
4. Examine the cover gasket and replace if necessary.  
See Fig. 38 for a view of the float valve design. For linear  
float valve designs, inspect the orientation of the float slide  
pin. It must be pointed toward the bubbler tube for proper  
operation.  
Inspect Relief Valves and Piping — The relief valves  
on this chiller protect the system against the potentially danger-  
ous effects of overpressure. To ensure against damage to the  
equipment and possible injury to personnel, these devices must  
be kept in peak operating condition.  
Inspect the Heat Exchanger Tubes and Flow  
Devices  
COOLER AND FLOW DEVICES — Inspect and clean the  
cooler tubes at the end of the first operating season. Because  
these tubes have internal ridges, a rotary-type tube cleaning  
system is needed to fully clean the tubes. Inspect the tubes’  
condition to determine the scheduled frequency for future  
cleaning and to determine whether water treatment in the  
chilled water/brine circuit is adequate. Inspect the entering and  
leaving chilled water temperature sensors and flow devices for  
signs of corrosion or scale. Replace a sensor or Schrader fitting  
if corroded or remove any scale if found.  
CONDENSER AND FLOW DEVICES — Since this water  
circuit is usually an open-type system, the tubes may be subject  
to contamination and scale. Clean the condenser tubes with a  
rotary tube cleaning system at least once per year and more of-  
ten if the water is contaminated. Inspect the entering and leav-  
ing condenser water sensors and flow devices for signs of cor-  
rosion or scale. Replace the sensor or Schrader fitting if corrod-  
ed or remove any scale if found.  
As a minimum, the following maintenance is required.  
1. At least once a year, disconnect the vent piping at the  
valve outlet and carefully inspect the valve body and  
mechanism for any evidence of internal corrosion or rust,  
dirt, scale, leakage, etc.  
2. If corrosion or foreign material is found, do not attempt to  
repair or recondition. Replace the valve.  
3. If the chiller is installed in a corrosive atmosphere or the  
relief valves are vented into a corrosive atmosphere, in-  
spect the relief valves at more frequent intervals.  
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 refrig-  
erant temperature against the leaving condenser water tempera-  
ture. If this reading is more than what the design difference is  
74  
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —  
Use oil conforming to Carrier specifications for reciprocat-  
ing compressor usage. Oil requirements are as follows:  
ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68  
Carrier Part Number . . . . . . . . . . . . . . . . . . . . . . . . PP23BZ103  
Water Treatment — Untreated or improperly treated wa-  
ter may result in corrosion, scaling, erosion, or algae. The ser-  
vices of a qualified water treatment specialist should be ob-  
tained to develop and monitor a treatment program.  
The total oil charge, 4.5 pints (2.6 L), consists of 3.5 pints  
(2.0 L) for the compressor and one additional pint (0.6 L) for  
the oil separator.  
Oil should be visible in one of the compressor sight glasses  
during both operation and at shutdown. Always check the oil  
level before operating the compressor. Before adding or chang-  
ing oil, relieve the refrigerant pressure as follows:  
Water must be within design flow limits, clean, and treated  
to ensure proper chiller performance and reduce the poten-  
tial of tube damage due to corrosion, scaling, erosion, and  
algae. Carrier assumes no responsibility for chiller damage  
resulting from untreated or improperly treated water.  
Inspect the Starting Equipment — Before working  
on any starter, shut off the chiller, open and tag all disconnects  
supplying power to the starter.  
1. Attach a pressure gage to the gage port of either compres-  
sor service valve (Fig. 36).  
2. Close the suction service valve and open the discharge  
line to the storage tank or the chiller.  
3. Operate the compressor until the crankcase pressure  
drops to 2 psig (13 kPa).  
4. Stop the compressor and isolate the system by closing the  
discharge service valve.  
The disconnect on the starter front panel does not deener-  
gize all internal circuits. Open all internal and remote dis-  
connects before servicing the starter.  
5. Slowly remove the oil return line connection (Fig. 36).  
Add oil as required.  
6. Replace the connection and reopen the compressor ser-  
vice valves.  
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS  
(Fig. 39) — The optional pumpout system high-pressure  
switch opens at 161 psig (1110 kPa) and closes at 130 psig  
(896 kPa). Check the switch setting by operating the pumpout  
compressor and slowly throttling the pumpout condenser  
water.  
Never open isolating knife switches while equipment is  
operating. Electrical arcing can cause serious injury.  
Inspect starter contact surfaces for wear or pitting on  
mechanical-type starters. Do not sandpaper or file silverplated  
contacts. Follow the starter manufacturer’s instructions for  
contact replacement, lubrication, spare parts ordering, and oth-  
er 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 re-  
tighten. Recheck annually thereafter.  
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.  
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 eight transducers: the 2 oil differential pres-  
sure transducers, the condenser pressure transducer, the cooler  
pressure transducer, and the waterside pressure transducers  
(consisting of 4 flow devices: 2 cooler, 2 condenser).  
Note the evaporator and condenser pressure readings on the  
HEAT_EX screen on the CVC/ICVC (EVAPORATOR PRES-  
SURE and CONDENSER PRESSURE). Attach an accurate set  
of refrigeration gages to the cooler and condenser Schrader fit-  
tings. Compare the two readings. If there is a difference in  
readings, the transducer can be calibrated as described in the  
Troubleshooting Guide section. Oil differential pressure (OIL  
PUMP DELTA P on the COMPRESS screen) should be zero  
whenever the compressor is off.  
Optional Pumpout System Maintenance — For  
pumpout unit compressor maintenance details, refer to the  
06D, 07D Installation, Start-Up, and Service Instructions.  
Fig. 39 — Optional Pumpout System Controls  
75  
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VOLTAGE DROP — The voltage drop across any energized  
sensor can be measured with a digital voltmeter while the con-  
trol is energized. Table 12A or 12B lists the relationship be-  
tween temperature and sensor voltage drop (volts dc measured  
across the energized sensor). Exercise care when measuring  
voltage to prevent damage to the sensor leads, connector plugs,  
and modules. Sensors should also be checked at the sensor  
plugs. Check the sensor wire at the sensor for 5 vdc if the con-  
trol is powered on.  
TROUBLESHOOTING GUIDE  
Overview — The PIC II has many features to help the op-  
erator and technician troubleshoot a 19XR chiller.  
• The CVC/ICVC shows the chiller’s actual operating con-  
ditions and can be viewed while the unit is running.  
• The CVC/ICVC default screen freezes when an alarm  
occurs. The freeze enables the operator to view the  
chiller conditions at the time of alarm. The STATUS  
screens continue to show current information. Once all  
alarms have been cleared (by correcting the problems  
and pressing the  
softkey), the CVC/ICVC  
RESET  
default screen returns to normal operation.  
Relieve all refrigerant pressure or drain the water before  
replacing the temperature sensors.  
• The CONTROL ALGORITHM STATUS screens (which  
include the CAPACITY, OVERRIDE, LL_MAINT,  
CHECK SENSOR ACCURACY — Place the sensor in a  
medium of known temperature and compare that temperature  
to the measured reading. The thermometer used to determine  
the temperature of the medium should be of laboratory quality  
with 0.5° F (.25° C) graduations. The sensor in question should  
be accurate to within 2° F (1.2° C).  
ISM_HIST,  
LOADSHED,  
WSMDEFME,  
and  
OCCDEFCM screens) display information that helps to  
diagnose problems with chilled water temperature  
control, chilled water temperature control overrides, hot  
gas bypass, surge algorithm status, and time schedule  
operation.  
• The control test feature facilitates the proper operation  
and test of temperature sensors, pressure transducers, the  
guide vane actuator, oil pump, water pumps, tower con-  
trol, and other on/off outputs while the compressor is  
stopped. It also has the ability to lock off the compressor  
and turn on water pumps for pumpout operation. The  
CVC/ICVC shows the temperatures and pressures  
required during these operations.  
• From other SERVICE tables, the operator/technician can  
access configured items, such as chilled water resets,  
override set points, etc.  
• If an operating fault is detected, an alarm message is gen-  
erated and displayed on the CVC/ICVC default screen.  
A more detailed message — along with a diagnostic  
message — is also stored into the ALARM HISTORY  
table.  
See Fig. 9 for sensor locations. The sensors are immersed  
directly in the refrigerant or water circuits. The wiring at each  
sensor is easily disconnected by unlatching the connector.  
These connectors allow only one-way connection to the sensor.  
When installing a new sensor, apply a pipe sealant or thread  
sealant to the sensor threads.  
DUAL TEMPERATURE SENSORS — For servicing con-  
venience, there are 2 sensors each on the bearing and motor  
temperature sensors. If one of the sensors is damaged, the other  
can be used by simply moving a wire. The number 2 terminal  
in the sensor terminal box is the common line. To use the sec-  
ond sensor, move the wire from the number 1 position to the  
number 3 position.  
Checking Pressure Transducers  
UNITS EQUIPPED WITH CVC — There are 8 pressure  
transducers on 19XR chillers. They determine cooler, condens-  
er, oil pressure, and cooler and condenser flow. The cooler and  
condenser transducers are also used by the PIC II to determine  
the refrigerant temperatures. The oil supply pressure transducer  
value and the oil transmission sump pressure transducer value  
difference is calculated by the CCM. The CVC module then  
displays the differential pressure. In effect, the CVC reads only  
one input for oil pressure for a total of 5 pressure inputs: cooler  
pressure, condenser pressure, oil differential pressure, cooler  
waterside differential pressure, and condenser waterside differ-  
ential pressure. See the Check Pressure Transducers section  
(page 75) under Scheduled Maintenance.  
UNITS EQUIPPED WITH ICVC — There are 6 factory-  
installed pressure transducers, with inputs available for both  
cooler and The ICVC software will display a default reading of  
26 psi during start-up and operation. An additional transducer,  
factory installed in the bottom of the cooler barrel, will read as  
EVAPORATOR SACTURATION TEMP on the HEAT_EX  
DISPLAY screen. This provides additional protection against a  
loss of water flow condition.  
These pressure transducers can be calibrated if necessary. It  
is not usually necessary to calibrate at initial start-up.  
However, at high altitude locations, it is necessary to calibrate  
the transducers to ensure the proper refrigerant temperature/  
pressure relationship. Each transducer is supplied with 5 vdc  
power from the CCM. If the power supply fails, a transducer  
voltage reference alarm occurs. If the transducer reading is  
suspected of being faulty, check the supply voltage. It should  
be 5 vdc ±.5 v displayed in CONTROL TEST under CCM  
Pressure Transducers. If the supply voltage is correct, the trans-  
ducer should be recalibrated or replaced.  
Checking Display Messages — The first area to  
check when troubleshooting the 19XR is the CVC/ICVC dis-  
play. If the alarm light is flashing, check the primary and sec-  
ondary message lines on the CVC/ICVC default screen  
(Fig. 14). These messages will indicate where the fault is oc-  
curring. These messages contain the alarm message with a  
specified code. This code or state appears with each alarm and  
alert message. The ALARM HISTORY table on the CVC/  
ICVC SERVICE menu also contains an alarm message to fur-  
ther expand on the alarm. For a complete list of possible alarm  
messages, see Table 11. If the alarm light starts to flash while  
accessing a menu screen, press the  
softkey to return to  
EXIT  
the default screen to read the alarm message. The STATUS  
screen can also be accessed to determine where an alarm exists.  
Checking Temperature Sensors — All temperature  
sensors are thermistor-type sensors. This means that the resis-  
tance of the sensor varies with temperature. All sensors have  
the same resistance characteristics. If the controls are on, deter-  
mine sensor temperature by measuring voltage drop; if the con-  
trols are powered off, determine sensor temperature by measur-  
ing resistance. Compare the readings to the values listed in  
Table 12A or 12B.  
RESISTANCE CHECK — Turn off the control power and,  
from the module, disconnect the terminal plug of the sensor in  
question. With a digital ohmmeter, measure sensor resistance  
between receptacles as designated by the wiring diagram. The  
resistance and corresponding temperature are listed in  
Table 12A or 12B. Check the resistance of both wires to  
ground. This resistance should be infinite.  
76  
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TRANSDUCER REPLACEMENT — Since the transducers  
are mounted on Schrader-type fittings, there is no need to re-  
move refrigerant from the vessel when replacing the transduc-  
ers. Disconnect the transducer wiring. Do not pull on the trans-  
ducer wires. Unscrew the transducer from the Schrader fitting.  
When installing a new transducer, do not use pipe sealer  
(which can plug the sensor). Put the plug connector back on the  
sensor and snap into place. Check for refrigerant leaks.  
Control Test — The Control Test feature can check all the  
thermistor temperature sensors, pressure transducers, pumps  
and their associated flow devices, the guide vane actuator, and  
other control outputs such as hot gas bypass. The tests can help  
to determine whether a switch is defective or a pump relay is  
not operating, as well as other useful troubleshooting issues.  
During pumpdown operations, the pumps are energized to pre-  
vent freeze-up and the vessel pressures and temperatures are  
displayed. The Pumpdown/Lockout feature prevents compres-  
sor start-up when there is no refrigerant in the chiller or if the  
vessels are isolated. The Terminate Lockout feature ends the  
Pumpdown/Lockout after the pumpdown procedure is reversed  
and refrigerant is added.  
Be sure to use a back-up wrench on the Schrader fitting  
whenever removing a transducer, since the Schrader fitting  
may back out with the transducer, causing a large leak and  
possible injury to personnel.  
LEGEND TO TABLES 11A-11J  
CCM — Chiller Control Module  
Control Algorithms Checkout Procedure — One  
of the tables on the CVC/ICVC SERVICE menu is CON-  
TROL ALGORITHM STATUS. The maintenance screens  
may be viewed from the CONTROL ALGORITHM STATUS  
table to see how a particular control algorithm is operating.  
These maintenance screens are very useful in helping to de-  
termine how the control temperature is calculated and guide  
vane positioned and for observing the reactions from load  
changes, control point overrides, hot gas bypass, surge preven-  
tion, etc. The tables are:  
CVC  
—
Chiller Visual Controller  
CHW — Chilled Water  
International Chiller Visual  
ICVC —  
Control  
ISM  
—
Integrated Starter Module  
PIC II — Product Integrated Controls II  
VFD  
—
Variable Frequency Drive  
CAPACITY  
Capacity  
Control  
This table shows all values used  
to calculate the chilled water/brine  
control point.  
OVERRIDE  
HEAT_EX  
Override  
Status  
Surge/  
HGBP  
Status  
Details of all chilled water control  
override values.  
The surge and hot gas bypass  
control algorithm status is viewed  
from this screen. All  
values dealing with this control  
are displayed.  
LL_MAINT  
LEAD/LAG  
Status  
Indicates LEAD/LAG operation  
status.  
OCCDEFCM  
Time  
Schedules  
Status  
The Local and CCN occupied  
schedules are displayed here to  
help the operator quickly deter-  
mine whether the schedule is in  
the “occupied” mode or not.  
WSMDEFME  
Water  
The water system manager is a  
CCN module that can turn on the  
chiller and change the chilled  
water control point. This screen  
indicates the  
System  
Manager  
Status  
status of this system.  
77  
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Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides  
A. MANUAL STOP  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
PROBABLE CAUSE/REMEDY  
MANUALLY STOPPED — PRESS CCN OR LOCAL TO START  
TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL  
PIC II in OFF mode, press CCN or LOCAL softkey to start unit.  
Enter the CONTROL TEST table and select TERMINATE LOCKOUT to  
B. READY TO START  
C. IN RECYCLE SHUTDOWN  
78  
Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)  
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.  
PRIMARY  
MESSAGE  
PRESTART  
ALERT  
SECONDARY  
MESSAGE  
STARTS LIMIT  
EXCEEDED  
ALARM MESSAGE  
PRIMARY CAUSE  
100->Excessive compressor  
starts (8 in 12 hours)  
STATE  
100  
ADDITIONAL CAUSE/REMEDY  
Depress the RESET softkey if additional start is  
required. Reassess start-up requirements.  
101  
PRESTART  
ALERT  
HIGH BEARING  
TEMPERATURE  
101->Comp Thrust Bearing  
Temp [VALUE] exceeded  
limit of [LIMIT]*.  
Check oil heater for proper operation.  
Check for low oil level, partially closed coil supply  
valves, clogged oil filters, etc.  
Check the sensor wiring and accuracy.  
Check configurable range in SETUP1 screen.  
102  
PRESTART  
ALERT  
HIGH MOTOR  
TEMPERATURE  
102->Comp Motor Winding Temp Check motor sensors for wiring and accuracy.  
[VALUE] exceeded limit  
of [LIMIT]*.  
Check motor cooling line for proper operation, or  
restrictions.  
Check for excessive starts within a short time span.  
Check configurable range in SETUP1 screen.  
103  
104  
PRESTART  
ALERT  
HIGH DISCHARGE  
TEMP  
103->Comp Discharge Temp  
[VALUE] exceeded limit of  
[LIMIT]*.  
Allow discharge sensor to cool.  
Check for sensor wiring and accuracy.  
Check for excessive starts.  
Check configurable range in SETUP1 screen.  
PRESTART  
ALERT  
LOW REFRIGERANT  
TEMP  
104->Evaporator Refrig Temp  
[VALUE] exceeded limit of  
[LIMIT]*.  
Check transducer wiring and accuracy.  
Check for low chilled fluid supply temperatures.  
Check refrigerant charge.  
105  
106  
PRESTART  
ALERT  
PRESTART  
ALERT  
LOW OIL  
105->Oil Sump Temp [VALUE]  
exceeded limit of [LIMIT]*.  
106->Condenser Pressure  
[VALUE] exceeded limit of  
[LIMIT]*.  
Check oil heater contactor/relay and power.  
Check oil level and oil pump operation.  
Check transducer wiring and accuracy.  
Check for high condenser water temperatures.  
TEMPERATURE  
HIGH CONDENSER  
PRESSURE  
107  
108  
109  
PRESTART  
ALERT  
LOW LINE  
VOLTAGE  
107->Average Line Voltage  
[VALUE] exceeded limit of  
[LIMIT]*.  
108->Average Line Voltage  
[VALUE] exceeded limit of  
[LIMIT]*.  
109->Actual Guide Vane  
Pos Calibration Required  
Before Start-Up  
Check voltage supply. Check voltage transformers.  
Consult power utility if voltage is low.  
PRESTART  
ALERT  
HIGH LINE  
VOLTAGE  
Check voltage supply.  
Check power transformers.  
Consult power utility if voltage is high.  
PRESTART  
ALERT  
GUIDE VANE  
CALIBRATION  
Calibrate guide vane actuator in Control Test.  
*[LIMIT] is shown on the CVC/ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.  
[VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.  
E. START-UP IN PROGRESS  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
OCCUPIED MODE  
REMOTE CONTACT CLOSED  
START COMMAND IN EFFECT  
CAUSE/REMEDY  
STARTUP IN PROGRESS  
STARTUP IN PROGRESS  
STARTUP IN PROGRESS  
Chiller is starting. Time schedule is occupied.  
Chiller is starting. Remote contacts are enabled and closed.  
Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to  
start.  
AUTORESTART IN PROGRESS OCCUPIED MODE  
Chiller is starting after power failure. Time schedule is occupied.  
AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED  
Chiller is starting after power failure. Remote contacts are enabled and  
closed.  
AUTORESTART IN PROGRESS START COMMAND IN EFFECT  
Chiller is starting after power failure. Chiller START/STOP on MAINSTAT  
manually forced to start.  
F. NORMAL RUN  
PRIMARY MESSAGE  
SECONDARY MESSAGE  
4-20 mA SIGNAL  
REMOTE TEMP SENSOR  
CHW TEMP DIFFERENCE  
LEAVING CHILLED WATER  
ENTERING CHILLED WATER  
CAUSE/REMEDY  
RUNNING — RESET ACTIVE  
RUNNING — RESET ACTIVE  
RUNNING — RESET ACTIVE  
RUNNING — TEMP CONTROL  
RUNNING — TEMP CONTROL  
RUNNING — TEMP CONTROL  
Auto chilled water reset active based on external input.  
Auto chilled water reset active based on external input.  
Auto chilled water reset active based on cooler ∆T.  
Default method of temperature control.  
Entering Chilled Water (ECW) control enabled in TEMP_CTL screen  
TEMPERATURE RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify.  
RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING  
RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT  
RUNNING — DEMAND LIMITED BY 4-20 mA SIGNAL  
RUNNING — DEMAND LIMITED BY CCN SIGNAL  
Ramp Loading in effect. Use RAMP_DEM screen to modify.  
Demand limit set point is less than actual demand.  
Demand limit is active based on external auto demand limit option.  
Demand limit is active based on control limit signal from CCN.  
Demand limit is active based on LOADSHED screen set-up.  
RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE  
RUNNING — TEMP CONTROL  
HOT GAS BYPASS  
Hot gas bypass option is energized. See stall prevention in the control  
section.  
RUNNING — DEMAND LIMITED BY LOCAL SIGNAL  
RUNNING —TEMP CONTROL ICE BUILD MODE  
Active demand limit manually overridden on MAINSTAT table.  
Chiller is running under Ice Build temperature control.  
79  
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Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)  
G. NORMAL RUN WITH OVERRIDES  
PRIMARY  
MESSAGE  
RUN CAPACITY HIGH CONDENSER  
LIMITED PRESSURE  
SECONDARY  
MESSAGE  
ALARM MESSAGE  
PRIMARY CAUSE  
120->Condenser Pressure  
[VALUE] exceeded limit of [LIMIT]*. Check setting in SETUP1.  
ADDITIONAL  
STATE  
120  
CAUSE/REMEDY  
Check for high condenser water temperatures.  
121  
RUN CAPACITY HIGH MOTOR  
LIMITED TEMPERATURE  
121->Comp Motor Winding Temp  
Check motor cooling lines.  
[VALUE] exceeded limit of [LIMIT]*. Check for closed valves.  
Check setting in SETUP1.  
122  
123  
124  
RUN CAPACITY LOW EVAP  
LIMITED REFRIG TEMP  
122->Evaporator Refrig Temp  
Check refrigerant charge.  
[VALUE] exceeded limit of [LIMIT]*. Check for low entering cooler temperatures.  
RUN CAPACITY HIGH COMPRESSOR 123->Surge Prevention Override:  
Check for high condenser water temperatures or  
low suction temperature.  
Target guide vane point has been forced in  
MAINSTAT screen. Release force to continue  
normal operation.  
LIMITED  
RUN CAPACITY MANUAL GUIDE  
LIMITED VANE TARGET  
LIFT  
Lift Too High For Compressor.  
124->Run Capacity Limited:  
Manual Guide Vane Target.  
125  
RUN CAPACITY LOW DISCHARGE  
LIMITED SUPERHEAT  
No messages.  
Check oil charge.  
Check refrigerant charge.  
*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,  
alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault con-  
dition.  
H. OUT-OF-RANGE SENSOR ALARMS  
PRIMARY  
MESSAGE  
SENSOR  
FAULT  
SECONDARY  
MESSAGE  
LEAVING CHILLED  
WATER  
ALARM MESSAGE  
PRIMARY CAUSE  
260->Sensor Fault:  
Leaving Chilled Water  
ADDITIONAL  
STATE  
260  
CAUSE/REMEDY  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
261  
262  
263  
264  
265  
266  
267  
268  
269  
270  
271  
273  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
SENSOR  
FAULT  
ENTERING CHILLED  
WATER  
CONDENSER  
PRESSURE  
EVAPORATOR  
PRESSURE  
COMPRESSOR  
BEARING TEMP  
COMPRESSOR  
MOTOR TEMP  
COMP DISCHARGE  
TEMP  
261->Sensor Fault:  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check sensor wiring.  
Entering Chilled Water  
262->Sensor Fault:  
Condenser Pressure  
263->Sensor Fault:  
Evaporator Pressure  
264->Sensor Fault:  
Comp Thrust Bearing Temp  
265->Sensor Fault:  
Comp Motor Winding Temp  
266->Sensor Fault:  
Comp Discharge Temp  
267->Sensor Fault:  
Oil Sump Temp  
268->Sensor Fault:  
Oil Pump Delta P  
269->Sensor Fault:  
Chilled Water Delta P  
270->Sensor Fault:  
Cond Water Delta P  
271->Sensor Fault:  
Check Actual VFD Speed Sensor  
Check sensor wiring.  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check sensor wiring and accuracy.  
Check sensor wiring and accuracy.  
Check sensor wiring and accuracy.  
OIL SUMP TEMP  
COMP OIL  
PRESS DIFF  
CHILLED WATER  
FLOW  
COND WATER  
FLOW  
VFD SPEED SENSOR  
OUT OF RANGE  
VFD SPEED OUT OF  
RANGE  
Check voltage input on terminals J6-1 and J6-2 on  
the ISM module. Check wiring.  
Check VFD feedback 0-5 vac. Calibrate VFD  
speed reference signal.  
273->Sensor Fault:  
Check Actual VFD Speed Sensor  
80  
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Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)  
I. CHILLER PROTECT LIMIT FAULTS  
PRIMARY  
MESSAGE  
PROTECTIVE  
LIMIT  
SECONDARY  
MESSAGE  
1M CONTACT  
FAULT  
ALARM MESSAGE  
PRIMARY CAUSE  
200->1M Aux Contact Fault;  
Check 1M Contactor and  
Aux  
ADDITIONAL  
CAUSE/REMEDY  
STATE  
200  
201  
202  
203  
PROTECTIVE  
LIMIT  
2M CONTACT  
FAULT  
201->2M Aux Contact Fault;  
Check 2M Contactor and  
Aux  
202->Motor Amps Not  
Sensed — Average Line  
Current [VALUE]  
203->Motor Acceleration  
Fault — Average Line  
Current [VALUE]  
PROTECTIVE  
LIMIT  
MOTOR AMPS  
NOT SENSED  
Check for wiring of current transformers to the ISM.  
Check main circuit breaker for trip.  
FAILURE TO  
START  
EXCESS  
ACCELERATION  
TIME  
Check to be sure that the inlet guide vanes are closed  
at start-up.  
Check starter for proper operation.  
Reduce unit pressure if possible.  
204  
205  
206  
207  
FAILURE TO  
STOP  
1M/2M CONTACT  
FAULT  
204->1M/2M Aux Contact  
Stop Fault; Check 1M/2M  
Contactors and Aux  
205->Motor Amps When  
Stopped — Average Line  
Current [VALUE]  
206->Starter Fault Cutout;  
Check Optional Starter  
Contacts  
207->High Cond Pressure  
cutout. [VALUE] exceeded  
limit of [LIMIT]*.  
FAILURE TO  
STOP  
MOTOR AMPS  
WHEN STOPPED  
PROTECTIVE  
LIMIT  
STARTER  
FAULT  
For Benshaw Inc. RediStart MICRO™ starters, view  
fault code at RediStart MICRO display. Press FAULT  
RESET to clear faults.  
Check for high condenser water temperatures, low  
water flow, fouled tubes.  
Check for division plate/gasket bypass.  
Check for noncondensables.  
PROTECTIVE  
LIMIT  
HIGH CONDENSER  
PRESSURE  
Check transducer wiring and accuracy.  
If [VALUE] is less than Limit then check the  
1CR Starting Circuit.  
208  
209  
PROTECTIVE  
LIMIT  
EXCESSIVE  
208->Compressor Motor  
Amps [VALUE] exceeded  
limit of [LIMIT]*.  
209->Line Phase Loss;  
Check ISM Fault History to  
Identify Phase  
Check motor current for proper calibration.  
Check inlet guide vane actuator.  
MOTOR AMPS  
PROTECTIVE  
LIMIT  
LINE PHASE  
LOSS  
Check transformers to ISM.  
Check power distribution bus.  
Consult power company.  
210  
211  
PROTECTIVE  
LIMIT  
PROTECTIVE  
LIMIT  
LINE VOLTAGE  
DROPOUT  
HIGH LINE  
VOLTAGE  
210->Single Cycle Line  
Voltage Dropout  
211->High Average Line  
Voltage [VALUE]  
Check transformers to ISM.  
Check distribution bus.  
Consult power company.  
212  
PROTECTIVE  
LIMIT  
81  
Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)  
I. CHILLER PROTECT LIMIT FAULTS (cont)  
PRIMARY  
MESSAGE  
PROTECTIVE  
LIMIT  
SECONDARY  
MESSAGE  
OIL PRESS  
SENSOR FAULT  
ALARM MESSAGE  
PRIMARY CAUSE  
227->Oil Pump Delta P  
[VALUE] exceeded limit of  
[LIMIT]*.  
ADDITIONAL  
STATE  
227  
CAUSE/REMEDY  
Check transducer wiring and accuracy.  
Check power supply to pump.  
Check pump operation.  
Check transducer calibration.  
228  
PROTECTIVE  
LIMIT  
LOW OIL  
PRESSURE  
228->Oil Pump Delta P  
[VALUE] exceeded limit of  
[LIMIT].*  
Check transducer wiring and accuracy.  
Check power supply to pump.  
Check pump operation.  
Check oil level.  
Check for partially closed service valves.  
Check oil filters.  
Check for foaming oil at start-up.  
Check transducer calibration.  
229  
230  
231  
PROTECTIVE  
LIMIT  
LOW CHILLED  
WATER FLOW  
229->Low Chilled Water  
Perform pump control test.  
Flow; Check Delta P Config Check transducer accuracy and wiring.  
& Calibration  
Check water valves.  
Check transducer calibration.  
PROTECTIVE  
LIMIT  
LOW CONDENSER  
WATER FLOW  
230->Low Condenser Water Perform pump control test.  
Flow; Check Delta P Config Check transducer accuracy and wiring.  
& Calibration  
Check water valves.  
Check transducer calibration.  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check for proper condenser flow and temperature.  
Check for proper inlet guide vane and diffuser  
actuator operation.  
Check for fouled tubes or noncondensables in the  
system.  
PROTECTIVE  
LIMIT  
HIGH DISCHARGE  
TEMP  
231->Comp Discharge  
Temp [VALUE] exceeded  
limit of [LIMIT].*  
232  
233  
234  
235  
PROTECTIVE  
LIMIT  
LOW REFRIGERANT  
TEMP  
232->Evaporator Refrig  
Temp [VALUE] exceeded  
limit of [LIMIT]*.  
Check for proper refrigerant charge.  
Check float operation.  
Check for proper fluid flow and temperature.  
Check for proper inlet guide vane operation.  
PROTECTIVE  
LIMIT  
HIGH MOTOR  
TEMPERATURE  
233->Comp Motor Winding Check motor sensors wiring and accuracy.  
Temp [VALUE] exceeded  
limit of [LIMIT]*.  
Check motor cooling line for proper operation, or  
restrictions.  
Check for excessive starts within a short time span.  
PROTECTIVE  
LIMIT  
HIGH BEARING  
TEMPERATURE  
234->Comp Thrust Bearing Check oil heater for proper operation.  
Temp [VALUE] exceeded  
limit of [LIMIT]*.  
Check for low oil level, partially closed oil supply  
valves, clogged oil filters, etc.  
Check the sensor wiring and accuracy.  
PROTECTIVE  
LIMIT  
HIGH CONDENSER  
PRESSURE  
235->Condenser Pressure  
[VALUE] exceeded limit of  
[LIMIT]*.  
Check for high condenser water temperatures, low  
water flow, fouled tubes.  
Check for division plate/gasket bypass.  
Check for noncondensables.  
Check transducer wiring and accuracy.  
236  
PROTECTIVE  
LIMIT  
CCN OVERRIDE  
STOP  
236->CCN Override Stop  
while in LOCAL run mode  
CCN has signaled the chiller to stop. Reset and  
restart when ready. If the signal was sent by the  
CVC/ICVC, release the stop signal on the STATUS01  
table.  
237  
238  
PROTECTIVE  
LIMIT  
PROTECTIVE  
LIMIT  
SPARE SAFETY  
DEVICE  
EXCESSIVE  
COMPR SURGE  
237->Spare Safety Device  
Spare safety input has tripped or factory installed  
jumper is not present.  
Check condenser flow and temperatures.  
Check surge protection configuration.  
238->Compressor Surge:  
Check condenser water  
temp and flow  
239  
240  
PROTECTIVE  
LIMIT  
TRANSDUCER  
VOLTAGE FAULT  
239->Transducer Voltage  
Ref [VALUE] exceeded limit  
of [LIMIT]*.  
240->Check for Oil in  
Refrigerant or Overcharge  
of Refrigerant  
PROTECTIVE  
LIMIT  
LOW DISCHARGE  
SUPERHEAT  
241  
242  
243  
LOSS OF  
WITH STARTER  
MODULE  
WITH CCM  
MODULE  
EVAP PRESS/TEMP  
TOO LOW  
241->Loss of Communica-  
tion With Starter.  
242->Loss of Communica-  
tion With CCM.  
243->Evaporator Refrig  
Temp [VALUE] exceeded  
limit of [LIMIT]*.  
Check wiring to ISM.  
Check wiring to CCM.  
COMMUNICATION  
LOSS OF  
COMMUNICATION  
POTENTIAL  
FREEZE-UP  
Check for proper refrigerant charge.  
Check float operation.  
Check for proper fluid flow and temperature.  
Check for proper inlet guide vane operation.  
244  
245  
POTENTIAL  
FREEZE-UP  
COND PRESS/TEMP  
TOO LOW  
244->Condenser Refrig  
Temp [VALUE] exceeded  
limit of [LIMIT]*.  
245->Actual VFD Speed  
[VALUE] exceeded limit of  
[LIMIT]*.  
PROTECTIVE  
LIMIT  
VFD SPEED  
OUT OF RANGE  
82  
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Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)  
I. CHILLER PROTECT LIMIT FAULTS (cont)  
PRIMARY  
MESSAGE  
PROTECTIVE  
LIMIT  
SECONDARY  
MESSAGE  
INVALID DIFFUSER  
CONFIG  
ALARM MESSAGE  
PRIMARY CAUSE  
246->Diffuser Control Invalid  
Configuration:  
Check SETUP2 Entries.  
ADDITIONAL  
STATE  
246  
CAUSE/REMEDY  
Check diffuser/guide vane schedule.  
PROTECTIVE  
LIMIT  
DIFFUSER POSITION  
FAULT  
247->Diffuser Position Fault:  
Check Guide Vane and Diffuser  
Actuators  
Check rotating stall transducer wiring and  
accuracy.  
Check diffuser schedule.  
247  
Check for proper operation of diffuser actuator  
and inlet guide vane actuator.  
Check diffuser coupling.  
Check inlet guide vane operation.  
Check inlet guide vane calibration.  
Check diffuser/inlet guide vane schedule.  
Check diffuser mechanical set-up for proper  
orientation.  
If not using variable diffuser, check that the  
option has not been enabled.  
PROTECTIVE  
LIMIT  
SPARE TEMPERATURE  
#1  
248->Spare Temperature #1  
[VALUE] exceeded limit of  
[LIMIT]*.  
248  
249  
PROTECTIVE  
LIMIT  
*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,  
alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.  
J. CHILLER ALERTS  
83  
Table 11 — CVC/ICVC Primary and Secondary Messages and  
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)  
J. CHILLER ALERTS (cont)  
PRIMARY  
MESSAGE  
SENSOR ALERT  
SECONDARY  
MESSAGE  
HIGH DISCHARGE  
TEMP  
ALARM MESSAGE  
PRIMARY CAUSE  
149->Comp Discharge Temp  
[VALUE] exceeded limit of  
[LIMIT]*.  
ADDITIONAL  
STATE  
149  
CAUSE/REMEDY  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
Check for proper condenser flow and  
temperature.  
Check for high lift or low load.  
Check for proper inlet guide vane and diffuser  
actuator operation (Size 5 compressor Only).  
Check for fouled tubes or noncondensables in  
the refrigerant system.  
SENSOR ALERT  
HIGH BEARING  
TEMPERATURE  
150->Comp Thrust Bearing  
Check sensor resistance or voltage drop.  
150  
Temp [VALUE] exceeded limit Check for proper wiring.  
of [LIMIT]*.  
Check for partially closed service valves.  
Check oil cooler TXV.  
Check oil filter.  
Check oil level.  
CONDENSER  
PUMP RELAY  
ENERGIZED  
151->High Condenser  
Pressure [VALUE]: Pump  
Energized to Reduce  
Pressure.  
Check sensor wiring and accuracy.  
Check condenser flow and fluid  
temperature.  
151  
152  
PRESSURE ALERT  
Check for fouled tubes. This alarm is not  
caused by the High Pressure Switch.  
RECYCLE  
ALERT  
EXCESSIVE RECYCLE  
STARTS  
152->Excessive recycle starts. Chiller load is too low to keep compressor on  
line and there has been more than  
5 starts in 4 hours. Increase chiller load,  
adjust hot gas bypass, increase RECYCLE  
RESTART DELTA T from SETUP1 Screen.  
no message:  
ALERT only  
no message;  
ALERT only  
153->Lead/Lag Disabled:  
Duplicate Chiller Address;  
Check Configuration  
154->Condenser freeze up  
prevention  
Illegal chiller address configuration in Lead/  
Lag screen. Both chillers require a different  
address.  
The condenser pressure transducer is read-  
ing a pressure that could freeze the con-  
denser tubes.  
Check for condenser refrigerant leaks.  
Check fluid temperature.  
153  
154  
POTENTIAL  
FREEZE-UP  
COND PRESS/TEMP  
TOO LOW  
Check sensor wiring and accuracy.  
Place the chiller in PUMPDOWN mode if the  
vessel is evacuated.  
OPTION SENSOR  
FAULT  
REMOTE RESET  
SENSOR  
155->Sensor Fault/Option  
Disabled:  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
155  
156  
157  
158  
159  
160  
Remote Reset Sensor  
OPTION SENSOR  
FAULT  
AUTO CHILLED  
WATER RESET  
156->Sensor Fault/Option  
Disabled:  
Auto Chilled Water Reset  
157->Sensor Fault/Option  
Disabled:  
Auto Demand Limit Input  
158->Spare Temperature #1  
[VALUE] exceeded limit of  
[LIMIT].*  
159->Spare Temperature #2  
[VALUE] exceeded limit of  
[LIMIT].*  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
OPTION SENSOR  
FAULT  
AUTO DEMAND  
LIMIT INPUT  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
SENSOR ALERT  
SENSOR ALERT  
SPARE TEMPERATURE  
#1  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
SPARE TEMPERATURE  
#2  
Check sensor resistance or voltage drop.  
Check for proper wiring.  
DIFFUSER  
ALERT  
DIFFUSER  
POSITION  
160->Diffuser Position Alert;  
Check Diffuser Configuration. screen.  
Check diffuser configuration in SETUP2  
*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,  
alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.  
84  
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Table 12A — Thermistor Temperature (F) vs. Resistance/Voltage Drop  
PIC II  
VOLTAGE  
DROP (V)  
PIC II  
VOLTAGE  
DROP (V)  
TEMPERATURE  
(F)  
RESISTANCE  
(Ohms)  
TEMPERATURE  
(F)  
RESISTANCE  
(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
4.700  
4.690  
4.680  
4.670  
4.659  
4.648  
4.637  
4.625  
4.613  
4.601  
4.588  
4.576  
4.562  
4.549  
4.535  
4.521  
4.507  
4.492  
4.477  
4.461  
4.446  
4.429  
4.413  
4.396  
4.379  
4.361  
4.344  
4.325  
4.307  
4.288  
4.269  
4.249  
4.229  
4.209  
4.188  
4.167  
4.145  
4.123  
4.101  
4.079  
3.056  
4.033  
4.009  
3.985  
3.960  
3.936  
3.911  
3.886  
3.861  
3.835  
3.808  
3.782  
3.755  
3.727  
3.700  
3.672  
3.644  
3.617  
3.588  
3.559  
3.530  
3.501  
3.471  
3.442  
3.412  
3.382  
3.353  
3.322  
3.291  
3.260  
3.229  
3.198  
3.167  
3.135  
3.104  
3.074  
3.042  
3.010  
2.978  
3.946  
2.914  
2.882  
2.850  
2.819  
2.788  
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  
60  
61  
2.756  
2.724  
2.692  
2.660  
2.628  
2.596  
2.565  
2.533  
2.503  
2.472  
2.440  
2.409  
2.378  
2.347  
2.317  
2.287  
2.256  
2.227  
2.197  
2.167  
2.137  
2.108  
2.079  
2.050  
2.021  
1.993  
1.965  
1.937  
1.989  
1.881  
1.854  
1.827  
1.800  
1.773  
1.747  
1.721  
1.695  
1.670  
1.644  
1.619  
1.595  
1.570  
1.546  
1.523  
1.499  
1.476  
1.453  
1.430  
1.408  
1.386  
1.364  
1.343  
1.321  
1.300  
1.279  
1.259  
1.239  
1.219  
1.200  
1.180  
1.161  
1.143  
1.124  
1.106  
1.088  
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  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
1
86  
2
87  
3
88  
4
89  
5
90  
6
91  
7
92  
8
93  
9
94  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
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  
9,717  
9,461  
9,213  
8,973  
8,739  
8,511  
8,291  
8,076  
7,868  
85  
Table 12B — Thermistor Temperature (C) vs. Resistance/Voltage Drop  
TEMPERATURE  
(C)  
PIC II  
VOLTAGE DROP (V)  
RESISTANCE  
(Ohms)  
TEMPERATURE  
(C)  
PIC II  
VOLTAGE DROP (V)  
RESISTANCE  
(Ohms)  
–33  
–32  
–31  
–30  
–29  
–28  
–27  
–26  
–25  
–24  
–23  
–22  
–21  
–20  
–19  
–18  
–17  
–16  
–15  
–14  
–13  
–12  
–11  
–10  
–9  
–8  
–7  
–6  
–5  
–4  
–3  
–2  
–1  
0
4.722  
4.706  
4.688  
4.670  
4.650  
4.630  
4.608  
4.586  
4.562  
4.538  
4.512  
4.486  
4.458  
4.429  
4.399  
4.368  
4.336  
4.303  
4.269  
4.233  
4.196  
4.158  
4.119  
4.079  
4.037  
3.994  
3.951  
3.906  
3.861  
3.814  
3.765  
3.716  
3.667  
3.617  
3.565  
3.512  
3.459  
3.406  
3.353  
3.298  
3.242  
3.185  
3.129  
3.074  
3.016  
2.959  
2.901  
2.844  
2.788  
2.730  
2.672  
2.615  
2.559  
2.503  
2.447  
2.391  
2.335  
2.280  
2.227  
2.173  
2.120  
2.067  
2.015  
1.965  
1.914  
1.865  
1.816  
1.768  
1.721  
1.675  
1.629  
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  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
102  
103  
104  
105  
106  
107  
1.585  
1.542  
1.499  
1.457  
1.417  
1.377  
1.338  
1.300  
1.263  
1.227  
1.192  
1.158  
1.124  
1.091  
1.060  
1.029  
0.999  
0.969  
0.941  
0.913  
0.887  
0.861  
0.835  
0.811  
0.787  
0.764  
0.741  
0.719  
0.698  
0.677  
0.657  
0.638  
0.619  
0.601  
0.583  
0.566  
0.549  
0.533  
0.518  
0.503  
0.488  
0.474  
0.460  
0.447  
0.434  
0.422  
0.410  
0.398  
0.387  
0.376  
0.365  
0.355  
0.344  
0.335  
0.325  
0.316  
0.308  
0.299  
0.291  
0.283  
0.275  
0.267  
0.260  
0.253  
0.246  
0.239  
0.233  
0.227  
0.221  
0.215  
2 888  
2 773  
2 663  
2 559  
2 459  
2 363  
2 272  
2 184  
2 101  
2 021  
1 944  
1 871  
1 801  
1 734  
1 670  
1 609  
1 550  
1 493  
1 439  
1 387  
1 337  
1 290  
1 244  
1 200  
1 158  
1 118  
1 079  
1 041  
1 006  
971  
938  
906  
876  
836  
1
805  
2
775  
3
747  
4
719  
5
693  
6
669  
7
645  
8
623  
9
602  
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  
583  
9 485  
564  
9 044  
547  
8 627  
531  
8 231  
516  
7 855  
502  
7 499  
489  
7 161  
477  
6 840  
466  
6 536  
456  
6 246  
446  
5 971  
436  
5 710  
427  
5 461  
419  
5 225  
410  
5 000  
402  
4 786  
393  
4 583  
385  
4 389  
376  
4 204  
367  
4 028  
357  
3 861  
346  
3 701  
335  
3 549  
324  
3 404  
312  
3 266  
299  
3 134  
285  
3 008  
86  
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Control Modules  
Notes on Module Operation  
1. The chiller operator monitors and modifies configura-  
tions in the microprocessor by using the 4 softkeys and  
the CVC/ICVC. Communications between the CVC/  
ICVC and the CCM is accomplished through the SIO  
(Sensor Input/Output) bus, which is a phone cable. The  
communication between the CCM and ISM is accom-  
plished through the sensor bus, which is a 3-wire cable.  
2. If a green LED is on continuously, check the communica-  
tion wiring. If a green LED is off, check the red LED  
operation. If the red LED is normal, check the module  
address switches (SW1) (Fig. 40 and 41). Confirm all  
switches are in OFF position.  
Turn controller power off before servicing controls. This  
ensures safety and prevents damage to the controller.  
The CVC/ICVC, CCM, and ISM modules perform continu-  
ous diagnostic evaluations of the hardware to determine its  
condition. Proper operation of all modules is indicated by  
LEDs (light-emitting diodes) located on the circuit board of the  
CVC/ICVC, CCM, and ISM.  
There is one green LED located on the CCM and ISM  
boards respectively, and one red LED located on the CVC/  
ICVC, CCM, and ISM boards respectively.  
All system operating intelligence resides in the CVC/  
ICVC. Some safety shutdown logic resides in the ISM in  
case communications are lost between the ISM and CVC/  
ICVC. Outputs are controlled by the CCM and ISM as  
well.  
RED LED (Labeled as STAT) — If the red LED:  
• blinks continuously at a 2-second interval, the module is  
operating properly  
• is lit continuously, there is a problem that requires  
replacing the module  
• is off continuously, the power should be checked  
• blinks 3 times per second, a software error has been dis-  
covered and the module must be replaced  
If there is no input power, check the fuses and circuit break-  
er. If the fuse is good, check for a shorted secondary of the  
transformer or, if power is present to the module, replace the  
module.  
3. Power is supplied to the modules within the control panel  
via 24-vac power sources.  
The transformers are located within the power panel, with  
the exception of the ISM, which operates from a 115-vac  
power source and has its own 24-vac transformer located  
in the module.  
In the power panel, T1 supplies power to the compressor  
oil heater, oil pump, and optional hot gas bypass, and T2  
supplies power to both the CVC/ICVC and CCM.  
GREED LED (Labeled as COM) — These LEDs indicate  
the communication status between different parts of the con-  
troller and the network modules and should blink continuously.  
Power is connected to Plug J1 on each module.  
MODULE PART NUMBER  
SOFTWARE PART NUMBER  
CCN INTERFACE  
CONNECTION  
DATALINK OR  
DATAPORT MODULE (OPTION)  
CVC/ICVC  
BACK OF CVC  
J7 SIO  
J1 POWER/  
CCN  
J8 SERVICE  
SW1  
Fig. 40 — Rear of CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller)  
87  
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7. The CVC/ICVC now automatically attaches to the local  
network device.  
Chiller Control Module (CCM) (Fig. 41)  
INPUTS — Each input channel has 2 or 3 terminals. Refer to  
individual chiller wiring diagrams for the correct terminal  
numbers for your application.  
OUTPUTS — Output is 24 vac. There are 2 terminals per out-  
put. Refer to the chiller wiring diagram for your specific appli-  
cation for the correct terminal numbers.  
8. Access the MAINSTAT table and highlight the TOTAL  
COMPRESSOR STARTS parameter. Press the  
softkey. Increase or decrease the value to match the starts  
value recorded in Step 3. Press the  
softkey  
when you reach the correct value. Now, move the high-  
light bar to the COMPRESSOR ONTIME parameter.  
Integrated Starter Module (Fig. 42)  
Press the  
hours value to match the value recorded in Step 2. Press  
the softkey when the correct value is reached.  
softkey. Increase or decrease the run  
INPUTS — Inputs on strips J3 through J6 are analog inputs  
and J2 is discrete (on/off) input. The specific application of the  
chiller determines which terminals are used. Refer to the indi-  
vidual chiller wiring diagram for the correct terminal numbers  
for your application.  
OUTPUTS — Outputs are 115-277 vac and wired to strip J9.  
There are 2 terminals per output.  
9. Complete the CVC/ICVC installation. Following the in-  
structions in the Input Service Configurations section,  
page 55, input all the proper configurations such as the  
time, date, etc. Check the pressure transducer calibra-  
tions. PSIO installation is now complete.  
Replacing Defective Processor Modules —  
The module replacement part number is printed on a small  
label on the rear of the CVC/ICVC module. The chiller model  
and serial numbers are printed on the chiller nameplate located  
on an exterior corner post. The proper software is factory-  
installed by Carrier in the replacement module. When ordering  
a replacement chiller visual control (CVC/ICVC) module,  
specify the complete replacement part number, full chiller  
model number, and chiller serial number. The installer must  
configure the new module to the original chiller data. Follow  
the procedures described in the Software Configuration section  
on page 55.  
Solid-State Starters — Troubleshooting information per-  
taining to the Benshaw, Inc., solid-state starter may be found  
INSTALLATION  
1. Verify the existing CVC/ICVC module is defective by us-  
ing the procedure described in the Troubleshooting Guide  
section, page 76, and the Control Modules section,  
page 87. Do not select the ATTACH TO NETWORK  
DEVICE table if the CVC/ICVC indicates a communica-  
tion failure.  
2. Data regarding the CVC/ICVC configuration should have  
been recorded and saved. This data must be reconfigured  
into the new CVC/ICVC. If this data is not available, fol-  
low the procedures described in the Software Configura-  
tion section.  
If a CCN Building Supervisor or Service Tool is avail-  
able, the module configuration should have already been  
uploaded into memory. When the new module is in-  
stalled, the configuration can be downloaded from the  
computer.  
Any communication wires from other chillers or CCN  
modules should be disconnected to prevent the new  
CVC/ICVC module from uploading incorrect run hours  
into memory.  
3. To install this module, record values for the TOTAL  
COMPRESSOR STARTS and the COMPRESSOR  
ONTIME from the MAINSTAT screen on the CVC/  
ICVC.  
4. Power off the controls.  
5. Remove the old CVC/ICVC.  
6. Install the new CVC/ICVC module. Turn the control  
power back on.  
88  
SW1  
J11  
DISCRETE  
OUTPUTS  
J12  
DISCRETE  
OUTPUTS  
J1  
24 VAC  
ANALOG OUT  
J8  
SIO  
J7  
SIO  
J6  
SW2  
V/I INPUTS  
J5  
STAT COMM  
THERMISTORS  
J4  
DIFF PRESSURE  
J3  
PRESSURE  
J2  
Fig. 41 — Chiller Control Module (CCM)  
J 9  
G
+
G
+
C O M T A S T  
-
G
+
1
1
1
J 7  
J 8  
-
P U M P  
C O N D  
A
C B  
C O M M  
T R I P  
P U M P  
N F A  
H I  
A R S E P V F D  
O U T 4 - 2 0 M A  
N F A  
L O  
A L A R M  
T R I P  
T R A N S  
S H U A N P T E V  
1 C R  
A C T S C O N T  
D I S C R E T E C O N T R O L  
R
INTEGRATEDSTARTERMODULE  
CONTACT INPUTS  
GROUND  
FAULTS  
1/4 2/5 3/6  
115 VAC  
LL1 LL2  
FUSE  
1A  
LINE VOLTAGES  
L2  
LINE CURRENTS  
IL1  
IL2 IL3  
SPAR ICE REM STRT 1M 2M  
SFTY BLD STRT FLT AUX AUX  
VFD  
HZ  
L1  
L3  
J5  
J4  
1A  
J2  
J6  
1
+
-
+
-
+
-
+
C
+
C
+
C
+
C
+
C
+
C
J3-1  
J3-2  
J3-3  
1
1
+
1
1
J1  
+
G
+
G
+
G
G
Fig. 42 — Integrated Starter Module (ISM)  
89  
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5. Using an ohmmeter, perform the following resistance  
measurements and record the results:  
5. Using quarter-turn increments, alternating between  
clamping bolts, apply the appropriate number of whole  
turns referencing the table in Fig. 43.  
SCR PAIRS  
MEASURE  
BETWEEN  
RECORDED  
VALUE  
BEING  
CHECKED  
T1 and T6  
T2 and T4  
T3 and T5  
3 and 6  
2 and 5  
1 and 4  
Care must be taken to prevent nut rotation while tightening  
the bolts. If the nut rotates while tightening the bolt, SCR  
replacement must be started over.  
If all measured values are greater than 5K ohms, proceed  
to Step 10. If any values are less than 5K ohms, one or  
more of the SCRs in that pair is shorted.  
6. Reconnect the red (cathode) wire from the SCR and the  
white (anode-gate) wire to the appropriate location on the  
firing card (i.e., SCR1 wires to firing card terminal  
G1-white wire, and K1-red wire).  
7. Reconnect all other wiring and bus work.  
8. Return starter to normal operation.  
6. Remove both SCRs in the pair (See SCR Removal/  
Installation).  
7. Using an ohmmeter, measure the resistance (anode to  
cathode) of each SCR to determine which device has  
failed.  
NOTE: Both SCRs may be defective, but typically, only  
one is shorted. If both SCRs provide acceptable resistance  
measurements, proceed to Step 10.  
NUT  
8. Replace the defective SCR(s).  
LOOSEN  
AND  
CLAMPING  
BOLT  
9. Retest the “pair” for resistance values indicated above.  
TIGHTEN  
BOLTS  
A
10. On the right side of the firing card, measure the resistance  
between the red and white gate/cathode leads for each  
SCR (1 through 6). A measurement between 5 and  
50 ohms is normal. Abnormally high values may indicate  
a failed gate for that SCR.  
FROM  
THIS END  
ALUMINUM  
HEATSINK  
ROLL PIN  
SCR  
If any red or white SCR gate leads are removed from the  
firing card or an SCR, care must be taken to ensure the  
leads are replaced EXACTLY as they were (white wires to  
gates, and red wires to cathodes on both the firing card and  
SCR), or damage to the starter and/or motor may result.  
SCR PART  
NUMBER  
BISCR  
A
BOLT  
LENGTH  
(in.)  
3.0  
(76 mm)  
3.0  
(76 mm)  
3.5  
(89 mm)  
3.0  
(89 mm)  
4.0  
(102 mm)  
5.0  
(127 mm)  
CLAMP  
SIZE  
NO. OF  
DIMENSION  
(in.)  
TURNS  
2.75  
(70 mm)  
2.75  
(70 mm)  
2.75  
(70 mm)  
2.75  
(70 mm)  
4.00  
(102 mm)  
4.00  
(102 mm)  
1
6601218  
6601818  
8801230  
8801830  
15001850  
15001850  
1030  
1030  
1035  
1035  
2040  
2050  
1 /  
2
2
4
4
4
4
11. Replace the SCRs and retest the pair.  
SCR REMOVAL/INSTALLATION — Refer to Fig. 43.  
1. Remove the SCR by loosening the clamping bolts on  
each side of the SCR,  
2. After the SCR has been removed and the bus work is  
loose, apply a thin coat of either silicon based thermal  
joint compound or a joint compound for aluminum or  
copper wire connections to the contact surfaces of the re-  
placement SCR. This allows for improved heat dissipa-  
tion and electrical conductivity.  
3. Place the SCR between the roll pins on the heatsink  
assemblies so the roll pins fit into the small holes in each  
side of the SCR.  
1
1 /  
3
1 /  
3
1 /  
3
2 /  
3
2 /  
220012100  
330018500  
Consult Benshaw Representative  
Consult Benshaw Representative  
Fig. 43 — SCR Installation  
NOTE: Ensure the SCR is installed so the cathode side is  
the side from which the red wire extends. The heatsink is  
labeled to show the correct orientation.  
Physical Data — Tables 13A-20 and Fig. 44-57 provide  
additional information on component weights, compressor fits  
and clearances, physical and electrical data, and wiring sche-  
matics for the operator’s convenience during troubleshooting.  
4. Hand tighten the bolts until the SCR contacts the  
heatsink.  
90  
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Table 13A — Heat Exchanger Data (English)  
ENGLISH  
NUMBER OF TUBES  
Dry (Rigging) Weight (lb)  
Chiller Charge  
Refrigerant Weight (lb) Water Volume (gal)  
CODE  
Cooler  
Only  
Condenser  
Only  
Cooler  
Condenser  
Cooler  
Condenser  
Cooler  
Condenser  
10  
11  
12  
142  
161  
180  
180  
200  
225  
2,742  
2,812  
2,883  
2,704  
2,772  
2,857  
290  
310  
330  
200  
200  
200  
34  
37  
40  
42  
45  
49  
15  
16  
17  
142  
161  
180  
180  
200  
225  
3,003  
3,089  
3,176  
2,984  
3,068  
3,173  
320  
340  
370  
250  
250  
250  
39  
43  
47  
48  
52  
57  
20  
21  
22  
200  
240  
282  
218  
266  
315  
3,442  
3,590  
3,746  
3,523  
3,690  
3,854  
345  
385  
435  
225  
225  
225  
48  
55  
62  
48  
55  
63  
30  
31  
32  
200  
240  
280  
218  
267  
315  
4,137  
4,319  
4,511  
3,694  
3,899  
4,100  
350  
420  
490  
260  
260  
260  
55  
64  
72  
55  
65  
74  
35  
36  
37  
200  
240  
280  
218  
267  
315  
4,409  
4,617  
4,835  
4,606  
4,840  
5,069  
400  
480  
550  
310  
310  
310  
61  
70  
80  
62  
72  
83  
40  
41  
42  
324  
364  
400  
370  
417  
463  
5,898  
6,080  
6,244  
6,054  
6,259  
6,465  
560  
630  
690  
280  
280  
280  
89  
97  
105  
96  
106  
114  
45  
46  
47  
324  
364  
400  
370  
417  
463  
6,353  
6,561  
6,748  
6,617  
6,851  
7,085  
640  
720  
790  
330  
330  
330  
98  
108  
116  
106  
117  
127  
50  
51  
52  
431  
485  
519  
509  
556  
602  
7,015  
7,262  
7,417  
7,285  
7,490  
7,683  
750  
840  
900  
400  
400  
400  
115  
126  
133  
128  
137  
136  
5A  
5B  
5C  
225  
241  
258  
—
—
—
6,426  
6,499  
6,577  
—
—
—
500  
520  
550  
—
—
—
106  
109  
112  
—
—
—
55  
56  
57  
431  
485  
519  
509  
556  
602  
7,559  
7,839  
8,016  
7,980  
8,214  
8,434  
870  
940  
980  
490  
490  
490  
127  
139  
147  
142  
152  
162  
5F  
5G  
5H  
225  
241  
258  
—
—
—
6,879  
6,962  
7,050  
—
—
—
550  
570  
600  
—
—
—
116  
120  
124  
—
—
—
60  
61  
62  
557  
599  
633  
648  
695  
741  
8,270  
8,462  
8,617  
8,286  
8,483  
8,676  
940  
980  
1020  
420  
420  
420  
144  
153  
160  
159  
168  
177  
65  
66  
67  
557  
599  
633  
648  
695  
741  
8,943  
9,161  
9,338  
9,204  
9,428  
9,648  
1020  
1060  
1090  
510  
510  
510  
160  
169  
177  
176  
187  
197  
70  
71  
72  
644  
726  
790  
781  
870  
956  
12,395  
12,821  
13,153  
13,139  
13,568  
13,969  
1220  
1340  
1440  
780  
780  
780  
224  
243  
257  
209  
229  
248  
75  
76  
77  
644  
726  
790  
781  
870  
956  
13,293  
13,780  
14,159  
14,211  
14,702  
15,160  
1365  
1505  
1625  
925  
925  
925  
245  
266  
283  
234  
257  
278  
80  
81  
82  
829  
901  
976  
990  
1080  
1170  
16,156  
16,530  
16,919  
15,746  
16,176  
16,606  
1500  
1620  
1730  
720  
720  
720  
285  
302  
319  
264  
284  
304  
85  
86  
87  
829  
901  
976  
990  
1080  
1170  
17,296  
17,723  
18,169  
17,001  
17,492  
17,984  
1690  
1820  
1940  
860  
860  
860  
313  
331  
351  
295  
318  
341  
NOTES:  
2. Condenser data: based on a condenser with standard wall tub-  
ing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic  
grooves. Weight includes the float valve, discharge elbow, and  
distribution piping. Weight does not include unit-mounted starter,  
isolation valves, and pumpout unit.  
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,  
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight  
includes suction elbow, control panel, and distribution piping.  
Weight does not include compressor.  
91  
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Table 13B — Heat Exchanger Data (SI)  
SI  
NUMBER OF TUBES  
Dry (Rigging) Weight (kg)  
Chiller Charge  
Refrigerant Weight (kg) Water Volume (L)  
Cooler Condenser  
CODE  
Cooler  
Only  
Condenser  
Only  
Cooler  
Condenser  
Cooler  
Condenser  
10  
11  
12  
142  
161  
180  
180  
200  
225  
1244  
1275  
1307  
1226  
1257  
1296  
132  
141  
150  
91  
91  
91  
129  
140  
152  
158  
170  
185  
15  
16  
17  
142  
161  
180  
180  
200  
225  
1362  
1401  
1440  
1353  
1391  
1439  
145  
154  
168  
113  
113  
113  
149  
163  
178  
183  
198  
216  
20  
21  
22  
200  
240  
282  
218  
266  
315  
1561  
1628  
1699  
1598  
1673  
1748  
157  
175  
197  
102  
102  
102  
183  
207  
234  
181  
210  
239  
30  
31  
32  
200  
240  
280  
218  
267  
315  
1876  
1958  
2046  
1675  
1768  
1859  
159  
190  
222  
118  
118  
118  
208  
242  
271  
210  
246  
282  
35  
36  
37  
200  
240  
280  
218  
267  
315  
2000  
2094  
2193  
2089  
2195  
2300  
181  
218  
249  
141  
141  
141  
232  
266  
301  
233  
273  
314  
40  
41  
42  
324  
364  
400  
370  
417  
463  
2675  
2757  
2832  
2745  
2839  
2932  
254  
286  
313  
127  
127  
127  
338  
368  
396  
365  
400  
433  
45  
46  
47  
324  
364  
400  
370  
417  
463  
2881  
2976  
3060  
3001  
3107  
3213  
290  
327  
358  
150  
150  
150  
372  
407  
438  
403  
442  
481  
50  
51  
52  
431  
485  
519  
509  
556  
602  
3181  
3293  
3364  
3304  
3397  
3484  
340  
381  
408  
181  
181  
181  
435  
477  
502  
483  
518  
552  
5A  
5B  
5C  
225  
241  
258  
—
—
—
2915  
2949  
2984  
—
—
—
227  
236  
250  
—
—
—
401  
412  
424  
—
—
—
55  
56  
57  
431  
485  
519  
509  
556  
602  
3428  
3555  
3635  
3619  
3725  
3825  
395  
426  
446  
222  
222  
222  
481  
527  
557  
536  
575  
613  
5F  
5G  
5H  
225  
241  
258  
—
—
—
3121  
3159  
3199  
—
—
—
250  
259  
273  
—
—
—
439  
454  
464  
—
—
—
60  
61  
62  
557  
599  
633  
648  
695  
741  
3751  
3838  
3908  
3758  
3847  
3935  
426  
444  
462  
190  
190  
190  
546  
578  
604  
601  
636  
669  
65  
66  
67  
557  
599  
633  
648  
695  
741  
4056  
4155  
4235  
4174  
4276  
4376  
462  
481  
494  
231  
231  
231  
605  
641  
671  
668  
707  
745  
70  
71  
72  
644  
726  
790  
781  
870  
956  
5622  
5814  
5965  
5959  
6153  
6335  
553  
608  
653  
354  
354  
354  
848  
919  
974  
791  
867  
937  
75  
76  
77  
644  
726  
790  
781  
870  
956  
6028  
6259  
6421  
6445  
6667  
6875  
619  
683  
737  
420  
420  
420  
927  
1009  
1072  
885  
971  
1052  
80  
81  
82  
829  
901  
976  
990  
1080  
1170  
7326  
7496  
7673  
7141  
7336  
7531  
680  
735  
785  
327  
327  
327  
1080  
1143  
1208  
1000  
1075  
1150  
85  
86  
87  
829  
901  
976  
990  
1080  
1170  
7844  
8037  
8240  
7710  
7933  
8156  
766  
825  
880  
390  
390  
390  
1183  
1254  
1329  
1118  
1205  
1291  
NOTES:  
2. Condenser data: based on a condenser with standard wall tub-  
ing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic  
grooves. Weight includes the float valve, discharge elbow, and  
distribution piping. Weight does not include unit-mounted starter,  
isolation valves, and pumpout unit.  
1. Cooler data: based on a cooler with standard wall tubing, 2-pass,  
1034 psig, nozzle-in-head waterbox with victaulic grooves.  
Weight includes suction elbow, control panel, and distribution pip-  
ing. Weight does not include compressor.  
92  
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Table 14 — 19XR Additional Data for Marine Waterboxes*  
ENGLISH  
Rigging Weight  
(lb)  
SI  
HEAT EXCHANGER  
FRAME, PASS  
Water Volume  
(gal)  
Rigging Weight  
(kg)  
Water Volume  
(L)  
Psig  
kPa  
FRAME 2, 1 AND 2 PASS  
FRAME 2, 2 PASS  
FRAME 3, 1 AND 2 PASS  
FRAME 3, 2 PASS  
FRAME 4, 1 AND 3 PASS  
FRAME 4, 2 PASS  
FRAME 5, 1 AND 3 PASS  
FRAME 5, 2 PASS  
FRAME 6, 1 AND 3 PASS  
FRAME 6, 2 PASS  
FRAME 7, 1 AND 3 PASS  
FRAME 7, 2 PASS  
FRAME 8, 1 AND 3 PASS  
FRAME 8, 2 PASS  
FRAME 2, 1 AND 3 PASS  
FRAME 2, 2 PASS  
FRAME 3, 1 AND 3 PASS  
FRAME 3, 2 PASS  
FRAME 4, 1 AND 3 PASS  
FRAME 4, 2 PASS  
FRAME 5, 1 AND 3 PASS  
FRAME 5, 2 PASS  
FRAME 6, 1 AND 3 PASS  
FRAME 6, 2 PASS  
FRAME 7, 1 AND 3 PASS  
FRAME 7, 2 PASS  
FRAME 8, 1 AND 3 PASS  
FRAME 8, 2 PASS  
150  
150  
150  
150  
150  
150  
150  
150  
150  
150  
150  
150  
150  
150  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
300  
730  
365  
730  
365  
1060  
530  
1240  
620  
1500  
750  
2010  
740  
1855  
585  
84  
42  
84  
42  
123  
61  
139  
69  
162  
81  
326  
163  
406  
203  
84  
42  
84  
42  
123  
61  
139  
69  
162  
81  
326  
163  
405  
203  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
1034  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
2068  
331  
166  
331  
166  
481  
240  
562  
281  
680  
340  
912  
336  
841  
265  
390  
195  
390  
195  
549  
272  
626  
313  
748  
374  
1406  
830  
1245  
766  
318  
159  
317  
159  
465  
231  
526  
263  
612  
306  
1234  
617  
1537  
768  
318  
159  
317  
159  
465  
231  
526  
263  
612  
306  
1234  
617  
1533  
768  
860  
430  
860  
430  
1210  
600  
1380  
690  
1650  
825  
3100  
1830  
2745  
1475  
*Add to heat exchanger data for total weights or volumes.  
NOTES:  
1. Weight adder shown is the same for cooler and condenser of equal frame size.  
2. For the total weight of a vessel with a marine waterbox, add these values to the heat  
exchanger weights (or volumes).  
Table 15 — Compressor Weights  
FRAME 4  
FRAME 3  
FRAME 4  
FRAME 2  
COMPRESSOR  
WEIGHT  
FRAME 5  
COMPRESSOR  
WEIGHT  
COMPRESSOR  
COMPRESSOR  
WEIGHT (With  
Split Ring Diffuser)  
COMPRESSOR  
WEIGHT  
WEIGHT (Without  
Split Ring Diffuser)  
COMPONENT  
lb  
50  
60  
320  
300  
35  
1260  
35  
125  
100  
kg  
23  
27  
145  
136  
16  
571  
16  
57  
lb  
54  
46  
730  
350  
80  
1050  
70  
150  
135  
kg  
24  
21  
331  
159  
36  
476  
32  
68  
lb  
175  
157  
656  
446  
126  
1589  
130  
150  
144  
kg  
79  
71  
298  
202  
57  
721  
59  
68  
lb  
175  
157  
656  
810  
200  
2022  
130  
150  
200  
kg  
79  
71  
298  
367  
91  
917  
59  
68  
lb  
kg  
181  
147  
454  
544  
113  
1676  
136  
84  
SUCTION ELBOW  
DISCHARGE ELBOW  
TRANSMISSION*  
SUCTION HOUSING  
IMPELLER SHROUD  
COMPRESSOR BASE  
DIFFUSER  
400  
325  
1000  
1200  
250  
3695  
300  
185  
220  
OIL PUMP  
MISCELLANEOUS  
45  
61  
65  
91  
100  
TOTAL WEIGHT  
(Less Motor and Elbows)  
2300  
1043  
2660  
1207  
3712  
1684  
4548  
2063  
6850  
3107  
*Transmission weight does not include rotor, shaft, and gear.  
93  
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Table 16 — 19XR Motor Weights Standard and High Efficiency Motors  
ENGLISH  
Rotor Weight†  
(lb)  
SI  
MOTOR  
SIZE  
Stator Weight*  
(lb)  
Stator Weight*  
(kg)  
Rotor Weight†  
End Bell  
Cover  
(lb)  
End Bell  
Cover  
(kg)  
(kg)  
60 Hz  
50 Hz  
1030  
1070  
1120  
1175  
1175  
1358  
1377  
1435  
1455  
1467  
1479  
1479  
1725  
1737  
2069  
2089  
2139  
2153  
2207  
2305  
3120  
3250  
3250  
3370  
3370  
3520  
3520  
60 Hz  
240  
250  
265  
290  
290  
258  
265  
280  
303  
316  
329  
329  
361  
391  
536  
550  
575  
599  
604  
614  
701  
716  
716  
737  
737  
801  
830  
50 Hz  
240  
250  
265  
290  
290  
273  
281  
296  
303  
316  
316  
316  
391  
404  
596  
550  
567  
599  
604  
614  
751  
751  
768  
801  
801  
851  
851  
60 Hz  
50 Hz  
60 Hz  
109  
50 Hz  
109  
BD  
BE  
BF  
BG  
BH  
CD  
CE  
CL  
CM  
CN  
CP  
CQ  
DB  
DC  
DD  
DE  
DF  
DG  
DH  
DJ  
EH  
EJ  
1030  
1070  
1120  
1175  
1175  
1286  
1305  
1324  
1347  
1358  
1401  
1455  
1665  
1681  
1977  
2018  
2100  
2187  
2203  
2228  
3060  
3105  
3180  
3180  
3270  
3270  
3340  
185  
185  
185  
185  
185  
274  
274  
274  
274  
274  
274  
274  
236  
236  
318  
318  
318  
318  
318  
318  
414  
414  
414  
414  
414  
414  
414  
467  
485  
467  
485  
84  
84  
84  
84  
84  
113  
120  
132  
132  
117  
120  
127  
137  
143  
149  
149  
164  
177  
243  
249  
261  
272  
274  
279  
318  
325  
325  
334  
334  
363  
376  
113  
120  
132  
132  
124  
127  
134  
137  
143  
143  
152  
177  
183  
248  
248  
257  
272  
274  
279  
341  
341  
348  
363  
363  
386  
386  
508  
508  
533  
533  
533  
533  
583  
616  
125  
125  
125  
125  
125  
125  
125  
107  
107  
144  
144  
144  
144  
144  
144  
188  
188  
188  
188  
188  
188  
188  
592  
625  
600  
651  
611  
660  
616  
665  
635  
671  
660  
671  
755  
782  
762  
788  
897  
938  
915  
948  
952  
970  
992  
977  
999  
1001  
1046  
1415  
1474  
1474  
1529  
1529  
1597  
1597  
1011  
1388  
1408  
1442  
1442  
1483  
1483  
1515  
EK  
EL  
EM  
EN  
EP  
*Stator weight includes stator and shell.  
†Rotor weight includes rotor and shaft.  
NOTE: When different voltage motors have different weights the largest weight is given.  
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Table 17A — 19XR Waterbox Cover Weights — English (lb)  
FRAME 1  
Standard  
Nozzles  
FRAME 2  
Standard  
Nozzles  
FRAME 3  
Standard  
Nozzles  
HEAT  
EXCHANGER  
WATERBOX  
DESCRIPTION  
Flanged  
Flanged  
Flanged  
LEGEND  
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.  
RIG MACHINE COMPONENTS — Refer to instructions  
below, Fig. 6-9, and Carrier Certified Prints for machine com-  
ponent disassembly.  
95  
Table 17B — 19XR Waterbox Cover Weights — SI (kg)  
FRAME 1  
FRAME 2  
FRAME 3  
HEAT  
WATERBOX  
Standard  
Standard  
Standard  
EXCHANGER  
DESCRIPTION  
Flanged  
Flanged  
Flanged  
Nozzles  
80  
Nozzles  
145  
Nozzles  
145  
NIH, 1 Pass Cover, 150 psig  
NIH, 2 Pass Cover, 150 psig  
NIH, 3 Pass Cover, 150 psig  
NIH/MWB End Cover, 150 psig  
NIH, 1 Pass Cover, 300 psig  
NIH, 2 Pass Cover, 300 psig  
NIH, 3 Pass Cover, 300 psig  
NIH/MWB End Cover, 300 psig  
93  
99  
89  
159  
159  
154  
136  
220  
235  
212  
181  
159  
159  
154  
136  
220  
235  
212  
181  
84  
82  
62  
112  
116  
115  
79  
145  
136  
136  
186  
186  
196  
181  
145  
140  
136  
186  
186  
196  
181  
62  
COOLER/  
CONDENSER  
137  
147  
131  
79  
FRAME 4  
FRAME 5  
Standard  
Nozzles  
FRAME 6  
HEAT  
EXCHANGER  
WATERBOX  
DESCRIPTION  
Standard  
Nozzles  
Flanged  
LEGEND  
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.  
96  
Table 18 — Optional Pumpout System  
Table 20 — Motor Voltage Code  
Electrical Data  
MOTOR VOLTAGE CODE  
MOTOR  
CODE  
CONDENSER  
UNIT  
19EA47-748  
19EA42-748  
19EA44-748  
19EA46-748  
MAX  
RLA  
3.8  
10.9  
9.5  
Code  
Volts  
200  
230  
380  
416  
Frequency  
VOLTS-PH-Hz  
LRA  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
50  
51  
52  
53  
54  
55  
60  
60  
60  
60  
60  
60  
60  
60  
60  
60  
50  
50  
50  
50  
50  
50  
1
4
5
6
575-3-60  
200/208-3-60  
230-3-60  
23.0  
63.5  
57.5  
28.8  
400/460-3-50/60  
4.7  
460  
575  
LEGEND  
LRA — Locked Rotor Amps  
RLA — Rated Load Amps  
2400  
3300  
4160  
6900  
230  
346  
400  
3000  
3300  
6300  
Table 19 — Additional Miscellaneous Weights  
ITEM  
CONTROL CABINET  
UNIT-MOUNTED STARTER  
OPTIONAL ISOLATION VALVES  
UNIT MOUNTED VFD  
Lb  
30  
500  
115  
Kg  
14  
227  
52  
1000  
454  
VFD — Variable Frequency Drive  
97  
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COMPRESSOR, TRANSMISSION AREA  
Compressor Assembly Torques  
TORQUE  
ITEM  
DESCRIPTION  
ft.-lb  
N•m  
1*  
2
Oil Heater Retaining Nut  
Bull Gear Retaining Bolt  
Demister Bolts  
Impeller Retaining Bolt  
Motor Terminals (Low Voltage)  
Guide Vane Shaft Seal Nut  
Motor Terminals (High Voltage)  
— Insulator  
— Packing Nut  
— Brass Jam Nut  
20  
80-85  
15-19  
44-46  
50  
28  
108-115  
20-26  
60-62  
68  
3
4
5*  
6*  
7*  
25  
34  
2-4  
5
10  
2.7-5.4  
6.8  
13.6  
LEGEND  
N•m — Newton meters  
*Not shown.  
NOTES:  
1. All clearances for cylindrical surfaces are diametrical.  
2. Dimensions are with rotor in thrust position.  
3. Dimensions shown are in inches.  
4. Impeller spacing should be performed in accordance with most  
recent Carrier Service Bulletin on impeller spacing.  
VIEW A  
LOW SPEED SHAFT THRUST DISK  
Fig. 44 — Compressor Fits and Clearances  
98  
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VIEW B — HIGH SPEED SHAFT  
19XR COMPRESSOR CLEARANCES  
COMPRESSOR CODE  
ITEM  
221-299  
321-389  
421-489  
521-599  
.0050  
.0040  
.0050  
.0040  
.0055  
.0043  
.0069  
.0059  
A
B
C
D
E
.0050  
.0040  
.0050  
.0040  
.0053  
.0043  
.0065  
.0055  
.0115  
.0055  
.0115  
.0080  
.0100  
.0050  
.0010  
.0060  
.0190  
.0040  
.022  
.012  
.027  
.017  
.0350  
.0250  
–.002  
–.0005  
–.0020  
–.0005  
–.0029  
–.0014  
–.0019  
–.0005  
.0050  
.0040  
.0050  
.0040  
.0048  
.0038  
.0062  
.0052  
F
G
—*  
—*  
—*  
—*  
*Depends on impeller size, contact your Carrier Service Representative for more information.  
NOTE: All clearances for cylindrical surfaces are diametrical.  
Fig. 44 — Compressor Fits and Clearances (cont)  
99  
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101  
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102  
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103  
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104  
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105  
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106  
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107  
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LEGEND  
NOTES:  
1. Power factor correction capacitors (when required) are connected ahead of all current  
transformers for proper calibration and sensing by the ISM and IQDP4130.  
2. For phase to phase ground fault protection refer to Fig. 51.  
3. For metering information refer to Fig. 52.  
HPR  
ISM  
L
—
—
—
—
—
—
—
—
High Pressure Relay  
Integrated Starter Module  
Main Supply Power  
Control Power Supply  
Contactor  
AUX  
C
CB  
CT  
DS  
FU  
G
—
—
—
—
—
—
—
Auxiliary  
Contactor  
Circuit Breaker  
Current Transformer  
Disconnect Switch  
Fuse  
LL  
M
RES  
S
Resistor  
Contactor  
Terminal Block  
Ground  
TB  
Fig. 49 — Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP  
108  
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LEGEND  
NOTES:  
1. Power factor correction capacitors (when required) are connected ahead of all current  
transformers for proper calibration and sensing by the ISM and IQDP4130.  
2. For metering option see Fig. 52.  
HPR  
ISM  
L
—
—
—
—
—
—
—
—
High Pressure Relay  
Integrated Starter Module  
Main Supply Power  
Control Power Supply  
Contactor  
AUX  
C
CB  
CT  
DS  
FU  
G
—
—
—
—
—
—
—
Auxiliary  
Contactor  
Circuit Breaker  
Current Transformer  
Disconnect Switch  
Fuse  
LL  
M
RES  
S
Resistor  
Contactor  
Terminal Block  
Ground  
TB  
Fig. 50 — Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP  
109  
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LEGEND  
CT  
— Current Transformer  
ISM — Integrated Starter Module  
VFD — Variable Frequency Drive  
Represents Twisted Wire  
To Door  
Fig. 51 — Ground Fault Phase Current Option  
LEGEND  
AM  
CT  
L
— Ammeter  
— Current Transformer  
— Main Power Supply  
— Voltmeter  
VM  
Represents Twisted Wire  
To Door  
Fig. 52 — Separate Metering Option  
110  
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Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)  
111  
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LEGEND  
AUX  
BR  
—
—
—
—
—
Auxiliary  
L
—
—
—
—
—
Main Supply Power  
Control Power Supply  
Contactor  
Wire Node Symbol  
PC Board Terminals  
Twisted Pair  
Bridge Rectifier  
Circuit Breaker  
Condenser  
LL  
may have terminal block  
CB  
M
O/L  
PFCC  
Benshaw supplied  
terminal block  
COND  
CPU  
CVC/  
ICVC  
CT  
EVAP  
FU  
GND  
Overload Reset  
Power Factor  
Central Processing Unit  
Chiller Visual Controller  
Twisted Shielded Pair  
Shield Wire  
Correction Capacitor  
Rated Load Amps  
—
Terminal Strip  
RLA  
SCR  
ST  
—
—
—
—
—
—
—
—
Current Transformer  
Evaporator  
Fuse  
Silicone Controller Rectifier  
Shunt Trip  
Power Connection  
Field Wiring  
TB  
Terminal Block  
Ground  
NOTES:  
"ON"  
LED status with power applied and prior to run command.  
1
"OFF"  
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1.  
Transformer connections per transformer nameplate connection diagram.  
MOVs are used on power stack assemblies for system voltages of 200 through 460 vac (as shown).  
Resistor/capacitor networks (DVDTs) are used on power stack assemblies in place of MOVs for a system  
voltage of 575 vac (not shown).  
2
3
K3 relay shown in deenergized state. K3 contact will close when power is supplied. K3 contact will open  
on stop command or system fault.  
CT1-CT3 are sized per Chart 2.  
4
5
6
Optional.  
Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)  
112  
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114  
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1A  
115  
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117  
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118  
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119  
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LEGEND FOR FIG. 57  
VFD  
1C  
— Variable Frequency Drive  
— Compressor Oil Heater Contactor  
— Start Contactor  
AUX  
CB  
—
—
—
—
Auxiliary  
Pressure Switch  
Circuit Breaker  
1M  
2C  
Compr Oil Pump Terminal  
Cartridge Fuse  
CCM  
CCN  
Chiller Control Module  
Carrier Comfort Network  
— Oil Pump Contactor  
— Hot Gas Bypass Relay  
Field Control Wiring  
3C  
COMM — Communications  
Earth Ground  
CT  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Current Transformer  
Chiller Visual Controller  
Data Port/Data Link  
Disconnect Switch  
Fused Disconnect  
Fan Relay  
Field Power Wiring  
Factory Wiring  
CVC  
DP/DL  
DS  
Resistor  
Shielded Cable  
Chassis Ground  
Light  
FD  
FR  
Twisted Pair Wiring  
FU  
Fuse  
Temperature Switch  
Common Potential  
G
Chassis Ground  
Male/Female Connector  
Terminal Block Connection  
Wire Splice or Junction  
Cam Switch  
GV  
Guide Vane  
HGBP  
HPR  
HPS  
HX  
Hot Gas Bypass  
High Discharge Pressure Relay  
High Pressure Switch  
Heat Exchanger  
Dry Contact  
VFD Terminal  
ICVC  
IGBT  
IGV  
ISM  
J
International Chiller Visual Controller  
Insulated Gate Bipolar Transistor  
Inlet Guide Vane  
Integrated Starter Module  
Junction  
Current Detector  
Module Adapter Board  
Regulator Controller  
Remote Metering Interface  
Shunt Trip  
Transformer  
Terminal Block  
Current Transformer, Polarized  
(Direction Determined by •)  
Component Terminal  
Thermistor  
Transformer  
LEM  
MAB  
RC  
-
IGBT  
Transducer  
+
Diode  
RMI  
ST  
Fusible Link  
Potentiometer  
Silicone Control Rectifier  
T
TB  
122  
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INDEX  
Abbreviations and Explanations, 4  
Adding Refrigerant, 71  
Motor and Lubricating Oil Cooling Cycle, 7  
Motor-Compressor, 5  
Motor Rotation (Check), 65  
Notes on Module Operation, 87  
Oil Changes, 73  
Oil Charge, 55  
Oil Cooler, 36  
Oil Pressure and Compressor Stop (Check), 65  
Oil Reclaim Filter, 73  
Oil Reclaim System, 8  
Oil Specification, 73  
Adjusting the Refrigerant Charge, 71  
After Extended Shutdown, 67  
After Limited Shutdown, 66  
Alarm (Trip) Output Contacts, 37  
Attach to Network Device Control, 44  
Automatic Soft Stop Amps Threshold, 47  
Auto. Restart After Power Failure, 38  
Before Initial Start-Up, 48  
Capacity Override, 36  
Carrier Comfort Network Interface, 54  
Changing Oil Filter, 73  
Oil Sump Temperature Control, 36  
Open Oil Circuit Valves, 48  
Operating Instructions, 66  
Operating the Optional Pumpout Unit, 67  
Operator Duties, 66  
Optional Pumpout Compressor Water Piping (Check), 53  
Optional Pumpout System Controls and  
Compressor (Check), 63  
Charge Refrigerant Into Chiller, 63  
Chilled Water Recycle Mode, 47  
Chiller Control Module (CCM), 88  
Chiller Dehydration, 53  
Chiller Familiarization, 5  
Chiller Information Nameplate, 5  
Chiller Operating Condition (Check), 65  
Chiller Tightness (Check), 48  
Chillers with Isolation Valves, 70  
Chillers with Storage Tanks, 69  
Cold Weather Operation, 67  
Compressor Bearing and Gear Maintenance, 74  
Condenser, 5  
Optional Pumpout System Maintenance, 75  
Ordering Replacement Chiller Parts, 75  
Overview (Troubleshooting Guide), 76  
Perform a Control Test, 62  
Physical Data, 90  
PIC II System Components, 11  
PIC II System Functions, 33  
Power Up the Controls and Check the Oil Heater, 55  
Preparation (Initial Start-Up), 64  
Preparation (Pumpout and Refrigerant Transfer  
Procedures), 67  
Condenser Freeze Prevention, 38  
Condenser Pump Control, 37  
Control Algorithms Checkout Procedure, 77  
Control Panel, 5  
Control Modules, 87  
Prepare the Chiller for Start-Up, 66  
Pressure Transducers (Check), 75, 76  
Prevent Accidental Start-Up, 65  
Pumpout and Refrigerant Transfer Procedures, 67  
Ramp Loading, 36  
Control Test, 77  
Controls, 10  
CVC/ICVC Operation and Menus, 15  
Cooler, 5  
Default Screen Freeze, 35  
Definitions (Controls), 10  
Refrigerant Filter, 73  
Refrigerant Float System (Inspect), 74  
Refrigerant Leak Detector, 37  
Refrigerant Leak Testing, 71  
Refrigerant Properties, 71  
Demand Limit Control Option, 39  
Design Set Points, (Input), 55  
Details (Lubrication Cycle), 8  
Display Messages (Check), 76  
Dry Run to Test Start-Up Sequence, 65  
Equipment Required, 48  
Refrigerant (Removing), 71  
Refrigerant Tracer, 48  
Refrigeration Cycle, 7  
Evaporator Freeze Protection, 38  
Extended Shutdown (Preparation for), 66  
Factory-Mounted Starter or Variable Frequency Drive, 7  
General (Controls), 11  
Refrigeration Log, 67  
Relief Valves (Check), 53  
Relief Valves and Piping (Inspect), 74  
Remote Reset of Alarms, 37  
Remote Start/Stop Controls, 36  
Repair the Leak, Retest, and  
Apply Standing Vacuum Test, 72  
Replacing Defective Processor Modules, 88  
Running System (Check), 66  
Safety and Operating Controls (Check Monthly), 73  
Safety Considerations, 1  
General Maintenance, 71  
Guide Vane Linkage (Check), 72  
Heat Exchanger Tubes and Flow Devices (Inspect), 74  
High Altitude Locations, 63  
High Discharge Temperature Control, 36  
Ice Build Control, 43  
Initial Start-Up, 64  
Initial Start-Up Checklist for 19XR,XRV Hermetic  
Centrifugal Liquid Chiller, CL-1  
Inspect the Control Panel, 73  
Instruct the Customer Operator, 65  
Integrated Starter Module (ISM), 88  
Introduction, 4  
Safety Controls, 34  
Safety Shutdown, 47  
Scheduled Maintenance, 73  
Service Configurations (Input), 55  
Service Ontime, 73  
Service Operation, 45  
Job Data Required, 48  
Shipping Packaging (Remove), 48  
Shunt Trip (Option), 35  
Kilowatt Output, 37  
Lead/Lag Control, 40  
Shutdown Sequence, 47  
Leak Rate, 71  
Software Configuration, 55  
Solid-State Starters, 88  
Leak Test Chiller, 50  
Local Occupied Schedule (Input), 55  
Local Start-Up, 46  
Spare Safety Inputs, 36  
Standing Vacuum Test, 50  
Lubrication Cycle, 8  
Lubrication System (Check), 72  
Manual Guide Vane Operation, 67  
Starter (Check), 54  
Starting Equipment, 9  
Starting Equipment (Inspect), 75  
123  
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INDEX (cont)  
Troubleshooting Guide, 76  
Start-Up/Shutdown/Recycle Sequence, 46  
Start the Chiller, 66  
Unit-Mounted Solid-State Starter, 9  
Unit-Mounted VFD, 10  
Unit-Mounted Wye-Delta Starter, 10  
Using the Optional Storage Tank and Pumpout  
System, 48  
Stop the Chiller, 66  
Storage Vessel, 7  
Summary (Lubrication Cycle), 8  
Surge Prevention Algorithm (Fixed Speed Chiller), 39  
Surge Prevention Algorithm with VFD, 40  
Surge Protection (Fixed Speed Chillers), 40  
Surge Protection VFD Units, 40  
System Components, 5  
VFD Cooling Cycle, 8  
Water/Brine Reset, 38  
Water Leaks, 74  
Water Piping (Inspect), 53  
Water Treatment, 75  
Temperature Sensors (Check), 76  
Test After Service, Repair, or Major Leak, 71  
Tighten All Gasketed Joints and Guide Vane Packing, 48  
Tower Fan Relay Low and High, 38  
Trim Refrigerant Charge, 72  
Weekly Maintenance, 72  
Wiring (Inspect), 53  
Copyright 2001 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 211 Catalog No. 531-982 Printed in U.S.A. Form 19XR-5SS Pg 124 6-01 Replaces: 19XR-4SS  
Book 2  
Tab 5a  
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INITIAL START-UP CHECKLIST  
FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER  
(Remove and use for job file.)  
MACHINE INFORMATION:  
NAME  
JOB NO.  
MODEL  
ZIP  
ADDRESS  
CITY  
STATE  
S/N  
DESIGN CONDITIONS:  
FLOW TEMPERATURE TEMPERATURE PRESSURE  
SUCTION  
CONDENSER  
TONS BRINE  
PASS  
RATE  
IN  
OUT  
DROP  
TEMPERATURE TEMPERATURE  
COOLER  
******  
CONDENSER  
******  
COMPRESSOR:  
STARTER:  
OIL PUMP:  
Volts  
Mfg  
Volts  
RLA  
Type  
RLA  
OLTA  
S/N  
OLTA  
CONTROL/OIL HEATER:  
REFRIGERANT: Type:  
Volts  
115  
230  
Charge  
CARRIER OBLIGATIONS:  
Assemble... . . . . . . . . . . . . . . . .  
Yes  
No  
No  
No  
No  
Leak Test . . . . . . . . . . . . . . . . . . . Yes  
Dehydrate . . . . . . . . . . . . . . . . . . Yes  
Charging . . . . . . . . . . . . . . . . . . . Yes  
Operating Instructions  
Hrs.  
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS  
JOB DATA REQUIRED:  
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . Yes  
2. Machine Assembly, Wiring and Piping Diagrams . . . . . . Yes  
3. Starting Equipment Details and Wiring Diagrams. . . . . . Yes  
4. Applicable Design Data (see above). . . . . . . . . . . . . . . . Yes  
5. Diagrams and Instructions for Special Controls . . . . . . . Yes  
No  
No  
No  
No  
No  
INITIAL MACHINE PRESSURE:  
YES  
NO  
Was Machine Tight?  
If Not, Were Leaks Corrected?  
Was Machine Dehydrated After Repairs?  
CHECK OIL LEVEL AND RECORD:  
3/4  
ADD OIL: Yes  
Amount:  
No  
1/2 Top sight glass  
1/4  
3/4  
1/2 Bottom sight glass  
1/4  
RECORD PRESSURE DROPS:  
Cooler  
Initial Charge  
Condenser  
Final Charge After Trim  
CHARGE REFRIGERANT:  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab  
2
PC 211  
Catalog No. 531-982  
Printed in U.S.A.  
Form 19XR-5SS  
Pg CL-1  
6-01  
Replaces: 19XR-4SS  
5a  
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INSPECT WIRING AND RECORD ELECTRICAL DATA:  
RATINGS:  
Motor Voltage  
Motor(s) Amps  
Oil Pump  
Oil Pump Voltage  
Starter LRA Rating  
Line Voltages: Motor  
Controls/Oil Heater  
FIELD-INSTALLED STARTERS ONLY:  
Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state  
starters; disconnect leads to motor and megger the leads.  
“PHASE TO PHASE”  
“PHASE TO GROUND”  
T1-G T2-G T3-G  
MEGGER MOTOR  
T1-T2  
T1-T3  
T2-T3  
10-Second Readings:  
60-Second Readings:  
Polarization Ratio:  
STARTER:  
Electro-Mechanical  
Solid-State  
Manufacturer  
Serial Number  
Motor Load Current Transformer Ratio  
Solid-State Overloads Yes No  
:
CONTROLS: SAFETY, OPERATING, ETC.  
Perform Controls Test (Yes/No)  
PIC II CAUTION  
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY  
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH  
CERTIFIED DRAWINGS).  
Yes  
RUN MACHINE: Do these safeties shut down machine?  
Condenser Water Flow  
Chilled Water Flow  
Pump Interlocks  
Yes  
Yes  
Yes  
No  
No  
No  
INITIAL START:  
Line Up All Valves in Accordance With Instruction Manual:  
Start Water Pumps and Establish Water Flow  
Oil Level OK and Oil Temperature OK  
Check Oil Pump Rotation-Pressure  
Clockwise  
Check Compressor Motor Rotation (Motor End Sight Glass) and Record:  
Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise?  
*If yes, determine cause.  
Yes*  
No  
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:  
A: Trim charge and record under Charge Refrigerant Into Chiller section on page 63.  
B: Complete any remaining control calibration and record under Controls section (pages 10-45).  
C: For unit mounted VFD complete pages 58-61.  
D: Take at least two sets of operational log readings and record.  
E: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.  
F: Give operating instructions to owner’s operating personnel.  
Hours Given:  
Hours  
G: Call your Carrier factory representative to report chiller start-up.  
SIGNATURES:  
CARRIER  
TECHNICIAN  
CUSTOMER  
REPRESENTATIVE  
DATE  
DATE  
CL-2  
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19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET  
DESCRIPTION  
Base Demand Limit  
ECW Setpoint  
RANGE  
40 to 100  
10 to 120  
15 to 120  
15 to 60  
UNITS  
%
DEFAULT  
100  
VALUE  
DEG F  
DEG F  
DEG F  
DEG F  
60.0  
LCW Setpoint  
50.0  
Ice Build Setpoint  
Tower Fan High Setpoint  
40.0  
55 to 105  
75  
CVC/ICVC  
Number:  
Software  
Version  
CVC/ICVC  
Identification: BUS:  
Controller  
ADDRESS:  
CL-3  
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19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S  
Day Flag  
M T W T  
Occupied  
Time  
Unoccupied  
Time  
F
S
S
H
Period 1:  
Period 2:  
Period 3:  
Period 4:  
Period 5:  
Period 6:  
Period 7:  
Period 8:  
NOTE: Default setting is OCCUPIED 24 hours/day.  
ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S  
Day Flag  
M T W T  
Occupied  
Time  
Unoccupied  
Time  
F
S
S
H
Period 1:  
Period 2:  
Period 3:  
Period 4:  
Period 5:  
Period 6:  
Period 7:  
Period 8:  
NOTE: Default setting is UNOCCUPIED 24 hours/day.  
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S  
Day Flag  
M T W T  
Occupied  
Time  
Unoccupied  
Time  
F
S
S
H
Period 1:  
Period 2:  
Period 3:  
Period 4:  
Period 5:  
Period 6:  
Period 7:  
Period 8:  
NOTE: Default setting is OCCUPIED 24 hours/day.  
CL-4  
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19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET  
DESCRIPTION RANGE UNITS DEFAULT  
Starter Type  
VALUE  
0 to 2  
1
(0=Full, 1=Red, 2=SS/VFD)  
Motor Rated Line Voltage  
Volt Transformer Ratio: 1  
Overvoltage Threshold  
Undervoltage Threshold  
Over/Under Volt Time  
Voltage% Imbalance  
Voltage Imbalance Time  
Motor Rated Load Amps  
Motor Locked Rotor Trip  
Locked Rotor Start Delay  
Starter LRA Rating  
Motor Current CT Ratio: 1  
Current% Imbalance  
Current Imbalance Time  
Grnd Fault CT’s?  
Ground Fault CT Ratio: 1  
Ground Fault Current  
Ground Fault Start Delay  
Ground Fault Persistence  
Single Cycle Dropout  
200 to 13200  
1 to 35  
105 to 115  
85 to 95  
1 to 10  
1 to 10  
1 to 10  
10 to 5000  
100 to 60000  
1 to 10  
100 to 60000  
3 to 1000  
5 to 40  
1 to 10  
0/1  
VOLTS  
460  
1
115  
85  
5
10  
5
200  
1000  
5
2000  
100  
15  
%
%
SEC  
%
SEC  
AMPS  
AMPS  
cycles  
AMPS  
%
SEC  
NO/YES  
5
YES  
150  
15  
10  
5
DSABLE  
YES  
DSABLE  
150  
1 to 25  
1 to 20  
1 to 10  
0/1  
AMPS  
cycles  
cycles  
DSABLE/ENABLE  
NO/YES  
Frequency-60 Hz? (No=50)  
Line Frequency Faulting  
0/1  
0/1  
DSABLE/ENABLE  
CL-5  
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19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET  
DESCRIPTION  
Auto Restart Option  
Remote Contacts Option  
Soft Stop Amps Threshold  
RANGE  
0/1  
0/1  
UNITS  
DSABLE/ENABLE  
DSABLE/ENABLE  
%
DEFAULT  
DSABLE  
DSABLE  
100  
VALUE  
40 to 100  
Surge/Hot Gas Bypass  
Surge Limit/HGBP Option  
Select: Surge=0, HGBP=1  
0/1  
0
Min. Load Point (T1, P1)  
Surge/HGBP Delta T1  
Surge/HGBP Delta P1  
Full Load Point (T2, P2)  
Surge/HGBP Delta T2  
Surge/HGBP Delta P2  
Surge/HGBP Deadband  
0.5 to 20  
30 to 170  
ˆF  
PSI  
1.5  
50  
0.5 to 20  
50 to 170  
0.5 to 3  
ˆF  
PSI  
ˆF  
10  
85  
1
Surge Protection  
Surge Delta% Amps  
Surge Time Period  
5 to 20  
7 to 10  
%
MIN  
10  
8
Ice Build Control  
Ice Build Option  
Ice Build Termination  
0=Temp, 1=Contacts, 2=Both  
0/1  
DSABLE/ENABLE  
DSABLE/ENABLE  
DSABLE  
0
0 to 2  
0/1  
Ice Build Recycle  
DSABLE  
Refrigerant Leak Option  
Refrigerant Leak Alarm mA  
0/1  
4 to 20  
DSABLE/ENABLE  
mA  
DSABLE  
20  
Head Pressure Reference  
Delta P at 0% (4 mA)  
Delta P at 100% (20 mA)  
Minimum Output  
20 to 60  
20 to 60  
0 to 100  
psi  
psi  
%
25  
35  
0
CL-6  
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19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET  
DESCRIPTION  
Comp Motor Temp Override  
Cond Press Override  
Comp Discharge Alert  
Comp Thrust Brg Alert  
RANGE  
150 to 200  
90 to 165  
125 to 200  
165 to 185  
UNITS  
DEG F  
PSI  
DEG F  
DEG F  
DEFAULT  
200  
125  
200  
175  
VALUE  
Chilled Medium  
0/1  
WATER/BRINE  
WATER  
Chilled Water Deadband  
Evap Refrig Trippoint  
Refrig Override Delta T  
Condenser Freeze Point  
.5 to 2.0  
0.0 to 40.0  
2.0 to 5.0  
–20 to 35  
ˆF  
DEG F  
ˆF  
1.0  
33  
3
DEG F  
34  
Evap Flow Delta P Cutout  
Cond Flow Delta P Cutout  
Water Flow Verify Time  
Oil Press Verify Time  
Recycle Control  
0.5 to 50.0  
0.5 to 50.0  
0.5 to 5  
PSI  
PSI  
MIN  
SEC  
5.0  
5.0  
5
15 to 300  
40  
Restart Delta T  
Shutdown Delta T  
2.0 to 10.0  
0.5 to 4.0  
DEG F  
DEG F  
5
1
SPARE ALERT/ALARM ENABLE  
Disable=0, Lo=1/3, Hi=2/4  
Spare Temp #1 Enable  
Spare Temp #1 Limit  
Spare Temp #2 Enable  
Spare Temp #2 Limit  
0 to 4  
–40 to 245  
0 to 4  
0
245  
0
DEG F  
DEG F  
–40 to 245  
245  
CL-7  
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19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET  
DESCRIPTION  
Capacity Control  
STATUS  
UNITS  
DEFAULT  
VALUE  
Proportional Inc Band  
Proportional DEC Band  
Proportional ECW Gain  
2 to 10  
2 to 10  
1 to 3  
6.5  
6.0  
2.0  
Guide Vane Travel Limit  
30 to 100  
%
80  
Diffuser Control  
Diffuser Option  
0 to 1  
DSABLE/ENABLE  
DSABLE  
Guide Vane 25% Load Pt  
Diffuser 25% Load Point  
Guide Vane 50% Load Pt  
Diffuser 50% Load Point  
Guide Vane 75% Load Pt  
Diffuser 75% Load Point  
Diffuser Full Span mA  
0 to 78  
0 to 100  
0 to 78  
0 to 100  
0 to 78  
0 to 100  
15 to 22  
%
%
%
%
%
%
mA  
25  
0
50  
0
50  
0
18  
VFD Speed Control  
VFD Option  
VFD Gain  
VFD Increase Step  
VFD Minimum Speed  
VFD Maximum Speed  
VFD Current Limit  
0/1  
0.1 to 1.5  
1 to 5  
65 to 100  
90 to 100  
0 to 99999  
DSABLE/ENABLE  
DSABLE  
0.75  
2
70  
100  
%
%
%
Amp  
250  
CL-8  
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19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET  
DESCRIPTION  
Lead Lag Control  
RANGE  
UNITS  
DEFAULT  
VALUE  
LEAD/LAG: Configuration  
DSABLE=0, LEAD=1,  
LAG=2, STANDBY=3  
0 to 3  
0
Load Balance Option  
Common Sensor Option  
LAG% Capacity  
LAG Address  
LAG START Timer  
LAG STOP Timer  
PRESTART FAULT Timer  
STANDBY Chiller Option  
STANDBY% Capacity  
STANDBY Address  
0/1  
0/1  
DSABLE/ENABLE  
DSABLE/ENABLE  
%
DSABLE  
DSABLE  
50  
92  
10  
10  
5
DSABLE  
50  
93  
25 to 75  
1 to 236  
2 to 60  
2 to 60  
2 to 30  
0/1  
MIN  
MIN  
MIN  
DSABLE/ENABLE  
%
25 to 75  
1 to 236  
CL-9  
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19XR, XRV PIC II RAMP_DEM TABLE CONFIGURATION SHEET  
DESCRIPTION RANGE UNITS DEFAULT  
0/1  
VALUE  
Pulldown Ramp Type:  
Select: Temp=0, Load=1  
1
Demand Limit + kW Ramp  
Demand Limit Source  
Select: Amps=0, kW=1  
0/1  
0
Motor Load Ramp% Min  
Demand Limit Prop Band  
Demand Limit At 20 mA  
20 mA Demand Limit Opt  
Motor Rated Kilowatts  
Demand Watts Interval  
5 to 20  
3 to 15  
40 to 100  
0/1  
50 to 9999  
5 to 60  
10  
10  
40  
DSABLE  
145  
%
%
DSABLE/ENABLE  
kW  
MIN  
15  
19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET  
DESCRIPTION  
Control Point  
RANGE  
UNITS  
DEFAULT  
VALUE  
ECW Control Option  
Temp Pulldown Deg/Min  
0/1  
2 to 10  
DSABLE/ENABLE  
ˆF  
DSABLE  
3
Temperature Reset  
RESET TYPE 1  
Degrees Reset At 20 mA  
RESET TYPE 2  
–30 to 30  
ˆF  
10  
Remote Temp -> No Reset  
Remote Temp -> Full Reset  
Degrees Reset  
–40 to 245  
–40 to 245  
–30 to 30  
DEG F  
DEG F  
ˆF  
85  
65  
10  
RESET TYPE 3  
CHW Delta T -> No Reset  
CHW Delta T -> Full Reset  
Degrees Reset  
0 to 15  
0 to 15  
–30 to 30  
ˆF  
ˆF  
ˆF  
10  
0
5
Select/Enable Reset Type  
0 to 3  
0
CL-10  
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BROADCAST (BRODEF) CONFIGURATION SHEET  
DESCRIPTION  
Time Broadcast Enable  
Daylight Savings  
Start Month  
RANGE  
DSABLE/ENABLE  
UNITS  
DEFAULT  
DSABLE  
VALUE  
1 to 12  
4
Start Day of Week  
Start Week  
1 to 7  
1 to 5  
7
3
Start Time  
Start Advance  
Stop Month  
Stop Day of Week  
Stop Week  
00:00 to 24:00  
0 to 360  
1 to 12  
1 to 7  
1 to 5  
HH:MM  
MIN  
02:00  
60  
10  
7
3
Stop Time  
Stop Back  
00:00 to 24:00  
0 to 360  
02:00  
60  
MIN  
CL-11  
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UNIT-MOUNTED VFD CONFIGURATION SHEET  
DESCRIPTION  
Maximum Speed  
Speed Display Scaling  
Motor Voltage  
Frequency  
Motor Amps  
PARAMETER  
P.004  
RANGE  
15 to H.022  
10 to 999  
100 to 690  
30 to 200  
Power Module Dependent  
300 to 565  
30 to 210  
DEFAULT  
COMMENTS  
Job Sheet; 60 for 60 Hz and 50 for 50 Hz  
Job Sheet; 60 for 60 Hz and 50 for 50 Hz  
Selected line voltage  
60 Hz = 60, 50 Hz = 50  
Selected motor 100% amps  
Selected line voltage  
*
*
*
*
*
*
*
P.028  
H.000  
H.001  
H.002  
H.021  
H.022  
Line Voltage  
Over Frequency Limit  
60 Hz = 69, 50 Hz = 57  
*Variable by job — refer to component nameplates and labels.  
CL-12  
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CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET  
PRIMARY MESSAGE:  
CL-13  
CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET  
PRIMARY MESSAGE:  
DATE:  
COMPRESSOR ONTIME:  
TIME:  
SECONDARY MESSAGE:  
CHW OUT  
CDW OUT  
OIL TEMP  
CHW IN  
EVAP REF  
CDW IN  
OILPRESS  
CL-14  
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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  

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