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)
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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
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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)
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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
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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
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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.
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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.
30
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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
51
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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
66
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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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68
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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.
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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
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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
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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)
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103
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104
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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
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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
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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
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Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)
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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)
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1A
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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
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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
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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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