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

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

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

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

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 chiller’s capacity as

required to maintain proper leaving chilled water temperature.

The control panel:

• registers cooler, condenser, and lubricating system

pressures

• shows chiller operating condition and alarm shutdown

conditions

• records the total chiller operating hours

• sequences chiller start, stop, and recycle under 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

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

18 19 20 21 22

31 30 29 28 27 26 25 24

33 24

15 14

Fig. 2 — Typical 19XR Components

LEGEND

1—Guide Vane Actuator

2—Suction Elbow

3—Chiller Visual Controller/ International Chiller

Visual Control (CVC/ICVC)

4—Chiller Identification Nameplate

5—Cooler, Auto Reset Relief Valves

6—Cooler Pressure Transducer

7—Condenser In/Out Temperature Thermistors

8—Condenser Waterflow Device (ICVC Inputs

available)

9—Cooler In/Out Temperature Thermistors

10 —Cooler Waterflow Device (ICVC Inputs 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

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

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.

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

Carrier’s 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 starter’s primary function is

to provide on-off control of the compressor motor. This type of

starter reduces the peak starting torque, reduces the motor in-

rush current, and decreases mechanical shock. This capability

is summed up by the phrase “soft starting.” The solid-state

starter is available as a 19XR option (factory supplied and in-

stalled). The solid-state starters manufacturer name is located

inside the starter access door.

A solid-state, reduced-voltage starter operates by reducing

the starting voltage. The starting torque of a motor at full volt-

age is typically 125% to 175% of the running torque. When the

voltage and the current are reduced at start-up, the starting

torque is reduced as well. The object is to reduce the starting

voltage to just the voltage necessary to develop the torque re-

quired to get the motor moving. The voltage is reduced by sili-

con controlled rectifiers (SCRs). The voltage and current are

then ramped up in a desired period of time. Once full voltage is

reached, a bypass contactor is energized to bypass the SCRs.

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

There is a display on the front of the Benshaw, Inc., solid-

state starters that is useful for troubleshooting and starter

checkout. The display indicates:

•voltage to the SCRs

•SCR control voltage

•power indication

•proper phasing for rotation

•start circuit energized

•over-temperature

•ground fault

•current unbalance

•run state

•software configuration

The starter is further explained in the Check Starter and

Troubleshooting Guide sections, pages 54 and 76.

Unit-Mounted Wye-Delta Starter (Optional) —

The 19XR chiller may be equipped with a wye-delta starter

mounted on the unit. This starter is used with low-voltage mo-

tors (under 600 v). It reduces the starting current inrush by con-

necting each phase of the motor windings into a wye configu-

ration. This occurs during the starting period when the motor is

accelerating up to speed. Once the motor is up to speed, the

starter automatically connects the phase windings into a delta

configuration. Starter control, monitoring, and motor protec-

tion is provided by Carrier’s Integrated Starter Module (ISM).

Unit-Mounted VFD (Optional) — The 19XRV unit

will be equipped with a variable frequency drive motor control-

ler mounted on the unit. See Fig. 7 and 8. This VFD is used

with low voltage motors between 380 and 480 VAC. It reduces

the starting current inrush by controlling the voltage and fre-

quency to the compressor motor. Once the motor has accelerat-

ed to minimum speed the PIC II modulates the compressor

speed and guide vane position to control chilled water tempera-

ture. The VFD is further explained in the Controls section and

Troubleshooting Guide section, pages 10 and 76.

There is a separate display located on the unit-mounted

VFD. Operational parameters and fault codes are displayed rel-

ative to the drive. Refer to specific drive literature along with

troubleshooting sections. The display is also the interface for

entering specific chiller operational parameters. These parame-

ters have been preprogrammed at the factory. An adhesive

backed label on the inside of the drive has been provided for

verification of the specific job parameters. See Initial Start-Up

Checklist section for details.

CONTROLS

Definitions

ANALOG SIGNAL — An analog signal varies in proportion

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.)

LEGEND

Fig. 5 — Solid-State Starter Box,

Internal View

1—RediStart MICRO™ Input/Output Card

2—Fuses 1-4 (Hidden, not depicted)

3—Circuit Breaker 2 (CB2): Machine Control and Heater Power

4—Circuit Breaker 3 (CB3): Oil Pump Power

5—RediStart MICRO Central Processing Unit Card (CPU)

6—RediStart MICRO Power Card (hidden, not depicted)

7—RediStart MICRO Bypass Card (hidden, not depicted)

Fig. 6 — Typical Starter External View

(Solid-State Starter Shown)

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

TORQUE

Password

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

PROGRAM

PRO-

GRAM

Forward

Reverse

ENTER

RUN

JOB

AUTO

MAN

SPEED

VOLTS

AMPS

TORQUE

Password

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

PROGRAM

Forward

Reverse

ENTER

RUN

JOB

AUTO

MAN

MANUAL RESET

OPTIONAL

METER

PACKAGE

SPEED

VOLTS

AMPS

TORQUE

Password

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

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

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

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)

Fig. 12 — Control Panel

Fig. 13 — Power Panel

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

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

•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

SELECT

EXIT

INCREASE DECREASE

STATUS

NEXT PREVIOUS

SELECT

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

NORMAL

STOP

Open

0.0 F

44.0 F

44.6 F

100%

0.0%

Fig. 16 — Example of Status Screen

•

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

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

Select a Schedule

Override

ENABLE DISABLE

EXIT

SELECT

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

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)

•

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

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

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

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)

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 II’s automatic control.

Override Indication — An override value is indicated by

“SUPVSR,” “SERVC,” or “BEST” flashing next to the point

value on the STATUS table.

TIME SCHEDULE OPERATION (Fig. 19)

1. On the Menu screen, press .

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

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

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

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

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

P—Pressure

PIC II —Product Integrated Controls II

SS —Solid State

T—Temperature

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

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

STATUS MAINSTAT

SELECT

STATUS

STARTUP

SELECT

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

STATUS

COMPRESS

SELECT

STATUS

HEAT_EX

SELECT

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

STATUS

POWER

SELECT

STATUS

ISM_STAT

SELECT

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

STATUS

CVC ICVC

SELECT

SETPOINT

SELECT

SERVICE

CONTROL ALGORITHM STATUS

SELECT

CAPACITY

SELECT

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

SERVICE

CONTROL ALGORITHM STATUS

SELECT

OVERRIDE

SELECT

SERVICE

CONTROL ALGORITHM STATUS

SELECT

LL_MAINT.

SELECT

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

SERVICE

CONTROL ALGORITHM STATUS

SELECT

ISM_HIST

SELECT

SERVICE

CONTROL ALGORITHM STATUS

SELECT

WSMDEFME

SELECT

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 CT’s? 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

SERVICE

EQUIPMENT CONFIGURATION

SELECT

NET_OPT

SELECT

SERVICE

ISM (STARTER) CONFIG DATA

SELECT

ISM_CONF

SELECT

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

SERVICE

EQUIPMENT SERVICE

SELECT

OPTIONS

SELECT

SERVICE

EQUIPMENT SERVICE

SELECT

SETUP1

SELECT

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

SERVICE

EQUIPMENT SERVICE

SELECT

SETUP2

SELECT

SERVICE

EQUIPMENT SERVICE

SELECT

LEADLAG

SELECT

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

SERVICE

EQUIPMENT SERVICE

SELECT

RAMP_DEM

SELECT

SERVICE

EQUIPMENT SERVICE

SELECT

TEMP_CTL

SELECT

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 IGV’s

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

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 building’s occu-

pancy schedule, or the chiller can be set so to run 100% of the

time, if the operator wishes. The schedules also can be by-

passed by forcing the CHILLER START/STOP parameter on

the MAINSTAT screen to START. For more information on

forced starts, see Local Start-Up, page 46.

The schedules also can be overridden to keep the chiller in

an occupied state for up to 4 hours, on a one time basis. See the

Time Schedule Operation section, page 20.

Figure 19 shows a schedule for a typical office building

with a 3-hour, off-peak, cool-down period from midnight to

3 a.m., following a weekend shutdown. Holiday periods are in

an unoccupied state 24 hours per day. The building operates

Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays

from 6:00 a.m. to 1:00 p.m. This schedule also includes the

Monday midnight to 3:00 a.m. weekend cool-down schedule.

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

chiller’s operating condition, the operator can define alert lim-

its on various monitored inputs. Safety contact and alert limits

are defined in Table 3. Alarm and alert messages are listed in

the Troubleshooting Guide section, page 76.

If compressor motor overload occurs, check the motor for

grounded or open phases before attempting a restart.

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

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

Table 4 — Capacity Overrides

Alarm (Trip) Output Contacts — One set of alarm

contacts is provided in the starter. The contact ratings are pro-

vided in the certified drawings. The contacts are located on ter-

minal strip J9, terminals 15 and 16.

Refrigerant Leak Detector — An input is available

on the CCM module [terminal J5-5 (–) and J5-6 (+)] for a

refrigerant leak detector. Enabling REFRIGERANT LEAK

OPTION (OPTIONS screen) will allow the PIC II controls to

go into an alarm state at a user configured level (REFRIGER-

ANT LEAK ALARM mA). The input is configured for 4 to

20 mA by setting the DIP switch 1 on SW2 at the ON position,

or configured for 1 to 5 vdc by setting switch 1 at the OFF posi-

tion. The output of the refrigerant leak detector is displayed as

REFRIGERANT LEAK SENSOR on the MAINSTAT screen.

For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed

and 5 vdc input represents 20 mA displayed.

Kilowatt Output — An output is available on the CCM

module [Terminal J8-1 (+) and J8-2 (–)] to represent the power

consumption of the chiller. The 4 to 20 mA signal generated by

the CCM module can be wired to the building automation or

energy management system to monitor the chiller’s energy

consumption. A 4 mA signal represents the chiller in an off

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

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.

(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

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 IGV’s 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

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

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

chiller’s 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 chiller’s address, the

lead/lag will be disabled and an alert (!) message displayed.

The lead/lag maintenance screen (LL_MAINT) displays the

message ‘INVALID CONFIG’ in the LEADLAG: 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-

er’s place as the lead chiller, and the standby chiller serves as

the lag chiller.

If the configured lead chiller does not complete the start-up

before the PRESTART FAULT TIMER (a user-configured

value) elapses, then the lag chiller starts and the lead chiller

shuts down. The lead chiller then monitors the start request

from the acting lead chiller. The PRESTART FAULT TIMER is

initiated at the time of a start request. The PRESTART FAULT

TIMER provides a timeout if there is a prestart alert condition

that prevents the chiller from starting in a timely manner. The

PRESTART FAULT TIMER parameter is on the LEADLAG

screen, which is accessed from the EQUIPMENT SERVICE

table of the SERVICE menu.

If the lag chiller does not achieve start-up before the PRE-

START FAULT TIMER elapses, the lag chiller stops, and the

standby chiller is requested to start, if configured and ready.

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

chiller’s compressor motor load value MOTOR PERCENT

KILOWATTS or AVERAGE LINE CURRENT on the MAIN-

STAT screen). This value has limits of 40% to 100%. When the

lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL

POINT must be modified to a value of 3° F (1.67° C) less than

the lead chiller’s CONTROL POINT value. If the LOAD BAL-

ANCE OPTION is disabled, the ACTIVE DEMAND LIMIT

and the CONTROL POINT are forced to the same value as the

lead chiller.

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

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 parameter’s value can be forced, that is, the value

can be manually changed at the CVC/ICVC by an operator,

changed from another CCN device, or changed by other algo-

rithms in the PIC II control system.

NOTE: The Ice Build steps do not occur if the chiller is config-

ured and operating as a lag or standby chiller for lead/lag oper-

ation and is actively being controlled by a lead chiller. The lead

chiller communicates the ICE BUILD SET POINT, the desired

CHILLER START/STOP state, and the ACTIVE DEMAND

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

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

Fig. 24 — Example of Attach to Network

Device Screen

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

SELECT

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENTER

EXIT

Fig. 25 — Example of Holiday Period Screen

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

STATUS

SELECT START

RELEASE

SCHEDULE

MENU STATUS

SELECT

CLOSE RELEASE

A—START INITIATED: Pre-start checks are made; evaporator pump

started.

B—Condenser water pump started (5 seconds after A).

C—Water flows verified (30 seconds to 5 minutes maximum after B).

Chilled water temperatures checked against control point. Guide

vanes checked for closure. Oil pump started; tower fan control

enabled.

D—Oil pressure verified (15 seconds minimum, 300 seconds maximum

after C).

E—Compressor motor starts; compressor ontime and service ontime

start, 15-minute inhibit timer starts (10 seconds after D), total com-

pressor starts advances by one, and the number of starts over a

12-hour period advances by one.

F—SHUTDOWN INITIATED — Compressor motor stops; compressor

ontime and service ontime stop, and 1-minute inhibit timer starts.

G—Oil pump and evaporator pumps deenergized (60 seconds after F).

Condenser pump and tower fan control may continue to operate if

condenser pressure is high. Evaporator pump may continue if in

RECYCLE mode.

O/A —Restart permitted (both inhibit timers expired: minimum of 15 minutes

after E; minimum of 1 minute after F).

Fig. 26 — Control Sequence

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

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

•mechanic’s tools (refrigeration)

•digital volt-ohmmeter (DVM)

•clamp-on ammeter

•electronic leak detector

•absolute pressure manometer or wet-bulb vacuum indi-

cator (Fig. 27)

•500-v insulation tester (megohmmeter) for compressor

motors with nameplate voltage of 600 v or less, or a

5000-v insulation tester for compressor motor rated

above 600 v

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

Fig. 28 — 19XR Leak Test Procedures

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.

Fig. 29 — Typical Optional Pumpout System Piping Schematic with Storage Tank

Fig. 30 — Typical Optional Pumpout System Piping Schematic without Storage Tank

Table 5A — HFC-134a Pressure —

Temperature (F)

Table 5B — HFC-134a Pressure —

Temperature (C)

TEMPERATURE,

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,

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

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

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 customer’s contractor has verified proper op-

eration of the pumps, cooling tower fans, and associated

auxiliary equipment. This includes ensuring motors are

properly lubricated and have proper electrical supply and

proper rotation.

9. For field-installed starters only, test the chiller compres-

sor motor and its power lead insulation resistance with a

500-v insulation tester such as a megohmmeter. (Use a

5000-v tester for motors rated over 600 v.) Factory-

mounted starters do not require a megohm test.

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.

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

Carrier’s specification for centrifugal compressor use as de-

scribed in the Oil Specification section. Charge the oil through

the oil charging valve located near the bottom of the transmis-

sion housing (Fig. 2). The oil must be pumped from the oil

container through the charging valve due to higher refrigerant

pressure. The pumping device must be able to lift from 0 to

200 psig (0 to 1380 kPa) or above unit pressure. Oil should

only be charged or removed when the chiller is shut down.

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-

er’s requirements. If no schedule is available, the default is fac-

tory set for 24 hours occupied, 7 days per week including

holidays.

For more information about how to set up a time schedule,

see the Controls section, page 10.

The CCN Occupied Schedule (OCCPC03S) should be con-

figured if a CCN system is being installed or if a secondary

time schedule is needed.

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.

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

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 mA

rating for 4 and 5 size compressor. Value is

located on label on side of diffuser actuator

motor.

Motor Rated

Kilowatts

RAMP_DEM — Enter value from chiller requisi-

tion form (product data submittal) if kilowatt ramp

demand is enabled.

CHANGE THE BENSHAW INC., RediStart MICRO™

SOFTWARE CONFIGURATION IF NECESSARY — Ben-

shaw starter configurations are checked and modified from the

menus in the Benshaw Redistart MICRO Default Display. See

Fig. 32 and Table 6 for default display and menu items. To ac-

cess the menus to perform checks and modifications, the Ben-

shaw starter must be powered up and its self-test must have

been successfully completed. The self-test takes place automat-

ically after power-up. Current transformer ratio configurations

and hardware switch settings checks are performed in the

MENU1 display screen. See Table 7 for menu structure and

Table 8 for switch settings.

1. Press the softkey until the desired menu is se-

lected on the display.

2. Press the softkey to access the displayed menu

items (Table 6).

3. Use the or arrow keys to scroll between menu

items until the desired item is reached on the display.

4. Press the softkey to access the value to be

changed.

5. Use the or arrow keys to adjust the new displayed

value. The key increases the value while the key

decreases the value. Holding the arrow key will progres-

sively increase the rate of change. The value will stop

changing when either the factory set minimum or maxi-

mum value is reached. To make fine adjustments press

and release the arrow key.

6. When the correct value has been selected, press the

key to store the new configuration. At this

point, there are two options. The key will return

the display to the main display. The or arrow keys

will move the display to the next menu item. When fin-

ished press the key to return to the main display.

To view other settings and troubleshooting guide consult the

Benshaw RediStart MICRO instructional manual included in

the starter.

Table 6 — Benshaw RediStart

MICRO Menu Structure

Table 7 — Benshaw RediStart MICRO Menu Items*

*These values are not displayed in the ISM_CONFIG table.

Table 8 — Benshaw RediStart MICRO Current Transformer DIP Switch Settings

LEGEND

CT — Current Transformer

ENTER

↓ ↑

ENTER

↑ ↓

ENTER MENU

↑ ↓

MENU 1

Starter Setup

MENU 2

Meter Setup

MENU 3

Event

Recorder

MENU 4

Dry Run

Mode

Initial Current

as % RLA

Meter #1

display

Events 1-99 Dry Run

Mode

Max. Cur

As% LRA

Meter #2

display

Ramp Time

(sec.)

CT Ratio: 1

DESCRIPTION RANGE UNITS DEFAULT

INITIAL CURRENT 50-300 % 125

MAX. CURR AS % LRA 30-70 % 55

RAMP TIME 5-30 SEC 15

CT RATIO 2640-5760 Enter Value from Table 8.

CURRENT TRANSFORMER CT1-CT3

Starter

Frame Size

(Amps)

Motor

RLA Range

(Amps)

Ratio

MIcro Power Card (BIPCMIPWR-C4)

Overload Switch Settings

SW1-1 SW1-2

200 Amps 95- 135 Amps 3900:1 OFF OFF

136- 200 Amps 5760:1 OFF OFF

300 Amps 201- 231 Amps 2640:1 ON OFF

232- 300 Amps 3900:1 ON OFF

480 Amps 301- 340 Amps 3900:1 ON OFF

341- 480 Amps 5760:1 ON OFF

600 Amps 481- 580 Amps 2640:1 ON ON

581- 600 Amps 3900:1 ON ON

740 Amps 601- 740 Amps 3900:1 ON ON

1250 Amps 741- 855 Amps 3900:1 ON ON

856-1250 Amps 5760:1 ON ON

FAULT

RESET

MENU ENTER

DISPLAY

SCROLL UP

SCROLL DOWN

SELECTION

MENU ENTRY

DATA ENTRY

STOP I = OA

READY V = 461V

RediStart MICRO

Fig. 32 — Benshaw RediStart

MICRO Default Display

VERIFY VFD CONFIGURATION AND CHANGE

PARAMETERS IF NECESSARY

Using the Keypad — The keypad display is used to monitor,

view fault history and adjust the program of the VFD

microprocessor. It operates in two modes: Monitor mode and

Program mode:

Use the and keys to:

•Step through the drive parameter menus and error log

when the keypad/display is in Program mode.

•Increase or decrease a numeric value such as the refer-

ence or parameter value.

•Hold down these keys to increase the scroll speed.

Use the softkey to:

•Display a parameter or a selection value in Program

mode.

•Save a value.

•Move through each monitor display item when in Moni-

tor mode.

Monitor Mode (Default Mode) — Specific drive conditions

may be monitored on the keypad when in this mode. An LED

will be illuminated next to the description of what is displayed

on the keypad. Use the softkey to scroll through and

monitor the following selections:

•All LEDs on — Speed request from the CVC/ICVC

•Motor Speed

•Output Frequency

•Output Voltage

•Output Current

Program Mode — This mode displays and modifies the con-

figuration parameters of the VFD microprocessor. Particular

parameters, parameter numbers, and error log information can

be displayed when in Program mode.

Press the softkey until the PROGRAM LED is

illuminated to enter the Program mode.

Use the and keys to move through the menus

Press softkey to select the desired menu.

Press and keys to move through following parameters.

*Vector control is not used in this configuration.

Press softkey to select a parameter menu screen.

Press and keys to adjust the selected parameter.

Press the softkey until the PROGRAM LED

turns off to exit the program.

Accessing Password Protected Parameters — Although the

VFD controller has been preconfigured as the factory, the user

will need to be able to access the parameters to verify the job

specific parameters are correct, tune the controller or correct a

problem. The two passwords protecting the VFD configuration

are Parameter Set Display password and Program Disable

password. The Parameter Set Display password restricts view-

ing. P.nnn parameters above 007 and all H.nnn and R.nnn

screens. The password can be accessed at parameter P.006 and

will switch between enabled and disabled each time the pass-

word 107 is entered. The Program Disable password restricts

the changing of the drive parameter set. To enable or disable

changes select parameter P.051 and enter the password 26.

NOTE: Some of the parameters can be changed only when the

drive is stopped.

See the Initial Start-Up Checklist section for VFD Job Specific

Configuration table. For job specific parameters see inside of

the VFD enclosure door, next to the keypad. Refer to the VFD

Configuration table for the entire list of parameters.

VFD CHILLER FIELD SET UP AND VERIFICATION

Label Locations — Verify the following labels have been

installed properly and match the chiller requisition:

•Surge parameters — Located inside the control panel.

•Chiller identification nameplate — Located on the right

side of the control panel.

•VFD Parameter — Located to the right of the VFD con-

troller keypad on the VFD module.

•VFD Nameplate — Located on the right side of the VFD

as viewed from its front.

•Record all nameplate information on the Reliance Con-

figuration sheet.

Drive Protection and Other Incoming Wiring

1. Verify that the branch disconnects or other local discon-

nects are open and properly tagged out.

2. Verify that the branch circuit protection and AC input

wiring to the VFD are in accordance with NEC/CEC

(National Electrical Code/California Energy Commis-

sion) and all other local codes.

3. Verify that the fuses are per the field wiring diagram.

4. Verify that the incoming source does not exceed 85 kA.

5. Verify the power lugs in the VFD and branch protection

are properly secured. Inspect the ground cable and ensure

it is properly connected at the branch and to the ground

lug in the VFD.

6. Verify the conduit for the power wiring in securely con-

nected to the VFD flanged cover and runs continuously to

the branch protection.

7. Verify that the incoming and outgoing wires have been

properly connected inside of the reactor enclosure if a

separate line reactor has been added to the chiller.

8. Ensure the control and signal wires connected to the chill-

er controller or the VFD are in separate conduit.

IMPORTANT: The VFD controller has been factory con-

figured for use and communications to the Chiller Visual

Controller/International Chiller Visual Controller (CVC/

ICVC). Some parameters are specific to the chiller config-

uration and will need to be verified prior to operation.

Speed control and starting the drive have been disabled at

the VFD keypad. All command functions must be initiated

from the CVC/ICVC.

P.nnn —General Parameters

U.nnn —Vector Control Parameters*

H.nnn —Volts/Hertz Control Parameters

R.nnn —RMI Remote Monitor Interface

Parameters

E.nnn —Error Log (See fault codes)

Changing parameters may adversely affect chiller

operation.

↑ ↓

ENTER

PROGRAM

↑ ↓

ENTER

↑ ↓

ENTER

↑ ↓

PROGRAM

It is the operator’s responsibility to distribute access to the

passwords. Carrier is not responsible for unauthorized

access violations within the operator’s organization. Failure

to observe this warning could result in bodily injury.

Restoring the default parameter P.050 will require all the

Carrier default parameters to be restored manually.

VFD Cooling System Leak Inspection

1. Check for leaks on the refrigerant cooling flange connec-

tions to the VFD enclosure.

2. Check for leaks on all tubing internal to the VFD enclo-

sure, the tubing flair connection to the VFD module and

the TXV valve.

3. Verify that the VFD refrigerant cooling system TXV

valve control bulb is securely inserted into the VFD drive

module heat sink.

Power Up Verification

1. Inspect control wiring inside the VFD and verify the in-

tegrity of the connections between the integrated starter

module (ISM) and the VFD module.

2. Close the control power switch in the VFD enclosure.

3. Close the oil pump power switch inside the VFD

enclosure.

4. Verify the VFD disconnect switch is in the open position.

5. Close and latch the doors of the VFD enclosure.

6. Apply power to the VFD enclosure. Remove lock outs

and close all disconnects.

7. Verify that the CVC/ICVC display powers up and goes to

the default screen.

8. Close the VFD disconnect switch.

9. Verify the following actions during the VFD start-up self

test:

• The display shows SELF and all LEDs are illumi-

nated for 5 to 6 seconds.

• The display reads a 0 after the diagnosis is

complete.

• If Err is displayed a fault has been detected.

Perform manual reset by establishing a reset

through the small hole under the VFD Keypad. If

this does not correct the fault contact your Carrier

representative.

• If AR with a counting down number is displayed

wait for the number to count to 0 and the display

should then revert to a 0. If the counter starts over

at 30 contact Carrier representative.

Configure VFD Parameters — The VFD controller must have

job specific parameters set as defined by the component name-

plates and labels. The parameters come preset by the factory,

but must be verified prior to start-up by accessing the PRO-

GRAM MODE of the VFD controller keypad. For information

on how to access the VFD keypad see page 58.

Press the softkey to access the parameter

screen to modify or view the following job specific parameters:.

Configure Chiller Visual Controller Parameter — The chiller

controller must have its job specific parameters set as defined

by the job sheet or installed nameplates. Below are the job spe-

cific parameters that must be set:

To access the ISM_CONF screen:

1. Press .

2. Press .

3. Enter the password 1111.

4. Select ISM (CONFIG STARTER DATA)

5. Scroll down and select the ISM_CONF DATA screen to

modify or view the ISM parameters:

6. Press to the softkey to save changes.

7. Press the softkey to and exit the ISM Configura-

tion Screen.

VFD Enable Configuration — To access the parameters:

1. Press .

2. Press .

3. Select EQUIPMENT SERVICE.

4. Scroll down and select SETUP2.

5. Verify the following parameters:

Configure Surge Parameters

1. Press .

2. Press .

3. Select EQUIPMENT SERVICE and OPTIONS to verify

the following:

VFD CONTROL VERFICATION (Non-Running) — In order

to verify and, if necessary, tune the speed control signal of the

chiller controller to the VFD (ISM terminal J8 1-2 labeled

4-20 mA OUT VFD) and the speed feedback signal from the

VFD to the chiller controller (ISM terminal J6 1-2 labeled

VFD HZ), follow the steps below.

Set TARGET VFD SPEED to 0%.

1. Press .

VFD

PARAMETER TITLE SETTING

P.004 Maximum

Speed

Line Frequency selected. Per

Compressor Nameplate.

P.006 Password 107

P.028 Speed

Display

Scaling

60 for 60 Hz selection and

50 for 50 Hz selection

H.000 Motor

Voltage

Compressor nameplate voltage.

H.001 Frequency Line Frequency selected. Per

Compressor Nameplate.

H.002 Motor

Amps

Compressor nameplate amps.

H.021 Line

Voltage

VFD nameplate voltage.

H.022 Over

Frequency

Limit

69 for 60 Hz selection and

57 for 50 Hz selection.

PROGRAM

DESCRIPTION SETTING

STARTER TYPE

(2 = SS/VFD)

MOTOR RATED

LINE VOLTAGE

VFD Nameplate Voltage.

MOTOR RATED

LOAD AMPS

VFD Nameplate Chiller Rated Load

Amps

MOTOR LOCKED

ROTOR TRIP

Compressor Nameplate

STARTER LRA RATING 600 for VFD

part #19XVR0414XXX

700 for VFD

part #19XVR0500XXX

900 for VFD

part #19XVR0643XXX

MOTOR CURRENT

CT RATIO:1

163

120 (414A)

3 GRND FAULT CT?

(1=NO)

FREQUENCY-60HZ

(NO=50)

NO for 50 Hz selection

YES for 60 Hz selection

VFD OPTION ENABLED

VFD CURRENT LIMIT COMPRESSOR NAMEPLATE AMPS

DESCRIPTION SETTINGS

SURGE/HGBP

DELTA T1

Surge parameter label

SURGE/HGBP

DELTA P1

Surge parameter label

SURGE/HGBP

DELTA T2

Surge parameter label

SURGE/HGBP

DELTA P2

Surge parameter label

ENTER

SERVICE

SAVE

EXIT

SERVICE

2. Press .

3. Press .

4. Press .

5. Set TARGET VFD SPEED to 0%.

Verify that the ACTUAL VFD SPEED shown on the VFD dis-

play is within 0 to 1 Hz.

1. Press the softkey on the VFD keypad until all

LEDs on the left side of the keypad are illuminated.

NOTE: The value displayed is the frequency at which the

VFD is being commanded to operate.

2. Adjust VFD parameter P.009 (Input Offset) if outside the

tolerance.

To confirm that the speed signal from the CVC/ICVC

corresponds to the value displayed at the VFD:

3. Verify that the actual speed signal feedback to the chiller

controller is 0% by accessing the COMPRESS screen.

4. Verify ACTUAL SPEED VFD is 0%-1% on CVC/ICVC.

5. Adjust VFD parameter r.002 (Analog Output Offset) if

outside the tolerance.

Set VFD TARGET VFD SPEED to 100%.

1. Press .

2. Press .

3. Press .

4. Press .

5. Set TARGET VFD SPEED to 100%.

Verify that the ACTUAL VFD SPEED shown on the VFD dis-

play corresponds to the 50 Hz or 60 Hz setting.

1. Check the ACTUAL VFD SPEED configuration (50 Hz

or 60 Hz) on the ISM_CONF screen.

2. Confirm that the VFD displays the configured line fre-

quency within ± 1 Hz.

3. Adjust parameter P.010 (Input Gain) if outside the

tolerance.

4. Release the TARGET VFD SPEED so that it can operate

in automatic mode. (Refer to Override Operations section

on page 16.)

VFD CONTROL VERIFICATION (Running)

Preparation

1. Disconnect power to the VFD. Verify that the branch dis-

connects or other local disconnects are open and properly

tagged out.

2. Connect a voltmeter and ampmeter to the line side of the

VFD. Locate meters safely away from the power cables.

3. Reconnect power to the VFD.

4. Measure the voltage on the line side of the drive.

5. Verify it is within 10% of the chiller nameplate voltage.

6. Set up the CVC/ICVC temperature controller per the re-

quirements of the job.

7. Start the chiller and verify the rotation of the compressor

just as it starts.

8. Allow the chiller to load up. Verify that the chiller loads

up smoothly.

NOTE: One or two surges may be counted during the first

minute of operation.

Verify That Actual VFD Speed is 100% (±2%)

1. Set the VFD speed to 100%.

2. Verify that the ACTUAL VFD SPEED is 100% (± 2%).

3. If outside the tolerance, adjust r.003 (Output Analog

Gain).

4. Leave running for the next test.

ISM Current Calibration Check

1. With the target VFD speed at 100%, load the chiller so

that the CVC/ICVC default display shows 75% to 100%

under the display title AMPS %. A higher load is

preferred.

2. Measure the incoming current with a separate amp meter.

3. Calculate the line side error ratio using the following

equation:

4. If the Line Side Error Ratio is greater than ± 0.02 adjust

the CVC/ICVC reading by adjusting the ISM CT

ratio.

5. Shut down the chiller.

Change CT Ratio

1. New CT Ratio = Present CT Ratio multiplied by (1+ Line

Side Error Ratio).

To access the ISM_CONF screen:

2. Press .

3. Press .

4. Enter the password 1111.

5. Select ISM (STARTER) CONFIG DATA.

6. Enter password 4444.

7. Select ISM_CONF.

8. Change present CT ratio to new ratio using calculation

above.

9. Press to the softkey to save changes.

10. Press the softkey to exit the ISM_CONF screen.

11. Repeat ISM Current Calibration Check.

VFD Current Control Calibration Check

1. With the target VFD speed at 100%, load the chiller so

that the CVC/ICVC default display shows 75% to 100%

under the display title AMPS %. A higher load is

preferred.

2. Access the current on the keypad of the VFD. Determine

the Load Side Current Ratio, using the equation below.

Load Side Current Ratio =

Next, access the VFD Load Factor on the Capacity Con-

trol screen. Calculate the Load Side Error Ratio using the

equation below:

3. If the load side error ratio is greater than ± 0.02, adjust the

VFD load factor by changing the VFD current limit on

the Setup 2 screen.

a. The new VFD current limit = old VFD current

limit multiplied by (1+ Load Side Error Ratio).

b. Recheck the VFD Current Control Calibration.

c. Release the Speed Control by accessing the TAR-

GET VFD SPEED control.

Press .

(Refer to Override Operations section on page 16.)

STATUS

COMPRESS

SELECT

ENTER

STATUS

COMPRESS

SELECT

Amp Meter current – Ave. ISM current

Amp Meter current

VFD Actual Load Amps

Motor Nameplate Amps

Load Side

Error Ratio =VFD Load Factor – Load Side Current Ratio

Load Side Current Ratio

ENTER

SERVICE

SAVE

EXIT

STATUS

COMPRESS

Protecting the VFD Configuration

1. Select parameter P.051 from the VFD keypad.

2. Press the softkey to access the parameter. A

zero will be displayed.

3. Use the arrow key to increment the value to 26. This is

the password number.

4. Press the softkey to save the value. P.051 will

by displayed.

NOTE: Parameter programming is disabled when the

PASSWORD LED is on and enabled when the PASS-

WORD LED is off.

5. Select parameter P.006 from the VFD Keypad.

6. Press the softkey to access the parameter.

7. Use the arrow key to increment the value to 107. This

is the password number to restrict displaying the remain-

ing P, and all of the H and r parameters.

8. Press the softkey to save the value.

Modify Minimum and Maximum Load Points (∆T1/P1; ∆T2/

P2) If Necessary — These pairs of chiller load points, located

on the OPTIONS screen, determine when to limit guide vane

travel or open the hot gas bypass valve when surge prevention

is needed. These points should be set based on individual

chiller operating conditions.

A label that lists the configuration values of the controls is

located on the inside of the unit’s control panel. These values

are based upon the original selection of the chiller. Jobsite con-

ditions may require a slight modification to these parameters.

If after configuring a value for these points, surge preven-

tion is operating too soon or too late for conditions, these pa-

rameters should be changed by the operator.

An example of such a configuration is shown below.

Refrigerant: HCFC-134a

Estimated Minimum Load Conditions:

44 F (6.7 C) LCW

45.5 F (7.5 C) ECW

43 F (6.1 C) Suction Temperature

70 F (21.1 C) Condensing Temperature

Estimated Maximum Load Conditions:

44 F (6.7 C) LCW

54 F (12.2 C) ECW

42 F (5.6 C) Suction Temperature

98 F (36.7 C) Condensing Temperature

Calculate Maximum Load — To calculate the maximum load

points, use the design load condition data. If the chiller full load

cooler temperature difference is more than 15 F (8.3 C), esti-

mate the refrigerant suction and condensing temperatures at

this difference. Use the proper saturated pressure and tempera-

ture for the particular refrigerant used.

Suction Temperature:

42 F (5.6 C) = 37 psig (255 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:

98 F (36.7 C) = 120 psig (1827 kPa) saturated

refrigerant pressure (HFC-134a)

Maximum Load ∆T2:

54 – 44 = 10º F (12.2 – 6.7 = 5.5º C)

Maximum Load ∆P2:

120 – 37 = 83 psid (827 – 255 = 572 kPad)

To avoid unnecessary surge prevention, add about 10 psid

(70 kPad) to ∆P2 from these conditions:

∆T2 = 10º F (5.5º C)

∆P2 = 93 psid (642 kPad)

Calculate Minimum Load — To calculate the minimum load

conditions, estimate the temperature difference the cooler will

have at 10% load, then estimate what the suction and condens-

ing temperatures will be at this point. Use the proper saturated

pressure and temperature for the particular refrigerant used.

Suction Temperature:

43 F (6.1 C) = 38 psig (262 kPa) saturated

refrigerant pressure (HFC-134a)

Condensing Temperature:

70 F (21.1 C) = 71 psig (490 kPa) saturated

refrigerant pressure (HFC-134a)

Minimum Load ∆T1 (at 20% Load): 2 F (1.1 C)

Minimum Load ∆P1:

71 – 38 = 33 psid (490 – 262 = 228 kPad)

Again, to avoid unnecessary surge prevention, add 20 psid

(140 kPad) at ∆P1 from these conditions:

∆T1 = 2 F (1.1 C)

∆P1 = 53 psid (368 kPad)

If surge prevention occurs too soon or too late:

The differential pressure (∆P) and temperature (∆T) can be

monitored during chiller operation by viewing ACTIVE

DELTA P and ACTIVE DELTA T (HEAT_EX screen). Com-

paring SURGE/HGBP DELTA T to ACTIVE DELTA T will de-

termine when the SURGE PREVENTION function will occur.

The smaller the difference between the SURGE/HGBP DELTA

T and the ACTIVE DELTA T values, the closer to surge

prevention.

Units with VFD — On units with VFD further adjustments can

be made if response to surge prevention or protection is not

functioning as desired. VFD GAIN and VFD INCREASE STEP

can be adjusted to allow for more aggressive changes in speed

when surge prevention or protection is active.

CONFIGURE DIFFUSER CONTROL IF NECES-

SARY — If the compressor is equipped with a variable dif-

fuser, (size 5 compressor) access the SETUP2 screen. Scroll to

DIFFUSER CONTROL and press the softkey.

Compare the diffuser and guide vane values (GUIDE VANE

25% LOAD PT, GUIDE VANE 50% LOAD PT, GUIDE VANE

75% LOAD PT, DIFFUSER 25% LOAD POINT, DIFFUSER

50% LOAD POINT, DIFFUSER 75% LOAD POINT) to the

values located on the label inside the control panel. See

Fig. 12.

Compressors with variable diffuser control have actuators

tested and stamped with the milliamp (mA) value that results in

100% actuator rotation. This value is configured on the

SETUP2 screen. It is labeled DIFFUSER FULL SPAN mA.

MODIFY EQUIPMENT CONFIGURATION IF NECES-

SARY — The EQUIPMENT SERVICE table has screens to

select, view, or modify parameters. Carrier’s certified drawings

have the configuration values required for the jobsite. Modify

these values only if requested.

SERVICE Screen Modifications — Change the values on

these screens according to specific job data. See the certified

drawings for the correct values. Modifications can include:

•chilled water reset

•entering chilled water control (Enable/Disable)

•4 to 20 mA demand limit

•auto restart option (Enable/Disable)

•remote contact option (Enable/Disable)

ENTER

↑

ENTER

↑

ENTER

LOAD SURGE PREVENTION

OCCURS TOO SOON

SURGE PREVENTION

OCCURS TOO LATE

At low loads

(<50%)

Increase P1 by

2 psid (14 kPad)

Decrease P1 by

2 psid (14 kPad)

At high loads

(>50%)

Increase P2 by

2 psid (14 kPad)

Decrease P2 by

2 psid (14 kPad)

ENABLE

Owner-Modified CCN Tables — The following EQUIP-

MENT CONFIGURATION screens are described for refer-

ence only.

OCCDEFCS — The OCCDEFCS screen contains the Local

and CCN time schedules, which can be modified here or on the

SCHEDULE screen as described previously.

HOLIDAYS — From the HOLIDAYS screen, the days of the

year that holidays are in effect can be configured. See the holi-

day paragraphs in the Controls section for more details.

BRODEF — The BRODEF screen defines the start and end of

daylight savings time. Enter the dates for the start and end of

daylight savings if required for your location. BRODEF also

activates the Broadcast function which enables the holiday

periods that are defined on the CVC/ICVC to take effect.

Other Tables — The CONSUME, NET_OPT, and RUN-

TIME screens contain parameters used with a CCN system.

See the applicable CCN manual for more information on these

screens. These tables can only be defined from a CCN Build-

ing Supervisor.

Perform a Control Test — Check the safety controls

status by performing an automated control test. Access the

CONTROL TEST table and select a test to be performed func-

tion (Table 9).

The Automated Control Test checks all outputs and inputs

for function. In order to successfully proceed with the controls

test, the compressor should be off, no alarms showing, and volt-

age should be within ±10% of rating plate value. The compres-

sor can be put in OFF mode by pressing the STOP push-button

on the CVC/ICVC. Each test asks the operator to confirm the

operation is occurring and whether or not to continue. If an er-

ror occurs, the operator can try to address the problem as the

test is being done or note the problem and proceed to the next

test.

NOTE: Enter guide vane calibration to calibrate guide

input on CCM (Plug J4 upper terminal 9 and 10).

NOTE: If during the control test the guide vanes do not open,

verify the low pressure alarm is not active. (An active low

pressure alarm causes the guide vanes to close.)

NOTE: The oil pump test will not energize the oil pump if

cooler pressure is below –5 psig (–35 kPa).

When the control test is finished or the softkey is

pressed, the test stops, and the CONTROL TEST menu dis-

plays. If a specific automated test procedure is not completed,

access the particular control test to test the function when ready.

The CONTROL TEST menu is described in the table below.

*Diffuser tests function only on size 4 and 5 compressor with diffuser control

enabled.

NOTE: During any of the tests, an out-of-range reading will have an asterisk

(*) next to the reading and a message will be displayed if you have diffuser

control enabled.

COOLER CONDENSER PRESSURE TRANSDUCER

AND WATERSIDE FLOW DEVICE CALIBRATION

(Optional with ICVC inputs available) — Calibration can be

checked by comparing the pressure readings from the

transducer to an accurate refrigeration gage reading. These

readings can be viewed or calibrated from the HEAT_EX

screen on the CVC/ICVC. The transducer can be checked and

calibrated at 2 pressure points. These calibration points are

0 psig (0 kPa) and between 25 and 250 psig (173 and

1724 kPa). To calibrate these transducers:

1. Shut down the compressor, cooler, and condenser pumps.

NOTE: There should be no flow through the heat

exchangers.

2. Disconnect the transducer in question from its Schrader

fitting for cooler or condenser transducer calibration. For

oil pressure or flow device calibration keep transducer in

place.

NOTE: If the cooler or condenser vessels are at 0 psig

(0 kPa) or are open to atmospheric pressure, the transduc-

ers can be calibrated for zero without removing the trans-

ducer from the vessel.

3. Access the HEAT_EX screen and view the particular

transducer reading (the EVAPORATOR PRESSURE or

CONDENSER PRESSURE parameter on the HEAT_EX

screen). To calibrate oil pressure or waterside flow de-

vice, view the particular reading (CHILLED WATER

DELTA P and CONDENSER WATER DELTA P on the

HEAT_EX screen and OIL PUMP DELTA P on the

COMPRESS screen). It should read 0 psi (0 kPa). If the

reading is not 0 psi (0 kPa), but within ±5 psi (35 kPa),

the value may be set to zero by pressing the

softkey while the appropriate transducer parameter is

highlighted on the CVC/ICVC screen. Then press the

softkey. The value will now go to zero. No high

end calibration is necessary for OIL PUMP DELTA P or

flow devices.

If the transducer value is not within the calibration range,

the transducer returns to the original reading. If the pres-

sure is within the allowed range (noted above), check the

voltage ratio of the transducer. To obtain the voltage ratio,

divide the voltage (dc) input from the transducer by the

supply voltage signal (displayed in CONTROL TEST

menu in the CCM PRESSURE TRANSDUCERS

screen) or measure across the positive (+ red) and nega-

tive (– black) leads of the transducer. For example, the

condenser transducer voltage input is measured at CCM

terminals J2-4 and J2-5. The voltage ratio must be be-

tween 0.80 and 0.11 for the software to allow calibration.

Rotate the waterside flow pressure device from the inlet

nozzle to the outlet nozzle and repeat this step. If rotating

the waterside flow device does not allow calibration then

pressurize the transducer until the ratio is within range.

Then attempt calibration again.

4. A high pressure point can also be calibrated between 25

and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-

lated 250 psig (1724 kPa) pressure (usually from a nitro-

gen cylinder). The high pressure point can be calibrated

by accessing the appropriate transducer parameter on the

HEAT_EX screen, highlighting the parameter, pressing

the softkey, and then using the

or softkeys to adjust the value to the exact

pressure on the refrigerant gage. Press the soft-

key to finish the calibration. Pressures at high altitude lo-

cations must be compensated for, so the chiller tempera-

ture/pressure relationship is correct.

The PIC II does not allow calibration if the transducer is too

far out of calibration. In this case, a new transducer must be

installed and recalibrated.

CCM Temperature Thermistors Check of all thermistors.

CCM Pressure Transducers Check of all transducers.

Pump

Checks operation of pump outputs;

pumps are activated. Also tests associ-

ated inputs such as flow or pressure.

Discrete outputs Activation of all on/off outputs individu-

ally.

Guide Vane Check of the guide vane operation.

Diffuser Actuator* Check of the diffuser actuator.

Pumpdown/Lockout

Pumpdown prevents the low refrigerant

alarm during evacuation so refrigerant

can be removed form the unit. Also locks

the compressor off and starts the water

pumps.

Terminate Lockout To charge refrigerant and enable the

chiller to run after pumpdown lockout.

Guide Vane Calibration Calibrates guide vane input on CCM.

EXIT

SELECT

ENTER

SELECT INCREASE

DECREASE ENTER

Check Optional Pumpout System Controls

and Compressor — Controls include an on/off switch,

a 3-amp fuse, the compressor overloads, an internal thermostat,

a compressor contactor, and a refrigerant high pressure cutout.

The high pressure cutout is factory set to open at 161 psig

(1110 kPa) and reset at 130 psig (896 kPa). Ensure the water-

cooled condenser has been connected. Loosen the compressor

holddown bolts to allow free spring travel. Open the compres-

sor suction and discharge the service valves. Ensure oil is visi-

ble in the compressor sight glass. Add oil if necessary.

See the Pumpout and Refrigerant Transfer Procedures and

Optional Pumpout System Maintenance sections, pages 67 and

75, for details on the transfer of refrigerant, oil specifications,

etc.

Table 9 — Control Test Menu Functions

High Altitude Locations — Because the chiller is ini-

tially calibrated at sea level, it is necessary to recalibrate the

pressure transducers if the chiller has been moved to a high alti-

tude location. See the calibration procedure in the Trouble-

shooting Guide section.

Charge Refrigerant into Chiller

The standard 19XR chiller is shipped with the refrigerant

already charged in the vessels. However, the 19XR may be or-

dered with a nitrogen holding charge of 15 psig (103 kPa).

Evacuate the nitrogen from the entire chiller, and charge the

chiller from refrigerant cylinders.

CHILLER EQUALIZATION WITHOUT A PUMPOUT

UNIT

To equalize the pressure differential on a refrigerant isolated

19XR chiller, use the terminate lockout function of the CON-

TROL TEST on the SERVICE menu. This helps to turn on

pumps and advises the operator on proper procedures.

The following steps describe how to equalize refrigerant

pressure in an isolated 19XR chiller without a pumpout unit.

1. Access terminate lockout function on the CONTROL

TEST screen.

3. Slowly open the refrigerant cooling isolation valve. The

chiller cooler and condenser pressures will gradually

equalize. This process takes approximately 15 minutes.

4. Once the pressures have equalized, the cooler isolation

valve, the condenser isolation valve, and the hot gas isola-

tion valve may now be opened. Refer to Fig. 29 and 30,

for the location of the valves.

TESTS TO BE

PERFORMED DEVICES TESTED

1. CCM Thermistors Entering Chilled Water

Evaporator Refrigerant Tempera-

ture (ICVC only)

Leaving Chilled Water

Entering Condenser Water

Leaving Condenser Water

Remote Reset Sensor

Comp Discharge Temp

Oil Sump Temp

Comp Motor Winding Temp

Space Temperature 1

Space Temperature 2

2. CCM Pressure

Transducers

Evaporator Pressure

Condenser Pressure

Oil Pump Delta P

Condenser Water Delta P

Transducer Voltage Ref

3. Pumps Chilled Water — Confirm pressure

Condenser Water — Confirm

Delta P

4. Discrete Outputs Oil Heater Relay

Hot Gas Bypass Relay

Tower Fan Relay Low

Tower Fan Relay High

Alarm Relay

Shunt Trip Relay

5. Guide Vane Actuator Open/Close

6. Diffuser Actuator Open/Close

7. Pumpdown Lockout When using pumpdown/lockout,

observe freeze up precautions when

removing charge:

Instructs operator which valves to

close and when.

Starts chilled water and condenser

water pumps and confirms flows.

Monitors

Evaporator pressure

Condenser pressure

Evaporator temperature during

pumpout procedures

Turns pumps off after pumpdown.

Locks out compressor.

8 Terminate Lockout Starts pumps and monitors flows.

Instructs operator which valves to

open and when.

Monitors

Evaporator pressure

Condenser pressure

Evaporator temperature during

charging process

Terminates compressor lockout.

The transfer, addition, or removal of refrigerant in spring

isolated chillers may place severe stress on external piping

if springs have not been blocked in both up and down

directions.

Always operate the condenser and chilled water pumps

during charging operations to prevent freeze-ups.

When equalizing refrigerant pressure on the 19XR chiller

after service work or during the initial chiller start-up, do

not use the discharge isolation valve to equalize. Either the

motor cooling isolation valve or the charging hose (con-

nected between the pumpout valves on top of the cooler

and condenser) should be used as the equalization valve.

Whenever turning the discharge isolation valve, be sure to

reattach the valve locking device. This prevents the valve

from opening or closing during service work or during

chiller operation.

IMPORTANT: Turn on the chilled water and con-

denser water pumps to prevent freezing.

CHILLER EQUALIZATION WITH PUMPOUT UNIT —

The following steps describe how to equalize refrigerant pres-

sure on an isolated 19XR chiller using the pumpout unit.

1. Access the terminate lockout function on the CONTROL

TEST screen.

3. Open valve 4 on the pumpout unit and open valves 1a and

1b on the chiller cooler and condenser, Fig. 29 and 30.

Slowly open valve 2 on the pumpout unit to equalize the

pressure. This process takes approximately 15 minutes.

4. Once the pressures have equalized, the discharge isola-

tion valve, cooler isolation valve, optional hot gas bypass

isolation valve, and the refrigerant isolation valve can be

opened. Close valves 1a and 1b, and all pumpout unit

valves.

The full refrigerant charge on the 19XR will vary with chill-

er components and design conditions, as indicated on the job

data specifications. An approximate charge may be determined

by adding the condenser charge to the cooler charge as listed in

Table 10.

Use the CONTROL TEST terminate lockout function to

monitor conditions and start the pumps.

If the chiller has been shipped with a holding charge, the

refrigerant is added through the pumpout charging connection

(Fig. 29 and 30, valve 1b). First evacuate the nitrogen holding

charge from the chiller vessels. Charge the refrigerant as a gas

until the system pressure exceeds 35 psig (141 kPa) for

HFC-134a. After the chiller is beyond this pressure the refrig-

erant should be charged as a liquid until all the recommended

refrigerant charge has been added. The charging valve (Fig. 29

and 30, valve 7) can be used to charge liquid to the cooler if the

cooler isolation valve (11) is present and is closed. Do not

charge liquid through the linear float to the condenser.

TRIMMING REFRIGERANT CHARGE — The 19XR is

shipped with the correct charge for the design duty of the chill-

er. Trimming the charge can best be accomplished when the

design load is available. To trim the charge, check the tempera-

ture difference between the leaving chilled water temperature

and cooler refrigerant temperature at full load design condi-

tions. If necessary, add or remove refrigerant to bring the

temperature difference to design conditions or minimum

differential.

Table 10 lists the 19XR chiller refrigerant charges for each

cooler and condenser code. Total refrigerant charge is the sum

of the cooler and condenser charge.

Table 10 — Refrigerant (HFC-134a) Charge

INITIAL START-UP

Preparation — Before starting the chiller, verify:

1. Power is on to the main starter, oil pump relay, tower fan

starter, oil heater relay, and the chiller control panel.

2. Cooling tower water is at proper level and at-or-below

design entering temperature.

3. Chiller is charged with refrigerant and all refrigerant and

oil valves are in their proper operating positions.

4. Oil is at the proper level in the reservoir sight glasses.

5. Oil reservoir temperature is above 140 F (60 C) or above

refrigerant temperature plus 50° F (28° C).

6. Valves in the evaporator and condenser water circuits are

open.

NOTE: If the pumps are not automatic, ensure water is

circulating properly.

7. Access the CONTROL TEST screen. Scroll down on the

TERMINATE LOCKOUT option. Press the SELECT (to

enable the chiller to start) and answer YES to reset unit to

operating mode. The chiller is locked out at the factory in

order to prevent accidental start-up.

Whenever turning the discharge isolation valve, be sure to

reattach the valve locking device. This prevents the valve

from opening or closing during service work or during

chiller operation.

Always operate the condenser and chilled water pumps

whenever charging, transferring, or removing refrigerant

from the chiller.

IMPORTANT: Turn on the chilled water and con-

denser water pumps to prevent freezing.

COOLER

CODE

REFRIGERANT

CHARGE CONDENSER

CODE

REFRIGERANT

CHARGE

lb kg lb kg

10 290 132 10 200 91

11 310 141 11 200 91

12 330 150 12 200 91

15 320 145 15 250 113

16 340 154 16 250 113

17 370 168 17 250 113

20 345 157 20 225 102

21 385 175 21 225 102

22 435 197 22 225 102

30 350 159 30 260 118

31 420 190 31 260 118

32 490 222 32 260 118

35 400 181 35 310 141

36 480 218 36 310 141

37 550 250 37 310 141

40 560 254 40 280 127

41 630 286 41 280 127

42 690 313 42 280 127

45 640 290 45 330 150

46 720 327 46 330 150

47 790 358 47 330 150

50 750 340 50 400 181

51 840 381 51 400 181

52 900 408 52 400 181

55 870 395 55 490 222

56 940 426 56 490 222

57 980 445 57 490 222

60 940 426 60 420 190

61 980 445 61 420 190

62 1020 463 62 420 190

65 1020 463 65 510 231

66 1060 481 66 510 231

67 1090 494 67 510 231

70 1220 553 70 780 354

71 1340 608 71 780 354

72 1440 653 72 780 354

75 1365 619 75 925 420

76 1505 683 76 925 420

77 1625 737 77 925 420

80 1500 680 80 720 327

81 1620 735 81 720 327

82 1730 785 82 720 327

85 1690 766 85 860 390

86 1820 825 86 860 390

87 1940 880 87 860 390

Do not permit water or brine that is warmer than 110 F

(43 C) to flow through the cooler or condenser. Refrigerant

overpressure may discharge through the relief valves and

result in the loss of refrigerant charge.

Dry Run to Test Start-Up Sequence

For electro-mechanical starters.

1. Disengage the main motor disconnect (CB1) on the start-

er front panel. This should only disconnect the motor

power. Power to the controls, oil pump, and starter con-

trol circuit should still be energized.

2. Observe the default screen on the CVC/ICVC: the status

message in the upper left-hand corner reads, “Manually

Stopped,” Press the or softkey to start.

If the chiller controls do not go into a start mode (“Unoc-

cupied Mode” is displayed) go to the SCHEDULE screen

and override the schedule or change the occupied

time. Press the softkey to begin the start-up

sequences.

3. View the STARTUP display screen and verify the chilled

water and condenser water pumps have energized.

4. Verify the oil pump has started and is pressurizing the

lubrication system. After the oil pump has run about

11 seconds, the starter energizes (COMPRESSOR START

CONTACT is closed) and goes through its start-up

sequence.

5. Check the main contactor (1M) for proper operation.

6. The PIC II eventually shows an alarm for motors amps

not sensed. Reset this alarm and continue with the initial

start-up.

For Benshaw Inc. solid-state starters:

1. Close the main motor disconnect (CB1). Voltage will be

applied to the compressor motor but the SCRs will not

fire (compressor motor will not rotate). Enter MENU 4 in

the Benshaw RediStart MICRO™ Menu structure at the

Benshaw display (see Input Service Configurations,

Change The Benshaw RediStart MICRO Software Con-

figuration page 57). Select Dry Run Mode and scroll to

YES.

2. Follow steps 2 through 4 for the electro-mechanical start-

ers. When the Ramp Time is set for less than 10 seconds

COMPRESSOR RUN CONTACT will close.

3. The PIC II eventually shows an alarm for motors amps

not sensed. Reset this alarm and enter MENU 4 in the

Benshaw display. Select Dry Run Mode and scroll to NO.

Continue with the initial start-up.

Check Motor Rotation

1. Engage the oil pump circuit breaker (CB3) located inside

the right hand side of the starter panel.

2. Then engage the control power circuit breaker (CB2) lo-

cated in the same section of the starter cabinet.

3. Finally close the main motor disconnect (CB1) on the

front of the starter panel.

4. The ISM mounted in the electro-mechanical starters

checks for proper phase rotation as soon as power is

applied to the starter and the PIC II controls power up.

Solid-state starters have phase protection and do not per-

mit a start if the phase rotation is not correct.

5. An alarm message will appear on the CVC/ICVC if the

phase rotation is incorrect. If this occurs reverse any 2 of

the 3 incoming power leads to the starter and reapply

power. The motor is now ready for a rotation check.

6. After the default screen status message states ‘Ready to

Start’ press the softkey. The PIC II control per-

forms start-up checks.

7. When the starter is energized and the motor begins to

turn, check for clockwise motor rotation (Fig. 33).

Check Oil Pressure and Compressor Stop

1. When the motor is at full speed, note the differential oil

pressure reading on the CVC/ICVC default screen. It

should be between 18 and 30 psid (124 to 206 kPad).

2. Press the Stop button and listen for any unusual sounds

from the compressor as it coasts to a stop.

To Prevent Accidental Start-Up — A chiller STOP

override setting may be entered to prevent accidental start-up

during service or whenever necessary. Access the MAINSTAT

screen and using the or softkeys, high-

light the CHILLER START/STOP parameter. Override the cur-

rent START value by pressing the softkey. Press the

softkey followed by the softkey. The word

SUPVSR! displays on the CVC/ICVC indicating the override

is in place.

To restart the chiller the STOP override setting must be re-

moved. Access the MAINSTAT screen and using or

softkeys highlight CHILLER START/STOP. The

3 softkeys that appear represent 3 choices:

• — forces the chiller ON

• — forces the chiller OFF

• — puts the chiller under remote or schedule

control.

To return the chiller to normal control, press the

softkey followed by the softkey. For

more information, see Local Start-Up, page 46.

The default CVC/ICVC screen message line indicates

which command is in effect.

Check Chiller Operating Condition — Check to

be sure that chiller temperatures, pressures, water flows, and

oil and refrigerant levels indicate the system is functioning

properly.

Instruct the Customer Operator — Ensure the op-

erator(s) understand all operating and maintenance procedures.

Point out the various chiller parts and explain their function as

part of the complete system.

COOLER-CONDENSER — Float chamber, relief valves, re-

frigerant charging valve, temperature sensor locations, pressure

transducer locations, Schrader fittings, waterboxes and tubes,

and vents and drains.

CCN LOCAL

LOCAL

Do not check motor rotation during coastdown. Rotation

may have reversed during equalization of vessel pressures.

NEXT PREVIOUS

SELECT

STOP ENTER

START

STOP

RELEASE

RELEASE ENTER

Fig. 33 — Correct Motor Rotation

OPTIONAL PUMPOUT STORAGE TANK AND PUMP-

OUT SYSTEM — Transfer valves and pumpout system, refrig-

erant charging and pumpdown procedure, and relief devices.

MOTOR COMPRESSOR ASSEMBLY — Guide vane actu-

ator, transmission, motor cooling system, oil cooling system,

temperature and pressure sensors, oil sight glasses, integral oil

pump, isolatable oil filter, extra oil and motor temperature sen-

sors, synthetic oil, and compressor serviceability.

MOTOR COMPRESSOR LUBRICATION SYSTEM —

Oil pump, cooler filter, oil heater, oil charge and specification,

operating and shutdown oil level, temperature and pressure,

and oil charging connections.

CONTROL SYSTEM — CCN and LOCAL start, reset,

menu, softkey functions, CVC/ICVC operation, occupancy

schedule, set points, safety controls, and auxiliary and optional

controls.

AUXILIARY EQUIPMENT — Starters and disconnects,

separate electrical sources, pumps, and cooling tower.

DESCRIBE CHILLER CYCLES — Refrigerant, motor

cooling, lubrication, and oil reclaim.

REVIEW MAINTENANCE — Scheduled, routine, and ex-

tended shutdowns, importance of a log sheet, importance of

water treatment and tube cleaning, and importance of maintain-

ing a leak-free chiller.

SAFETY DEVICES AND PROCEDURES — Electrical dis-

connects, relief device inspection, and handling refrigerant.

CHECK OPERATOR KNOWLEDGE — Start, stop, and

shutdown procedures, safety and operating controls, refrigerant

and oil charging, and job safety.

REVIEW THE START-UP OPERATION, AND MAINTE-

NANCE MANUAL.

OPERATING INSTRUCTIONS

Operator Duties

1. Become familiar with the chiller and related equipment

before operating the chiller.

2. Prepare the system for start-up, start and stop the chiller,

and place the system in a shutdown condition.

3. Maintain a log of operating conditions and document any

abnormal readings.

4. Inspect the equipment, make routine adjustments, and

perform a Control Test. Maintain the proper oil and re-

frigerant levels.

5. Protect the system from damage during shutdown periods.

6. Maintain the set point, time schedules, and other PIC

functions.

Prepare the Chiller for Start-Up — Follow the steps

described in the Initial Start-Up section, page 64.

To Start the Chiller

1. Start the water pumps, if they are not automatic.

2. On the CVC/ICVC default screen, press the or

softkey to start the system. If the chiller is in the

OCCUPIED mode and the start timers have expired, the

start sequence will start. Follow the procedure described

in the Start-Up/Shutdown/Recycle Sequence section,

page 46.

Check the Running System — After the compres-

sor starts, the operator should monitor the CVC/ICVC display

and observe the parameters for normal operating conditions:

1. The oil reservoir temperature should be above 120 F

(49 C) during shutdown.

2. The bearing oil temperature accessed on the COMPRESS

table should be 120 to 165 F (49 to 74 C). If the bearing

temperature reads more than 180 F (83 C) with the oil

pump running, stop the chiller and determine the cause of

the high temperature. Do not restart the chiller until

corrected.

3. The oil level should be visible anywhere in one of the two

sight glasses. Foaming oil is acceptable as long as the oil

pressure and temperature are within limits.

4. The oil pressure should be between 18 and 30 psid (124

to 207 kPad) differential, as seen on the CVC/ICVC de-

fault screen. Typically the reading will be 18 to 25 psid

(124 to 172 kPad) at initial start-up.

5. The moisture indicator sight glass on the refrigerant

motor cooling line should indicate refrigerant flow and a

dry condition.

6. The condenser pressure and temperature varies with the

chiller design conditions. Typically the pressure will

range between 60 and 135 psig (390 to 950 kPa) with a

corresponding temperature range of 60 to 105 F (15 to

41 C). The condenser entering water temperature should

be controlled below the specified design entering

water temperature to save on compressor kilowatt

requirements.

7. Cooler pressure and temperature also will vary with the

design conditions. Typical pressure range will be between

60 and 80 psig (410 and 550 kPa), with temperature rang-

ing between 34 and 45 F (1 and 8 C).

8. The compressor may operate at full capacity for a short

time after the pulldown ramping has ended, even though

the building load is small. The active electrical demand

setting can be overridden to limit the compressor IkW, or

the pulldown rate can be decreased to avoid a high

demand charge for the short period of high demand oper-

ation. Pulldown rate can be based on load rate or temper-

ature rate and is accessed on the EQUIPMENT SER-

VICE screen, RAMP_DEM table (Table 2, Example 21).

To Stop the Chiller

1. The occupancy schedule starts and stops the chiller auto-

matically once the time schedule is configured.

2. By pressing the STOP button for one second, the alarm

light blinks once to confirm the button has been pressed.

The compressor will then follow the normal shutdown

sequence as described in the Shutdown Sequence, Start-

Up/Shutdown/Recycle Sequence section, page 46. The

chiller will not restart until the or soft-

key is pressed. The chiller is now in the OFF control

mode.

Do not restart the chiller until the problem is diagnosed

and corrected.

After Limited Shutdown — No special preparations

should be necessary. Follow the regular preliminary checks and

starting procedures.

Preparation for Extended Shutdown — The refrig-

erant should be transferred into the pumpout storage tank (if

supplied; see Pumpout and Refrigerant Transfer Procedures) to

reduce chiller pressure and the possibility of leaks. Maintain a

holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant or

nitrogen to prevent air from leaking into the chiller.

If freezing temperatures are likely to occur in the chiller ar-

ea, drain the chilled water, condenser water, and the pumpout

condenser water circuits to avoid freeze-up. Keep the waterbox

drains open.

LOCAL

CCN

IMPORTANT: Do not attempt to stop the chiller by opening

an isolating knife switch. High intensity arcing may occur.

CCN LOCAL

Leave the oil charge in the chiller with the oil heater and

controls energized to maintain the minimum oil reservoir

temperature.

After Extended Shutdown — Ensure the water sys-

tem drains are closed. It may be advisable to flush the water

circuits to remove any soft rust which may have formed. This

is a good time to brush the tubes and inspect the Schrader fit-

tings on the waterside flow devices for fouling, if necessary.

Check the cooler pressure on the CVC/ICVC default screen

and compare it to the original holding charge that was left in

the chiller. If (after adjusting for ambient temperature changes)

any loss in pressure is indicated, check for refrigerant leaks.

See Check Chiller Tightness section, page 48.

Recharge the chiller by transferring refrigerant from the

pumpout storage tank (if supplied). Follow the Pumpout and

Refrigerant Transfer Procedures section, below. Observe

freeze-up precautions.

Carefully make all regular preliminary and running system

checks. Perform a Control Test before start-up. If the compres-

sor oil level appears abnormally high, the oil may have

absorbed refrigerant. Ensure that the oil temperature is above

140 F (60 C) or above the cooler refrigerant temperature plus

50° F (27° C).

Cold Weather Operation — When the entering con-

denser water temperature drops very low, the operator should

automatically cycle the cooling tower fans off to keep the tem-

perature up. Piping may also be arranged to bypass the cooling

tower. The PIC II controls have a low limit tower fan output

that can be used to assist in this control (terminal 11 and 12 on

ISM).

Manual Guide Vane Operation — It is possible to

manually operate the guide vanes in order to check control

operation or to control the guide vanes in an emergency. Manu-

al operation is possible by overriding the target guide vane

position. Access the COMPRESS screen on the CVC/ICVC

and scroll down to highlight TARGET GUIDE VANE POS. To

control the position, use the or

softkey to adjust to the percentage of guide vane opening that is

desired. Zero percent is fully closed; 100% is fully open. To

release the guide vanes to automatic control, press the

softkey.

NOTE: Manual control overrides the configured pulldown rate

during start-up and permits the guide vanes to open at a faster

rate. Motor current above the electrical demand setting, capac-

ity overrides, and chilled water temperature below the control

point override the manual target and close the guide vanes. For

descriptions of capacity overrides and set points, see the Con-

trols section.

Refrigeration Log — A refrigeration log (as shown in

Fig. 34), is a convenient checklist for routine inspection and

maintenance and provides a continuous record of chiller per-

formance. It is also an aid when scheduling routine mainte-

nance and diagnosing chiller problems.

Keep a record of the chiller pressures, temperatures, and liquid

levels on a sheet similar to the one in Fig. 34. Automatic

recording of PIC II data is possible by using CCN devices such

as the Data Collection module and a Building Supervisor.

Contact a Carrier representative for more information.

PUMPOUT AND REFRIGERANT

TRANSFER PROCEDURES

Preparation — The 19XR may come equipped with an

optional pumpout storage tank, pumpout system, or pumpout

compressor. The refrigerant can be pumped for service work to

either the chiller compressor vessel or chiller condenser vessel

by using the optional pumpout system. If a pumpout storage

tank is supplied, the refrigerant can be isolated in the storage

tank. The following procedures describe how to transfer refrig-

erant from vessel to vessel and perform chiller evacuations.

Operating the Optional Pumpout Unit

1. Be sure that the suction and the discharge service valves

on the optional pumpout compressor are open (back-

seated) during operation. Rotate the valve stem fully

counterclockwise to open. Front-seating the valve closes

the refrigerant line and opens the gage port to compressor

pressure.

2. Ensure that the compressor hold-down bolts have been

loosened to allow free spring travel.

3. Open the refrigerant inlet valve on the pumpout

compressor.

4. Oil should be visible in the pumpout unit compressor

sight glass under all operating conditions and during

shutdown. If oil is low, add oil as described under

Optional Pumpout System Maintenance section, page 75.

The pumpout unit control wiring schematic is detailed in

Fig. 35.

TO READ REFRIGERANT PRESSURES during pumpout or

leak testing:

1. The CVC/ICVC display on the chiller control panel is

suitable for determining refrigerant-side pressures and

low (soft) vacuum. To assure the desired range and accu-

racy when measuring evacuation and dehydration, use a

quality vacuum indicator or manometer. This can be

placed on the Schrader connections on each vessel (Fig.

9) by removing the pressure transducer.

2. To determine pumpout storage tank pressure, a 30 in.

-0-400 psi (-101-0-2769 kPa) gage is attached to the stor-

age tank.

3. Refer to Fig. 29, 30, and 36 for valve locations and

numbers.

INCREASE DECREASE

RELEASE

Always run the chiller cooler and condenser water pumps

and always charge or transfer refrigerant as a gas when the

chiller pressure is less than 30 psig (207 kPa). Below these

pressures, liquid refrigerant flashes into gas, resulting in

extremely low temperatures in the cooler/condenser tubes

and possibly causing tube freeze-up.

During transfer of refrigerant into and out of the optional

storage tank, carefully monitor the storage tank level gage.

Do not fill the tank more than 90% of capacity to allow for

refrigerant expansion. Overfilling may result in damage to

the tank or personal injury.

Do not mix refrigerants from chillers that use different

compressor oils. Compressor damage can result.

Transfer, addition, or removal of refrigerant in spring-

isolated chillers may place severe stress on external piping

if springs have not been blocked in both up and down

directions.

REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

Plant MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPE

REMARKS: Indicate shutdowns on safety controls, repairs made and oil or refrigerant added or removed. Include amounts.

Fig. 34 — Refrigeration Log

DATE COOLER CONDENSER COMPRESSOR

OPER-

ATO R

INITIALS

REMARKS

TIME

Refrigerant Water Refrigerant Water

BEARING

TEMP

Oil Motor

Press. Temp

Pressure Temp

Press. Temp

Pressure Temp

Press.

Diff.

Temp

(reser-

voir)

Level

FLA

In Out GPM In Out In Out GPM In Out

Amperage

(or vane

position)

DATE

Chillers with Storage Tanks — If the chiller has iso-

lation valves, leave them open for the following procedures.

The letter “C” describes a closed valve. See Fig. 17, 18, 29,

and 30.

TRANSFER REFRIGERANT FROM PUMPOUT STOR-

AGE TANK TO CHILLER

1. Equalize refrigerant pressure.

a. Use the PIC II terminate lockout function on the

PUMPDOWN LOCKOUT screen, accessed from

the CONTROL TEST table to turn on the water

pumps and monitor pressures.

b. Close pumpout unit valves 2, 4, 5, 8, and 10, and

close chiller charging valve 7; open chiller isola-

tion valves 11, 12, 13, and 14 (if present).

c. Open pumpout unit/storage tank valves 3 and 6,

open chiller valves 1a and 1b.

d. Slowly open valve 5 to increase chiller pressure to

68 psig 35 psig (141 kPa) for HFC-134a. Feed

refrigerant slowly to prevent freeze up.

e. Open valve 5 fully after the pressure rises above

the freeze point of the refrigerant. Open liquid line

valves 7 and 10 until refrigerant pressure

equalizes.

2. Transfer the remaining refrigerant.

a. Close valve 5 and open valve 4.

b. Turn off the chiller water pumps using the CVC/

ICVC (or manually, if necessary).

c. Turn off the pumpout condenser water, and turn on

the pumpout compressor to push liquid out of the

storage tank.

d. Close liquid line valve 7.

e. Turn off the pumpout compressor.

f. Close valves 3 and 4.

g. Open valves 2 and 5.

h. Turn on the pumpout condenser water.

i. Run the pumpout compressor until the pumpout

storage tank pressure reaches 5 psig (34 kPa)

(18 in. Hg [40 kPa absolute] if repairing the tank).

j. Turn off the pumpout compressor.

k. Close valves 1a, 1b, 2, 5, 6, and 10.

l. Turn off pumpout condenser water.

If the chilled water and condenser water pumps are not

controlled by the PIC II, these pumps must be started and

stopped manually at the appropriate times during the refrig-

erant transfer procedure.

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CCCCCC

Follow Steps d and e carefully to prevent damage from

freeze-up.

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CC C

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CCC

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CC CC

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CCCCCCCCCC

OIL RETURN

LINE

CONNECTION

CONDENSER

WATER

CONNECTIONS

REFRIGERANT

INLET VALVE

LEGEND

*Bimetal thermal protector imbedded in motor winding.

Fig. 35 — 19XR Pumpout Unit Wiring Schematic

C—Contactor

FU —Fuse, 3 Amps

HP —High-Pressure Cutout

OL —Compressor Overload

T’STAT —Internal Thermostat

Compressor Terminal

Contactor Terminal

Overload Terminal

Pumpout Unit Terminal

Fig. 36 — Optional Pumpout Unit

TRANSFER REFRIGERANT FROM CHILLER TO PUMP-

OUT STORAGE TANK

1. Equalize refrigerant pressure.

a. Valve positions:

b. Slowly open valve 5. When the pressures are

equalized, open liquid line valve 7 to allow liquid

refrigerant to drain by gravity into the pumpout

storage tank.

2. Transfer the remaining liquid.

a. Turn off the pumpout condenser water. Place the

valves in the following positions:

b. Run the pumpout compressor for approximately

30 minutes; then close valve 10.

c. Turn off the pumpout compressor.

3. Remove any remaining refrigerant.

a. Turn on the chiller water pumps using the PUMP-

DOWN LOCKOUT screen, accessed from the

CONTROL TEST table. Turn on the pumps manu-

ally, if they are not controlled by the PIC II.

b. Turn on the pumpout condenser water.

c. Place valves in the following positions:

d. Run the pumpout compressor until the chiller pres-

sure reaches 30 psig (207 kPa) for HFC-134a.

Then, shut off the pumpout compressor. Warm

condenser water will boil off any entrapped liquid

refrigerant and the chiller pressure will rise.

e. When the pressure rises to 40 psig (276 kPa) for

HFC-134a, turn on the pumpout compressor until

the pressure again reaches 30 psig (207 kPa), and

then turn off the pumpout compressor. Repeat this

process until the pressure no longer rises. Then,

turn on the pumpout compressor and pump until

the pressure reaches18 in. Hg. (40 kPa absolute).

f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.

g. Turn off the pumpout condenser water and con-

tinue to use the PIC II PUMPDOWN LOCKOUT

screen functions, which lock out the chiller com-

pressor for operation.

4. Establish a vacuum for service.

To conserve refrigerant, operate the pumpout compressor

until the chiller pressure is reduced to 18 in. Hg vac., ref

30 in. bar. (40 kPa abs.) following Step 3e.

Chillers with Isolation Valves

TRANSFER ALL REFRIGERANT TO CHILLER CON-

DENSER VESSEL — For chillers with isolation valves,

refrigerant can be stored in one chiller vessel or the other with-

out the need for an external storage tank.

1. Push refrigerant into the chiller condenser.

a. Valve positions:

b. Using the PIC II controls, turn off the chiller water

pumps and pumpout condenser water. If the chiller

water pumps are not controlled through the PIC II,

turn them off manually.

c. Turn on the pumpout compressor to push the liquid

refrigerant out of the chiller cooler vessel.

d. When all liquid refrigerant has been pushed into

the chiller condenser vessel, close chiller isolation

valve 11.

e. Access the PUMPDOWN LOCKOUT screen on

the PIC II CONTROL TEST table to turn on the

chiller water pumps. If the chiller water pumps

are not controlled by the PIC II, turn them on

manually.

f. Turn off the pumpout compressor.

2. Evacuate the refrigerant gas from chiller cooler vessel.

a. Close pumpout compressor valves 2 and 5, and

open valves 3 and 4.

b. Turn on the pumpout condenser water.

c. Run the pumpout compressor until the chiller

cooler vessel pressure reaches 18 in. Hg vac

(40 kPa abs.). Monitor pressures on the CVC/

ICVC and on refrigerant gages.

d. Close valve 1a.

e. Turn off the pumpout compressor.

f. Close valves 1b, 3, and 4.

g. Turn off the pumpout condenser water.

h. Proceed to the PUMPDOWN/LOCKOUT function

accessed from the CONTROL TEST table to turn

off the chiller water pumps and lock out the chiller

compressor. Turn off the chiller water pumps man-

ually if they are not controlled by the PIC II.

TRANSFER ALL REFRIGERANT TO CHILLER

COOLER VESSEL

1. Push the refrigerant into the chiller cooler vessel.

a. Valve positions:

b. Turn off the chiller water pumps (either through

the PIC II controls or manually, if necessary) and

the pumpout condenser water.

c. Turn on the pumpout compressor to push the

refrigerant out of the chiller condenser.

d. When all liquid refrigerant is out of the chiller con-

denser, close the cooler isolation valve 11.

e. Turn off the pumpout compressor.

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CCCCC

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CC C

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CC C

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CC CC

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CCCC

VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14

CONDITION CCCCCCCCCC

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION CC C CCC

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION C CCCCCC

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION CCCCCCCCCCC

VALVE 1a1b 2 3 4 5 8 11121314

CONDITION CCCCCC

2. Evacuate the refrigerant gas from the chiller condenser

vessel.

a. Access the PUMPDOWN LOCKOUT function

accessed from the CVC/ICVC CONTROL TEST

table to turn on the chiller water pumps. Turn the

chiller water pumps on manually if they are not

controlled by the PIC II.

b. Close pumpout unit valves 3 and 4; open valves 2

and 5.

c. Turn on the pumpout condenser water.

d. Run the pumpout compressor until the chiller

condenser pressure reaches 18 in. Hg vac (40 kPa

abs.). Monitor pressure at the CVC/ICVC and at

refrigerant gages.

e. Close valve 1b.

f. Turn off the pumpout compressor.

g. Close valves 1a, 2, and 5.

h. Turn off the pumpout condenser water.

i. Proceed to the PUMPDOWN LOCKOUT test

from the CVC/ICVC CONTROL TEST table to

turn off the chiller water pumps and lock out the

chiller compressor. Turn off the chiller water

pumps manually if they are not controlled by the

PIC II.

RETURN CHILLER TO NORMAL OPERATING

CONDITIONS

1. Ensure vessel that was opened has been evacuated.

2. Access the TERMINATE LOCKOUT function CVC/

ICVC from the CONTROL TEST table to view vessel

pressures and turn on chiller water pumps. If the chiller

water pumps are not controlled by the PIC II, turn them

on manually.

3. Open valves 1a, 1b, and 3.

4. Slowly open valve 5, gradually increasing pressure in the

evacuated vessel to 35 psig (141 kPa). Feed refrigerant

slowly to prevent tube freeze up.

5. Leak test to ensure vessel integrity.

6. Open valve 5 fully.

7. Open valve 11 to equalize the liquid refrigerant level be-

tween the vessels.

8. Close valves 1a, 1b, 3, and 5.

9. Open isolation valves 12, 13, and 14 (if present).

10. Proceed to the TERMINATE LOCKOUT screen (access-

ed from the CONTROL TEST table) to turn off the water

pumps and enable the chiller compressor for start-up. If

the chiller water pumps are not controlled by the PIC II,

turn them off manually.

GENERAL MAINTENANCE

Refrigerant Properties — The standard refrigerant for

the 19XR chiller is HFC-134a. At normal atmospheric pres-

sure, HFC-134a will boil at –14 F (–25 C) and must, therefore,

be kept in pressurized containers or storage tanks. The refriger-

ant is practically odorless when mixed with air and is noncom-

bustible at atmospheric pressure. Read the Material Safety

Data Sheet and the latest ASHRAE Safety Guide for Mechani-

cal Refrigeration to learn more about safe handling of this

refrigerant.

Adding Refrigerant — Follow the procedures de-

scribed in Trim Refrigerant Charge section, page 72.

Removing Refrigerant — If the optional pumpout sys-

tem is used, the 19XR refrigerant charge may be transferred to

a pumpout storage tank or to the chiller condenser or cooler

vessels. Follow the procedures in the Pumpout and Refrigerant

Transfer Procedures section when transferring refrigerant from

one vessel to another.

Adjusting the Refrigerant Charge — If the addi-

tion or removal of refrigerant is required to improve chiller per-

formance, follow the procedures given under the Trim Refrig-

erant Charge section, page 72.

Refrigerant Leak Testing — Because HFC-134a is

above atmospheric pressure at room temperature, leak testing

can be performed with refrigerant in the chiller. Use an elec-

tronic halide leak detector, soap bubble solution, or ultrasonic

leak detector. Ensure that the room is well ventilated and free

from concentration of refrigerant to keep false readings to a

minimum. Before making any necessary repairs to a leak,

transfer all refrigerant from the leaking vessel.

Leak Rate — It is recommended by ASHRAE that chillers

be taken off line immediately and repaired if the refrigerant

leak rate for the entire chiller is more than 10% of the operating

refrigerant charge per year.

In addition, Carrier recommends that leaks totalling less

than the above rate but more than a rate of 0.1% of the total

charge per year should be repaired during annual maintenance

or whenever the refrigerant is transferred for other service

work.

Test After Service, Repair, or Major Leak — If

all the refrigerant has been lost or if the chiller has been opened

for service, the chiller or the affected vessels must be pressure

tested and leak tested. Refer to the Leak Test Chiller section to

perform a leak test.

VALVE 1a 1b 2 3 4 5 8 11 12 13 14

CONDITION CC CCCCC

VALVE 1a 1b 2 3 4 5 8 11 12 13 14

CONDITION CCCCCCCCCCC

VALVE 1a 1b 2 3 4 5 8 11 12 13 14

CONDITION C CCCCCCC

VALVE 1a 1b 2 3 4 5 8 11 12 13 14

CONDITION C C CCCCC

VALVE 1a 1b 2 3 4 5 8 11 12 13 14

CONDITION CCCCCCC

HFC-134a will dissolve oil and some nonmetallic materi-

als, dry the skin, and, in heavy concentrations, may dis-

place enough oxygen to cause asphyxiation. When

handling this refrigerant, protect the hands and eyes and

avoid breathing fumes.

Always use the compressor pumpdown function in the

Control Test table to turn on the cooler pump and lock out

the compressor when transferring refrigerant. Liquid refrig-

erant may flash into a gas and cause possible freeze-up

when the chiller pressure is below 30 psig (207 kPa) for

HFC-134a.

TESTING WITH REFRIGERANT TRACER — Use an en-

vironmentally acceptable refrigerant as a tracer for leak test

procedures. Use dry nitrogen to raise the machine pressure to

leak testing levels.

TESTING WITHOUT REFRIGERANT TRACER — An-

other method of leak testing is to pressurize with nitrogen only

and to use a soap bubble solution or an ultrasonic leak detector

to determine if leaks are present.

TO PRESSURIZE WITH DRY NITROGEN

NOTE: Pressurizing with dry nitrogen for leak testing should

not be done if the full refrigerant charge is in the vessel

because purging the nitrogen is very difficult.

1. Connect a copper tube from the pressure regulator on the

cylinder to the refrigerant charging valve. Never apply

full cylinder pressure to the pressurizing line. Follow the

listed sequence.

2. Open the charging valve fully.

3. Slowly open the cylinder regulating valve.

4. Observe the pressure gage on the chiller and close the

regulating valve when the pressure reaches test level. Do

not exceed 140 psig (965 kPa).

5. Close the charging valve on the chiller. Remove the cop-

per tube if it is no longer required.

Repair the Leak, Retest, and Apply Standing

Vacuum Test — After pressurizing the chiller, test for

leaks with an electronic halide leak detector, soap bubble solu-

tion, or an ultrasonic leak detector. Bring the chiller back to at-

mospheric pressure, repair any leaks found, and retest.

After retesting and finding no leaks, apply a standing vacu-

um test. Then dehydrate the chiller. Refer to the Standing Vacu-

um Test and Chiller Dehydration section (pages 50 and 53) in

the Before Initial Start-Up section.

Checking Guide Vane Linkage — When the chiller

is off, the guide vanes are closed and the actuator mechanism is

in the position shown in Fig. 37. If slack develops in the drive

chain, do the following to eliminate backlash:

1. With the chiller shut down and the actuator fully closed,

remove the chain guard and loosen the actuator bracket

hold-down bolts.

2. Loosen guide vane sprocket adjusting bolts.

3. Pry bracket upwards to remove slack, then retighten the

bracket hold-down bolts.

4. Retighten the guide vane sprocket adjusting bolts. Ensure

that the guide vane shaft is rotated fully in the clockwise

direction in order close it fully.

Trim Refrigerant Charge — If, to obtain optimal chill-

er performance, it becomes necessary to adjust the refrigerant

charge, operate the chiller at design load and then add or re-

move refrigerant slowly until the difference between the leav-

ing chilled water temperature and the cooler refrigerant tem-

perature reaches design conditions or becomes a minimum. Do

not overcharge.

Refrigerant may be added either through the storage tank or

directly into the chiller as described in the Charge Refrigerant

into Chiller section.

To remove any excess refrigerant, follow the procedure in

Transfer Refrigerant from Chiller to Pumpout Storage Tank

section, Steps 1a and b, page 70.

WEEKLY MAINTENANCE

Check the Lubrication System — Mark the oil lev-

el on the reservoir sight glass, and observe the level each week

while the chiller is shut down.

If the level goes below the lower sight glass, check the oil

reclaim system for proper operation. If additional oil is re-

quired, add it through the oil drain charging valve (Fig. 2). A

pump is required when adding oil against refrigerant pressure.

The oil charge for the 19XR compressor depends on the com-

pressor Frame size:

•Frame 2 compressor — 5 gal (18.9 L)

•Frame 3 compressor — 8 gal (30 L)

•Frame 4 compressor — 10 gal (37.8 L)

•Frame 5 compressor — 18 gal (67.8 L)

The added oil must meet Carrier specifications for the

19XR. Refer to Changing Oil Filter and Oil Changes section

on page 73. Any additional oil that is added should be logged

by noting the amount and date. Any oil that is added due to oil

loss that is not related to service will eventually return to the

sump. It must be removed when the level is high.

An oil heater is controlled by the PIC II to maintain oil tem-

perature (see the Controls section) when the compressor is off.

The CVC/ICVC COMPRESS screen displays whether the

heater is energized or not. The heater is energized if the OIL

HEATER RELAY parameter reads ON. If the PIC II shows that

the heater is energized and if the sump is still not heating up,

the power to the oil heater may be off or the oil level may be

too low. Check the oil level, the oil heater contactor voltage,

and oil heater resistance.

The PIC II does not permit compressor start-up if the oil

temperature is too low. The PIC II continues with start-up only

after the temperature is within allowable limits.

HFC-134a should not be mixed with air or oxygen and

pressurized for leak testing. In general, this refrigerant

should not be present with high concentrations of air or

oxygen above atmospheric pressures, because the mixture

can undergo combustion.

Fig. 37 —Guide Vane Actuator Linkage

SCHEDULED MAINTENANCE

Establish a regular maintenance schedule based on your ac-

tual chiller requirements such as chiller load, run hours, and

water quality. The time intervals listed in this section are

offered as guides to service only.

Service Ontime — The CVC/ICVC will display a SER-

VICE ONTIME value on the MAINSTAT screen. This value

should be reset to zero by the service person or the operator

each time major service work is completed so that the time

between service can be viewed and tracked.

Inspect the Control Panel — Maintenance consists of

general cleaning and tightening of connections. Vacuum the

cabinet to eliminate dust build-up. If the chiller control mal-

functions, refer to the Troubleshooting Guide section for con-

trol checks and adjustments.

Check Safety and Operating Controls Monthly —

To ensure chiller protection, the automated Control Test

should be performed at least once per month. See Table 3

for safety control settings. See Table 9 for Control Test

functions.

Changing Oil Filter — Change the oil filter on a

yearly basis or when the chiller is opened for repairs. The

19XR has an isolatable oil filter so that the filter may be

changed with the refrigerant remaining in the chiller. Use

the following procedure:

1. Ensure the compressor is off and the disconnect for the

compressor is open.

2. Disconnect the power to the oil pump.

3. Close the oil filter isolation valves located behind power

panel on top of oil pump assembly.

4. Connect an oil charging hose from the oil charging valve

(Fig. 2) and place the other end in a clean container suit-

able for used oil. The oil drained from the filter housing

should be used as an oil sample and sent to a laboratory

for proper analysis. Do not contaminate this sample.

5. Slowly open the charging valve to drain the oil from the

housing.

6. Once all oil has been drained, place some rags or absor-

bent material under the oil filter housing to catch any

drips once the filter is opened. Remove the 4 bolts from

the end of the filter housing and remove the filter cover.

7. Remove the filter retainer by unscrewing the retainer nut.

The filter may now be removed and disposed of properly.

8. Replace the old filter with a new filter. Install the filter re-

tainer and tighten down the retainer nut. Install the filter

cover and tighten the 4 bolts.

9. Evacuate the filter housing by placing a vacuum pump on

the charging valve. Follow the normal evacuation proce-

dures. Shut the charging valve when done and reconnect

the valve so that new oil can be pumped into the filter

housing. Fill with the same amount that was removed;

then close the charging valve.

10. Remove the hose from the charging valve, open the isola-

tion valves to the filter housing, and turn on the power to

the pump and the motor.

Oil Specification — If oil is added, it must meet the fol-

lowing Carrier specifications:

Oil Type for units using R-134a . . . . . . . . . . . . . . . . . . Inhibited

polyolester-based synthetic

compressor oil formatted for

use with HFC, gear-driven,

hermetic compressors.

ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

The polyolester-based oil (P/N: PP23BZ103) may be

ordered from your local Carrier representative.

Oil Changes — Carrier recommends changing the oil af-

ter the first year of operation and every five years thereafter as

a minimum in addition to a yearly oil analysis. However, if a

continuous oil monitoring system is functioning and a yearly

oil analysis is performed, the time between oil changes can be

extended.

TO CHANGE THE OIL

1. Transfer the refrigerant into the chiller condenser vessel

(for isolatable vessels) or to a pumpout storage tank.

2. Mark the existing oil level.

3. Open the control and oil heater circuit breaker.

4. When the chiller pressure is 5 psig (34 kPa) or less, drain

the oil reservoir by opening the oil charging valve

(Fig. 2). Slowly open the valve against refrigerant

pressure.

5. Change the oil filter at this time. See Changing Oil Filter

section.

6. Change the refrigerant filter at this time, see the next sec-

tion, Refrigerant Filter.

7. Charge the chiller with oil. Charge until the oil level is

equal to the oil level marked in Step 2. Turn on the power

to the oil heater and let the PIC II warm it up to at least

140 F (60 C). Operate the oil pump manually, using the

Control Test function, for 2 minutes. For shutdown condi-

tions, the oil level should be full in the lower sight glass.

If the oil level is above 1/2 full in the upper sight glass, re-

move the excess oil. The oil level should now be equal to

the amount shown in Step 2.

Refrigerant Filter — A refrigerant filter/drier, located on

the refrigerant cooling line to the motor, should be changed

once a year or more often if filter condition indicates a need for

more frequent replacement. Change the filter by closing the fil-

ter isolation valves (Fig. 4) and slowly opening the flare fittings

with a wrench and back-up wrench to relieve the pressure. A

moisture indicator sight glass is located beyond this filter to in-

dicate the volume and moisture in the refrigerant. If the mois-

ture indicator indicates moisture, locate the source of water im-

mediately by performing a thorough leak check.

Oil Reclaim Filter — The oil reclaim system has a

strainer on the eductor suction line, a strainer on the discharge

pressure line, and a filter on the cooler scavenging line.

Replace the filter once per year or more often if filter condition

indicates a need for more frequent replacement. Change the fil-

ter by closing the filter isolation valves and slowly opening the

flare fitting with a wrench and back-up wrench to relieve the

pressure. Change the strainers once every 5 years or whenever

refrigerant is evacuated from the cooler.

Ensure power to the control center is off when cleaning and

tightening connections inside the control panel.

The oil filter housing is at a high pressure. Relieve this

pressure slowly.

Inspect Refrigerant Float System — Perform this

inspection every 5 years or when the condenser is opened for

service.

1. Transfer the refrigerant into the cooler vessel or into a

pumpout storage tank.

2. Remove the float access cover.

3. Clean the chamber and valve assembly thoroughly. Be

sure the valve moves freely. Ensure that all openings are

free of obstructions.

4. Examine the cover gasket and replace if necessary.

See Fig. 38 for a view of the float valve design. For linear

float valve designs, inspect the orientation of the float slide

pin. It must be pointed toward the bubbler tube for proper

operation.

Inspect Relief Valves and Piping — The relief valves

on this chiller protect the system against the potentially danger-

ous effects of overpressure. To ensure against damage to the

equipment and possible injury to personnel, these devices must

be kept in peak operating condition.

As a minimum, the following maintenance is required.

1. At least once a year, disconnect the vent piping at the

valve outlet and carefully inspect the valve body and

mechanism for any evidence of internal corrosion or rust,

dirt, scale, leakage, etc.

2. If corrosion or foreign material is found, do not attempt to

repair or recondition. Replace the valve.

3. If the chiller is installed in a corrosive atmosphere or the

relief valves are vented into a corrosive atmosphere, in-

spect the relief valves at more frequent intervals.

Compressor Bearing and Gear Maintenance —

The key to good bearing and gear maintenance is proper

lubrication. Use the proper grade of oil, maintained at rec-

ommended level, temperature, and pressure. Inspect the

lubrication system regularly and thoroughly.

To inspect the bearings, a complete compressor teardown is

required. Only a trained service technician should remove and

examine the bearings. The cover plate on older compressor

bases was used for factory-test purposes and is not usable

for bearing or gear inspection. The bearings and gears should

be examined on a scheduled basis for signs of wear. The

frequency of examination is determined by the hours of chiller

operation, load conditions during operation, and the condition

of the oil and the lubrication system. Excessive bearing wear

can sometimes be detected through increased vibration or

increased bearing temperature. If either symptom appears, con-

tact an experienced and responsible service organization for

assistance.

Inspect the Heat Exchanger Tubes and Flow

Devices

COOLER AND FLOW DEVICES — Inspect and clean the

cooler tubes at the end of the first operating season. Because

these tubes have internal ridges, a rotary-type tube cleaning

system is needed to fully clean the tubes. Inspect the tubes’

condition to determine the scheduled frequency for future

cleaning and to determine whether water treatment in the

chilled water/brine circuit is adequate. Inspect the entering and

leaving chilled water temperature sensors and flow devices for

signs of corrosion or scale. Replace a sensor or Schrader fitting

if corroded or remove any scale if found.

CONDENSER AND FLOW DEVICES — Since this water

circuit is usually an open-type system, the tubes may be subject

to contamination and scale. Clean the condenser tubes with a

rotary tube cleaning system at least once per year and more of-

ten if the water is contaminated. Inspect the entering and leav-

ing condenser water sensors and flow devices for signs of cor-

rosion or scale. Replace the sensor or Schrader fitting if corrod-

ed or remove any scale if found.

Higher than normal condenser pressures, together with the

inability to reach full refrigeration load, usually indicate dirty

tubes or air in the chiller. If the refrigeration log indicates a rise

above normal condenser pressures, check the condenser refrig-

erant temperature against the leaving condenser water tempera-

ture. If this reading is more than what the design difference is

supposed to be, the condenser tubes may be dirty or water flow

may be incorrect. Because HFC-134a is a high-pressure refrig-

erant, air usually does not enter the chiller.

During the tube cleaning process, use brushes specially de-

signed to avoid scraping and scratching the tube wall. Contact

your Carrier representative to obtain these brushes. Do not use

wire brushes.

Water Leaks — The refrigerant moisture indicator on the

refrigerant motor cooling line (Fig. 2) indicates whether there

is water leakage during chiller operation. Water leaks should be

repaired immediately.

Hard scale may require chemical treatment for its preven-

tion or removal. Consult a water treatment specialist for

proper treatment.

The chiller must be dehydrated after repair of water leaks.

See Chiller Dehydration section, page 53.

LEGEND

Fig. 38 — 19XR Float Valve Design

1—Refrigerant Inlet from FLASC Chamber

2—Linear Float Assembly

3—Float Screen

4—Bubble Line

5—Float Cover

6—Bubble Line Connection

7—Refrigerant Outlet to Cooler

8—Gasket

Water Treatment — Untreated or improperly treated wa-

ter may result in corrosion, scaling, erosion, or algae. The ser-

vices of a qualified water treatment specialist should be ob-

tained to develop and monitor a treatment program.

Inspect the Starting Equipment — Before working

on any starter, shut off the chiller, open and tag all disconnects

supplying power to the starter.

Inspect starter contact surfaces for wear or pitting on

mechanical-type starters. Do not sandpaper or file silverplated

contacts. Follow the starter manufacturer’s instructions for

contact replacement, lubrication, spare parts ordering, and oth-

er maintenance requirements.

Periodically vacuum or blow off accumulated debris on the

internal parts with a high-velocity, low-pressure blower.

Power connections on newly installed starters may relax

and loosen after a month of operation. Turn power off and re-

tighten. Recheck annually thereafter.

Check Pressure Transducers — Once a year, the

pressure transducers should be checked against a pressure gage

reading. Check all eight transducers: the 2 oil differential pres-

sure transducers, the condenser pressure transducer, the cooler

pressure transducer, and the waterside pressure transducers

(consisting of 4 flow devices: 2 cooler, 2 condenser).

Note the evaporator and condenser pressure readings on the

HEAT_EX screen on the CVC/ICVC (EVAPORATOR PRES-

SURE and CONDENSER PRESSURE). Attach an accurate set

of refrigeration gages to the cooler and condenser Schrader fit-

tings. Compare the two readings. If there is a difference in

readings, the transducer can be calibrated as described in the

Troubleshooting Guide section. Oil differential pressure (OIL

PUMP DELTA P on the COMPRESS screen) should be zero

whenever the compressor is off.

Optional Pumpout System Maintenance — For

pumpout unit compressor maintenance details, refer to the

06D, 07D Installation, Start-Up, and Service Instructions.

OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —

Use oil conforming to Carrier specifications for reciprocat-

ing compressor usage. Oil requirements are as follows:

ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Carrier Part Number . . . . . . . . . . . . . . . . . . . . . . . . PP23BZ103

The total oil charge, 4.5 pints (2.6 L), consists of 3.5 pints

(2.0 L) for the compressor and one additional pint (0.6 L) for

the oil separator.

Oil should be visible in one of the compressor sight glasses

during both operation and at shutdown. Always check the oil

level before operating the compressor. Before adding or chang-

ing oil, relieve the refrigerant pressure as follows:

1. Attach a pressure gage to the gage port of either compres-

sor service valve (Fig. 36).

2. Close the suction service valve and open the discharge

line to the storage tank or the chiller.

3. Operate the compressor until the crankcase pressure

drops to 2 psig (13 kPa).

4. Stop the compressor and isolate the system by closing the

discharge service valve.

5. Slowly remove the oil return line connection (Fig. 36).

Add oil as required.

6. Replace the connection and reopen the compressor ser-

vice valves.

OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS

(Fig. 39) — The optional pumpout system high-pressure

switch opens at 161 psig (1110 kPa) and closes at 130 psig

(896 kPa). Check the switch setting by operating the pumpout

compressor and slowly throttling the pumpout condenser

water.

Ordering Replacement Chiller Parts — When

ordering Carrier specified parts, the following information

must accompany an order:

•chiller model number and serial number

•name, quantity, and part number of the part required

•delivery address and method of shipment.

Water must be within design flow limits, clean, and treated

to ensure proper chiller performance and reduce the poten-

tial of tube damage due to corrosion, scaling, erosion, and

algae. Carrier assumes no responsibility for chiller damage

resulting from untreated or improperly treated water.

The disconnect on the starter front panel does not deener-

gize all internal circuits. Open all internal and remote dis-

connects before servicing the starter.

Never open isolating knife switches while equipment is

operating. Electrical arcing can cause serious injury.

Loose power connections can cause voltage spikes, over-

heating, malfunctioning, or failures.

Fig. 39 — Optional Pumpout System Controls

TROUBLESHOOTING GUIDE

Overview — The PIC II has many features to help the op-

erator and technician troubleshoot a 19XR chiller.

•The CVC/ICVC shows the chiller’s actual operating con-

ditions and can be viewed while the unit is running.

•The CVC/ICVC default screen freezes when an alarm

occurs. The freeze enables the operator to view the

chiller conditions at the time of alarm. The STATUS

screens continue to show current information. Once all

alarms have been cleared (by correcting the problems

and pressing the softkey), the CVC/ICVC

default screen returns to normal operation.

•The CONTROL ALGORITHM STATUS screens (which

include the CAPACITY, OVERRIDE, LL_MAINT,

ISM_HIST, LOADSHED, WSMDEFME, and

OCCDEFCM screens) display information that helps to

diagnose problems with chilled water temperature

control, chilled water temperature control overrides, hot

gas bypass, surge algorithm status, and time schedule

operation.

•The control test feature facilitates the proper operation

and test of temperature sensors, pressure transducers, the

guide vane actuator, oil pump, water pumps, tower con-

trol, and other on/off outputs while the compressor is

stopped. It also has the ability to lock off the compressor

and turn on water pumps for pumpout operation. The

CVC/ICVC shows the temperatures and pressures

required during these operations.

•From other SERVICE tables, the operator/technician can

access configured items, such as chilled water resets,

override set points, etc.

•If an operating fault is detected, an alarm message is gen-

erated and displayed on the CVC/ICVC default screen.

A more detailed message — along with a diagnostic

message — is also stored into the ALARM HISTORY

table.

Checking Display Messages — The first area to

check when troubleshooting the 19XR is the CVC/ICVC dis-

play. If the alarm light is flashing, check the primary and sec-

ondary message lines on the CVC/ICVC default screen

(Fig. 14). These messages will indicate where the fault is oc-

curring. These messages contain the alarm message with a

specified code. This code or state appears with each alarm and

alert message. The ALARM HISTORY table on the CVC/

ICVC SERVICE menu also contains an alarm message to fur-

ther expand on the alarm. For a complete list of possible alarm

messages, see Table 11. If the alarm light starts to flash while

accessing a menu screen, press the softkey to return to

the default screen to read the alarm message. The STATUS

screen can also be accessed to determine where an alarm exists.

Checking Temperature Sensors — All temperature

sensors are thermistor-type sensors. This means that the resis-

tance of the sensor varies with temperature. All sensors have

the same resistance characteristics. If the controls are on, deter-

mine sensor temperature by measuring voltage drop; if the con-

trols are powered off, determine sensor temperature by measur-

ing resistance. Compare the readings to the values listed in

Table 12A or 12B.

RESISTANCE CHECK — Turn off the control power and,

from the module, disconnect the terminal plug of the sensor in

question. With a digital ohmmeter, measure sensor resistance

between receptacles as designated by the wiring diagram. The

resistance and corresponding temperature are listed in

Table 12A or 12B. Check the resistance of both wires to

ground. This resistance should be infinite.

VOLTAGE DROP — The voltage drop across any energized

sensor can be measured with a digital voltmeter while the con-

trol is energized. Table 12A or 12B lists the relationship be-

tween temperature and sensor voltage drop (volts dc measured

across the energized sensor). Exercise care when measuring

voltage to prevent damage to the sensor leads, connector plugs,

and modules. Sensors should also be checked at the sensor

plugs. Check the sensor wire at the sensor for 5 vdc if the con-

trol is powered on.

CHECK SENSOR ACCURACY — Place the sensor in a

medium of known temperature and compare that temperature

to the measured reading. The thermometer used to determine

the temperature of the medium should be of laboratory quality

with 0.5° F (.25° C) graduations. The sensor in question should

be accurate to within 2° F (1.2° C).

See Fig. 9 for sensor locations. The sensors are immersed

directly in the refrigerant or water circuits. The wiring at each

sensor is easily disconnected by unlatching the connector.

These connectors allow only one-way connection to the sensor.

When installing a new sensor, apply a pipe sealant or thread

sealant to the sensor threads.

DUAL TEMPERATURE SENSORS — For servicing con-

venience, there are 2 sensors each on the bearing and motor

temperature sensors. If one of the sensors is damaged, the other

can be used by simply moving a wire. The number 2 terminal

in the sensor terminal box is the common line. To use the sec-

ond sensor, move the wire from the number 1 position to the

number 3 position.

Checking Pressure Transducers

UNITS EQUIPPED WITH CVC — There are 8 pressure

transducers on 19XR chillers. They determine cooler, condens-

er, oil pressure, and cooler and condenser flow. The cooler and

condenser transducers are also used by the PIC II to determine

the refrigerant temperatures. The oil supply pressure transducer

value and the oil transmission sump pressure transducer value

difference is calculated by the CCM. The CVC module then

displays the differential pressure. In effect, the CVC reads only

one input for oil pressure for a total of 5 pressure inputs: cooler

pressure, condenser pressure, oil differential pressure, cooler

waterside differential pressure, and condenser waterside differ-

ential pressure. See the Check Pressure Transducers section

(page 75) under Scheduled Maintenance.

UNITS EQUIPPED WITH ICVC — There are 6 factory-

installed pressure transducers, with inputs available for both

cooler and The ICVC software will display a default reading of

26 psi during start-up and operation. An additional transducer,

factory installed in the bottom of the cooler barrel, will read as

EVAPORATOR SACTURATION TEMP on the HEAT_EX

DISPLAY screen. This provides additional protection against a

loss of water flow condition.

These pressure transducers can be calibrated if necessary. It

is not usually necessary to calibrate at initial start-up.

However, at high altitude locations, it is necessary to calibrate

the transducers to ensure the proper refrigerant temperature/

pressure relationship. Each transducer is supplied with 5 vdc

power from the CCM. If the power supply fails, a transducer

voltage reference alarm occurs. If the transducer reading is

suspected of being faulty, check the supply voltage. It should

be 5 vdc ±.5 v displayed in CONTROL TEST under CCM

Pressure Transducers. If the supply voltage is correct, the trans-

ducer should be recalibrated or replaced.

RESET

EXIT

Relieve all refrigerant pressure or drain the water before

replacing the temperature sensors.

TRANSDUCER REPLACEMENT — Since the transducers

are mounted on Schrader-type fittings, there is no need to re-

move refrigerant from the vessel when replacing the transduc-

ers. Disconnect the transducer wiring. Do not pull on the trans-

ducer wires. Unscrew the transducer from the Schrader fitting.

When installing a new transducer, do not use pipe sealer

(which can plug the sensor). Put the plug connector back on the

sensor and snap into place. Check for refrigerant leaks.

Control Algorithms Checkout Procedure — One

of the tables on the CVC/ICVC SERVICE menu is CON-

TROL ALGORITHM STATUS. The maintenance screens

may be viewed from the CONTROL ALGORITHM STATUS

table to see how a particular control algorithm is operating.

These maintenance screens are very useful in helping to de-

termine how the control temperature is calculated and guide

vane positioned and for observing the reactions from load

changes, control point overrides, hot gas bypass, surge preven-

tion, etc. The tables are:

Control Test — The Control Test feature can check all the

thermistor temperature sensors, pressure transducers, pumps

and their associated flow devices, the guide vane actuator, and

other control outputs such as hot gas bypass. The tests can help

to determine whether a switch is defective or a pump relay is

not operating, as well as other useful troubleshooting issues.

During pumpdown operations, the pumps are energized to pre-

vent freeze-up and the vessel pressures and temperatures are

displayed. The Pumpdown/Lockout feature prevents compres-

sor start-up when there is no refrigerant in the chiller or if the

vessels are isolated. The Terminate Lockout feature ends the

Pumpdown/Lockout after the pumpdown procedure is reversed

and refrigerant is added.

LEGEND TO TABLES 11A-11J

Be sure to use a back-up wrench on the Schrader fitting

whenever removing a transducer, since the Schrader fitting

may back out with the transducer, causing a large leak and

possible injury to personnel.

CAPACITY Capacity

Control

This table shows all values used

to calculate the chilled water/brine

control point.

OVERRIDE Override

Status

Details of all chilled water control

override values.

HEAT_EX Surge/

HGBP

Status

The surge and hot gas bypass

control algorithm status is viewed

from this screen. All

values dealing with this control

are displayed.

LL_MAINT LEAD/LAG

Status

Indicates LEAD/LAG operation

status.

OCCDEFCM Time

Schedules

Status

The Local and CCN occupied

schedules are displayed here to

help the operator quickly deter-

mine whether the schedule is in

the “occupied” mode or not.

WSMDEFME Water

System

Manager

Status

The water system manager is a

CCN module that can turn on the

chiller and change the chilled

water control point. This screen

indicates the

status of this system.

CCM —Chiller Control Module

CVC —Chiller Visual Controller

CHW —Chilled Water

ICVC —International Chiller Visual

Control

ISM —Integrated Starter Module

PIC II —Product Integrated Controls II

VFD —Variable Frequency Drive

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides

A. MANUAL STOP

B. READY TO START

C. IN RECYCLE SHUTDOWN

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

MANUALLY STOPPED — PRESS CCN OR LOCAL TO START PIC II in OFF mode, press CCN or LOCAL softkey to start unit.

TERMINATE PUMPDOWN MODE TO SELECT CCN OR LOCAL Enter the CONTROL TEST table and select TERMINATE LOCKOUT to

unlock compressor.

SHUTDOWN IN PROGRESS COMPRESSOR UNLOADING Chiller unloading before shutdown due to soft/stop feature.

SHUTDOWN IN PROGRESS COMPRESSOR DEENERGIZED Chiller compressor is being commanded to stop. Water pumps are

deenergized within one minute.

ICE BUILD OPERATION COMPLETE Chiller shutdown from Ice Build operation.

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

READY TO START IN XX MIN UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chillers will start only when

occupied.

READY TO START IN XX MIN REMOTE CONTACTS OPEN Remote contacts are open. Close contacts to start.

READY TO START IN XX MIN STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release

point to start.

READY TO START IN XX MIN OCCUPIED MODE Chiller timer counting down. Unit ready to start.

READY TO START IN XX MIN REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready to start. Remote contact enabled

and closed.

READY TO START IN XX MIN START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start. Release

value to start under normal control.

READY TO START IN XX MIN RECYCLE RESTART PENDING Chiller in recycle mode.

READY TO START UNOCCUPIED MODE Time schedule for PIC II is unoccupied. Chiller will start when occupied.

Make sure the time and date are correct. Change values in TIME AND

DATE screen.

READY TO START REMOTE CONTACTS OPEN Remote contacts have stopped the chiller. Close contacts to start.

READY TO START STOP COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to stop. Release

point to start.

READY TO START OCCUPIED MODE Chiller timers complete, unit start will commence.

READY TO START REMOTE CONTACTS CLOSED Chiller timer counting down. Unit ready for start.

READY TO START START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT has been manually forced to start.

Chiller will start regardless of time schedule or remote contact status.

STARTUP INHIBITED LOADSHED IN EFFECT CCN loadshed module commanding chiller to stop.

PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY

RECYCLE RESTART PENDING OCCUPIED MODE Unit in recycle mode, chilled water temperature is not sufficiently

above set point to start.

RECYCLE RESTART PENDING REMOTE CONTACT CLOSED Unit in recycle mode, chilled water temperature is not sufficiently

above set point to start.

RECYCLE RESTART PENDING START COMMAND IN EFFECT Chiller START/STOP on MAINSTAT manually forced to start, chilled

water temperature is not sufficiently above set point to start.

RECYCLE RESTART PENDING ICE BUILD MODE Chiller in ICE BUILD mode. Chilled fluid temperature is satisfied for

ICE BUILD conditions.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.

*[LIMIT] is shown on the CVC/ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.

[VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

E. START-UP IN PROGRESS

F. NORMAL RUN

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

100 PRESTART

ALERT

STARTS LIMIT

EXCEEDED

100->Excessive compressor

starts (8 in 12 hours)

Depress the RESET softkey if additional start is

required. Reassess start-up requirements.

101 PRESTART

ALERT

HIGH BEARING

TEMPERATURE

101->Comp Thrust Bearing

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check oil heater for proper operation.

Check for low oil level, partially closed coil supply

valves, clogged oil filters, etc.

Check the sensor wiring and accuracy.

Check configurable range in SETUP1 screen.

102 PRESTART

ALERT

HIGH MOTOR

TEMPERATURE

102->Comp Motor Winding Temp

[VALUE] exceeded limit

of [LIMIT]*.

Check motor sensors for wiring and accuracy.

Check motor cooling line for proper operation, or

restrictions.

Check for excessive starts within a short time span.

Check configurable range in SETUP1 screen.

103 PRESTART

ALERT

HIGH DISCHARGE

TEMP

103->Comp Discharge Temp

[VALUE] exceeded limit of

[LIMIT]*.

Allow discharge sensor to cool.

Check for sensor wiring and accuracy.

Check for excessive starts.

Check configurable range in SETUP1 screen.

104 PRESTART

ALERT

LOW REFRIGERANT

TEMP

104->Evaporator Refrig Temp

[VALUE] exceeded limit of

[LIMIT]*.

Check transducer wiring and accuracy.

Check for low chilled fluid supply temperatures.

Check refrigerant charge.

105 PRESTART

ALERT

LOW OIL

TEMPERATURE

105->Oil Sump Temp [VALUE]

exceeded limit of [LIMIT]*.

Check oil heater contactor/relay and power.

Check oil level and oil pump operation.

106 PRESTART

ALERT

HIGH CONDENSER

PRESSURE

106->Condenser Pressure

[VALUE] exceeded limit of

[LIMIT]*.

Check transducer wiring and accuracy.

Check for high condenser water temperatures.

107 PRESTART

ALERT

LOW LINE

VOLTAGE

107->Average Line Voltage

[VALUE] exceeded limit of

[LIMIT]*.

Check voltage supply. Check voltage transformers.

Consult power utility if voltage is low.

108 PRESTART

ALERT

HIGH LINE

VOLTAGE

108->Average Line Voltage

[VALUE] exceeded limit of

[LIMIT]*.

Check voltage supply.

Check power transformers.

Consult power utility if voltage is high.

109 PRESTART

ALERT

GUIDE VANE

CALIBRATION

109->Actual Guide Vane

Pos Calibration Required

Before Start-Up

Calibrate guide vane actuator in Control Test.

PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY

STARTUP IN PROGRESS OCCUPIED MODE Chiller is starting. Time schedule is occupied.

STARTUP IN PROGRESS REMOTE CONTACT CLOSED Chiller is starting. Remote contacts are enabled and closed.

STARTUP IN PROGRESS START COMMAND IN EFFECT Chiller is starting. Chiller START/STOP in MAINSTAT manually forced to

start.

AUTORESTART IN PROGRESS OCCUPIED MODE Chiller is starting after power failure. Time schedule is occupied.

AUTORESTART IN PROGRESS REMOTE CONTACT CLOSED Chiller is starting after power failure. Remote contacts are enabled and

closed.

AUTORESTART IN PROGRESS START COMMAND IN EFFECT Chiller is starting after power failure. Chiller START/STOP on MAINSTAT

manually forced to start.

PRIMARY MESSAGE SECONDARY MESSAGE CAUSE/REMEDY

RUNNING — RESET ACTIVE 4-20 mA SIGNAL Auto chilled water reset active based on external input.

RUNNING — RESET ACTIVE REMOTE TEMP SENSOR Auto chilled water reset active based on external input.

RUNNING — RESET ACTIVE CHW TEMP DIFFERENCE Auto chilled water reset active based on cooler ∆T.

RUNNING — TEMP CONTROL LEAVING CHILLED WATER Default method of temperature control.

RUNNING — TEMP CONTROL ENTERING CHILLED WATER Entering Chilled Water (ECW) control enabled in TEMP_CTL screen

RUNNING — TEMP CONTROL TEMPERATURE RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify.

RUNNING — DEMAND LIMITED BY DEMAND RAMP LOADING Ramp Loading in effect. Use RAMP_DEM screen to modify.

RUNNING — DEMAND LIMITED BY LOCAL DEMAND SETPOINT Demand limit set point is less than actual demand.

RUNNING — DEMAND LIMITED BY 4-20 mA SIGNAL Demand limit is active based on external auto demand limit option.

RUNNING — DEMAND LIMITED BY CCN SIGNAL Demand limit is active based on control limit signal from CCN.

RUNNING — DEMAND LIMITED BY LOADSHED/REDLINE Demand limit is active based on LOADSHED screen set-up.

RUNNING — TEMP CONTROL HOT GAS BYPASS Hot gas bypass option is energized. See stall prevention in the control

section.

RUNNING — DEMAND LIMITED BY LOCAL SIGNAL Active demand limit manually overridden on MAINSTAT table.

RUNNING —TEMP CONTROL ICE BUILD MODE Chiller is running under Ice Build temperature control.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

G. NORMAL RUN WITH OVERRIDES

*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,

alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control has recorded at the time of the fault con-

dition.

H. OUT-OF-RANGE SENSOR ALARMS

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

120 RUN CAPACITY

LIMITED

HIGH CONDENSER

PRESSURE

120->Condenser Pressure

[VALUE] exceeded limit of [LIMIT]*.

Check for high condenser water temperatures.

Check setting in SETUP1.

121 RUN CAPACITY

LIMITED

HIGH MOTOR

TEMPERATURE

121->Comp Motor Winding Temp

[VALUE] exceeded limit of [LIMIT]*.

Check motor cooling lines.

Check for closed valves.

Check setting in SETUP1.

122 RUN CAPACITY

LIMITED

LOW EVAP

REFRIG TEMP

122->Evaporator Refrig Temp

[VALUE] exceeded limit of [LIMIT]*.

Check refrigerant charge.

Check for low entering cooler temperatures.

123 RUN CAPACITY

LIMITED

HIGH COMPRESSOR

LIFT

123->Surge Prevention Override:

Lift Too High For Compressor.

Check for high condenser water temperatures or

low suction temperature.

124 RUN CAPACITY

LIMITED

MANUAL GUIDE

VANE TARGET

124->Run Capacity Limited:

Manual Guide Vane Target.

Target guide vane point has been forced in

MAINSTAT screen. Release force to continue

normal operation.

125 RUN CAPACITY

LIMITED

LOW DISCHARGE

SUPERHEAT

No messages. Check oil charge.

Check refrigerant charge.

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

260 SENSOR

FAULT

LEAVING CHILLED

WATER

260->Sensor Fault:

Leaving Chilled Water

Check sensor resistance or voltage drop.

Check for proper wiring.

261 SENSOR

FAULT

ENTERING CHILLED

WATER

261->Sensor Fault:

Entering Chilled Water

Check sensor resistance or voltage drop.

Check for proper wiring.

262 SENSOR

FAULT

CONDENSER

PRESSURE

262->Sensor Fault:

Condenser Pressure

Check sensor wiring.

263 SENSOR

FAULT

EVAPORATOR

PRESSURE

263->Sensor Fault:

Evaporator Pressure

Check sensor wiring.

264 SENSOR

FAULT

COMPRESSOR

BEARING TEMP

264->Sensor Fault:

Comp Thrust Bearing Temp

Check sensor resistance or voltage drop.

Check for proper wiring.

265 SENSOR

FAULT

COMPRESSOR

MOTOR TEMP

265->Sensor Fault:

Comp Motor Winding Temp

Check sensor resistance or voltage drop.

Check for proper wiring.

266 SENSOR

FAULT

COMP DISCHARGE

TEMP

266->Sensor Fault:

Comp Discharge Temp

Check sensor resistance or voltage drop.

Check for proper wiring.

267 SENSOR

FAULT

OIL SUMP TEMP 267->Sensor Fault:

Oil Sump Temp

Check sensor resistance or voltage drop.

Check for proper wiring.

268 SENSOR

FAULT

COMP OIL

PRESS DIFF

268->Sensor Fault:

Oil Pump Delta P

Check sensor wiring and accuracy.

269 SENSOR

FAULT

CHILLED WATER

FLOW

269->Sensor Fault:

Chilled Water Delta P

Check sensor wiring and accuracy.

270 SENSOR

FAULT

COND WATER

FLOW

270->Sensor Fault:

Cond Water Delta P

Check sensor wiring and accuracy.

271 SENSOR

FAULT

VFD SPEED SENSOR

OUT OF RANGE

271->Sensor Fault:

Check Actual VFD Speed Sensor

Check voltage input on terminals J6-1 and J6-2 on

the ISM module. Check wiring.

273 SENSOR

FAULT

VFD SPEED OUT OF

RANGE

273->Sensor Fault:

Check Actual VFD Speed Sensor

Check VFD feedback 0-5 vac. Calibrate VFD

speed reference signal.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

I. CHILLER PROTECT LIMIT FAULTS

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

200 PROTECTIVE

LIMIT

1M CONTACT

FAULT

200->1M Aux Contact Fault;

Check 1M Contactor and

Aux

201 PROTECTIVE

LIMIT

2M CONTACT

FAULT

201->2M Aux Contact Fault;

Check 2M Contactor and

Aux

202 PROTECTIVE

LIMIT

MOTOR AMPS

NOT SENSED

202->Motor Amps Not

Sensed — Average Line

Current [VALUE]

Check for wiring of current transformers to the ISM.

Check main circuit breaker for trip.

203 FAILURE TO

START

EXCESS

ACCELERATION

TIME

203->Motor Acceleration

Fault — Average Line

Current [VALUE]

Check to be sure that the inlet guide vanes are closed

at start-up.

Check starter for proper operation.

Reduce unit pressure if possible.

204 FAILURE TO

STOP

1M/2M CONTACT

FAULT

204->1M/2M Aux Contact

Stop Fault; Check 1M/2M

Contactors and Aux

205 FAILURE TO

STOP

MOTOR AMPS

WHEN STOPPED

205->Motor Amps When

Stopped — Average Line

Current [VALUE]

206 PROTECTIVE

LIMIT

STARTER

FAULT

206->Starter Fault Cutout;

Check Optional Starter

Contacts

For Benshaw Inc. RediStart MICRO™ starters, view

fault code at RediStart MICRO display. Press FAULT

RESET to clear faults.

207 PROTECTIVE

LIMIT

HIGH CONDENSER

PRESSURE

207->High Cond Pressure

cutout. [VALUE] exceeded

limit of [LIMIT]*.

Check for high condenser water temperatures, low

water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables.

Check transducer wiring and accuracy.

If [VALUE] is less than Limit then check the

1CR Starting Circuit.

208 PROTECTIVE

LIMIT

EXCESSIVE

MOTOR AMPS

208->Compressor Motor

Amps [VALUE] exceeded

limit of [LIMIT]*.

Check motor current for proper calibration.

Check inlet guide vane actuator.

209 PROTECTIVE

LIMIT

LINE PHASE

LOSS

209->Line Phase Loss;

Check ISM Fault History to

Identify Phase

Check transformers to ISM.

Check power distribution bus.

Consult power company.

210 PROTECTIVE

LIMIT

LINE VOLTAGE

DROPOUT

210->Single Cycle Line

Voltage Dropout

211 PROTECTIVE

LIMIT

HIGH LINE

VOLTAGE

211->High Average Line

Voltage [VALUE]

Check transformers to ISM.

Check distribution bus.

Consult power company.

212 PROTECTIVE

LIMIT

LOW LINE

VOLTAGE

212->Low Average Line

Voltage [VALUE]

Check transformers to ISM.

Check distribution bus.

Consult power company.

213 PROTECTIVE

LIMIT

STARTER MODULE

RESET

213->Starter Module Power-

On Reset When Running

214 PROTECTIVE

LIMIT

POWER LOSS 214->Power Loss:

Check voltage supply

Check transformers to ISM.

Check distribution bus.

Consult power company.

215 PROTECTIVE

LIMIT

LINE CURRENT

IMBALANCE

215->Line Current

Imbalance; Check ISM Fault

History to Identify Phase

Check upstream equipment.

216 PROTECTIVE

LIMIT

LINE VOLTAGE

IMBALANCE

216->Line Voltage

Imbalance; Check ISM Fault

History to Identify Phase

Check upstream equipment.

217 PROTECTIVE

LIMIT

MOTOR OVERLOAD

TRIP

217->Motor Overload Trip;

Check ISM configurations

Check ISM configuration.

218 PROTECTIVE

LIMIT

MOTOR LOCKED

ROTOR TRIP

218->Motor Locked Rotor

Amps exceeded; Check

Motor & ISM Config

Check ISM configuration.

219 PROTECTIVE

LIMIT

STARTER LOCK

ROTOR TRIP

219->Starter Locked Rotor

Amps Rating exceeded

Check ISM configuration.

220 PROTECTIVE

LIMIT

GROUND FAULT 220->Ground Fault Trip;

Check Motor and Current

Transformers

221 PROTECTIVE

LIMIT

PHASE REVERSAL

TRIP

221->Phase Reversal Trip;

Check Power Supply

222 PROTECTIVE

LIMIT

LINE FREQUENCY

TRIP

222->Line Frequency —

[VALUE] exceeded limit of

[LIMIT]. Check Power

Supply.

223 PROTECTIVE

LIMIT

STARTER MODULE

FAIL UR E

223->Starter Module

Hardware Failure

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

I. CHILLER PROTECT LIMIT FAULTS (cont)

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

227 PROTECTIVE

LIMIT

OIL PRESS

SENSOR FAULT

227->Oil Pump Delta P

[VALUE] exceeded limit of

[LIMIT]*.

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

Check transducer calibration.

228 PROTECTIVE

LIMIT

LOW OIL

PRESSURE

228->Oil Pump Delta P

[VALUE] exceeded limit of

[LIMIT].*

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

Check oil level.

Check for partially closed service valves.

Check oil filters.

Check for foaming oil at start-up.

Check transducer calibration.

229 PROTECTIVE

LIMIT

LOW CHILLED

WATER FLOW

229->Low Chilled Water

Flow; Check Delta P Config

& Calibration

Perform pump control test.

Check transducer accuracy and wiring.

Check water valves.

Check transducer calibration.

230 PROTECTIVE

LIMIT

LOW CONDENSER

WATER FLOW

230->Low Condenser Water

Flow; Check Delta P Config

& Calibration

Perform pump control test.

Check transducer accuracy and wiring.

Check water valves.

Check transducer calibration.

231 PROTECTIVE

LIMIT

HIGH DISCHARGE

TEMP

231->Comp Discharge

Temp [VALUE] exceeded

limit of [LIMIT].*

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for proper condenser flow and temperature.

Check for proper inlet guide vane and diffuser

actuator operation.

Check for fouled tubes or noncondensables in the

system.

232 PROTECTIVE

LIMIT

LOW REFRIGERANT

TEMP

232->Evaporator Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check for proper refrigerant charge.

Check float operation.

Check for proper fluid flow and temperature.

Check for proper inlet guide vane operation.

233 PROTECTIVE

LIMIT

HIGH MOTOR

TEMPERATURE

233->Comp Motor Winding

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check motor sensors wiring and accuracy.

Check motor cooling line for proper operation, or

restrictions.

Check for excessive starts within a short time span.

234 PROTECTIVE

LIMIT

HIGH BEARING

TEMPERATURE

234->Comp Thrust Bearing

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check oil heater for proper operation.

Check for low oil level, partially closed oil supply

valves, clogged oil filters, etc.

Check the sensor wiring and accuracy.

235 PROTECTIVE

LIMIT

HIGH CONDENSER

PRESSURE

235->Condenser Pressure

[VALUE] exceeded limit of

[LIMIT]*.

Check for high condenser water temperatures, low

water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables.

Check transducer wiring and accuracy.

236 PROTECTIVE

LIMIT

CCN OVERRIDE

STOP

236->CCN Override Stop

while in LOCAL run mode

CCN has signaled the chiller to stop. Reset and

restart when ready. If the signal was sent by the

CVC/ICVC, release the stop signal on the STATUS01

table.

237 PROTECTIVE

LIMIT

SPARE SAFETY

DEVICE

237->Spare Safety Device Spare safety input has tripped or factory installed

jumper is not present.

238 PROTECTIVE

LIMIT

EXCESSIVE

COMPR SURGE

238->Compressor Surge:

Check condenser water

temp and flow

Check condenser flow and temperatures.

Check surge protection configuration.

239 PROTECTIVE

LIMIT

TRANSDUCER

VOLTAGE FAULT

239->Transducer Voltage

Ref [VALUE] exceeded limit

of [LIMIT]*.

240 PROTECTIVE

LIMIT

LOW DISCHARGE

SUPERHEAT

240->Check for Oil in

Refrigerant or Overcharge

of Refrigerant

241 LOSS OF

COMMUNICATION

WITH STARTER

MODULE

241->Loss of Communica-

tion With Starter.

Check wiring to ISM.

242 LOSS OF

COMMUNICATION

WITH CCM

MODULE

242->Loss of Communica-

tion With CCM.

Check wiring to CCM.

243 POTENTIAL

FREEZE-UP

EVAP PRESS/TEMP

TOO LOW

243->Evaporator Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check for proper refrigerant charge.

Check float operation.

Check for proper fluid flow and temperature.

Check for proper inlet guide vane operation.

244 POTENTIAL

FREEZE-UP

COND PRESS/TEMP

TOO LOW

244->Condenser Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

245 PROTECTIVE

LIMIT

VFD SPEED

OUT OF RANGE

245->Actual VFD Speed

[VALUE] exceeded limit of

[LIMIT]*.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

I. CHILLER PROTECT LIMIT FAULTS (cont)

*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,

alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

J. CHILLER ALERTS

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

246 PROTECTIVE

LIMIT

INVALID DIFFUSER

CONFIG

246->Diffuser Control Invalid

Configuration:

Check SETUP2 Entries.

Check diffuser/guide vane schedule.

247 PROTECTIVE

LIMIT

DIFFUSER POSITION

FAULT

247->Diffuser Position Fault:

Check Guide Vane and Diffuser

Actuators

Check rotating stall transducer wiring and

accuracy.

Check diffuser schedule.

Check for proper operation of diffuser actuator

and inlet guide vane actuator.

Check diffuser coupling.

Check inlet guide vane operation.

Check inlet guide vane calibration.

Check diffuser/inlet guide vane schedule.

Check diffuser mechanical set-up for proper

orientation.

If not using variable diffuser, check that the

option has not been enabled.

248 PROTECTIVE

LIMIT

SPARE TEMPERATURE

248->Spare Temperature #1

[VALUE] exceeded limit of

[LIMIT]*.

249 PROTECTIVE

LIMIT

SPARE TEMPERATURE

249->Spare Temperature #2

[VALUE] exceeded limit of

[LIMIT]*.

250 PROTECTIVE

LIMIT

REFRIGERANT LEAK

SENSOR

250->Refrigerant Leak Sensor

[VALUE] exceeded Limit of

[LIMIT]*.

The refrigerant leak detector’s output wired to

J5-5 and J5-6 on the CCM module has

reached the alarm limit.

Check leak detector and for leaks.

251 PROTECTIVE

LIMIT

ISM CONFIG

CONFLICT

251->ISM Config Conflict (ISM

Uploaded); Verify to Reset Alarm

Confirm valid settings in ISM_CONF screen.

252 PROTECTIVE

LIMIT

ISM CONFIG

CONFLICT

252->ISM Config Conflict (ISM

Downloaded); Verify to Reset

Alarm

Confirm valid settings in ISM_CONF screen.

253 PROTECTIVE

LIMIT

GUIDE VANE

CALIBRATION

253->Guide Vane Fault [VALUE].

Check Calibration.

Enter Control Test and execute Guide Vane

Calibration. Check guide vane feedback (ter-

minals J4-9 and J4-10) on the CCM module.

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

140 SENSOR ALERT LEAVING COND

WATER TEMP

140->Sensor Fault:

Check Leaving Cond Water

Sensor

Check sensor resistance or voltage drop.

Check for proper wiring.

141 SENSOR ALERT ENTERING COND

WATER TEMP

141->Sensor Fault:

Check Entering Cond Water

Sensor

Check sensor resistance or voltage drop.

Check for proper wiring.

142 LOW OIL PRESSURE

ALERT

CHECK OIL FILTER 142->Low Oil Pressure Alert.

Check Oil Filter.

Check for partially or closed shut-off valves.

Check oil filter.

Check oil pump and power supply.

Check oil level.

Check for foaming oil at start-up.

Check transducer wiring and accuracy.

143 AUTORESTART

PENDING

LINE PHASE

LOSS

143->Line Phase Loss Power loss has been detected in any phase.

Chiller automatically restarting.

144 AUTORESTART

PENDING

LINE VOLTAGE

DROP OUT

144->Single Cycle Line

Voltage Dropout

A drop in line voltage has been detected within

2 voltage cycles. Chiller automatically restarting if

Autorestart option is enabled.

145 AUTORESTART

PENDING

HIGH LINE

VOLTAGE

145>Line Overvoltage —

Average Line Volt [VALUE]

Check line power.

146 AUTORESTART

PENDING

LOW LINE

VOLTAGE

146->Line Undervoltage —

Average Line Volt [VALUE]

Check line power.

147 AUTORESTART

PENDING

STARTER MODULE

RESET

147->Starter Module Power-

On Reset When Running

ISM has detected a hardware fault and has reset.

Chiller automatically restarting.

148 AUTORESTART

PENDING

POWER LOSS 148->Control Power-Loss

When Running

Check control power.

Table 11 — CVC/ICVC Primary and Secondary Messages and

Custom Alarm/Alert Messages with Troubleshooting Guides (cont)

J. CHILLER ALERTS (cont)

*[LIMIT] is shown on the CVC/ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override,

alert, or alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

STATE PRIMARY

MESSAGE

SECONDARY

MESSAGE

ALARM MESSAGE

PRIMARY CAUSE

ADDITIONAL

CAUSE/REMEDY

149 SENSOR ALERT HIGH DISCHARGE

TEMP

149->Comp Discharge Temp

[VALUE] exceeded limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for proper condenser flow and

temperature.

Check for high lift or low load.

Check for proper inlet guide vane and diffuser

actuator operation (Size 5 compressor Only).

Check for fouled tubes or noncondensables in

the refrigerant system.

150 SENSOR ALERT HIGH BEARING

TEMPERATURE

150->Comp Thrust Bearing

Temp [VALUE] exceeded limit

of [LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for partially closed service valves.

Check oil cooler TXV.

Check oil filter.

Check oil level.

151 CONDENSER

PRESSURE ALERT

PUMP RELAY

ENERGIZED

151->High Condenser

Pressure [VALUE]: Pump

Energized to Reduce

Pressure.

Check sensor wiring and accuracy.

Check condenser flow and fluid

temperature.

Check for fouled tubes. This alarm is not

caused by the High Pressure Switch.

152 RECYCLE

ALERT

EXCESSIVE RECYCLE

STARTS

152->Excessive recycle starts. Chiller load is too low to keep compressor on

line and there has been more than

5 starts in 4 hours. Increase chiller load,

adjust hot gas bypass, increase RECYCLE

RESTART DELTA T from SETUP1 Screen.

153 no message:

ALERT only

no message;

ALERT only

153->Lead/Lag Disabled:

Duplicate Chiller Address;

Check Configuration

Illegal chiller address configuration in Lead/

Lag screen. Both chillers require a different

address.

154 POTENTIAL

FREEZE-UP

COND PRESS/TEMP

TOO LOW

154->Condenser freeze up

prevention

The condenser pressure transducer is read-

ing a pressure that could freeze the con-

denser tubes.

Check for condenser refrigerant leaks.

Check fluid temperature.

Check sensor wiring and accuracy.

Place the chiller in PUMPDOWN mode if the

vessel is evacuated.

155 OPTION SENSOR

FAULT

REMOTE RESET

SENSOR

155->Sensor Fault/Option

Disabled:

Remote Reset Sensor

Check sensor resistance or voltage drop.

Check for proper wiring.

156 OPTION SENSOR

FAULT

AUTO CHILLED

WATER RESET

156->Sensor Fault/Option

Disabled:

Auto Chilled Water Reset

Check sensor resistance or voltage drop.

Check for proper wiring.

157 OPTION SENSOR

FAULT

AUTO DEMAND

LIMIT INPUT

157->Sensor Fault/Option

Disabled:

Auto Demand Limit Input

Check sensor resistance or voltage drop.

Check for proper wiring.

158 SENSOR ALERT SPARE TEMPERATURE

158->Spare Temperature #1

[VALUE] exceeded limit of

[LIMIT].*

Check sensor resistance or voltage drop.

Check for proper wiring.

159 SENSOR ALERT SPARE TEMPERATURE

159->Spare Temperature #2

[VALUE] exceeded limit of

[LIMIT].*

Check sensor resistance or voltage drop.

Check for proper wiring.

160 DIFFUSER

ALERT

DIFFUSER

POSITION

160->Diffuser Position Alert;

Check Diffuser Configuration.

Check diffuser configuration in SETUP2

screen.

Table 12A — Thermistor Temperature (F) vs. Resistance/Voltage Drop

TEMPERATURE

(F)

PIC II

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

–25 4.700 98,010

–24 4.690 94,707

–23 4.680 91,522

–22 4.670 88,449

–21 4.659 85,486

–20 4.648 82,627

–19 4.637 79,871

–18 4.625 77,212

–17 4.613 74,648

–16 4.601 72,175

–15 4.588 69,790

–14 4.576 67,490

–13 4.562 65,272

–12 4.549 63,133

–11 4.535 61,070

–10 4.521 59,081

–94.507 57,162

–84.492 55,311

–74.477 53,526

–64.461 51,804

–54.446 50,143

–44.429 48,541

–34.413 46,996

–24.396 45,505

–14.379 44,066

04.361 42,679

14.344 41,339

24.325 40,047

34.307 38,800

44.288 37,596

54.269 36,435

64.249 35,313

74.229 34,231

84.209 33,185

94.188 32,176

10 4.167 31,202

11 4.145 30,260

12 4.123 29,351

13 4.101 28,473

14 4.079 27,624

15 3.056 26,804

16 4.033 26,011

17 4.009 25,245

18 3.985 24,505

19 3.960 23,789

20 3.936 23,096

21 3.911 22,427

22 3.886 21,779

23 3.861 21,153

24 3.835 20,547

25 3.808 19,960

26 3.782 19,393

27 3.755 18,843

28 3.727 18,311

29 3.700 17,796

30 3.672 17,297

31 3.644 16,814

32 3.617 16,346

33 3.588 15,892

34 3.559 15,453

35 3.530 15,027

36 3.501 14,614

37 3.471 14,214

38 3.442 13,826

39 3.412 13,449

40 3.382 13,084

41 3.353 12,730

42 3.322 12,387

43 3.291 12,053

44 3.260 11,730

45 3.229 11,416

46 3.198 11,112

47 3.167 10,816

48 3.135 10,529

49 3.104 10,250

50 3.074 9,979

51 3.042 9,717

52 3.010 9,461

53 2.978 9,213

54 3.946 8,973

55 2.914 8,739

56 2.882 8,511

57 2.850 8,291

58 2.819 8,076

59 2.788 7,868

TEMPERATURE

(F)

PIC II

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

60 2.756 7,665

61 2.724 7,468

62 2.692 7,277

63 2.660 7,091

64 2.628 6,911

65 2.596 6,735

66 2.565 6,564

67 2.533 6,399

68 2.503 6,238

69 2.472 6,081

70 2.440 5,929

71 2.409 5,781

72 2.378 5,637

73 2.347 5,497

74 2.317 5,361

75 2.287 5,229

76 2.256 5,101

77 2.227 4,976

78 2.197 4,855

79 2.167 4,737

80 2.137 4,622

81 2.108 4,511

82 2.079 4,403

83 2.050 4,298

84 2.021 4,196

85 1.993 4,096

86 1.965 4,000

87 1.937 3,906

88 1.989 3,814

89 1.881 3,726

90 1.854 3,640

91 1.827 3,556

92 1.800 3,474

93 1.773 3,395

94 1.747 3,318

95 1.721 3,243

96 1.695 3,170

97 1.670 3,099

98 1.644 3,031

99 1.619 2,964

100 1.595 2,898

101 1.570 2,835

102 1.546 2,773

103 1.523 2,713

104 1.499 2,655

105 1.476 2,597

106 1.453 2,542

107 1.430 2,488

108 1.408 2,436

109 1.386 2,385

110 1.364 2,335

111 1.343 2,286

112 1.321 2,239

113 1.300 2,192

114 1.279 2,147

115 1.259 2,103

116 1.239 2,060

117 1.219 2,018

118 1.200 1,977

119 1.180 1,937

120 1.161 1,898

121 1.143 1,860

122 1.124 1,822

123 1.106 1,786

124 1.088 1,750

125 1.070 1,715

126 1.053 1,680

127 1.036 1,647

128 1.019 1,614

129 1.002 1,582

130 0.986 1,550

131 0.969 1,519

132 0.953 1,489

133 0.938 1,459

134 0.922 1,430

135 0.907 1,401

136 0.893 1,373

137 0.878 1,345

138 0.864 1,318

139 0.849 1,291

140 0.835 1,265

141 0.821 1,240

142 0.808 1,214

143 0.795 1,190

144 0.782 1,165

TEMPERATURE

(F)

PIC II

VOLTAGE

DROP (V)

RESISTANCE

(Ohms)

145 0.769 1,141

146 0.756 1,118

147 0.744 1,095

148 0.731 1,072

149 0.719 1,050

150 0.707 1,029

151 0.696 1,007

152 0.684 986

153 0.673 965

154 0.662 945

155 0.651 925

156 0.640 906

157 0.630 887

158 0.619 868

159 0.609 850

160 0.599 832

161 0.589 815

162 0.579 798

163 0.570 782

164 0.561 765

165 0.551 750

166 0.542 734

167 0.533 719

168 0.524 705

169 0.516 690

170 0.508 677

171 0.499 663

172 0.491 650

173 0.484 638

174 0.476 626

175 0.468 614

176 0.460 602

177 0.453 591

178 0.445 581

179 0.438 570

180 0.431 561

181 0.424 551

182 0.418 542

183 0.411 533

184 0.404 524

185 0.398 516

186 0.392 508

187 0.385 501

188 0.379 494

189 0.373 487

190 0.367 480

191 0.361 473

192 0.356 467

193 0.350 461

194 0.344 456

195 0.339 450

196 0.333 445

197 0.328 439

198 0.323 434

199 0.318 429

200 0.313 424

201 0.308 419

202 0.304 415

203 0.299 410

204 0.294 405

205 0.290 401

206 0.285 396

207 0.281 391

208 0.277 386

209 0.272 382

210 0.268 377

211 0.264 372

212 0.260 367

213 0.256 361

214 0.252 356

215 0.248 350

216 0.245 344

217 0.241 338

218 0.237 332

219 0.234 325

220 0.230 318

221 0.227 311

222 0.224 304

223 0.220 297

224 0.217 289

225 0.214 282

Table 12B — Thermistor Temperature (C) vs. Resistance/Voltage Drop

TEMPERATURE

(C)

PIC II

VOLTAGE DROP (V)

RESISTANCE

(Ohms)

–33 4.722 106 880

–32 4.706 100 260

–31 4.688 94 165

–30 4.670 88 480

–29 4.650 83 170

–28 4.630 78 125

–27 4.608 73 580

–26 4.586 69 250

–25 4.562 65 205

–24 4.538 61 420

–23 4.512 57 875

–22 4.486 54 555

–21 4.458 51 450

–20 4.429 48 536

–19 4.399 45 807

–18 4.368 43 247

–17 4.336 40 845

–16 4.303 38 592

–15 4.269 38 476

–14 4.233 34 489

–13 4.196 32 621

–12 4.158 30 866

–11 4.119 29 216

–10 4.079 27 633

–94.037 26 202

–83.994 24 827

–73.951 23 532

–63.906 22 313

–53.861 21 163

–43.814 20 079

–33.765 19 058

–23.716 18 094

–13.667 17 184

03.617 16 325

13.565 15 515

23.512 14 749

33.459 14 026

43.406 13 342

53.353 12 696

63.298 12 085

73.242 11 506

83.185 10 959

93.129 10 441

10 3.074 9 949

11 3.016 9 485

12 2.959 9 044

13 2.901 8 627

14 2.844 8 231

15 2.788 7 855

16 2.730 7 499

17 2.672 7 161

18 2.615 6 840

19 2.559 6 536

20 2.503 6 246

21 2.447 5 971

22 2.391 5 710

23 2.335 5 461

24 2.280 5 225

25 2.227 5 000

26 2.173 4 786

27 2.120 4 583

28 2.067 4 389

29 2.015 4 204

30 1.965 4 028

31 1.914 3 861

32 1.865 3 701

33 1.816 3 549

34 1.768 3 404

35 1.721 3 266

36 1.675 3 134

37 1.629 3 008

TEMPERATURE

(C)

PIC II

VOLTAGE DROP (V)

RESISTANCE

(Ohms)

38 1.585 2 888

39 1.542 2 773

40 1.499 2 663

41 1.457 2 559

42 1.417 2 459

43 1.377 2 363

44 1.338 2 272

45 1.300 2 184

46 1.263 2 101

47 1.227 2 021

48 1.192 1 944

49 1.158 1 871

50 1.124 1 801

51 1.091 1 734

52 1.060 1 670

53 1.029 1 609

54 0.999 1 550

55 0.969 1 493

56 0.941 1 439

57 0.913 1 387

58 0.887 1 337

59 0.861 1 290

60 0.835 1 244

61 0.811 1 200

62 0.787 1 158

63 0.764 1 118

64 0.741 1 079

65 0.719 1 041

66 0.698 1 006

67 0.677 971

68 0.657 938

69 0.638 906

70 0.619 876

71 0.601 836

72 0.583 805

73 0.566 775

74 0.549 747

75 0.533 719

76 0.518 693

77 0.503 669

78 0.488 645

79 0.474 623

80 0.460 602

81 0.447 583

82 0.434 564

83 0.422 547

84 0.410 531

85 0.398 516

86 0.387 502

87 0.376 489

88 0.365 477

89 0.355 466

90 0.344 456

91 0.335 446

92 0.325 436

93 0.316 427

94 0.308 419

95 0.299 410

96 0.291 402

97 0.283 393

98 0.275 385

99 0.267 376

100 0.260 367

101 0.253 357

102 0.246 346

103 0.239 335

104 0.233 324

105 0.227 312

106 0.221 299

107 0.215 285

Control Modules

The CVC/ICVC, CCM, and ISM modules perform continu-

ous diagnostic evaluations of the hardware to determine its

condition. Proper operation of all modules is indicated by

LEDs (light-emitting diodes) located on the circuit board of the

CVC/ICVC, CCM, and ISM.

There is one green LED located on the CCM and ISM

boards respectively, and one red LED located on the CVC/

ICVC, CCM, and ISM boards respectively.

RED LED (Labeled as STAT) — If the red LED:

•blinks continuously at a 2-second interval, the module is

operating properly

•is lit continuously, there is a problem that requires

replacing the module

•is off continuously, the power should be checked

•blinks 3 times per second, a software error has been dis-

covered and the module must be replaced

If there is no input power, check the fuses and circuit break-

er. If the fuse is good, check for a shorted secondary of the

transformer or, if power is present to the module, replace the

module.

GREED LED (Labeled as COM) — These LEDs indicate

the communication status between different parts of the con-

troller and the network modules and should blink continuously.

Notes on Module Operation

1. The chiller operator monitors and modifies configura-

tions in the microprocessor by using the 4 softkeys and

the CVC/ICVC. Communications between the CVC/

ICVC and the CCM is accomplished through the SIO

(Sensor Input/Output) bus, which is a phone cable. The

communication between the CCM and ISM is accom-

plished through the sensor bus, which is a 3-wire cable.

2. If a green LED is on continuously, check the communica-

tion wiring. If a green LED is off, check the red LED

operation. If the red LED is normal, check the module

address switches (SW1) (Fig. 40 and 41). Confirm all

switches are in OFF position.

All system operating intelligence resides in the CVC/

ICVC. Some safety shutdown logic resides in the ISM in

case communications are lost between the ISM and CVC/

ICVC. Outputs are controlled by the CCM and ISM as

well.

3. Power is supplied to the modules within the control panel

via 24-vac power sources.

The transformers are located within the power panel, with

the exception of the ISM, which operates from a 115-vac

power source and has its own 24-vac transformer located

in the module.

In the power panel, T1 supplies power to the compressor

oil heater, oil pump, and optional hot gas bypass, and T2

supplies power to both the CVC/ICVC and CCM.

Power is connected to Plug J1 on each module.

Turn controller power off before servicing controls. This

ensures safety and prevents damage to the controller.

CCN INTERFACE

CONNECTION

DATALINK OR

DATAPORT MODULE (OPTION)

SW1BACK OF CVC

MODULE PART NUMBER

SOFTWARE PART NUMBER

J7 SIO J1 POWER/

CCN

J8 SERVICE

CVC/ICVC

Fig. 40 — Rear of CVC/ICVC (Chiller Visual Controller/International Chiller Visual Controller)

Chiller Control Module (CCM) (Fig. 41)

INPUTS — Each input channel has 2 or 3 terminals. Refer to

individual chiller wiring diagrams for the correct terminal

numbers for your application.

OUTPUTS — Output is 24 vac. There are 2 terminals per out-

put. Refer to the chiller wiring diagram for your specific appli-

cation for the correct terminal numbers.

Integrated Starter Module (Fig. 42)

INPUTS — Inputs on strips J3 through J6 are analog inputs

and J2 is discrete (on/off) input. The specific application of the

chiller determines which terminals are used. Refer to the indi-

vidual chiller wiring diagram for the correct terminal numbers

for your application.

OUTPUTS — Outputs are 115-277 vac and wired to strip J9.

There are 2 terminals per output.

Replacing Defective Processor Modules —

The module replacement part number is printed on a small

label on the rear of the CVC/ICVC module. The chiller model

and serial numbers are printed on the chiller nameplate located

on an exterior corner post. The proper software is factory-

installed by Carrier in the replacement module. When ordering

a replacement chiller visual control (CVC/ICVC) module,

specify the complete replacement part number, full chiller

model number, and chiller serial number. The installer must

configure the new module to the original chiller data. Follow

the procedures described in the Software Configuration section

on page 55.

INSTALLATION

1. Verify the existing CVC/ICVC module is defective by us-

ing the procedure described in the Troubleshooting Guide

section, page 76, and the Control Modules section,

page 87. Do not select the ATTACH TO NETWORK

DEVICE table if the CVC/ICVC indicates a communica-

tion failure.

2. Data regarding the CVC/ICVC configuration should have

been recorded and saved. This data must be reconfigured

into the new CVC/ICVC. If this data is not available, fol-

low the procedures described in the Software Configura-

tion section.

If a CCN Building Supervisor or Service Tool is avail-

able, the module configuration should have already been

uploaded into memory. When the new module is in-

stalled, the configuration can be downloaded from the

computer.

Any communication wires from other chillers or CCN

modules should be disconnected to prevent the new

CVC/ICVC module from uploading incorrect run hours

into memory.

3. To install this module, record values for the TOTAL

COMPRESSOR STARTS and the COMPRESSOR

ONTIME from the MAINSTAT screen on the CVC/

ICVC.

4. Power off the controls.

5. Remove the old CVC/ICVC.

6. Install the new CVC/ICVC module. Turn the control

power back on.

7. The CVC/ICVC now automatically attaches to the local

network device.

8. Access the MAINSTAT table and highlight the TOTAL

COMPRESSOR STARTS parameter. Press the

softkey. Increase or decrease the value to match the starts

value recorded in Step 3. Press the softkey

when you reach the correct value. Now, move the high-

light bar to the COMPRESSOR ONTIME parameter.

Press the softkey. Increase or decrease the run

hours value to match the value recorded in Step 2. Press

the softkey when the correct value is reached.

9. Complete the CVC/ICVC installation. Following the in-

structions in the Input Service Configurations section,

page 55, input all the proper configurations such as the

time, date, etc. Check the pressure transducer calibra-

tions. PSIO installation is now complete.

Solid-State Starters — Troubleshooting information per-

taining to the Benshaw, Inc., solid-state starter may be found

in the following paragraphs and in the Carrier RediStart

MICRO™ Instruction Manual supplied by the starter vendor.

Attempt to solve the problem by using the following prelim-

inary checks before consulting the troubleshooting tables found

in the Benshaw manual.

With power off:

•Inspect for physical damage and signs of arcing, over-

heating, etc.

•Verify the wiring to the starter is correct.

•Verify all connections in the starter are tight.

•Check the control transformer fuses.

TESTING SILICON CONTROL RECTIFIERS IN THE

BENSHAW, INC., SOLID-STATE STARTERS — If an SCR

is suspected of being defective, use the following procedure as

part of a general troubleshooting guide.

1. Verify power is applied.

2. Verify the state of each SCR light-emitting diode (LED)

on the micropower card.

NOTE: All LEDs should be lit. If any red or green side of

these LEDs is not lit, the line voltage is not present or one

or more SCRs has failed.

3. Check incoming power. If voltage is not present check

the incoming line. If voltage is present, proceed to Steps 4

through 11.

NOTE: If after completing Steps 4 - 11 all measurements

are within specified limits, the SCRs are functioning nor-

mally. If after completing Steps 4 - 11 resistance measure-

ments are outside the specified limits, the motor leads on

the starter power lugs T1 through T6 should be removed

and the steps repeated. This will identify if abnormal re-

sistance measurements are being influenced by the motor

windings.

4. Remove power from the starter unit.

Electrical shock can cause personal injury. Disconnect all

electrical power before servicing.

1. Motor terminals or starter output lugs or wire should

not be touched without disconnecting the incoming

power supply. The silicon control rectifiers (SCRs)

although technically turned off still have AC mains

potential on the output of the starter.

2. Power is present on all yellow wiring throughout the

system even though the main circuit breaker in the

unit is off.

SELECT

ENTER

SELECT

ENTER

STAT COMM THERMISTORS

DIFF PRESSURE

PRESSURE

SW2

V/I INPUTS

SIO

ANALOG OUT

J11

DISCRETE

OUTPUTS

J12

DISCRETE

OUTPUTS

24 VAC

SIO

SW1

115 VAC

LL1 LL2 1A

CONTACT INPUTS

SPAR ICE REM STRT 1M 2M

SFTY BLD STRT FLT AUX AUX

FUSE LINE VOLTAGES

L1 L2 L3 IL1

LINE CURRENTS GROUND

FAULTS

IL2 IL3 1/4 2/5 3/6 VFD

INTEGRATED STARTER MODULE

INTERGRATED STARTER MODULE

J11 1+ C + C + C + C + C + C

J3-1 J3-2 J3-3

1+ - + - + -

1+ G + G + G + G

STAT COM

-J7

- G + 1G + G +

1J9 1

COMM

C B A

4-20 MA OUT

SPARE VFD

TRIP

ALARM HI

FAN

FAN COND

PUMP

EVAP

PUMP

SHUNT

TRIP

DISCRETE CONTROL CONTACTS

TRANS 1CR

WARNING

HIGH VOLTAGE

DISCONNECT POWER BEFORE SERVICING

ISM 19XR04012201 9925

CEPL13025901 PCB05

CEPP130173-03-04-01 00001328

WARNING

HIGH VOLTAGE

DISCONNECT POWER BEFORE SERVICING

Fig. 41 — Chiller Control Module (CCM)

Fig. 42 — Integrated Starter Module (ISM)

5. Using an ohmmeter, perform the following resistance

measurements and record the results:

If all measured values are greater than 5K ohms, proceed

to Step 10. If any values are less than 5K ohms, one or

more of the SCRs in that pair is shorted.

6. Remove both SCRs in the pair (See SCR Removal/

Installation).

7. Using an ohmmeter, measure the resistance (anode to

cathode) of each SCR to determine which device has

failed.

NOTE: Both SCRs may be defective, but typically, only

one is shorted. If both SCRs provide acceptable resistance

measurements, proceed to Step 10.

8. Replace the defective SCR(s).

9. Retest the “pair” for resistance values indicated above.

10. On the right side of the firing card, measure the resistance

between the red and white gate/cathode leads for each

SCR (1 through 6). A measurement between 5 and

50 ohms is normal. Abnormally high values may indicate

a failed gate for that SCR.

11. Replace the SCRs and retest the pair.

SCR REMOVAL/INSTALLATION — Refer to Fig. 43.

1. Remove the SCR by loosening the clamping bolts on

each side of the SCR,

2. After the SCR has been removed and the bus work is

loose, apply a thin coat of either silicon based thermal

joint compound or a joint compound for aluminum or

copper wire connections to the contact surfaces of the re-

placement SCR. This allows for improved heat dissipa-

tion and electrical conductivity.

3. Place the SCR between the roll pins on the heatsink

assemblies so the roll pins fit into the small holes in each

side of the SCR.

NOTE: Ensure the SCR is installed so the cathode side is

the side from which the red wire extends. The heatsink is

labeled to show the correct orientation.

4. Hand tighten the bolts until the SCR contacts the

heatsink.

5. Using quarter-turn increments, alternating between

clamping bolts, apply the appropriate number of whole

turns referencing the table in Fig. 43.

6. Reconnect the red (cathode) wire from the SCR and the

white (anode-gate) wire to the appropriate location on the

firing card (i.e., SCR1 wires to firing card terminal

G1-white wire, and K1-red wire).

7. Reconnect all other wiring and bus work.

8. Return starter to normal operation.

Physical Data — Tables 13A-20 and Fig. 44-57 provide

additional information on component weights, compressor fits

and clearances, physical and electrical data, and wiring sche-

matics for the operator’s convenience during troubleshooting.

MEASURE

BETWEEN

SCR PAIRS

BEING

CHECKED

RECORDED

VALU E

T1 and T6 3 and 6

T2 and T4 2 and 5

T3 and T5 1 and 4

If any red or white SCR gate leads are removed from the

firing card or an SCR, care must be taken to ensure the

leads are replaced EXACTLY as they were (white wires to

gates, and red wires to cathodes on both the firing card and

SCR), or damage to the starter and/or motor may result.

Care must be taken to prevent nut rotation while tightening

the bolts. If the nut rotates while tightening the bolt, SCR

replacement must be started over.

Fig. 43 — SCR Installation

SCR PART

NUMBER

BISCR

CLAMP

SIZE

DIMENSION

(in.)

NO. OF

TURNS

BOLT

LENGTH

(in.)

6601218 1030 2.75

(70 mm) 11/23.0

(76 mm)

6601818 1030 2.75

(70 mm) 11/23.0

(76 mm)

8801230 1035 2.75

(70 mm) 13/43.5

(89 mm)

8801830 1035 2.75

(70 mm) 13/43.0

(89 mm)

15001850 2040 4.00

(102 mm) 23/44.0

(102 mm)

15001850 2050 4.00

(102 mm) 23/45.0

(127 mm)

220012100 Consult Benshaw Representative

330018500 Consult Benshaw Representative

LOOSEN

AND

TIGHTEN

BOLTS

FROM

THIS END

CLAMPING

BOLT

NUT

ALUMINUM

HEATSINK

ROLL PIN

SCR

Table 13A — Heat Exchanger Data (English)

NOTES:

1. Cooler data: based on a cooler with standard wall tubing, 2-pass,

150 psig, nozzle-in-head waterbox with victaulic grooves. Weight

includes suction elbow, control panel, and distribution piping.

Weight does not include compressor.

2. Condenser data: based on a condenser with standard wall tub-

ing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic

grooves. Weight includes the float valve, discharge elbow, and

distribution piping. Weight does not include unit-mounted starter,

isolation valves, and pumpout unit.

CODE

NUMBER OF TUBES ENGLISH

Dry (Rigging) Weight (lb) Chiller Charge

Cooler Condenser Cooler

Only

Condenser

Only

Refrigerant Weight (lb) Water Volume (gal)

Cooler Condenser Cooler Condenser

10 142 180 2,742 2,704 290 200 34 42

11 161 200 2,812 2,772 310 200 37 45

12 180 225 2,883 2,857 330 200 40 49

15 142 180 3,003 2,984 320 250 39 48

16 161 200 3,089 3,068 340 250 43 52

17 180 225 3,176 3,173 370 250 47 57

20 200 218 3,442 3,523 345 225 48 48

21 240 266 3,590 3,690 385 225 55 55

22 282 315 3,746 3,854 435 225 62 63

30 200 218 4,137 3,694 350 260 55 55

31 240 267 4,319 3,899 420 260 64 65

32 280 315 4,511 4,100 490 260 72 74

35 200 218 4,409 4,606 400 310 61 62

36 240 267 4,617 4,840 480 310 70 72

37 280 315 4,835 5,069 550 310 80 83

40 324 370 5,898 6,054 560 280 89 96

41 364 417 6,080 6,259 630 280 97 106

42 400 463 6,244 6,465 690 280 105 114

45 324 370 6,353 6,617 640 330 98 106

46 364 417 6,561 6,851 720 330 108 117

47 400 463 6,748 7,085 790 330 116 127

50 431 509 7,015 7,285 750 400 115 128

51 485 556 7,262 7,490 840 400 126 137

52 519 602 7,417 7,683 900 400 133 136

5A 225 —6,426 —500 —106 —

5B 241 —6,499 —520 —109 —

5C 258 —6,577 —550 —112 —

55 431 509 7,559 7,980 870 490 127 142

56 485 556 7,839 8,214 940 490 139 152

57 519 602 8,016 8,434 980 490 147 162

5F 225 —6,879 —550 —116 —

5G 241 —6,962 —570 —120 —

5H 258 —7,050 —600 —124 —

60 557 648 8,270 8,286 940 420 144 159

61 599 695 8,462 8,483 980 420 153 168

62 633 741 8,617 8,676 1020 420 160 177

65 557 648 8,943 9,204 1020 510 160 176

66 599 695 9,161 9,428 1060 510 169 187

67 633 741 9,338 9,648 1090 510 177 197

70 644 781 12,395 13,139 1220 780 224 209

71 726 870 12,821 13,568 1340 780 243 229

72 790 956 13,153 13,969 1440 780 257 248

75 644 781 13,293 14,211 1365 925 245 234

76 726 870 13,780 14,702 1505 925 266 257

77 790 956 14,159 15,160 1625 925 283 278

80 829 990 16,156 15,746 1500 720 285 264

81 901 1080 16,530 16,176 1620 720 302 284

82 976 1170 16,919 16,606 1730 720 319 304

85 829 990 17,296 17,001 1690 860 313 295

86 901 1080 17,723 17,492 1820 860 331 318

87 976 1170 18,169 17,984 1940 860 351 341

Table 13B — Heat Exchanger Data (SI)

NOTES:

1. Cooler data: based on a cooler with standard wall tubing, 2-pass,

1034 psig, nozzle-in-head waterbox with victaulic grooves.

Weight includes suction elbow, control panel, and distribution pip-

ing. Weight does not include compressor.

2. Condenser data: based on a condenser with standard wall tub-

ing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic

grooves. Weight includes the float valve, discharge elbow, and

distribution piping. Weight does not include unit-mounted starter,

isolation valves, and pumpout unit.

CODE

NUMBER OF TUBES SI

Dry (Rigging) Weight (kg) Chiller Charge

Cooler Condenser Cooler

Only

Condenser

Only

Refrigerant Weight (kg) Water Volume (L)

Cooler Condenser Cooler Condenser

10 142 180 1244 1226 132 91 129 158

11 161 200 1275 1257 141 91 140 170

12 180 225 1307 1296 150 91 152 185

15 142 180 1362 1353 145 113 149 183

16 161 200 1401 1391 154 113 163 198

17 180 225 1440 1439 168 113 178 216

20 200 218 1561 1598 157 102 183 181

21 240 266 1628 1673 175 102 207 210

22 282 315 1699 1748 197 102 234 239

30 200 218 1876 1675 159 118 208 210

31 240 267 1958 1768 190 118 242 246

32 280 315 2046 1859 222 118 271 282

35 200 218 2000 2089 181 141 232 233

36 240 267 2094 2195 218 141 266 273

37 280 315 2193 2300 249 141 301 314

40 324 370 2675 2745 254 127 338 365

41 364 417 2757 2839 286 127 368 400

42 400 463 2832 2932 313 127 396 433

45 324 370 2881 3001 290 150 372 403

46 364 417 2976 3107 327 150 407 442

47 400 463 3060 3213 358 150 438 481

50 431 509 3181 3304 340 181 435 483

51 485 556 3293 3397 381 181 477 518

52 519 602 3364 3484 408 181 502 552

5A 225 —2915 —227 —401 —

5B 241 —2949 —236 —412 —

5C 258 —2984 —250 —424 —

55 431 509 3428 3619 395 222 481 536

56 485 556 3555 3725 426 222 527 575

57 519 602 3635 3825 446 222 557 613

5F 225 —3121 —250 —439 —

5G 241 —3159 —259 —454 —

5H 258 —3199 —273 —464 —

60 557 648 3751 3758 426 190 546 601

61 599 695 3838 3847 444 190 578 636

62 633 741 3908 3935 462 190 604 669

65 557 648 4056 4174 462 231 605 668

66 599 695 4155 4276 481 231 641 707

67 633 741 4235 4376 494 231 671 745

70 644 781 5622 5959 553 354 848 791

71 726 870 5814 6153 608 354 919 867

72 790 956 5965 6335 653 354 974 937

75 644 781 6028 6445 619 420 927 885

76 726 870 6259 6667 683 420 1009 971

77 790 956 6421 6875 737 420 1072 1052

80 829 990 7326 7141 680 327 1080 1000

81 901 1080 7496 7336 735 327 1143 1075

82 976 1170 7673 7531 785 327 1208 1150

85 829 990 7844 7710 766 390 1183 1118

86 901 1080 8037 7933 825 390 1254 1205

87 976 1170 8240 8156 880 390 1329 1291

Table 14 — 19XR Additional Data for Marine Waterboxes*

*Add to heat exchanger data for total weights or volumes.

NOTES:

1. Weight adder shown is the same for cooler and condenser of equal frame size.

2. For the total weight of a vessel with a marine waterbox, add these values to the heat

exchanger weights (or volumes).

Table 15 — Compressor Weights

*Transmission weight does not include rotor, shaft, and gear.

HEAT EXCHANGER

FRAME, PASS

ENGLISH SI

Psig Rigging Weight

(lb)

Water Volume

(gal) kPa Rigging Weight

(kg)

Water Volume

(L)

FRAME 2, 1 AND 2 PASS 150 730 84 1034 331 318

FRAME 2, 2 PASS 150 365 42 1034 166 159

FRAME 3, 1 AND 2 PASS 150 730 84 1034 331 317

FRAME 3, 2 PASS 150 365 42 1034 166 159

FRAME 4, 1 AND 3 PASS 150 1060 123 1034 481 465

FRAME 4, 2 PASS 150 530 61 1034 240 231

FRAME 5, 1 AND 3 PASS 150 1240 139 1034 562 526

FRAME 5, 2 PASS 150 620 69 1034 281 263

FRAME 6, 1 AND 3 PASS 150 1500 162 1034 680 612

FRAME 6, 2 PASS 150 750 81 1034 340 306

FRAME 7, 1 AND 3 PASS 150 2010 326 1034 912 1234

FRAME 7, 2 PASS 150 740 163 1034 336 617

FRAME 8, 1 AND 3 PASS 150 1855 406 1034 841 1537

FRAME 8, 2 PASS 150 585 203 1034 265 768

FRAME 2, 1 AND 3 PASS 300 860 84 2068 390 318

FRAME 2, 2 PASS 300 430 42 2068 195 159

FRAME 3, 1 AND 3 PASS 300 860 84 2068 390 317

FRAME 3, 2 PASS 300 430 42 2068 195 159

FRAME 4, 1 AND 3 PASS 300 1210 123 2068 549 465

FRAME 4, 2 PASS 300 600 61 2068 272 231

FRAME 5, 1 AND 3 PASS 300 1380 139 2068 626 526

FRAME 5, 2 PASS 300 690 69 2068 313 263

FRAME 6, 1 AND 3 PASS 300 1650 162 2068 748 612

FRAME 6, 2 PASS 300 825 81 2068 374 306

FRAME 7, 1 AND 3 PASS 300 3100 326 2068 1406 1234

FRAME 7, 2 PASS 300 1830 163 2068 830 617

FRAME 8, 1 AND 3 PASS 300 2745 405 2068 1245 1533

FRAME 8, 2 PASS 300 1475 203 2068 766 768

COMPONENT

FRAME 2

COMPRESSOR

WEIGHT

FRAME 3

COMPRESSOR

WEIGHT

FRAME 4

COMPRESSOR

WEIGHT (Without

Split Ring Diffuser)

FRAME 4

COMPRESSOR

WEIGHT (With

Split Ring Diffuser)

FRAME 5

COMPRESSOR

WEIGHT

lb kg lb kg lb kg lb kg lb kg

SUCTION ELBOW 50 23 54 24 175 79 175 79 400 181

DISCHARGE ELBOW 60 27 46 21 157 71 157 71 325 147

TRANSMISSION* 320 145 730 331 656 298 656 298 1000 454

SUCTION HOUSING 300 136 350 159 446 202 810 367 1200 544

IMPELLER SHROUD 35 16 80 36 126 57 200 91 250 113

COMPRESSOR BASE 1260 571 1050 476 1589 721 2022 917 3695 1676

DIFFUSER 35 16 70 32 130 59 130 59 300 136

OIL PUMP 125 57 150 68 150 68 150 68 185 84

MISCELLANEOUS 100 45 135 61 144 65 200 91 220 100

TOTAL WEIGHT

(Less Motor and Elbows) 2300 1043 2660 1207 3712 1684 4548 2063 6850 3107

Table 16 — 19XR Motor Weights Standard and High Efficiency Motors

*Stator weight includes stator and shell.

†Rotor weight includes rotor and shaft.

NOTE: When different voltage motors have different weights the largest weight is given.

MOTOR

SIZE

ENGLISH SI

Stator Weight*

(lb)

Rotor Weight†

(lb) End Bell

Cover

(lb)

Stator Weight*

(kg)

Rotor Weight†

(kg) End Bell

Cover

(kg)

60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz

BD 1030 1030 240 240 185 467 467 109 109 84

BE 1070 1070 250 250 185 485 485 113 113 84

BF 1120 1120 265 265 185 508 508 120 120 84

BG 1175 1175 290 290 185 533 533 132 132 84

BH 1175 1175 290 290 185 533 533 132 132 84

CD 1286 1358 258 273 274 583 616 117 124 125

CE 1305 1377 265 281 274 592 625 120 127 125

CL 1324 1435 280 296 274 600 651 127 134 125

CM 1347 1455 303 303 274 611 660 137 137 125

CN 1358 1467 316 316 274 616 665 143 143 125

CP 1401 1479 329 316 274 635 671 149 143 125

CQ 1455 1479 329 316 274 660 671 149 152 125

DB 1665 1725 361 391 236 755 782 164 177 107

DC 1681 1737 391 404 236 762 788 177 183 107

DD 1977 2069 536 596 318 897 938 243 248 144

DE 2018 2089 550 550 318 915 948 249 248 144

DF 2100 2139 575 567 318 952 970 261 257 144

DG 2187 2153 599 599 318 992 977 272 272 144

DH 2203 2207 604 604 318 999 1001 274 274 144

DJ 2228 2305 614 614 318 1011 1046 279 279 144

EH 3060 3120 701 751 414 1388 1415 318 341 188

EJ 3105 3250 716 751 414 1408 1474 325 341 188

EK 3180 3250 716 768 414 1442 1474 325 348 188

EL 3180 3370 737 801 414 1442 1529 334 363 188

EM 3270 3370 737 801 414 1483 1529 334 363 188

EN 3270 3520 801 851 414 1483 1597 363 386 188

EP 3340 3520 830 851 414 1515 1597 376 386 188

Table 17A — 19XR Waterbox Cover Weights — English (lb)

LEGEND

NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.

RIG MACHINE COMPONENTS — Refer to instructions

below, Fig. 6-9, and Carrier Certified Prints for machine com-

ponent disassembly.

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 1 FRAME 2 FRAME 3

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 177 204 320 350 320 350

NIH, 2 Pass Cover, 150 psig 185 218 320 350 320 350

NIH, 3 Pass Cover, 150 psig 180 196 300 340 300 340

NIH/MWB End Cover, 150 psig 136 136 300 300 300 300

NIH, 1 Pass Cover, 300 psig 248 301 411 486 411 486

NIH, 2 Pass Cover, 300 psig 255 324 411 518 411 518

NIH, 3 Pass Cover, 300 psig 253 288 433 468 433 468

NIH/MWB End Cover, 300 psig 175 175 400 400 400 400

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 4 FRAME 5 FRAME 6

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 148 185 168 229 187 223

NIH, 2 Pass Cover, 150 psig 202 256 224 298 257 330

NIH, 3 Pass Cover, 150 psig 473 489 629 655 817 843

NIH/MWB End Cover, 150 psig 317 317 393 393 503 503

NIH, 1 Pass Cover, 300 psig 593 668 764 839 959 1035

NIH, 2 Pass Cover, 300 psig 594 700 761 878 923 1074

NIH, 3 Pass Cover, 300 psig 621 656 795 838 980 1031

NIH/MWB End Cover, 300 psig 569 569 713 713 913 913

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 7 COOLER FRAME 7 CONDENSER

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 329 441 329 441

NIH, 2 Pass Cover, 150 psig 426 541 426 541

NIH, 3 Pass Cover, 150 psig 1202 1239 1113 1171

NIH/MWB End Cover, 150 psig 789 789 703 703

NIH, 1 Pass Cover, 300 psig 1636 1801 1472 1633

NIH, 2 Pass Cover, 300 psig 1585 1825 1410 1644

NIH, 3 Pass Cover, 300 psig 1660 1741 1496 1613

NIH/MWB End Cover, 300 psig 1451 1451 1440 1440

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 8 COOLER FRAME 8 CONDENSER

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 417 494 417 494

NIH, 2 Pass Cover, 150 psig 531 685 531 685

NIH, 3 Pass Cover, 150 psig 1568 1626 1438 1497

NIH/MWB End Cover, 150 psig 1339 1339 898 898

NIH, 1 Pass Cover, 300 psig 2265 2429 1860 2015

NIH, 2 Pass Cover, 300 psig 2170 2499 1735 2044

NIH, 3 Pass Cover, 300 psig 2273 2436 1883 1995

NIH/MWB End Cover, 300 psig 1923 1923 1635 1635

NIH —Nozzle-in-Head

MWB —Marine Waterbox

IMPORTANT: Only a qualified service technician should

perform this operation.

Do not attempt to disconnect flanges while the machine is

under pressure. Failure to relieve pressure can result in per-

sonal injury or damage to the unit.

Before rigging the compressor, disconnect all wires enter-

ing the power panel.

Table 17B — 19XR Waterbox Cover Weights — SI (kg)

LEGEND

NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Table 6.

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 1 FRAME 2 FRAME 3

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 80 93 145 159 145 159

NIH, 2 Pass Cover, 150 psig 84 99 145 159 145 159

NIH, 3 Pass Cover, 150 psig 82 89 136 154 140 154

NIH/MWB End Cover, 150 psig 62 62 136 136 136 136

NIH, 1 Pass Cover, 300 psig 112 137 186 220 186 220

NIH, 2 Pass Cover, 300 psig 116 147 186 235 186 235

NIH, 3 Pass Cover, 300 psig 115 131 196 212 196 212

NIH/MWB End Cover, 300 psig 79 79 181 181 181 181

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 4 FRAME 5 FRAME 6

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 67 84 76 104 85 101

NIH, 2 Pass Cover, 150 psig 92 116 107 135 117 150

NIH, 3 Pass Cover, 150 psig 214 222 285 297 371 382

NIH/MWB End Cover, 150 psig 144 144 178 178 228 228

NIH, 1 Pass Cover, 300 psig 269 303 347 381 435 470

NIH, 2 Pass Cover, 300 psig 269 317 345 398 419 487

NIH, 3 Pass Cover, 300 psig 282 298 361 380 445 468

NIH/MWB End Cover, 300 psig 258 258 323 323 414 414

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 7 COOLER FRAME 7 CONDENSER

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 149 200 149 200

NIH, 2 Pass Cover, 150 psig 193 245 193 245

NIH, 3 Pass Cover, 150 psig 545 562 505 531

NIH/MWB End Cover, 150 psig 357 358 319 319

NIH, 1 Pass Cover, 300 psig 742 817 668 741

NIH, 2 Pass Cover, 300 psig 719 828 640 746

NIH, 3 Pass Cover, 300 psig 753 790 679 732

NIH/MWB End Cover, 300 psig 658 658 653 653

HEAT

EXCHANGER

WATERBOX

DESCRIPTION

FRAME 8 COOLER FRAME 8 CONDENSER

Standard

Nozzles Flanged Standard

Nozzles Flanged

COOLER/

CONDENSER

NIH, 1 Pass Cover, 150 psig 189 224 189 224

NIH, 2 Pass Cover, 150 psig 241 311 241 311

NIH, 3 Pass Cover, 150 psig 711 738 652 679

NIH/MWB End Cover, 150 psig 607 607 407 407

NIH, 1 Pass Cover, 300 psig 1027 1102 844 914

NIH, 2 Pass Cover, 300 psig 984 1134 787 927

NIH, 3 Pass Cover, 300 psig 1031 1105 854 905

NIH/MWB End Cover, 300 psig 872 872 742 742

NIH —Nozzle-in-Head

MWB —Marine Waterbox

Table 18 — Optional Pumpout System

Electrical Data

LEGEND

Table 19 — Additional Miscellaneous Weights

VFD — Variable Frequency Drive

Table 20 — Motor Voltage Code

MOTOR

CODE

CONDENSER

UNIT VOLTS-PH-Hz MAX

RLA LRA

119EA47-748 575-3-60 3.8 23.0

419EA42-748 200/208-3-60 10.9 63.5

519EA44-748 230-3-60 9.5 57.5

619EA46-748 400/460-3-50/60 4.7 28.8

LRA —Locked Rotor Amps

RLA —Rated Load Amps

ITEM Lb Kg

CONTROL CABINET 30 14

UNIT-MOUNTED STARTER 500 227

OPTIONAL ISOLATION VALVES 115 52

UNIT MOUNTED VFD 1000 454

MOTOR VOLTAGE CODE

Code Volts Frequency

60 200 60

61 230 60

62 380 60

63 416 60

64 460 60

65 575 60

66 2400 60

67 3300 60

68 4160 60

69 6900 60

50 230 50

51 346 50

52 400 50

53 3000 50

54 3300 50

55 6300 50

Compressor Assembly Torques

LEGEND

*Not shown.

NOTES:

1. All clearances for cylindrical surfaces are diametrical.

2. Dimensions are with rotor in thrust position.

3. Dimensions shown are in inches.

4. Impeller spacing should be performed in accordance with most

recent Carrier Service Bulletin on impeller spacing.

ITEM DESCRIPTION TORQUE

ft.-lb N•m

1* Oil Heater Retaining Nut 20 28

2Bull Gear Retaining Bolt 80-85 108-115

3Demister Bolts 15-19 20-26

4Impeller Retaining Bolt 44-46 60-62

5* Motor Terminals (Low Voltage) 50 68

6* Guide Vane Shaft Seal Nut 25 34

7* Motor Terminals (High Voltage)

— Insulator 2-4 2.7-5.4

— Packing Nut 5 6.8

— Brass Jam Nut 10 13.6

N•m—Newton meters

VIEW A

LOW SPEED SHAFT THRUST DISK

Fig. 44 — Compressor Fits and Clearances

COMPRESSOR, TRANSMISSION AREA

VIEW B — HIGH SPEED SHAFT

19XR COMPRESSOR CLEARANCES

*Depends on impeller size, contact your Carrier Service Representative for more information.

NOTE: All clearances for cylindrical surfaces are diametrical.

Fig. 44 — Compressor Fits and Clearances (cont)

ITEM COMPRESSOR CODE

221-299 321-389 421-489 521-599

A.0050

.0040

.0050

.0040

.0055

.0043

.0069

.0059

B.0050

.0040

.0050

.0040

.0053

.0043

.0065

.0055

C.0115

.0055

.0115

.0080

.0100

.0050

.0010

.0060

D.0190

.0040

.022

.012

.027

.017

.0350

.0250

E–.002

–.0005

–.0020

–.0005

–.0029

–.0014

–.0019

–.0005

F.0050

.0040

.0050

.0040

.0048

.0038

.0062

.0052

G—*—*—*—*

100

Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter

101

Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter (cont)

102

Fig. 45 — Allen-Bradley Wye-Delta Unit-Mounted Starter (cont)

C—Contactor

CB —Circuit Breaker

CP —Control Power

CT —Current Transformer

DS —Disconnect Switch

FU —Fuse

GRD —Ground

HPR —High Pressure Relay

ISM —Integrated Starter Module

L—Main Supply Power

LL —Control Power Supply

M—Contactor

OP —Oil Pump

PFCC —Power Factor Correction Capacitor

RES —Resistor

S—Contactor

ST —Shunt Trip

TB —Terminal Block

TC —Transition Contactor

VL —Wire Label

LEGEND NOTES:

1. Remote device.

2. Transformer connected for 480 v primary 120 v secondary. For other

voltages see chart:

3. Current transformer

•amps nameplate ratio

•amps effective ratio with primary turns

•polarity marking

Be sure to connect per polarity markings.

4. “S” - “2M” contactors are electrically and mechanically interlocked.

5. Live capacitor unit. Deenergize starter. Wait one (1) minute and ground

terminals before servicing.

6. All control wiring 14 gage red except as noted.

PRIMARY SECONDARY

H1-H2 H1-H3 H1-H4 H1-H5 X1-X2 X1-X3 X1-X4

240 416 480 600 99 120 130

230 400 460 575 95 115 125

220 380 440 550 91 110 120

208 500 85 100 110

103

LEGEND

AUX —Auxiliary

BRG —Bearing

C—Contactor

CB —Circuit Breaker

CCM —Chiller Control Module

CCN —Carrier Comfort Network

COMP’R—Compressor

COND —Condenser

CVC —Chiller Visual Controller

DISCH —Discharge

DL/DP —Datalink or Dataport

ENT —Entering

EVAP —Evaporator

EXT —External

FR —Frame

GND —Ground

G.V. —Guide Vane

HGBP —Hot Gas Bypass

HT EXCH —Heat Exchanger

LEGEND (cont)

ISM —Integrated Starter Module

L—Main Supply Power

LVG —Leaving

N.O. —Normally Open

PRESS —Pressure

REQM’T—Requirement

TEMP —Temperature

TB —Terminal Board

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

** Denotes Motor Starter Panel Conn.

Denotes Component Terminal

Wire Splice

Denotes Conductor

Male/Female Connector

Option Wiring

Fig. 46A — Electronic PIC II Control Panel Wiring Schematic For CVC (Frame 2, 3, 4 Compressor)

104

LEGEND

AUX —Auxiliary

BRG —Bearing

C—Contactor

CB —Circuit Breaker

CCM —Chiller Control Module

CCN —Carrier Comfort Network

COMP’R—Compressor

COND —Condenser

DISCH —Discharge

DL/DP —Datalink or Dataport

ENT —Entering

EVAP —Evaporator

EXT —External

FR —Frame

GND —Ground

G.V. —Guide Vane

HGBP —Hot Gas Bypass

HT EXCH —Heat Exchanger

ICVC —International Chiller Visual Controller

LEGEND (cont)

ISM —Integrated Starter Module

L—Main Supply Power

LVG —Leaving

N.O. —Normally Open

PRESS —Pressure

REQM’T—Requirement

TEMP —Temperature

TB —Terminal Board

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

** Denotes Motor Starter Panel Conn.

Denotes Component Terminal

Wire Splice

Denotes Conductor

Male/Female Connector

Option Wiring

Fig. 46B — Electronic PIC II Control Panel Wiring Schematic For ICVC (Frame 2, 3, 4 Compressor)

105

LEGEND

AUX —Auxiliary

BRG —Bearing

C—Contactor

CB —Circuit Breaker

CCM —Chiller Control Module

CCN —Carrier Comfort Network

COMP’R—Compressor

COND —Condenser

CVC —Chiller Visual Controller

DISCH —Discharge

DL/DP —Datalink or Dataport

ENT —Entering

EVAP —Evaporator

EXT —External

FR —Frame

GND —Ground

G.V. —Guide Vane

HGBP —Hot Gas Bypass

HT EXCH —Heat Exchanger

LEGEND (cont)

ISM —Integrated Starter Module

L—Main Supply Power

LVG —Leaving

N.O. —Normally Open

PRESS —Pressure

REQM’T—Requirement

TEMP —Temperature

TB —Te r m i n a l B o a r d

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

** Denotes Motor Starter Panel Conn.

Denotes Component Terminal

Wire Splice

Denotes Conductor Male/Female Connector

Option Wiring

Fig. 47A — Electronic PIC II Control Panel Wiring Schematic For CVC (Frame 4 with Split Ring Diffuser and Frame 5 Compressor)

106

LEGEND

AUX —Auxiliary

BRG —Bearing

C—Contactor

CB —Circuit Breaker

CCM —Chiller Control Module

CCN —Carrier Comfort Network

COMP’R—Compressor

COND —Condenser

DISCH —Discharge

DL/DP —Datalink or Dataport

ENT —Entering

EVAP —Evaporator

EXT —External

FR —Frame

GND —Ground

G.V. —Guide Vane

HGBP —Hot Gas Bypass

HT EXCH —Heat Exchanger

ICVC —International Chiller Visual Controller

ISM —Integrated Starter Module

LEGEND (cont)

L—Main Supply Power

LVG —Leaving

N.O. —Normally Open

PRESS —Pressure

REQM’T—Requirement

TEMP —Temperature

TB —Terminal Board

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

** Denotes Motor Starter Panel Conn.

Denotes Component Terminal

Wire Splice

Denotes Conductor Male/Female Connector

Option Wiring

Fig. 47B — Electronic PIC II Control Panel Wiring Schematic For ICVC (Frame 4 with Split Ring Diffuser and Frame 5 Compressor)

107

AUX —Auxiliary

C—Contactor

CB —Circuit Breaker

CCM —Chiller Control Module

COMM —Communication

COMPR —Compressor

DISCH —Discharge

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

*Denotes Mach. Control Panel Conn.

** Denotes Motor Starter Panel Conn.

Fig. 48 — Power Panel Wiring Schematic

FR —Frame

G—Ground

GRD —Ground

GVA —Guide Vane Actuator

HGBP —Hot Gas Bypass

HT EXCH —Heat Exchanger

ISM —Integrated Starter Module

L—Main Supply Power

N.O. —Normally Open

PRESS —Pressure

REQM’T—Requirement

T—Transformer

TB —Terminal Board

Denotes Component Terminal

Wire Splice

Denotes Conductor Male/Female Connector

Option Wiring

LEGEND

108

AUX —Auxiliary

C—Contactor

CB —Circuit Breaker

CT —Current Transformer

DS —Disconnect Switch

FU —Fuse

G—Ground

Fig. 49 — Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP

HPR —High Pressure Relay

ISM —Integrated Starter Module

L—Main Supply Power

LL —Control Power Supply

M—Contactor

RES —Resistor

S—Contactor

TB —Te r m i n a l B l ock

LEGEND NOTES:

1. Power factor correction capacitors (when required) are connected ahead of all current

transformers for proper calibration and sensing by the ISM and IQDP4130.

2. For phase to phase ground fault protection refer to Fig. 51.

3. For metering information refer to Fig. 52.

109

AUX —Auxiliary

C—Contactor

CB —Circuit Breaker

CT —Current Transformer

DS —Disconnect Switch

FU —Fuse

G—Ground

Fig. 50 — Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP

HPR —High Pressure Relay

ISM —Integrated Starter Module

L—Main Supply Power

LL —Control Power Supply

M—Contactor

RES —Resistor

S—Contactor

TB —Te r m i n a l B l ock

LEGEND NOTES:

1. Power factor correction capacitors (when required) are connected ahead of all current

transformers for proper calibration and sensing by the ISM and IQDP4130.

2. For metering option see Fig. 52.

110

Fig. 51 — Ground Fault Phase Current Option

Fig. 52 — Separate Metering Option

LEGEND

AM —Ammeter

CT —Current Transformer

L—Main Power Supply

VM —Voltmeter

Represents Twisted Wire

To Door

LEGEND

CT —Current Transformer

ISM —Integrated Starter Module

VFD —Variable Frequency Drive

Represents Twisted Wire

To Door

111

Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)

112

Fig. 53 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)

AUX —Auxiliary

BR —Bridge Rectifier

CB —Circuit Breaker

COND —Condenser

CPU —Central Processing Unit

CVC/

ICVC —Chiller Visual Controller

CT —Current Transformer

EVAP —Evaporator

FU —Fuse

GND —Ground

L—Main Supply Power

LL —Control Power Supply

M—Contactor

O/L —Overload Reset

PFCC —Power Factor

Correction Capacitor

RLA —Rated Load Amps

SCR —Silicone Controller Rectifier

ST —Shunt Trip

TB —Te r m i n a l B l o ck

Wire Node Symbol

may have terminal block

Benshaw supplied

terminal block

Te r m i na l S t r ip

Power Connection

PC Board Terminals

Twisted Pair

Twisted Shielded Pair

Shield Wire

Field Wiring

LEGEND

NOTES:

LED status with power applied and prior to run command.

Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1.

Transformer connections per transformer nameplate connection diagram.

MOVs are used on power stack assemblies for system voltages of 200 through 460 vac (as shown).

Resistor/capacitor networks (DVDTs) are used on power stack assemblies in place of MOVs for a system

voltage of 575 vac (not shown).

K3 relay shown in deenergized state. K3 contact will close when power is supplied. K3 contact will open

on stop command or system fault.

CT1-CT3 are sized per Chart 2.

Optional.

"ON"

"OFF"

113

Fig. 54 — Typical Across-the-Line Starter Wiring Schematic (Medium Voltage)

LEGEND

AUX —Auxiliary

C—Contactor

CB —Circuit Breaker

COMM —Communication

COND —Condenser

CPT —Control Power

Transformer

CR —Control Relay

CT —Current Transformer

DS —Disconnect Switch

EVAP —Evaporator

FU —Fuse

G—Ground

GFCT —Ground Fault Current

Transformer

HPR —High Pressure Relay

ISM —Integrated Starter

Module

L—Main Power Supply

LL —Control Power Supply

LVG —Leaving

M—Contactor

MTR —Motor

PRESS —Pressure

PT —Power Transformer

ST —Shunt Trip

STAT —Status

TB —Terminal Block

TRANS —Transition

VFD —Variable Frequency

Drive

VL —Wire Label

Starter Vendor

Power Wiring

Starter Vendor

Control Wiring

Field Installed

Power Wiring

(supplied by others)

Field Installed

Control Wiring

(supplied by others)

Option — Starter

Vendor Wiring

Twisted Pair Wiring

by Starter Vendor

Customer Terminal

Connection

114

Fig. 55 — Typical Primary Reactor Starter Wiring Schematic (Medium Voltage)

LEGEND

AUX —Auxiliary

C—Contactor

CB —Circuit Breaker

COMM —Communication

COND —Condenser

CPT —Control Power

Transformer

CR —Control Relay

CT —Current Transformer

DS —Disconnect Switch

EVAP —Evaporator

FU —Fuse

G—Ground

GFCT —Ground Fault Current

Transformer

HPR —High Pressure Relay

ISM —Integrated Starter

Module

L—Main Power Supply

LL —Control Power Supply

LVG —Leaving

M—Contactor

MTR —Motor

PRESS —Pressure

PT —Power Transformer

ST —Shunt Trip

STAT —Status

TB —Terminal Block

TRANS —Transition

VFD —Variable Frequency

Drive

VL —Wire Label

Starter Vendor

Power Wir ing

Starter Vendor

Control Wiring

Field Installed

Power Wir ing

(supplied by others)

Field Installed

Control Wiring

(supplied by others)

Option — Starter

Vendor Wiring

Twisted Pair Wiring

by Starter Vendor

Customer Terminal

Connection

115

Fig. 56 — Typical Autotransformer Starter Wiring Schematic (Medium Voltage)

LEGEND

AUX —Auxiliary

C—Contactor

CB —Circuit Breaker

COMM —Communication

COND —Condenser

CPT —Control Power

Transformer

CR —Control Relay

CT —Current Transformer

DISCH —Discharge

DS —Disconnect Switch

EVAP —Evaporator

FU —Fuse

GFCT —Ground Fault Current

Transformer

HPR —High Pressure Relay

ISM —Integrated Starter

Module

L—Main Power Supply

LL —Control Power Supply

MTR —Motor

PRESS —Pressure

PT —Power Transformer

ST —Shunt Trip

STAT —Status

TB —Te r m i n a l B l o c k

TC —Transition Clear

TRANS —Transition

VFD —Variable Frequency

Drive

VL —Wire Label

Starter Vendor

Power Wir ing

Starter Vendor

Control Wiring

Field Installed

Power Wir ing

(supplied by others)

Field Installed

Control Wiring

(supplied by others)

Option — Starter

Vendor Wiring

Twisted Pair Wiring

by Starter Vendor

Customer Terminal

Connection

116

Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic

117

Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)

118

Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)

119

Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)

120

Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)

121

Fig. 57 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)

122

LEGEND FOR FIG. 57

AUX —Auxiliary

CB —Circuit Breaker

CCM —Chiller Control Module

CCN —Carrier Comfort Network

COMM —Communications

CT —Current Transformer

CVC —Chiller Visual Controller

DP/DL —Data Port/Data Link

DS —Disconnect Switch

FD —Fused Disconnect

FR —Fan Relay

FU —Fuse

G—Chassis Ground

GV —Guide Vane

HGBP —Hot Gas Bypass

HPR —High Discharge Pressure Relay

HPS —High Pressure Switch

HX —Heat Exchanger

ICVC —International Chiller Visual Controller

IGBT —Insulated Gate Bipolar Transistor

IGV —Inlet Guide Vane

ISM —Integrated Starter Module

J—Junction

LEM —Current Detector

MAB —Module Adapter Board

RC —Regulator Controller

RMI —Remote Metering Interface

ST —Shunt Trip

T—Transformer

TB —Terminal Block

VFD —Variable Frequency Drive

1C —Compressor Oil Heater Contactor

1M —Start Contactor

2C —Oil Pump Contactor

3C —Hot Gas Bypass Relay

Field Control Wiring

Field Power Wiring

Factory Wiring

Shielded Cable

Twisted Pair Wiring

Male/Female Connector

Terminal Block Connection

Wire Splice or Junction

Cam Switch

Component Terminal

Thermistor

Transducer

Fusible Link

Potentiometer

Pressure Switch

Compr Oil Pump Terminal

Cartridge Fuse

Earth Ground

Resistor

Chassis Ground

Light

Temperature Switch

Common Potential

Dry Contact

VFD Terminal

Current Transformer, Polarized

(Direction Determined by •)

Transformer

IGBT

Diode

Silicone Control Rectifier

123

INDEX

Abbreviations and Explanations, 4

Adding Refrigerant, 71

Adjusting the Refrigerant Charge, 71

After Extended Shutdown, 67

After Limited Shutdown, 66

Alarm (Trip) Output Contacts, 37

Attach to Network Device Control, 44

Automatic Soft Stop Amps Threshold, 47

Auto. Restart After Power Failure, 38

Before Initial Start-Up, 48

Capacity Override, 36

Carrier Comfort Network Interface, 54

Changing Oil Filter, 73

Charge Refrigerant Into Chiller, 63

Chilled Water Recycle Mode, 47

Chiller Control Module (CCM), 88

Chiller Dehydration, 53

Chiller Familiarization, 5

Chiller Information Nameplate, 5

Chiller Operating Condition (Check), 65

Chiller Tightness (Check), 48

Chillers with Isolation Valves, 70

Chillers with Storage Tanks, 69

Cold Weather Operation, 67

Compressor Bearing and Gear Maintenance, 74

Condenser, 5

Condenser Freeze Prevention, 38

Condenser Pump Control, 37

Control Algorithms Checkout Procedure, 77

Control Panel, 5

Control Modules, 87

Control Test, 77

Controls, 10

CVC/ICVC Operation and Menus, 15

Cooler, 5

Default Screen Freeze, 35

Definitions (Controls), 10

Demand Limit Control Option, 39

Design Set Points, (Input), 55

Details (Lubrication Cycle), 8

Display Messages (Check), 76

Dry Run to Test Start-Up Sequence, 65

Equipment Required, 48

Evaporator Freeze Protection, 38

Extended Shutdown (Preparation for), 66

Factory-Mounted Starter or Variable Frequency Drive, 7

General (Controls), 11

General Maintenance, 71

Guide Vane Linkage (Check), 72

Heat Exchanger Tubes and Flow Devices (Inspect), 74

High Altitude Locations, 63

High Discharge Temperature Control, 36

Ice Build Control, 43

Initial Start-Up, 64

Initial Start-Up Checklist for 19XR,XRV Hermetic

Centrifugal Liquid Chiller, CL-1

Inspect the Control Panel, 73

Instruct the Customer Operator, 65

Integrated Starter Module (ISM), 88

Introduction, 4

Job Data Required, 48

Kilowatt Output, 37

Lead/Lag Control, 40

Leak Rate, 71

Leak Test Chiller, 50

Local Occupied Schedule (Input), 55

Local Start-Up, 46

Lubrication Cycle, 8

Lubrication System (Check), 72

Manual Guide Vane Operation, 67

Motor and Lubricating Oil Cooling Cycle, 7

Motor-Compressor, 5

Motor Rotation (Check), 65

Notes on Module Operation, 87

Oil Changes, 73

Oil Charge, 55

Oil Cooler, 36

Oil Pressure and Compressor Stop (Check), 65

Oil Reclaim Filter, 73

Oil Reclaim System, 8

Oil Specification, 73

Oil Sump Temperature Control, 36

Open Oil Circuit Valves, 48

Operating Instructions, 66

Operating the Optional Pumpout Unit, 67

Operator Duties, 66

Optional Pumpout Compressor Water Piping (Check), 53

Optional Pumpout System Controls and

Compressor (Check), 63

Optional Pumpout System Maintenance, 75

Ordering Replacement Chiller Parts, 75

Overview (Troubleshooting Guide), 76

Perform a Control Test, 62

Physical Data, 90

PIC II System Components, 11

PIC II System Functions, 33

Power Up the Controls and Check the Oil Heater, 55

Preparation (Initial Start-Up), 64

Preparation (Pumpout and Refrigerant Transfer

Procedures), 67

Prepare the Chiller for Start-Up, 66

Pressure Transducers (Check), 75, 76

Prevent Accidental Start-Up, 65

Pumpout and Refrigerant Transfer Procedures, 67

Ramp Loading, 36

Refrigerant Filter, 73

Refrigerant Float System (Inspect), 74

Refrigerant Leak Detector, 37

Refrigerant Leak Testing, 71

Refrigerant Properties, 71

Refrigerant (Removing), 71

Refrigerant Tracer, 48

Refrigeration Cycle, 7

Refrigeration Log, 67

Relief Valves (Check), 53

Relief Valves and Piping (Inspect), 74

Remote Reset of Alarms, 37

Remote Start/Stop Controls, 36

Repair the Leak, Retest, and

Apply Standing Vacuum Test, 72

Replacing Defective Processor Modules, 88

Running System (Check), 66

Safety and Operating Controls (Check Monthly), 73

Safety Considerations, 1

Safety Controls, 34

Safety Shutdown, 47

Scheduled Maintenance, 73

Service Configurations (Input), 55

Service Ontime, 73

Service Operation, 45

Shipping Packaging (Remove), 48

Shunt Trip (Option), 35

Shutdown Sequence, 47

Software Configuration, 55

Solid-State Starters, 88

Spare Safety Inputs, 36

Standing Vacuum Test, 50

Starter (Check), 54

Starting Equipment, 9

Starting Equipment (Inspect), 75

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 211 Catalog No. 531-982 Printed in U.S.A. Form 19XR-5SS Pg 124 6-01 Replaces: 19XR-4SS

Book 2

Ta b 5 a

INDEX (cont)

Start-Up/Shutdown/Recycle Sequence, 46

Start the Chiller, 66

Stop the Chiller, 66

Storage Vessel, 7

Summary (Lubrication Cycle), 8

Surge Prevention Algorithm (Fixed Speed Chiller), 39

Surge Prevention Algorithm with VFD, 40

Surge Protection (Fixed Speed Chillers), 40

Surge Protection VFD Units, 40

System Components, 5

Temperature Sensors (Check), 76

Test After Service, Repair, or Major Leak, 71

Tighten All Gasketed Joints and Guide Vane Packing, 48

Tower Fan Relay Low and High, 38

Trim Refrigerant Charge, 72

Troubleshooting Guide, 76

Unit-Mounted Solid-State Starter, 9

Unit-Mounted VFD, 10

Unit-Mounted Wye-Delta Starter, 10

Using the Optional Storage Tank and Pumpout

System, 48

VFD Cooling Cycle, 8

Water/Brine Reset, 38

Water Leaks, 74

Water Piping (Inspect), 53

Water Treatment, 75

Weekly Maintenance, 72

Wiring (Inspect), 53

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 CL-1 6-01 Replaces: 19XR-4SS

Book 2

Ta b 5 a

INITIAL START-UP CHECKLIST

FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER

(Remove and use for job file.)

MACHINE INFORMATION:

DESIGN CONDITIONS:

CONTROL/OIL HEATER: Volts 115 230

REFRIGERANT: Type: Charge

START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP INSTRUCTIONS

JOB DATA REQUIRED:

1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . Yes No

2. Machine Assembly, Wiring and Piping Diagrams . . . . . . Yes No

3. Starting Equipment Details and Wiring Diagrams. . . . . . Yes No

4. Applicable Design Data (see above). . . . . . . . . . . . . . . . Yes No

5. Diagrams and Instructions for Special Controls . . . . . . . Yes No

INITIAL MACHINE PRESSURE:

RECORD PRESSURE DROPS: Cooler Condenser

CHARGE REFRIGERANT: Initial Charge Final Charge After Trim

NAME JOB NO.

ADDRESS MODEL

CITY STATE ZIP S/N

TONS BRINE FLOW

RATE

TEMPERATURE

OUT

PRESSURE

DROP PA S S SUCTION

TEMPERATURE

CONDENSER

TEMPERATURE

COOLER ******

CONDENSER ******

COMPRESSOR: Volts RLA OLTA

STARTER: Mfg Type S/N

OIL PUMP: Volts RLA OLTA

CARRIER OBLIGATIONS: Assemble... . . . . . . . . . . . . . . . . Yes No

Leak Test . . . . . . . . . . . . . . . . . . . Yes No

Dehydrate . . . . . . . . . . . . . . . . . . Yes No

Charging . . . . . . . . . . . . . . . . . . . Yes No

Operating Instructions Hrs.

YES NO

Was Machine Tight?

If Not, Were Leaks Corrected?

Was Machine Dehydrated After Repairs?

CHECK OIL LEVEL AND RECORD: ADD OIL: Yes No

Amount:

1/2 Top sight glass

1/2 Bottom sight glass

3/4

1/4

3/4

1/4

CL-2

INSPECT WIRING AND RECORD ELECTRICAL DATA:

RATINGS:

Motor Voltage Motor(s) Amps Oil Pump Voltage Starter LRA Rating

Line Voltages: Motor Oil Pump Controls/Oil Heater

FIELD-INSTALLED STARTERS ONLY:

Check continuity T1 to T1, etc. (Motor to starter, disconnect motor leads T4, T5, T6.) Do not megger solid-state

starters; disconnect leads to motor and megger the leads.

STARTER: Electro-Mechanical Solid-State Manufacturer

Serial Number

Motor Load Current Transformer Ratio :

Solid-State Overloads Yes No

CONTROLS: SAFETY, OPERATING, ETC.

Perform Controls Test (Yes/No)

INITIAL START:

Line Up All Valves in Accordance With Instruction Manual:

Start Water Pumps and Establish Water Flow

Oil Level OK and Oil Temperature OK Check Oil Pump Rotation-Pressure

Check Compressor Motor Rotation (Motor End Sight Glass) and Record: Clockwise

Restart Compressor, Bring Up To Speed. Shut Down. Any Abnormal Coastdown Noise? Yes* No

*If yes, determine cause.

START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

A: Trim charge and record under Charge Refrigerant Into Chiller section on page 63.

B: Complete any remaining control calibration and record under Controls section (pages 10-45).

C: For unit mounted VFD complete pages 58-61.

D: Take at least two sets of operational log readings and record.

E: After machine has been successfully run and set up, shut down and mark shutdown oil and refrigerant levels.

F: Give operating instructions to owner’s operating personnel. Hours Given: Hours

G: Call your Carrier factory representative to report chiller start-up.

SIGNATURES:

CARRIER

TECHNICIAN

DATE

CUSTOMER

REPRESENTATIVE

DATE

MEGGER MOTOR “PHASE TO PHASE”“PHASE TO GROUND”

T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G

10-Second Readings:

60-Second Readings:

Polarization Ratio:

PIC II CAUTION

COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY

CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH

CERTIFIED DRAWINGS).

Ye s

RUN MACHINE: Do these safeties shut down machine?

Condenser Water Flow Yes No

Chilled Water Flow Yes No

Pump Interlocks Yes No

CL-3

19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET

CVC/ICVC Software Version

Number:

CVC/ICVC Controller

Identification: BUS: ADDRESS:

DESCRIPTION RANGE UNITS DEFAULT VALUE

Base Demand Limit 40 to 100 % 100

ECW Setpoint 10 to 120 DEG F 60.0

LCW Setpoint 15 to 120 DEG F 50.0

Ice Build Setpoint 15 to 60 DEG F 40.0

Tower Fan High Setpoint 55 to 105 DEG F 75

CL-4

NOTE: Default setting is OCCUPIED 24 hours/day.

NOTE: Default setting is UNOCCUPIED 24 hours/day.

NOTE: Default setting is OCCUPIED 24 hours/day.

19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S

Day Flag Occupied

Time Unoccupied

Time

MTWT F S SH

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S

Day Flag Occupied

Time Unoccupied

Time

MTWT F S SH

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S

Day Flag Occupied

Time Unoccupied

Time

MTWT F S SH

Period 1:

Period 2:

Period 3:

Period 4:

Period 5:

Period 6:

Period 7:

Period 8:

CL-5

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -

19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Starter Type

(0=Full, 1=Red, 2=SS/VFD) 0 to 2 1

Motor Rated Line Voltage 200 to 13200 VOLTS 460

Volt Transformer Ratio: 1 1 to 35 1

Overvoltage Threshold 105 to 115 % 115

Undervoltage Threshold 85 to 95 % 85

Over/Under Volt Time 1 to 10 SEC 5

Voltage% Imbalance 1 to 10 % 10

Voltage Imbalance Time 1 to 10 SEC 5

Motor Rated Load Amps 10 to 5000 AMPS 200

Motor Locked Rotor Trip 100 to 60000 AMPS 1000

Locked Rotor Start Delay 1 to 10 cycles 5

Starter LRA Rating 100 to 60000 AMPS 2000

Motor Current CT Ratio: 1 3 to 1000 100

Current% Imbalance 5 to 40 % 15

Current Imbalance Time 1 to 10 SEC 5

Grnd Fault CT’s? 0/1 NO/YES YES

Ground Fault CT Ratio: 1 150 150

Ground Fault Current 1 to 25 AMPS 15

Ground Fault Start Delay 1 to 20 cycles 10

Ground Fault Persistence 1 to 10 cycles 5

Single Cycle Dropout 0/1 DSABLE/ENABLE DSABLE

Frequency-60 Hz? (No=50) 0/1 NO/YES YES

Line Frequency Faulting 0/1 DSABLE/ENABLE DSABLE

CL-6

19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Auto Restart Option 0/1 DSABLE/ENABLE DSABLE

Remote Contacts Option 0/1 DSABLE/ENABLE DSABLE

Soft Stop Amps Threshold 40 to 100 % 100

Surge/Hot Gas Bypass

Surge Limit/HGBP Option

Select: Surge=0, HGBP=1 0/1 0

Min. Load Point (T1, P1)

Surge/HGBP Delta T1 0.5 to 20 ˆF1.5

Surge/HGBP Delta P1 30 to 170 PSI 50

Full Load Point (T2, P2)

Surge/HGBP Delta T2 0.5 to 20 ˆF10

Surge/HGBP Delta P2 50 to 170 PSI 85

Surge/HGBP Deadband 0.5 to 3 ˆF1

Surge Protection

Surge Delta% Amps 5 to 20 % 10

Surge Time Period 7 to 10 MIN 8

Ice Build Control

Ice Build Option 0/1 DSABLE/ENABLE DSABLE

Ice Build Termination

0=Temp, 1=Contacts, 2=Both 0 to 2 0

Ice Build Recycle 0/1 DSABLE/ENABLE DSABLE

Refrigerant Leak Option 0/1 DSABLE/ENABLE DSABLE

Refrigerant Leak Alarm mA 4 to 20 mA 20

Head Pressure Reference

Delta P at 0% (4 mA) 20 to 60 psi 25

Delta P at 100% (20 mA) 20 to 60 psi 35

Minimum Output 0 to 100 % 0

CL-7

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Comp Motor Temp Override 150 to 200 DEG F 200

Cond Press Override 90 to 165 PSI 125

Comp Discharge Alert 125 to 200 DEG F 200

Comp Thrust Brg Alert 165 to 185 DEG F 175

Chilled Medium 0/1 WATER/BRINE WATER

Chilled Water Deadband .5 to 2.0 ˆF1.0

Evap Refrig Trippoint 0.0 to 40.0 DEG F 33

Refrig Override Delta T 2.0 to 5.0 ˆF3

Condenser Freeze Point –20 to 35 DEG F 34

Evap Flow Delta P Cutout 0.5 to 50.0 PSI 5.0

Cond Flow Delta P Cutout 0.5 to 50.0 PSI 5.0

Water Flow Verify Time 0.5 to 5 MIN 5

Oil Press Verify Time 15 to 300 SEC 40

Recycle Control

Restart Delta T 2.0 to 10.0 DEG F 5

Shutdown Delta T 0.5 to 4.0 DEG F 1

SPARE ALERT/ALARM ENABLE

Disable=0, Lo=1/3, Hi=2/4

Spare Temp #1 Enable 0 to 4 0

Spare Temp #1 Limit –40 to 245 DEG F 245

Spare Temp #2 Enable 0 to 4 0

Spare Temp #2 Limit –40 to 245 DEG F 245

CL-8

19XR, XRV PIC II SETUP2 TABLE CONFIGURATION SHEET

DESCRIPTION STATUS UNITS DEFAULT VALUE

Capacity Control

Proportional Inc Band 2 to 10 6.5

Proportional DEC Band 2 to 10 6.0

Proportional ECW Gain 1 to 3 2.0

Guide Vane Travel Limit 30 to 100 % 80

Diffuser Control

Diffuser Option 0 to 1 DSABLE/ENABLE DSABLE

Guide Vane 25% Load Pt 0 to 78 % 25

Diffuser 25% Load Point 0 to 100 % 0

Guide Vane 50% Load Pt 0 to 78 % 50

Diffuser 50% Load Point 0 to 100 % 0

Guide Vane 75% Load Pt 0 to 78 % 50

Diffuser 75% Load Point 0 to 100 % 0

Diffuser Full Span mA 15 to 22 mA 18

VFD Speed Control

VFD Option 0/1 DSABLE/ENABLE DSABLE

VFD Gain 0.1 to 1.5 0.75

VFD Increase Step 1 to 5 % 2

VFD Minimum Speed 65 to 100 % 70

VFD Maximum Speed 90 to 100 % 100

VFD Current Limit 0 to 99999 Amp 250

CL-9

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Lead Lag Control

LEAD/LAG: Configuration

DSABLE=0, LEAD=1,

LAG=2, STANDBY=3 0 to 3 0

Load Balance Option 0/1 DSABLE/ENABLE DSABLE

Common Sensor Option 0/1 DSABLE/ENABLE DSABLE

LAG% Capacity 25 to 75 % 50

LAG Address 1 to 236 92

LAG START Timer 2 to 60 MIN 10

LAG STOP Timer 2 to 60 MIN 10

PRESTART FAULT Timer 2 to 30 MIN 5

STANDBY Chiller Option 0/1 DSABLE/ENABLE DSABLE

STANDBY% Capacity 25 to 75 % 50

STANDBY Address 1 to 236 93

CL-10

19XR, XRV PIC II RAMP_DEM TABLE CONFIGURATION SHEET

19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Pulldown Ramp Type:

Select: Temp=0, Load=1 0/1 1

Demand Limit + kW Ramp

Demand Limit Source

Select: Amps=0, kW=1 0/1 0

Motor Load Ramp% Min 5 to 20 10

Demand Limit Prop Band 3 to 15 % 10

Demand Limit At 20 mA 40 to 100 % 40

20 mA Demand Limit Opt 0/1 DSABLE/ENABLE DSABLE

Motor Rated Kilowatts 50 to 9999 kW 145

Demand Watts Interval 5 to 60 MIN 15

DESCRIPTION RANGE UNITS DEFAULT VALUE

Control Point

ECW Control Option 0/1 DSABLE/ENABLE DSABLE

Temp Pulldown Deg/Min 2 to 10 ˆF3

Temperature Reset

RESET TYPE 1

Degrees Reset At 20 mA –30 to 30 ˆF10

RESET TYPE 2

Remote Temp -> No Reset –40 to 245 DEG F 85

Remote Temp -> Full Reset –40 to 245 DEG F 65

Degrees Reset –30 to 30 ˆF10

RESET TYPE 3

CHW Delta T -> No Reset 0 to 15 ˆF10

CHW Delta T -> Full Reset 0 to 15 ˆF0

Degrees Reset –30 to 30 ˆF5

Select/Enable Reset Type 0 to 3 0

CL-11

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BROADCAST (BRODEF) CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE

Time Broadcast Enable DSABLE/ENABLE DSABLE

Daylight Savings

Start Month 1 to 12 4

Start Day of Week 1 to 7 7

Start Week 1 to 5 3

Start Time 00:00 to 24:00 HH:MM 02:00

Start Advance 0 to 360 MIN 60

Stop Month 1 to 12 10

Stop Day of Week 1 to 7 7

Stop Week 1 to 5 3

Stop Time 00:00 to 24:00 02:00

Stop Back 0 to 360 MIN 60

CL-12

UNIT-MOUNTED VFD CONFIGURATION SHEET

*Variable by job — refer to component nameplates and labels.

DESCRIPTION PARAMETER RANGE DEFAULT COMMENTS

Maximum Speed P.004 15 to H.022 * Job Sheet; 60 for 60 Hz and 50 for 50 Hz

Speed Display Scaling P.028 10 to 999 * Job Sheet; 60 for 60 Hz and 50 for 50 Hz

Motor Voltage H.000 100 to 690 * Selected line voltage

Frequency H.001 30 to 200 * 60 Hz = 60, 50 Hz = 50

Motor Amps H.002 Power Module Dependent * Selected motor 100% amps

Line Voltage H.021 300 to 565 * Selected line voltage

Over Frequency Limit H.022 30 to 210 * 60 Hz = 69, 50 Hz = 57

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CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET

PRIMARY MESSAGE:

SECONDARY MESSAGE:

DATE: TIME:

COMPRESSOR ONTIME:

CHW IN

OILPRESS

CHW OUT

OIL TEMP

CDW IN CDW OUT

EVAP REF

COND REF

AMPS %

COMMUNICATION MESSAGE

CCN LOCAL RESET MENU

CL-14

CVC/ICVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET

PRIMARY MESSAGE:

SECONDARY MESSAGE:

DATE: TIME:

COMPRESSOR ONTIME:

CHW IN

OILPRESS

CHW OUT

OIL TEMP

CDW IN CDW OUT

EVAP REF

COND REF

AMPS %

COMMUNICATION MESSAGE

CCN LOCAL RESET MENU

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 CL-16 6-01 Replaces: 19XR-4SS

Book 2

Ta b 5 a

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Carrier Evergreen 19Xr Users Manual

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

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