Carrier Evergreen 19Xr Users Manual

19XR to the manual 04da73d4-0b4a-4d5a-b5cf-630745b3c66b

2015-01-24

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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
Ta b 5 a
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.
Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions as
well as those listed in this guide.
DO NOT VENT refrigerant relief valves within a building. Outlet
from rupture disc or relief valve must be vented outdoors in 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 VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and
functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High voltage is
present on motor leads even though the motor is not running when a
solid-state or inside-delta mechanical starter is used. Open the power
supply disconnect before touching motor leads or terminals.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until
all refrigerant (liquid and vapor) has been removed from chiller.
Traces of vapor should be displaced with dry air or nitrogen and the
work area should be well ventilated. Refrigerant in contact with an
open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the
entire assembly.
DO NOT work on high-voltage equipment unless you are a qualified
electrician.
DO NOT WORK ON electrical components, including control 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
soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder.
Dangerous over pressure can result. When it is necessary to heat
refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause 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 ATTEMPT TO REMOVE fittings, covers, etc., while
chiller is under pressure or while chiller is running. Be sure pressure is
at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs, and other
relief devices AT LEAST ONCE A YEAR. If chiller operates in a
corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
device when corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. Replace the
device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring.
Sudden release of the spring can cause it and objects in its path to act
as projectiles.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging. 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.
PROVIDE A DRAIN connection in the vent line near each pressure
relief device to prevent a build-up of condensate or rain water.
19XR,XRV
Hermetic Centrifugal Liquid Chillers
50/60 Hz
With PIC II Controls and HFC-134a
2
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Factory-Mounted Starter or Variable
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
MOTOR AND LUBRICATING OIL
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PRIMARY OIL RECOVERY MODE
SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10
Unit-Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit-Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ANALOG SIGNAL
DISCRETE SIGNAL
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 11
CHILLER VISUAL CONTROLLER (CVC)
INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
INTEGRATED STARTER MODULE (ISM)
CHILLER CONTROL MODULE (CCM)
OIL HEATER CONTACTOR (1C)
OIL PUMP CONTACTOR (2C)
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
CONTROL TRANSFORMERS (T1, T2)
OPTIONAL TRANSFORMER (T3)
CVC/ICVC Operation and Menus. . . . . . . . . . . . . . . . . 15
• GENERAL
ALARMS AND ALERTS
CVC/ICVC MENU ITEMS
BASIC CVC/ICVC OPERATIONS (Using the Softkeys)
TO VIEW STATUS
OVERRIDE OPERATIONS
TIME SCHEDULE OPERATION
TO VIEW AND CHANGE SET POINTS
SERVICE OPERATION
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33
CAPACITY CONTROL FIXED SPEED
CAPACITY CONTROL VFD
ECW CONTROL OPTION
CONTROL POINT DEADBAND
DIFFUSER CONTROL
PROPORTIONAL BANDS AND GAIN
DEMAND LIMITING
CHILLER TIMERS
OCCUPANCY SCHEDULE
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Page
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Discharge Temperature Control . . . . . . . . . . . . 36
Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . . 37
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 37
Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 37
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 37
Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 38
Evaporator Freeze Protection (ICVC Only). . . . . . . 38
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 38
Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 38
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RESET TYPE 1
RESET TYPE 2
RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 39
Surge Prevention Algorithm
(Fixed Speed Chiller) . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Surge Prevention Algorithm with VFD . . . . . . . . . . . 40
Surge Protection VFD Units . . . . . . . . . . . . . . . . . . . . . 40
Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 40
HEAD PRESSURE REFERENCE OUTPUT
Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
COMMON POINT SENSOR INSTALLATION
CHILLER COMMUNICATION WIRING
LEAD/LAG OPERATION
FAULTED CHILLER OPERATION
LOAD BALANCING
AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ICE BUILD INITIATION
START-UP/RECYCLE OPERATION
TEMPERATURE CONTROL DURING ICE BUILD
TERMINATION OF ICE BUILD
RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . . . . 44
ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
TO ACCESS THE SERVICE SCREENS
TO LOG OUT OF NETWORK DEVICE
HOLIDAY SCHEDULING
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47
Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 47
Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 48
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 48
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3
CONTENTS (cont)
Page
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
MECHANICAL STARTER
BENSHAW, INC. RediStart MICRO™
SOLID-STATE STARTER
VFD STARTER
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55
• PASSWORD
INPUT TIME AND DATE
CHANGE CVC/ICVC CONFIGURATION
IF NECESSARY
TO CHANGE THE PASSWORD
TO CHANGE THE CVC/ICVC DISPLAY FROM
ENGLISH TO METRIC UNITS
CHANGE LANGUAGE (ICVC ONLY)
MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
CHANGE THE BENSHAW, INC., RediStart
MICRO SOFTWARE CONFIGURATION
IF NECESSARY
VERIFY VFD CONFIGURATION AND CHANGE
PARAMETERS IF NECESSARY
VFD CHILLER FIELD SET UP AND VERIFICATION
VFD CONTROL VERIFICATION (Non-Running)
VFD CONTROL VERIFICATION (Running)
CONFIGURE DIFFUSER CONTROL IF
NECESSARY
MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62
COOLER CONDENSER PRESSURE TRANSDUCER
AND WATERSIDE FLOW DEVICE CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63
CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
CHILLER EQUALIZATION WITH
PUMPOUT UNIT
TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check Oil Pressure and Compressor Stop . . . . . . 65
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65
Check Chiller Operating Condition . . . . . . . . . . . . . . 65
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65
•COOLER-CONDENSER
OPTIONAL PUMPOUT STORAGE TANK AND
PUMPOUT SYSTEM
MOTOR COMPRESSOR ASSEMBLY
Page
MOTOR COMPRESSOR LUBRICATION
SYSTEM
CONTROL SYSTEM
AUXILIARY EQUIPMENT
DESCRIBE CHILLER CYCLES
REVIEW MAINTENANCE
SAFETY DEVICES AND PROCEDURES
CHECK OPERATOR KNOWLEDGE
REVIEW THE START-UP, OPERATION, AND
MAINTENANCE MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check the Running System . . . . . . . . . . . . . . . . . . . . . 66
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66
Preparation for Extended Shutdown . . . . . . . . . . . . 66
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operating the Optional Pumpout Unit . . . . . . . . . . . 67
TO READ REFRIGERANT PRESSURES
Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69
TRANSFER REFRIGERANT FROM
PUMPOUT STORAGE TANK TO CHILLER
TRANSFER REFRIGERANT FROM
CHILLER TO PUMPOUT STORAGE TANK
Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70
TRANSFER ALL REFRIGERANT TO
CHILLER CONDENSER VESSEL
TRANSFER ALL REFRIGERANT TO
CHILLER COOLER VESSEL
RETURN CHILLER TO NORMAL
OPERATING CONDITIONS
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adding Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removing Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Test After Service, Repair, or Major Leak . . . . . . . . 71
TESTING WITH REFRIGERANT TRACER
TESTING WITHOUT REFRIGERANT TRACER
TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72
WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72
Check the Lubrication System . . . . . . . . . . . . . . . . . . 72
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74
4
CONTENTS (cont)
Page
Inspect Relief Valves and Piping. . . . . . . . . . . . . . . . . 74
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
COOLER AND FLOW DEVICES
CONDENSER AND FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75
Optional Pumpout System Maintenance. . . . . . . . . 75
OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking Display Messages. . . . . . . . . . . . . . . . . . . . . 76
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76
RESISTANCE CHECK
VOLTAGE DROP
CHECK SENSOR ACCURACY
DUAL TEMPERATURE SENSORS
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76
UNITS EQUIPPED WITH CVC
UNITS EQUIPPED WITH ICVC
TRANSDUCER REPLACEMENT
Control Algorithms Checkout Procedure . . . . . . . . 77
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
RED LED (Labeled as STAT)
GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88
• INPUTS
• OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88
• INPUTS
• OUTPUTS
Replacing Defective Processor Modules . . . . . . . . 88
• INSTALLATION
Solid-State Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
SCR REMOVAL/INSTALLATION
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124
INITIAL START-UP CHECKLIST FOR
19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16
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.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
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-
tures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the CVC/ICVC control panel (e.g., ,
, , , etc.).
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dis-
sipate body electrostatic charge before working inside con-
trol center.
Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may cause interference to radio com-
munications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Sub-
part J of Part 15 of FCC Rules, which are designed to pro-
vide reasonable protection against such interference when
operated in a commercial environment. Operation of this
equipment in a residential area is likely to cause interfer-
ence, in which case the user, at his own expense, will be
required to take whatever measures may be required to cor-
rect the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
CCM Chiller Control Module
CCN Carrier Comfort Network
CCW Counterclockwise
CVC Chiller Visual Controller
CW Clockwise
ECDW Entering Condenser Water
ECW Entering Chilled Water
EMS Energy Management System
HGBP Hot Gas Bypass
I/O Input/Output
ICVC International Chiller Visual Controller
ISM Integrated Starter Module
LCD Liquid Crystal Display
LCDW Leaving Condenser Water
LCW Leaving Chilled Water
LED Light-Emitting Diode
OLTA Overload Trip Amps
PIC II Product Integrated Controls II
RLA Rated Load Amps
SCR Silicon Controlled Rectifier
SI International System of Units
TXV Thermostatic Expansion Valve
VFD Variable Frequency Drive
ENTER
EXIT INCREASE QUIT
5
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.
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.
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
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 chillers capacity as
required to maintain proper leaving chilled water temperature.
The control panel:
registers cooler, condenser, and lubricating system
pressures
shows chiller operating condition and alarm shutdown
conditions
records the total chiller operating hours
sequences chiller start, stop, and recycle under 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).
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
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)
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
Compressor Code
(First Digit Indicates Compressor Frame Size)*
Motor Efficiency Code
H — High Efficiency
S — Standard Efficiency
Motor Code
BD CD DB EH
BE CE DC EJ
BF CL DD EK
BG CM DE EL
BH CN DF EM
CP DG EN
CQ DH EP
DJ
27 99 Q 59843
Week of Year
Year of Manufacture
Unique Number
Place of Manufacture
MODEL NUMBER NOMENCLATURE
SERIAL NUMBER BREAKDOWN
Cooler Size
10-12 (Frame 1 XR)
15-17 (Frame 1 XR)
20-22 (Frame 2 XR)
30-32 (Frame 3 XR)
35-37 (Frame 3 XR)
40-42 (Frame 4 XR)
45-47 (Frame 4 XR)
50-52 (Frame 5 XR)
5A (Frame 5 XR)
5B (Frame 5 XR)
5C (Frame 5 XR)
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)
*Second digit will be a letter (example 4G3)
on units equipped with split ring diffuser.
Fig. 1 19XR Identification
6
34
18 19 20 21 22
23
31 30 29 28 27 26 25 24
32
33 24
1
2
3
5
6
4
11
12
13
16
15 14
17
7
9
10
8
Fig. 2 Typical 19XR Components
LEGEND
1Guide Vane Actuator
2Suction Elbow
3Chiller Visual Controller/ International Chiller
Visual Control (CVC/ICVC)
4Chiller Identification Nameplate
5Cooler, Auto Reset Relief Valves
6Cooler Pressure Transducer
7Condenser In/Out Temperature Thermistors
8Condenser Waterflow Device (ICVC Inputs
available)
9Cooler 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
LEGEND
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
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
REAR VIEW
FRONT VIEW
7
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
one-inch FPT drain valve, and a 1/2-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.
After taking heat from the water, the refrigerant vapor is
compressed. Compression adds still more heat energy, and the
refrigerant is quite warm (typically 98 to 102 F [37 to 40 C])
when it is discharged from the compressor into the condenser.
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.
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.
Fig. 3 Refrigerant Motor Cooling and Oil Cooling Cycles
8
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.
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).
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
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.
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.
9
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.
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.
Circuit breaker CB2 supplies power to the control panel, oil
heater, and portions of the starter controls.
Circuit breaker CB3 supplies power to the oil pump. Both
CB2 and CB3 are wired in parallel with CB1 so that power is
supplied to them if the CB1 disconnect is open.
All starters must include a Carrier control module called the
Integrated Starter Module (ISM), excluding the Benshaw
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
Carriers Replacement Component Division [RCD]).
Unit-Mounted Solid-State Starter (Optional)
The 19XR chiller may be equipped with a solid-state, reduced-
voltage starter (Fig. 5 and 6). This starters 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.
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.
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.
REAR MOTOR
BEARING
ISOLATION
VALVE
SIGHT
GLASS
FILTER
ISOLATION
VALVE
FILTEREDUCTOR
OIL
PUMP
TXV BULB PRESSURE
TRANSDUCER
ISOLATION
VALVE
OIL
COOLER OIL PUMP
MOTOR
OIL
HEATER
MOTOR
COOLING LINE
LABYRINTH
GAS LINE
FWD MOTOR
BEARING
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
SIGHT GLASS
OIL SKIMMER LINE
Fig. 4 Lubrication System
10
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 Carriers 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
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device be-
cause its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL A discrete signal is a 2-position rep-
resentation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
5
1
2
3
6
4
7
LEGEND
Fig. 5 Solid-State Starter Box,
Internal View
1RediStart MICRO Input/Output Card
2Fuses 1-4 (Hidden, not depicted)
3Circuit Breaker 2 (CB2): Machine Control and Heater Power
4Circuit Breaker 3 (CB3): Oil Pump Power
5RediStart MICRO Central Processing Unit Card (CPU)
6RediStart MICRO Power Card (hidden, not depicted)
7RediStart MICRO Bypass Card (hidden, not depicted)
Fig. 6 Typical Starter External View
(Solid-State Starter Shown)
11
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.
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM
PRO-
GRAM
Forward
Reverse
ENTER
RUN
JOB
AUTO
MAN
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM
PROGRAM
Forward
Reverse
ENTER
RUN
JOB
AUTO
MAN
MANUAL RESET
OPTIONAL
METER
PACKAGE
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM
PROGRAM
Forward
Reverse
ENTER
RUN
JOB
AUTO
MAN
DANGER
HIGH VOLTAGE
+-
INITIAL DC BUS
MEASUREMENT
POINT
DC BUS BAR
MEASUREMENT
POINT
+
-
VFD
MODULE
COOLING LINES
COMPRESSOR
MOTOR
DISCONNECT TXV
CONTROL
AND OIL
HEATER
DISCONNECT
OIL PUMP
DISCONNECT
INTEGRATED
STARTER
MODULE
(ISM)
LINE
LOAD
Fig. 7 Variable Frequency Drive (VFD)
Fig. 8 Variable Frequency Drive (VFD) Starter Internal View
12
FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE
WATER
SENSOR
CABLES
WATER
SENSOR
CABLES
COOLER
PRESSURE
TRANSDUCER
CONNECTION
CONDENSER
PRESSURE
CABLE
SCHRADER
FITTING (HIDDEN)
CONDENSER
PRESSURE
TRANSDUCER
CONNECTION
CONDENSER
SERVICE
VALVE
COMPRESSOR
DISCHARGE
ELBOW JOINTS
MOTOR WINDING
TEMPERATURE
CABLE
DISCHARGE
ISOLATION
VALVE
(OPTIONAL)
TOP VIEW
COMPRESSOR DETAIL
Fig. 9 19XR Controls and Sensor Locations
13
The PIC II can interface with the Carrier Comfort Network
(CCN) if desired. It can communicate with other PIC I or PIC
II equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
control panel
all extra low-voltage wiring (24 v or less)
power panel
230 or 115 v control voltage (per job requirement)
up to 600 v for oil pump power
starter cabinet
chiller power wiring (per job requirement)
Table 1 Major PIC II Components and
Panel Locations*
*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,
ground fault, remote start contact, spare safety, condenser high
pressure, oil pump interlock, starter 1M, and run contacts. The
ISM contains logic capable of safety shutdown. It shuts down
the chiller if communications with the CVC/ICVC are lost.
The ISM can also act as the interface for PIC II to the VFD
controller.
CHILLER CONTROL MODULE (CCM) This module is
located in the control panel. The CCM provides the input and
outputs necessary to control the chiller. This module monitors
refrigerant pressure, entering and leaving water temperatures,
and outputs control for the guide vane actuator, oil heaters, and
oil pump. The CCM is the connection point for optional de-
mand limit, chilled water reset, remote temperature reset, re-
frigerant leak sensor and motor kilowatt output.
OIL HEATER CONTACTOR (1C) This contactor is lo-
cated in the power panel (Fig. 13) and operates the heater at
either 115 or 230 v. It is controlled by the PIC II to maintain oil
temperature during chiller shutdown. The XR4 with split ring
diffuser has a line voltage oil heater. Refer to the control panel
wiring schematic.
OIL PUMP CONTACTOR (2C) This contactor is located
in the power panel. It operates all 200 to 575-v oil pumps.
The PIC II energizes the contactor to turn on the oil pump as
necessary.
HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional) This relay, located in the power panel, controls
the opening of the hot gas bypass valve. The PIC II energizes
the relay during low load, high lift conditions.
CONTROL TRANSFORMERS (T1, T2) These transform-
ers convert incoming control voltage to 24 vac power for the
3 power panel contactor relays, CCM, and CVC/ICVC.
OPTIONAL TRANSFORMER (T3) This transformer pro-
vides control power to Dataport/DataLINK modules.
PIC II COMPONENT PANEL LOCATION
Chiller Visual Controller (CVC/ICVC) and
Display
Control Panel
Integrated Starter Module (ISM) Starter Cabinet
Chiller Control Module (CCM) Control Panel
Oil Heater Contactor (1C) Power Panel
Oil Pump Contactor (2C) Power Panel
Hot Gas Bypass Relay (3C) (Optional) Power Panel
Control Transformers (T1, T2) Power Panel
Temperature Sensors See Fig. 9.
Pressure Transducers See Fig. 9.
Fig. 10 Control Sensors (Temperature)
Fig. 11 Control Sensors
(Pressure Transducers, Typical)
14
Fig. 12 Control Panel
Fig. 13 Power Panel
15
CVC/ICVC Operation and Menus (Fig. 14-20)
GENERAL
The CVC/ICVC display automatically reverts to the
default screen after 15 minutes if no softkey activity
takes place and if the chiller is not in the pumpdown
mode (Fig. 14).
If a screen other than the default screen is displayed on
the CVC/ICVC, the name of that screen is in the upper
right corner (Fig. 15).
The CVC/ICVC may be set to display either English or
SI units. Use the CVC/ICVC configuration screen
(accessed from the Service menu) to change the units.
See the Service Operation section, page 45.
Local Operation The PIC II can be placed in local
operating mode by pressing the softkey. The
PIC II then accepts commands from the CVC/ICVC only
and uses the Local Time Schedule to determine chiller
start and stop times.
CCN Operation The PIC II can be placed in the CCN
operating mode by pressing the softkey. The PIC
II then accepts modifications from any CCN interface or
module (with the proper authority), as well as from the
CVC/ICVC. The PIC II uses the CCN time schedule to
determine start and stop times.
ALARMS AND ALERTS An alarm shuts down the 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.
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.
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.
Press the softkey to view the list of menu struc-
tures: , , , and
.
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.
For more information on the menu structures, refer to
Fig. 17.
Press the softkey that corresponds to the menu structure to
be viewed: , , or
. To view or change parameters within any of these
menu structures, use the and softkeys
to scroll down to the desired item or table. Use the
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.
LOCAL
CCN
RESET
MENU
STATUS SCHEDULE SETPOINT
SERVICE
STATUS SCHEDULE SETPOINT
SERVICE NEXT PREVIOUSSELECT
RUNNING TEMP CONTROL
LEAVING CHILLED WATER 01-01-95 11:48
28.8 HOURS
CHW IN CHW OUT EVAP REF
CDW IN CDW OUT COND REF
OIL PRESS OIL TEMP AMPS %
CCN LOCAL RESET MENU
55.1 44.1 40.7
85.0 95.0 98.1
21.8 132.9 93
PRIMARY STATUS
MESSAGE
COMPRESSOR
ON TIME
DATE TIME
SOFT KEYS MENU
LINE
EACH KEY'S FUNCTION IS
DEFINED BY THE MENU DESCRIPTION
ON MENU LINE ABOVE
ALARM LIGHT
(ILLUMINATED
WHEN POWER ON)
STOP BUTTON
HOLD FOR ONE
SECOND TO STOP
BLINKS CONTINUOUSLY
ON FOR AN ALARM
BLINKS ONCE TO
CONFIRM A STOP
SECONDARY
STATUS
MESSAGE
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
ALARM HISTORY
19XR_II SERVICE
Fig. 15 CVC/ICVC Service Screen
Fig. 14 CVC/ICVC Default Screen
16
Press to leave the selected decision or field with-
out saving any changes.
Press to leave the selected decision or field and
save changes.
Press to scroll the cursor bar down in order to
highlight a point or to view more points below the cur-
rent screen.
Press to scroll the cursor bar up in order to
highlight a point or to view points above the current
screen.
Press to view the next screen level (high-
lighted with the cursor bar), or to override (if allowable)
the highlighted point value.
Press to return to the previous screen level.
Press or to change the high-
lighted point value.
TO VIEW STATUS (Fig. 16) The status table shows the
actual value of overall chiller status such as CONTROL
MODE, RUN STATUS, AUTO CHILLED WATER RESET,
and REMOTE RESET SENSOR.
1. On the menu screen, press to view the list of
point status tables.
2. Press or to highlight the desired
status table. The list of tables is:
MAINSTAT Overall chiller status
STARTUP Status required to perform start-up of
chiller
COMPRESS Status of sensors related to the
compressor
HEAT_EX Status of sensors related to the heat
exchangers
POWER Status of motor input power
ISM_STAT Status of motor starter
CVC_PSWD Service menu password forcing
access screen
ICVC_PSWD Service menu password forcing
access screen
3. Press to view the desired point status table.
4. On the point status table, press or
until the desired point is displayed on the screen.
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press or
to highlight the desired value.
2. Press to select the highlighted value. Then:
QUIT
ENTER
NEXT
PREVIOUS
SELECT
EXIT
INCREASE DECREASE
STATUS
NEXT PREVIOUS
SELECT
NEXT PREVIOUS
NEXT
PREVIOUS
SELECT
19XR_II MAINSTAT POINT STATUS
Control Mode
Run Status
Start Inhibit Timer
Occupied?
System Alert/Alarm
Chiller Start/Stop
Remote Start Contact
Temperature Reset
Control Point
Chilled Water Temp
Active Demand Limit
Average Line Current
OFF
Ready
0.0 Min
NO
NORMAL
STOP
Open
0.0 F
44.0 F
44.6 F
100%
0.0%
Fig. 16 Example of Status Screen
17
CCN LOCAL RESET MENU
DEFAULT SCREEN
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms
STATUS SCHEDULE SETPOINT SERVICE
(SOFTKEYS)
Access Main Menu
List the
Status Tables
Display The Setpoint Table
(ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)
List the Service Tables
OCCPC01S LOCAL TIME SCHEDULE
OCCPC02S ICE BUILD TIME SCHEDULE
OCCPC03S CCN TIME SCHEDULE
List the Schedules
1
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
Base Demand Limit
LCW Setpoint
ECW Setpoint
Ice Build Setpoint
Tower Fan High Setpoint
EXIT
SELECT
PREVIOUS
NEXT
Select a Schedule
1
2
3
4
5
6
7
8
Override
ENABLE DISABLE
EXIT
SELECT
PREVIOUS
NEXT
Select a Time Period/Override
Modify a Schedule Time
ENTER EXIT
INCREASE DECREASE ENTER EXIT (ANALOG VALUES)
(DISCRETE VALUES)
Add/Eliminate a Day
111
Select a Status Table
NEXT PREVIOUS SELECT EXIT
START
ON
STOP
OFF
RELEASE ENTER
EXIT
NEXT PREVIOUS SELECT
ENTER
ENABLE DISABLE QUIT
DECREASE
INCREASE ENTER
RELEASE
Select a Modification Point
Modify a Discrete Point
Modify an Analog Point
Modify Control Options
MAINSTAT
STARTUP
COMPRESS
HEAT_EX
POWER
ISM_STAT
CVC_PSWD
Modify the Setpoint
DECREASE
INCREASE QUIT ENTER
NEXT PREVIOUS SELECT EXIT
Select the Setpoint
NEXT PREVIOUS SELECT EXIT
SEE FIGURE 18
Fig. 17 19XR Chiller Display Menu Structure (CVC/ICVC)
18
NEXT PREVIOUS SELECT EXIT
SERVICE TABLE
Display Alarm History
(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CCM Thermistors
CCM Pressure Transducers
Pumps
Discrete Outputs
Guide Vane Actuator
Diffuser Actuator
Pumpdown/Lockout
Terminate Lockout
Guide Vane Calibration
CONTINUED
ON NEXT PAGE
CONTROL ALGORITHM STATUS
CONTROL TEST
ALARM HISTORY
List the Control Tests
NEXT PREVIOUS SELECT EXIT
Select a Test
List the Control Algorithm Status Tables
CAPACITY (Capacity Control)
OVERRIDE (Override Status)
LL_MAINT (Lead Lag Status)
ISM_HIST (ISM Alarm History)
LOADSHED
WSMDEFME (Water System Manager Control Status)
OCCDEFCM (Time Schedule Status)
NEXT PREVIOUS SELECT EXIT
Select a Table
NET_OPT
BRODEF
OCCEFCS
HOLIDAYS
CONSUME
RUNTIME
(ANALOG VALUES)
(DISCRETE VALUES)
Select a Parameter
NEXT PREVIOUS SELECT EXIT
Modify a Parameter
ENTER
ENABLE DISABLE QUIT
DECREASE
INCREASE ENTER
QUIT
NEXT PREVIOUS SELECT EXIT
Select a Table
EQUIPMENT CONFIGURATION List the Equipment Configuration Tables
CAPACITY (Capacity Control Algorithm)
OVERRIDE (Override Status)
LL_MAINT (LEADLAG Status)
WSMDEFM2 (Water System Manager Control Status)
Maintenance Table Data
NEXT PREVIOUS SELECT EXIT
Data Select Table
OCCPC01S (Local Status)
OCCPC02S (CCN, ICE BUILD Status)
OCCPC03S (CCN Status)
OCCDEFM (Time Schedule Status)
ICVC CONFIGURATION
SELECT (USE ENTER) TO SCROLL DOWN
LID LANGUAGE
INCREASE DECREASE ENTER EXIT
Fig. 18 19XR Service Menu Structure
19
NEXT PREVIOUS SELECT EXIT
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
Select a Service Table
Select a Service Table Parameter
NEXT PREVIOUS SELECT EXIT
Modify a Service Table Parameter
(ANALOG VALUES)
(DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:
To Modify Current Time Day of Week
Current Date Holiday Today
ATTACH TO NETWORK DEVICE
ENTER
DECREASE
INCREASE EXIT
ENTER
ENABLE DISABLE QUIT
DECREASE
INCREASE ENTER
QUIT
Select a Device
ATTACH
NEXT PREVIOUS SELECT
Modify Device Address
EXIT
INCREASE DECREASE ENTER
Use to attach CVC to another CCN network or device
Attach to "LOCAL" to enter this machine
To upload new tables
Default Screen
MENU
RESET
CCN LOCAL
LOG OUT OF DEVICE
List Network Devices
Local
Device 1
Device 2
Device 3
Device 4
Device 5
Device 6
Device 7
Device 8
Device 9
Service Tables:
OPTIONS
SETUP1
SETUP2
LEADLAG
RAMP_DEM
TEMP_CTL
EQUIPMENT SERVICE
ISM (STARTER) CONFIG DATA
Service Tables:
ISM (STARTER) CONFIG PASSWORD
ISM_CONF
(ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)
4444
CVC CONFIGURATION
EXIT
INCREASE DECREASE ENTER
CVC Configuration Table
To Modify CVC CCN Address
English (U.S. IMP.) or S.I. Metric Units
Password
To View CVC Software Version
(last 2 digits of part number
indicate software version)
ENTER
NO
YES EXIT
(ANALOG VALUE)
(DISCRETE VALUE)
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)
20
For Discrete Points Press or to se-
lect the desired state.
For Analog Points Press or
to select the desired value.
3. Press to register the new value.
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.
To Remove an Override
1. On the point status table press or
to highlight the desired value.
2. Press to access the highlighted value.
3. Press to remove the override and return the
point to the PIC IIs 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 .
2. Press or to highlight the desired
schedule.
OCCPC01S LOCAL Time Schedule
OCCPC02S ICE BUILD Time Schedule
OCCPC03S CCN Time Schedule
3. Press to view the desired time schedule.
4. Press or to highlight the desired
period or override to change.
5. Press to access the highlighted period or
override.
6. a. Press or to change the
time values. Override values are in one-hour
increments, up to 4 hours.
b. Press to select days in the day-of-week
fields. Press to eliminate days from the
period.
START STOP
INCREASE
DECREASE
ENTER
NEXT PREVIOUS
SELECT
RELEASE
SCHEDULE
NEXT PREVIOUS
SELECT
NEXT PREVIOUS
SELECT
INCREASE DECREASE
ENABLE
DISABLE
Fig. 19 Example of Time Schedule
Operation Screen
21
7. Press to register the values and to move hori-
zontally (left to right) within a period.
8. Press to leave the period or override.
9. Either return to Step 4 to select another period or over-
ride, or press again to leave the current time
schedule screen and save the changes.
10. The Holiday Designation (HOLIDEF table) may be
found in the Service Operation section, page 45. The
month, day, and duration for the holiday must be
assigned. The Broadcast function in the BRODEF
table also must be enabled for holiday periods to
function.
TO VIEW AND CHANGE SET POINTS (Fig. 20)
1. To view the SETPOINT table, from the MENU screen
press .
2. There are 5 set points on this screen: BASE DEMAND
LIMIT, LCW SETPOINT (leaving chilled water set
point), ECW SETPOINT (entering chilled water set
point), ICE BUILD SETPOINT, and TOWER FAN
HIGH SETPOINT. Only one of the chilled water set
points can be active at one time. The set point that is
active is determined from the SERVICE menu. See the
Service Operation section, page 45. The ice build (ICE
BUILD) function is also activated and configured from
the SERVICE menu.
3. Press or to highlight the desired
set point entry.
4. Press to modify the highlighted set point.
5. Press or to change the select-
ed set point value.
6. Press to save the changes and return to the pre-
vious screen.
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.
ENTER
EXIT
EXIT
SETPOINT
NEXT PREVIOUS
SELECT
INCREASE DECREASE
ENTER
19XR_II SETPOINT SELECT
SETPOINT
Base Demand Limit
Control Point
LCW Setpoint
ECW Setpoint
ICE BUILD Setpoint
Tower Fan High Setpoint
100%
50.0 F
60.0 F
40.0 F
85.0 F
Fig. 20 Example of Set Point Screen
22
Table 2 CVC/ICVC Display Data
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.
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
is, written to) by the CCN, BS, and the CVC/ICVC. Capitalized
Reference Point Names preceded by two asterisks can be
changed only from the CVC/ICVC. Reference Point Names in
lower case type can be viewed by CCN or BS only by viewing the
whole table.
7. Alarms and Alerts: An asterisk in the far right field of a CVC/
ICVC status screen indicates that the chiller is in an alarm state;
an exclamation point in the far right field of the CVC/ICVC screen
indicates an alert state. The asterisk (or exclamation point) indi-
cates that the value on that line has exceeded (or is approach-
ing) a limit. For more information on alarms and alerts, see the
Alarms and Alerts section, page 15.
LEGEND
EXAMPLE 1 CHILLER DISPLAY DEFAULT SCREEN
The following data is displayed in the Default screen.
NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC/ICVC only.
IMPORTANT: The following notes apply to all Table 2
examples.
NEXT PREVIOUS
NEXT
PREVIOUS
SERVICE
CCN Carrier Comfort Network
CHW Chilled Water
CHWR Chilled Water Return
CHWS Chilled Water Supply
CVC Chiller Visual Controller
CT Current Transformer
ECW Entering Chilled Water
HGBP Hot Gas Bypass
ICVC International Chiller Visual Controller
ISM Integrated Starter Module
LCW Leaving Chilled Water
LRA Locked Rotor Amps
mA Milliamps
PPressure
PIC II Product Integrated Controls II
SS Solid State
TTemperature
VFD Variable Frequency Drive
WSM Water System Manager
DESCRIPTION STATUS UNITS REFERENCE POINT NAME
(ALARM HISTORY) DISPLAY
(PRIMARY MESSAGE)
(SECONDARY MESSAGE)
(DATE AND TIME)
Compressor Ontime 0-500000.0 HOURS C_HRS
Entering Chilled Water 40-245 DEG F ECW CHW IN
Leaving Chilled Water 40-245 DEG F LCW CHW OUT
Evaporator Temperature 40-245 DEG F ERT EVAP REF
Entering Condenser Water 40-245 DEG F ECDW CDW IN
Leaving Condenser Water 40-245 DEG F LCDW CDW OUT
Condenser Temperature 40-245 DEG F CRT COND REF
Oil Pressure 0-420 PSI OILPD OILPRESS
Oil Sump Temp 40-245 DEG F OILT OIL TEMP
Average Line Current 0-999 % AMPS_% AMPS%
0-1 CCN
0-1 LOCAL
0-1 RESET
23
Table 2 CVC/ICVC Display Data (cont)
EXAMPLE 2 MAINTSTAT DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press .
2. Press ( will be highlighted).
3. Press .
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 .
2. Press .
3. Scroll down to highlight .
4. Press .
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.
DESCRIPTION STATUS UNITS POINT
Control Mode NOTE 1 NOTE 1 MODE
Run Status NOTE 2 NOTE 2 STATUS
Start Inhibit Timer 0-15 min T_START
Occupied? 0/1 NO/YES OCC
System Alert/Alarm 0-2 NOTE 3 SYS_ALM
*Chiller Start/Stop 0/1 STOP/START CHIL_S_S
*Remote Start Contact 0/1 OPEN/CLOSE REMCON
Temperature Reset 30-30 DEG F T_RESET
*Control Point 10-120 DEG F LCW_STPT
Chilled Water Temp 40-245 DEG F CHW_TMP
*Active Demand Limit 40-100 % DEM_LIM
Average Line Current 0-999 % %_AMPS
Motor Percent Kilowatts 0-999 % KW_P
Auto Demand Limit Input 4-20 mA AUTODEM
Auto Chilled Water Reset 4-20 mA AUTORES
Remote Reset Sensor 40-245 DEG F R_RESET
Total Compressor Starts 0-99999 c_starts
Starts in 12 Hours 0-8 STARTS
Compressor Ontime 0-500000.0 HOURS c_hrs
*Service Ontime 0-32767 HOURS S_HRS
Ice Build Contact 0-1 OPEN/CLOSE ICE_CON
Refrigerant Leak Sensor 0-20 mA REF_LEAK
DESCRIPTION STATUS UNITS POINT
Actual Guide Vane Pos 0-100 % GV_ACT
**Chilled Water Pump 0-1 OFF/ON CHWP
Chilled Water Flow 0-1 NO/YES CHW_FLOW
**Condenser Water Pump 0-1 OFF/ON CDP
Condenser Water Flow 0-1 NO/YES CDW_FLOW
Oil Pump Relay 0-1 OFF/ON OILR
**Oil Pump Delta P 6.7-200 ^PSI OILPD
Compressor Start Relay 0-1 OFF/ON CMPR
Compressor Start Contact 0-1 OPEN/CLOSED CR_AUX
Starter Trans Relay 0-1 OFF/ON CMPTRANS
Compressor Run Contact 0-1 OPEN/CLOSED RUN_AUX
**Tower Fan Relay Low 0-1 OFF/ON TFR_LOW
**Tower Fan Relay High 0-1 OFF/ON TFR_HIGH
Starter Fault 0-1 ALARM/NORMAL STR_FLT
Spare Safety Input 0-1 ALARM/NORMAL SAFETY
Shunt Trip Relay 0-1 OFF/ON TRIPR
ISM Fault Status 0-255 STRSTAT
MENU
STATUS MAINSTAT
SELECT
MENU
STATUS
STARTUP
SELECT
24
Table 2 CVC/ICVC Display Data (cont)
EXAMPLE 4 COMPRESS DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
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 .
2. Press .
3. Scroll down to highlight .
4. Press .
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.
DESCRIPTION STATUS UNITS POINT
Actual Guide Vane Pos 0-100 % GV_ACT
Guide Vane Delta 0-100 % GV_DELTA
**Target Guide Vane Pos 0-100 % GV_TRG
Oil Sump Temp 40-245 DEG F OILT
**Oil Pump Delta P 6.7-200 ^PSI OILPD
Comp Discharge Temp 40-245 DEG F CMPD
Comp Thrust Brg Temp 40-245 DEG F MTRB
Comp Motor Winding Temp 40-245 DEG F MTRW
Spare Temperature 1 40-245 DEG F SPARE1
Spare Temperature 2 40-245 DEG F SPARE2
Oil Heater Relay 0/1 OFF/ON OILH
Diffuser Actuator 0-100 % DIFF_ACT
**Target VFD Speed 0-100 % VFD_OUT
**Actual VFD Speed 0-110 % VFD_ACT
Surge Protection Counts 0-5 SPC
DESCRIPTION STATUS UNITS POINT
**Chilled Water Delta P 6.7-420 PSI CHW_PD
Entering Chilled Water 40-245 DEG F ECW
Leaving Chilled Water 40-245 DEG F LCW
Chilled Water Delta T 6.7-420 ^F CHW_DT
Chill Water Pulldown/Min 20-20 ^F CHW_PULL
Evaporator Refrig Temp 40-245 DEG F ERT
**Evaporator Pressure 6.7-420 PSI ERP
Evaporator Approach 0-99 ^F EVAP_APP
**Condenser Water Delta P 6.7-420 PSI COND_PD
Entering Condenser Water 40-245 DEG F ECDW
Leaving Condenser Water 40-245 DEG F LCDW
Condenser Refrig Temp 40-245 DEG F CRT
**Condenser Pressure 6.7-420 PSI CRP
Condenser Approach 0-99 ^F COND_APP
Hot Gas Bypass Relay 0/1 OFF/ON HGBR
Surge / HGBP Active? 0/1 NO/YES SHG_ACT
Active Delta P 0-200 PSI dp_a
Active Delta T 0-200 DEG F dt_a
Surge / HGBP Delta T 0-200 DEG F dt_c
Head Pressure Reference 0-100 % hpr
Evaporator Saturation Temp
(ICVC only)
40-245 ^F EST
MENU
STATUS
COMPRESS
SELECT
MENU
STATUS
HEAT_EX
SELECT
25
Table 2 CVC/ICVC Display Data (cont)
EXAMPLE 6 POWER DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
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 .
2. Press .
3. Scroll down to highlight .
4. Press .
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
DESCRIPTION STATUS UNITS POINT
Average Line Current 0-999 % %_AMPS
Actual Line Current 0-99999 AMPS AMP_A
Average Line Voltage 0-999 % VOLT_P
Actual Line Voltage 0-99999 VOLTS VOLT_A
Power Factor 0.0-1.0 PF
Motor Kilowatts 0-99999 kW KW_A
**Motor Kilowatt-Hours 0-99999 kWH KWH
Demand Kilowatts 0-99999 kWH DEM_KWH
Line Current Phase 1 0-99999 AMPS AMPS_1
Line Current Phase 2 0-99999 AMPS AMPS_2
Line Current Phase 3 0-99999 AMPS AMPS_3
Line Voltage Phase 1 0-99999 VOLTS VOLTS_1
Line Voltage Phase 2 0-99999 VOLTS VOLTS_2
Line Voltage Phase 3 0-99999 VOLTS VOLTS_3
Ground Fault Phase 1 0-999 AMPS GF_1
Ground Fault Phase 2 0-999 AMPS GF_2
Ground Fault Phase 3 0-999 AMPS GF_3
Frequency 0-99 Hz FREQ
I2T Sum Heat-Phase 1 0-200 % HEAT1SUM
I2T Sum Heat-Phase 2 0-200 % HEAT2SUM
I2T Sum Heat-Phase 3 0-200 % HEAT3SUM
DESCRIPTION STATUS UNITS POINT
ISM Fault Status 0-223 ISMFLT
Single Cycle Dropout 0-1 NORMAL/ALARM CYCLE_1
Phase Loss 0-1 NORMAL/ALARM PH_LOSS
Overvoltage 0-1 NORMAL/ALARM OV_VOLT
Undervoltage 0-1 NORMAL/ALARM UN_VOLT
Current Imbalance 0-1 NORMAL/ALARM AMP_UNB
Voltage Imbalance 0-1 NORMAL/ALARM VOLT_UNB
Overload Trip 0-1 NORMAL/ALARM OVERLOAD
Locked Rotor Trip 0-1 NORMAL/ALARM LRATRIP
Starter LRA Trip 0-1 NORMAL/ALARM SLRATRIP
Ground Fault 0-1 NORMAL/ALARM GRND_FLT
Phase Reversal 0-1 NORMAL/ALARM PH_REV
Frequency Out of Range 0-1 NORMAL/ALARM FREQFLT
ISM Power on Reset 0-1 NORMAL/ALARM ISM_POR
Phase 1 Fault 0-1 NORMAL/ALARM PHASE_1
Phase 2 Fault 0-1 NORMAL/ALARM PHASE_2
Phase 3 Fault 0-1 NORMAL/ALARM PHASE_3
1CR Start Complete 0-1 FALSE/TRUE START_OK
1M Start/Run Fault 0-1 NORMAL/ALARM 1M_FLT
2M Start/Run Fault 0-1 NORMAL/ALARM 2M_FLT
Pressure Trip Contact 0-1 NORMAL/ALARM PRS_RIP
Starter Fault 0-1 NORMAL/ALARM STRT_FLT
Motor Amps Not Sensed 0-1 NORMAL/ALARM NO_AMPS
Starter Acceleration Fault 0-1 NORMAL/ALARM ACCELFLT
High Motor Amps 0-1 NORMAL/ALARM HIGHAMPS
1CR Stop Complete 0-1 FALSE/TRUE STOP_OK
1M/2M Stop Fault 0-1 NORMAL/ALARM 1M2MSTOP
Motor Amps When Stopped 0-1 NORMAL/ALARM AMPSTOP
Hardware Failure 0-1 NORMAL/ALARM HARDWARE
MENU
STATUS
POWER
SELECT
MENU
STATUS
ISM_STAT
SELECT
26
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 .
2. Press .
3. Scroll down to highlight .or
4. Press .
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 .
2. Press .
3. Press .
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 .
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
screen.
DESCRIPTION STATUS UNITS POINT
Disable Service Password 0-1 DSABLE/ENABLE PSWD_DIS
**Remote Reset Option 0-1 DSABLE/ENABLE RESETOPT
Reset Alarm? 0-1 NO/YES REMRESET
CCN Mode? 0-1 NO/YES REM_CCN
DESCRIPTION STATUS UNITS POINT DEFAULT
Base Demand Limit 40-100 % DLM 100
Control Point
ECW Setpoint 15-120 DEG F ecw_sp 60.0
LCW Setpoint 10-120 DEG F lcw_sp 50.0
Ice Build Setpoint 15-60 DEG F ice_sp 40.0
Tower Fan High Setpoint 55-105 DEG F tf2_sp 75
DESCRIPTION STATUS UNITS POINT
Entering Chilled Water 40-245 DEG F ECW
Leaving Chilled Water 40-245 DEG F LCW
Capacity Control
Control Point 10-120 DEG F ctrlpt
Control Point Error 99-99 ^F cperr
ECW Delta T 99-99 ^F ecwdt
ECW Reset 99-99 ^F ecwres
LCW Reset 99-99 ^F lcwres
Total Error + Resets 99-99 ^F error
Guide Vane Delta 2-2 % gvd
Target Guide Vane Pos 0-100 % GV_TRG
Actual Guide Vane Pos 0-100 % GV_ACT
Target VFD Speed 0-100 % VFD_IN
Actual VFD Speed 0-100 % VFD_ACT
VFD Gain 0.1-1.5 vfd_gain
Demand Limit Inhibit 0-100 % DEM_INH
Amps/kW Ramp 0-100 % DMD_RAMP
VFD Load Factor 0-200 VFD_LF
MENU
STATUS
CVC ICVC
SELECT
MENU
SETPOINT
SELECT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
CAPACITY
SELECT
27
Table 2 CVC/ICVC Display Data (cont)
EXAMPLE 11 OVERRIDE 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
screens.
EXAMPLE 12 LL_MAINT 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 .
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.
DESCRIPTION STATUS UNITS POINT
Comp Motor Winding Temp 40-245 DEG F MTRW
Comp Motor Temp Override 150-200 DEG F mt_over
Condenser Pressure 0-420 PSI CRP
Cond Press Override 90-180 PSI cp_over
Evaporator Refrig Temp 40-245 DEG F ERT
Evap Ref Override Temp 2-45 DEG F rt_over
Comp Discharge Temp 40-245 DEG F CMPD
Comp Discharge Alert 125-200 DEG F cd_alert
Comp Thrust Brg Temp 40-245 DEG F MTRB
Comp Thrust Brg Alert 165-185 DEG F tb_alert
Actual Superheat 20-99 ^F SUPRHEAT
Superheat Required 6-99 ^F SUPR_REQ
Condenser Refrig Temp 40-245 DEG F CRT
DESCRIPTION STATUS UNITS POINT
LeadLag Control
LEADLAG: Configuration NOTE 1 leadlag
Current Mode NOTE 2 llmode
Load Balance Option 0/1 DSABLE/ENABLE loadbal
LAG START Time 2-60 MIN lagstart
LAG STOP Time 2-60 MIN lagstop
Prestart Fault Time 2-30 MIN preflt
Pulldown: Delta T / Min x.xx ^F pull_dt
Satisfied? 0/1 NO/YES pull_sat
LEAD CHILLER in Control 0/1 NO/YES leadctrl
LAG CHILLER: Mode NOTE 3 lagmode
Run Status NOTE 4 lagstat
Start/Stop NOTE 5 lag_s_s
Recovery Start Request 0/1 NO/YES lag_rec
STANDBY CHILLER: Mode NOTE 3 stdmode
Run Status NOTE 4 stdstat
Start/Stop NOTE 5 Std_s_s
Recovery Start Request 0/1 NO/YES std_rec
Spare Temperature 1 40-245 DEG F SPARE_1
Spare Temperature 2 40-245 DEG F SPARE_2
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
OVERRIDE
SELECT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
LL_MAINT.
SELECT
28
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
screens.
EXAMPLE 14 WSMDEFME 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
screens.
DESCRIPTION STATUS UNITS POINT
ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1 0-99999 AMPS AMPS_1F
Line Current Phase 2 0-99999 AMPS AMPS_2F
Line Current Phase 3 0-99999 AMPS AMPS_3F
Line Voltage Phase 1 0-99999 VOLTS VOLTS_1F
Line Voltage Phase 2 0-99999 VOLTS VOLTS_2F
Line Voltage Phase 3 0-99999 VOLTS VOLTS_3F
Ground Fault Phase 1 0-999 AMPS GF_1F
Ground Fault Phase 2 0-999 AMPS GF_2F
Ground Fault Phase 3 0-999 AMPS GF_3F
I2T Sum Heat-Phase 1 0-200 % HEAT1SUMF
I2T Sum Heat-Phase 2 0-200 % HEAT2SUMF
I2T Sum Heat-Phase 3 0-200 % HEAT3SUMF
Phase 1 Faulted? 0/1 NO/YES PH1_FLT
Phase 2 Faulted? 0/1 NO/YES PH2_FLT
Phase 3 Faulted? 0/1 NO/YES PH3_FLT
Line Frequency 0-99 Hz FREQ_ F
ISM Fault Status 0-9999 ISM_STAT
DESCRIPTION STATUS UNITS POINT
WSM Active? 0/1 NO/YES WSMSTAT
Chilled Water Temp 0.0-99.9 DEG F CHWTEMP
Equipment Status 0/1 OFF/ON CHLRST
Commanded State XXXXXXXX TEXT CHLRENA
CHW setpt Reset Value 0.0-25.0 DEG F CHWRVAL
Current CHW Set Point 0.0-99.9 DEG F CHWSTPT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
ISM_HIST
SELECT
MENU
SERVICE
CONTROL ALGORITHM STATUS
SELECT
WSMDEFME
SELECT
29
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 .
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 16 ISM_CONF DISPLAY SCREEN
To access this display from the CVC/ICVC default screen:
1. Press .
2. Press .
3. Scroll down to highlight .
4. Press .
5. Enter password (4444 Factory Default).
6. Scroll down to highlight .
7. Press .
DESCRIPTION STATUS UNITS POINT DEFAULT
Loadshed Function
Group Number 0-99 ldsgrp 0
Demand Limit Decrease 0-60 % ldsdelta 20
Maximum Loadshed Time 0-120 MIN maxldstm 60
CCN Occupancy Config:
Schedule Number 3-99 occpcxxe 3
Broadcast Option 0-1 DSABLE/ENABLE occbrcst DSABLE
Alarm Configuration
Re-Alarm Time 0-1440 MIN 30
Alarm Routing 0-1 10000000
DESCRIPTION STATUS UNITS POINT DEFAULT
Starter Type 0-2 starter 1
(0 = Full, 1 = Red, 2 = SS/VFD)
Motor Rated Line Voltage 200-13200 VOLTS v_fs 460
Volt Transformer Ratio:1 1-35 vt_rat 1
Overvoltage Threshold 105-115 % overvolt 115
Undervoltage Threshold 85-95 % undvolt 85
Over/Under Volt Time 1-10 SEC uvuntime 5
Voltage % Imbalance 1-10 % v_unbal 10
Voltage Imbalance Time 1-10 SEC v_time 5
Motor Rated Load Amps 10-5000 AMPS a_fs 200
Motor Locked Rotor Trip 100-60000 AMPS motor_lr 1000
Locked Rotor Start Delay 1-10 cycles lrdelay 5
Starter LRA Rating 100-60000 AMPS start_lr 2000
Motor Current CT Ratio:1 3-1000 ct_turns 100
Current % Imbalance 5-40 % c_unbal 15
Current Imbalance Time 1-10 SEC c_time 5
Grnd Fault CTs? 0-1 NO/YES gf_phase YES
Ground Fault CT Ratio:1 150 gf_ctr 150
Ground Fault Current 1-25 AMPS gf_amps 15
Ground Fault Start Delay 1-20 cycles gf_delay 10
Ground Fault Persistence 1-10 cycles gf_pers 5
Single Cycle Dropout 0/1 DSABLE/ENABLE cycdrop DSABLE
Frequency = 60 Hz? (No = 50) 0/1 NO/YES freq YES
Line Frequency Faulting 0/1 DSABLE/ENABLE freq_en DSABLE
MENU
SERVICE
EQUIPMENT CONFIGURATION
SELECT
NET_OPT
SELECT
MENU
SERVICE
ISM (STARTER) CONFIG DATA
SELECT
ISM_CONF
SELECT
30
Table 2 CVC/ICVC Display Data (cont)
EXAMPLE 17 OPTIONS 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 18 SETUP1 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; forcing shall not be supported on service screens.
DESCRIPTION STATUS UNITS POINT DEFAULT
Auto Restart Option 0/1 DSABLE/ENABLE start DSABLE
Remote Contacts Option 0/1 DSABLE/ENABLE r_contact DSABLE
Soft Stop Amps Threshold 40-100 % softstop 100
Surge / Hot Gas Bypass
Surge Limit/HGBP Option 0/1 srg_hgbp 0
Select: Surge=0, HGBP=1
Min. Load Point (T1,P1)
Surge/HGBP Delta T1 0.5-20 ^F hgb_dt1 1.5
Surge/HGBP Delta P1 30-170 PSI hgb_dp1 50
Full Load Point (T2,P2)
Surge/HGBP Delta T2 0.5-20 ^F hbg_dt2 10
Surge/HGBP Delta P2 50-170 PSI hgb_dp2 85
Surge/HGBP Deadband 0.5-3 ^F hbg_db 1
Surge Protection
Surge Delta% Amps 5-20 % surge_a 10
Surge Time Period 7-10 MIN surge_t 8
Ice Build Control
Ice Build Option 0/1 DSABLE/ENABLE ibopt DSABLE
Ice Build Termination 0-2 ibterm 0
0=Temp, 1=Contacts, 2=Both
Ice Build Recycle 0/1 DSABLE/ENABLE ibrecyc DSABLE
Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE
Refrigerant Leak Alarm mA 4-20 mA REF_LEAK 20
Head Pressure Reference
Delta P at 0% (4mA) 20-60 PSI HPDPO 25
Delta P at 100% (20mA) 20-60 PSI HPDP100 35
Minimum Output 0-100 % HPDPMIN% 0
DESCRIPTION STATUS UNITS POINT DEFAULT
Comp Motor Temp Override 150-200 DEG F mt_over 200
Cond Press Override 90-165 PSI cp_over 125
Comp Discharge Alert 125-200 DEG F cd_alert 200
Comp Thrust Brg Alert 165-185 DEG F tb_alert 175
Chilled Medium 0/1 WATER/BRINE medium WATER
Chilled Water Deadband .5-2.0 ^F cw _db 1.0
Evap Refrig Trippoint 0.0-40.0 DEG F ert_trip 33
Refrig Override Delta T 2.0-5.0 ^F ref_over 3
Condenser Freeze Point 20 - 35 DEG F cdfreeze 34
Evap Flow Delta P Cutout 0.5 - 50.0 PSI evap_cut 5.0
Cond Flow Delta P Cutout 0.5 - 50.0 PSI cond_cut 5.0
Water Flow Verify Time 0.5-5 MIN wflow_t 5
Oil Pressure Verify Time 15-300 SEC oilpr_t 40
Recycle Control
Restart Delta T 2.0-10.0 DEG F rcycr_dt 5
Shutdown Delta T 0.5-4.0 DEG F rcycs_dt 1
SPARE ALERT/ALARM ENABLE
Disable=0, Lo=1/3, Hi=2/4
Spare Temp #1 Enable 0-4 sp1_en 0
Spare Temp #1 Limit 40-245 DEG F sp1_lim 245
Spare Temp #2 Enable 0-4 sp2_ en 0
Spare Temp #2 Limit 40-245 DEG F sp2_ lim 245
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
OPTIONS
SELECT
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
SETUP1
SELECT
31
Table 2 CVC/ICVC Display Data (cont)
EXAMPLE 19 SETUP2 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; 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 .
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.
DESCRIPTION STATUS UNITS POINT DEFAULT
Capacity Control
Proportional Inc Band 2-10 gv_inc 6.5
Proportional DEC Band 2-10 gv_dec 6.0
Proportional ECW Band 1-3 gw_ecw 2
Guide Vane Travel Limit 30-100 % gv_lim 80
Diffuser Control
Diffuser Option 0-1 DSABLE/ENABLE diff_opt DSABLE
Guide Vane 25% Load Pt 0-78 % gv_25 25
Diffuser 25% Load Point 0-100 % df_25 0
Guide Vane 50% Load Pt 0-78 % gv_50 50
Diffuser 50% Load Point 0-100 % df_50 0
Guide Vane 75% Load Pt 0-78 % gv_75 75
Diffuser 75% Load Point 0-100 % df_75 0
Diffuser Full Span mA 15-22 mA diff_ma 18
VFD Speed Control
VFD Option 0/1 DSABLE/ENABLE vfd_opt DSABLE
VFD Gain 0.1-1.5 vfd_gain 0.75
VFD Increase Step 1-5 % vfd_step 2
VFD Minimum Speed 65-100 % vfd_min 70
VFD Maximum Speed 90-100 % vfd_max 100
VFD Current Limit 0-99999 Amps vfdlim_i 250
DESCRIPTION STATUS UNITS POINT DEFAULT
Lead Lag Control
LEAD/LAG: Configuration 0-3 leadlag 0
DSABLE=0, Lead=1
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE load/bal DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE commsens DSABLE
LAG % Capacity 25-75 % lag_per 50
LAG Address 1-236 lag_add 92
LAG START Timer 2-60 MIN lagstart 10
LAG STOP Timer 2-60 MIN lagstop 10
PRESTART FAULT Timer 2-30 MIN preft 5
STANDBY Chiller Option 0/1 DSABLE/ENABLE stndopt DSABLE
STANDBY % Capacity 25-75 % stnd_per 50
STANDBY Address 1-236 stnd_add 93
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
SETUP2
SELECT
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
LEADLAG
SELECT
32
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 .
DESCRIPTION STATUS UNITS POINT DEFAULT
Pulldown Ramp Type: 0/1 ramp_opt 1
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source 0/1 dem_src 0
Select: Amps=0, kW=1
Motor Load Ramp% Min 5-20 kw_ramp 10
Demand Limit Prop Band 3-15 % dem_prop 10
Demand Limit At 20 mA 40-100 % dem_20ma 40
20 mA Demand Limit Opt 0/1 DSABLE/ENABLE dem_sel DSABLE
Motor Rated Kilowatts 50-9999 kW motor_kw 145
Demand Watts Interval 5-60 MIN dw_int 15
DESCRIPTION STATUS UNITS POINT DEFAULT
Control Point
ECW Control Option 0/1 DSABLE/ENABLE ecw_opt DSABLE
Temp Pulldown Deg/Min 2-10 ^F temp_ramp 3
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA 30- 30 ^F deg_20ma 10
RESET TYPE 2
Remote Temp > No Reset 40-245 DEG F res_rt1 85
Remote Temp > Full Reset 40-245 DEG F res_rt2 65
Degrees Reset 30-30 ^F deg_rt 10
RESET TYPE 3
CHW Delta T > No Reset 0-15 ^F restd_1 10
CHW Delta T > Full Reset 0-15 ^F restd_2 0
Degrees Reset 30-30 ^F deg_chw 5
Select/Enable Reset Type 0-3 res_sel 0
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
RAMP_DEM
SELECT
MENU
SERVICE
EQUIPMENT SERVICE
SELECT
TEMP_CTL
SELECT
33
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
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 IGVs
and VFD SPEED will be affected by the GUIDE VANE DEL-
TA and the Surge Control Algorithm can be seen below:
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
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.
The Proportional Band There are two response modes, one
for temperature response above the control point, the other for
the response below the control point.
The temperature response above the control point is called
the PROPORTIONAL INC BAND, and it can slow or quicken
guide vane response to chilled water/brine temperatures above
the DEADBAND. The PROPORTIONAL INC BAND can be
adjusted from a setting of 2 to 10; the default setting is 6.5.
The response below the control point is called the 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.
GUIDE VANE
DELTA
NORMAL
CONTROL
MODE
SURGE
PREVENTION
MODE
IGV VFD IGV VFD
From +0.2 to +2.0 1st 2nd 2nd 1st
From 0.2 to 2.0 2nd 1st 1st
ENTER EXIT
34
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.
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.
These schedules can be set up to follow a buildings 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.
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
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
excessive motor acceleration time
excessive starter transition time
lack of motor current signal
excessive motor amps
excessive compressor surge
temperature and transducer faults
*Superheat is the difference between saturation temperature
and sensible temperature. The high discharge temperature
safety measures only sensible temperature.
Starter faults or optional protective devices within the starter
can shut down the chiller. The protective devices you have for
your application depend on what options were purchased.
If 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
chillers 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.
If compressor motor overload occurs, check the motor for
grounded or open phases before attempting a restart.
35
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. If
the value in alarm is one normally displayed on the default
screen, it flashes between normal and reverse video. The CVC/
ICVC default screen remains frozen until the condition that
caused the alarm is remedied by the operator. Use CVC/ICVC
display and alarm shutdown record sheet (CL-13) to record all
values from default screen freeze.
Knowledge of the operating state of the chiller at the time an
alarm occurs is useful when troubleshooting. Additional chiller
information can be viewed on the status screens and the
ISM_HIST screen. Troubleshooting information is recorded in
the ALARM HISTORY table, which can be accessed from the
SERVICE menu.
To determine what caused the alarm, the operator should
read both the primary and secondary default screen messages,
as well as the alarm history. The primary message indicates the
most recent alarm condition. The secondary message gives
more detail on the alarm condition. Since there may be more
than one alarm condition, another alarm message may appear
after the first condition is cleared. Check the ALARM HISTO-
RY screen for additional help in determining the reasons for the
alarms. Once all existing alarms are cleared (by pressing the
softkey), the default CVC/ICVC display returns to
normal operation.
MONITORED PARAMETER LIMIT APPLICABLE COMMENTS
TEMPERATURE SENSORS OUT OF
RANGE
40 to 245 F (40 to 118.3 C) Must be outside range for 2 seconds
PRESSURE TRANSDUCERS OUT OF
RANGE
0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds.
Ratio = Input Voltage ÷ Voltage Reference
COMPRESSOR DISCHARGE
TEMPERATURE
>220 F (104.4 C) Preset, alert setting configurable
MOTOR WINDING TEMPERATURE >220 F (104.4 C) Preset, alert setting configurable
BEARING TEMPERATURE >185 F (85 C) Preset, alert setting configurable
EVAPORATOR REFRIGERANT
TEMPERATURE
<33 F (for water chilling) (0.6°C) Preset, configurable chilled medium for water
(SETUP1 table)
<EVAP REFRIG TRIPPOINT (set point adjustable
from 0 to 40 F [18 to 4 C]) for brine chilling)
Configure chilled medium for brine (SETUP1
table). Adjust EVAP REFRIG TRIPPOINT for
proper cutout
TRANSDUCER VOLTAGE <4.5 vdc> 5.5 vdc Preset
CONDENSER PRESSURE SWITCH 165 ± 5 psig (1138 ± 34 kPa), reset at
110 ± 7 psig (758 ± 48 kPa)
Preset
CONTROL 165 psig (1138 kPa) Preset
OIL PRESSURE Cutout <15 psid (103 kPad)
Alert <18 psid (124 kPad)
Preset
LIN E VOLTAG E HIGH >150% for one second or >115% for ten seconds Preset, based on transformed line voltage
to ISM. Also monitored at CVC/ICVC and
CCM power input.
LOW <85% for ten seconds or 80 for 5 seconds or
<75% for one second
SINGLE-CYCLE <50% for one cycle (if enabled) Default is disabled.
COMPRESSOR MOTOR LOAD >110% for 30 seconds Preset
<15% with compressor running Preset
>15% with compressor off Preset
STARTER ACCELERATION TIME
(Determined by inrush current)
150% RLA for 20 sec. For chillers with reduced voltage mechanical
and solid-state starters
>100% RLA for 45 sec.
>100% RLA for 10 sec. For chillers with full voltage starters
(Configures on ISM_CONF table).
STARTER TRANSITION If ISM contact open >20 sec. Reduced voltage starters only
CONDENSER FREEZE PROTECTION Energizes condenser pump relay if
condenser refrigerant temperature or condenser
entering water temperature is below the configured
condenser freeze point temperature. Deenergizes
when the temperature is 5 F (3 C) above con-
denser freeze point temperature.
CONDENSER FREEZE POINT configured in
SETUP1 table with a default setting of 34 F
(1 C).
DISCHARGE SUPERHEAT Minimum value calculated based on
operating conditions and then compared
to actual superheat.
Calculated minimum required superheat
and actual superheat are shown on
OVERRIDE screen.
VARIABLE DIFFUSER OPERATION Detects discharge pulses caused by
incorrect diffuser position.
Preset, no calibration needed.
RESET
36
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.
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.
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).
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
valves (TXVs) regulate refrigerant flow to control the oil tem-
perature entering the bearings. The bulbs for the expansion
valves are strapped to the oil supply line leaving the heat ex-
changer, and the valves are set to maintain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump tempera-
ture may be at a lower temperature during compressor
operations.
Remote Start/Stop Controls A remote device, such
as a timeclock that uses a set of contacts, may be used to start
and stop the chiller. However, the device should not be pro-
grammed to start and stop the chiller in excess of 2 or 3 times
every 12 hours. If more than 8 starts in 12 hours (the STARTS
IN 12 HOURS parameter on the MAINSTAT screen) occur, an
excessive starts alarm displays, preventing the chiller from
starting. The operator must press the softkey on the
CVC/ICVC to override the starts counter and start the chiller.
If the chiller records 12 starts (excluding recycle starts) in a
sliding 12-hour period, it can be restarted only by pressing the
softkey followed by the or softkey.
This ensures that, if the automatic system is malfunctioning,
the chiller will not repeatedly cycle on and off. If the automatic
restart after a power failure option (AUTO RESTART OPTION
on the OPTIONS screen) is not activated when a power failure
occurs, and if the remote contact is closed, the chiller will indi-
cate an alarm because of the loss of voltage.
The contacts for remote start are wired into the starter at ter-
minal strip J2, terminals 5 and 6 on the ISM. See the certified
drawings for further details on contact ratings. The contacts
must have 24 vac dry contact rating.
Spare Safety Inputs Normally closed (NC) discrete
inputs for additional field-supplied safeties may be wired to the
spare protective limits input channel in place of the factory-
installed jumper. (Wire multiple inputs in series.) The opening
of any contact will result in a safety shutdown and a display on
the CVC/ICVC. Refer to the certified drawings for safety con-
tact ratings.
Analog temperature sensors may also be added to the mod-
ule (SPARE TEMP #1 and #2). The analog temperature sen-
sors may be configured to cause an alert or alarm on the CCN
network. The alert will not shut the chiller down. Configuring
for alarm state will cause the chiller to shut down.
RESET
RESET LOCAL CCN
37
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 chillers energy
consumption. A 4 mA signal represents the chiller in an off
state and a 20 mA signal represents the chiller operating at its
rated peak kilowatt consumption. The rated peak kilowatt con-
sumption is configured by the user in the RAMP_DEM display
screen by the setting the MOTOR RATED KILOWATTS from
the job data sheet.
Remote Reset of Alarms A standard feature of the
PIC II controls is the ability to reset a chiller in a shutdown
alarm state from a remote location. If the condition which
caused the alarm has cleared the chiller can be placed back into
a normal CCN operating mode when the REMOTE RESET
OPTION (CVC_PSWD/ICVC_PSWD menu) is set to EN-
ABLE. A variety of Carrier Comfort Network software sys-
tems including ComfortVIEW or Network Service Tool
can access the PIC II controls and reset the displayed alarm.
Third party software from building automation systems (BAS)
or energy management systems (EMS) can also access the
PIC II controls through a Carrier DataLINK module and re-
set the fault displayed. Both methods would access the
CVC_PSWD/ICVC_PSWD screen and force the RESET
ALARM? point to YES to reset the fault condition. If the PIC II
controls have determined that is safe to start the chiller the
CCN MODE? point (CVC_PSWD/ICVC_PSWD screen) can
be forced to YES to place the chiller back into normal CCN op-
erating mode. The only exceptions are the following alarms
that cannot be reset from a remote location: STATE #100, 205,
217-220, 223, 233, 234, 247, and 250. To view alarm codes, re-
fer to Troubleshooting Guide, Checking Display Messages,
page 76. After the alarm has been reset the PIC II control will
increment the Starts in 12 Hours counter by one upon restart. If
the limit of 8 starts in a 12-hour period occurs the alarm will be
required to be reset at the chiller control panel (CVC/ICVC).
Condenser Pump Control The chiller will moni-
tor the condenser pressure (CONDENSER PRESSURE) and
may turn on the condenser pump if the condenser pressure be-
comes too high while the compressor is shut down. The con-
denser pressure override (COND PRESS OVERRIDE) parame-
ter is used to determine this pressure point. COND PRESS
OVERRIDE is found in the SETUP1 display screen, which is
accessed from the EQUIPMENT SERVICE table. The default
value is 125 psig (862 kPa).
If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, and the entering condenser
water temperature (ENTERING CONDENSER WATER) is less
than 115 F (46 C), the condenser pump will energize to try to
decrease the pressure. The pump will turn off when the con-
denser pressure is 3.5 psi (24.1 kPa) less than the pressure over-
ride or when the condenser refrigerant temperature (CON-
DENSER REFRIG TEMP) is within 3° F (1.7° C) of the enter-
ing condenser water temperature (ENTERING CONDENSER
WATER).
OVERRIDE
CAPACITY CONTROL
FIRST STAGE SET POINT SECOND STAGE SET
POINT
OVERRIDE
TERMINATION
View/Modify
on CVC/ICVC
Screen
Default
Value
Configurable
Range Value Value
HIGH CONDENSER
PRESSURE SETUP1 125 psig
(862 kPa)
90 to 165 psig
(620 to 1138 kPa)
>Override
Set Point
+2.4 psid (16.5 kPad)
<Override
Set Point
HIGH MOTOR
TEMPERATURE SETUP1 >200 F
(93.3 C)
150 to 200 F
(66 to 93 C)
>Override
Set Point
+10° F (6° C)
<Override
Set Point
LOW REFRIGERANT
TEMPERATURE
(Refrigerant
Override Delta
Temperature)
SETUP1 3° F (1.6° C) 2° to 5° F
(1° to 3° C)
Trippoint
+ Override
T 1° F (0.56° C)
>Trippoint
+ Override
T+2° F (1.2° C)
HIGH COMPRESSOR
LIFT
(Surge Prevention)
OPTIONS
Min: T1 1.5° F
(0.8° C)
P1 50 psid
(345 kPad)
Max: T2 10° F
(5.6° C)
P2 85 psid
(586 kPad)
0.5° to 20° F
(0.3° to 8.3° C)
30 to 170 psid
(207 to 1172 kPad)
0.5° to 20° F
(0.3° to 8.3° C)
50 to 170 psid
(348 to 1172 kPad)
None
Within Lift Limits
Plus Surge/HGBP
Deadband Setting
MANUAL GUIDE VANE
TARGET CAPACITY Automatic 0 to 100% None Release of
Manual Control
MOTOR LOAD
ACTIVE DEMAND LIMIT MAINSTAT 100% 40 to 100% 5% of
Set Point
2% Lower
Than Set Point
LOW DISCHARGE
SUPERHEAT OVERRIDE
Calculated Minimum
Superheat for
Conditions
None
2° F (1.1° C)
Below Calculated
Minimum Superheat
1° F (0.56° C)
Above Calculated
Minimum Superheat
38
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.
Evaporator Freeze Protection (ICVC only) A
refrigerant temperature sensor is installed at the bottom of the
cooler to provide redundant freeze protection. In place of the
cooler and condenser water pressure transducer inputs on the
CCM is a 4.3k ohm resister and a jumper lead. When the
EVAPORATOR REFRIGERANT TEMPERATURE is less
than the EVAP REFRIG TRIPPOINT plus the REFRIG
OVERRIDE DELTA T (configurable from 2° to 5°), state 122
will be displayed and a capacity override will occur. If the
EVAPORATOR REFRIG TEMP is equal to or less than the
EVAP Refrig TRIPPOINT, Protective Limit ALARM STATE
232 will be displayed and the unit will shut down.
Tower Fan Relay Low and High Low condenser
water temperature can cause the chiller to shut down when 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 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).
The TOWER FAN RELAY LOW and HIGH parameters are
accessed from the STARTUP screen.
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.
If power to the CVC/ICVC module has been off for more
than 3 hours or the timeclock has been set for the first time,
start the compressor with the slowest temperature-based ramp
load rate possible in order to minimize oil foaming.
The oil pump is energized occasionally during the time the
oil is being brought up to proper temperature in order to 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-
ature reset based on a remote temperature sensor input config-
ured for either an externally powered 4 to 20 mA or a 1 to
5 vdc signal. Reset Type 1 permits up to ±30 F (±16 C) of
automatic reset to the chilled water set point.
The auto, chilled water reset is hardwired to terminals
J5-3 () and J5-4 (+) on the CCM. Switch setting number 2 on
SW2 will determine the type of input signal. With the switch
set at the ON position the input is configured for an externally
powered 4 to 20 mA signal. With the switch in the OFF posi-
tion the input is configured for an external 1 to 5 vdc signal.
RESET TYPE 2: REMOTE TEMPERATURE RESET
Reset Type 2 is an automatic chilled water temperature reset
based on a remote temperature sensor input signal. Reset Type
2 permits ± 30° F (± 16° C) of automatic reset to the set point
based on a temperature sensor wired to the CCM module
IMPORTANT: A field-supplied water temperature control
system for condenser water should be installed. The system
should maintain the leaving condenser water temperature
at a temperature that is 20° F (11° C) above the leaving
chilled water temperature.
The tower fan relay control is not a substitute for a con-
denser water temperature control. When used with a water
temperature control system, the tower fan relay control can
be used to help prevent low condenser water temperatures.
39
(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.
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.
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.
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
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,
LEGEND
P = (Condenser Psi) (Cooler Psi)
T = (ECW) (LCW)
Fig. 21 19XR Hot Gas Bypass/Surge
Prevention with Default English Settings
ECW Entering Chilled Water
HGBP Hot Gas Bypass
LCW Leaving Chilled Water
LEGEND
P = (Condenser kPa) (Cooler kPa)
T = (ECW) (LCW)
Fig. 22 19XR Hot Gas Bypass/Surge
Prevention with Default Metric Settings
ECW Entering Chilled Water
HGBP Hot Gas Bypass
LCW Leaving Chilled Water
40
Capacity Overrides. Both of these corrective actions try to
reduce the lift experienced by the compressor and help prevent
a surge condition.
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.
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.
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 IGVs open. When in Surge
Prevention mode, with a command to decrease capacity only
the IGVs will close.
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.
On VFD units, if a surge count is registered and if ACTUAL
VFD SPEED is less than VFD MAXIMUM SPEED then motor
speed will be increased by the configured VFD increase step.
While the SURGE PROTECTION COUNTS are >0, a speed
decrease will not be honored.
The surge limit can be adjusted from the OPTIONS screen
(see Table 2). Scroll down to the SURGE DELTA % AMPS
parameter, and use the or softkey
to adjust the percent of surge. The default setting is 10% amps.
The surge time period can also be adjusted from the
OPTIONS screen. Scroll to the SURGE TIME PERIOD
parameter, and use the or softkey
to adjust the amount of time. The default setting is 8 minutes.
Access the display screen (COMPRESS) to monitor the
surge count (SURGE PROTECTION COUNTS).
Surge 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
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 or softkey
to adjust the amount of time. The default setting is 8 minutes.
Access the display screen (COMPRESS) to monitor the
surge count (SURGE PROTECTION COUNTS).
HEAD PRESSURE REFERENCE OUTPUT (See
Fig. 23) The PIC II control outputs a 4 to 20 mA signal for
the configurable Delta P (condenser pressure minus evaporator
pressure) reference curve shown in Fig. 23. An output is 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.
INCREASE DECREASE
INCREASE DECREASE
INCREASE DECREASE
INCREASE DECREASE
MINIMUM
REFERENCE
OUTPUT
DELTA P
AT 100%
DELTA P
AT 0%
DELTA P
0 mA 2 mA 4 mA
(0%) 20 mA
(100%)
4 T0 20 mA OUTPUT
Fig. 23 Head Pressure Reference Output
41
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
Spare Temp #1 position on the CCM.
If the entering chilled water control option (ECW CON-
TROL OPTION) is enabled (configured in TEMP_CTL
screen) and a common point sensor is desired (COMMON
SENSOR OPTION in LEADLAG screen selected as 1) then
the sensor is wired in Spare Temp #2 position on the CCM.
When installing chillers in series, a common point sensor
should be used. If a common point sensor is not used, the leav-
ing chilled water sensor of the upstream chiller must be moved
into the leaving chilled water pipe of the downstream chiller.
If return chilled water control is required on chillers piped in
series, the common point return chilled water sensor should be
installed. If this sensor is not installed, the return chilled water
sensor of the downstream chiller must be relocated to the return
chilled water pipe of the upstream chiller.
To properly control the common supply point temperature
sensor when chillers are piped in parallel, the water flow
through the shutdown chillers must be isolated so no water by-
pass around the operating chiller occurs. The common point
sensor option must not be used if water bypass around the oper-
ating chiller is occurring.
CHILLER COMMUNICATION WIRING Refer to the
chillers Installation Instructions, Carrier Comfort Network
Interface section for information on chiller communication
wiring.
LEAD/LAG OPERATION The PIC II not only has the
ability to operate 2 chillers in lead/lag, but it can also start a
designated standby chiller when either the lead or lag chiller is
faulted and capacity requirements are not met. The lead/lag op-
tion only operates when the chillers are in CCN mode. If any
other chiller configured for lead/lag is set to the LOCAL or
OFF modes, it will be unavailable for lead/lag operation.
Lead/Lag Chiller Configuration and Operation
A chiller is designated the lead chiller when its
LEADLAG: CONFIGURATION value on the LEAD-
LAG screen is set to 1.
A chiller is designated the lag chiller when its
LEADLAG: CONFIGURATION value is set to 2.
A chiller is designated as a standby chiller when its
LEADLAG: CONFIGURATION value is set to 3.
A value of 0 disables the lead/lag designation of a
chiller.
To configure the LAG ADDRESS value on the LEADLAG
screen, always enter the address of the other chiller on the sys-
tem. For example, if you are configuring chiller A, enter the ad-
dress for chiller B as the lag address. If you are configuring
chiller B, enter the address for chiller A as the lag address. This
makes it easier to rotate the lead and lag chillers.
If the address assignments in the LAG ADDRESS and
STANDBY ADDRESS parameters conflict, the lead/lag func-
tion is disabled and an alert (!) message displays. For example,
if the LAG ADDRESS matches the lead chillers address, the
lead/lag will be disabled and an alert (!) message displayed.
The lead/lag maintenance screen (LL_MAINT) displays the
message INVALID CONFIG in the LEADLAG: CONFIGU-
RATION and CURRENT MODE fields.
The lead chiller responds to normal start/stop controls such
as the occupancy schedule, a forced start or stop, and remote
start contact inputs. After completing start-up and ramp load-
ing, the PIC II evaluates the need for additional capacity. If ad-
ditional capacity is needed, the PIC II initiates the start-up of
the chiller configured at the LAG ADDRESS. If the lag chiller
is faulted (in alarm) or is in the OFF or LOCAL modes, the
chiller at the STANDBY ADDRESS (if configured) is requested
to start. After the second chiller is started and is running, the
lead chiller monitors conditions and evaluates whether the ca-
pacity has been reduced enough for the lead chiller to sustain
the system alone. If the capacity is reduced enough for the lead
chiller to sustain the CONTROL POINT temperatures alone,
then the operating lag chiller is stopped.
If the lead chiller is stopped in CCN mode for any reason
other than an alarm (*) condition, the lag and standby chillers
are also stopped. If the configured lead chiller stops for an
alarm condition, the configured lag chiller takes the lead chill-
ers place as the lead chiller, and the standby chiller serves as
the lag chiller.
If the configured lead chiller does not complete the start-up
before the PRESTART FAULT TIMER (a user-configured
value) elapses, then the lag chiller starts and the lead chiller
shuts down. The lead chiller then monitors the start request
from the acting lead chiller. The PRESTART FAULT TIMER is
initiated at the time of a start request. The PRESTART FAULT
TIMER provides a timeout if there is a prestart alert condition
that prevents the chiller from starting in a timely manner. The
PRESTART FAULT TIMER parameter is on the LEADLAG
screen, which is accessed from the EQUIPMENT SERVICE
table of the SERVICE menu.
If the lag chiller does not achieve start-up before the PRE-
START FAULT TIMER elapses, the lag chiller stops, and the
standby chiller is requested to start, if configured and ready.
42
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.
Lag Chiller Start-Up Requirements Before the lag chiller
can be started, the following conditions must be met:
1. Lead chiller ramp loading must be complete.
2. Lead chilled water temperature must be greater than the
CONTROL POINT temperature (see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND
temperature (see the SETUP1 screen).
NOTE: The chilled water temperature sensor may be the
leaving chilled water sensor, the return water sensor, the
common supply water sensor, or the common return 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.
5. The lag chiller status indicates it is in CCN mode and is
not in an alarm condition. If the current lag chiller is in an
alarm condition, the standby chiller becomes the active
lag chiller, if it is configured and available.
6. The configured LAG START TIMER entry has elapsed.
The LAG START TIMER starts when the lead chiller ramp
loading is completed. The LAG START TIMER entry is
on the LEADLAG screen, which is accessed from the
EQUIPMENT SERVICE table of the SERVICE menu.
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (SUPVSR flashing
next to the point value on the STATUS table). The PIC II 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.
NOTE: Lead chiller percent capacity = 115 LAG % CA-
PACI T Y. The LAG % CAPACITY parameter is on the
LEADLAG screen, which is accessed from the EQUIP-
MENT SERVICE table on the SERVICE menu.
2. The lead chiller chilled water temperature is less than the
CONTROL POINT temperature (see the MAINSTAT
screen) plus 1/2 the CHILLED WATER DEADBAND 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.
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.
If the lag chiller goes into alarm when the lead chiller is also
in alarm, the standby chiller reverts to a stand-alone CCN
mode of operation.
If the lead chiller is in an alarm (*) condition (as shown on
the CVC/ICVC panel), press the softkey to clear the
alarm. The chiller is placed in CCN mode. The lead chiller
communicates and monitors the RUN STATUS of the lag and
standby chillers. If both the lag and standby chillers are 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.
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
greater than CONTROL POINT plus 1/2 the CHILLED
WATER DEADBAND temperature.
3. Lag chiller ACTIVE DEMAND LIMIT value must be
greater than 95% of full load amps.
4. Lag chiller temperature pulldown rate (TEMP 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.
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
chillers 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 chillers 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.
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.
RESET
43
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.
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 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.
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 parameters 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
LIMIT to the lag or standby chiller as required for ice build, if
configured to do so.
START-UP/RECYCLE OPERATION If the chiller is not
running when ice build activates, the PIC II checks the 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.
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.
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.
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
44
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.
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.
To attach any CCN device, highlight it using the
softkey and press the softkey. The message UP-
LOADING TABLES, PLEASE WAIT displays. The CVC/
ICVC then uploads the highlighted device or module. If the
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.
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.
NOTE: The CVC/ICVC will not automatically reattach to the
local module on the chiller. Press the softkey to
attach to the LOCAL device and view the chiller operation.
SELECT
ATTACH
ATTACH
ATTACH
Fig. 24 Example of Attach to Network
Device Screen
45
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.
1. From the main MENU screen, press the
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
NOTE: The initial factory-set password is 1-1-1-1. If the
password is incorrect, an error message is displayed
If this occurs, return to Step 1 and try to access the SER-
VICE screens again. If the password is correct, the soft-
key labels change to:
NOTE: The SERVICE screen password can be changed
by entering the CVC/ICVC CONFIGURATION screen
under SERVICE menu. The password is located at the
bottom of the menu.
The CVC/ICVC screen displays the following list of
available SERVICE screens:
Alarm History
Control Test
Control Algorithm Status
Equipment Configuration
ISM (Starter) Config Data
Equipment Service
Time and Date
Attach to Network Device
Log Out of Device
CVC/ICVC Configuration
See Fig. 18 for additional screens and tables available from
the SERVICE screens listed above. Use the softkey to
return to the main MENU screen.
NOTE: To prevent unauthorized persons from accessing the
CVC/ICVC service screens, the CVC/ICVC automatically
signs off and password-protects itself if a key has not been
pressed for 15 minutes. The sequence is as follows. Fifteen
minutes after the last key is pressed, the default screen 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.
Enter the password and, from the SERVICE menu, highlight
LOG OUT OF NETWORK DEVICE and press the
softkey. The CVC/ICVC default screen will now be displayed.
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.)
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.
To access the BRODEF screen, see the SERVICE menu
structure, Fig. 18.
To view or change the holiday periods for up to 18 different
holidays, perform the following operation:
1. At the Menu screen, press to access the Ser-
vice menu.
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.
3. Once Equipment Configuration is highlighted, press
to access.
4. Press until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press to enter the Data Table Select screen.
This screen lists 18 holiday tables.
6. Press to highlight the holiday table that is to be
viewed or changed. Each table is one holiday period,
starting on a specific date, and lasting up to 99 days.
7. Press to access the holiday table. The Config-
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,
day, or duration.
9. Press to modify the month, day, or duration.
10. Press or to change the
selected value.
11. Press to save the changes.
12. Press to return to the previous menu.
SERVICE
EXIT
MENU SERVICE
SELECT
SERVICE
NEXT
SELECT
NEXT
SELECT
NEXT
SELECT
NEXT PREVIOUS
SELECT
INCREASE DECREASE
ENTER
EXIT
Fig. 25 Example of Holiday Period Screen
46
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
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.
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
softkeys. Scroll to highlight MAINSTAT. Press the
softkey. Scroll to highlight CHILLER START/STOP.
Press the softkey to override the schedule and start
the chiller.
NOTE: The chiller will continue to run until this forced start is
released, regardless of the programmed schedule. To release
the forced start, highlight CHILLER START/STOP from the
MAINSTAT screen and press the softkey. This
action returns the chiller to the start and stop times established
by the schedule.
The chiller may also be started by overriding the time
schedule. From the default screen, press the and
softkeys. Scroll down and select the current
schedule. Select OVERRIDE, and set the desired override
time.
Another condition for start-up must be met for chillers that
have the REMOTE CONTACTS OPTION on the 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 and softkeys. Scroll to
highlight MAINSTAT and press the softkey. Scroll
down the MAINSTAT screen to highlight REMOTE START
CONTACT and press the softkey. Then, press the
softkey. To end the override, select REMOTE CON-
TACTS INPUT and press the softkey.
Once local start-up begins, the PIC II performs a series of
pre-start tests to verify that all pre-start alerts and safeties are
within the limits shown in Table 4. The RUN STATUS 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.
Five seconds later, the condenser pump relay energizes.
Thirty seconds later the PIC II monitors the chilled water and
condenser water flow devices and waits until the WATER
FLOW VERIFY TIME (operator-configured, default 5 minutes)
expires to confirm flow. After flow is verified, the chilled water
temperature is compared to CONTROL POINT plus 1/2
CHILLED WATER DEADBAND. If the temperature is less
than or equal to this value, the PIC II turns off the condenser
pump relay and goes into a RECYCLE mode.
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.
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.
LOCAL
MENU
STATUS
SELECT START
RELEASE
MENU
SCHEDULE
MENU STATUS
SELECT
SELECT
CLOSE RELEASE
ASTART INITIATED: Pre-start checks are made; evaporator pump
started.
BCondenser water pump started (5 seconds after A).
CWater 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.
DOil pressure verified (15 seconds minimum, 300 seconds maximum
after C).
ECompressor 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.
FSHUTDOWN INITIATED Compressor motor stops; compressor
ontime and service ontime stop, and 1-minute inhibit timer starts.
GOil pump and evaporator pumps deenergized (60 seconds after F).
Condenser pump and tower fan control may continue to operate if
condenser pressure is high. Evaporator pump may continue if in
RECYCLE mode.
O/A Restart permitted (both inhibit timers expired: minimum of 15 minutes
after E; minimum of 1 minute after F).
Fig. 26 Control Sequence
47
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.
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
or softkey to set the SOFT STOP
AMPS THRESHOLD parameter to the percent of amps at
which the motor will shut down. The default setting is 100%
amps (no soft stop). The range is 40 to 100%.
When the soft stop amps threshold feature is being applied,
a status message, SHUTDOWN IN PROGRESS, 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.
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 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.
After a safety shutdown, the softkey must be
pressed to clear the alarm. If the alarm condition is still present,
the alarm light continues to blink. Once the alarm is cleared,
the operator must press the or softkeys to re-
start the chiller.
INCREASE DECREASE
RESET
CCN LOCAL
48
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
mechanics 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
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.
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.
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.
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.
Do not use air or oxygen as a means of pressurizing
the chiller. Mixtures of HFC-134a and air can undergo
combustion.
Fig. 27 Typical Wet-Bulb Type
Vacuum Indicator
49
Fig. 28 19XR Leak Test Procedures
50
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.
1. If the pressure readings are normal for the chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at the equivalent 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. Leak test chiller as outlined in Steps 3 - 9.
2. If the pressure readings are abnormal for the chiller
condition:
a. Prepare to leak test chillers shipped with 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.
f. Retest the joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished by
following the dehydration procedure, outlined in
the Chiller Dehydration section, page 53.
h. Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).
3. Check the chiller carefully with an electronic leak 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. 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.
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.
b. If the chiller fails the standing vacuum test, check
for large leaks (Step 2b).
c. If the chiller passes the standing vacuum test,
dehydrate the chiller. Follow the procedure in
the Chiller Dehydration section. Charge the chiller
with refrigerant (see Transfer Refrigerant from
Pumpout Storage Tank to Chiller section,
page 69).
7. If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
present, pump the refrigerant into the non-leaking
vessel (see Pumpout and Refrigerant Transfer procedures
section).
8. Transfer the refrigerant until the chiller pressure is at
18 in. Hg (40 kPa absolute).
9. Repair the leak and repeat the procedure, beginning from
Step 2h, to ensure a leak-tight repair. (If the chiller is
opened to the atmosphere for an extended period, evacu-
ate it before repeating the leak test.)
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.
4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa) in
24 hours, the chiller is sufficiently tight.
b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa) in
24 hours, repressurize the vessel and test for leaks.
If refrigerant is available in the other vessel, 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.
5. Repair the leak, retest, and proceed with dehydration.
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.
51
Fig. 29 Typical Optional Pumpout System Piping Schematic with Storage Tank
Fig. 30 Typical Optional Pumpout System Piping Schematic without Storage Tank
52
Table 5A HFC-134a Pressure
Temperature (F)
Table 5B HFC-134a Pressure
Temperature (C)
TEMPERATURE,
F
PRESSURE
(psig)
06.50
27.52
48.60
69.66
810.79
10 11.96
12 13.17
14 14.42
16 15.72
18 17.06
20 18.45
22 19.88
24 21.37
26 22.90
28 24.48
30 26.11
32 27.80
34 29.53
36 31.32
38 33.17
40 35.08
42 37.04
44 39.06
46 41.14
48 43.28
50 45.48
52 47.74
54 50.07
56 52.47
58 54.93
60 57.46
62 60.06
64 62.73
66 65.47
68 68.29
70 71.18
72 74.14
74 77.18
76 80.30
78 83.49
80 86.17
82 90.13
84 93.57
86 97.09
88 100.70
90 104.40
92 108.18
94 112.06
96 116.02
98 120.08
100 124.23
102 128.47
104 132.81
106 137.25
108 141.79
110 146.43
112 151.17
114 156.01
116 160.96
118 166.01
120 171.17
122 176.45
124 181.83
126 187.32
128 192.93
130 198.66
132 204.50
134 210.47
136 216.55
138 222.76
140 229.09
TEMPERATURE,
C
PRESSURE
(kPa)
18.0 44.8
16.7 51.9
15.6 59.3
14.4 66.6
13.3 74.4
12.2 82.5
11.1 90.8
10.0 99.4
8.9 108.0
7.8 118.0
6.7 127.0
5.6 137.0
4.4 147.0
3.3 158.0
2.2 169.0
1.1 180.0
0.0 192.0
1.1 204.0
2.2 216.0
3.3 229.0
4.4 242.0
5.0 248.0
5.6 255.0
6.1 261.0
6.7 269.0
7.2 276.0
7.8 284.0
8.3 290.0
8.9 298.0
9.4 305.0
10.0 314.0
11.1 329.0
12.2 345.0
13.3 362.0
14.4 379.0
15.6 396.0
16.7 414.0
17.8 433.0
18.9 451.0
20.0 471.0
21.1 491.0
22.2 511.0
23.3 532.0
24.4 554.0
25.6 576.0
26.7 598.0
27.8 621.0
28.9 645.0
30.0 669.0
31.1 694.0
32.2 720.0
33.3 746.0
34.4 773.0
35.6 800.0
36.7 828.0
37.8 857.0
38.9 886.0
40.0 916.0
41.1 946.0
42.2 978.0
43.3 1010.0
44.4 1042.0
45.6 1076.0
46.7 1110.0
47.8 1145.0
48.9 1180.0
50.0 1217.0
51.1 1254.0
52.2 1292.0
53.3 1330.0
54.4 1370.0
55.6 1410.0
56.7 1451.0
57.8 1493.0
58.9 1536.0
60.0 1580.0
53
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.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 31) may substantially reduce the time required
to complete the dehydration. The higher the room temperature,
the faster dehydration takes place. At low room temperatures, a
very deep vacuum is required to boil off any moisture. If low
ambient temperatures are involved, contact a qualified service
representative for the dehydration techniques required.
Perform dehydration as follows:
1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the refrigerant charging
valve (Fig. 2). Tubing from the pump to the chiller should
be as short in length and as large in diameter as possible to
provide least resistance to gas flow.
2. Use an absolute pressure manometer or a wet bulb 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.
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.
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.
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.
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
1. Examine the wiring for conformance to the job wiring di-
agrams and all applicable electrical codes.
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.
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.
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.
Do not check the voltage supply without proper equipment
and precautions. Serious injury may result. Follow power
company recommendations.
Do not apply any kind of test voltage, even for a rotation
check, if the chiller is under a dehydration vacuum. Insula-
tion breakdown and serious damage may result.
Fig. 31 Dehydration Cold Trap
54
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.
6. Ensure that fused disconnects or circuit breakers have
been supplied for the oil pump, power panel, and
pumpout unit.
7. Ensure all electrical equipment and controls are properly
grounded in accordance with job drawings, certified
drawings, and all applicable electrical codes.
8. Ensure the customers 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.
a. Open the starter main disconnect switch and follow
lockout/tagout rules.
b. With the tester connected to the motor leads, take
10-second and 60-second megohm readings as
follows:
6-Lead Motor Tie all 6 leads together and test
between the lead group and ground. Next tie the
leads in pairs: 1 and 4, 2 and 5, and 3 and 6. Test
between each pair while grounding the third pair.
3-Lead Motor Tie terminals 1, 2, and 3 together
and test between the group and ground.
c. Divide the 60-second resistance reading by the
10-second reading. The ratio, or polarization
index, must be one or higher. Both the 10- and
60-second readings must be at least 50 megohms.
If the readings on a field-installed starter are 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.
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.
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.
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:
Check Starter
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 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.
MANUFACTURER CABLE NO.
Alpha 2413 or 5463
American A22503
Belden 8772
Columbia 02525
SIGNAL TYPE
CCN BUS
CONDUCTOR
INSULATION
COLOR
CCN TERMINAL
CONNECTION
+Red RED (+)
Ground White WHITE (G)
Black BLACK ()
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.
The main disconnect on the starter front panel may not
deenergize all internal circuits. Open all internal and
remote disconnects before servicing the starter.
55
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.
3. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through a
complete and proper start cycle.
BENSHAW, INC. RediStart MICRO SOLID-STATE
STARTER
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.
5. Apply power to the starter
VFD STARTER
1. Turn off unit, tag and lock disconnects and wait 5 minutes.
2. Verify that the DC voltage is zero.
3. Ensure there is adequate clearance around the drive.
4. Verify that the wiring to the terminal strip and power 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.
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)
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
Carriers 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.
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
powered, the CVC/ICVC should display the default screen
within a short period of time.
The oil heater is energized by powering the control circuit.
This should be done several hours before start-up to minimize
oil-refrigerant migration. The oil heater is controlled by the
PIC II and is powered through a contactor in the power panel.
Starters contain a separate circuit breaker to power the heater
and the control circuit. This arrangement allows the heater to
energize when the main motor circuit breaker is off for service
work or extended shutdowns. The oil heater relay status (OIL
HEATER RELAY) can be viewed on the COMPRESS table on
the CVC/ICVC. Oil sump temperature can be viewed on the
CVC/ICVC default screen.
SOFTWARE VERSION The software part number is 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.
Software Configuration
As the 19XR unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
CL-1 to CL-16, provides a list for configuration values.
Input the Design Set Points Access the CVC/
ICVC set point screen and view/modify the base demand limit
set point, and either the LCW set point or the ECW set point.
The PIC II can control a set point to either the leaving or enter-
ing chilled water. This control method is set in the EQUIP-
MENT SERVICE (TEMP_CTL) table.
Input the Local Occupied Schedule (OCCPC01S)
Access the schedule OCCPC01S screen on the CVC/ICVC
and set up the occupied time schedule according to the custom-
ers 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.
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.
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.
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.
56
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 and softkeys. Enter the
current password and highlight CVC/ICVC CONFIGU-
RATION. Press the softkey. Only the last
5 entries on the CVC/ICVC CONFIG screen can be
changed: BUS #, ADDRESS #, BAUD RATE, US IMP/
METRIC, and PASSWORD.
2. Use the 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.
2. Use the softkey to scroll to LID LANGUAGE.
3. Press the INCREASE or DECREASE softkey until the
desired language is displayed. Press to confirm
desired language.
MODIFY CONTROLLER IDENTIFICATION IF NECES-
SARY The CVC/ICVC module address can be changed
from the CVC/ICVC CONFIGURATION screen. Change this
address for each chiller if there is more than one chiller at the
jobsite. Write the new address on the CVC/ICVC module for
future reference.
INPUT EQUIPMENT SERVICE PARAMETERS IF NEC-
ESSARY The EQUIPMENT SERVICE table has six
service tables.
Configure SERVICE Tables Access the SERVICE tables,
shown in Table 2, to modify or view job site parameters:
*With variable flow systems this point may be configured to the lower end of
the range.
NOTE: Other parameters: Screens are normally left at the default settings; they
may be changed by the operator as required. The time and persistence set-
tings on the ISM_CONF table can be adjusted to increase or decrease the sen-
sitivity to a fault condition. Increasing time or persistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault condition.
Be sure to remember the password. Retain a copy
for future reference. Without the password, access to the
SERVICE menu will not be possible unless the CVC/
ICVC_PSWD menu on the STATUS screen is accessed by
a Carrier representative.
MENU SERVICE
SELECT
ENTER
INCREASE
DECREASE
ENTER
EXIT
MENU SERVICE
SELECT
ENTER
MENU SERVICE
SELECT
ENTER
ENTER
PARAMETER TABLE
Starter Type ISM_CONF Select 0 for full voltage, 1 for
reduced voltage, or 2 for solid state/variable fre-
quency drive.
Motor Rated Line
Voltage
ISM_CONF Motor rated voltage from chiller
information nameplate.
Volt Transformer
Ratio
ISM_CONF Enter ratio (reduced to a ratio to
1) of power transformer wired to terminal J3 of
ISM. If no transformer is used enter 1.
Motor Rated
Load Amps
ISM_CONF Per chiller identification name-
plate data.
Motor Locked
Rotor Trip
ISM_CONF Per chiller identification name-
plate data. Enter locked rotor delta amps (LR
AMPS D-).
Starter LRA
Rating
ISM_CONF Enter value from nameplate in
starter cabinet
Allen -Bradley this appears as max locked rotor
current @100% nom. voltage.
Benshaw Starters: value is entered as 9999.
Motor Current
CT Ratio
ISM_CONF Enter ratio (reduced to a ratio to
1) of current transformers wired to terminal J4 of
ISM. For Benshaw Inc. RediStart MICRO
Starters set to 100.
Ground Fault
Current
Transformers
ISM_CONF Enter 0 if no ground fault CTs are
wired to terminal J5 of ISM. Enter 1 if ground
fault CTs are used.
Ground Fault
CT Ratio
ISM_CONF Enter ratio (reduced to a ratio to
1) of ground fault CT.
Single Cycle
Dropout
ISM_CONF ENABLE if motor protection
required from drop in line voltage within one
cycle.
Line Frequency ISM_CONF Enter YES for 60 Hz or NO for 50
Hz.
Line Frequency
Faulting
ISM_CONF ENABLE if motor
protection required for drop in line
frequency.
Surge Limiting or
Hot Gas Bypass
Option
OPTIONS Enter 1 if HGBP is installed.
Minimum Load
Points (T1, P1)
OPTIONS Per Chiller Requisition (DT1, DP2)
if available or per job data See modify load
points section.
Full (Maximum)
Load Points (T2, P2)
OPTIONS Per Chiller Requisition (DT2, DP2)
if available or per job data See modify load
points section. For VFD units refer to table
located in control panel.
Chilled Medium SETUP1 Enter water or brine.
Evaporator
Refrigerant
Trippoint
SETUP1 Usually 3° F (1.7° C) below design
refrigerant temperature.
Evaporator Flow
Delta P Cutout
SETUP1 Per Chiller Requisition if available or
enter 50% of design pressure drop to 0.5 psi (3.4
kPa).*
Condenser Flow
Delta P Cutout
SETUP1 Per Chiller Requisition if available or
enter 50% of design pressure drop to 0.5 psi (3.4
kPa).*
Diffuser Option
(Compressors with Split
Ring Diffusers)
SETUP2 ENABLE for 4 and 5 size compres-
sor. See model number nomenclature.
Diffuser Full Span
mA Rating
(Compressors with Split
Ring Diffusers)
SETUP2 Enter diffuser actuator full span