Pic Ii

19XR,XRV
Hermetic Centrifugal Liquid Chillers

50/60 Hz
With PIC II Controls and HFC-134a
Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY
reliable service when operated within design specifica- FLUSH EYES with water and consult a physician.
tions. When operating this equipment, use good judgment NEVER APPLY an open flame or live steam to a refrigerant cylinder.
and safety precautions to avoid damage to equipment and Dangerous over pressure can result. When it is necessary to heat
property or injury to personnel. refrigerant, use only warm (110 F [43 C]) water.
Be sure you understand and follow the procedures and DO NOT REUSE disposable (nonreturnable) cylinders or attempt to
safety precautions contained in the chiller instructions as refill them. It is DANGEROUS AND ILLEGAL. When cylinder is
well as those listed in this guide. 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
DO NOT VENT refrigerant relief valves within a building. Outlet the chiller. The introduction of the wrong refrigerant can cause dam-
from rupture disc or relief valve must be vented outdoors in accor- age or malfunction to this chiller.
dance with the latest edition of ANSI/ASHRAE 15 (American Operation of this equipment with refrigerants other than those
National Standards Institute/American Society of Heating, Refrigera- cited herein should comply with ANSI/ASHRAE 15 (latest edition).
tion, and Air Conditioning Engineers). The accumulation of refriger- Contact Carrier for further information on use of this chiller with other
ant in an enclosed space can displace oxygen and cause asphyxiation. refrigerants.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while
15, especially for enclosed and low overhead spaces. Inhalation of chiller is under pressure or while chiller is running. Be sure pressure is
high concentrations of vapor is harmful and may cause heart irregular- at 0 psig (0 kPa) before breaking any refrigerant connection.
ities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier
than air and reduces the amount of oxygen available for breathing. CAREFULLY INSPECT all relief devices, rupture discs, and other
Product causes eye and skin irritation. Decomposition products are relief devices AT LEAST ONCE A YEAR. If chiller operates in a
hazardous. corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
any purpose. Oxygen gas reacts violently with oil, grease, and other device when corrosion or build-up of foreign material (rust, dirt, scale,
common substances. etc.) is found within the valve body or mechanism. Replace the
device.
NEVER EXCEED specified test pressures, VERIFY the allowable
test pressure by checking the instruction literature and the design pres- DO NOT install relief devices in series or backwards.
sures on the equipment nameplate. USE CARE when working near or in line with a compressed spring.
DO NOT USE air for leak testing. Use only refrigerant or dry Sudden release of the spring can cause it and objects in its path to act
nitrogen. as projectiles.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and DO NOT STEP on refrigerant lines. Broken lines can whip about and
functioning before operating any chiller. release refrigerant, causing personal injury.
RISK OF INJURY OR DEATH by electrocution. High voltage is DO NOT climb over a chiller. Use platform, catwalk, or staging. Fol-
present on motor leads even though the motor is not running when a low safe practices when using ladders.
solid-state or inside-delta mechanical starter is used. Open the power USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
supply disconnect before touching motor leads or terminals. 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.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until BE AWARE that certain automatic start arrangements CAN
all refrigerant (liquid and vapor) has been removed from chiller. ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the
Traces of vapor should be displaced with dry air or nitrogen and the disconnect ahead of the starter, tower fans, or pumps.
work area should be well ventilated. Refrigerant in contact with an USE only repair or replacement parts that meet the code requirements
open flame produces toxic gases. of the original equipment.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the DO NOT VENT OR DRAIN waterboxes containing industrial brines,
entire assembly. liquid, gases, or semisolids without the permission of your process
control group.
DO NOT work on high-voltage equipment unless you are a qualified
electrician. DO NOT LOOSEN waterbox cover bolts until the waterbox has been
completely drained.
DO NOT WORK ON electrical components, including control pan-
els, switches, starters, or oil heater until you are sure ALL POWER IS DOUBLE-CHECK that coupling nut wrenches, dial indicators, or
OFF and no residual voltage can leak from capacitors or solid-state other items have been removed before rotating any shafts.
components. DO NOT LOOSEN a packing gland nut before checking that the nut
LOCK OPEN AND TAG electrical circuits during servicing. IF has a positive thread engagement.
WORK IS INTERRUPTED, confirm that all circuits are deenergized PERIODICALLY INSPECT all valves, fittings, and piping for corro-
before resuming work. sion, rust, leaks, or damage.
AVOID SPILLING liquid refrigerant on skin or getting it into the PROVIDE A DRAIN connection in the vent line near each pressure
eyes. USE SAFETY GOGGLES. Wash any spills from the skin with relief device to prevent a build-up of condensate or rain water.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2 PC 211 Catalog No. 531-980 Printed in U.S.A. Form 19XR-4SS Pg 1 1-00 Replaces: 19XR-3SS
Tab 5a
CONTENTS
Page Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 Ramp Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Discharge Temperature Control . . . . . . . . . . . . 36
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4 Oil Sump Temperature Control . . . . . . . . . . . . . . . . . . 36
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chiller Information Nameplate . . . . . . . . . . . . . . . . . . . . 5 Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 36
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Spare Safety Alarm Contacts . . . . . . . . . . . . . . . . . . . . 37
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 37
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Kilowatt Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remote Reset of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . 37
Factory-Mounted Starter or Variable Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 37
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7 Condenser Freeze Prevention . . . . . . . . . . . . . . . . . . . 38
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7 Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 38
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 7 Auto. Restart After Power Failure. . . . . . . . . . . . . . . . 38
Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
MOTOR AND LUBRICATING OIL
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8 • RESET TYPE 1
• RESET TYPE 2
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • RESET TYPE 3
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9 Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 39
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Surge Prevention Algorithm
Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 (Fixed Speed Chiller) . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Reclaim System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Surge Prevention Algorithm with VFD . . . . . . . . . . . 40
• PRIMARY OIL RECOVERY MODE Surge Protection VFD Units . . . . . . . . . . . . . . . . . . . . . 40
• SECONDARY OIL RECOVERY METHOD Surge Protection (Fixed Speed Chiller) . . . . . . . . . . 40
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10 • HEAD PRESSURE REFERENCE OUTPUT
Unit-Mounted Solid-State Starter Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • COMMON POINT SENSOR INSTALLATION
Unit-Mounted Wye-Delta Starter • CHILLER COMMUNICATION WIRING
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 • LEAD/LAG OPERATION
Unit-Mounted VFD (Optional) . . . . . . . . . . . . . . . . . . . . 10 • FAULTED CHILLER OPERATION
• LOAD BALANCING
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 • AUTO. RESTART AFTER POWER FAILURE
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
• ANALOG SIGNAL • ICE BUILD INITIATION
• DISCRETE SIGNAL • START-UP/RECYCLE OPERATION
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 • TEMPERATURE CONTROL DURING ICE BUILD
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 11 • TERMINATION OF ICE BUILD
• CHILLER VISUAL CONTROLLER (CVC) • RETURN TO NON-ICE BUILD OPERATIONS
• INTEGRATED STARTER MODULE (ISM) Attach to Network Device Control . . . . . . . . . . . . . . . 44
• CHILLER CONTROL MODULE (CCM) • ATTACHING TO OTHER CCN MODULES
• OIL HEATER CONTACTOR (1C) Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
• OIL PUMP CONTACTOR (2C) • TO ACCESS THE SERVICE SCREENS
• HOT GAS BYPASS CONTACTOR RELAY (3C) • TO LOG OUT OF NETWORK DEVICE
(Optional) • HOLIDAY SCHEDULING
• CONTROL TRANSFORMERS (T1, T2)
CVC Operation and Menus . . . . . . . . . . . . . . . . . . . . . . 15 START-UP/SHUTDOWN/RECYCLE
• GENERAL SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47
• ALARMS AND ALERTS Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
• CVC MENU ITEMS Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
• BASIC CVC OPERATIONS (Using the Softkeys) Automatic Soft Stop Amps Threshold . . . . . . . . . . . 47
• TO VIEW STATUS Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 47
• OVERRIDE OPERATIONS Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
• TIME SCHEDULE OPERATION BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64
• TO VIEW AND CHANGE SET POINTS Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• SERVICE OPERATION Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 33 Using the Optional Storage Tank
• CAPACITY CONTROL FIXED SPEED and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 48
• CAPACITY CONTROL VFD Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 48
• ECW CONTROL OPTION Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• CONTROL POINT DEADBAND Tighten All Gasketed Joints and
• DIFFUSER CONTROL Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . . 48
• PROPORTIONAL BANDS AND GAIN Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 48
• DEMAND LIMITING Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• CHILLER TIMERS Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
• OCCUPANCY SCHEDULE Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Safety Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Chiller Dehydration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2
CONTENTS (cont)
Page Page
Check Optional Pumpout Compressor • DESCRIBE CHILLER CYCLES
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 • REVIEW MAINTENANCE
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 • SAFETY DEVICES AND PROCEDURES
Inspect Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 • CHECK OPERATOR KNOWLEDGE
Carrier Comfort Network Interface. . . . . . . . . . . . . . . 54 • REVIEW THE START-UP, OPERATION, AND
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 MAINTENANCE MANUAL
• MECHANICAL STARTER OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67
• BENSHAW, INC. RediStart MICRO™ Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SOLID-STATE STARTER Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Power Up the Controls and Check the Running System . . . . . . . . . . . . . . . . . . . . . 66
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 55 To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• SOFTWARE VERSION After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 66
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 55 Preparation for Extended Shutdown . . . . . . . . . . . . 66
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 55 After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67
Input the Local Occupied Schedule Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . 67
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 67
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 55 Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• PASSWORD
• INPUT TIME AND DATE PUMPOUT AND REFRIGERANT TRANSFER
• CHANGE CVC CONFIGURATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71
IF NECESSARY Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• TO CHANGE THE PASSWORD Operating the Optional Pumpout Unit . . . . . . . . . . . 67
• TO CHANGE THE CVC DISPLAY FROM • TO READ REFRIGERANT PRESSURES
ENGLISH TO METRIC UNITS Chillers with Storage Tanks . . . . . . . . . . . . . . . . . . . . . 69
• MODIFY CONTROLLER IDENTIFICATION • TRANSFER REFRIGERANT FROM
IF NECESSARY PUMPOUT STORAGE TANK TO CHILLER
• INPUT EQUIPMENT SERVICE PARAMETERS • TRANSFER REFRIGERANT FROM
IF NECESSARY CHILLER TO PUMPOUT STORAGE TANK
• CHANGE THE BENSHAW, INC., RediStart Chillers with Isolation Valves. . . . . . . . . . . . . . . . . . . . 70
MICRO SOFTWARE CONFIGURATION • TRANSFER ALL REFRIGERANT TO
IF NECESSARY CHILLER CONDENSER VESSEL
• VERIFY VFD CONFIGURATION AND CHANGE • TRANSFER ALL REFRIGERANT TO
PARAMETERS IF NECESSARY CHILLER COOLER VESSEL
• VFD CHILLER FIELD SET UP AND VERIFICATION • RETURN CHILLER TO NORMAL
• VFD CONTROL VERIFICATION (Non-Running) OPERATING CONDITIONS
• VFD CONTROL VERIFICATION (Running) GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72
• CONFIGURE DIFFUSER CONTROL IF Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 71
NECESSARY Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
• MODIFY EQUIPMENT CONFIGURATION Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
IF NECESSARY Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 71
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 71
• COOLER CONDENSER PRESSURE TRANSDUCER Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
AND WATERSIDE FLOW DEVICE CALIBRATION Test After Service, Repair, or Major Leak . . . . . . . . 71
Check Optional Pumpout System • TESTING WITH REFRIGERANT TRACER
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 63 • TESTING WITHOUT REFRIGERANT TRACER
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63 • TO PRESSURIZE WITH DRY NITROGEN
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 63 Repair the Leak, Retest, and Apply
• CHILLER EQUALIZATION WITHOUT A Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72
PUMPOUT UNIT Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 72
• CHILLER EQUALIZATION WITH Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 72
PUMPOUT UNIT WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 72
• TRIMMING REFRIGERANT CHARGE Check the Lubrication System . . . . . . . . . . . . . . . . . . 72
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 64 Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Check Safety and Operating Controls
Check Oil Pressure and Compressor Stop . . . . . . 65 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 65 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Check Chiller Operating Condition . . . . . . . . . . . . . . 65 Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 65 Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
• COOLER-CONDENSER • TO CHANGE THE OIL
• OPTIONAL PUMPOUT STORAGE TANK AND Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PUMPOUT SYSTEM Oil Reclaim Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
• MOTOR COMPRESSOR ASSEMBLY Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74
• MOTOR COMPRESSOR LUBRICATION Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 74
SYSTEM Compressor Bearing and Gear
• CONTROL SYSTEM Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
• AUXILIARY EQUIPMENT
3
CONTENTS (cont)
Page Page
Inspect the Heat Exchanger Tubes • TRANSDUCER REPLACEMENT
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Control Algorithms Checkout Procedure . . . . . . . . 77
• COOLER AND FLOW DEVICES Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
• CONDENSER AND FLOW DEVICES Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 • RED LED (Labeled as STAT)
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 • GREEN LED (Labeled as COM)
Inspect the Starting Equipment. . . . . . . . . . . . . . . . . . 75 Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 87
Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 75 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 88
Optional Pumpout System Maintenance . . . . . . . . . 75 • INPUTS
• OPTIONAL PUMPOUT COMPRESSOR OIL • OUTPUTS
CHARGE Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . . 88
• OPTIONAL PUMPOUT SAFETY CONTROL • INPUTS
SETTINGS • OUTPUTS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 75 Replacing Defective Processor Modules . . . . . . . . 88
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-117 • INSTALLATION
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Checking the Display Messages . . . . . . . . . . . . . . . . . 76 • TESTING SILICON CONTROL RECTIFIERS IN
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 76 BENSHAW, INC. SOLID-STATE STARTERS
• RESISTANCE CHECK • SCR REMOVAL/INSTALLATION
• VOLTAGE DROP Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
• CHECK SENSOR ACCURACY INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118,119
• DUAL TEMPERATURE SENSORS INITIAL START-UP CHECKLIST FOR
Checking Pressure Transducers. . . . . . . . . . . . . . . . . 76 19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-14
INTRODUCTION ABBREVIATIONS AND EXPLANATIONS

Prior to initial start-up of the 19XR unit, those involved in Frequently used abbreviations in this manual include:
the start-up, operation, and maintenance should be thoroughly CCM — Chiller Control Module
familiar with these instructions and other necessary job data. CCN — Carrier Comfort Network
This book is outlined to familiarize those involved in the start- CCW — Counterclockwise
CVC — Chiller Visual Controller
up, operation and maintenance of the unit with the control sys- CW — Clockwise
tem before performing start-up procedures. Procedures in this ECDW — Entering Condenser Water
manual are arranged in the sequence required for proper chiller ECW — Entering Chilled Water
start-up and operation. EMS — Energy Management System
HGBP — Hot Gas Bypass
I/O — Input/Output
ISM — Integrated Starter Module
LCD — Liquid Crystal Display
This unit uses a microprocessor control system. Do not LCDW — Leaving Condenser Water
LCW — Leaving Chilled Water
short or jumper between terminations on circuit boards or LED — Light-Emitting Diode
modules; control or board failure may result. OLTA — Overload Trip Amps
PIC II — Product Integrated Controls II
Be aware of electrostatic discharge (static electricity) when RLA — Rated Load Amps
handling or making contact with circuit boards or module SCR — Silicon Controlled Rectifier
connections. Always touch a chassis (grounded) part to dis- SI — International System of Units
sipate body electrostatic charge before working inside con- TXV — Thermostatic Expansion Valve
VFD — Variable Frequency Drive
trol center.
Use extreme care when handling tools near boards and Words printed in all capital letters or in italics may be
when connecting or disconnecting terminal plugs. Circuit viewed on the Chiller Visual Control (CVC) (e.g., LOCAL,
boards can easily be damaged. Always hold boards by the CCN, ALARM, etc.).
edges and avoid touching components and connections. Words printed in both all capital letters and italics can also
This equipment uses, and can radiate, radio frequency be viewed on the CVC and are parameters (e.g., CONTROL
energy. If not installed and used in accordance with the MODE, COMPRESSOR START RELAY, ICE BUILD
instruction manual, it may cause interference to radio com- OPTION, etc.) with associated values (e.g., modes, tempera-
munications. It has been tested and found to comply with tures, percentages, pressures, on, off, etc.).
the limits for a Class A computing device pursuant to Sub- Words printed in all capital letters and in a box represent
part J of Part 15 of FCC Rules, which are designed to pro- softkeys on the CVC control panel (e.g., ENTER , EXIT ,
vide reasonable protection against such interference when INCREASE , QUIT , etc.).
operated in a commercial environment. Operation of this
equipment in a residential area is likely to cause interfer- Factory-installed additional components are referred to as
ence, in which case the user, at his own expense, will be options in this manual; factory-supplied but field-installed ad-
required to take whatever measures may be required to cor- ditional components are referred to as accessories.
rect the interference. The chiller software part number of the 19XR unit is located
Always store and transport replacement or defective boards on the back of the CVC.
in anti-static shipping bag.
4
CHILLER FAMILIARIZATION Motor-Compressor — This component maintains sys-
(Fig. 1 and 2) tem temperature and pressure differences and moves the heat-
carrying refrigerant from the cooler to the condenser.
Chiller Information Nameplate — The information
nameplate is located on the right side of the chiller control Control Panel — The control panel is the user interface
panel. for controlling the chiller. It regulates the chiller’s capacity as
required to maintain proper leaving chilled water temperature.
System Components — The components include the The control panel:
cooler and condenser heat exchangers in separate vessels,
motor-compressor, lubrication package, control panel, and mo- • registers cooler, condenser, and lubricating system
tor starter. All connections from pressure vessels have external pressures
threads to enable each component to be pressure tested with a • shows chiller operating condition and alarm shutdown
threaded pipe cap during factory assembly. conditions
• records the total chiller operating hours
Cooler — This vessel (also known as the evaporator) is lo- • sequences chiller start, stop, and recycle under micro-
cated underneath the compressor. The cooler is maintained at processor control
lower temperature/pressure so evaporating refrigerant can re- • displays status of motor starter
move heat from water flowing through its internal tubes. • provides access to other CCN (Carrier Comfort Net-
work) devices and energy management systems
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.
19XRV 52 51 473 DG H 64 –
19XR- — High Efficiency Hermetic

Centrifugal Liquid Chiller
19XRV — High Efficiency Hermetic
Centrifugal Liquid Chiller with Special Order Indicator
Variable Frequency Drive – — Standard
Unit-Mounted S — Special Order
Motor Voltage Code

Cooler Size Code Volts-Phase-Hertz
10-12 (Frame 1 XR) 55-57 (Frame 5 XR) 60 — 200-3-60
15-17 (Frame 1 XR) 5F (Frame 5 XR) 61 — 200-3-60
20-22 (Frame 2 XR) 5G (Frame 5 XR) 62 — 380-3-60
30-32 (Frame 3 XR) 5H (Frame 5 XR) 63 — 416-3-60
35-37 (Frame 3 XR) 60-62 (Frame 6 XR) 64 — 460-3-60
40-42 (Frame 4 XR) 65-67 (Frame 6 XR) 65 — 575-3-60
45-47 (Frame 4 XR) 70-72 (Frame 7 XR) 66 — 2400-3-60
50-52 (Frame 5 XR) 75-77 (Frame 7 XR) 67 — 3300-3-60
5A (Frame 5 XR) 80-82 (Frame 8 XR) 68 — 4160-3-60
5B (Frame 5 XR) 85-87 (Frame 8 XR) 69 — 6900-3-60
5C (Frame 5 XR) 50 — 230-3-50
51 — 346-3-50
52 — 400-3-50
53 — 3000-3-50
54 — 3300-3-50
Condenser Size 55 — 6300-3-50
10-12 (Frame 1 XR)
15-17 (Frame 1 XR)
20-22 (Frame 2 XR) Motor Efficiency Code
30-32 (Frame 3 XR) H — High Efficiency
35-37 (Frame 3 XR) S — Standard Efficiency
40-42 (Frame 4 XR)
45-47 (Frame 4 XR)
50-52 (Frame 5 XR) Motor Code
55-57 (Frame 5 XR) BD CD DB EH
60-62 (Frame 6 XR) BE CE DC EJ
65-67 (Frame 6 XR) BF CL DD EK
70-72 (Frame 7 XR) BG CM DE EL
75-77 (Frame 7 XR) BH CN DF EM
80-82 (Frame 8 XR) CP DG EN
85-87 (Frame 8 XR) CQ DH EP
DJ
Compressor Code
(First Digit Indicates Compressor Frame Size)
MODEL NUMBER NOMENCLATURE
27 99 Q 59843
Week of Year Unique Number
Year of Manufacture Place of Manufacture
SERIAL NUMBER BREAKDOWN
Fig. 1 — 19XR Identification
5
FRONT VIEW
1
2
3
4
5
17
LEGEND
6
1 — Guide Vane Actuator
2 — Suction Elbow
3 — Chiller Visual Controller (CVC)
4 — Chiller Identification Nameplate
5 — Cooler, Auto Reset Relief Valves
16 6 — Cooler Pressure Transducer
7 — Condenser In/Out Temperature Thermistors
8 — Condenser Waterflow Device
9 — Cooler In/Out Temperature Thermistors
7 10 — Cooler Waterflow Device
11 — Refrigerant Charging Valve
12 — Typical Flange Connection
13 — Oil Drain Charging Valve
14 — Oil Level Sight Glasses
8 15 — Refrigerant Oil Cooler (Hidden)
16 — Auxiliary Power Panel
17 — Compressor Motor Housing
15 14
13
12
9
11 10
REAR VIEW
18 19 20 21 22
LEGEND
34 18 — Condenser Auto. Reset Relief Valves
23 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
33 24
32
31 30 29 28 27 26 25 24
Fig. 2 — Typical 19XR Components
6
Factory-Mounted Starter or Variable Fre- refrigerant is quite warm (typically 98 to 102 F [37 to 40 C])
quency Drive (Optional) — The starter allows for the when it is discharged from the compressor into the condenser.
proper start and disconnect of electrical energy for the com- Relatively cool (typically 65 to 90 F [18 to 32 C]) water
pressor-motor, oil pump, oil heater, and control panel. flowing into the condenser tubes removes heat from the refrig-
erant and the vapor condenses to liquid.
Storage Vessel (Optional) — There are 2 sizes of
storage vessels available. The vessels have double relief valves, The liquid refrigerant passes through orifices into the
a magnetically-coupled dial-type refrigerant level gage, a FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC
one-inch FPT drain valve, and a 1/2-in. male flare vapor con- chamber is at a lower pressure, part of the liquid refrigerant
nection for the pumpout unit. flashes to vapor, thereby cooling the remaining liquid. The
FLASC vapor is recondensed on the tubes which are cooled by
NOTE: If a storage vessel is not used at the jobsite, factory- entering condenser water. The liquid drains into a float cham-
installed isolation valves on the chiller may be used to isolate ber between the FLASC chamber and cooler. Here a float valve
the chiller charge in either the cooler or condenser. An optional forms a liquid seal to keep FLASC chamber vapor from enter-
pumpout system is used to transfer refrigerant from vessel to ing the cooler. When liquid refrigerant passes through the
vessel. valve, some of it flashes to vapor in the reduced pressure on the
cooler side. In flashing, it removes heat from the remaining liq-
REFRIGERATION CYCLE uid. The refrigerant is now at a temperature and pressure at
The compressor continuously draws refrigerant vapor from which the cycle began.
the cooler at a rate set by the amount of guide vane opening or
compressor speed (19XRV only). As the compressor suction MOTOR AND LUBRICATING OIL
reduces the pressure in the cooler, the remaining refrigerant COOLING CYCLE
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- The motor and the lubricating oil are cooled by liquid re-
ter flowing through the cooler tubes. With heat energy refrigerant taken from the bottom of the condenser vessel
moved, the water becomes cold enough to use in an air condi- (Fig. 3). Refrigerant flow is maintained by the pressure differ-
tioning circuit or for process liquid cooling. ential that exists due to compressor operation. After the refrig-
erant flows past an isolation valve, an in-line filter, and a sight
After taking heat from the water, the refrigerant vapor is glass/moisture indicator, the flow is split between the motor
compressed. Compression adds still more heat energy, and the cooling and oil cooling systems.
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
7
Flow to the motor cooling system passes through an orifice cooler heat exchanger. The oil cooler uses refrigerant from the
and into the motor. Once past the orifice, the refrigerant is condenser as the coolant. The refrigerant cools the oil to a tem-
directed over the motor by a spray nozzle. The refrigerant perature between 120 and 140 F (49 to 60 C).
collects in the bottom of the motor casing and is then drained As the oil leaves the oil cooler, it passes the oil pressure
back into the cooler through the motor refrigerant drain line. transducer and the thermal bulb for the refrigerant expansion
An orifice (in the motor shell) maintains a higher pressure in valve on the oil cooler. The oil is then divided. Part of the oil
the motor shell than in the cooler. The motor is protected by a flows to the thrust bearing, forward pinion bearing, and gear
temperature sensor imbedded in the stator windings. An spray. The rest of the oil lubricates the motor shaft bearings and
increase in motor winding temperature past the motor override the rear pinion bearing. The oil temperature is measured in the
set point overrides the temperature capacity control to hold, bearing housing as it leaves the thrust and forward journal
and if the motor temperature rises 10° F (5.5° C) above this set bearings. The oil then drains into the oil reservoir at the base of
point, closes the inlet guide vanes. If the temperature rises the compressor. The PIC II (Product Integrated Control II)
above the safety limit, the compressor shuts down. measures the temperature of the oil in the sump and maintains
Refrigerant that flows to the oil cooling system is regulated the temperature during shutdown (see Oil Sump Temperature
by thermostatic expansion valves (TXVs). The TXVs regulate Control section, page 36). This temperature is read on the CVC
flow into the oil/refrigerant plate and frame-type heat exchang- default screen.
er (the oil cooler in Fig. 3). The expansion valve bulbs control During the chiller start-up, the PIC II energizes the oil pump
oil temperature to the bearings. The refrigerant leaving the oil and provides 45 seconds of prelubrication to the bearings after
cooler heat exchanger returns to the chiller cooler. pressure is verified before starting the compressor. During
shutdown, the oil pump will run for 60 seconds to post-
VFD COOLING CYCLE lubricate after the compressor shuts down. The oil pump can
also be energized for testing purposes during a Control Test.
The unit-mounted variable frequency drive (VFD) is cooled
in a manner similar to the motor and lubricating oil cooling cy- Ramp loading can slow the rate of guide vane opening to
cle (Fig. 3). minimize oil foaming at start-up. If the guide vanes open
quickly, the sudden drop in suction pressure can cause any re-
If equipped with a unit-mounted VFD, the refrigerant line frigerant in the oil to flash. The resulting oil foam cannot be
that feeds the motor cooling and oil cooler also feeds the heat pumped efficiently; therefore, oil pressure falls off and lubrica-
exchanger on the unit-mounted VFD. Refrigerant is metered tion is poor. If oil pressure falls below 15 psid (103 kPad) dif-
through a thermostatic expansion valve (TXV). To maintain ferential, the PIC II will shut down the compressor.
proper operating temperature in the VFD, the TXV bulb is
mounted to the heat exchanger to regulate the flow of refriger- If the controls are subject to a power failure that lasts more
ant. The refrigerant leaving the heat exchanger returns to the than 3 hours, the oil pump will be energized periodically when
cooler. 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
LUBRICATION CYCLE the chiller is started.
Summary — The oil pump, oil filter, and oil cooler make Oil Reclaim System — The oil reclaim system returns
up a package located partially in the transmission casing of the oil lost from the compressor housing back to the oil reservoir
compressor-motor assembly. The oil is pumped into a filter by recovering the oil from 2 areas on the chiller. The guide
assembly to remove foreign particles and is then forced into an vane housing is the primary area of recovery. Oil is also recov-
oil cooler heat exchanger where the oil is cooled to proper ered by skimming it from the operating refrigerant level in the
operational temperatures. After the oil cooler, part of the flow cooler vessel.
is directed to the gears and the high speed shaft bearings; the
remaining flow is directed to the motor shaft bearings. Oil PRIMARY OIL RECOVERY MODE — Oil is normally re-
drains into the transmission oil sump to complete the cycle covered through the guide vane housing on the chiller. This is
(Fig. 4). possible because oil is normally entrained with refrigerant in
the chiller. As the compressor pulls the refrigerant up from the
Details — Oil is charged into the lubrication system through cooler into the guide vane housing to be compressed, the oil
a hand valve. Two sight glasses in the oil reservoir permit oil normally drops out at this point and falls to the bottom of the
level observation. Normal oil level is between the middle of the guide vane housing where it accumulates. Using discharge gas
upper sight glass and the top of the lower sight glass when the pressure to power an eductor, the oil is drawn from the housing
compressor is shut down. The oil level should be visible in at and is discharged into the oil reservoir.
least one of the 2 sight glasses during operation. Oil sump tem- SECONDARY OIL RECOVERY METHOD — The sec-
perature is displayed on the CVC (Chiller Visual Controller) ondary method of oil recovery is significant under light load
default screen. During compressor operation, the oil sump tem- conditions, when the refrigerant going up to the compressor
perature ranges between 125 to 150 F (52 to 66 C). suction does not have enough velocity to bring oil along. Under
The oil pump suction is fed from the oil reservoir. An oil these conditions, oil collects in a greater concentration at the
pressure relief valve maintains 18 to 25 psid (124 to172 kPad) top level of the refrigerant in the cooler. This oil and refrigerant
differential pressure in the system at the pump discharge. This mixture is skimmed from the side of the cooler and is then
differential pressure can be read directly from the CVC default drawn up to the guide vane housing. There is a filter in this line.
screen. The oil pump discharges oil to the oil filter assembly. Because the guide vane housing pressure is much lower than
This filter can be closed to permit removal of the filter without the cooler pressure, the refrigerant boils off, leaving the oil be-
draining the entire oil system (see Maintenance sections, hind to be collected by the primary oil recovery method.
pages 71 to 75, for details). The oil is then piped to the oil
8
REAR MOTOR FWD MOTOR OIL SUPPLY TO
BEARING BEARING FORWARD HIGH
SPEED BEARING
LABYRINTH
GAS LINE
MOTOR
COOLING LINE
ISOLATION
VALVE
OIL FILTER
TXV BULB PRESSURE ISOLATION PUMP
TRANSDUCER VALVE
OIL SIGHT
OIL HEATER GLASS
COOLER OIL PUMP EDUCTOR FILTER
MOTOR ISOLATION
SIGHT GLASS VALVE
OIL SKIMMER LINE
Fig. 4 — Lubrication System
STARTING EQUIPMENT solid-state starters. This module controls and monitors all as-
pects of the starter. See the Controls section on page 10 for ad-
The 19XR requires a motor starter to operate the centrifugal ditional ISM information. All starter replacement parts are sup-
hermetic compressor motor, the oil pump, and various auxilia- plied by the starter manufacturer excluding the ISM (contact
ry equipment. The starter is the main field wiring interface for Carrier’s Replacement Component Division [RCD]).
the contractor.
Unit-Mounted Solid-State Starter (Optional) —
See Carrier Specification Z-415 for specific starter require- The 19XR chiller may be equipped with a solid-state, reduced-
ments, Z-416 for free-standing VFD requirements and Z-417 voltage starter (Fig. 5 and 6). This starter’s primary function is
for unit-mounted VFD requirements. All starters must meet to provide on-off control of the compressor motor. This type of
these specifications in order to properly start and satisfy me- starter reduces the peak starting torque, reduces the motor in-
chanical safety requirements. Starters may be supplied as sepa- rush current, and decreases mechanical shock. This capability
rate, free-standing units or may be mounted directly on the is summed up by the phrase “soft starting.” The solid-state
chiller (unit mounted) for low voltage units only. starter is available as a 19XR option (factory supplied and in-
Three separate circuit breakers are inside the starter. Circuit stalled). The solid-state starters manufacturer name is located
breaker CB1 is the compressor motor circuit breaker. The dis- inside the starter access door.
connect switch on the starter front cover is connected to this A solid-state, reduced-voltage starter operates by reducing
breaker. Circuit breaker CB1 supplies power to the compressor the starting voltage. The starting torque of a motor at full volt-
motor. 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-
The main circuit breaker (CB1) on the front of the starter quired to get the motor moving. The voltage is reduced by sili-
disconnects the main motor current only. Power is still con controlled rectifiers (SCRs). The voltage and current are
energized for the other circuits. Two more circuit breakers then ramped up in a desired period of time. Once full voltage is
inside the starter must be turned off to disconnect power to reached, a bypass contactor is energized to bypass the SCRs.
the oil pump, PIC II controls, and oil heater.
Circuit breaker CB2 supplies power to the control panel, oil
heater, and portions of the starter controls.
When voltage is supplied to the solid-state circuitry (CB1
Circuit breaker CB3 supplies power to the oil pump. Both is closed), the heat sinks in the starter as well as the wires
CB2 and CB3 are wired in parallel with CB1 so that power is leading to the motor and the motor terminal are at line volt-
supplied to them if the CB1 disconnect is open. age. Do not touch the heat sinks, power wiring, or motor
All starters must include a Carrier control module called the terminals while voltage is present or serious injury will
Integrated Starter Module (ISM), excluding the Benshaw result.
9
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
7 • SCR control voltage
• power indication
• proper phasing for rotation
1 • start circuit energized
• over-temperature
• ground fault
2 • current unbalance
• run state
• software configuration
3
The starter is further explained in the Check Starter and
Troubleshooting Guide sections, pages 54 and 76.
4
6 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
5
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
LEGEND unit will be equipped with a variable frequency drive motor
1 — RediStart™ MICRO Input/Output Card controller mounted on the unit. See Fig. 7 and 8. This VFD is
2 — Fuses 1-4 (Hidden, not depicted) used with low voltage motors between 380 and 480 VAC. It re-
3 — Circuit Breaker 2 (CB2): Machine Control and Heater Power
4 — Circuit Breaker 3 (CB3): Oil Pump Power duces the starting current inrush by controlling the voltage and
5 — RediStart MICRO Central Processing Unit Card (CPU) frequency to the compressor motor. Once the motor has accel-
6 — RediStart MICRO Power Card (hidden, not depicted) lerated to minimum speed the PIC II modulates the compressor
7 — RediStart MICRO Bypass Card (hidden, not depicted) speed and guide vane position to control chilled water tempera-
Fig. 5 — Solid-State Starter Box, ture. The VFD is further explained in the Controls section and
Internal View 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.)
Fig. 6 — Typical Starter External View
(Solid-State Starter Shown)
10
AUTO Forward
SPEED RUNNING MAN Reverse
VOLTS REMOTE
AMPS JOG RUN
PROGRAM
Hz AUTO JOB
Kw FORWARD
TORQUE REVERSE
AUTO Forward
Password PROGRAM ENTER
VOLTS REMOTE
AMPS JOG PRO- RUN
Hz AUTO GRAM JOB
Kw FORWARD
TORQUE REVERSE
Password PROGRAM ENTER
OPTIONAL
METER
PACKAGE
MANUAL RESET
Fig. 7 — Variable Frequency Drive (VFD)

+ DC BUS BAR
MEASUREMENT
- POINT
INTEGRATED
STARTER
MODULE
(ISM)
INITIAL DC BUS
MEASUREMENT
POINT
OIL PUMP + DANGER -

DISCONNECT HIGH VOLTAGE
CONTROL
AUTO Forward
VOLTS REMOTE
AMPS JOG RUN
PROGRAM
Hz AUTO JOB
AND OIL LINE

Kw
TORQUE
Password
FORWARD
REVERSE
PROGRAM ENTER
HEATER
DISCONNECT
VFD
MODULE
LOAD
COOLING LINES
COMPRESSOR
MOTOR
DISCONNECT
TXV
Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View
General — The 19XR hermetic centrifugal liquid chiller PIC II System Components — The chiller control
contains a microprocessor-based control center that monitors system is called the PIC II (Product Integrated Control II). See
and controls all operations of the chiller (see Fig. 9). The mi- Table 1. The PIC II controls the operation of the chiller by
croprocessor control system matches the cooling capacity of monitoring all operating conditions. The PIC II can diagnose a
the chiller to the cooling load while providing state-of-the-art problem and let the operator know what the problem is and
chiller protection. The system controls cooling load within the what to check. It promptly positions the guide vanes to main-
set point plus the deadband by sensing the leaving chilled water tain leaving chilled water temperature. It can interface with
or brine temperature and regulating the inlet guide vane via a auxiliary equipment such as pumps and cooling tower fans to
mechanically linked actuator motor. The guide vane is a vari- turn them on when required. It continually checks all safeties to
able flow pre-whirl assembly that controls the refrigeration ef- prevent any unsafe operating condition. It also regulates the oil
fect in the cooler by regulating the amount of refrigerant vapor heater while the compressor is off and regulates the hot gas by-
flow into the compressor. An increase in guide vane opening pass valve, if installed. The PIC II controls provide critical pro-
increases capacity. A decrease in guide vane opening decreases tection for the compressor motor and controls the motor starter.
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.
11
FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE
WATER
SENSOR
CABLES WATER
SENSOR
CABLES
COOLER
PRESSURE
TRANSDUCER
CONNECTION
CONDENSER SCHRADER CONDENSER DISCHARGE COMPRESSOR MOTOR WINDING

PRESSURE FITTING (HIDDEN) SERVICE ISOLATION DISCHARGE TEMPERATURE
CABLE CONDENSER VALVE VALVE ELBOW JOINTS CABLE
PRESSURE (OPTIONAL)
TRANSDUCER
CONNECTION
TOP VIEW
COMPRESSOR DETAIL
Fig. 9 — 19XR Controls and Sensor Locations
12
The PIC II can interface with the Carrier Comfort Network CHILLER CONTROL MODULE (CCM) — This module is
(CCN) if desired. It can communicate with other PIC I or PIC located in the control panel. The CCM provides the input and
II equipped chillers and other CCN devices. outputs necessary to control the chiller. This module monitors
The PIC II consists of 3 modules housed inside 3 major refrigerant pressure, entering and leaving water temperatures,
components. The component names and corresponding control and outputs control for the guide vane actuator, oil heaters, and
voltages are listed below (also see Table 1): oil pump. The CCM is the connection point for optional de-
mand limit, chilled water reset, remote temperature reset, re-
• control panel frigerant leak sensor and motor kilowatt output.
— all extra low-voltage wiring (24 v or less)
• power panel OIL HEATER CONTACTOR (1C) — This contactor is lo-
— 230 or 115 v control voltage (per job requirement) cated in the power panel (Fig. 13) and operates the heater at
— up to 600 v for oil pump power either 115 or 230 v. It is controlled by the PIC II to maintain oil
• starter cabinet temperature during chiller shutdown.
— chiller power wiring (per job requirement) 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
Table 1 — Major PIC II Components and necessary.
Panel Locations* HOT GAS BYPASS CONTACTOR RELAY (3C) (Op-
tional) — This relay, located in the power panel, controls the
PIC II COMPONENT PANEL LOCATION opening of the hot gas bypass valve. The PIC II energizes the
Chiller Visual Controller (CVC) and Display Control Panel relay during low load, high lift conditions.
Integrated Starter Module (ISM) Starter Cabinet
CONTROL TRANSFORMERS (T1, T2) — These trans-
Chiller Control Module (CCM) Control Panel
formers convert incoming control voltage to 24 vac power for
Oil Heater Contactor (1C) Power Panel
the 3 power panel contactor relays, CCM, and CVC.
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.
*See Fig. 5 and Fig. 9-13.
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 Fig. 10 — Control Sensors (Temperature)
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.
INTEGRATED STARTER MODULE (ISM) — This mod-
ule is located in the starter cabinet. This module initiates com-
mands from the CVC for starter functions such as starting and
stopping the compressor, condenser, chilled water pumps, tow-
er fan, spare alarm contacts, and the shunt trip. The ISM moni- Fig. 11 — Control Sensors
tors starter inputs such as line voltage, motor current, ground (Pressure Transducers, Typical)
fault, remote start contact, spare safety, condenser high pres-
sure, 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 are lost. The ISM can
also act as the interface for PIC II to the VFD controller.
13
Fig. 12 — Control Panel
Fig. 13 — Power Panel
14
CVC Operation and Menus (Fig. 14-20) PRIMARY STATUS COMPRESSOR DATE TIME
MESSAGE ON TIME
GENERAL
SECONDARY
• The CVC display automatically reverts to the default STATUS RUNNING TEMP CONTROL 01-01-95 11:48
MESSAGE
screen after 15 minutes if no softkey activity takes place LEAVING CHILLED WATER
CHW IN CHW OUT
28.8 HOURS
EVAP REF
and if the chiller is not in the pumpdown mode (Fig. 14). ALARM LIGHT
(ILLUMINATED 55.1 44.1 40.7
• If a screen other than the default screen is displayed on WHEN POWER ON)
CDW IN
85.0
CDW OUT
95.0
COND REF
98.1
the CVC, the name of that screen is in the upper right • BLINKS CONTINUOUSLY
ON FOR AN ALARM
OIL PRESS OIL TEMP AMPS %
corner (Fig. 15). 21.8 132.9 93

• BLINKS ONCE TO
• The CVC may be set to display either English or SI CONFIRM A STOP CCN LOCAL RESET MENU
units. Use the CVC configuration screen (accessed from

the Service menu) to change the units. See the Service
Operation section, page 45. STOP BUTTON
• Local Operation — The PIC II can be placed in local • HOLD FOR ONE
SECOND TO STOP
operating mode by pressing the LOCAL softkey. The
SOFT KEYS
PIC II then accepts commands from the CVC only and EACH KEY'S FUNCTION IS MENU
uses the Local Time Schedule to determine chiller start DEFINED BY THE MENU DESCRIPTION LINE
ON MENU LINE ABOVE
and stop times.
• CCN Operation — The PIC II can be placed in the CCN Fig. 14 — CVC Default Screen
operating mode by pressing the CCN softkey. The PIC
II then accepts modifications from any CCN interface or
module (with the proper authority), as well as from the
CVC. The PIC II uses the CCN time schedule to deter-
mine 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 19XR_II SERVICE
far right field of the CVC display screen. ALARM HISTORY
CONTROL TEST
Alarms are indicated when the control center alarm light (!) CONTROL ALGORITHM STATUS
EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
flashes. The primary alarm message is displayed on the default EQUIPMENT SERVICE
TIME AND DATE
screen. An additional, secondary message and troubleshooting ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
information are sent to the ALARM HISTORY table. CVC CONFIGURATION
When an alarm is detected, the CVC default screen will

freeze (stop updating) at the time of alarm. The freeze enables
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 RESET soft-
key), the default CVC screen will return to normal operation.
CVC MENU ITEMS — To perform any of the operations de-
scribed below, the PIC II must be powered up and have suc- Fig. 15 — CVC Service Screen
cessfully completed its self test. The self test takes place auto-
matically, after power-up.
Press the MENU softkey to view the list of menu struc-
tures: STATUS , SCHEDULE , SETPOINT , and
SERVICE . Press the softkey that corresponds to the menu structure to
• The STATUS menu allows viewing and limited calibra- be viewed: STATUS SCHEDULE , SETPOINT , or
tion or modification of control points and sensors, relays SERVICE . To view or change parameters within any of these
and contacts, and the options board. menu structures, use the NEXT and PREVIOUS softkeys
• The SCHEDULE menu allows viewing and modifica- to scroll down to the desired item or table. Use the SELECT
tion of the local and CCN time schedules and Ice Build softkey to select that item. The softkey choices that then appear
time schedules. depend on the selected table or menu. The softkey choices and
• The SETPOINT menu allows set point adjustments, their functions are described below.
such as the entering chilled water and leaving chilled BASIC CVC OPERATIONS (Using the Softkeys) — To
water set points. perform any of the operations described below, the PIC II must
• The SERVICE menu can be used to view or modify be powered up and have successfully completed its self test.
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 Net-
work Device, and CVC Configuration screens.
For more information on the menu structures, refer to
Fig. 17.
15
• Press QUIT to leave the selected decision or field with- 2. Press NEXT or PREVIOUS to highlight the desired
out saving any changes. status table. The list of tables is:
•MAINSTAT — Overall chiller status
•STARTUP — Status required to perform start-up of
chiller
•COMPRESS — Status of sensors related to the
compressor
• Press ENTER to leave the selected decision or field and •HEAT_EX — Status of sensors related to the heat
save changes. exchangers
•POWER — Status of motor input power
•ISM_STAT — Status of motor starter
•CVC_PSWD — Service menu password forcing
access screen
• Press NEXT to scroll the cursor bar down in order to

highlight a point or to view more points below the cur-
rent screen.
3. Press SELECT to view the desired point status table.
• Press PREVIOUS to scroll the cursor bar up in order to

highlight a point or to view points above the current
screen. 4. On the point status table, press NEXT or PREVIOUS
until the desired point is displayed on the screen.
• Press SELECT to view the next screen level (high-

lighted with the cursor bar), or to override (if allowable)
the highlighted point value.
19XR_II MAINSTAT POINT STATUS
Control Mode OFF
Run Status Ready
Start Inhibit Timer 0.0 Min
Occupied? NO
System Alert/Alarm NORMAL
Chiller Start/Stop STOP
Remote Start Contact Open
Temperature Reset 0.0 F
Control Point 44.0 F
• Press EXIT to return to the previous screen level. Chilled Water Temp 44.6 F
Active Demand Limit 100%
Average Line Current 0.0%
• Press INCREASE or DECREASE to change the high-

lighted point value.
Fig. 16 — Example of Status Screen
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press NEXT or
TO VIEW STATUS (Fig. 16) — The status table shows the PREVIOUS to highlight the desired value.
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 STATUS to view the list of
point status tables.
2. Press SELECT to select the highlighted value. Then:
16
• DEFAULT SCREEN
CCN LOCAL RESET MENU (SOFTKEYS)
Start Chiller In CCN Control
Start Chiller in Local Control
Clear Alarms Access Main Menu
STATUS SCHEDULE SETPOINT SERVICE
1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)

List the
Status Tables List the Service Tables
Display The Setpoint Table

• MAINSTAT
• STARTUP
• COMPRESS List the Schedules
• HEAT_EX • Base Demand Limit
• POWER • LCW Setpoint
• ISM_STAT • ECW Setpoint
• CVC_PSWD • Ice Build Setpoint
• Tower Fan High Setpoint
Select a Status Table Select the Setpoint
NEXT PREVIOUS SELECT EXIT NEXT PREVIOUS SELECT EXIT
Modify the Setpoint
Select a Modification Point
INCREASE DECREASE QUIT ENTER
NEXT PREVIOUS SELECT EXIT
Modify a Discrete Point

START STOP RELEASE ENTER
ON OFF
Modify an Analog Point

INCREASE DECREASE RELEASE ENTER • OCCPC01S – LOCAL TIME SCHEDULE
• OCCPC02S – ICE BUILD TIME SCHEDULE
Modify Control Options • OCCPC03S – CCN TIME SCHEDULE
ENABLE DISABLE QUIT ENTER Select a Schedule
1
2
3
4
5
6
7
8
Override
Select a Time Period/Override
Modify a Schedule Time
INCREASE DECREASE ENTER EXIT (ANALOG VALUES)
Add/Eliminate a Day
ENABLE DISABLE ENTER EXIT (DISCRETE VALUES)
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
SEE FIGURE 18
Fig. 17 — 19XR CVC Menu Structure
17
• SERVICE TABLE
ALARM HISTORY
Display Alarm History

(The table holds up to 25 alarms and
alerts with the most recent alarm
at the top of the screen.)
CONTROL TEST List the Control Tests
• CCM Thermistors
CONTROL ALGORITHM STATUS • CCM Pressure Transducers
• Pumps
• Discrete Outputs
List the Control Algorithm Status Tables • Guide Vane Actuator
• CAPACITY (Capacity Control) • Diffuser Actuator
• OVERRIDE (Override Status) • Pumpdown/Lockout
• LL_MAINT (Lead Lag Status) • Terminate Lockout
• ISM_HIST (ISM Alarm History) • Guide Vane Calibration
• LOADSHED Select a Test
• WSMDEFME (Water System Manager Control Status) NEXT PREVIOUS SELECT EXIT
• OCCDEFCM (Time Schedule Status)
Select a Table
OCCDEFM (Time Schedule Status)

• CAPACITY (Capacity Control Algorithm)
Data Select Table • OVERRIDE (Override Status)
NEXT PREVIOUS SELECT EXIT • LL_MAINT (LEADLAG Status)
• WSMDEFM2 (Water System Manager Control Status)
OCCPC01S (Local Status)

OCCPC02S (CCN, ICE BUILD Status) Maintenance Table Data
OCCPC03S (CCN Status)
EQUIPMENT CONFIGURATION List the Equipment Configuration Tables
• NET_OPT
• BRODEF
• OCCEFCS
• HOLIDAYS
• CONSUME
• RUNTIME
Select a Table
Select a Parameter
Modify a Parameter
INCREASE DECREASE QUIT ENTER (ANALOG VALUES)
ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)
CONTINUED
ON NEXT PAGE
Fig. 18 — 19XR Service Menu Structure
18
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
ISM (STARTER) CONFIG DATA
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
(VALUES SHOWN AT FACTORY DEFAULT)
Service Tables:
• OPTIONS Service Tables:
• SETUP1 • ISM (STARTER) CONFIG PASSWORD
• SETUP2 • ISM_CONF
• LEADLAG
• RAMP_DEM
• TEMP_CTL
Select a Service Table

Select a Service Table Parameter
Modify a Service Table Parameter

INCREASE DECREASE QUIT ENTER (ANALOG VALUES)
ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)
TIME AND DATE
Display Time and Date Table:

• To Modify — Current Time — Day of Week
ATTACH TO NETWORK DEVICE — Current Date — Holiday Today
INCREASE DECREASE ENTER EXIT (ANALOG VALUE)
List Network Devices
• Local • Device 6 YES NO ENTER EXIT (DISCRETE VALUE)
• Device 1 • Device 7
• Device 4
• Device 5
Select a Device
NEXT PREVIOUS SELECT ATTACH
Modify Device Address

INCREASE DECREASE ENTER EXIT
• Use to attach CVC to another CCN network or device
• Attach to "LOCAL" to enter this machine
• To upload new tables
LOG OUT OF DEVICE
Default Screen
CCN LOCAL RESET MENU
CVC CONFIGURATION
CVC Configuration Table
INCREASE DECREASE ENTER EXIT
• To Modify — CVC CCN Address • To View — CVC Software Version
— English (U.S. IMP.) or S.I. Metric Units (last 2 digits of part number
— Password indicate software version)
LEGEND
CCN — Carrier Comfort Network
PIC II — Product Integrated Control II
Fig. 18 — 19XR Service Menu Structure (cont)
19
For Discrete Points — Press START or STOP to se- OCCPC02S — ICE BUILD Time Schedule
lect the desired state. OCCPC03S — CCN Time Schedule
For Analog Points — Press INCREASE or 3. Press SELECT to view the desired time schedule.
DECREASE to select the desired value.
4. Press NEXT or PREVIOUS to highlight the desired

3. Press ENTER to register the new value. period or override to change.
NOTE: When overriding or changing metric values, it is nec- 5. Press SELECT to access the highlighted period or
essary to hold down the softkey for a few seconds in order to override.
see a value change, especially on kilopascal values.
To Remove an Override
1. On the point status table press NEXT or PREVIOUS
to highlight the desired value.
6. a Press INCREASE or DECREASE to change the
time values. Override values are in one-hour
increments, up to 4 hours.
2. Press SELECT to access the highlighted value.
b. Press ENABLE to select days in the day-of-week

fields. Press DISABLE to eliminate days from the
period.
3. Press RELEASE 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 SCHEDULE .

schedule.
OCCPC01S — LOCAL Time Schedule
Fig. 19 — Example of Time Schedule
Operation Screen
20
7. Press ENTER to register the values and to move hori- 2. There are 5 set points on this screen: BASE DEMAND
zontally (left to right) within a period. 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 ac-
tive is determined from the SERVICE menu. See the Ser-
vice Operation section, page 45. The ice build (ICE
8. Press EXIT to leave the period or override. BUILD) function is also activated and configured from
the SERVICE menu.
set point entry.
9. Either return to Step 4 to select another period or over-

ride, or press EXIT again to leave the current time
schedule screen and save the changes.
4. Press SELECT to modify the highlighted set point.
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 5. Press INCREASE or DECREASE to change the se-
assigned. The Broadcast function in the BRODEF lected set point value.
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 SETPOINT .
6. Press ENTER to save the changes and return to the pre-
vious screen.
19XR_II SETPOINT SETPOINT SELECT SERVICE OPERATION — To view the menu-driven pro-
Base Demand Limit 100%
Control Point grams available for Service Operation, see Service Operation
LCW Setpoint 50.0 F
ECW Setpoint 60.0 F section, page 45. For examples of CVC display screens, see
ICE BUILD Setpoint 40.0 F
Tower Fan High Setpoint 85.0 F Table 2.
Fig. 20 — Example of Set Point Screen
21
Table 2 — CVC Display Data
6. Reference Point Names shown in these tables in all capital let-
IMPORTANT: The following notes apply to all Table 2 ters can be read by CCN and BS software. Of these capitalized
examples. names, those preceded by a dagger can also be changed (that
is, written to) by the CCN, BS, and the CVC. Capitalized Refer-
1. Only 12 lines of information appear on the CVC screen at any ence Point Names preceded by two asterisks can be changed
one time. Press the NEXT or PREVIOUS softkey to highlight only from the CVC. Reference Point Names in lower case type
can be viewed by CCN or BS only by viewing the whole table.
a point or to view items below or above the current screen.
7. Alarms and Alerts: An asterisk in the far right field of a CVC
Press the NEXT softkey twice to page forward; press the status screen indicates that the chiller is in an alarm state; an
PREVIOUS softkey twice to page back. exclamation point in the far right field of the CVC screen indi-
cates an alert state. The asterisk (or exclamation point) indicates
2. To access the information shown in Examples 10 through 22, that the value on that line has exceeded (or is approaching) a
enter your 4-digit password after pressing the SERVICE soft- limit. For more information on alarms and alerts, see the Alarms
and Alerts section, page 15.
key. If no softkeys are pressed for 15 minutes, the CVC automat-
LEGEND
ically logs off (to prevent unrestricted access to PIC II controls)
and reverts to the default screen. If this happens, you must re- CCN — Carrier Comfort Network
CHW — Chilled Water
enter your password to access the tables shown in Examples 10 CHWR — Chilled Water Return
through 22. CHWS — Chilled Water Supply
3. Terms in the Description column of these tables are listed as CT — Current Transformer
they appear on the CVC screen. ECW — Entering Chilled Water
4. The CVC may be configured in English or Metric (SI) units using HGBP — Hot Gas Bypass
the CVC CONFIGURATION screen. See the Service Operation ISM — Integrated Starter Module
section, page 45, for instructions on making this change. LCW — Leaving Chilled Water
5. The items in the Reference Point Name column do not appear on LRA — Locked Rotor Amps
mA — Milliamps
the CVC screen. They are data or variable names used in CCN
or Building Supervisor (BS) software. They are listed in these P — Pressure
tables as a convenience to the operator if it is necessary to cross PIC II — Product Integrated Controls II
SS — Solid State
reference CCN/BS documentation or use CCN/BS programs. For
more information, see the 19XR CCN literature. T — Temperature
WSM — Water System Manager
EXAMPLE 1 — CVC DEFAULT SCREEN

The following data is displayed in the CVC Default screen.
REFERENCE POINT NAME

DESCRIPTION STATUS UNITS (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
NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC only.
22
Table 2 — CVC Display Data (cont)
EXAMPLE 2 — MAINTSTAT DISPLAY SCREEN
To access this display from the CVC default screen:
1. Press MENU .
2. Press STATUS ( MAINSTAT will be highlighted).
3. Press SELECT .
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
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

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight STARTUP .
4. Press SELECT .

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
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write
operations for the CVC only.
23
EXAMPLE 4 — COMPRESS DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight COMPRESS .
4. Press SELECT .

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
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation. Those shown with (**) shall support write operations
for the CVC only.
EXAMPLE 5 — HEAT_EX DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight HEAT_EX .
4. Press SELECT .

**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
for the CVC only.
24
EXAMPLE 6 — POWER DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight POWER .
4. Press SELECT .

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 Voltage Phase 1 0-99999 VOLTS VOLTS_1
Ground Fault Phase 1 0-999 AMPS GF_1
Frequency 0-99 Hz FREQ
I2T Sum Heat-Phase 1 0-200 % HEAT1SUM
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 only.
EXAMPLE 7 — ISM_STAT DISPLAY SCREEN

1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight ISM_STAT .
4. Press SELECT .

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
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
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
25
EXAMPLE 8 — CVC_PSWD DISPLAY SCREEN
1. Press MENU .
2. Press STATUS .
3. Scroll down to highlight CVC_PSWD .
4. Press SELECT .

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
for the CVC only.
EXAMPLE 9 — SETPOINT DISPLAY SCREEN

1. Press MENU .
2. Press SETPOINT .
3. Press SELECT .
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
NOTE: All variables are available for CCN read operation; forcing shall not be supported on setpoint screens.
EXAMPLE 10 — CAPACITY DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight CONTROL ALGORITHM STATUS .
4. Press SELECT .
5. Scroll down to highlight CAPACITY .
6. Press SELECT .

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
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
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
26
EXAMPLE 11 — OVERRIDE DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight OVERRIDE .
6. Press SELECT .

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
screens.
EXAMPLE 12 — LL_MAINT DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LL_MAINT.
6. Press SELECT .

Lead Lag 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
NOTES:
1. DISABLE, LEAD, LAG, STANDBY, INVALID
2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG
3. Reset, Off, Local, CCN
4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout
5. Stop, Start, Retain
6. All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.
27
EXAMPLE 13 — ISM_HIST DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight ISM_HIST .
6. Press SELECT .

ISM FAULT HISTORY
Values At Last Fault:
Line Current Phase 1 0-99999 AMPS AMPS_1F
Line Voltage Phase 1 0-99999 VOLTS VOLTS_1F
Ground Fault Phase 1 0-999 AMPS GF_1F
I2T Sum Heat-Phase 1 0-200 % HEAT1SUMF
Phase 1 Faulted? 0/1 NO/YES PH1_FLT
Line Frequency 0-99 Hz FREQ_ F
ISM Fault Status 0-9999 ISM_STAT
screens.
EXAMPLE 14 — WSMDEFME DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight WSMDEFME .
6. Press SELECT .

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
screens.
28
EXAMPLE 15 — NET_OPT DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT CONFIGURATION .
4. Press SELECT .
5. Scroll down to highlight NET_OPT .
6. Press SELECT .

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
NOTE: No variables are available for CCN read or write operation.
EXAMPLE 16 — ISM_CONF DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight ISM (STARTER) CONFIG DATA .
4. Press SELECT .
5. Enter password (4444 Factory Default).
6. Scroll down to highlight ISM_CONF .
7. Press SELECT .

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 1-33 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: 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
29
EXAMPLE 17 — OPTIONS DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight EQUIPMENT SERVICE .
4. Press SELECT .
5. Scroll down to highlight OPTIONS .
6. Press SELECT .

Auto Restart Option 0/1 DSABLE/ENABLE astart DSABLE
Remote Contacts Open 0/1 DSABLE/ENABLE r_contact DSABLE
Soft Stop Amps Threshold 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) 20-30 PSI HPDPO 25
Delta P at 100% (20mA) 35-50 PSI HPDP100 35
Minimum Output 0-10 % HPDPMIN% 0
EXAMPLE 18 — SETUP1 DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP1 .
6. Press SELECT .

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
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
30
EXAMPLE 19 — SETUP2 DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP2 .
6. Press SELECT .

Capacity Control
Proportional Inc Band 2-10 gv_inc 6.0
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
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
NOTE: No variables are available for CCN read or write operation; forcing shall not be supported on service screens.
EXAMPLE 20 — LEAD/LAG DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LEAD/LAG .
6. Press SELECT .

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 25-57 % stnd_per 50
STANDBY Address 1-236 stnd_add 93
31
EXAMPLE 21 — RAMP_DEM DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight RAMP_DEM .
6. Press SELECT .

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
EXAMPLE 22 — TEMP_CTL DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight TMP_CTL .
6. Press SELECT .

Control Point
ECW Control Option 0/1 DSABLE/ENABLE ecw_opt DSABLE
Temp Pulldown Deg/Min 2-10 ^F tmp_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
32
PIC II System Functions display screen. The TARGET VFD SPEED can be manually
NOTE: Words not part of paragraph headings and printed in all overridden by the operator from the COMPRESS screen. The
capital letters can be viewed on the CVC (e.g., LOCAL, CCN, VFD MINIMUM SPEED, MAXIMUM SPEED, VFD GAIN
RUNNING, ALARM, etc.). Words printed both in all capital and INCREASE STEP can be viewed and modified in the
letters and italics can also be viewed on the CVC and are SETUP2 display screen. TARGET and ACTUAL VFD SPEED
parameters (CONTROL MODE, TARGET GUIDE VANE can be viewed in the COMPRESS DISPLAY screen.
POS, etc.) with associated values (e.g., modes, temperatures, ECW CONTROL OPTION — If this option is enabled, the
pressures, percentages, on, off, enable, disable, etc.). Words PIC II uses the ENTERING CHILLED WATER temperature to
printed in all capital letters and in a box represent softkeys on modulate the vanes instead of the LEAVING CHILLED
the CVC (e.g., ENTER and EXIT ). See Table 2 for exam- WATER temperature. The ECW CONTROL OPTION may be
ples of the type of information that can appear on the CVC viewed on the TEMP_CTL screen, which is accessed from the
screens. Figures 14-20 give an overview of CVC operations EQUIPMENT SERVICE screen.
and menus. CONTROL POINT DEADBAND — This is the tolerance
CAPACITY CONTROL FIXED SPEED — The PIC II con- range on the chilled water/brine temperature control point. If
trols the chiller capacity by modulating the inlet guide vanes in the water temperature goes outside the CHILLED WATER
response to chilled water temperature deviation from the CON- DEADBAND, the PIC II opens or closes the guide vanes until
TROL POINT. The CONTROL POINT may be changed by a the temperature is within tolerance. The PIC II may be config-
CCN network device or is determined by the PIC II adding any ured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED
active chilled water reset to the SET POINT. The PIC II uses WATER DEADBAND may be viewed or modified on the
the PROPORTIONAL INC (Increase) BAND, PROPOR- SETUP1 screen, which is accessed from the EQUIPMENT
TIONAL DEC (Decrease) BAND, and the PROPORTIONAL SERVICE table.
ECW (Entering Chilled Water) GAIN to determine how fast or For example, a 1° F (0.6° C) deadband setting controls the
slow to respond. CONTROL POINT may be viewed or over- water temperature within ±0.5° F (0.3° C) of the control point.
ridden from the MAINSTAT screen. This may cause frequent guide vane movement if the chilled
CAPACITY CONTROL VFD — The PIC II controls the water load fluctuates frequently. A value of 1° F (0.6° C) is the
machine capacity by modulating the motor speed and inlet default setting.
guide vanes in response to chilled water temperature deviation DIFFUSER CONTROL — On 19XR FRAME 5 compres-
from the CONTROL POINT. The controller will maintain the sors equipped with a variable discharge diffuser, the PIC II
highest inlet guide vane setting at the lowest speed to maxi- adjusts the diffuser actuator position (DIFFUSER ACTUATOR
mize efficiency while avoiding surge. The CONTROL POINT on the COMPRESS screen) to correspond to the actual guide
may be changed by a CCN network device or is determined by vane position (ACTUAL GUIDE VANE POS on the COM-
the PIC II adding any active chilled water reset to the to the PRESS screen).
SET POINT. CONTROL POINT may be viewed or overridden The diffuser control can be enabled or disabled from the
from the MAINSTAT screen. The PIC II uses the PROPOR- SETUP2 screen. See Table 2, Example 19. In addition, the dif-
TIONAL INC (Increase) BAND, PROP DEC (Decrease) fuser and guide vane load points may be viewed and modified
BAND, and the PROPORTIONAL ECW (Entering Chilled from this screen. These points must be correct for the compres-
Water) GAIN to determine how fast or slow it takes the system sor size. The diffuser opening can be incremented from fully
to respond. The VFD GAIN allows for additional adjustment of open to completely closed. A 0% setting is fully open; a 100%
the VFD response. At start-up, the inlet guide vanes (IGV) setting is completely closed. To obtain the proper settings for
start in the closed position and the VFD ramps to its minimum Diffuser Control, contact a Carrier Engineering representative.
speed setting.
PROPORTIONAL BANDS AND GAIN — Proportional
The PIC II controller then initiates the Capacity Control al- band is the rate at which the guide vane position is corrected in
gorithm to maintain the chilled water temperature at the CON- proportion to how far the chilled water/brine temperature is
TROL POINT. During operation when the CONTROL POINT from the control point. Proportional gain determines how
is not met, the controller will establish a GUIDE VANE DELTA quickly the guide vanes react to how quickly the temperature is
which will either affect a percentage change to the GUIDE moving from the CONTROL POINT. The proportional bands
VANES or the VFD TARGET SPEED. Any change that will be and gain may be viewed or modified from the SETUP2 screen,
made to the IGV position or the VFD SPEED will depend on which is accessed from the EQUIPMENT SERVICE table.
whether the GUIDE VANE DELTA is positive or negative, and
the status of the Surge Control Algorithm. The Surge Control The Proportional Band — There are two response modes, one
Algorithm determines if the chiller should operate in Normal for temperature response above the control point, the other for
Mode or Surge Prevention Mode. The logic for how the IGV’s the response below the control point.
and VFD SPEED will be affected by the GUIDE VANE DEL- The temperature response above the control point is called
TA and the Surge Control Algorithm can be seen below: the PROPORTIONAL INC BAND, and it can slow or quicken
guide vane response to chilled water/brine temperatures above
NORMAL SURGE the DEADBAND. The PROPORTIONAL INC BAND can be
GUIDE VANE CONTROL PREVENTION
DELTA MODE MODE adjusted from a setting of 2 to 10; the default setting is 6.5.
IGV VFD IGV VFD The response below the control point is called the PRO-
From +0.2 to +2.0 1st 2nd 2nd 1st PORTIONAL DEC BAND, and it can slow or quicken the
From –0.2 to –2.0 2nd 1st 1st — guide vane response to chilled water temperature below the
deadband plus the control point. The PROPORTIONAL DEC
Normal Control mode occurs when ACTIVE DELTA T > BAND can be adjusted on the CVC from a setting of 2 to 10.
SURGE/HGBP DELTA T. The default setting is 6.0.
Surge Prevention Mode occurs when ACTIVE DELTA T NOTE: Increasing either of these settings causes the guide
≤ SURGE/HGBP DELTA T. vanes to respond more slowly than they would at a lower
The TARGET VFD SPEED, ACTUAL VFD SPEED and the setting.
VFD GAIN can be viewed and modified in the CAPACITY
33
The PROPORTIONAL ECW GAIN can be adjusted on the ICE BUILD mode, it uses Occupancy Schedule 02
CVC display for values of 1, 2, or 3; the default setting is 2. (OCCPC02S). When the chiller is in CCN mode, it uses
Increase this setting to increase guide vane response to a Occupancy Schedule 03 (OCCPC03S).
change in entering chilled water temperature. The CCN SCHEDULE NUMBER is configured on the
DEMAND LIMITING — The PIC II responds to the NET_OPT display screen, accessed from the EQUIPMENT
ACTIVE DEMAND LIMIT set point by limiting the opening of CONFIGURATION table. See Table 2, Example 15. SCHED-
the guide vanes. It compares the ACTIVE DEMAND LIMIT set ULE NUMBER can be changed to any value from 03 to 99. If
point to the DEMAND LIMIT SOURCE (either the AVERAGE this number is changed on the NET_OPT screen, the operator
LINE CURRENT or the MOTOR KW). Depending on how the must go to the ATTACH TO NETWORK DEVICE screen to
control is configured. DEMAND LIMIT SOURCE is on the upload the new number into the SCHEDULE screen. See
RAMP_DEM screen. The default source is the compressor Fig. 18.
motor current.
Safety Controls — The PIC II monitors all safety control
CHILLER TIMERS — The PIC II maintains 2 run time inputs and, if required, shuts down the chiller or limits the
clocks, known as COMPRESSOR ONTIME and SERVICE guide vanes to protect the chiller from possible damage from
ONTIME. COMPRESSOR ONTIME indicates the total life- any of the following conditions:
time compressor run hours. This timer can register up to
500,000 hours before the clock turns back to zero. The SER- • high bearing temperature
VICE ONTIME is a reset table timer that can be used to indi- • high motor winding temperature
cate the hours since the last service visit or any other event. • high discharge temperature
The time can be changed from the CVC to whatever value is • low discharge superheat*
desired. This timer can register up to 32,767 hours before it • low oil pressure
rolls over to zero. • low cooler refrigerant temperature/pressure
• condenser high pressure or low pressure
The chiller also maintains a start-to-start timer and a stop- • inadequate water/brine cooler and condenser flow
to-start timer. These timers limit how soon the chiller can be • high, low, or loss of voltage
started. START INHIBIT TIMER is displayed on the MAIN- • ground fault
STAT screen. See the Start-Up/Shutdown/Recycle Sequence • voltage imbalance
section, page 46, for more information on this topic. • current imbalance
OCCUPANCY SCHEDULE — The chiller schedule, de- • excessive motor acceleration time
scribed in the Time Schedule Operation section (page 20), de- • excessive starter transition time
termines when the chiller can run. Each schedule consists of • lack of motor current signal
from 1 to 8 occupied or unoccupied time periods, set by the op- • excessive motor amps
erator. The chiller can be started and run during an occupied • excessive compressor surge
time period (when OCCUPIED ? is set to YES on the MAIN- • temperature and transducer faults
STAT display screen). It cannot be started or run during an un- *Superheat is the difference between saturation temperature
occupied time period (when OCCUPIED ? is set to NO on the and sensible temperature. The high discharge temperature
MAINSTAT display screen). These time periods can be set for safety measures only sensible temperature.
each day of the week and for holidays. The day begins with
0000 hours and ends with 2400 hours. The default setting for Starter faults or optional protective devices within the starter
OCCUPIED ? is YES, unless an unoccupied time period is in can shut down the chiller. The protective devices you have for
effect. your application depend on what options were purchased.
These schedules can be set up to follow a building’s occu-
pancy schedule, or the chiller can be set so to run 100% of the
time, if the operator wishes. The schedules also can be by-
passed by forcing the CHILLER START/STOP parameter on If compressor motor overload occurs, check the motor for
the MAINSTAT screen to START. For more information on grounded or open phases before attempting a restart.
forced starts, see Local Start-Up, page 46. If the PIC II control initiates a safety shutdown, it displays
The schedules also can be overridden to keep the chiller in the reason for the shutdown (the fault) on the CVC display
an occupied state for up to 4 hours, on a one time basis. See the screen along with a primary and secondary message, energizes
Time Schedule Operation section, page 20. an alarm relay in the starter, and blinks the alarm light on the
Figure 19 shows a schedule for a typical office building control panel. The alarm is stored in memory and can be
with a 3-hour, off-peak, cool-down period from midnight to viewed on the ALARM HISTORY and ISM_HIST screens on
3 a.m., following a weekend shutdown. Holiday periods are in the CVC, along with a message for troubleshooting. If the safe-
an unoccupied state 24 hours per day. The building operates ty shutdown was also initiated by a fault detected in the motor
Monday through Friday, 7:00 a.m. to 6:00 p.m., and Saturdays starter, the conditions at the time of the fault will be stored in
from 6:00 a.m. to 1:00 p.m. This schedule also includes the ISM_HIST.
Monday midnight to 3:00 a.m. weekend cool-down schedule. To give more precise information or warnings on the
NOTE: This schedule is for illustration only and is not chiller’s operating condition, the operator can define alert lim-
intended to be a recommended schedule for chiller operation. its on various monitored inputs. Safety contact and alert limits
Whenever the chiller is in the LOCAL mode, it uses Occu- are defined in Table 3. Alarm and alert messages are listed in
pancy Schedule 01 (OCCPC01S). When the chiller is in the the Troubleshooting Guide section, page 76.
34
Table 3 — Protective Safety Limits and Control Settings
MONITORED PARAMETER LIMIT APPLICABLE COMMENTS
TEMPERATURE SENSORS OUT OF –40 to 245 F (–40 to 118.3 C) Must be outside range for 2 seconds
RANGE
PRESSURE TRANSDUCERS OUT OF 0.06 to 0.98 Voltage Ratio Must be outside range for 3 seconds.
RANGE Ratio = Input Voltage ÷ Voltage Reference
COMPRESSOR DISCHARGE >220 F (104.4 C) Preset, alert setting configurable
TEMPERATURE
MOTOR WINDING TEMPERATURE >220 F (104.4 C) Preset, alert setting configurable
BEARING TEMPERATURE >185 F (85 C) Preset, alert setting configurable
EVAPORATOR REFRIGERANT <33 F (for water chilling) (0.6°C) Preset, configurable chilled medium for water
TEMPERATURE (SETUP1 table)
<EVAP REFRIG TRIPPOINT (set point adjustable Configure chilled medium for brine (SETUP1
from 0 to 40 F (–18 to 4 C) for brine chilling) 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 Preset
110 ± 7 psig (758 ± 48 kPa)
— CONTROL 165 psig (1138 kPa) Preset
OIL PRESSURE Cutout <15 psid (103 kPad) Preset
Alert <18 psid (124 kPad)
LINE VOLTAGE — HIGH >150% for one second or >115% for ten seconds Preset, based on transformed line voltage
— LOW <85% for ten seconds or ≤80 for 5 seconds or to ISM. Also monitored at CVC and CCM
<75% for one second power input.
— 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 150% RLA for 20 sec. For chillers with reduced voltage mechanical
(Determined by inrush current) >100% RLA for 45 sec. and solid-state starters
>100% RLA for 10 sec. For chillers with full voltage starters
(Configures on ISM_CONF table).
STARTER TRANSITION If IM contact open >20 sec. Reduced voltage starters only
CONDENSER FREEZE PROTECTION Energizes condenser pump relay if CONDENSER FREEZE POINT configured in
condenser refrigerant temperature or condenser SETUP1 table with a default setting of 34 F
entering water temperature is below the configured (1 C).
condenser freeze point temperature. Deenergizes
when the temperature is 5 F (3 C) above con-
denser freeze point temperature.
DISCHARGE SUPERHEAT Minimum value calculated based on Calculated minimum required superheat
operating conditions and then compared and actual superheat are shown on
to actual superheat. OVERRIDE screen.
VARIABLE DIFFUSER OPERATION Detects discharge pulses caused by Preset, no calibration needed.
incorrect diffuser position.
Shunt Trip (Option) — The function of the shunt trip is remedied by the operator. Use CVC display and alarm shut-
option on the PIC II is to act as a safety trip. The shunt trip is down record sheet (CL-14) to record all values from default
wired from an output on the ISM to a shunt trip equipped mo- screen freeze.
tor circuit breaker. If the PIC II tries to shut down the compres- Knowledge of the operating state of the chiller at the time an
sor using a normal shutdown procedure but is unsuccessful for alarm occurs is useful when troubleshooting. Additional chiller
20 seconds, the shunt trip output is energized and causes the information can be viewed on the status screens and the
circuit breaker to trip off. If ground fault protection has been ISM_HIST screen. Troubleshooting information is recorded in
applied to the starter, the ground fault trip also energizes the the ALARM HISTORY table, which can be accessed from the
shunt trip to trip the circuit breaker. Protective devices in the SERVICE menu.
starter can also energize the shunt trip. The shunt trip feature
can be tested using the Control Test feature. To determine what caused the alarm, the operator should
read both the primary and secondary default screen messages,
Default Screen Freeze — When the chiller is in an as well as the alarm history. The primary message indicates the
alarm state, the default CVC display “freezes,” that is, it stops most recent alarm condition. The secondary message gives
updating. The first line of the CVC default screen displays a more detail on the alarm condition. Since there may be more
primary alarm message; the second line displays a secondary than one alarm condition, another alarm message may appear
alarm message. after the first condition is cleared. Check the ALARM HISTO-
The CVC default screen freezes to enable the operator to RY screen for additional help in determining the reasons for the
see the conditions of the chiller at the time of the alarm. If the alarms. Once all existing alarms are cleared (by pressing the
value in alarm is one normally displayed on the default screen, RESET softkey), the default CVC display returns to normal
it flashes between normal and reverse video. The CVC default operation.
screen remains frozen until the condition that caused the alarm
35
Ramp Loading — The ramp loading control slows down Oil Sump Temperature Control — The oil sump
the rate at which the compressor loads up. This control can pre- temperature control is regulated by the PIC II, which uses the
vent the compressor from loading up during the short period of oil heater relay when the chiller is shut down.
time when the chiller is started and the chilled water loop has to As part of the pre-start checks executed by the controls, the
be brought down to CONTROL POINT. This helps reduce oil sump temperature (OIL SUMP TEMP) is compared to the
electrical demand charges by slowly bringing the chilled water cooler refrigerant temperature (EVAPORATOR REFRIG
to CONTROL POINT. The total power draw during this period TEMP). If the difference between these 2 temperatures is 50 F
remains almost unchanged. (27.8 C) or less, the start-up will be delayed until the oil tem-
There are two methods of ramp loading with the PIC II. perature is 50 F (27.8 C) or more. Once this temperature is con-
Ramp loading can be based on chilled water temperature or on firmed, the start-up continues.
motor load. Either method is selected from the RAMP__DEM The oil heater relay is energized whenever the chiller com-
screen. pressor is off and the oil sump temperature is less than 140 F
1. Temperature ramp loading (TEMP PULLDOWN DEG/ (60.0 C) or the oil sump temperature is less than the cooler re-
MIN) limits the degrees per minute rate at which either frigerant temperature plus 53° F (11.7° C). The oil heater is
leaving chilled water or entering chilled water tempera- turned off when the oil sump temperature is either
ture decreases. This rate is configured by the operator on • more than 152 F (66.7 C), or
the TEMP_CTL screen. The lowest temperature ramp • more than 142 F (61.1 C) and more than the cooler
rate will also be used if chiller power has been off for refrigerant temperature plus 55° F (12.8° C).
3 hours or more (even if the motor ramp load is selected The oil heater is always off during start-up or when the
as the ramp loading method). compressor is running.
2. Motor load ramp loading (LOAD PULLDOWN) limits The oil pump is also energized during the time the oil is be-
the degrees per minute rate at which the compressor mo- ing heated (for 60 seconds at the end of every 30 minutes).
tor current or compressor motor load increases. The Oil Cooler — The oil must be cooled when the compres-
LOAD PULLDOWN rate is configured by the operator sor is running. This is accomplished through a small, plate-type
on the RAMP_DEM screen in amps or kilowatts. The heat exchanger (also called the oil cooler) located behind the
point name is MOTOR LOAD RAMP 2/MIN. oil pump. The heat exchanger uses liquid condenser refrigerant
If kilowatts is selected for the DEMAND LIMIT SOURCE, as the cooling liquid. Refrigerant thermostatic expansion
the MOTOR RATED KILOWATTS must be entered (informa- valves (TXVs) regulate refrigerant flow to control the oil tem-
tion found on the chiller Requisition form). perature entering the bearings. The bulbs for the expansion
The TEMP PULLDOWN DEG/MIN may be viewed or valves are strapped to the oil supply line leaving the heat ex-
modified on the TEMP_CTL screen which is accessed from changer, and the valves are set to maintain 110 F (43 C).
the EQUIPMENT SERVICE screen. PULLDOWN RAMP NOTE: The TXVs are not adjustable. The oil sump temper-
TYPE, DEMAND LIMIT SOURCE, and MOTOR LOAD ature may be at a lower temperature during compressor
RAMP %/MIN may be viewed or modified on the operations.
RAMP_DEM screen.
Remote Start/Stop Controls — A remote device,
Capacity Override (Table 4) — Capacity overrides such as a timeclock that uses a set of contacts, may be used to
can prevent some safety shutdowns caused by exceeding the start and stop the chiller. However, the device should not be
motor amperage limit, refrigerant low temperature safety limit, programmed to start and stop the chiller in excess of 2 or
motor high temperature safety limit, and condenser high pres- 3 times every 12 hours. If more than 8 starts in 12 hours (the
sure limit. In all cases there are 2 stages of compressor vane STARTS IN 12 HOURS parameter on the MAINSTAT screen)
control. occur, an excessive starts alarm displays, preventing the chiller
1. The vanes are prevented from opening further, and the from starting. The operator must press the RESET softkey on
status line on the CVC indicates the reason for the the CVC to override the starts counter and start the chiller. If
override. the chiller records 12 starts (excluding recycle starts) in a slid-
2. The vanes are closed until the condition decreases to being 12-hour period, it can be restarted only by pressing the
low the first step set point. Then the vanes are released to RESET softkey followed by the LOCAL or CCN softkey.
normal capacity control. This ensures that, if the automatic system is malfunctioning,
Whenever the motor current demand limit set point the chiller will not repeatedly cycle on and off. If the automatic
(ACTIVE DEMAND LIMIT) is reached, it activates a capacity restart after a power failure option (AUTO RESTART OPTION
override, again, with a 2-step process. Exceeding 110% of the on the OPTIONS screen) is not activated when a power failure
rated load amps for more than 30 seconds will initiate a safety occurs, and if the remote contact is closed, the chiller will indi-
shutdown. cate an alarm because of the loss of voltage.
The compressor high lift (surge prevention) set point will The contacts for remote start are wired into the starter at ter-
cause a capacity override as well. When the surge prevention minal strip J2, terminals 5 and 6 on the ISM. See the certified
set point is reached, the controller normally will only prevent drawings for further details on contact ratings. The contacts
the guide vanes from opening. If so equipped, the hot gas by- must have 24 vac dry contact rating.
pass valve will open instead of holding the vanes. See the Spare Safety Inputs — Normally closed (NC) discrete
Surge Prevention Algorithm section, page 39. inputs for additional field-supplied safeties may be wired to the
High Discharge Temperature Control — If the spare protective limits input channel in place of the factory-
discharge temperature increases above 160 F (71.1 C), the installed jumper. (Wire multiple inputs in series.) The opening
guide vanes are proportionally opened to increase gas flow of any contact will result in a safety shutdown and a display on
through the compressor. If the leaving chilled water tempera- the CVC. Refer to the certified drawings for safety contact
ture is then brought 5° F (2.8° C) below the control set point ratings.
temperature, the PIC II will bring the chiller into the recycle Analog temperature sensors may also be added to the mod-
mode. 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.
36
Table 4 — Capacity Overrides
SECOND STAGE SET OVERRIDE
FIRST STAGE SET POINT POINT TERMINATION
OVERRIDE
CAPACITY CONTROL View/Modify Default Configurable Value Value
on CVC Screen Value Range
125 psig 90 to 165 psig >Override <Override
HIGH CONDENSER SETUP1 Set Point
PRESSURE (862 kPa) (620 to 1138 kPa) Set Point
+2.4 psid (16.5 kPad)
>Override
HIGH MOTOR >200 F 150 to 200 F <Override
SETUP1 (93.3 C) (66 to 93 C)
Set Point
Set Point
TEMPERATURE +10° F (6° C)
LOW REFRIGERANT
TEMPERATURE ≤Trippoint >Trippoint
SETUP1 3° F (1.6° C) 2° to 5° F + Override + Override
(Refrigerant (1° to 3° C)
Override Delta ∆T –1° F (0.56° C) ∆T+2° F (1.2° C)
Temperature)
Min: T1 — 1.5° F 0.5° to 20° F
(0.8° C) (0.3° to 8.3° C)
P1 — 50 psid 30 to 170 psid
HIGH COMPRESSOR Within Lift Limits
(345 kPad) (207 to 1172 kPad)
LIFT OPTIONS None Plus Surge/HGBP
Max: T2 — 10° F 0.5° to 20° F
(Surge Prevention) (0.3° to 8.3° C) Deadband Setting
(5.6° C)
P2 — 85 psid 50 to 170 psid
(586 kPad) (348 to 1172 kPad)
MANUAL GUIDE VANE Release of
CAPACITY Automatic 0 to 100% None
TARGET Manual Control
MOTOR LOAD — ≥5% of 2% Lower
MAINSTAT 100% 40 to 100% Set Point Than Set Point
ACTIVE DEMAND LIMIT
Calculated Minimum 2° F (1.1° C) 1° F (0.56° C)
LOW DISCHARGE OVERRIDE Superheat for None Below Calculated Above Calculated
SUPERHEAT Conditions Minimum Superheat Minimum Superheat
Spare Safety Alarm Contacts — One set of alarm from building automation systems (BAS) or energy manage-
contacts is provided in the starter. The contact ratings are pro- ment systems (EMS) can also access the PIC II controls
vided in the certified drawings. The contacts are located on ter- through a Carrier DataLINK™ module and reset the fault dis-
minal strip JP, terminals 15 and 16. played. Both methods would access the CVC_PSWD screen
and force the RESET ALARM ? point to YES to reset the fault
Refrigerant Leak Detector — An input is available condition. If the PIC II controls have determined that is safe to
on the CCM module [terminal J5-5 (–) and J5-6 (+)] for a start the chiller the CCN MODE ? point (CVC_PSWD screen)
refrigerant leak detector. Enabling REFRIGERANT LEAK can be forced to YES to place the chiller back into normal
OPTION (OPTIONS screen) will allow the PIC II controls to CCN operating mode. The only exceptions are the following
go into an alarm state at a user configured level (REFRIGER- alarms that cannot be reset from a remote location: STATE
ANT LEAK ALARM mA). The input is configured for 4 to #100, 205, 217-220, 223, 233, 234, 247, and 250. To view
20 mA by setting the DIP switch 1 on SW2 at the ON position, alarm codes, refer to Troubleshooting Guide, Checking Dis-
or configured for 1 to 5 vdc by setting switch 1 at the OFF posi- play Messages, page 76. After the alarm has been reset the PIC
tion. The output of the refrigerant leak detector is displayed as II control will increment the Starts in 12 Hours counter by one
REFRIGERANT LEAK SENSOR on the MAINSTAT screen. upon restart. If the limit of 8 starts in a 12-hour period occurs
For a 1 to 5 vdc input, 1 vdc input represents 4 mA displayed the alarm will be required to be reset at the chiller control panel
and 5 vdc input represents 20 mA displayed. (CVC).
Kilowatt Output — An output is available on the CCM Condenser Pump Control — The chiller will moni-
module [Terminal J8-1 (+) and J8-2 (–)] to represent the power tor the condenser pressure (CONDENSER PRESSURE) and
consumption of the chiller. The 4 to 20 mA signal generated by may turn on the condenser pump if the condenser pressure be-
the CCM module can be wired to the building automation or comes too high while the compressor is shut down. The con-
energy management system to monitor the chiller’s energy denser pressure override (COND PRESS OVERRIDE) parame-
consumption. A 4 mA signal represents the chiller in an off ter is used to determine this pressure point. COND PRESS
state and a 20 mA signal represents the chiller operating at its OVERRIDE is found in the SETUP1 display screen, which is
rated peak kilowatt consumption. The rated peak kilowatt con- accessed from the EQUIPMENT SERVICE table. The default
sumption is configured by the user in the RAM_DEM display value is 125 psig (862 kPa).
screen by the setting the MOTOR RATED KILOWATTS from
the job data sheet. If the CONDENSER PRESSURE is greater than or equal to
the COND PRESS OVERRIDE, and the entering condenser
Remote Reset of Alarms — A standard feature of the water temperature (ENTERING CONDENSER WATER) is less
PIC II controls is the ability to reset a chiller in a shutdown than 115 F (46 C), the condenser pump will energize to try to
alarm state from a remote location. If the condition which decrease the pressure. The pump will turn off when the con-
caused the alarm has cleared the chiller can be placed back into denser pressure is 3.5 psi (24.1 kPa) less than the pressure over-
a normal CCN operating mode when the REMOTE RESET ride or when the condenser refrigerant temperature (CON-
OPTION (CVC_PSWD menu) is set to ENABLE. A variety of DENSER REFRIG TEMP) is within 3° F (1.7° C) of the enter-
Carrier Comfort Network software systems including Comfort- ing condenser water temperature (ENTERING CONDENSER
VIEW™ or Network Service Tool™ can access the PIC II WATER).
controls and reset the displayed alarm. Third party software
37
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 The tower fan relay control is not a substitute for a con-
starting it, helps to prevent the water in the condenser from denser water temperature control. When used with a water
freezing. The PIC II can perform this function whenever the temperature control system, the tower fan relay control can
chiller is not running except when it is either actively in pump- be used to help prevent low condenser water temperatures.
down or in pumpdown/lockout with the freeze prevention
disabled. Auto. Restart After Power Failure — This option
When the CONDENSER REFRIG TEMP is less than or may be enabled or disabled and may be viewed or modified on
equal to the CONDENSER FREEZE POINT, the CONDENS- the OPTIONS screen, which is accessed from the EQUIP-
ER WATER PUMP is energized until the CONDENSER RE- MENT CONFIGURATION table. If the AUTO. RESTART
FRIG TEMP is greater than the CONDENSER FREEZE option is enabled, the chiller will start up automatically after a
POINT plus 5° F (2.7° C) and the ENTERING CONDENSER power failure has occurred (after a single cycle dropout; low,
WATER TEMPERATURE is less than or equal to the CON- high, or loss of voltage; and the power is within ± 15% of nor-
DENSER FREEZE POINT. An alarm is generated if the chiller mal). The 15- and 5-minute inhibit timers are ignored during
is in PUMPDOWN mode and the pump is energized. An alert this type of start-up.
is generated if the chiller is not in PUMPDOWN mode and the When power is restored after the power failure and if the
pump is energized. If the chiller is in RECYCLE SHUT- compressor had been running, the oil pump will energize for
DOWN mode, the mode will transition to a non-recycle one minute before energizing the cooler pump. AUTO.
shutdown. RESTART will then continue like a normal start-up.
Tower Fan Relay Low and High — Low condenser If power to the CVC module has been off for more than 3
water temperature can cause the chiller to shut down when re- hours or the timeclock has been set for the first time, start the
frigerant temperature is low. The tower fan relays, located in compressor with the slowest temperature-based ramp load rate
the starter, are controlled by the PIC II to energize and deener- possible in order to minimize oil foaming.
gize as the pressure differential between cooler and condenser The oil pump is energized occasionally during the time the
vessels changes. This prevents low condenser water tempera- oil is being brought up to proper temperature in order to elimi-
ture and maximizes chiller efficiency. The tower fan relay can nate refrigerant that has migrated to the oil sump during the
only accomplish this if the relay has been added to the cooling power failure. The pump turns on for 60 seconds at the end of
tower temperature controller. every 30-minute period until the chiller is started.
The tower fan relay low is turned on whenever the condens-
er water pump is running, flow is verified, and the difference Water/Brine Reset — Three types of chilled water or
between cooler and condenser pressure is more than 30 psid brine reset are available and can be viewed or modified on the
(207 kPad) for entering condenser water temperature greater TEMP_CTL screen, which is accessed from the EQUIPMENT
than 65 F (18.3 C). SERVICE table.
The tower fan relay low is turned off when the condenser The CVC default screen indicates when the chilled water re-
pump is off, flow is stopped, or the cooler refrigerant tempera- set is active. TEMPERATURE RESET on the MAINSTAT
ture is less than the override temperature for ENTERING CON- screen indicates the amount of reset. The CONTROL POINT
DENSER WATER temperature less than 62 F (16.7 C), or the will be determined by adding the TEMPERATURE RESET to
differential pressure is less than 25 psid(172.4 kPad) for enter- the SETPOINT.
ing condenser water less than 80 F (27 C). To activate a reset type, access the TEMP_CTL screen and
The tower fan relay high is turned on whenever the input all configuration information for that reset type. Then, in-
condenser water pump is running, flow is verified and the dif- put the reset type number (1, 2, or 3) in the SELECT/ENABLE
ference between cooler and condenser pressure is more than RESET TYPE input line.
35 psid (241.3 kPa) for entering condenser water temperature RESET TYPE 1: 4 to 20 mA (1 to 5 vdc) TEMPERATURE
greater than the TOWER FAN HIGH SETPOINT (SETPOINT RESET — Reset Type 1 is an automatic chilled water temper-
menu, default 75 F [23.9 C]). ature reset based on a remote temperature sensor input config-
The tower fan relay high is turned off when the condenser ured for either an externally powered 4 to 20 mA or a 1 to
pump is off, flow is stopped, or the cooler refrigerant tempera- 5 vdc signal. Reset Type 1 permits up to ±30 F (±16 C) of
ture is less than the override temperature and ENTERING automatic reset to the chilled water set point.
CONDENSER WATER is less than 70 F (21.1 C), or the differ- The auto, chilled water reset is hardwired to terminals J5-3 (–)
ence between cooler and condenser pressure is less than and J5-4 (+) on the CCM. Switch setting number 2 on SW2
28 Psid (193 kPa), or ENTERING CONDENSER WATER will determine the type of input signal. With the switch set at
temperature is less than TOWER FAN HIGH SETPOINT the ON position the input is configured for an externally pow-
minus 3 F (–16.1 C). ered 4 to 20 mA signal. With the switch in the OFF position
The TOWER FAN RELAY LOW and HIGH parameter is ac- the input is configured for an external 1 to 5 vdc signal.
cessed from the STARTUP screen. RESET TYPE 2: REMOTE TEMPERATURE RESET —
Reset Type 2 is an automatic chilled water temperature reset
IMPORTANT: A field-supplied water temperature con- based on a remote temperature sensor input signal. Reset Type
trol system for condenser water should be installed. The 2 permits ± 30° F (± 16° C) of automatic reset to the set point
system should maintain the leaving condenser water based on a temperature sensor wired to the CCM module (see
temperature at a temperature that is 20° F (11° C) above wiring diagrams or certified drawings). The temperature sensor
the leaving chilled water temperature. must be wired to terminal J4-13 and J4-14.
38
To configure Reset Type 2, enter the temperature of the re- determined by the configured valves before the HOT GAS
mote sensor at the point where no temperature reset will occur BYPASS/SURGE PREVENTION will be turned on. As the
(REMOTE TEMP –> NO RESET). Next, enter the temperature point moves from the region where the HOT GAS BYPASS/
at which the full amount of reset will occur (REMOTE TEMP SURGE PREVENTION is on, the point must pass through the
–> FULL RESET). Then, enter the maximum amount of reset deadband region before the HOT GAS BYPASS/SURGE
required to operate the chiller (DEGREES RESET). Reset Type PREVENTION is turned off. Information on modifying the de-
2 can now be activated. fault set points of the minimum and full load points may be
RESET TYPE 3 — Reset Type 3 is an automatic chilled water found in the Input Service Configurations section, page 55.
temperature reset based on cooler temperature difference. The state of the surge/hot gas bypass algorithm on the
Reset Type 3 adds ± 30° F (± 16° C) based on the temperature HEAT_EX DISPLAY SCREEN (Surge/HGBP Active?).
difference between the entering and leaving chilled water Corrective action can be taken by making one of 2 choices.
temperature. If a hot gas bypass line is present and the hot gas option is
To configure Reset Type 3, enter the chilled water tempera- selected on the OPTIONS table (SURGE LIMIT/HGBP
ture difference (the difference between entering and leaving OPTION is set to 1), the hot gas bypass valve can be energized.
chilled water) at which no temperature reset occurs (CHW If the hot gas bypass option is not selected (SURGE LIMIT/
DELTA T –> NO RESET). This chilled water temperature dif- HGBP OPTION is set to 0), hold the guide vanes. See Table 4,
ference is usually the full design load temperature difference. Capacity Overrides. Both of these corrective actions try to
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.
LEGEND
Surge Prevention Algorithm (Fixed Speed ECW — Entering Chilled Water
Chiller) — This is an operator-configurable feature that can HGBP — Hot Gas Bypass
LCW — Leaving Chilled Water
determine if lift conditions are too high for the compressor and
then take corrective action. Lift is defined as the difference be- ∆P = (Condenser Psi) – (Cooler Psi)
∆T = (ECW) – (LCW)
tween the pressure at the impeller eye and at the impeller dis-
charge. The maximum lift a particular impeller wheel can per- Fig. 21 — 19XR Hot Gas Bypass/Surge
form varies with the gas flow across the impeller and the size Prevention with Default English Settings
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- LEGEND
gorithm goes into a corrective action mode. If the actual values ECW — Entering Chilled Water
are below the line and outside of the deadband region, the algo- LCW — Leaving Chilled Water
rithm takes no action. When the point defined by the ACTIVE ∆P = (Condenser kPa) – (Cooler kPa)
DELTA P and ACTIVE DELTA T, moves from the region ∆T = (ECW) – (LCW)
where the HOT GAS BYPASS/SURGE PREVENTION is off, Fig. 22 — 19XR Hot Gas Bypass/Surge
the point must pass through the deadband region to the line Prevention with Default Metric Settings
39
reduce the lift experienced by the compressor and help prevent The surge time period can also be adjusted from the
a surge condition. OPTIONS screen. Scroll to the SURGE TIME PERIOD
parameter, and use the INCREASE or DECREASE softkey
Surge Prevention Algorithm with VFD — This is to adjust the amount of time. The default setting is 8 minutes.
an operator configurable feature that can determine if lift con-
ditions are too high for the compressor and then take corrective Access the display screen (COMPRESS) to monitor the
action. Lift is defined as the difference between the pressure at surge count (SURGE PROTECTION COUNTS).
the impeller eye and at the impeller discharge. The maximum Surge Protection (Fixed Speed Chiller) — The
lift a particular impeller wheel can perform varies with the gas PIC II monitors surge, which is a fluctuation in compressor
flow through the impeller and the diameter of the impeller. motor amperage. Each time the fluctuation exceeds an opera-
A surge condition occurs when the lift becomes so high the tor-specified limit (SURGE DELTA % AMPS), the PIC II
gas flow across the impeller reverses. This condition can even- counts the surge. If more than 5 surges occur within an opera-
tually cause chiller damage. When enabled, the Surge Preven- tor-specified time (SURGE TIME PERIOD), the PIC II ini-
tion Algorithm will adjust either the inlet guide vane (IGV) tiates a surge protection shutdown of the chiller.
position or compressor speed to maintain the compressor at a The surge limit can be adjusted from the OPTIONS screen.
safe distance from surge while maintaining machine efficiency. Scroll down to the SURGE DELTA % AMPS parameter, and
If the surge condition degrades then the algorithm will move
aggressively away from surge. This condition can be identified use the INCREASE or DECREASE softkey to adjust the
when the SURGE/HGBP ACTIVE ? on the HEAT_EX display percent of surge. The default setting is 10% amps.
screen displays a YES. The surge time period can also be adjusted from the
The surge prevention algorithm first determines if correc- OPTIONS screen. Scroll to the SURGE TIME PERIOD
tive action is necessary. The algorithm checks two sets of oper- parameter, and use the INCREASE or DECREASE softkey
ator-configured data points, the lower surge point (MIN. LOAD to adjust the amount of time. The default setting is 8 minutes.
POINT [T1,P1]) and the upper surge point (FULL LOAD Access the display screen (COMPRESS) to monitor the
POINT [T2,P2]). The surge characteristics vary between dif- surge count (SURGE PROTECTION COUNTS).
ferent chiller configurations and operating conditions. The HEAD PRESSURE REFERENCE OUTPUT (See
surge characteristics are factory set based on the original selec- Fig. 23) — The PIC II control outputs a 4 to 20 mA signal for
ton with the values displayed inside the control panel of the the configurable Delta P (condenser pressure minus evaporator
chiller. Since operating conditions may affect the surge preven- pressure) reference curve shown in Fig. 23. An output is avail-
tion algorithm, some field adjustments may be necessary. able on the ISM module [Terminal J8 (+), J8 (–) labeled spare].
The surge prevention algorithm function and settings are For chillers with Benshaw Inc. solid-state starters terminal strip
graphically displayed on Fig. 21 and 22. The two sets of load labeled J8 (+), J8 (–) located next to the RediStart MICRO™
points on the graph (default settings are shown) describe a line input/output card is provided. The Delta P at 100% (chiller at
the algorithm uses to determine the maximum lift of the com- maximum load condition default at 35 psi), Delta P at 0%
pressor for the particular maximum operating speed. When the (chiller at minimum load condition default at 25 psi) and Mini-
actual differential pressure between the cooler and condenser mum Output points are configurable in the EQUIPMENT
and the temperature difference between the entering and leav- SERVICE-OPTIONS table. When configuring this output en-
ing chilled water are above the line on the graph (as defined by sure that minimum requirements for oil pressure and proper
the minimum and full load points), the algorithm operates in condenser FLASC orifice performance are maintained. The 4
Surge Prevention mode. This is determined when the ACTIVE to 20 mA output can be used as a reference to control a
DELTA T is less than SURGE/HGBP DELTA T minus the tower bypass valve, tower speed control, or condenser pump
deadband. speed control.
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 DELTA P
AT 100%
Prevention mode, with a command to decrease capacity only
the IGVs will close.
Surge Protection VFD Units — The PIC II monitors MINIMUM
surge, which is detected as a fluctuation in compressor motor REFERENCE
DELTA P
amperage. Each time the fluctuation exceeds an operator- OUTPUT
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 DELTA P
speed will be increased by the configured VFD increase step. AT 0%
While the SURGE PROTECTION COUNTS are >0, a speed
decrease will not be honored.
The surge limit can be adjusted from the OPTIONS screen 0 mA 2 mA 4 mA 20 mA
(see Table 2). Scroll down to the SURGE DELTA % AMPS (0%) (100%)
parameter, and use the INCREASE or DECREASE softkey 4 T0 20 mA OUTPUT
to adjust the percent of surge. The default setting is 10% amps. Fig. 23 — Head Pressure Reference Output
40
Lead/Lag Control — The lead/lag control system auto- Interface section for information on chiller communication
matically starts and stops a lag or second chiller in a 2-chiller wiring.
water system. A third chiller can be added to the lead/lag sys- LEAD/LAG OPERATION — The PIC II not only has the
tem as a standby chiller to start up in case the lead or lag chiller ability to operate 2 chillers in lead/lag, but it can also start a
in the system has shut down during an alarm condition and ad- designated standby chiller when either the lead or lag chiller is
ditional cooling is required. Refer to Fig. 17 and 18 for menu, faulted and capacity requirements are not met. The lead/lag op-
table, and screen selection information. tion only operates when the chillers are in CCN mode. If any
NOTE: The lead/lag function can be configured on the LEAD- other chiller configured for lead/lag is set to the LOCAL or
LAG screen, which is accessed from the SERVICE menu and OFF modes, it will be unavailable for lead/lag operation.
EQUIPMENT SERVICE table. See Table 2, Example 20. Lead/Lag Chiller Configuration and Operation
Lead/lag status during chiller operation can be viewed on the • A chiller is designated the lead chiller when its LEAD/
LL_MAINT display screen, which is accessed from the SER- LAG CONFIGURATION value on the LEADLAG
VICE menu and CONTROL ALGORITHM STATUS table. screen is set to “1.”
See Table 2, Example 12. • A chiller is designated the lag chiller when its LEAD/
Lead/Lag System Requirements: LAG CONFIGURATION value is set to “2.”
• all chillers in the system must have software capable of • A chiller is designated as a standby chiller when its
performing the lead/lag function LEAD/LAG CONFIGURATION value is set to “3.”
• water pumps MUST be energized from the PIC II • A value of “0” disables the lead/lag designation of a
controls chiller.
• water flows should be constant To configure the LAG ADDRESS value on the LEADLAG
• the CCN time schedules for all chillers must be identical screen, always enter the address of the other chiller on the sys-
Operation Features: tem. For example, if you are configuring chiller A, enter the ad-
• 2 chiller lead/lag dress for chiller B as the lag address. If you are configuring
• addition of a third chiller for backup chiller B, enter the address for chiller A as the lag address. This
• manual rotation of lead chiller makes it easier to rotate the lead and lag chillers.
• load balancing if configured If the address assignments in the LAG ADDRESS and
• staggered restart of the chillers after a power failure STANDBY ADDRESS parameters conflict, the lead/lag func-
• chillers may be piped in parallel or in series chilled tion is disabled and an alert (!) message displays. For example,
water flow if the LAG ADDRESS matches the lead chiller’s address, the
COMMON POINT SENSOR INSTALLATION — Lead/ lead/lag will be disabled and an alert (!) message displayed.
lag operation does not require a common chilled water point The lead/lag maintenance screen (LL_MAINT) displays the
sensor. Common point sensors (Spare Temp #1 and #2) can be message ‘INVALID CONFIG’ in the LEAD/LAG CONFIGU-
added to the CCM module, if desired. Spare Temp #1 and #2 RATION and CURRENT MODE fields.
are wired to plug J4 terminals 25-26 and 27-28 (J4 lower, re- The lead chiller responds to normal start/stop controls such
spectively). as the occupancy schedule, a forced start or stop, and remote
NOTE: If the common point sensor option is chosen on a start contact inputs. After completing start-up and ramp load-
chilled water system, each chiller should have its own common ing, the PIC II evaluates the need for additional capacity. If ad-
point sensor installed. Each chiller uses its own common point ditional capacity is needed, the PIC II initiates the start-up of
sensor for control when that chiller is designated as the lead the chiller configured at the LAG ADDRESS. If the lag chiller
chiller. The PIC II cannot read the value of common point sen- is faulted (in alarm) or is in the OFF or LOCAL modes, the
sors installed on the other chillers in the chilled water system. chiller at the STANDBY ADDRESS (if configured) is requested
If leaving chilled water control (ECW CONTROL OPTION to start. After the second chiller is started and is running, the
is set to 0 [DSABLE] TEMP_CTL screen) and a common lead chiller monitors conditions and evaluates whether the ca-
point sensor is desired (COMMON SENSOR OPTION in pacity has been reduced enough for the lead chiller to sustain
LEADLAG screen selected as 1) then the sensor is wired in the system alone. If the capacity is reduced enough for the lead
Spare Temp #1 position on the CCM. chiller to sustain the CONTROL POINT temperatures alone,
then the operating lag chiller is stopped.
If the entering chilled water control option (ECW CON-
TROL OPTION) is enabled (configured in TEMP_CTL If the lead chiller is stopped in CCN mode for any reason
screen) and a common point sensor is desired (COMMON other than an alarm (*) condition, the lag and standby chillers
SENSOR OPTION in LEADLAG screen selected as 1) then are also stopped. If the configured lead chiller stops for an
the sensor is wired in Spare Temp #2 position on the CCM. alarm condition, the configured lag chiller takes the lead chill-
er’s place as the lead chiller, and the standby chiller serves as
When installing chillers in series, a common point sensor the lag chiller.
should be used. If a common point sensor is not used, the leav-
ing chilled water sensor of the upstream chiller must be moved If the configured lead chiller does not complete the start-up
into the leaving chilled water pipe of the downstream chiller. before the PRESTART FAULT TIMER (a user-configured
value) elapses, then the lag chiller starts and the lead chiller
If return chilled water control is required on chillers piped in shuts down. The lead chiller then monitors the start request
series, the common point return chilled water sensor should be from the acting lead chiller. The PRESTART FAULT TIMER is
installed. If this sensor is not installed, the return chilled water initiated at the time of a start request. The PRESTART FAULT
sensor of the downstream chiller must be relocated to the return TIMER provides a timeout if there is a prestart alert condition
chilled water pipe of the upstream chiller. that prevents the chiller from starting in a timely manner. The
To properly control the common supply point temperature PRESTART FAULT TIMER parameter is on the LEAD-LAG
sensor when chillers are piped in parallel, the water flow screen, which is accessed from the EQUIPMENT SERVICE
through the shutdown chillers must be isolated so no water by- table of the SERVICE menu.
pass around the operating chiller occurs. The common point If the lag chiller does not achieve start-up before the PRE-
sensor option must not be used if water bypass around the oper- START FAULT TIMER elapses, the lag chiller stops, and the
ating chiller is occurring. standby chiller is requested to start, if configured and ready.
CHILLER COMMUNICATION WIRING — Refer to the
chiller’s Installation Instructions, Carrier Comfort Network
41
Standby Chiller Configuration and Operation — A chiller is NOTE: Lead chiller percent capacity = 115 – LAG % CAPAC-
designated as a standby chiller when its LEAD/LAG CONFIG- ITY. The LAG % CAPACITY parameter is on the LEADLAG
URATION value on the LEADLAG screen is set to “3.” The screen, which is accessed from the EQUIPMENT SERVICE
standby chiller can operate as a replacement for the lag chiller table on the SERVICE menu.
only if one of the other two chillers is in an alarm (*) condition FAULTED CHILLER OPERATION — If the lead chiller
(as shown on the CVC panel). If both lead and lag chillers are shuts down because of an alarm (*) condition, it stops commu-
in an alarm (*) condition, the standby chiller defaults to oper- nicating to the lag and standby chillers. After 30 seconds, the
ate in CCN mode, based on its configured occupancy schedule lag chiller becomes the acting lead chiller and starts and stops
and remote contacts input. the standby chiller, if necessary.
Lag Chiller Start-Up Requirements — Before the lag chiller If the lag chiller goes into alarm when the lead chiller is also
can be started, the following conditions must be met: in alarm, the standby chiller reverts to a stand-alone CCN
1. Lead chiller ramp loading must be complete. mode of operation.
2. Lead chilled water temperature must be greater than the If the lead chiller is in an alarm (*) condition (as shown on
CONTROL POINT temperature (see the MAINSTAT the CVC panel), press the RESET softkey to clear the alarm.
screen) plus 1/2 the CHILLED WATER DEADBAND The chiller is placed in CCN mode. The lead chiller communi-
temperature (see the SETUP1 screen). cates and monitors the RUN STATUS of the lag and standby
NOTE: The chilled water temperature sensor may be the chillers. If both the lag and standby chillers are running, the
leaving chilled water sensor, the return water sensor, the lead chiller does not attempt to start and does not assume the
common supply water sensor, or the common return wa- role of lead chiller until either the lag or standby chiller shuts
ter sensor, depending on which options are configured down. If only one chiller is running, the lead chiller waits for a
and enabled. start request from the operating chiller. When the configured
3. Lead chiller ACTIVE DEMAND LIMIT (see the MAIN- lead chiller starts, it assumes its role as lead chiller.
STAT screen) value must be greater than 95% of full load If the lag chiller is the only chiller running when the lead
amps. chiller assumes its role as a lead chiller then the lag chiller will
4. Lead chiller temperature pulldown rate (TEMP PULL- perform a RECOVERY START REQUEST (LL_MAINT
DOWN DEG/MIN on the TEMP_CTL screen) of the screen). The lead chiller will start up when the following condi-
chilled water temperature is less than 0.5° F (0.27° C) per tions are met.
minute. 1. Lag chiller ramp loading must be complete.
5. The lag chiller status indicates it is in CCN mode and is 2. Lag CHILLED WATER TEMP (MAINSTAT screen) is
not in an alarm condition. If the current lag chiller is in an greater than CONTROL POINT plus 1/2 the CHILLED
alarm condition, the standby chiller becomes the active WATER DEADBAND temperature.
lag chiller, if it is configured and available. 3. Lag chiller ACTIVE DEMAND LIMIT value must be
6. The configured LAG START TIMER entry has elapsed. greater than 95% of full load amps.
The LAG START TIMER starts when the lead chiller ramp 4. Lag chiller temperature pulldown rate (TEMP PULL-
loading is completed. The LAG START TIMER entry is DOWN DEG/MIN) of the chilled water temperature is
on the LEADLAG screen, which is accessed from the less than 0.5 F (0.27 C) per minute.
EQUIPMENT SERVICE table of the SERVICE menu. 5. The standby chiller is not running as a lag chiller.
When all the above requirements have been met, the lag 6. The configured LAG START TIMER has elapsed. The
chiller is commanded to a STARTUP mode (SUPVSR flashing LAG START TIMER is started when ramp loading is
next to the point value on the STATUS table). The PIC II con- completed.
trol then monitors the lag chiller for a successful start. If the lag
chiller fails to start, the standby chiller, if configured, is started. LOAD BALANCING — When the LOAD BALANCE
OPTION (see LEADLAG screen) is enabled, the lead chiller
Lag Chiller Shutdown Requirements — The following condi- sets the ACTIVE DEMAND LIMIT in the lag chiller to the lead
tions must be met in order for the lag chiller to be stopped. chiller’s compressor motor load value MOTOR PERCENT
1. Lead chiller compressor motor average line current or KILOWATTS or AVERAGE LINE CURRENT on the MAIN-
load value (MOTOR PERCENT KILOWATTS on the STAT screen). This value has limits of 40% to 100%. When the
MAINSTAT screen) is less than the lead chiller percent lag chiller ACTIVE DEMAND LIMIT is set, the CONTROL
capacity. POINT must be modified to a value of 3° F (1.67° C) less than
NOTE: Lead chiller percent capacity = 115 – LAG % CA- the lead chiller’s CONTROL POINT value. If the LOAD BAL-
PACITY. The LAG % CAPACITY parameter is on the ANCE OPTION is disabled, the ACTIVE DEMAND LIMIT
LEADLAG screen, which is accessed from the EQUIP- and the CONTROL POINT are forced to the same value as the
MENT SERVICE table on the SERVICE menu. lead chiller.
2. The lead chiller chilled water temperature is less than the AUTO. RESTART AFTER POWER FAILURE — When an
CONTROL POINT temperature (see the MAINSTAT auto. restart condition occurs, each chiller may have a delay
screen) plus 1/2 the CHILLED WATER DEADBAND tem- added to the start-up sequence, depending on its lead/lag con-
perature (see the SETUP1 screen). figuration. The lead chiller does not have a delay. The lag chill-
3. The configured LAG STOP TIMER entry has elapsed. er has a 45-second delay. The standby chiller has a 90-second
The LAG STOP TIMER starts when the lead chiller delay. The delay time is added after the chiller water flow is
chilled water temperature is less than the chilled water verified. The PIC II ensures the guide vanes are closed. After
CONTROL POINT plus 1/2 of the CHILLED WATER the guide vane position is confirmed, the delay for lag and
DEADBAND and the lead chiller compressor motor load standby chillers occurs prior to energizing the oil pump. The
(MOTOR PERCENT KILOWATT or AVERAGE LINE normal start-up sequence then continues. The auto. restart de-
CURRENT on the MAINSTAT screen) is less than the lay sequence occurs whether the chiller is in CCN or LOCAL
lead chiller percent capacity. 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.
42
Ice Build Control — The ice build control option auto- NOTE: Items 1-3 (shown above) do not occur if the chiller is
matically sets the CONTROL POINT of the chiller to a temper- configured and operating as a lag or standby chiller for lead/lag
ature that allows ice building for thermal storage. operation and is actively being controlled by a lead chiller. The
NOTE: For ice build control to operate properly, the PIC II lead chiller communicates the ICE BUILD SET POINT, the
must be in CCN mode desired CHILLER START/STOP state, and the ACTIVE
DEMAND LIMIT to the lag or standby chiller as required for
NOTE: See Fig. 17 and 18 for more information on ice build- ice build, if configured to do so.
related menus.
START-UP/RECYCLE OPERATION — If the chiller is not
The PIC II can be configured for ice build operation. running when ice build activates, the PIC II checks the fol-
• From the SERVICE menu, access the EQUIPMENT lowing conditions, based on the ICE BUILD TERMINATION
SERVICE table. From there, select the OPTIONS screen value, to avoid starting the compressor unnecessarily:
to enable or disable the ICE BUILD OPTION. See • if ICE BUILD TERMINATION is set to the TEMP
Table 2, Example 17. option and the ENTERING CHILLED WATER tempera-
• The ICE BUILD SETPOINT can be configured from the ture is less than or equal to the ICE BUILD SETPOINT;
SETPOINT display, which is accessed from the PIC II • if ICE BUILD TERMINATION is set to the CONTACTS
main menu. See Table 2, Example 9. option and the remote contacts are open;
• The ice build schedule can be viewed or modified from • if the ICE BUILD TERMINATION is set to the BOTH
the SCHEDULE table. From this table, select the ice (temperature and contacts) option and the ENTERING
build schedule (OCCPC02S) screen. See Fig. 19 and the CHILLED WATER temperature is less than or equal to
section on Time Schedule Operation, page 20, for more the ICE BUILD SETPOINT and the remote contacts are
information on modifying chiller schedules. open.
The ice build time schedule defines the period(s) during The ICE BUILD RECYCLE on the OPTIONS screen deter-
which ice build is active if the ice build option is enabled. If the mines whether or not the chiller will go into an ice build RE-
ice build time schedule overlaps other schedules, the ice build CYCLE mode.
time schedule takes priority. During the ice build period, the • If the ICE BUILD RECYCLE is set to DSABLE (dis-
CONTROL POINT is set to the ICE BUILD SETPOINT for able), the PIC II reverts to normal temperature control
temperature control. The ICE BUILD RECYCLE and ICE when the ice build function terminates.
BUILD TERMINATION parameters, accessed from the • If the ICE BUILD RECYCLE is set to ENABLE, the PIC
OPTIONS screen, allow the chiller operator to recycle or ter- II goes into an ICE BUILD RECYCLE mode and the
minate the ice build cycle. The ice build cycle can be config- chilled water pump relay remains energized to keep the
ured to terminate if: chilled water flowing when the ice build function termi-
• the ENTERING CHILLED WATER temperature is less nates. If the temperature of the ENTERING CHILLED
than the ICE BUILD SETPOINT. In this case, the opera- WATER increases above the ICE BUILD SETPOINT
tor sets the ICE BUILD TERMINATION parameter to 0 plus the RECYCLE RESTART DELTA T value, the com-
on the OPTIONS screen. pressor restarts and controls the chilled water/brine tem-
• the REMOTE CONTACT inputs from an ice level indi- perature to the ICE BUILD SETPOINT.
cator are opened. In this case, the operator sets the ICE TEMPERATURE CONTROL DURING ICE BUILD —
BUILD TERMINATION parameter to 1 on the During ice build, the capacity control algorithm shall use the
OPTIONS screen. CONTROL POINT minus 5 F (–2.8 C) for control of the
• the chilled water temperature is less than the ice build LEAVING CHILLED WATER temperature. (See Table 2, ex-
set point and the remote contact inputs from an ice level ample 10, the CAPACITY CONTROL parameter on the CA-
indicator are open. In this case, the operator sets the ICE PACITY screen.) The ECW CONTROL OPTION and any tem-
BUILD TERMINATION parameter to 2 on the perature reset option shall be ignored, if enabled, during ice
OPTIONS screen. build. The AUTO DEMAND LIMIT INPUT shall also be
• the end of the ice build time schedule has been reached. ignored if enabled during ice build.
ICE BUILD INITIATION — The ice build time schedule • ECW CONTROL OPTION and any temperature reset
(OCCPC02S) is the means for activating the ice build option. options (configured on TEMP_CTL screen).
The ice build option is enabled if: • 20 mA DEMAND LIMIT OPT (configured on
• a day of the week and a time period on the ice build time RAMP_DEM screen).
schedule are enabled. The SCHEDULE screen shows an TERMINATION OF ICE BUILD — The ice build function
X in the day field and ON/OFF times are designated for terminates under the following conditions:
the day(s),
• and the ICE BUILD OPTION is enabled. 1. Time Schedule — When the current time on the ice build
time schedule (OCCPC02S) is not set as an ice build time
The following events take place (unless overridden by a period.
higher authority CCN device).
2. Entering Chilled Water Temperature — Compressor
• CHILLER START/STOP is forced to START. operation terminates, based on temperature, if the ICE
• The CONTROL POINT is forced to the ICE BUILD BUILD TERMINATION parameter is set to 0 (TEMP),
SETPOINT. the ENTERING CHILLED WATER temperature is less
• Any force (Auto) is removed from the ACTIVE than the ICE BUILD SETPOINT, and the ICE BUILD
DEMAND LIMIT. RECYCLE is set to DSABLE. If the ICE BUILD RECY-
NOTE: A parameter’s value can be forced, that is, the value CLE OPTION is set to ENABLE, a recycle shutdown oc-
can be manually changed at the CVC by an operator, changed curs and recycle start-up depends on the LEAVING
from another CCN device, or changed by other algorithms in CHILLED WATER temperature being greater than the
the PIC II control system. water/brine CONTROL POINT plus the RESTART
DELTA T temperature.
43
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. Fig. 24 — Example of Attach to Network
4. Entering Chilled Water Temperature and ICE BUILD Device Screen
Contacts — Compressor operation terminates when the
ICE BUILD TERMINATION parameter is set to To attach any CCN device, highlight it using the SELECT
2 (BOTH) and the conditions described above in items softkey and press the ATTACH softkey. The message “UP-
2 and 3 for entering chilled water temperature and remote LOADING TABLES, PLEASE WAIT” displays. The CVC
contacts have occurred. then uploads the highlighted device or module. If the module
NOTE: It is not possible to override the CHILLER START/ address cannot be found, the message “COMMUNICATION
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT FAILURE” appears. The CVC then reverts back to the AT-
variables from CCN devices (with a priority 4 or greater) dur- TACH TO DEVICE screen. Try another device or check the
ing the ice build period. However, a CCN device can override address of the device that would not attach. The upload process
these settings during 2-chiller lead/lag operation. time for each CCN module is different. In general, the upload-
RETURN TO NON-ICE BUILD OPERATIONS — The ice ing process takes 1 to 2 minutes. Before leaving the ATTACH
build function forces the chiller to start, even if all other sched- TO NETWORK DEVICE screen, select the local device. Oth-
ules indicate that the chiller should stop. When the ice build erwise, the CVC will be unable to display information on the
function terminates, the chiller returns to normal temperature local chiller.
control and start/stop schedule operation. The CHILLER ATTACHING TO OTHER CCN MODULES — If the chill-
START/STOP and CONTROL POINT return to normal opera- er CVC has been connected to a CCN Network or other PIC
tion. If the CHILLER START/STOP or CONTROL POINT has controlled chillers through CCN wiring, the CVC can be used
been forced (with a device of less than 4 priority) before the ice to view or change parameters on the other controllers. Other
build function started, when the ice build function ends, the PIC II chillers can be viewed and set points changed (if the oth-
previous forces (of less than 4 priority) are not automatically er unit is in CCN control), if desired, from this particular CVC
restored. module.
If the module number is not valid, the “COMMUNICA-
Attach to Network Device Control — The Service TION FAILURE” message will show and a new address num-
menu includes the ATTACH TO NETWORK DEVICE ber must be entered or the wiring checked. If the module is
screen. From this screen, the operator can: communicating properly, the “UPLOAD IN PROGRESS”
• enter the time schedule number (if changed) for message will flash and the new module can now be viewed.
OCCPC03S, as defined in the NET_OPT screen
• attach the CVC to any CCN device, if the chiller has Whenever there is a question regarding which module on
been connected to a CCN network. This may include the CVC is currently being shown, check the device name de-
other PIC-controlled chillers. scriptor on the upper left hand corner of the CVC screen. See
• upgrade software Fig. 24.
Figure 24 shows the ATTACH TO NETWORK DEVICE When the CCN device has been viewed, the ATTACH TO
screen. The LOCAL parameter is always the CVC module ad- NETWORK DEVICE table should be used to attach to the PIC
dress of the chiller on which it is mounted. Whenever the con- that is on the chiller. Move to the ATTACH TO NETWORK
troller identification of the CVC changes, the change is reflect- DEVICE table (LOCAL should be highlighted) and press the
ed automatically in the BUS and ADDRESS columns for the ATTACH softkey to upload the LOCAL device. The CVC for
local device. See Fig. 18. Default address for local device is the 19XR will be uploaded and default screen will display.
BUS 0 ADDRESS 1. NOTE: The CVC will not automatically reattach to the local
When the ATTACH TO NETWORK DEVICE screen is ac- module on the chiller. Press the ATTACH softkey to attach to
cessed, information can not be read from the CVC on any de- the LOCAL device and view the chiller operation.
vice until one of the devices listed on that screen is attached.
The CVC erases information about the module to which it was
attached to make room for information on another device.
Therefore, a CCN module must be attached when this screen is
entered.
44
Service Operation — An overview of the tables and HOLIDAY SCHEDULING (Fig. 25) — The time schedules
screens available for the SERVICE function is shown in may be configured for special operation during a holiday peri-
Fig. 18. od. When modifying a time period, the “H” at the end of the
TO ACCESS THE SERVICE SCREENS — When the SER- days of the week field signifies that the period is applicable to a
VICE screens are accessed, a password must be entered. holiday. (See Fig. 19.)
1. From the main MENU screen, press the SERVICE The broadcast function must be activated for the holidays
configured on the HOLIDEF screen to work properly. Access
softkey. The softkeys now correspond to the numerals the BRODEF screen from the EQUIPMENT CONFIGURA-
1, 2, 3, 4. TION table and select ENABLE to activate function. Note that
2. Press the four digits of the password, one at a time. An when the chiller is connected to a CCN Network, only one
asterisk (*) appears as each digit is entered 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
NOTE: The initial factory-set password is 1-1-1-1. If the holidays, perform the following operation:
password is incorrect, an error message is displayed 1. At the Menu screen, press SERVICE 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
NEXT until Equipment Configuration is highlighted.
3. Once Equipment Configuration is highlighted, press
If this occurs, return to Step 1 and try to access the SER- SELECT to access.
VICE screens again. If the password is correct, the soft- 4. Press NEXT until HOLIDAYS is highlighted. This is
key labels change to: the Holiday Definition table.
5. Press SELECT to enter the Data Table Select
screen.This screen lists 18 holiday tables.
6. Press NEXT to highlight the holiday table that is to be
viewed or changed. Each table is one holiday period,
NOTE: The SERVICE screen password can be changed starting on a specific date, and lasting up to 99 days.
by entering the CVC CONFIGURATION screen under 7. Press SELECT to access the holiday table. The Con-fig-
SERVICE menu. The password is located at the bottom uration Select table now shows the holiday start month
of the menu. and day, and how many days the holiday period will last.
The CVC screen displays the following list of available 8. Press NEXT or PREVIOUS to highlight the month,
SERVICE screens: day, or duration.
• Alarm History
• Control Test 9. Press SELECT to modify the month, day, or duration.
• Control Algorithm Status 10. Press INCREASE or DECREASE to change the
• Equipment Configuration selected value.
• ISM (Starter) Config Data 11. Press ENTER to save the changes.
• Equipment Service
• Time and Date 12. Press EXIT to return to the previous menu.
• Attach to Network Device
• Log Out of Device
• CVC Configuration
See Fig. 18 for additional screens and tables available from
the SERVICE screens listed above. Use the EXIT softkey to
return to the main MENU screen.
NOTE: To prevent unauthorized persons from accessing the
CVC service screens, the CVC 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 displays, the CVC
screen light goes out (analogous to a screen saver), and the
CVC 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
screen, press the MENU and SERVICE softkeys. Enter the
password and, from the SERVICE menu, highlight LOG OUT
OF NETWORK DEVICE and press the SELECT softkey. Fig. 25 — Example of Holiday Period Screen
The CVC default screen will now be displayed.
45
START-UP/SHUTDOWN/ If the water/brine temperature is high enough, the start-up
RECYCLE SEQUENCE (Fig. 26) sequence continues and checks the guide vane position. If the
guide vanes are more than 4% open, the start-up waits until the
Local Start-Up — Local start-up (or a manual start-up) is PIC II closes the vanes. If the vanes are closed and the oil pump
initiated by pressing the LOCAL menu softkey on the default pressure is less than 4 psi (28 kPa), the oil pump relay energiz-
CVC screen. Local start-up can proceed when the chiller es. The PIC II then waits until the oil pressure (OIL PRESS
schedule indicates that the current time and date have been VERIFY TIME, operator-configured, default of 40 seconds)
established as a run time and date, and after the internal reaches a maximum of 18 psi (124 kPa). After oil pressure is
15-minute start-to-start and the 1-minute stop-to-start inhibit verified, the PIC II waits 40 seconds, and the compressor start
timers have expired. These timers are represented in the START relay (1CR) energizes to start the compressor.
INHIBIT TIMER and can be viewed on the MAINSTAT screen Compressor ontime and service ontime timers start, and the
and DEFAULT screen. The timer must expire before the chiller compressor STARTS IN 12 HOURS counter and the number of
will start. If the timers have not expired the RUN STATUS pa- starts over a 12-hour period counter advance by one.
rameter on the MAINSTAT screen now reads TIMEOUT.
Failure to verify any of the requirements up to this point will
NOTE: The time schedule is said to be “occupied” if the result in the PIC II aborting the start and displaying the applica-
OCCUPIED ? parameter on the MAINSTAT screen is set to ble pre-start mode of failure on the CVC default screen. A pre-
YES. For more information on occupancy schedules, see the start failure does not advance the STARTS IN 12 HOURS
sections on Time Schedule Operation (page 20), Occupancy counter. Any failure after the 1CR relay has energized results in
Schedule (page 34), and To Prevent Accidental Start-Up a safety shutdown, advances the starts in 12 hours counter by
(page 65), and Fig. 19. one, and displays the applicable shutdown status on the CVC
If the OCCUPIED ? parameter on the MAINSTAT screen display.
is set to NO, the chiller can be forced to start as follows. From
the default CVC screen, press the MENU and STATUS
softkeys. Scroll to highlight MAINSTAT. Press the SELECT
softkey. Scroll to highlight CHILLER START/STOP. Press the
START 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 RELEASE 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 MENU and
SCHEDULE 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 CONTACTS INPUT parameter on the MAIN-
STAT screen must be CLOSED. From the CVC default screen, A — START INITIATED: Pre-start checks are made; evaporator pump
started.
press the MENU and STATUS softkeys. Scroll to high- B — Condenser water pump started (5 seconds after A).
light MAINSTAT and press the SELECT softkey. Scroll C — Water flows verified (30 seconds to 5 minutes maximum after B).
down the MAINSTAT screen to highlight REMOTE START Chilled water temperatures checked against control point. Guide
vanes checked for closure. Oil pump started; tower fan control
CONTACT and press the SELECT softkey. Then, press the enabled.
CLOSE softkey. To end the override, select REMOTE CON- D — Oil pressure verified (15 seconds minimum, 300 seconds maximum
after C).
TACTS INPUT and press the RELEASE softkey. E — Compressor motor starts; compressor ontime and service ontime
Once local start-up begins, the PIC II performs a series of start, 15-minute inhibit timer starts (10 seconds after D), total com-
pressor starts advances by one, and the number of starts over a
pre-start tests to verify that all pre-start alerts and safeties are 12-hour period advances by one.
within the limits shown in Table 4. The RUN STATUS parame- F — SHUTDOWN INITIATED — Compressor motor stops; compressor
ter on the MAINSTAT screen line now reads PRESTART. If a ontime and service ontime stop, and 1-minute inhibit timer starts.
test is not successful, the start-up is delayed or aborted. If the G — Oil pump and evaporator pumps deenergized (60 seconds after F).
Condenser pump and tower fan control may continue to operate if
tests are successful, the chilled water/brine pump relay ener- condenser pressure is high. Evaporator pump may continue if in
gizes, and the MAINSTAT screen line now reads STARTUP. RECYCLE mode.
O/A — Restart permitted (both inhibit timers expired: minimum of 15 minutes
Five seconds later, the condenser pump relay energizes. after E; minimum of 1 minute after F).
Thirty seconds later the PIC II monitors the chilled water and
condenser water flow devices and waits until the WATER Fig. 26 — Control Sequence
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.
46
Shutdown Sequence — Chiller shutdown begins if Chilled Water Recycle Mode — The chiller may cy-
any of the following occurs: cle off and wait until the load increases to restart when the
• the STOP button is pressed for at least one second (the compressor is running in a lightly loaded condition. This cy-
alarm light blinks once to confirm the stop command) cling is normal and is known as “recycle.” A recycle shutdown
• a recycle condition is present (see Chilled Water Recycle is initiated when any of the following conditions are true:
Mode section) • the chiller is in LCW control, the difference between the
• the time schedule has gone into unoccupied mode LEAVING CHILLED WATER temperature and ENTER-
• the chiller protective limit has been reached and chiller ING CHILLED WATER temperature is less than the
is in alarm RECYCLE SHUTDOWN DELTA T (found in the
• the start/stop status is overridden to stop from the CCN SETUP1 table) the LEAVING CHILLED WATER tem-
network or the CVC perature is 5° F (2.8° C) below the CONTROL POINT,
When a stop signal occurs, the shutdown sequence first the CONTROL POINT has not increased in the last
stops the compressor by deactivating the start relay (1CR). A 5 minutes and ICE BUILD is not active.
status message of “SHUTDOWN IN PROGRESS, COM- • the ECW CONTROL OPTION is enabled, the difference
PRESSOR DEENERGIZED” is displayed, and the compres- between the ENTERING CHILLED WATER temperature
sor ontime and service ontime stop. The guide vanes are then and the LEAVING CHILLED WATER temperature is less
brought to the closed position. The oil pump relay and the than the RECYCLE SHUTDOWN DELTA T (found in
chilled water/brine pump relay shut down 60 seconds after the the SETUP1 table), the ENTERING CHILLED WATER
compressor stops. The condenser water pump shuts down at temperature is 5° F (2.8° C) below the CONTROL
the same time if the ENTERING CONDENSER WATER tem- POINT, and the CONTROL POINT has not increased in
perature is greater than or equal to 115 F (46.1 C) and the the last 5 minutes.
CONDENSER REFRIG TEMP is greater than the CONDENS- • the LEAVING CHILLED WATER temperature is within
ER FREEZE POINT plus 5 F (–15.0 C). The stop-to-start timer 3° F (2° C) of the EVAP REFRIG TRIPPOINT.
now begins to count down. If the start-to-start timer value is When the chiller is in RECYCLE mode, the chilled water
still greater than the value of the start-to-stop timer, then this pump relay remains energized so the chilled water temper-
time displays on the CVC. ature can be monitored for increasing load. The recycle control
Certain conditions that occur during shutdown can change uses RESTART DELTA T to check when the compressor should
this sequence. be restarted. This is an operator-configured function which de-
• If the AVERAGE LINE CURRENT is greater than 5% faults to 5° F (3° C). This value can be viewed or modified on
after shutdown, or the starter contacts remain energized, the SETUP1 table. The compressor will restart when the chiller
the oil pump and chilled water pump remain energized is:
and the alarm is displayed. • in LCW CONTROL and the LEAVING CHILLED
• The condenser pump shuts down when the CON- WATER temperature is greater than the CONTROL
DENSER PRESSURE is less than the COND PRESS POINT plus the RECYCLE RESTART DELTA T.
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the • in ECW CONTROL and the ENTERING CHILLED
CONDENSER REFRIG TEMP is less than or equal to WATER temperature is greater than the CONTROL
the ENTERING CONDENSER WATER temperature plus POINT plus the RECYCLE RESTART DELTA T.
3° F (–1.6° C). Once these conditions are met, the compressor initiates a
• If the chiller shuts down due to low refrigerant tempera- start-up with a normal start-up sequence.
ture, the chilled water pump continues to run until the
LEAVING CHILLED WATER temperature is greater An alert condition may be generated if 5 or more recycle
than the CONTROL POINT temperature, plus 5° F start-ups occur in less than 4 hours. Excessive recycling can
(3° C). reduce chiller life; therefore, compressor recycling due to ex-
tremely low loads should be reduced.
Automatic Soft Stop Amps Threshold — The soft To reduce compressor recycling, use the time schedule to
stop amps threshold feature closes the guide vanes of the com- shut the chiller down during known low load operation period,
pressor automatically if a non-recycle, non-alarm stop signal or increase the chiller load by running the fan systems. If the
occurs before the compressor motor is deenergized. hot gas bypass is installed, adjust the values to ensure that hot
If the STOP button is pressed, the guide vanes close to a gas is energized during light load conditions. Increase the
preset amperage percent until the guide vane is less than 4% RECYCLE RESTART DELTA T on the SETUP1 table to
open or 4 minutes have passed. The compressor then shuts off. lengthen the time between restarts.
If the chiller enters an alarm state or if the compressor enters The chiller should not be operated below design minimum
a RECYCLE mode, the compressor deenergizes immediately. load without a hot gas bypass installed.
To activate the soft stop amps threshold feature, scroll to the Safety Shutdown — A safety shutdown is identical to
bottom of OPTIONS screen on the CVC. Use the INCREASE a manual shutdown with the exception that, during a safety
or DECREASE softkey to set the SOFT STOP AMPS shutdown, the CVC displays the reason for the shutdown, the
THRESHOLD parameter to the percent of amps at which the alarm light blinks continuously, and the spare alarm contacts
motor will shut down. The default setting is 100% amps (no are energized.
soft stop). The range is 40 to 100%. After a safety shutdown, the RESET softkey must be
When the soft stop amps threshold feature is being applied, pressed to clear the alarm. If the alarm condition is still present,
a status message, “SHUTDOWN IN PROGRESS, COM- the alarm light continues to blink. Once the alarm is cleared,
PRESSOR UNLOADING” displays on the CVC. the operator must press the CCN or LOCAL softkeys to re-
The soft stop amps threshold function can be terminated and start the chiller.
the compressor motor deenergized immediately by depressing
the STOP button twice.
47
BEFORE INITIAL START-UP To determine if there are any leaks, the chiller should be
charged with refrigerant. Use an electronic leak detector to
Job Data Required check all flanges and solder joints after the chiller is pressur-
• list of applicable design temperatures and pressures ized. If any leaks are detected, follow the leak test procedure.
(product data submittal) If the chiller is spring isolated, keep all springs blocked in
• chiller certified prints both directions to prevent possible piping stress and damage
• starting equipment details and wiring diagrams during the transfer of refrigerant from vessel to vessel during
• diagrams and instructions for special controls or options the leak test process, or any time refrigerant is being trans-
• 19XR Installation Instructions ferred. Adjust the springs when the refrigerant is in operating
• pumpout unit instructions condition and the water circuits are full.
Equipment Required Refrigerant Tracer — Carrier recommends the use of an
• mechanic’s tools (refrigeration) environmentally acceptable refrigerant tracer for leak testing
• digital volt-ohmmeter (DVM) with an electronic detector or halide torch.
• clamp-on ammeter Ultrasonic leak detectors can also be used if the chiller is
• electronic leak detector under pressure.
• 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 Do not use air or oxygen as a means of pressurizing
a5000-v insulation tester for compressor motor rated the chiller. Mixtures of HFC-134a and air can undergo
above 600 v combustion.
Using the Optional Storage Tank and Pump-
out System — Refer to Chillers with Storage Tanks sec-
tion, page 69 for pumpout system preparation, refrigerant
transfer, and chiller evacuation.
Remove Shipping Packaging — Remove any pack-
aging material from the control center, power panel, guide vane
actuator, motor cooling and oil reclaim solenoids, motor and
bearing temperature sensor covers, and the factory-mounted
starter.
Open Oil Circuit Valves — Check to ensure the oil fil-
ter isolation valves (Fig. 4) are open by removing the valve cap
and checking the valve stem.
Tighten All Gasketed Joints and Guide Vane
Shaft Packing — Gaskets and packing normally relax by
the time the chiller arrives at the jobsite. Tighten all gasketed
joints and the guide vane shaft packing to ensure a leak-tight
chiller.
Check Chiller Tightness — Figure 28 outlines the
proper sequence and procedures for leak testing.
19XR chillers are shipped with the refrigerant contained in Fig. 27 — Typical Wet-Bulb Type
the condenser shell and the oil charge in the compressor. The Vacuum Indicator
cooler is shipped with a 15 psig (103 kPa) refrigerant charge.
Units may be ordered with the refrigerant shipped separately,
along with a 15 psig (103 kPa) nitrogen-holding charge in each
vessel.
48
49
Fig. 28 — 19XR Leak Test Procedures
Leak Test Chiller — Due to regulations regarding refrig- at rates greater than 1 lb/year (0.45 kg/year) for the entire
erant emissions and the difficulties associated with separating chiller must be repaired. Note the total chiller leak rate on
contaminants from the refrigerant, Carrier recommends the the start-up report.
following leak test procedure. See Fig. 28 for an outline of the 5. If no leak is found during the initial start-up procedures,
leak test procedure. Refer to Fig. 29 and 30 during pumpout complete the transfer of refrigerant gas from the pumpout
procedures and Tables 5A and 5B for refrigerant pressure/ storage tank to the chiller (see Transfer Refrigerant from
temperature values. Pumpout Storage Tank to Chiller section, page 70). Re-
1. If the pressure readings are normal for the chiller test for leaks.
condition: 6. If no leak is found after a retest:
a. Evacuate the holding charge from the vessels, if a. Transfer the refrigerant to the pumpout storage
present. tank and perform a standing vacuum test as out-
b. Raise the chiller pressure, if necessary, by adding lined in the Standing Vacuum Test section, below.
refrigerant until pressure is at the equivalent satu- b. If the chiller fails the standing vacuum test, check
rated pressure for the surrounding temperature. for large leaks (Step 2b).
Follow the pumpout procedures in the Transfer
Refrigerant from Pumpout Storage Tank to Chiller c. If the chiller passes the standing vacuum test,
section, Steps 1a - e, page 69. 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).
Never charge liquid refrigerant into the chiller if the pres-
sure in the chiller is less than 35 psig (241 kPa) for 7. If a leak is found after a retest, pump the refrigerant back
HFC-134a. Charge as a gas only, with the cooler and con- into the pumpout storage tank or, if isolation valves are
denser pumps running, until this pressure is reached, using present, pump the refrigerant into the non-leaking
PUMPDOWN LOCKOUT and TERMINATE LOCK- vessel (see Pumpout and Refrigerant Transfer procedures
OUT mode on the PIC II. Flashing of liquid refrigerant at section).
low pressures can cause tube freeze-up and considerable 8. Transfer the refrigerant until the chiller pressure is at 18
damage. in. Hg (40 kPa absolute).
9. Repair the leak and repeat the procedure, beginning from
c. Leak test chiller as outlined in Steps 3 - 9. Step 2h, to ensure a leak-tight repair. (If the chiller is
2. If the pressure readings are abnormal for the chiller opened to the atmosphere for an extended period, evacu-
condition: ate it before repeating the leak test.)
a. Prepare to leak test chillers shipped with refriger- Standing Vacuum Test — When performing the
ant (Step 2h). standing vacuum test or chiller dehydration, use a manometer
b. Check for large leaks by connecting a nitrogen or a wet bulb indicator. Dial gages cannot indicate the small
bottle and raising the pressure to 30 psig amount of acceptable leakage during a short period of time.
(207 kPa). Soap test all joints. If the test pressure 1. Attach an absolute pressure manometer or wet bulb indi-
holds for 30 minutes, prepare the test for small cator to the chiller.
leaks (Steps 2g - h).
2. Evacuate the vessel (see Pumpout and Refrigerant Trans-
c. Plainly mark any leaks that are found. fer Procedures section, page 67) to at least 18 in. Hg vac,
d. Release the pressure in the system. ref 30-in. bar (41 kPa), using a vacuum pump or the
e. Repair all leaks. pump out unit.
f. Retest the joints that were repaired. 3. Valve off the pump to hold the vacuum and record the
g. After successfully completing the test for large manometer or indicator reading.
leaks, remove as much nitrogen, air, and moisture 4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)
as possible, given the fact that small leaks may be in 24 hours, the chiller is sufficiently tight.
present in the system. This can be accomplished b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)
by following the dehydration procedure, outlined in 24 hours, repressurize the vessel and test for
in the Chiller Dehydration section, page 53. leaks. If refrigerant is available in the other vessel,
h. Slowly raise the system pressure to a maximum pressurize by following Steps 2-10 of Return
of160 psig (1103 kPa) but no less than 35 psig Chiller To Normal Operating Conditions section,
(241 kPa) for HFC-134a by adding refrigerant. page 71. If not, use nitrogen and a refrigerant
Proceed with the test for small leaks (Steps 3-9). tracer. Raise the vessel pressure in increments
3. Check the chiller carefully with an electronic leak detec- until the leak is detected. If refrigerant is used, the
tor, halide torch, or soap bubble solution. maximum gas pressure is approximately 70 psig
(483 kPa) for HFC-134a at normal ambient tem-
4. Leak Determination — If an electronic leak detector indi- perature. If nitrogen is used, limit the leak test
cates a leak, use a soap bubble solution, if possible, to pressure to 230 psig (1585 kPa) maximum.
confirm. Total all leak rates for the entire chiller. Leakage
5. Repair the leak, retest, and proceed with dehydration.
50
Fig. 29 — Typical Optional Pumpout System Piping Schematic with Storage Tank
Fig. 30 — Typical Optional Pumpout System Piping Schematic without Storage Tank
51
Table 5A — HFC-134a Pressure — Table 5B — HFC-134a Pressure —
Temperature (F) Temperature (C)
TEMPERATURE, PRESSURE TEMPERATURE, PRESSURE
F (psig) C (kPa)
0 6.50 –18.0 44.8
2 7.52 –16.7 51.9
4 8.60 –15.6 59.3
6 9.66 –14.4 66.6
8 10.79 –13.3 74.4
10 11.96 –12.2 82.5
12 13.17 –11.1 90.8
14 14.42 –10.0 99.4
16 15.72 –8.9 108.0
18 17.06 –7.8 118.0
20 18.45 –6.7 127.0
22 19.88 –5.6 137.0
24 21.37 –4.4 147.0
26 22.90 –3.3 158.0
28 24.48 –2.2 169.0
30 26.11 –1.1 180.0
32 27.80 0.0 192.0
34 29.53 1.1 204.0
36 31.32 2.2 216.0
38 33.17 3.3 229.0
40 35.08 4.4 242.0
42 37.04 5.0 248.0
44 39.06 5.6 255.0
46 41.14 6.1 261.0
48 43.28 6.7 269.0
50 45.48 7.2 276.0
52 47.74 7.8 284.0
54 50.07 8.3 290.0
56 52.47 8.9 298.0
58 54.93 9.4 305.0
60 57.46 10.0 314.0
62 60.06 11.1 329.0
64 62.73 12.2 345.0
66 65.47 13.3 362.0
68 68.29 14.4 379.0
70 71.18 15.6 396.0
72 74.14 16.7 414.0
74 77.18 17.8 433.0
76 80.30 18.9 451.0
78 83.49 20.0 471.0
80 86.17 21.1 491.0
82 90.13 22.2 511.0
84 93.57 23.3 532.0
86 97.09 24.4 554.0
88 100.70 25.6 576.0
90 104.40 26.7 598.0
92 108.18 27.8 621.0
94 112.06 28.9 645.0
96 116.02 30.0 669.0
98 120.08 31.1 694.0
100 124.23 32.2 720.0
102 128.47 33.3 746.0
104 132.81 34.4 773.0
106 137.25 35.6 800.0
108 141.79 36.7 828.0
110 146.43 37.8 857.0
112 151.17 38.9 886.0
114 156.01 40.0 916.0
116 160.96 41.1 946.0
118 166.01 42.2 978.0
120 171.17 43.3 1010.0
122 176.45 44.4 1042.0
124 181.83 45.6 1076.0
126 187.32 46.7 1110.0
128 192.93 47.8 1145.0
130 198.66 48.9 1180.0
132 204.50 50.0 1217.0
134 210.47 51.1 1254.0
136 216.55 52.2 1292.0
138 222.76 53.3 1330.0
140 229.09 54.4 1370.0
55.6 1410.0
56.7 1451.0
57.8 1493.0
58.9 1536.0
60.0 1580.0
52
Chiller Dehydration — Dehydration is recommended if
the chiller has been open for a considerable period of time, if
the chiller is known to contain moisture, or if there has been a
complete loss of chiller holding charge or refrigerant pressure.
Do not start or megohm-test the compressor motor or oil

pump motor, even for a rotation check, if the chiller is
under dehydration vacuum. Insulation breakdown and
severe damage may result.
Fig. 31 — Dehydration Cold Trap
Inspect Water Piping — Refer to piping diagrams pro-

Inside-delta type starters must be disconnected by an isola- vided in the certified drawings and the piping instructions in
tion switch before placing the machine under a vacuum the 19XR Installation Instructions manual. Inspect the piping to
because one lead of each phase is live with respect to the cooler and condenser. Be sure that the flow directions are
ground even though there is not a complete circuit to run correct and that all piping specifications have been met.
the motor. To be safe, isolate any starter before evacuating
the chiller if you are not sure if there are live leads to the Piping systems must be properly vented with no stress on
hermetic motor. waterbox nozzles and covers. Water flows through the cooler
and condenser must meet job requirements. Measure the pres-
Dehydration can be done at room temperatures. Using a sure drop across the cooler and the condenser.
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 Water must be within design limits, clean, and treated to
ambient temperatures are involved, contact a qualified service ensure proper chiller performance and to reduce the poten-
representative for the dehydration techniques required. tial of tube damage due to corrosion, scaling, or erosion.
Carrier assumes no responsibility for chiller damage result-
Perform dehydration as follows: ing from untreated or improperly treated water.
1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the refrigerant charging Check Optional Pumpout Compressor Water
valve (Fig. 2). Tubing from the pump to the chiller should Piping — If the optional pumpout storage tank and/or
be as short in length and as large in diameter as possible pumpout system are installed, check to ensure the pumpout
to provide least resistance to gas flow. condenser water has been piped in. Check for field-supplied
2. Use an absolute pressure manometer or a wet bulb vacu- shutoff valves and controls as specified in the job data. Check
um indicator to measure the vacuum. Open the shutoff for refrigerant leaks on field-installed piping. See Fig. 29 and
valve to the vacuum indicator only when taking a read- 30.
ing. Leave the valve open for 3 minutes to allow the indi-
cator vacuum to equalize with the chiller vacuum. Check Relief Valves — Be sure the relief valves have
been piped to the outdoors in compliance with the latest edition
3. If the entire chiller is to be dehydrated, open all isolation of ANSI/ASHRAE Standard 15 and applicable local safety
valves (if present). codes. Piping connections must allow for access to the valve
4. With the chiller ambient temperature at 60 F (15.6 C) or mechanism for periodic inspection and leak testing.
higher, operate the vacuum pump until the manometer The 19XR relief valves are set to relieve at the 185 psig
reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (1275 kPa) chiller design pressure.
(–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C).
Operate the pump an additional 2 hours. Inspect Wiring
Do not apply a greater vacuum than 29.82 in. Hg vac
(757.4 mm Hg) or go below 33 F (.56 C) on the wet bulb
vacuum indicator. At this temperature and pressure, iso-
lated pockets of moisture can turn into ice. The slow rate Do not check the voltage supply without proper equipment
of evaporation (sublimation) of ice at these low tempera- and precautions. Serious injury may result. Follow power
tures and pressures greatly increases dehydration time. company recommendations.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If Do not apply any kind of test voltage, even for a rotation
the reading indicates vacuum loss, repeat Steps 4 and 5. check, if the chiller is under a dehydration vacuum. Insula-
tion breakdown and serious damage may result.
7. If the reading continues to change after several attempts,
perform a leak test up to the maximum 160 psig 1. Examine the wiring for conformance to the job wiring di-
(1103 kPa) pressure. Locate and repair the leak, and re- agrams and all applicable electrical codes.
peat dehydration.
53
2. On low-voltage compressors (600 v or less) connect a 11. On chillers with free-standing starters, inspect the power
voltmeter across the power wires to the compressor start- panel to ensure that the contractor has fed the wires into
er and measure the voltage. Compare this reading to the the bottom of the panel. Wiring into the top of the panel
voltage rating on the compressor and starter nameplates. can cause debris to fall into the contactors. Clean and in-
3. Compare the ampere rating on the starter nameplate to spect the contactors if this has occurred.
rating on the compressor nameplate. The overload trip Carrier Comfort Network Interface — The Carrier
amps must be 108% to 120% of the rated load amps. Comfort Network (CCN) communication bus wiring is sup-
4. The starter for a centrifugal compressor motor must plied and installed by the electrical contractor. It consists of
contain the components and terminals required for PIC II shielded, 3-conductor cable with drain wire.
refrigeration control. Check the certified drawings. The system elements are connected to the communication
5. Check the voltage to the following components and bus in a daisy chain arrangement. The positive pin of each sys-
compare it to the nameplate values: oil pump contact, tem element communication connector must be wired to the
pumpout compressor starter, and power panel. positive pins of the system element on either side of it. The
6. Ensure that fused disconnects or circuit breakers have negative pins must be wired to the negative pins. The signal
been supplied for the oil pump, power panel, and ground pins must be wired to the signal ground pins. See instal-
pumpout unit. lation manual.
7. Ensure all electrical equipment and controls are properly NOTE: Conductors and drain wire must be 20 AWG
grounded in accordance with job drawings, certified (American Wire Gage) minimum stranded, tinned copper.
drawings, and all applicable electrical codes. Individual conductors must be insulated with PVC, PVC/
nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester
8. Ensure the customer’s contractor has verified proper op- 100% foil shield and an outer jacket of PVC, PVC/nylon,
eration of the pumps, cooling tower fans, and associated chrome vinyl, or Teflon with a minimum operating tempera-
auxiliary equipment. This includes ensuring motors are ture range of –4 F to 140 F (–20 C to 60 C) is required. See
properly lubricated and have proper electrical supply and table below for cables that meet the requirements.
proper rotation.
9. For field-installed starters only, test the chiller compres- MANUFACTURER CABLE NO.
sor motor and its power lead insulation resistance with a Alpha 2413 or 5463
500-v insulation tester such as a megohmmeter. (Use a American A22503
5000-v tester for motors rated over 600 v.) Factory- Belden 8772
mounted starters do not require a megohm test. Columbia 02525
a. Open the starter main disconnect switch and fol-
low lockout/tagout rules. When connecting the CCN communication bus to a system
element, a color code system for the entire network is recom-
mended to simplify installation and checkout. The following
color code is recommended:
If the motor starter is a solid-state starter, the motor leads
must be disconnected from the starter before an insulation CCN BUS
test is performed. The voltage generated from the tester can CONDUCTOR CCN TERMINAL
SIGNAL TYPE
damage the starter solid-state components. INSULATION CONNECTION
COLOR
b. With the tester connected to the motor leads, take + Red RED (+)
10-second and 60-second megohm readings as Ground White WHITE (G)
follows: – Black BLACK (–)
6-Lead Motor — Tie all 6 leads together and test
between the lead group and ground. Next tie the Check Starter
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. BE AWARE that certain automatic start arrangements can
engage the starter. Open the disconnect ahead of the starter
c. Divide the 60-second resistance reading by the in addition to shutting off the chiller or pump.
10-second reading. The ratio, or polarization
index, must be one or higher. Both the 10- and Use the instruction and service manual supplied by the start-
60-second readings must be at least 50 megohms. er manufacturer to verify the starter has been installed correct-
If the readings on a field-installed starter are ly, to set up and calibrate the starter, and for complete trouble-
unsatisfactory, repeat the test at the motor with the shooting information.
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 The main disconnect on the starter front panel may not
megohm tested. deenergize all internal circuits. Open all internal and
10. Tighten all wiring connections to the plugs on the ISM remote disconnects before servicing the starter.
and CCM modules.
54
MECHANICAL STARTER work or extended shutdowns. The oil heater relay status (OIL
1. Check all field wiring connections for tightness, clear- HEATER RELAY) can be viewed on the COMPRESS table on
ance from moving parts, and correct connection. the CVC. Oil sump temperature can be viewed on the CVC
default screen.
2. Check the contactor(s) to ensure they move freely. Check
the mechanical interlock between contactors to ensure SOFTWARE VERSION — The software part number is la-
that 1S and 2M contactors cannot be closed at the same beled on the backside of the CVC module. The software ver-
time. Check all other electro-mechanical devices, such as sion also appears on the CVC configuration screen as the last
relays, for free movement. If the devices do not move two digits of the software part number.
freely, contact the starter manufacturer for replacement Software Configuration
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 Do not operate the chiller before the control configurations
complete and proper start cycle. have been checked and a Control Test has been
BENSHAW, INC. RediStart MICRO™ SOLID-STATE satisfactorily completed. Protection by safety controls can-
STARTER not be assumed until all control configurations have been
confirmed.
As the 19XR unit is configured, all configuration settings
should be written down. A log, such as the one shown on pages
This equipment is at line voltage when AC power is con- CL-1 to CL-14, provides a convenient list for configuration
nected. Pressing the STOP button does not remove voltage. values.
1. Ensure all wiring connections are properly terminated to Input the Design Set Points — Access the CVC set
the starter. point screen and view/modify the base demand limit set point,
2. Verify the ground wire to the starter is installed properly and either the LCW set point or the ECW set point. The PIC II
and is sufficient size. can control a set point to either the leaving or entering chilled
3. Verify the motors are properly grounded to the starter. water. This control method is set in the EQUIPMENT SER-
VICE (TEMP_CTL) table.
4. Verify the proper ac input voltage is brought into the start-
er according to the certified drawings. Input the Local Occupied Schedule (OCCPC01S) —
5. Apply power to the starter. Access the schedule OCCPC01S screen on the CVC and set up
the occupied time schedule according to the customer’s re-
Oil Charge — The oil charge for the 19XR compressor de- quirements. If no schedule is available, the default is factory set
pends on the compressor Frame size: for 24 hours occupied, 7 days per week including holidays.
• Frame 2 compressor — 5 gal (18.9 L) For more information about how to set up a time schedule,
• Frame 3 compressor — 8 gal (30 L) see the Controls section, page 10.
• Frame 4 compressor — 10 gal (37.8 L) The CCN Occupied Schedule (OCCPC03S) should be con-
• Frame 5 compressor — 18 gal (67.8 L) figured if a CCN system is being installed or if a secondary
The chiller is shipped with oil in the compressor. When the time schedule is needed.
sump is full, the oil level should be no higher than the middle NOTE: The default CCN Occupied Schedule OCCPC03S is
of the upper sight glass, and minimum level is the bottom configured to be unoccupied.
of the lower sight glass (Fig. 2). If oil is added, it must meet
Carrier’s specification for centrifugal compressor use as de- Input Service Configurations — The following con-
scribed in the Oil Specification section. Charge the oil through figurations require the CVC screen to be in the SERVICE por-
the oil charging valve located near the bottom of the transmis- tion of the menu.
sion housing (Fig. 2). The oil must be pumped from the oil • password
container through the charging valve due to higher refrigerant • input time and date
pressure. The pumping device must be able to lift from 0 to • CVC configuration
200 psig (0 to 1380 kPa) or above unit pressure. Oil should • service parameters
only be charged or removed when the chiller is shut down. • equipment configuration
Power Up the Controls and Check the Oil • automated control test
Heater — Ensure that an oil level is visible in the compres- PASSWORD — When accessing the SERVICE tables, a pass-
sor before energizing the controls. A circuit breaker in the start- word must be entered. All CVC are initially set for a password
er energizes the oil heater and the control circuit. When first of 1-1-1-1.
powered, the CVC should display the default screen within a INPUT TIME AND DATE — Access the TIME AND DATE
short period of time. table on the SERVICE menu. Input the present time of day,
The oil heater is energized by powering the control circuit. date, and day of the week. The HOLIDAY TODAY parameter
This should be done several hours before start-up to minimize should only be configured to YES if the present day is a
oil-refrigerant migration. The oil heater is controlled by the holiday.
PIC II and is powered through a contactor in the power panel. NOTE: Because a schedule is integral to the chiller control
Starters contain a separate circuit breaker to power the heater sequence, the chiller will not start until the time and date have
and the control circuit. This arrangement allows the heater to been set.
energize when the main motor circuit breaker is off for service
55
CHANGE CVC CONFIGURATION IF NECESSARY — Configure SERVICE Tables — Access the SERVICE tables,
From the SERVICE table, access the CVC CONFIGU- shown in Table 2, to modify or view the following job site
RATION screen. From there, view or modify the CVC CCN parameters:
address, change to English or SI units, and change the pass-
word. If there is more than one chiller at the jobsite, change the PARAMETER TABLE
CVC address on each chiller so that each chiller has its own Starter Type ISM_CONF — Select 0 for full voltage,
1 for reduced voltage, or 2 for solid
address. Note and record the new address. Change the screen state/variable frequency drive.
to SI units as required, and change the password if desired. Motor Rated Line ISM_CONF — Motor rated voltage
TO CHANGE THE PASSWORD — The password may be Voltage from chiller information nameplate.
changed from the CVC CONFIGURATION screen. Volt Transformer ISM_CONF — Enter ratio (reduced to
Ratio a ratio to 1) of power transformer wired
1. Press the MENU and SERVICE softkeys. Enter the to terminal J3 of ISM. If no transformer
current password and highlight CVC CONFIGURA- is used enter 1.
TION. Press the SELECT softkey. Only the last Motor Rated ISM_CONF — Per chiller identification
Load Amps nameplate data.
5 entries on the CVC CONFIG screen can be changed:
Motor Locked ISM_CONF — Per chiller identification
BUS #, ADDRESS #, BAUD RATE, US IMP/METRIC, Rotor Trip nameplate data. Enter locked rotor
and PASSWORD. delta amps (LR AMPS D-).
2. Use the ENTER softkey to scroll to PASSWORD. The Starter LRA ISM_CONF — Enter value from name-
Rating plate in starter cabinet.
first digit of the password is highlighted on the screen.
Motor Current ISM_CONF — Enter ratio (reduced to
3. To change the digit, press the INCREASE or CT Ratio a ratio to 1) of current transformers
wired to terminal J4 of ISM. For
DECREASE softkey. When the desired digit is seen, Benshaw Inc. RediStart MICRO™
press the ENTER softkey. Starters set to 100.
4. The next digit is highlighted. Change it, and the third and Ground Fault ISM_CONF — Enter 0 if no ground
Current fault CTs are wired to terminal J5 of
fourth digits in the same way the first was changed. Transformers ISM. Enter 1 if ground fault CTs are
5. After the last digit is changed, the CVC goes to the BUS used.
parameter. Press the EXIT softkey to leave that screen Ground Fault ISM_CONF — Enter ratio (reduced to
CT Ratio a ratio to 1) of ground fault CT.
and return to the SERVICE menu.
Single Cycle ISM_CONF — ENABLE if motor
Dropout protection required from drop in line
voltage within one cycle.
Line Frequency ISM_CONF — Enter YES for 60 Hz or
Be sure to remember the password. Retain a copy NO for 50 Hz.
for future reference. Without the password, access to the Line Frequency ISM_CONF — ENABLE if motor
SERVICE menu will not be possible unless the Faulting protection required for drop in line
frequency.
CVC_PSWD menu on the STATUS screen is accessed by
Surge Limiting or OPTIONS — Enter 1 if HGBP is
a Carrier representative. Hot Gas Bypass installed.
Option
TO CHANGE THE CVC DISPLAY FROM ENGLISH TO Minimum Load OPTIONS — Per Chiller Requisition
METRIC UNITS — By default, the CVC displays informa- Points (T1, P1) (DT1, DP2) if available or per job data
tion in English units. To change to metric units, access the — See modify load points section.
CVC CONFIGURATION screen: Full (Maximum) OPTIONS — Per Chiller Requisition
Load Points (T2, P2) (DT2, DP2) if available or per job data
1. Press the MENU and SERVICE softkeys. Enter the — See modify load points section. For
password and highlight CVC CONFIGURATION. Press VFD units refer to table located in con-
trol panel.
the SELECT softkey.
Chilled Medium SETUP1 — Enter water or brine.
2. Use the ENTER softkey to scroll to US IMP/METRIC. Evaporator SETUP1 — Usually 3° F (1.7° C)
Refrigerant below design refrigerant temperature.
3. Press the softkey that corresponds to the units desired for Trippoint
display on the CVC (e.g., US or METRIC). Evaporator Flow SETUP1 — Per Chiller Requisition if
MODIFY CONTROLLER IDENTIFICATION IF NECES- Delta P Cutout available or enter 50% of design pres-
SARY — The CVC module address can be changed from the sure drop to 0.5 psi (3.4 kPa).*
CVC CONFIGURATION screen. Change this address for each Condenser Flow SETUP1 — Per Chiller Requisition if
Delta P Cutout available or enter 50% of design pres-
chiller if there is more than one chiller at the jobsite. Write the sure drop to 0.5 psi (3.4 kPa).*
new address on the CVC module for future reference. Diffuser Option SETUP2 — ENABLE for 5 size com-
INPUT EQUIPMENT SERVICE PARAMETERS IF NEC- pressor only. See model number
ESSARY — The EQUIPMENT SERVICE table has six nomenclature.
Diffuser Full Span SETUP2 — Enter diffuser actuator full
service tables. mA Rating span mA rating for 5 size compressor
only. Value is located on label on side
of diffuser actuator motor.
Motor Rated RAMP_DEM — Enter value from
Kilowatts chiller requisition form (product data
submittal) if kilowatt ramp demand is
enabled.
*With variable flow systems this point may be configured to the lower
end of the range.
NOTE: Other parameters on these screens are normally left at the
default settings; however, they may be changed by the operator as
required. The time and persistence settings on the ISM_CONF table
can be adjusted to increase or decrease the sensitivity to a fault
condition. Increasing time or persistence decreases sensitivity.
Decreasing time or persistence increases sensitivity to the fault
condition.
56
CHANGE THE BENSHAW INC., RediStart MICRO™ To view other settings and troubleshooting guide consult the
SOFTWARE CONFIGURATION IF NECESSARY — Ben- Benshaw RediStart MICRO instructional manual included in
shaw starter configurations are checked and modified from the the starter.
menus in the Benshaw Redistart MICRO Default Display. See
Fig. 32 and Table 6 for default display and menu items. To ac- DISPLAY
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- RediStart MICRO
ically after power-up. Current transformer ratio configurations
STOP I = OA
and hardware switch settings checks are performed in the READY V = 461V
FAULT
RESET
MENU1 display screen. See Table 7 for menu structure and SCROLL UP
Table 8 for switch settings.

SCROLL DOWN MENU ENTER
1. Press the MENU softkey until the desired menu is se-
lected on the display.
2. Press the ENTER softkey to access the displayed menu
items (Table 6).
3. Use the ↓ or ↑ arrow keys to scroll between menu MENU
SELECTION
MENU ENTRY
DATA ENTRY
items until the desired item is reached on the display.
Fig. 32 — Benshaw RediStart
4. Press the ENTER softkey to access the value to be MICRO Default Display
changed.
5. Use the ↑ or ↓ arrow keys to adjust the new displayed
value. The ↑ key increases the value while the ↓ key Table 6 — Benshaw RediStart
decreases the value. Holding the arrow key will progres- MICRO Menu Structure
sively increase the rate of change. The value will stop
changing when either the factory set minimum or maxi- MENU 3 MENU 4
MENU 1 MENU 2
mum value is reached. To make fine adjustments press Starter Setup Meter Setup
Event Dry Run
and release the arrow key. Recorder Mode
Initial Current Meter #1 Events 1-99 Dry Run
6. When the correct value has been selected, press the as % RLA display Mode
ENTER key to store the new configuration. At this Max. Cur Meter #2
point, there are two options the MENU key will return As % LRA display
Ramp Time
the display to the main display. The ↑ or ↓ arrow keys (sec.)
will move the display to the next menu item. When fin- CT Ratio: 1
ished press the MENU key to return to the main display.
Table 7 — Benshaw RediStart MICRO Menu Items*

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.
*These values are not displayed in the ISM_CONFIG table.
Table 8 — Benshaw RediStart MICRO Current Transformer DIP Switch Settings

CURRENT TRANSFORMER CT1-CT3
Starter Motor MIcro Power Card (BIPCMIPWR-C4)
Frame Size RLA Range CT Overload Switch Settings
Ratio
(Amps) (Amps) SW1-1 SW1-2
95- 135 Amps 3900:1 OFF OFF
200 Amps
136- 200 Amps 5760:1 OFF OFF
201- 231 Amps 2640:1 ON OFF
300 Amps
232- 300 Amps 3900:1 ON OFF
301- 340 Amps 3900:1 ON OFF
480 Amps
341- 480 Amps 5760:1 ON OFF
481- 580 Amps 2640:1 ON ON
600 Amps
581- 600 Amps 3900:1 ON ON
740 Amps 601- 740 Amps 3900:1 ON ON
741- 855 Amps 3900:1 ON ON
1250 Amps
856-1250 Amps 5760:1 ON ON
LEGEND
CT — Current Transformer
57
VERIFY VFD CONFIGURATION AND CHANGE Accessing Password Protected Parameters — Although the
PARAMETERS IF NECESSARY VFD controller has been preconfigured as the factory, the user
will need to be able to access the parameters to verify the job
IMPORTANT: The VFD controller has been factory specific parameters are correct, tune the controller or correct a
configured for use and communications to the Chiller problem. The two passwords protecting the VFD configuration
Visual Controller (CVC). Some parameters are specific are Parameter Set Display password and Program Disable
to the chiller configuration and will need to be verified password. The Parameter Set Display password restricts view-
prior to operation. Speed control and starting the drive ing. P.nnn parameters above 007 and all H.nnn and R.nnn
have been disabled at the VFD keypad. All command screens. The password can be accessed at parameter P.006 and
functions must be initiated from the CVC. will switch between enabled and disabled each time the pass-
word 107 is entered. The Program Disable password restricts
Using the Keypad — The keypad display is used to monitor, the changing of the drive parameter set. To enable or disable
view fault history and adjust the program of the VFD changes select parameter P.051 and enter the password 26.
microprocessor. It operates in two modes: Monitor mode and
Program Mode: NOTE: Some of the parameters can be changed only when the
drive is stopped.
Use the ↑ and ↓ keys to:
• Step through the drive parameter menus and error log
when the keypad/display is in Program mode.
• Increase or decrease a numeric value such as the refer- It is the operator’s responsibility to distribute access to the
ence or parameter value. passwords. Carrier is not responsible for unauthorized
• Hold down these keys to increase the scroll speed. access violations within the operator’s organization. Failure
Use the ENTER softkey to: to observe this warning could result in bodily injury.
• Display a parameter or a selection value in Program
mode. See the Initial Start-Up Checklist section for VFD Job Specific
• Save a value. Configuration table. For job specific parameters see inside of
• Move through each monitor display item when in Moni- the VFD enclosure door, next to the keypad. Refer to the VFD
tor mode. Configuration table for the entire list of parameters.
Monitor Mode (Default Mode) — Specific drive conditions
may be monitored on the keypad when in this mode. An LED
will be illuminated next to the description of what is displayed Restoring the default parameter P.050 will require all the
on the keypad. Use the ENTER softkey to scroll through and Carrier default parameters to be restored manually.
monitor the following selections:
• All LEDs on — Speed request from the CVC VFD CHILLER FIELD SET UP AND VERIFICATION
• Motor Speed
• Output Frequency Label Locations — Verify the following labels have been
• Output Voltage installed properly and match the chiller requisition:
• Output Current • Surge parameters — Located inside the control panel.
• Chiller identification nameplate — Located on the right
Program Mode — This mode displays and modifies the con- side of the control panel.
figuration parameters of the VFD microprocessor. Particular • VFD Parameter — Located to the right of the VFD con-
parameters, parameter numbers, and error log information can troller keypad on the VFD module.
be displayed when in Program mode. • VFD Nameplate — Located on the right side of the VFD
Press the PROGRAM softkey until the PROGRAM LED is as viewed from its front.
illuminated to enter the Program mode. • Record all nameplate information on the Reliance Con-
figuration sheet.
Use the ↑ and ↓ keys to move through the menus
Drive Protection and Other Incoming Wiring
Press ENTER softkey to select the desired menu. 1. Verify that the branch disconnects or other local discon-
Press ↑ and ↓ keys to move through following parameters. nects are open and properly tagged out.
P.nnn — General Parameters 2. Verify that the branch circuit protection and AC input
U.nnn — Vector Control Parameters* wiring to the VFD are in accordance with NEC/CEC
H.nnn — Volts/Hertz Control Parameters (National Electrical Code/California Energy Commis-
R.nnn — RMI Remote Monitor Interface sion) and all other local codes.
Parameters 3. Verify that the fuses are per the field wiring diagram.
E.nnn — Error Log (See fault codes) 4. Verify that the incoming source does not exceed 85 kA.
*Vector control is not used in this configuration. 5. Verify the power lugs in the VFD and branch protection
Press ENTER softkey to select a parameter menu screen. are properly secured. Inspect the ground cable and ensure
it is properly connected at the branch and to the ground
Press ↑ and ↓ keys to adjust the selected parameter. lug in the VFD.
6. Verify the conduit for the power wiring in securely con-
Press the PROGRAM softkey until the PROGRAM LED nected to the VFD flanged cover and runs continuously to
turns off to exit the program. the branch protection.
7. Verify that the incoming and outgoing wires have been
properly connected inside of the reactor enclosure if a
Changing parameters may adversely affect chiller separate line reactor has been added to the chiller.
operation. 8. Ensure the control and signal wires connected to the chill-
er controller or the VFD are in separate conduit.
58
VFD Cooling System Leak Inspection Configure Chiller Visual Controller Parameter — The chiller
1. Check for leaks on the refrigerant cooling flange connec- controller must have its job specific parameters set as defined
tions to the VFD enclosure. by the job sheet or installed nameplates. Below are the job spe-
cific parameters that must be set:
2. Check for leaks on all tubing internal to the VFD enclo-
sure, the tubing flair connection to the VFD module and To access the ISM_CONF screen:
the TXV valve. 1. Press ENTER .
3. Verify that the VFD refrigerant cooling system TXV 2. Press SERVICE .
valve control bulb is securely inserted into the VFD drive 3. Enter the password 1111.
module heat sink.
4. Select ISM (CONFIG STARTER DATA)
Power Up Verification
5. Scroll down and select the ISM_CONF DATA screen to
1. Inspect control wiring inside the VFD and verify the in- modify or view the ISM parameters:
tegrity of the connections between the integrated starter
module (ISM) and the VFD module. DESCRIPTION SETTING
2. Close the control power switch in the VFD enclosure. STARTER TYPE 2
(2 = SS/VFD)
3. Close the oil pump power switch inside the VFD MOTOR RATED VFD Nameplate Voltage.
enclosure. LINE VOLTAGE
4. Verify the VFD disconnect switch is in the open position. MOTOR RATED VFD Nameplate Chiller Rated Load
LOAD AMPS Amps
5. Close and latch the doors of the VFD enclosure. MOTOR LOCKED Compressor Nameplate
6. Apply power to the VFD enclosure. Remove lock outs ROTOR TRIP
and close all disconnects. STARTER LRA RATING 700 for VFD
part #19XVR0500XXX
7. Verify that the CVC display powers up and goes to the 900 for VFD
default screen. part #19XVR0643XXX
MOTOR CURRENT 163
8. Close the VFD disconnect switch. CT RATIO:1
9. Verify the following actions during the VFD start-up self 3 GRND FAULT CT? NO
test: (1=NO)
FREQUENCY-60HZ NO for 50 Hz selection
• The display shows SELF and all LEDs are illumi- (NO=50) YES for 60 Hz selection
nated for 5 to 6 seconds.
• The display reads a 0 after the diagnosis is 6. Press to the SAVE softkey to save changes.
complete. 7. Press the EXIT softkey to and exit the ISM Configura-
• If Err is displayed a fault has been detected. tion Screen.
Perform manual reset by establishing a reset VFD Enable Configuration — To access the parameters:
through the small hole under the VFD Keypad. If
this does not correct the fault contact your Carrier 1. Press MENU .
representative. 2. Press SERVICE .
• If AR with a counting down number is displayed 3. Select EQUIPMENT SERVICE.
wait for the number to count to 0 and the display
should then revert to a 0. If the counter starts over 4. Scroll down and select SETUP2.
at 30 contact Carrier representative. 5. Verify the following parameters:
Configure VFD Parameters — The VFD controller must have VFD OPTION ENABLED
job specific parameters set as defined by the component name- VFD CURRENT LIMIT COMPRESSOR NAMEPLATE AMPS
plates and labels. The parameters come preset by the factory,
but must be verified prior to start-up by accessing the PRO- Configure Surge Parameters
GRAM MODE of the VFD controller keypad. For information 1. Press MENU .
on how to access the VFD keypad see page 57. 2. Press SERVICE .
Press the PROGRAM softkey to access the param- 3. Select EQUIPMENT SERVICE and OPTIONS to verify
eter screen to modify or view the following job specific the following:
parameters:.
DESCRIPTION SETTINGS
VFD SURGE/HGBP Surge parameter label
TITLE SETTING
PARAMETER DELTA T1
P.004 Maximum Line Frequency selected. Per SURGE/HGBP Surge parameter label
Speed Compressor Nameplate. DELTA P1
P.006 Password 107 SURGE/HGBP Surge parameter label
P.028 Speed 60 for 60 Hz selection and DELTA T2
Display 50 for 50 Hz selection SURGE/HGBP Surge parameter label
Scaling DELTA P2
H.000 Motor Compressor nameplate voltage.
Voltage VFD CONTROL VERFICATION (NON-RUNNING) —
H.001 Frequency Line Frequency selected. Per
In order to verify and, if necessary, tune the speed control sig-
Compressor Nameplate. nal of the chiller controller to the VFD (ISM terminal J8 1-2
H.002 Motor Compressor nameplate amps. labeled 4-20 mA OUT VFD) and the speed feedback signal
Amps from the VFD to the chiller controller (ISM terminal J6 1-2
H.021 Line VFD nameplate voltage. labeled VFD HZ), follow the steps below.
Voltage Set TARGET VFD SPEED to 0%.
H.022 Over 69 for 60 Hz selection and
Frequency 57 for 50 Hz selection. 1. Press MENU .
Limit
59
2. Press STATUS . 3. If outside the tolerance, adjust r.003 (Output Analog
3. Press COMPRESS . Gain).
4. Press SELECT . 4. Leave running for the next test.
5. Set TARGET VFD SPEED to 0%. ISM Current Calibration Check
Verify that the ACTUAL VFD SPEED shown on the VFD dis- 1. With the target VFD speed at 100%, load the chiller so
play is within 0 to 1 Hz. that the CVC default display shows 75%-100% under the
display title AMPS %. A higher load is preferred.
1. Press the ENTER softkey on the VFD keypad until all
LEDs on the left side of the keypad are illuminated. 2. Measure the incoming current with a separate amp meter.
NOTE: The value displayed is the frequency at which the 3. Calculate the line side error ratio using the following
VFD is being commanded to operate. equation:
2. Adjust VFD parameter P.009 (Input Offset) if outside the Amp Meter current – Ave. ISM current
tolerance. Amp Meter current
To confirm that the speed signal from the CVC corre- 4. If the Line Side Error Ratio is greater than ± 0.02 adjust
sponds to the value displayed at the VFD: the CVC reading by adjusting the ISM CT ratio.
3. Verify that the actual speed signal feedback to the chiller 5. Shut down the chiller.
controller is 0% by accessing the COMPRESS screen.
Change CT Ratio
4. Verify ACTUAL SPEED VFD is 0%-1%. 1. New CT Ratio = Present CT Ratio multiplied by (1+ Line
5. Adjust VFD parameter r.002 (Analog Output Offset) if Side Error Ratio).
outside the tolerance. To access the ISM_CONF screen:
Set VFD TARGET VFD SPEED to 100%.
2. Press ENTER .
1. Press MENU .
3. Press SERVICE .
2. Press STATUS . 4. Enter the password 1111.
3. Press COMPRESS .
5. Select ISM (STARTER) CONFIG DATA.
4. Press SELECT .
6. Enter password 4444.
5. Set TARGET VFD SPEED to 100%. 7. Select ISM_CONF.
Verify that the ACTUAL VFD SPEED shown on the VFD dis-
play corresponds to the 50 Hz or 60 Hz setting. 8. Change present CT ratio to new ratio using calculation
above.
1. Check the ACTUAL VFD SPEED configuration (50 Hz 9. Press to the SAVE softkey to save changes.
or 60 Hz) on the ISM_CONF screen.
2. Confirm that the VFD displays the configured line fre- 10. Press the EXIT softkey to exit the ISM_Conf screen.
quency within ± 1 Hz. 11. Repeat ISM Current Calibration Check.
3. Adjust parameter P.010 (Input Gain) if outside the VFD Current Control Calibration Check
tolerance. 1. With the target VFD speed at 100%, load the chiller so
4. Release the TARGET VFD SPEED so that it can operate that the CVC default display shows 75%-100% under the
in automatic mode. (Refer to Override Operations section display title AMPS %. A higher load is preferred.
on page 16.) 2. Access the current on the keypad of the VFD. Determine
VFD CONTROL VERIFICATION (RUNNING) the Load Side Current Ratio, using the equation below.
Load Side Current Ratio =
Preparation
1. Disconnect power to the VFD. Verify that the branch dis- VFD Actual Amps
connects or other local disconnects are open and properly Motor Nameplate Amps
tagged out.
2. Connect a voltmeter and ampmeter to the line side of the Next, access the VFD Load Factor on the capacity control
algorithm status screen. Calculate the Load Side Error
VFD. Locate meters safely away from the power cables. Ratio using the equation below:
3. Reconnect power to the VFD.
Load Side VFD Load Factor – Load Side Current Ratio
4. Measure the voltage on the line side of the drive. Error Ratio = Load Side Current Ratio
5. Verify it is within 10% of the chiller nameplate voltage.
3. If the load side error ratio is greater than ± 0.02, adjust the
6. Set up the CVC temperature controller per the require- VFD load factor by changing the VFD current limit on
ments of the job. the Service 2 screen.
7. Start the chiller and verify the rotation of the compressor a. The new VFD current limit = old VFD current
just as it starts. limit multiplied by (1+ Load Side Error Ratio).
8. Allow the chiller to load up. Verify that the chiller loads b. Recheck the VFD Current Control Calibration.
up smoothly.
c. Release the Speed Control by accessing the TAR-
NOTE: One or two surges may be counted during the first GET VFD SPEED control.
minute of operation.
Press MENU .
Verify That Actual VFD Speed is 100% (±2%) Press STATUS .
1. Set the VFD speed to 100%. Press COMPRESS .
2. Verify that the ACTUAL VFD SPEED is 100% (± 2%). (Refer to Override Operations section on page 16.)
60
Protection the VFD Configuration Calculate Minimum Load — To calculate the minimum load
1. Select parameter P.051 from the VFD keypad. conditions, estimate the temperature difference the cooler will
have at 10% load, then estimate what the suction and condens-
2. Press the ENTER softkey to access the parameter. A ing temperatures will be at this point. Use the proper saturated
zero will be displayed. pressure and temperature for the particular refrigerant used.
3. Use the ↑ arrow key to increment the value to 26. This is Suction Temperature:
the password number.
43 F (6.1 C) = 38 psig (262 kPa) saturated
4. Press the ENTER softkey to save the value. P.051 will refrigerant pressure (HFC-134a)
by displayed. Condensing Temperature:
NOTE: Parameter programming is disabled when the 70 F (21.1 C) = 71 psig (490 kPa) saturated
PASSWORD LED is on and enabled when the PASS- refrigerant pressure (HFC-134a)
WORD LED is off.
Minimum Load ∆T1 (at 20% Load): 2 F (1.1 C)
5. Select parameter P.006 from the VFD Keypad.
Minimum Load ∆P1:
6. Press the ENTER softkey to access the parameter. 71 – 38 = 33 psid (490 – 262 = 228 kPad)
7. Use the ↑ arrow key to increment the value to 107. This
is the password number to restrict displaying the remain- Again, to avoid unnecessary surge prevention, add 20 psid
ing P, and all of the H and r parameters. (140 kPad) at ∆P1 from these conditions:
∆T1 = 2 F (1.1 C)
8. Press the ENTER softkey to save the value. ∆P1 = 53 psid (368 kPad)
Modify Minimum and Maximum Load Points (∆T1/P1; ∆T2/ If surge prevention occurs too soon or too late:
P2) If Necessary — These pairs of chiller load points, located
on the OPTIONS screen, determine when to limit guide vane SURGE PREVENTION SURGE PREVENTION
LOAD
travel or open the hot gas bypass valve when surge prevention OCCURS TOO SOON OCCURS TOO LATE
is needed. These points should be set based on individual At low loads Increase P1 by Decrease P1 by
chiller operating conditions. (<50%) 2 psid (14 kPad) 2 psid (14 kPad)
A label that lists the configuration values of the controls is At high loads Increase P2 by Decrease P2 by
(>50%) 2 psid (14 kPad) 2 psid (14 kPad)
located on the inside of the unit’s control panel. These values
are based upon the original selection of the chiller. Job site con- The differential pressure (∆P) and temperature (∆T) can be
ditions may require a slight modification to these parameters. monitored during chiller operation by viewing ACTIVE
If after configuring a value for these points, surge preven- DELTA P and ACTIVE DELTA T (HEAT_EX screen). Com-
tion is operating too soon or too late for conditions, these pa- paring SURGE/HGBP DELTA T to ACTIVE DELTA T will de-
rameters should be changed by the operator. termine when the SURGE PREVENTION function will occur.
An example of such a configuration is shown below. The smaller the difference between the SURGE/HGBP DELTA
T and the ACTIVE DELTA T values, the closer to surge
Refrigerant: HCFC-134a prevention.
Estimated Minimum Load Conditions: Units with VFD — On units with VFD further adjustments can
44 F (6.7 C) LCW be made if response to surge prevention or protection is not
45.5 F (7.5 C) ECW functioning as desired. VFD GAIN and VFD INCREASE STEP
43 F (6.1 C) Suction Temperature can be adjusted to allow for more aggressive changes in speed
70 F (21.1 C) Condensing Temperature when surge prevention or protection is active.
Estimated Maximum Load Conditions: CONFIGURE DIFFUSER CONTROL IF NECES-
44 F (6.7 C) LCW SARY — If the compressor is equipped with a variable dif-
54 F (12.2 C) ECW fuser, (size 5 compressor) access the SETUP2 screen. Scroll to
42 F (5.6 C) Suction Temperature DIFFUSER CONTROL and press the ENABLE softkey.
98 F (36.7 C) Condensing Temperature Compare the diffuser and guide vane values (GUIDE VANE
Calculate Maximum Load — To calculate the maximum load 25% LOAD PT, GUIDE VANE 50% LOAD PT, GUIDE VANE
points, use the design load condition data. If the chiller full load 75% LOAD PT, DIFFUSER 25% LOAD POINT, DIFFUSER
cooler temperature difference is more than 15 F (8.3 C), esti- 50% LOAD POINT, DIFFUSER 75% LOAD POINT) to the
mate the refrigerant suction and condensing temperatures at values located on the label inside the control panel. See
this difference. Use the proper saturated pressure and tempera- Fig. 12.
ture for the particular refrigerant used. Compressors with variable diffuser control have actuators
Suction Temperature: tested and stamped with the milliamp (mA) value that results in
42 F (5.6 C) = 37 psig (255 kPa) saturated 100% actuator rotation. This value is configured on the
refrigerant pressure (HFC-134a) SETUP2 screen. It is labeled DIFFUSER FULL SPAN mA.
Condensing Temperature: MODIFY EQUIPMENT CONFIGURATION IF NECES-
SARY — The EQUIPMENT SERVICE table has screens to
98 F (36.7 C) = 120 psig (1827 kPa) saturated select, view, or modify parameters. Carrier’s certified drawings
refrigerant pressure (HFC-134a) have the configuration values required for the jobsite. Modify
Maximum Load ∆T2: these values only if requested.
54 – 44 = 10º F (12.2 – 6.7 = 5.5º C) SERVICE Screen Modifications — Change the values on
Maximum Load ∆P2: these screens according to specific job data. See the certified
120 – 37 = 83 psid (827 – 255 = 572 kPad) drawings for the correct values. Modifications can include:
To avoid unnecessary surge prevention, add about 10 psid • chilled water reset
(70 kPad) to ∆P2 from these conditions: • entering chilled water control (Enable/Disable)
• 4 to 20 mA demand limit
∆T2 = 10º F (5.5º C) • auto restart option (Enable/Disable)
∆P2 = 93 psid (642 kPad) • remote contact option (Enable/Disable)
61
Owner-Modified CCN Tables — The following EQUIP- COOLER CONDENSER PRESSURE TRANSDUCER
MENT CONFIGURATION screens are described for refer- AND WATERSIDE FLOW DEVICE CALIBRATION —
ence only. Calibration can be checked by comparing the pressure read-
OCCDEFCS — The OCCDEFCS screen contains the Local ings from the transducer to an accurate refrigeration gage read-
and CCN time schedules, which can be modified here or on the ing. These readings can be viewed or calibrated from the
SCHEDULE screen as described previously. HEAT_EX screen on the CVC. The transducer can be checked
and calibrated at 2 pressure points. These calibration points are
HOLIDAYS — From the HOLIDAYS screen, the days of the 0 psig (0 kPa) and between 25 and 250 psig (173 and
year that holidays are in effect can be configured. See the holi- 1724 kPa). To calibrate these transducers:
day paragraphs in the Controls section for more details.
1. Shut down the compressor, cooler, and condenser pumps.
BRODEF — The BRODEF screen defines the start and end of
daylight savings time. Enter the dates for the start and end of NOTE: There should be no flow through the heat ex-
daylight savings if required for your location. BRODEF also changers.
activates the Broadcast function which enables the holiday 2. Disconnect the transducer in question from its Schrader
periods that are defined on the CVC to take effect. fitting for cooler or condenser transducer calibration. For
Other Tables — The CONSUME, NET_OPT, and RUN- oil pressure or flow device calibration keep transducer in
TIME screens contain parameters used with a CCN system. place.
See the applicable CCN manual for more information on these NOTE: If the cooler or condenser vessels are at 0 psig
screens. These tables can only be defined from a CCN Build- (0 kPa) or are open to atmospheric pressure, the transduc-
ing Supervisor. ers can be calibrated for zero without removing the trans-
ducer from the vessel.
Perform a Control Test — Check the safety controls
status by performing an automated control test. Access the 3. Access the HEAT_EX screen and view the particular
CONTROL TEST table and select a test to be performed func- transducer reading (the EVAPORATOR PRESSURE or
tion (Table 9). CONDENSER PRESSURE parameter on the HEAT_EX
screen). To calibrate oil pressure or waterside flow de-
The Automated Control Test checks all outputs and inputs vice, view the particular reading (CHILLED WATER
for function. The compressor must be in the OFF mode to op- DELTA P and CONDENSER WATER DELTA P on the
erate the controls test. The compressor can be put in OFF mode HEAT_EX screen and OIL PUMP DELTA P on the
by pressing the STOP push-button on the CVC. Each test asks COMPRESS screen). It should read 0 psi (0 kPa). If the
the operator to confirm the operation is occurring and whether reading is not 0 psi (0 kPa), but within ±5 psi (35 kPa),
or not to continue. If an error occurs, the operator can try to ad- the value may be set to zero by pressing the SELECT
dress the problem as the test is being done or note the problem softkey while the appropriate transducer parameter is
and proceed to the next test.
highlighted on the CVC screen. Then press the ENTER
NOTE: Enter guide vane calibration to calibrate guide softkey. The value will now go to zero. No high end
input on CCM (Plug J4 upper terminal 9 and 10). calibration is necessary for OIL PUMP DELTA P or flow
NOTE: If during the control test the guide vanes do not open, devices.
verify the low pressure alarm is not active. (An active low If the transducer value is not within the calibration range,
pressure alarm causes the guide vanes to close.) the transducer returns to the original reading. If the pres-
NOTE: The oil pump test will not energize the oil pump if sure is within the allowed range (noted above), check the
cooler pressure is below –5 psig (–35 kPa). voltage ratio of the transducer. To obtain the voltage ratio,
When the control test is finished or the EXIT softkey is divide the voltage (dc) input from the transducer by the
pressed, the test stops, and the CONTROL TEST menu dis- supply voltage signal (displayed in CONTROL TEST
plays. If a specific automated test procedure is not completed, menu in the CCM PRESSURE TRANSDUCERS
access the particular control test to test the function when screen) or measure across the positive (+ red) and nega-
ready. The CONTROL TEST menu is described in the table tive (– black) leads of the transducer. For example, the
below. condenser transducer voltage input is measured at CCM
terminals J2-4 and J2-5. The voltage ratio must be be-
CCM Pressure Thermistors Check of all thermistors. tween 0.80 and 0.11 for the software to allow calibration.
CCM Pressure Transducers Check of all transducers. Rotate the waterside flow pressure device from the inlet
Checks operation of pump outputs; nozzle to the outlet nozzle and repeat this step. If rotating
pumps are activated. Also tests the waterside flow device does not allow calibration then
Pump associated inputs such as flow or pressurize the transducer until the ratio is within range.
pressure. Then attempt calibration again.
Activation of all on/off outputs indi-
Discrete outputs vidually. 4. A high pressure point can also be calibrated between 25
Guide Vane Check of the guide vane operation.
and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-
lated 250 psig (1724 kPa) pressure (usually from a nitro-
Diffuser Actuator* Check of the diffuser actuator.
gen cylinder). The high pressure point can be calibrated
Pumpdown prevents the low refrig- by accessing the appropriate transducer parameter on the
erant alarm during evacuation so
Pumpdown/Lockout refrigerant can be removed form HEAT_EX screen, highlighting the parameter, pressing
the unit. Also locks the compressor the SELECT softkey, and then using the INCREASE
off and starts the water pumps.
or DECREASE softkeys to adjust the value to the exact
To charge refrigerant and enable
Terminate Lockout the chiller to run after pumpdown pressure on the refrigerant gage. Press the ENTER soft-
lockout. key to finish the calibration. Pressures at high altitude lo-
Calibrates guide vane input on cations must be compensated for, so the chiller tempera-
Guide Vane Calibration CCM. ture/pressure relationship is correct.
*Diffuser tests function only on size 5 compressor with diffuser con- The PIC II does not allow calibration if the transducer is too
trol enabled. far out of calibration. In this case, a new transducer must be
installed and recalibrated.
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.
62
Check Optional Pumpout System Controls Charge Refrigerant into Chiller
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 The transfer, addition, or removal of refrigerant in spring
(1110 kPa) and reset at 130 psig (896 kPa). Ensure the water- isolated chillers may place severe stress on external piping
cooled condenser has been connected. Loosen the compressor if springs have not been blocked in both up and down
holddown bolts to allow free spring travel. Open the compres- directions.
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, Always operate the condenser and chilled water pumps
etc. during charging operations to prevent freeze-ups.
Table 9 — Control Test Menu Functions
The standard 19XR chiller is shipped with the refrigerant
TESTS TO BE already charged in the vessels. However, the 19XR may be or-
PERFORMED DEVICES TESTED dered with a nitrogen holding charge of 15 psig (103 kPa).
1. CCM Thermistors Entering Chilled Water Evacuate the nitrogen from the entire chiller, and charge the
Leaving Chilled Water chiller from refrigerant cylinders.
Entering Condenser Water
Leaving Condenser Water CHILLER EQUALIZATION WITHOUT A PUMPOUT
Remote Reset Sensor UNIT
Comp Discharge Temp
Oil Sump Temp
Comp Motor Winding Temp
Spare Temperature 1
Space Temperature 2 When equalizing refrigerant pressure on the 19XR chiller
2. CCM Pressure Evaporator Pressure after service work or during the initial chiller start-up, do
Transducers Condenser Pressure not use the discharge isolation valve to equalize. Either the
Oil Pump Delta P
Condenser Water Delta P motor cooling isolation valve or the charging hose (con-
Transducer Voltage Ref nected between the pumpout valves on top of the cooler
3. Pumps Chilled Water — Confirm pressure and condenser) should be used as the equalization valve.
Condenser Water — Confirm
Delta P To equalize the pressure differential on a refrigerant isolated
4. Discrete Outputs Oil Heater Relay 19XR chiller, use the terminate lockout function of the CON-
Hot Gas Bypass Relay
Tower Fan Relay Low TROL TEST on the SERVICE menu. This helps to turn on
Tower Fan Relay High pumps and advises the operator on proper procedures.
Alarm Relay The following steps describe how to equalize refrigerant
Shunt Trip Relay
5. Guide Vane Actuator Open/Close
pressure in an isolated 19XR chiller without a pumpout unit.
6. Diffuser Actuator Open/Close 1. Access terminate lockout function on the CONTROL
7. Pumpdown Lockout When using pumpdown/lockout, TEST screen.
observe freeze up precautions 2. IMPORTANT: Turn on the chilled water and con-
when removing charge:
Instructs operator which valves to denser water pumps to prevent freezing.
close and when.
Starts chilled water and condenser 3. Slowly open the refrigerant cooling isolation valve. The
water pumps and confirms flows.
chiller cooler and condenser pressures will gradually
Monitors equalize. This process takes approximately 15 minutes.
Evaporator pressure
Condenser pressure 4. Once the pressures have equalized, the cooler isolation
Evaporator temperature during valve, the condenser isolation valve, and the hot gas isola-
pumpout procedures tion valve may now be opened. Refer to Fig. 29 and 30,
Turns pumps off after pumpdown. for the location of the valves.
Locks out compressor.
8 Terminate Lockout Starts pumps and monitors flows.
Instructs operator which valves to
open and when. Whenever turning the discharge isolation valve, be sure to
Monitors reattach the valve locking device. This prevents the valve
Evaporator pressure from opening or closing during service work or during
Condenser pressure chiller operation.
Evaporator temperature during
charging process
CHILLER EQUALIZATION WITH PUMPOUT UNIT —
Terminates compressor lockout.
The following steps describe how to equalize refrigerant pres-
sure on an isolated 19XR chiller using the pumpout unit.
High Altitude Locations — Because the chiller is ini- 1. Access the terminate lockout function on the CONTROL
tially calibrated at sea level, it is necessary to recalibrate the TEST screen.
pressure transducers if the chiller has been moved to a high alti- 2. IMPORTANT: Turn on the chilled water and con-
tude location. See the calibration procedure in the Trouble- denser water pumps to prevent freezing.
shooting Guide section.
63
3. Open valve 4 on the pumpout unit and open valves 1a and If the chiller has been shipped with a holding charge, the
1b on the chiller cooler and condenser, Fig. 29 and 30. refrigerant is added through the pumpout charging connection
Slowly open valve 2 on the pumpout unit to equalize the (Fig. 29 and 30, valve 1b). First evacuate the nitrogen holding
pressure. This process takes approximately 15 minutes. charge from the chiller vessels. Charge the refrigerant as a gas
4. Once the pressures have equalized, the discharge isola- until the system pressure exceeds 35 psig (141 kPa) for
tion valve, cooler isolation valve, optional hot gas bypass HFC-134a. After the chiller is beyond this pressure the refrig-
isolation valve, and the refrigerant isolation valve can be erant should be charged as a liquid until all the recommended
opened. Close valves 1a and 1b, and all pumpout unit refrigerant charge has been added. The charging valve (Fig. 29
valves. 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
Whenever turning the discharge isolation valve, be sure to shipped with the correct charge for the design duty of the chill-
reattach the valve locking device. This prevents the valve er. Trimming the charge can best be accomplished when the
from opening or closing during service work or during design load is available. To trim the charge, check the tempera-
chiller operation. ture difference between the leaving chilled water temperature
and cooler refrigerant temperature at full load design condi-
The full refrigerant charge on the 19XR will vary with chill- tions. If necessary, add or remove refrigerant to bring the
er components and design conditions, as indicated on the job temperature difference to design conditions or minimum
data specifications. An approximate charge may be determined differential.
by adding the condenser charge to the cooler charge as listed in
Table 10. 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.
Always operate the condenser and chilled water pumps INITIAL START-UP
whenever charging, transferring, or removing refrigerant
from the chiller. Preparation — Before starting the chiller, verify:
1. Power is on to the main starter, oil pump relay, tower fan
Use the CONTROL TEST terminate lockout function to starter, oil heater relay, and the chiller control panel.
monitor conditions and start the pumps.
2. Cooling tower water is at proper level and at-or-below
Table 10 — Refrigerant (HFC-134a) Charge design entering temperature.
REFRIGERANT REFRIGERANT 3. Chiller is charged with refrigerant and all refrigerant and
COOLER CHARGE CONDENSER CHARGE oil valves are in their proper operating positions.
CODE CODE
lb kg lb kg 4. Oil is at the proper level in the reservoir sight glasses.
10 290 132 10 200 91 5. Oil reservoir temperature is above 140 F (60 C) or above
11 310 141 11 200 91
12 330 150 12 200 91 refrigerant temperature plus 50° F (28° C).
15 320 145 15 250 113 6. Valves in the evaporator and condenser water circuits are
16 340 154 16 250 113
17 370 168 17 250 113 open.
20 345 157 20 225 102 NOTE: If the pumps are not automatic, ensure water is
21 385 175 21 225 102 circulating properly.
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 Do not permit water or brine that is warmer than 110 F
37 550 250 37 310 141 (43 C) to flow through the cooler or condenser. Refrigerant
40 560 254 40 280 127 overpressure may discharge through the relief valves and
41 630 286 41 280 127 result in the loss of refrigerant charge.
42 690 313 42 280 127
45 640 290 45 330 150
46 720 327 46 330 150 7. Access the CONTROL TEST screen. Scroll down on the
47 790 358 47 330 150 TERMINATE LOCKOUT option. Press the SELECT (to
50 750 340 50 400 181 enable the chiller to start) and answer YES to reset unit to
51 840 381 51 400 181 operating mode. The chiller is locked out at the factory in
52 900 408 52 400 181
55 870 395 55 490 222 order to prevent accidental start-up.
56 940 426 56 490 222
57 980 445 57 490 222 Dry Run to Test Start-Up Sequence
60 940 426 60 420 190 For electro-mechanical starters.
61 980 445 61 420 190
62 1020 463 62 420 190 1. Disengage the main motor disconnect (CB1) on the start-
65 1020 463 65 510 231 er front panel. This should only disconnect the motor
66 1060 481 66 510 231
67 1090 494 67 510 231 power. Power to the controls, oil pump, and starter con-
70 1220 553 70 780 354 trol circuit should still be energized.
71 1340 608 71 780 354 2. Observe the default screen on the CVC: the status mes-
72 1440 653 72 780 354
75 1365 619 75 925 420 sage in the upper left-hand corner reads, “Manually
76 1505 683 76 925 420 Stopped,” Press the CCN or LOCAL softkey to start.
77 1625 737 77 925 420 If the chiller controls do not go into a start mode (“Unoc-
80 1500 680 80 720 327 cupied Mode” is displayed) go to the SCHEDULE screen
81 1620 735 81 720 327
82 1730 785 82 720 327 and override the schedule or change the occupied
85 1690 766 85 860 390 time. Press the LOCAL softkey to begin the start-up
86 1820 825 86 860 390 sequences.
87 1940 880 87 860 390
64
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 Fig. 33 — Correct Motor Rotation
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. To Prevent Accidental Start-Up — A chiller STOP
3. The PIC II eventually shows an alarm for motors amps override setting may be entered to prevent accidental start-up
not sensed. Reset this alarm and enter MENU 4 in the during service or whenever necessary. Access the MAINSTAT
Benshaw display. Select Dry Run Mode and scroll to NO. screen and using the NEXT or PREVIOUS softkeys, high-
Continue with the initial start-up. light the CHILLER START/STOP parameter. Override the cur-
rent START value by pressing the SELECT softkey. Press the
Check Motor Rotation STOP softkey followed by the ENTER softkey. The word
1. Engage the oil pump circuit breaker (CB3) located inside SUPVSR! displays on the CVC indicating the override is in
the right hand side of the starter panel. place.
2. Then engage the control power circuit breaker (CB2) lo- To restart the chiller the STOP override setting must be re-
cated in the same section of the starter cabinet. moved. Access the MAINSTAT screen and using NEXT or
3. Finally close the main motor disconnect (CB1) on the PREVIOUS softkeys highlight CHILLER START/STOP. The
front of the starter panel. 3 softkeys that appear represent 3 choices:
4. The ISM mounted in the electro-mechanical starters • START — forces the chiller ON
checks for proper phase rotation as soon as power is • STOP — forces the chiller OFF
applied to the starter and the PIC II controls power up. • RELEASE — puts the chiller under remote or schedule
Solid-state starters have phase protection and do not per- control.
mit a start if the phase rotation is not correct.
To return the chiller to normal control, press the
5. An alarm message will appear on the CVC if the phase RELEASE softkey followed by the ENTER softkey. For
rotation is incorrect. If this occurs reverse any 2 of the 3 more information, see Local Start-Up, page 46.
incoming power leads to the starter and reapply power.
The motor is now ready for a rotation check. The default CVC screen message line indicates which com-
mand is in effect.
6. After the default screen status message states ‘Ready to
Start’ press the LOCAL softkey. The PIC II control per- Check Chiller Operating Condition — Check to
forms start-up checks. be sure that chiller temperatures, pressures, water flows, and
7. When the starter is energized and the motor begins to oil and refrigerant levels indicate the system is functioning
turn, check for clockwise motor rotation (Fig. 33). properly.
Instruct the Customer Operator — Ensure the op-
erator(s) understand all operating and maintenance procedures.
Do not check motor rotation during coastdown. Rotation Point out the various chiller parts and explain their function as
may have reversed during equalization of vessel pressures. part of the complete system.
COOLER-CONDENSER — Float chamber, relief valves, re-
Check Oil Pressure and Compressor Stop frigerant charging valve, temperature sensor locations, pressure
1. When the motor is at full speed, note the differential oil transducer locations, Schrader fittings, waterboxes and tubes,
pressure reading on the CVC default screen. It should be and vents and drains.
between 18 and 30 psid (124 to 206 kPad). OPTIONAL PUMPOUT STORAGE TANK AND PUMP-
2. Press the Stop button and listen for any unusual sounds OUT SYSTEM — Transfer valves and pumpout system,
from the compressor as it coasts to a stop. refrigerant charging and pumpdown procedure, and relief
devices.
65
MOTOR COMPRESSOR ASSEMBLY — Guide vane actu- the high temperature. Do not restart the chiller until
ator, transmission, motor cooling system, oil cooling system, corrected.
temperature and pressure sensors, oil sight glasses, integral oil 3. The oil level should be visible anywhere in one of the two
pump, isolatable oil filter, extra oil and motor temperature sen- sight glasses. Foaming oil is acceptable as long as the oil
sors, synthetic oil, and compressor serviceability. pressure and temperature are within limits.
MOTOR COMPRESSOR LUBRICATION SYSTEM — 4. The oil pressure should be between 18 and 30 psid (124
Oil pump, cooler filter, oil heater, oil charge and specification, to 207 kPad) differential, as seen on the CVC default
operating and shutdown oil level, temperature and pressure, screen. Typically the reading will be 18 to 25 psid (124 to
and oil charging connections. 172 kPad) at initial start-up.
CONTROL SYSTEM — CCN and LOCAL start, reset, 5. The moisture indicator sight glass on the refrigerant
menu, softkey functions, CVC operation, occupancy schedule, motor cooling line should indicate refrigerant flow and a
set points, safety controls, and auxiliary and optional controls. dry condition.
AUXILIARY EQUIPMENT — Starters and disconnects, 6. The condenser pressure and temperature varies with the
separate electrical sources, pumps, and cooling tower. chiller design conditions. Typically the pressure will
DESCRIBE CHILLER CYCLES — Refrigerant, motor range between 100 and 210 psig (690 to 1450 kPa) with
cooling, lubrication, and oil reclaim. a corresponding temperature range of 60 to 105 F (15 to
REVIEW MAINTENANCE — Scheduled, routine, and ex- 41 C). The condenser entering water temperature should
tended shutdowns, importance of a log sheet, importance of be controlled below the specified design entering
water treatment and tube cleaning, and importance of maintain- water temperature to save on compressor kilowatt
ing a leak-free chiller. requirements.
SAFETY DEVICES AND PROCEDURES — Electrical dis- 7. Cooler pressure and temperature also will vary with the
connects, relief device inspection, and handling refrigerant. design conditions. Typical pressure range will be between
60 and 80 psig (410 and 550 kPa), with temperature rang-
CHECK OPERATOR KNOWLEDGE — Start, stop, and ing between 34 and 45 F (1 and 8 C).
shutdown procedures, safety and operating controls, refrigerant
and oil charging, and job safety. 8. The compressor may operate at full capacity for a short
time after the pulldown ramping has ended, even though
REVIEW THE START-UP OPERATION, AND MAINTE- the building load is small. The active electrical demand
NANCE MANUAL. setting can be overridden to limit the compressor IkW, or
the pulldown rate can be decreased to avoid a high
OPERATING INSTRUCTIONS demand charge for the short period of high demand oper-
ation. Pulldown rate can be based on load rate or temper-
Operator Duties ature rate. It is accessed on the Equipment SERVICE
1. Become familiar with the chiller and related equipment screen, RAMP_DEM table (Table 2, Example 21).
before operating the chiller.
To Stop the Chiller
2. Prepare the system for start-up, start and stop the chiller,
and place the system in a shutdown condition. 1. The occupancy schedule starts and stops the chiller auto-
matically once the time schedule is configured.
3. Maintain a log of operating conditions and document any
abnormal readings. 2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed.
4. Inspect the equipment, make routine adjustments, and The compressor will then follow the normal shutdown
perform a Control Test. Maintain the proper oil and re- sequence as described in the Shutdown Sequence, Start-
frigerant levels. Up/Shutdown/Recycle Sequence section, page 46. The
5. Protect the system from damage during shutdown peri- chiller will not restart until the CCN or LOCAL soft-
ods. key is pressed. The chiller is now in the OFF control
6. Maintain the set point, time schedules, and other PIC mode.
functions.
IMPORTANT: Do not attempt to stop the chiller by
Prepare the Chiller for Start-Up — Follow the opening an isolating knife switch. High intensity arcing
steps described in the Initial Start-Up section, page 64. may occur.
To Start the Chiller
Do not restart the chiller until the problem is diagnosed
1. Start the water pumps, if they are not automatic. and corrected.
2. On the CVC default screen, press the LOCAL or CCN After Limited Shutdown — No special preparations
softkey to start the system. If the chiller is in the should be necessary. Follow the regular preliminary checks and
OCCUPIED mode and the start timers have expired, the starting procedures.
start sequence will start. Follow the procedure described
in the Start-Up/Shutdown/Recycle Sequence section, Preparation for Extended Shutdown — The re-
page 46. frigerant should be transferred into the pumpout storage tank
(if supplied; see Pumpout and Refrigerant Transfer Procedures)
Check the Running System — After the compres- to reduce chiller pressure and the possibility of leaks. Maintain
sor starts, the operator should monitor the CVC display and a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant or
observe the parameters for normal operating conditions: nitrogen to prevent air from leaking into the chiller.
1. The oil reservoir temperature should be above 120 F If freezing temperatures are likely to occur in the chiller ar-
(49 C) during shutdown and above 125 F (58 C) during ea, drain the chilled water, condenser water, and the pump-out
compressor operation. condenser water circuits to avoid freeze-up. Keep the waterbox
2. The bearing oil temperature accessed on the COMPRESS drains open.
table should be 120 to 165 F (49 to 74 C). If the bearing Leave the oil charge in the chiller with the oil heater and
temperature reads more than 180 F (83 C) with the oil controls energized to maintain the minimum oil reservoir
pump running, stop the chiller and determine the cause of temperature.
66
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 Always run the chiller cooler and condenser water pumps
is a good time to brush the tubes and inspect the Schrader fit- and always charge or transfer refrigerant as a gas when the
tings on the waterside flow devices for fouling, if necessary. chiller pressure is less than 30 psig (207 kPa). Below these
Check the cooler pressure on the CVC default screen and pressures, liquid refrigerant flashes into gas, resulting in
compare it to the original holding charge that was left in the extremely low temperatures in the cooler/condenser tubes
chiller. If (after adjusting for ambient temperature changes) any and possibly causing tube freeze-up.
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. During transfer of refrigerant into and out of the optional
Carefully make all regular preliminary and running system storage tank, carefully monitor the storage tank level gage.
checks. Perform a Control Test before start-up. If the compres- Do not fill the tank more than 90% of capacity to allow for
sor oil level appears abnormally high, the oil may have refrigerant expansion. Overfilling may result in damage to
absorbed refrigerant. Ensure that the oil temperature is above the tank or personal injury.
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- Do not mix refrigerants from chillers that use different
perature up. Piping may also be arranged to bypass the cooling compressor oils. Compressor damage can result.
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 Operating the Optional Pumpout Unit
ISM). 1. Be sure that the suction and the discharge service valves
Manual Guide Vane Operation — It is possible to on the optional pumpout compressor are open (back-
manually operate the guide vanes in order to check control seated) during operation. Rotate the valve stem fully
operation or to control the guide vanes in an emergency. Manu- counterclockwise to open. Frontseating the valve closes
al operation is possible by overriding the target guide vane the refrigerant line and opens the gage port to compressor
position. Access the COMPRESS screen on the CVC and pressure.
scroll down to highlight TARGET GUIDE VANE POS. To con- 2. Ensure that the compressor holddown bolts have been
trol the position, use the INCREASE or DECREASE soft- loosened to allow free spring travel.
key to adjust to the percentage of guide vane opening that is 3. Open the refrigerant inlet valve on the pumpout
desired. Zero percent is fully closed; 100% is fully open. To compressor.
release the guide vanes to automatic control, press the
4. Oil should be visible in the pumpout unit compressor
RELEASE softkey. sight glass under all operating conditions and during
NOTE: Manual control overrides the configured pulldown rate shutdown. If oil is low, add oil as described under
during start-up and permits the guide vanes to open at a faster Optional Pumpout System Maintenance section, page 75.
rate. Motor current above the electrical demand setting, capac- The pumpout unit control wiring schematic is detailed in
ity overrides, and chilled water temperature below the control Fig. 35.
point override the manual target and close the guide vanes. For
descriptions of capacity overrides and set points, see the Con- TO READ REFRIGERANT PRESSURES during pumpout or
trols section. leak testing:
1. The CVC display on the chiller control panel is suitable
Refrigeration Log — A refrigeration log (as shown in for determining refrigerant-side pressures and low (soft)
Fig. 34), is a convenient checklist for routine inspection and vacuum. To assure the desired range and accuracy when
maintenance and provides a continuous record of chiller per- measuring evacuation and dehydration, use a quality vac-
formance. It is also an aid when scheduling routine mainte- uum indicator or manometer. This can be placed on the
nance and diagnosing chiller problems. Schrader connections on each vessel (Fig. 9) by removing
Keep a record of the chiller pressures, temperatures, and liquid the pressure transducer.
levels on a sheet similar to the one in Fig. 34. Automatic 2. To determine pumpout storage tank pressure, a 30 in.
recording of PIC II data is possible by using CCN devices such -0-400 psi (-101-0-2769 kPa) gage is attached to the stor-
as the Data Collection module and a Building Supervisor. age tank.
Contact a Carrier representative for more information. 3. Refer to Fig. 29, 30, and 36 for valve locations and
numbers.
PUMPOUT AND REFRIGERANT
TRANSFER PROCEDURES
Preparation — The 19XR may come equipped with an Transfer, addition, or removal of refrigerant in spring-
optional pumpout storage tank, pumpout system, or pumpout
compressor. The refrigerant can be pumped for service work to isolated chillers may place severe stress on external piping
either the chiller compressor vessel or chiller condenser vessel if springs have not been blocked in both up and down
by using the optional pumpout system. If a pumpout storage directions.
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.
67
DATE
REFRIGERATION LOG CARRIER 19XR HERMETIC CENTRIFUGAL REFRIGERATION MACHINE

Plant MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPE
DATE COOLER CONDENSER COMPRESSOR
Refrigerant Water Refrigerant Water Oil Motor
OPER-
Pressure Temp Pressure Temp FLA ATOR REMARKS
BEARING Temp
TIME Press. Amperage INITIALS
Press. Temp Press. Temp TEMP (reser- Level
In Out GPM In Out In Out GPM In Out Diff. (or vane
voir)
position)
68
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water
drained from dehydrator. Include amounts.
Fig. 34 — Refrigeration Log
If the chilled water and condenser water pumps are not
controlled by the PIC II, these pumps must be started and
stopped manually at the appropriate times during the refrig-
erant transfer procedure.
b. Close pumpout unit valves 2, 4, 5, 8, and 10, and
close chiller charging valve 7; open chiller isola-
tion valves 11, 12, 13, and 14 (if present).
c. Open pumpout unit/storage tank valves 3 and 6,
open chiller valves 1a and 1b.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C
LEGEND
C — Contactor
FU — Fuse, 3 Amps
HP — High-Pressure Cutout
OL — Compressor Overload Follow Steps d and e carefully to prevent damage from
T’STAT — Internal Thermostat freeze-up.
Compressor Terminal
Contactor Terminal d. Slowly open valve 5 to increase chiller pressure to
68 psig 35 psig (141 kPa) for HFC-134a. Feed
Overload Terminal
refrigerant slowly to prevent freeze up.
Pumpout Unit Terminal
e. Open valve 5 fully after the pressure rises above
*Bimetal thermal protector imbedded in motor winding. the freeze point of the refrigerant. Open liquid line
valves 7 and 10 until refrigerant pressure
Fig. 35 — 23XL Pumpout Unit Wiring Schematic
equalizes.
OIL RETURN VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
LINE
CONNECTION CONDITION C C C
2. Transfer the remaining refrigerant.

a. Close valve 5 and open valve 4.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
b. Turn off the chiller water pumps using the CVC

(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.
CONDENSER REFRIGERANT
WATER VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
INLET VALVE
CONNECTIONS CONDITION C C C C
Fig. 36 — Optional Pumpout Unit h. Turn on the pumpout condenser water.

i. Run the pumpout compressor until the pumpout
storage tank pressure reaches 5 psig (34 kPa)
Chillers with Storage Tanks — If the chiller has iso- (18 in. Hg [40 kPa absolute] if repairing the tank).
lation valves, leave them open for the following procedures.
The letter “C” describes a closed valve. See Fig. 17, 18, 29, j. Turn off the pumpout compressor.
and 30. k. Close valves 1a, 1b, 2, 5, 6, and 10.
TRANSFER REFRIGERANT FROM PUMPOUT STOR- VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
AGE TANK TO CHILLER CONDITION C C C C C C C C C C
1. Equalize refrigerant pressure.
l. Turn off pumpout condenser water.
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.
69
TRANSFER REFRIGERANT FROM CHILLER TO PUMP- Chillers with Isolation Valves
OUT STORAGE TANK TRANSFER ALL REFRIGERANT TO CHILLER CON-
1. Equalize refrigerant pressure. DENSER VESSEL — For chillers with isolation valves,
a. Valve positions: refrigerant can be stored in one chiller vessel or the other with-
out the need for an external storage tank.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
1. Push refrigerant into the chiller condenser.
CONDITION C C C C C
a. Valve positions:
b. Slowly open valve 5. When the pressures are
equalized, open liquid line valve 7 to allow liquid VALVE 1a 1b 2 3 4 5 8 11 12 13 14
refrigerant to drain by gravity into the pumpout CONDITION C C C C C C
storage tank. b. Using the PIC II controls, turn off the chiller water
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14 pumps and pumpout condenser water. If the chiller
CONDITION C C C water pumps are not controlled through the PIC II,
turn them off manually.
2. Transfer the remaining liquid. c. Turn on the pumpout compressor to push the liq-
a. Turn off the pumpout condenser water. Place the uid refrigerant out of the chiller cooler vessel.
valves in the following positions: d. When all liquid refrigerant has been pushed into
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14 the chiller condenser vessel, close chiller isolation
C C C
valve 11.
CONDITION
e. Access the PUMPDOWN LOCKOUT screen on
b. Run the pumpout compressor for approximately the PIC II CONTROL TEST table to turn on the
30 minutes; then close valve 10. chiller water pumps. If the chiller water pumps
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
are not controlled by the PIC II, turn them on
manually.
CONDITION C C C C
f. Turn off the pumpout compressor.
c. Turn off the pumpout compressor. 2. Evacuate the refrigerant gas from chiller cooler vessel.
3. Remove any remaining refrigerant. a. Close pumpout compressor valves 2 and 5, and
a. Turn on the chiller water pumps using the PUMP- open valves 3 and 4.
DOWN LOCKOUT screen, accessed from the
CONTROL TEST table. Turn on the pumps man- VALVE 1a 1b 2 3 4 5 8 11 12 13 14
ually, if they are not controlled by the PIC II. CONDITION C C C C C C C
b. Turn on the pumpout condenser water. b. Turn on the pumpout condenser water.
c. Place valves in the following positions: c. Run the pumpout compressor until the chiller
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
cooler vessel pressure reaches 18 in. Hg vac
(40 kPa abs.). Monitor pressures on the CVC and
CONDITION C C C C
on refrigerant gages.
d. Run the pumpout compressor until the chiller d. Close valve 1a.
pressure reaches 30 psig (207 kPa) for HFC-134a. e. Turn off the pumpout compressor.
Then, shut off the pumpout compressor. Warm
condenser water will boil off any entrapped liquid f. Close valves 1b, 3, and 4.
refrigerant and the chiller pressure will rise. VALVE 1a 1b 2 3 4 5 8 11 12 13 14
e. When the pressure rises to 40 psig (276 kPa) for CONDITION C C C C C C C C C C C
HFC-134a, turn on the pumpout compressor until
the pressure again reaches 30 psig (207 kPa), and g. Turn off the pumpout condenser water.
then turn off the pumpout compressor. Repeat this h. Proceed to the PUMPDOWN/LOCKOUT func-
process until the pressure no longer rises. Then, tion accessed from the CONTROL TEST table to
turn on the pumpout compressor and pump until turn off the chiller water pumps and lock out the
the pressure reaches18 in. Hg. (40 kPa absolute). chiller compressor. Turn off the chiller water
f. Close valves 1a, 1b, 3, 4, 6, 7, and 10. pumps manually if they are not controlled by the
PIC II.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
TRANSFER ALL REFRIGERANT TO CHILLER
CONDITION C C C C C C C C C C COOLER VESSEL
g. Turn off the pumpout condenser water and con- 1. Push the refrigerant into the chiller cooler vessel.
tinue to use the PIC II PUMPDOWN LOCKOUT a. Valve positions:
screen functions, which lock out the chiller com-
pressor for operation. VALVE 1a 1b 2 3 4 5 8 11 12 13 14
4. Establish a vacuum for service. CONDITION C C C C C C
To conserve refrigerant, operate the pumpout compressor b. Turn off the chiller water pumps (either through
until the chiller pressure is reduced to 18 in. Hg vac., ref the PIC II controls or manually, if necessary) and
30 in. bar. (40 kPa abs.) following Step 3e. 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
condenser, close the cooler isolation valve 11.
e. Turn off the pumpout compressor.
70
2. Evacuate the refrigerant gas from the chiller condenser GENERAL MAINTENANCE
vessel.
a. Access the PUMPDOWN LOCKOUT function
Refrigerant Properties — The standard refrigerant for
the 19XR chiller is HFC-134a. At normal atmospheric pres-
accessed from the CVC CONTROL TEST table to sure, HFC-134a will boil at –14 F (–25 C) and must, therefore,
turn on the chiller water pumps. Turn the chiller be kept in pressurized containers or storage tanks. The refriger-
water pumps on manually if they are not con- ant is practically odorless when mixed with air and is noncom-
trolled by the PIC II. bustible at atmospheric pressure. Read the Material Safety
b. Close pumpout unit valves 3 and 4; open valves 2 Data Sheet and the latest ASHRAE Safety Guide for Mechani-
and 5. cal Refrigeration to learn more about safe handling of this
refrigerant.
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C
c. Turn on the pumpout condenser water.

d. Run the pumpout compressor until the chiller HFC-134a will dissolve oil and some nonmetallic materi-
condenser pressure reaches 18 in. Hg vac (40 kPa als, dry the skin, and, in heavy concentrations, may dis-
abs.). Monitor pressure at the CVC and at refriger- place enough oxygen to cause asphyxiation. When
ant gages. handling this refrigerant, protect the hands and eyes and
avoid breathing fumes.
e. Close valve 1b.
f. Turn off the pumpout compressor. Adding Refrigerant — Follow the procedures de-
g. Close valves 1a, 2, and 5. scribed in Trim Refrigerant Charge section, this page.
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C C C C C
Always use the compressor pumpdown function in the
h. Turn off the pumpout condenser water. Control Test table to turn on the cooler pump and lock out
i. Proceed to the PUMPDOWN LOCKOUT test the compressor when transferring refrigerant. Liquid refrig-
from the CVC CONTROL TEST table to turn off erant may flash into a gas and cause possible freeze-up
the chiller water pumps and lock out the chiller when the chiller pressure is below 30 psig (207 kPa) for
compressor. Turn off the chiller water pumps man- HFC-134a.
ually if they are not controlled by the PIC II.
RETURN CHILLER TO NORMAL OPERATING Removing Refrigerant — If the optional pumpout sys-
CONDITIONS tem is used, the 19XR refrigerant charge may be transferred to
a pumpout storage tank or to the chiller condenser or cooler
1. Ensure vessel that was opened has been evacuated. vessels. Follow the procedures in the Pumpout and Refrigerant
2. Access the TERMINATE LOCKOUT function CVC Transfer Procedures section when transferring refrigerant from
from the CONTROL TEST table to view vessel pressures one vessel to another.
and turn on chiller water pumps. If the chiller water
pumps are not controlled by the PIC II, turn them on Adjusting the Refrigerant Charge — If the addi-
manually. tion or removal of refrigerant is required to improve chiller per-
3. Open valves 1a, 1b, and 3. formance, follow the procedures given under the Trim Refrig-
erant Charge section, this page.
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C C Refrigerant Leak Testing — Because HFC-134a is
above atmospheric pressure at room temperature, leak testing
4. Slowly open valve 5, gradually increasing pressure in the can be performed with refrigerant in the chiller. Use an elec-
evacuated vessel to 35 psig (141 kPa). Feed refrigerant tronic halide leak detector, soap bubble solution, or ultra-sonic
slowly to prevent tube freeze up. leak detector. Ensure that the room is well ventilated and free
5. Leak test to ensure vessel integrity. from concentration of refrigerant to keep false readings to a
minimum. Before making any necessary repairs to a leak,
6. Open valve 5 fully. transfer all refrigerant from the leaking vessel.
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
C C C C C C C
Leak Rate — It is recommended by ASHRAE that chillers
CONDITION
be taken off line immediately and repaired if the refrigerant
7. Open valve 11 to equalize the liquid refrigerant level be- leak rate for the entire chiller is more than 10% of the operating
tween the vessels. refrigerant charge per year.
8. Close valves 1a, 1b, 3, and 5. In addition, Carrier recommends that leaks totalling less
9. Open isolation valves 12, 13, and 14 (if present). than the above rate but more than a rate of 0.1% of the total
charge per year should be repaired during annual maintenance
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 or whenever the refrigerant is transferred for other service
CONDITION C C C C C C C work.
10. Proceed to the TERMINATE LOCKOUT screen (access- Test After Service, Repair, or Major Leak — If
ed from the CONTROL TEST table) to turn off the water all the refrigerant has been lost or if the chiller has been opened
pumps and enable the chiller compressor for start-up. If for service, the chiller or the affected vessels must be pressure
the chiller water pumps are not controlled by the PIC II, tested and leak tested. Refer to the Leak Test Chiller section to
turn them off manually. perform a leak test.
71
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.
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. Fig. 37 —Guide Vane Actuator Linkage
2. Open the charging valve fully.
3. Slowly open the cylinder regulating valve.
4. Observe the pressure gage on the chiller and close the To remove any excess refrigerant, follow the procedure in
regulating valve when the pressure reaches test level. Do Transfer Refrigerant from Chiller to Pumpout Storage Tank
not exceed 140 psig (965 kPa). section, Steps 1a and b, page 70.
5. Close the charging valve on the chiller. Remove the cop-
per tube if it is no longer required. WEEKLY MAINTENANCE
Repair the Leak, Retest, and Apply Standing Check the Lubrication System — Mark the oil lev-
Vacuum Test — After pressurizing the chiller, test for el on the reservoir sight glass, and observe the level each week
leaks with an electronic halide leak detector, soap bubble solu- while the chiller is shut down.
tion, or an ultrasonic leak detector. Bring the chiller back to at- If the level goes below the lower sight glass, check the oil
mospheric pressure, repair any leaks found, and retest. reclaim system for proper operation. If additional oil is re-
After retesting and finding no leaks, apply a standing vacu- quired, add it through the oil drain charging valve (Fig. 2). A
um test. Then dehydrate the chiller. Refer to the Standing Vacu- pump is required when adding oil against refrigerant pressure.
um Test and Chiller Dehydration section (pages 50 and 53) in The oil charge for the 19XR compressor depends on the com-
the Before Initial Start-Up section. pressor Frame size:
• Frame 2 compressor — 5 gal (18.9 L)
Checking Guide Vane Linkage — When the chiller • Frame 3 compressor — 8 gal (30 L)
is off, the guide vanes are closed and the actuator mechanism is • Frame 4 compressor — 10 gal (37.8 L)
in the position shown in Fig. 37. If slack develops in the drive • Frame 5 compressor — 18 gal (67.8 L)
chain, do the following to eliminate backlash:
The added oil must meet Carrier specifications for the
1. With the chiller shut down and the actuator fully closed, 19XR. Refer to Changing Oil Filter and Oil Changes section
remove the chain guard and loosen the actuator bracket on page 73. Any additional oil that is added should be logged
holddown bolts. by noting the amount and date. Any oil that is added due to oil
2. Loosen guide vane sprocket adjusting bolts. loss that is not related to service will eventually return to the
3. Pry bracket upwards to remove slack, then retighten the sump. It must be removed when the level is high.
bracket holddown bolts. An oil heater is controlled by the PIC II to maintain oil tem-
4. Retighten the guide vane sprocket adjusting bolts. Ensure perature (see the Controls section) when the compressor is off.
that the guide vane shaft is rotated fully in the clockwise The CVC COMPRESS screen displays whether the heater is
direction in order close it fully. energized or not. The heater is energized if the OIL HEATER
RELAY parameter reads ON. If the PIC II shows that the heater
Trim Refrigerant Charge — If, to obtain optimal chill- is energized and if the sump is still not heating up, the power to
er performance, it becomes necessary to adjust the refrigerant the oil heater may be off or the oil level may be too low. Check
charge, operate the chiller at design load and then add or re- the oil level, the oil heater contactor voltage, and oil heater
move refrigerant slowly until the difference between the leav- resistance.
ing chilled water temperature and the cooler refrigerant tem- The PIC II does not permit compressor start-up if the oil
perature reaches design conditions or becomes a minimum. Do temperature is too low. The PIC II continues with start-up only
not overcharge. after the temperature is within allowable limits.
Refrigerant may be added either through the storage tank or
directly into the chiller as described in the Charge Refrigerant
into Chiller section.
72
SCHEDULED MAINTENANCE housing. Fill with the same amount that was removed;
then close the charging valve.
Establish a regular maintenance schedule based on your ac-
tual chiller requirements such as chiller load, run hours, and 10. Remove the hose from the charging valve, open the isola-
water quality. The time intervals listed in this section are of- tion valves to the filter housing, and turn on the power to
fered as guides to service only. the pump and the motor.
Service Ontime — The CVC will display a SERVICE Oil Specification — If oil is added, it must meet the fol-
ONTIME value on the MAINSTAT screen. This value should lowing Carrier specifications:
be reset to zero by the service person or the operator each time Oil Type for units using R-134a . . . . . . . . . . . . . . . . . . Inhibited
major service work is completed so that the time between ser- polyolester-based synthetic
vice can be viewed and tracked. compressor oil formatted for
use with HFC, gear-driven,
Inspect the Control Panel — Maintenance consists of hermetic compressors.
general cleaning and tightening of connections. Vacuum the
cabinet to eliminate dust build-up. If the chiller control mal- ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
functions, refer to the Troubleshooting Guide section for con- The polyolester-based oil (P/N: PP23BZ103) may be
trol checks and adjustments. 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
Ensure power to the control center is off when cleaning and continuous oil monitoring system is functioning and a yearly
tightening connections inside the control panel. oil analysis is performed, the time between oil changes can be
extended.
Check Safety and Operating Controls Monthly —
To ensure chiller protection, the automated Control Test TO CHANGE THE OIL
should be performed at least once per month. See Table 3 1. Transfer the refrigerant into the chiller condenser vessel
for safety control settings. See Table 9 for Control Test (for isolatable vessels) or to a pumpout storage tank.
functions. 2. Mark the existing oil level.
Changing Oil Filter — Change the oil filter on a 3. Open the control and oil heater circuit breaker.
yearly basis or when the chiller is opened for repairs. The 4. When the chiller pressure is 5 psig (34 kPa) or less, drain
19XR has an isolatable oil filter so that the filter may be the oil reservoir by opening the oil charging valve
changed with the refrigerant remaining in the chiller. Use (Fig. 2). Slowly open the valve against refrigerant
the following procedure: pressure.
1. Ensure the compressor is off and the disconnect for the 5. Change the oil filter at this time. See Changing Oil Filter
compressor is open. section.
2. Disconnect the power to the oil pump. 6. Change the refrigerant filter at this time, see the next sec-
3. Close the oil filter isolation valves located behind power tion, Refrigerant Filter.
panel on top of oil pump assembly. 7. Charge the chiller with oil. Charge until the oil level is
4. Connect an oil charging hose from the oil charging valve equal to the oil level marked in Step 2. Turn on the power
(Fig. 2) and place the other end in a clean container suit- to the oil heater and let the PIC II warm it up to at least
able for used oil. The oil drained from the filter housing 140 F (60 C). Operate the oil pump manually, using the
should be used as an oil sample and sent to a laboratory Control Test function, for 2 minutes. For shutdown condi-
for proper analysis. Do not contaminate this sample. tions, the oil level should be full in the lower sight glass.
5. Slowly open the charging valve to drain the oil from the If the oil level is above 1/2 full in the upper sight glass, re-
housing. 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
The oil filter housing is at a high pressure. Relieve this once a year or more often if filter condition indicates a need for
pressure slowly. more frequent replacement. Change the filter by closing the fil-
ter isolation valves (Fig. 4) and slowly opening the flare fittings
6. Once all oil has been drained, place some rags or absor- with a wrench and back-up wrench to relieve the pressure. A
bent material under the oil filter housing to catch any moisture indicator sight glass is located beyond this filter to in-
drips once the filter is opened. Remove the 4 bolts from dicate the volume and moisture in the refrigerant. If the mois-
the end of the filter housing and remove the filter cover. ture indicator indicates moisture, locate the source of water im-
7. Remove the filter retainer by unscrewing the retainer nut. mediately by performing a thorough leak check.
The filter may now be removed and disposed of properly.
Oil Reclaim Filter — The oil reclaim system has a
8. Replace the old filter with a new filter. Install the filter re- strainer on the eductor suction line, a strainer on the discharge
tainer and tighten down the retainer nut. Install the filter pressure line, and a filter on the cooler scavenging line.
cover and tighten the 4 bolts. Replace the filter once per year or more often if filter condition
9. Evacuate the filter housing by placing a vacuum pump on indicates a need for more frequent replacement. Change the fil-
the charging valve. Follow the normal evacuation proce- ter by closing the filter isolation valves and slowly opening the
dures. Shut the charging valve when done and reconnect flare fitting with a wrench and back-up wrench to relieve the
the valve so that new oil can be pumped into the filter pressure. Change the strainers once every 5 years or whenever
refrigerant is evacuated from the cooler.
73
Inspect Refrigerant Float System — Perform this Compressor Bearing and Gear Maintenance —
inspection every 5 years or when the condenser is opened for The key to good bearing and gear maintenance is proper
service. lubrication. Use the proper grade of oil, maintained at rec-
1. Transfer the refrigerant into the cooler vessel or into a ommended level, temperature, and pressure. Inspect the
pumpout storage tank. lubrication system regularly and thoroughly.
2. Remove the float access cover. To inspect the bearings, a complete compressor teardown is
required. Only a trained service technician should remove and
3. Clean the chamber and valve assembly thoroughly. Be examine the bearings. The cover plate on older compressor
sure the valve moves freely. Ensure that all openings are bases was used for factory-test purposes and is not usable
free of obstructions. for bearing or gear inspection. The bearings and gears should
4. Examine the cover gasket and replace if necessary. be examined on a scheduled basis for signs of wear. The
See Fig. 38 for a view of the float valve design. For linear frequency of examination is determined by the hours of chiller
float valve designs, inspect the orientation of the float slide operation, load conditions during operation, and the condition
pin. It must be pointed toward the bubbler tube for proper of the oil and the lubrication system. Excessive bearing wear
operation. can sometimes be detected through increased vibration or
increased bearing temperature. If either symptom appears, con-
Inspect Relief Valves and Piping — The relief valves tact an experienced and responsible service organization for
on this chiller protect the system against the potentially danger- assistance.
ous effects of overpressure. To ensure against damage to the
equipment and possible injury to personnel, these devices must Inspect the Heat Exchanger Tubes and Flow
be kept in peak operating condition. Devices
As a minimum, the following maintenance is required. COOLER AND FLOW DEVICES — Inspect and clean the
1. At least once a year, disconnect the vent piping at the cooler tubes at the end of the first operating season. Because
valve outlet and carefully inspect the valve body and these tubes have internal ridges, a rotary-type tube cleaning
mechanism for any evidence of internal corrosion or rust, system is needed to fully clean the tubes. Inspect the tubes’
dirt, scale, leakage, etc. condition to determine the scheduled frequency for future
cleaning and to determine whether water treatment in the
2. If corrosion or foreign material is found, do not attempt to chilled water/brine circuit is adequate. Inspect the entering and
repair or recondition. Replace the valve. leaving chilled water temperature sensors and flow devices for
3. If the chiller is installed in a corrosive atmosphere or the signs of corrosion or scale. Replace a sensor or Schrader fitting
relief valves are vented into a corrosive atmosphere, in- if corroded or remove any scale if found.
spect the relief valves at more frequent intervals. 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.
Hard scale may require chemical treatment for its preven-

tion or removal. Consult a water treatment specialist for
proper treatment.
LEGEND Water Leaks — The refrigerant moisture indicator on the
1 — Refrigerant Inlet from FLASC Chamber refrigerant motor cooling line (Fig. 2) indicates whether there
2 — Linear Float Assembly
3 — Float Screen is water leakage during chiller operation. Water leaks should be
4 — Bubble Line repaired immediately.
5 — Float Cover
6 — Bubble Line Connection
7 — Refrigerant Outlet to Cooler
8 — Gasket
The chiller must be dehydrated after repair of water leaks.
Fig. 38 — 19XL Float Valve Design See Chiller Dehydration section, page 53.
74
Water Treatment — Untreated or improperly treated wa- OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
ter may result in corrosion, scaling, erosion, or algae. The ser- Use oil conforming to Carrier specifications for reciprocat-
vices of a qualified water treatment specialist should be ob- ing compressor usage. Oil requirements are as follows:
tained to develop and monitor a treatment program. ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Carrier Part Number . . . . . . . . . . . . . . . . . . . . . . . . PP23BZ103
The total oil charge, 4.5 pints (2.6 L), consists of3.5 pints
Water must be within design flow limits, clean, and treated (2.0 L) for the compressor and one additional pint (0.6 L) for
to ensure proper chiller performance and reduce the poten- the oil separator.
tial of tube damage due to corrosion, scaling, erosion, and Oil should be visible in one of the compressor sight glasses
algae. Carrier assumes no responsibility for chiller damage during both operation and at shutdown. Always check the oil
resulting from untreated or improperly treated water. level before operating the compressor. Before adding or chang-
ing oil, relieve the refrigerant pressure as follows:
Inspect the Starting Equipment — Before working 1. Attach a pressure gage to the gage port of either compres-
on any starter, shut off the chiller, open and tag all disconnects sor service valve (Fig. 36).
supplying power to the starter.
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
The disconnect on the starter front panel does not deener- drops to 2 psig (13 kPa).
gize all internal circuits. Open all internal and remote dis- 4. Stop the compressor and isolate the system by closing the
connects before servicing the starter. 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.
Never open isolating knife switches while equipment is OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS
operating. Electrical arcing can cause serious injury. (Fig. 39) — The optional pumpout system high-pressure
switch opens at 161 psig (1110 kPa) and closes at 130 psig
Inspect starter contact surfaces for wear or pitting on me- (896 kPa). Check the switch setting by operating the pumpout
chanical-type starters. Do not sandpaper or file silverplated compressor and slowly throttling the pumpout condenser
contacts. Follow the starter manufacturer’s instructions for water.
contact replacement, lubrication, spare parts ordering, and oth- Ordering Replacement Chiller Parts — When
er maintenance requirements. ordering Carrier specified parts, the following information
Periodically vacuum or blow off accumulated debris on the must accompany an order:
internal parts with a high-velocity, low-pressure blower. • chiller model number and serial number
Power connections on newly installed starters may relax • name, quantity, and part number of the part required
and loosen after a month of operation. Turn power off and re- • delivery address and method of shipment.
tighten. Recheck annually thereafter.
Loose power connections can cause voltage spikes, over-

heating, malfunctioning, or failures.
Check Pressure Transducers — Once a year, the
pressure transducers should be checked against a pressure gage
reading. Check all 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 (EVAPORATOR PRESSURE
and CONDENSER PRESSURE). Attach an accurate set of re-
frigeration gages to the cooler and condenser Schrader fittings.
Compare the two readings. If there is a difference in readings,
the transducer can be calibrated as described in the Trouble-
shooting Guide section. Oil differential pressure (OIL PUMP
DELTA P on the COMPRESS screen) should be zero whenev-
er the compressor is off.
Optional Pumpout System Maintenance — For
pumpout unit compressor maintenance details, refer to the
06D, 07D Installation, Start-Up, and Service Instructions. Fig. 39 — Optional Pumpout System Controls
75
TROUBLESHOOTING GUIDE resistance and corresponding temperature are listed in Table
12A or 12B. Check the resistance of both wires to ground. This
Overview — The PIC II has many features to help the op- resistance should be infinite.
erator and technician troubleshoot a 19XR chiller.
VOLTAGE DROP — The voltage drop across any energized
• The CVC shows the chiller’s actual operating conditions sensor can be measured with a digital voltmeter while the con-
and can be viewed while the unit is running. trol is energized. Table 12A or 12B lists the relationship be-
• The CVC default screen freezes when an alarm occurs. tween temperature and sensor voltage drop (volts dc measured
The freeze enables the operator to view the chiller condi- across the energized sensor). Exercise care when measuring
tions at the time of alarm. The STATUS screens continue voltage to prevent damage to the sensor leads, connector plugs,
to show current information. Once all alarms have been and modules. Sensors should also be checked at the sensor
cleared (by correcting the problems and pressing the plugs. Check the sensor wire at the sensor for 5 vdc if the con-
RESET softkey), the CVC default screen returns to nor- trol is powered on.
mal operation.
• The CONTROL ALGORITHM STATUS screens
(which include the CAPACITY, OVERRIDE,
LL_MAINT,ISM_HIST, LOADSHED, WSMDEFME, Relieve all refrigerant pressure or drain the water before
and OCCDEFCM screens) display information that replacing the temperature sensors.
helps to diagnose problems with chilled water tempera-
ture control, chilled water temperature control overrides, CHECK SENSOR ACCURACY — Place the sensor in a
hot gas bypass, surge algorithm status, and time sched- medium of known temperature and compare that temperature
ule operation. to the measured reading. The thermometer used to determine
• The control test feature facilitates the proper operation the temperature of the medium should be of laboratory quality
and test of temperature sensors, pressure transducers, the with 0.5° F (.25° C) graduations. The sensor in question should
guide vane actuator, oil pump, water pumps, tower con- be accurate to within 2° F (1.2° C).
trol, and other on/off outputs while the compressor is See Fig. 9 for sensor locations. The sensors are immersed
stopped. It also has the ability to lock off the compressor directly in the refrigerant or water circuits. The wiring at each
and turn on water pumps for pumpout operation. The sensor is easily disconnected by unlatching the connector.
CVC shows the temperatures and pressures required These connectors allow only one-way connection to the sensor.
during these operations. When installing a new sensor, apply a pipe sealant or thread
• From other SERVICE tables, the operator/technician can sealant to the sensor threads.
access configured items, such as chilled water resets,
override set points, etc. DUAL TEMPERATURE SENSORS — For servicing con-
• If an operating fault is detected, an alarm message is venience, there are 2 sensors each on the bearing and motor
generated and displayed on the CVC default screen. temperature sensors. If one of the sensors is damaged, the other
A more detailed message — along with a diagnostic can be used by simply moving a wire. The number 2 terminal
message — is also stored into the ALARM HISTORY in the sensor terminal box is the common line. To use the sec-
table. ond sensor, move the wire from the number 1 position to the
number 3 position.
Checking Display Messages — The first area to
check when troubleshooting the 19XR is the CVC display. If Checking Pressure Transducers — There are 8
the alarm light is flashing, check the primary and secondary pressure transducers on 19XR chillers. They determine cooler,
message lines on the CVC default screen (Fig. 14). These mes- condenser, oil pressure, and cooler and condenser flow. The
sages will indicate where the fault is occurring. These messag- cooler and condenser transducers are also used by the PIC II to
es contain the alarm message with a specified code. This code determine the refrigerant temperatures. The oil supply pressure
or state appears with each alarm and alert message. The transducer value and the oil transmission sump pressure trans-
ALARM HISTORY table on the CVC SERVICE menu also ducer value difference is calculated by the CCM. The CVC
contains an alarm message to further expand on the alarm. For module then displays the differential pressure. In effect, the
a complete list of possible alarm messages, see Table 11. If the CVC reads only one input for oil pressure for a total of 5 pres-
alarm light starts to flash while accessing a menu screen, press sure inputs: cooler pressure, condenser pressure, oil differential
the EXIT softkey to return to the default screen to read the pressure, cooler waterside differential pressure, and condenser
alarm message. The STATUS screen can also be accessed to waterside differential pressure. See the Check Pressure
determine where an alarm exists. Transducers section (page 75) under Scheduled Maintenance.
These 5 pressure transducers can be calibrated if necessary.
Checking Temperature Sensors — All tempera- It is not usually necessary to calibrate at initial start-up.
ture sensors are thermistor-type sensors. This means that the re- However, at high altitude locations, it is necessary to calibrate
sistance of the sensor varies with temperature. All sensors have the transducers to ensure the proper refrigerant temperature/
the same resistance characteristics. If the controls are on, deter- pressure relationship. Each transducer is supplied with 5 vdc
mine sensor temperature by measuring voltage drop; if the con- power from the CCM. If the power supply fails, a transducer
trols are powered off, determine sensor temperature by measur- voltage reference alarm occurs. If the transducer reading is
ing resistance. Compare the readings to the values listed in suspected of being faulty, check the supply voltage. It should
Table 12A or 12B. be 5 vdc ± .5 v displayed in CONTROL TEST under CCM
RESISTANCE CHECK — Turn off the control power and, Pressure Transducers. If the supply voltage is correct, the trans-
from the module, disconnect the terminal plug of the sensor in ducer should be recalibrated or replaced.
question. With a digital ohmmeter, measure sensor resistance
between receptacles as designated by the wiring diagram. The
76
TRANSDUCER REPLACEMENT — Since the transducers Control Test — The Control Test feature can check all the
are mounted on Schrader-type fittings, there is no need to re- thermistor temperature sensors, pressure transducers, pumps
move refrigerant from the vessel when replacing the transduc- and their associated flow devices, the guide vane actuator, and
ers. Disconnect the transducer wiring by pulling up on the other control outputs such as hot gas bypass. The tests can help
locking tab while pulling up on the weather-tight connecting to determine whether a switch is defective or a pump relay is
plug from the end of the transducer. Do not pull on the trans- not operating, as well as other useful troubleshooting issues.
ducer wires. Unscrew the transducer from the Schrader fitting. During pumpdown operations, the pumps are energized to pre-
When installing a new transducer, do not use pipe sealer vent freeze-up and the vessel pressures and temperatures are
(which can plug the sensor). Put the plug connector back on the displayed. The Pumpdown/Lockout feature prevents compres-
sensor and snap into place. Check for refrigerant leaks. sor start-up when there is no refrigerant in the chiller or if the
vessels are isolated. The Terminate Lockout feature ends the
Pumpdown/Lockout after the pumpdown procedure is reversed
and refrigerant is added.
Be sure to use a back-up wrench on the Schrader fitting
whenever removing a transducer, since the Schrader fitting LEGEND TO TABLES 11A-11J
may back out with the transducer, causing a large leak and
possible injury to personnel. CCM — Chiller Control Module
CHW — Chilled Water
Control Algorithms Checkout Procedure — One ISM — Integrated Starter Module
of the tables on the CVC SERVICE menu is CONTROL PIC II — Product Integrated Controls II
ALGORITHM STATUS. The maintenance screens may be VFD — Variable Frequency Drive
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:
CAPACITY Capacity This table shows all values used
Control to calculate the chilled water/
brine control point.
OVERRIDE Override Details of all chilled water con-
Status trol override values.
HEAT_EX Surge/ The surge and hot gas bypass
HGBP control algorithm status is
Status viewed from this screen. All
values dealing with this control
are displayed.
LL_MAINT LEAD/LAG Indicates LEAD/LAG operation
Status status.
OCCDEFCM Time The Local and CCN occupied
Schedules schedules are displayed here to
Status help the operator quickly deter-
mine whether the schedule is in
the “occupied” mode or not.
WSMDEFME Water The water system manager is a
System CCN module that can turn on
Manager the chiller and change the
Status chilled water control point. This
screen indicates the
status of this system.
77
Table 11 — CVC Primary and Secondary Messages and
Custom Alarm/Alert Messages with Troubleshooting Guides
A. MANUAL STOP
PRIMARY MESSAGE SECONDARY MESSAGE PROBABLE CAUSE/REMEDY
MANUALLY STOPPED — PRESS CCN OR LOCAL TO START 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.
B. READY TO START
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.
C. IN RECYCLE SHUTDOWN
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.
78
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
PRIMARY SECONDARY ALARM MESSAGE

STATE ADDITIONAL CAUSE/REMEDY
MESSAGE MESSAGE PRIMARY CAUSE
100 PRESTART STARTS LIMIT 100->Excessive compressor Depress the RESET softkey if additional start is
ALERT EXCEEDED starts (8 in 12 hours) required. Reassess start-up requirements.
101 PRESTART HIGH BEARING 101->Comp Thrust Bearing Check oil heater for proper operation.
ALERT TEMPERATURE Temp [VALUE] exceeded Check for low oil level, partially closed coil supply
limit of [LIMIT]*. valves, clogged oil filters, etc.
Check the sensor wiring and accuracy.
Check configurable range in SETUP1 screen.
102 PRESTART HIGH MOTOR 102->Comp Motor Winding Check motor sensors for wiring and accuracy.
ALERT TEMPERATURE Temp [VALUE] exceeded limit Check motor cooling line for proper operation, or
of [LIMIT]*. restrictions.
Check for excessive starts within a short time span.
103 PRESTART HIGH DISCHARGE 103->Comp Discharge Temp Allow discharge sensor to cool.
ALERT TEMP [VALUE] exceeded limit of Check for sensor wiring and accuracy.
[LIMIT]*. Check for excessive starts.
104 PRESTART LOW REFRIGERANT 104->Evaporator Refrig Temp Check transducer wiring and accuracy.
ALERT TEMP [VALUE] exceeded limit of Check for low chilled fluid supply temperatures.
[LIMIT]*. Check refrigerant charge.
105 PRESTART LOW OIL 105->Oil Sump Temp [VALUE] Check oil heater contactor/relay and power.
ALERT TEMPERATURE exceeded limit of [LIMIT]*. Check oil level and oil pump operation.
106 PRESTART HIGH CONDENSER 106->Condenser Pressure Check transducer wiring and accuracy.
ALERT PRESSURE [VALUE] exceeded limit of Check for high condenser water temperatures.
[LIMIT]*.
107 PRESTART LOW LINE 107->Average Line Voltage Check voltage supply. Check voltage transformers.
ALERT VOLTAGE [VALUE] exceeded limit of Consult power utility if voltage is low.
[LIMIT]*.
108 PRESTART HIGH LINE 108->Average Line Voltage Check voltage supply.
ALERT VOLTAGE [VALUE] exceeded limit of Check power transformers.
[LIMIT]*. Consult power utility if voltage is high.
109 PRESTART GUIDE VANE 109->Actual Guide Vane Calibrate guide vane actuator in Control Test.
ALERT CALIBRATION Pos Calibration Required
Before Start-Up
*[LIMIT] is shown on the CVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is
the actual pressure, temperature, voltage, etc., at which the control tripped.
E. START-UP IN PROGRESS
PRIMARY MESSAGE SECONDARY MESSAGE 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.
F. NORMAL RUN
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.
79
G. NORMAL RUN WITH OVERRIDES
PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL

STATE
MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY
120 RUN CAPACITY HIGH CONDENSER 120->Condenser Pressure Check for high condenser water temperatures.
LIMITED PRESSURE [VALUE] exceeded limit of [LIMIT]*.
Check setting in SETUP1.
121 RUN CAPACITY HIGH MOTOR 121->Comp Motor Winding Temp
Check motor cooling lines.
LIMITED TEMPERATURE [VALUE] exceeded limit of [LIMIT]*.
Check for closed valves.
Check setting in SETUP1.
122 RUN CAPACITY LOW EVAP 122->Evaporator Refrig Temp Check refrigerant charge.
LIMITED REFRIG TEMP [VALUE] exceeded limit of [LIMIT]*. Check for low entering cooler temperatures.
123 RUN CAPACITY HIGH COMPRESSOR 123->Surge Prevention Override: Check for high condenser water temperatures or
LIMITED LIFT Lift Too High For Compressor. low suction temperature.
124 RUN CAPACITY MANUAL GUIDE 124->Run Capacity Limited: Target guide vane point has been forced in
LIMITED VANE TARGET Manual Guide Vane Target. MAINSTAT screen. Release force to continue
normal operation.
125 RUN CAPACITY LOW DISCHARGE No messages. Check oil charge.
LIMITED SUPERHEAT Check refrigerant charge.
*[LIMIT] is shown on the CVC 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 condition.
H. OUT-OF-RANGE SENSOR ALARMS

STATE MESSAGE MESSAGE PRIMARY CAUSE CAUSE/REMEDY
260 SENSOR LEAVING CHILLED 260->Sensor Fault: Check sensor resistance or voltage drop.
FAULT WATER Leaving Chilled Water Check for proper wiring.
261 SENSOR ENTERING CHILLED 261->Sensor Fault: Check sensor resistance or voltage drop.
FAULT WATER Entering Chilled Water Check for proper wiring.
262 SENSOR CONDENSER 262->Sensor Fault: Check sensor wiring.
FAULT PRESSURE Condenser Pressure
263 SENSOR EVAPORATOR 263->Sensor Fault: Check sensor wiring.
FAULT PRESSURE Evaporator Pressure
264 SENSOR COMPRESSOR 264->Sensor Fault: Check sensor resistance or voltage drop.
FAULT BEARING TEMP Comp Thrust Bearing Temp Check for proper wiring.
265 SENSOR COMPRESSOR 265->Sensor Fault: Check sensor resistance or voltage drop.
FAULT MOTOR TEMP Comp Motor Winding Temp Check for proper wiring.
266 SENSOR COMP DISCHARGE 266->Sensor Fault: Check sensor resistance or voltage drop.
FAULT TEMP Comp Discharge Temp Check for proper wiring.
267 SENSOR OIL SUMP TEMP 267->Sensor Fault: Check sensor resistance or voltage drop.
FAULT Oil Sump Temp Check for proper wiring.
268 SENSOR COMP OIL 268->Sensor Fault: Check sensor wiring and accuracy.
FAULT PRESS DIFF Oil Pump Delta P
269 SENSOR CHILLED WATER 269->Sensor Fault: Check sensor wiring and accuracy.
FAULT FLOW Chilled Water Delta P
270 SENSOR COND WATER 270->Sensor Fault: Check sensor wiring and accuracy.
FAULT FLOW Cond Water Delta P
271 SENSOR VFD SPEED SENSOR 271->Sensor Fault: Check voltage input on terminals J6-1 and J6-2 on
FAULT OUT OF RANGE Check Actual VFD Speed Sensor the ISM module. Check wiring.
273 SENSOR VFD SPEED OUT OF 273->Sensor Fault: Check VFD feedback 0-5 vac. Calibrate VFD
FAULT RANGE Check Actual VFD Speed Sensor speed reference signal.
80
I. CHILLER PROTECT LIMIT FAULTS

STATE
200 PROTECTIVE 1M CONTACT 200->1M Aux Contact Fault;
LIMIT FAULT Check 1M Contactor and
Aux
201 PROTECTIVE 2M CONTACT 201->2M Aux Contact Fault;
LIMIT FAULT Check 2M Contactor and
Aux
202 PROTECTIVE MOTOR AMPS 202->Motor Amps Not Check for wiring of current transformers to the ISM.
LIMIT NOT SENSED Sensed — Average Line Check main circuit breaker for trip.
Current [VALUE]
203 FAILURE TO EXCESS 203->Motor Acceleration Check to be sure that the inlet guide vanes are closed
START ACCELERATION Fault — Average Line at start-up.
TIME Current [VALUE] Check starter for proper operation.
Reduce unit pressure if possible.
204 FAILURE TO 1M/2M CONTACT 204->1M/2M Aux Contact
STOP FAULT Stop Fault; Check 1M/2M
Contactors and Aux
205 FAILURE TO MOTOR AMPS 205->Motor Amps When
STOP WHEN STOPPED Stopped — Average Line
Current [VALUE]
206 PROTECTIVE STARTER 206->Starter Fault Cutout; For Benshaw Inc. RediStart MICRO™ starters, view
LIMIT FAULT Check Optional Starter fault code at RediStart MICRO display. Press FAULT
Contacts RESET to clear faults.
207 PROTECTIVE HIGH CONDENSER 207->High Cond Pressure Check for high condenser water temperatures, low
LIMIT PRESSURE cutout. [VALUE] exceeded water flow, fouled tubes.
limit of [LIMIT]*. 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 EXCESSIVE 208->Compressor Motor Check motor current for proper calibration.
LIMIT MOTOR AMPS Amps [VALUE] exceeded Check inlet guide vane actuator.
limit of [LIMIT]*.
209 PROTECTIVE LINE PHASE 209->Line Phase Loss; Check transformers to ISM.
LIMIT LOSS Check ISM Fault History to Check power distribution bus.
Identify Phase Consult power company.
210 PROTECTIVE LINE VOLTAGE 210->Single Cycle Line
LIMIT DROPOUT Voltage Dropout
211 PROTECTIVE HIGH LINE 211->High Average Line Check transformers to ISM.
LIMIT VOLTAGE Voltage [VALUE] Check distribution bus.
Consult power company.
212 PROTECTIVE LOW LINE 212->Low Average Line Check transformers to ISM.
LIMIT VOLTAGE Voltage [VALUE] Check distribution bus.
213 PROTECTIVE STARTER MODULE 213->Starter Module Power-
LIMIT RESET On Reset When Running
214 PROTECTIVE POWER LOSS 214->Power Loss: Check transformers to ISM.
LIMIT Check voltage supply Check distribution bus.
215 PROTECTIVE LINE CURRENT 215->Line Current Check upstream equipment.
LIMIT IMBALANCE Imbalance; Check ISM Fault
History to Identify Phase
216 PROTECTIVE LINE VOLTAGE 216->Line Voltage Check upstream equipment.
LIMIT IMBALANCE Imbalance; Check ISM Fault
History to Identify Phase
217 PROTECTIVE MOTOR OVERLOAD 217->Motor Overload Trip; Check ISM configuration.
LIMIT TRIP Check ISM configurations
218 PROTECTIVE MOTOR LOCKED 218->Motor Locked Rotor Check ISM configuration.
LIMIT ROTOR TRIP Amps exceeded; Check
Motor & ISM Config
219 PROTECTIVE STARTER LOCK 219->Starter Locked Rotor Check ISM configuration.
LIMIT ROTOR TRIP Amps Rating exceeded
220 PROTECTIVE GROUND FAULT 220->Ground Fault Trip;
LIMIT Check Motor and Current
Transformers
221 PROTECTIVE PHASE REVERSAL 221->Phase Reversal Trip;
LIMIT TRIP Check Power Supply
222 PROTECTIVE LINE FREQUENCY 222->Line Frequency —
LIMIT TRIP [VALUE] exceeded limit of
[LIMIT]. Check Power
Supply.
223 PROTECTIVE STARTER MODULE 223->Starter Module
LIMIT FAILURE Hardware Failure
81
I. CHILLER PROTECT LIMIT FAULTS (cont)

STATE
227 PROTECTIVE OIL PRESS 227->Oil Pump Delta P Check transducer wiring and accuracy.
LIMIT SENSOR FAULT [VALUE] exceeded limit of Check power supply to pump.
[LIMIT]*. Check pump operation.
Check transducer calibration.
228 PROTECTIVE LOW OIL 228->Oil Pump Delta P Check transducer wiring and accuracy.
LIMIT PRESSURE [VALUE] exceeded limit of Check power supply to pump.
[LIMIT].* Check pump operation.
Check oil level.
Check for partially closed service valves.
Check oil filters.
Check for foaming oil at start-up.
229 PROTECTIVE LOW CHILLED 229->Low Chilled Water Perform pump control test.
LIMIT WATER FLOW Flow; Check Delta P Config Check transducer accuracy and wiring.
& Calibration Check water valves.
230 PROTECTIVE LOW CONDENSER 230->Low Condenser Water Perform pump control test.
LIMIT WATER FLOW Flow; Check Delta P Config Check transducer accuracy and wiring.
& Calibration Check water valves.
231 PROTECTIVE HIGH DISCHARGE 231->Comp Discharge Check sensor resistance or voltage drop.
LIMIT TEMP Temp [VALUE] exceeded Check for proper wiring.
limit of [LIMIT].* 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 LOW REFRIGERANT 232->Evaporator Refrig Check for proper refrigerant charge.
LIMIT TEMP Temp [VALUE] exceeded Check float operation.
limit of [LIMIT]*. Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
233 PROTECTIVE HIGH MOTOR 233->Comp Motor Winding Check motor sensors wiring and accuracy.
LIMIT TEMPERATURE Temp [VALUE] exceeded Check motor cooling line for proper operation, or
limit of [LIMIT]*. restrictions.
Check for excessive starts within a short time span.
234 PROTECTIVE HIGH BEARING 234->Comp Thrust Bearing Check oil heater for proper operation.
LIMIT TEMPERATURE Temp [VALUE] exceeded Check for low oil level, partially closed oil supply
limit of [LIMIT]*. valves, clogged oil filters, etc.
Check the sensor wiring and accuracy.
235 PROTECTIVE HIGH CONDENSER 235->Condenser Pressure Check for high condenser water temperatures, low
LIMIT PRESSURE [VALUE] exceeded limit of water flow, fouled tubes.
[LIMIT]*. Check for division plate/gasket bypass.
Check for noncondensables.
236 PROTECTIVE CCN OVERRIDE 236->CCN Override Stop CCN has signaled the chiller to stop. Reset and
LIMIT STOP while in LOCAL run mode restart when ready. If the signal was sent by the
CVC, release the stop signal on the STATUS01 table.
237 PROTECTIVE SPARE SAFETY 237->Spare Safety Device Spare safety input has tripped or factory installed
LIMIT DEVICE jumper is not present.
238 PROTECTIVE EXCESSIVE 238->Compressor Surge: Check condenser flow and temperatures.
LIMIT COMPR SURGE Check condenser water Check surge protection configuration.
temp and flow
239 PROTECTIVE TRANSDUCER 239->Transducer Voltage
LIMIT VOLTAGE FAULT Ref [VALUE] exceeded limit
of [LIMIT]*.
240 PROTECTIVE LOW DISCHARGE 240->Check for Oil in
LIMIT SUPERHEAT Refrigerant or Overcharge
of Refrigerant
241 LOSS OF WITH STARTER 241->Loss of Communica- Check wiring to ISM.
COMMUNICATION MODULE tion With Starter.
242 LOSS OF WITH CCM 242->Loss of Communica- Check wiring to CCM.
COMMUNICATION MODULE tion With CCM.
243 POTENTIAL EVAP PRESS/TEMP 243->Evaporator Refrig Check for proper refrigerant charge.
FREEZE-UP TOO LOW Temp [VALUE] exceeded Check float operation.
limit of [LIMIT]*. Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
244 POTENTIAL COND PRESS/TEMP 244->Condenser Refrig
FREEZE-UP TOO LOW Temp [VALUE] exceeded
limit of [LIMIT]*.
245 PROTECTIVE VFD SPEED 245->Actual VFD Speed
LIMIT OUT OF RANGE [VALUE] exceeded limit of
[LIMIT]*.
82
I. CHILLER PROTECT LIMIT FAULTS (cont)

STATE
246 PROTECTIVE INVALID DIFFUSER 246->Diffuser Control Invalid Check diffuser/guide vane schedule.
LIMIT CONFIG Configuration:
Check SETUP2 Entries.
247 PROTECTIVE DIFFUSER POSITION 247->Diffuser Position Fault: Check rotating stall transducer wiring and
LIMIT FAULT Check Guide Vane and Diffuser accuracy.
Actuators Check diffuser schedule.
Check for proper operation of diffuser actua-
tor 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 SPARE TEMPERATURE 248->Spare Temperature #1
LIMIT #1 [VALUE] exceeded limit of
[LIMIT]*.
249 PROTECTIVE SPARE TEMPERATURE 249->Spare Temperature #2
LIMIT #2 [VALUE] exceeded limit of
[LIMIT]*.
250 PROTECTIVE REFRIGERANT LEAK 250->Refrigerant Leak Sensor The refrigerant leak detector’s output wired
LIMIT SENSOR [VALUE] exceeded Limit of to J5-5 and J5-6 on the CCM module has
[LIMIT]*. reached the alarm limit.
Check leak detector and for leaks.
251 PROTECTIVE ISM CONFIG 251->ISM Config Conflict (ISM Confirm valid settings in ISM_CONF screen.
LIMIT CONFLICT Uploaded); Verify to Reset
Alarm
252 PROTECTIVE ISM CONFIG 252->ISM Config Conflict (ISM Confirm valid settings in ISM_CONF screen.
LIMIT CONFLICT Downloaded); Verify to Reset
Alarm
253 PROTECTIVE GUIDE VANE 253->Guide Vane Fault Enter Control Test and execute Guide Vane
LIMIT CALIBRATION [VALUE]. Check Calibration. Calibration. Check guide vane feedback
(terminals J4-9 and J4-10) on the CCM
module.
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
J. CHILLER ALERTS

STATE
140 SENSOR ALERT LEAVING COND 140->Sensor Fault: Check sensor resistance or voltage drop.
WATER TEMP Check Leaving Cond Water Check for proper wiring.
Sensor
141 SENSOR ALERT ENTERING COND 141->Sensor Fault: Check sensor resistance or voltage drop.
WATER TEMP Check Entering Cond Water Check for proper wiring.
Sensor
142 LOW OIL PRESSURE CHECK OIL FILTER 142->Low Oil Pressure Alert. Check for partially or closed shut-off valves.
ALERT Check Oil Filter. Check oil filter.
Check oil pump and power supply.
Check oil level.
Check for foaming oil at start-up.
143 AUTORESTART LINE PHASE 143->Line Phase Loss Power loss has been detected in any phase.
PENDING LOSS Chiller automatically restarting.
144 AUTORESTART LINE VOLTAGE 144->Single Cycle Line A drop in line voltage has been detected within
PENDING DROP OUT Voltage Dropout 2 voltage cycles. Chiller automatically restarting if
Autorestart option is enabled.
145 AUTORESTART HIGH LINE 145>Line Overvoltage — Check line power.
PENDING VOLTAGE Average Line Volt [VALUE]
146 AUTORESTART LOW LINE 146->Line Undervoltage — Check line power.
PENDING VOLTAGE Average Line Volt [VALUE]
147 AUTORESTART STARTER MODULE 147->Starter Module Power- ISM has detected a hardware fault and has reset.
PENDING RESET On Reset When Running Chiller automatically restarting.
148 AUTORESTART POWER LOSS 148->Control Power-Loss Check control power.
PENDING When Running
83
J. CHILLER ALERTS (cont)

STATE
149 SENSOR ALERT HIGH DISCHARGE 149->Comp Discharge Temp Check sensor resistance or voltage drop.
TEMP [VALUE] exceeded limit of Check for proper wiring.
[LIMIT]*. 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 150->Comp Thrust Bearing Check sensor resistance or voltage drop.
TEMPERATURE Temp [VALUE] exceeded limit Check for proper wiring.
of [LIMIT]*. Check for partially closed service valves.
Check oil cooler TXV.
Check oil filter.
Check oil level.
151 CONDENSER PUMP RELAY 151->High Condenser Check sensor wiring and accuracy.
PRESSURE ALERT ENERGIZED Pressure [VALUE]: Pump Check condenser flow and fluid
Energized to Reduce temperature.
Pressure. Check for fouled tubes. This alarm is not
caused by the High Pressure Switch.
152 RECYCLE EXCESSIVE RECYCLE 152->Excessive recycle starts. Chiller load is too low to keep compressor on
ALERT STARTS 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: no message; 153->Lead/Lag Disabled: Illegal chiller address configuration in Lead/
ALERT only ALERT only Duplicate Chiller Address; Lag screen. Both chillers require a different
Check Configuration address.
154 POTENTIAL COND PRESS/TEMP 154->Condenser freeze up The condenser pressure transducer is read-
FREEZE-UP TOO LOW prevention 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 REMOTE RESET 155->Sensor Fault/Option Check sensor resistance or voltage drop.
FAULT SENSOR Disabled: Check for proper wiring.
Remote Reset Sensor
156 OPTION SENSOR AUTO CHILLED 156->Sensor Fault/Option Check sensor resistance or voltage drop.
FAULT WATER RESET Disabled: Check for proper wiring.
Auto Chilled Water Reset
157 OPTION SENSOR AUTO DEMAND 157->Sensor Fault/Option Check sensor resistance or voltage drop.
FAULT LIMIT INPUT Disabled: Check for proper wiring.
Auto Demand Limit Input
158 SENSOR ALERT SPARE TEMPERATURE 158->Spare Temperature #1 Check sensor resistance or voltage drop.
#1 [VALUE] exceeded limit of Check for proper wiring.
[LIMIT].*
159 SENSOR ALERT SPARE TEMPERATURE 159->Spare Temperature #2 Check sensor resistance or voltage drop.
#2 [VALUE] exceeded limit of Check for proper wiring.
[LIMIT].*
160 DIFFUSER DIFFUSER 160->Diffuser Position Alert; Check diffuser configuration in SETUP2
ALERT POSITION Check Diffuser Configuration. screen.
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
84
Table 12A — Thermistor Temperature (F) vs Resistance/Voltage Drop
PIC II PIC II PIC II

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE
VOLTAGE VOLTAGE VOLTAGE
(F) DROP (V) (Ohms) (F) DROP (V) (Ohms) (F) DROP (V) (Ohms)
–25 4.700 98,010 60 2.756 7,665 145 0.769 1,141
–24 4.690 94,707 61 2.724 7,468 146 0.756 1,118
–23 4.680 91,522 62 2.692 7,277 147 0.744 1,095
–22 4.670 88,449 63 2.660 7,091 148 0.731 1,072
–21 4.659 85,486 64 2.628 6,911 149 0.719 1,050
–20 4.648 82,627 65 2.596 6,735 150 0.707 1,029
–19 4.637 79,871 66 2.565 6,564 151 0.696 1,007
–18 4.625 77,212 67 2.533 6,399 152 0.684 986
–17 4.613 74,648 68 2.503 6,238 153 0.673 965
–16 4.601 72,175 69 2.472 6,081 154 0.662 945
–15 4.588 69,790 70 2.440 5,929 155 0.651 925
–14 4.576 67,490 71 2.409 5,781 156 0.640 906
–13 4.562 65,272 72 2.378 5,637 157 0.630 887
–12 4.549 63,133 73 2.347 5,497 158 0.619 868
–11 4.535 61,070 74 2.317 5,361 159 0.609 850
–10 4.521 59,081 75 2.287 5,229 160 0.599 832
–9 4.507 57,162 76 2.256 5,101 161 0.589 815
–8 4.492 55,311 77 2.227 4,976 162 0.579 798
–7 4.477 53,526 78 2.197 4,855 163 0.570 782
–6 4.461 51,804 79 2.167 4,737 164 0.561 765
–5 4.446 50,143 80 2.137 4,622 165 0.551 750
–4 4.429 48,541 81 2.108 4,511 166 0.542 734
–3 4.413 46,996 82 2.079 4,403 167 0.533 719
–2 4.396 45,505 83 2.050 4,298 168 0.524 705
–1 4.379 44,066 84 2.021 4,196 169 0.516 690
0 4.361 42,679 85 1.993 4,096 170 0.508 677
1 4.344 41,339 86 1.965 4,000 171 0.499 663
2 4.325 40,047 87 1.937 3,906 172 0.491 650
3 4.307 38,800 88 1.989 3,814 173 0.484 638
4 4.288 37,596 89 1.881 3,726 174 0.476 626
5 4.269 36,435 90 1.854 3,640 175 0.468 614
6 4.249 35,313 91 1.827 3,556 176 0.460 602
7 4.229 34,231 92 1.800 3,474 177 0.453 591
8 4.209 33,185 93 1.773 3,395 178 0.445 581
9 4.188 32,176 94 1.747 3,318 179 0.438 570
10 4.167 31,202 95 1.721 3,243 180 0.431 561
11 4.145 30,260 96 1.695 3,170 181 0.424 551
12 4.123 29,351 97 1.670 3,099 182 0.418 542
13 4.101 28,473 98 1.644 3,031 183 0.411 533
14 4.079 27,624 99 1.619 2,964 184 0.404 524
15 3.056 26,804 100 1.595 2,898 185 0.398 516
16 4.033 26,011 101 1.570 2,835 186 0.392 508
17 4.009 25,245 102 1.546 2,773 187 0.385 501
18 3.985 24,505 103 1.523 2,713 188 0.379 494
19 3.960 23,789 104 1.499 2,655 189 0.373 487
20 3.936 23,096 105 1.476 2,597 190 0.367 480
21 3.911 22,427 106 1.453 2,542 191 0.361 473
22 3.886 21,779 107 1.430 2,488 192 0.356 467
23 3.861 21,153 108 1.408 2,436 193 0.350 461
24 3.835 20,547 109 1.386 2,385 194 0.344 456
25 3.808 19,960 110 1.364 2,335 195 0.339 450
26 3.782 19,393 111 1.343 2,286 196 0.333 445
27 3.755 18,843 112 1.321 2,239 197 0.328 439
28 3.727 18,311 113 1.300 2,192 198 0.323 434
29 3.700 17,796 114 1.279 2,147 199 0.318 429
30 3.672 17,297 115 1.259 2,103 200 0.313 424
31 3.644 16,814 116 1.239 2,060 201 0.308 419
32 3.617 16,346 117 1.219 2,018 202 0.304 415
33 3.588 15,892 118 1.200 1,977 203 0.299 410
34 3.559 15,453 119 1.180 1,937 204 0.294 405
35 3.530 15,027 120 1.161 1,898 205 0.290 401
36 3.501 14,614 121 1.143 1,860 206 0.285 396
37 3.471 14,214 122 1.124 1,822 207 0.281 391
38 3.442 13,826 123 1.106 1,786 208 0.277 386
39 3.412 13,449 124 1.088 1,750 209 0.272 382
40 3.382 13,084 125 1.070 1,715 210 0.268 377
41 3.353 12,730 126 1.053 1,680 211 0.264 372
42 3.322 12,387 127 1.036 1,647 212 0.260 367
43 3.291 12,053 128 1.019 1,614 213 0.256 361
44 3.260 11,730 129 1.002 1,582 214 0.252 356
45 3.229 11,416 130 0.986 1,550 215 0.248 350
46 3.198 11,112 131 0.969 1,519 216 0.245 344
47 3.167 10,816 132 0.953 1,489 217 0.241 338
48 3.135 10,529 133 0.938 1,459 218 0.237 332
49 3.104 10,250 134 0.922 1,430 219 0.234 325
50 3.074 9,979 135 0.907 1,401 220 0.230 318
51 3.042 9,717 136 0.893 1,373 221 0.227 311
52 3.010 9,461 137 0.878 1,345 222 0.224 304
53 2.978 9,213 138 0.864 1,318 223 0.220 297
54 3.946 8,973 139 0.849 1,291 224 0.217 289
55 2.914 8,739 140 0.835 1,265 225 0.214 282
56 2.882 8,511 141 0.821 1,240
57 2.850 8,291 142 0.808 1,214
58 2.819 8,076 143 0.795 1,190
59 2.788 7,868 144 0.782 1,165
85
Table 12B — Thermistor Temperature (C) vs Resistance/Voltage Drop
TEMPERATURE PIC II RESISTANCE TEMPERATURE PIC II RESISTANCE
(C) VOLTAGE DROP (V) (Ohms) (C) VOLTAGE DROP (V) (Ohms)
–33 4.722 106 880 38 1.585 2 888
–32 4.706 100 260 39 1.542 2 773
–31 4.688 94 165 40 1.499 2 663
–30 4.670 88 480 41 1.457 2 559
–29 4.650 83 170 42 1.417 2 459
–28 4.630 78 125 43 1.377 2 363
–27 4.608 73 580 44 1.338 2 272
–26 4.586 69 250 45 1.300 2 184
–25 4.562 65 205 46 1.263 2 101
–24 4.538 61 420 47 1.227 2 021
–23 4.512 57 875 48 1.192 1 944
–22 4.486 54 555 49 1.158 1 871
–21 4.458 51 450 50 1.124 1 801
–20 4.429 48 536 51 1.091 1 734
–19 4.399 45 807 52 1.060 1 670
–18 4.368 43 247 53 1.029 1 609
–17 4.336 40 845 54 0.999 1 550
–16 4.303 38 592 55 0.969 1 493
–15 4.269 38 476 56 0.941 1 439
–14 4.233 34 489 57 0.913 1 387
–13 4.196 32 621 58 0.887 1 337
–12 4.158 30 866 59 0.861 1 290
–11 4.119 29 216 60 0.835 1 244
–10 4.079 27 633 61 0.811 1 200
–9 4.037 26 202 62 0.787 1 158
–8 3.994 24 827 63 0.764 1 118
–7 3.951 23 532 64 0.741 1 079
–6 3.906 22 313 65 0.719 1 041
–5 3.861 21 163 66 0.698 1 006
–4 3.814 20 079 67 0.677 971
–3 3.765 19 058 68 0.657 938
–2 3.716 18 094 69 0.638 906
–1 3.667 17 184 70 0.619 876
0 3.617 16 325 71 0.601 836
1 3.565 15 515 72 0.583 805
2 3.512 14 749 73 0.566 775
3 3.459 14 026 74 0.549 747
4 3.406 13 342 75 0.533 719
5 3.353 12 696 76 0.518 693
6 3.298 12 085 77 0.503 669
7 3.242 11 506 78 0.488 645
8 3.185 10 959 79 0.474 623
9 3.129 10 441 80 0.460 602
10 3.074 9 949 81 0.447 583
11 3.016 9 485 82 0.434 564
12 2.959 9 044 83 0.422 547
13 2.901 8 627 84 0.410 531
14 2.844 8 231 85 0.398 516
15 2.788 7 855 86 0.387 502
16 2.730 7 499 87 0.376 489
17 2.672 7 161 88 0.365 477
18 2.615 6 840 89 0.355 466
19 2.559 6 536 90 0.344 456
20 2.503 6 246 91 0.335 446
21 2.447 5 971 92 0.325 436
22 2.391 5 710 93 0.316 427
23 2.335 5 461 94 0.308 419
24 2.280 5 225 95 0.299 410
25 2.227 5 000 96 0.291 402
26 2.173 4 786 97 0.283 393
27 2.120 4 583 98 0.275 385
28 2.067 4 389 99 0.267 376
29 2.015 4 204 100 0.260 367
30 1.965 4 028 101 0.253 357
31 1.914 3 861 102 0.246 346
32 1.865 3 701 103 0.239 335
33 1.816 3 549 104 0.233 324
34 1.768 3 404 105 0.227 312
35 1.721 3 266 106 0.221 299
36 1.675 3 134 107 0.215 285
37 1.629 3 008
86
Control Modules Notes on Module Operation
1. The chiller operator monitors and modifies configura-
tions in the microprocessor by using the 4 softkeys and
the CVC. Communications between the CVC and the
Turn controller power off before servicing controls. This CCM is accomplished through the SIO (Sensor Input/
ensures safety and prevents damage to the controller. Output) bus, which is a phone cable. The communication
between the CCM and ISM is accomplished through the
The CVC, CCM, and ISM modules perform continuous di- sensor bus, which is a 3-wire cable.
agnostic evaluations of the hardware to determine its condition.
Proper operation of all modules is indicated by LEDs (light- 2. If a green LED is on continuously, check the communica-
emitting diodes) located on the circuit board of the CVC, tion wiring. If a green LED is off, check the red LED
CCM, and ISM. operation. If the red LED is normal, check the module
address switches (SW1) (Fig. 40 and 41). Confirm all
There is one green LED located on the CCM and ISM switches are in OFF position.
boards respectively, and one red LED located on the CVC,
CCM, and ISM boards respectively. All system operating intelligence resides in the CVC.
Some safety shutdown logic resides in the ISM in case
RED LED (Labeled as STAT) — If the red LED: communications are lost between the ISM and CVC.
• blinks continuously at a 2-second interval, the module is Outputs are controlled by the CCM and ISM as well.
operating properly 3. Power is supplied to the modules within the control panel
• is lit continuously, there is a problem that requires via 24-vac power sources.
replacing the module
• is off continuously, the power should be checked The transformers are located within the power panel, with
• blinks 3 times per second, a software error has been dis- the exception of the ISM, which operates from a 115-vac
covered and the module must be replaced power source and has its own 24-vac transformer located
in the module.
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 In the power panel, T1 supplies power to the compressor
transformer or, if power is present to the module, replace the oil heater, oil pump, and optional hot gas bypass, and T2
module. supplies power to both the CVC and CCM.
GREED LED (Labeled as COM) — These LEDs indicate Power is connected to Plug J1 on each module.
the communication status between different parts of the con-
troller and the network modules and should blink continuously.
MODULE PART NUMBER CCN INTERFACE DATALINK OR

SOFTWARE PART NUMBER CONNECTION DATAPORT MODULE (OPTION)
BACK OF CVC J7 SIO J1 POWER/ J8 SERVICE SW1

CCN
Fig. 40 — Rear of CVC (Chiller Visual Controller)
87
Chiller Control Module (CCM) (Fig. 41) 8. Access the MAINSTAT table and highlight the TOTAL
INPUTS — Each input channel has 2 or 3 terminals. Refer to COMPRESSOR STARTS parameter. Press the SELECT
individual chiller wiring diagrams for the correct terminal softkey. Increase or decrease the value to match the starts
numbers for your application. value recorded in Step 3. Press the ENTER softkey
OUTPUTS — Output is 24 vac. There are 2 terminals per out- when you reach the correct value. Now, move the high-
put. Refer to the chiller wiring diagram for your specific appli- light bar to the COMPRESSOR ONTIME parameter.
cation for the correct terminal numbers. Press the SELECT softkey. Increase or decrease the run
hours value to match the value recorded in Step 2. Press
Integrated Starter Module (Fig. 42) the ENTER softkey when the correct value is reached.
INPUTS — Inputs on strips J3 through J6 are analog inputs 9. Complete the CVC installation. Following the instruc-
and J2 is discrete (on/off) input. The specific application of the tions in the Input Service Configurations section, page 55,
chiller determines which terminals are used. Refer to the indi- input all the proper configurations such as the time, date,
vidual chiller wiring diagram for the correct terminal numbers etc. Check the pressure transducer calibrations. PSIO
for your application. installation is now complete.
OUTPUTS — Outputs are 115-277 vac and wired to strip J9. Solid-State Starters — Troubleshooting information per-
There are 2 terminals per output. taining to the Benshaw, Inc., solid-state starter may be found
Replacing Defective Processor Modules — in the following paragraphs and in the Carrier RediStart
The module replacement part number is printed on a small MICRO™ Instruction Manual supplied by the starter vendor.
label on the rear of the CVC module. The chiller model and Attempt to solve the problem by using the following prelim-
serial numbers are printed on the chiller nameplate located on inary checks before consulting the troubleshooting tables found
an exterior corner post. The proper software is factory-installed in the Benshaw manual.
by Carrier in the replacement module. When ordering a
replacement chiller visual control (CVC) module, specify the
complete replacement part number, full chiller model number,
and chiller serial number. The installer must configure the new 1. Motor terminals or starter output lugs or wire should
module to the original chiller data. Follow the procedures not be touched without disconnecting the incoming
described in the Software Configuration section on page 55. 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
Electrical shock can cause personal injury. Disconnect all system even though the main circuit breaker in the
electrical power before servicing. unit is off.
INSTALLATION With power off:
1. Verify the existing CVC module is defective by using the • Inspect for physical damage and signs of arcing, over-
procedure described in the Troubleshooting Guide sec- heating, etc.
tion, page 76, and the Control Modules section, page 87. • Verify the wiring to the starter is correct.
Do not select the ATTACH TO NETWORK DEVICE • Verify all connections in the starter are tight.
table if the CVC indicates a communication failure. • Check the control transformer fuses.
2. Data regarding the CVC configuration should have been TESTING SILICON CONTROL RECTIFIERS IN THE
recorded and saved. This data must be reconfigured into BENSHAW, INC., SOLID-STATE STARTERS — If an SCR
the new CVC. If this data is not available, follow the pro- is suspected of being defective, use the following procedure as
cedures described in the Software Configuration section. part of a general troubleshooting guide.
If a CCN Building Supervisor or Service Tool is avail- 1. Verify power is applied.
able, the module configuration should have already been 2. Verify the state of each SCR light-emitting diode (LED)
uploaded into memory. When the new module is in- on the micropower card.
stalled, the configuration can be downloaded from the
computer. 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
Any communication wires from other chillers or CCN or more SCRs has failed.
modules should be disconnected to prevent the new CVC
module from uploading incorrect run hours into memory. 3. Check incoming power. If voltage is not present check
the incoming line. If voltage is present, proceed to Steps 4
3. To install this module, record values for the TOTAL through 11.
COMPRESSOR STARTS and the COMPRESSOR
ONTIME from the MAINSTAT screen on the CVC. NOTE: If after completing Steps 4 - 11 all measurements
are within specified limits, the SCRs are functioning nor-
4. Power off the controls. mally. If after completing Steps 4 - 11 resistance measure-
5. Remove the old CVC. ments are outside the specified limits, the motor leads on
6. Install the new CVC module. Turn the control power the starter power lugs T1 through T6 should be removed
back on. and the steps repeated. This will identify if abnormal re-
sistance measurements are being influenced by the motor
7. The CVC now automatically attaches to the local net- windings.
work device.
4. Remove power from the starter unit.
88
J11 J12 SW1
DISCRETE DISCRETE J1
OUTPUTS OUTPUTS 24 VAC
ANALOG OUT
J8
SIO
J7
SIO
J6
SW2
V/I INPUTS
J5
STAT COMM THERMISTORS DIFF PRESSURE PRESSURE

J4 J3 J2
Fig. 41 — Chiller Control Module (CCM)
J9 G + G + - G + 1 COM STAT
1 1
J8 J7 -
PUMP TRIP PUMP FAN FAN ALARM SPARE VFD CBA

1CR EVAP SHUNT TRANS COND LO HI TRIP 4-20 MA OUT COMM
DISCRETE CONTROL CONTACTS
INTERGRATED STARTER MODULE
CEPP130173-03-04-01
CEPL13025901 PCB05
ISM 19XR04012201 9925
DISCONNECT POWER BEFORE SERVICING

DISCONNECT POWER BEFORE SERVICING
HIGH VOLTAGE
HIGH VOLTAGE
WARNING
WARNING
R
00001328
INTEGRATEDSTARTERMODULE
CONTACT INPUTS
GROUND
115 VAC FUSE SPAR ICE REM STRT 1M 2M LINE VOLTAGES LINE CURRENTS FAULTS VFD
LL1 LL2 1A SFTY BLD STRT FLT AUX AUX L1 L2 L3 IL1 IL2 IL3 1/4 2/5 3/6 HZ
J5
1A J4
J2 J6
1 J1 1 + C + C + C + C + C + C J3-1 J3-2 J3-3 1 + - + - + - 1 + G + G + G1 + G
Fig. 42 — Integrated Starter Module (ISM)
89
5. Using an ohmmeter, perform the following resistance 5. Using quarter-turn increments, alternating between
measurements and record the results: clamping bolts, apply the appropriate number of whole
turns referencing the table in Fig. 43.
SCR PAIRS
MEASURE RECORDED
BEING
BETWEEN VALUE
CHECKED
T1 and T6 3 and 6
T2 and T4 2 and 5
Care must be taken to prevent nut rotation while tightening
the bolts. If the nut rotates while tighting the bolt, SCR
T3 and T5 1 and 4
replacement must be started over.
If all measured values are greater than 5K ohms, proceed 6. Reconnect the red (cathode) wire from the SCR and the
to Step 10. If any values are less than 5K ohms, one or white (anode-gate) wire to the appropriate location on the
more of the SCRs in that pair is shorted. firing card (i.e., SCR1 wires to firing card terminal
G1-white wire, and K1-red wire).
6. Remove both SCRs in the pair (See SCR Removal/
Installation). 7. Reconnect all other wiring and bus work.
7. Using an ohmmeter, measure the resistance (anode to 8. Return starter to normal operation.
cathode) of each SCR to determine which device has
failed.
NOTE: Both SCRs may be defective, but typically, only
one is shorted. If both SCRs provide acceptable resistance
measurements, proceed to Step 10. NUT
8. Replace the defective SCR(s). LOOSEN
CLAMPING AND
9. Retest the “pair” for resistance values indicated above. BOLT TIGHTEN
A BOLTS
10. On the right side of the firing card, measure the resistance ALUMINUM FROM
HEATSINK THIS END
between the red and white gate/cathode leads for each
SCR (1 through 6). A measurement between 5 and ROLL PIN
50 ohms is normal. Abnormally high values may indicate
a failed gate for that SCR. SCR
If any red or white SCR gate leads are removed from the
firing card or an SCR, care must be taken to ensure the
SCR PART A BOLT
leads are replaced EXACTLY as they were (white wires to NUMBER
CLAMP
DIMENSION
NO. OF
LENGTH
gates, and red wires to cathodes on both the firing card and SIZE TURNS
BISCR (in.) (in.)
SCR), or damage to the starter and/or motor may result. 2.75 3.0
6601218 1030 11/2
(70 mm) (76 mm)
11. Replace the SCRs and retest the pair. 6601818 1030
2.75
11/2 3.0
(70 mm) (76 mm)
SCR REMOVAL/INSTALLATION — Refer to Fig. 43.
2.75 3.5
1. Remove the SCR by loosening the clamping bolts on 8801230 1035 13/4
(70 mm) (89 mm)
each side of the SCR, 8801830 1035 2.75
13/4
3.0
(70 mm) (89 mm)
2. After the SCR has been removed and the bus work is
4.00 4.0
loose, apply a thin coat of either silicon based thermal 15001850 2040
(102 mm)
23/4
(102 mm)
joint compound or a joint compound for aluminum or 4.00 5.0
copper wire connections to the contact surfaces of the re- 15001850 2050 (102 mm) 23/4 (127 mm)
placement SCR. This allows for improved heat dissipa- 220012100 Consult Benshaw Representative
tion and electrical conductivity. 330018500 Consult Benshaw Representative
3. Place the SCR between the roll pins on the heatsink Fig. 43 — SCR Installation
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 Physical Data — Tables 13A-20 and Fig. 44-56 provide
the side from which the red wire extends. The heatsink is additional information on component weights, compressor fits
labeled to show the correct orientation. and clearances, physical and electrical data, and wiring sche-
matics for the operator’s convenience during troubleshooting.
4. Hand tighten the bolts until the SCR contacts the
heatsink.
90
Table 13A — Heat Exchanger Data (English)
ENGLISH
NUMBER OF TUBES
Dry (Rigging) Weight (lb) Chiller Charge
CODE
Cooler Condenser Refrigerant Weight (lb) Water Volume (gal)
Cooler Condenser
Only Only 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
NOTES: 2. Condenser data: based on a condenser with standard wall tub-
1. Cooler data: based on a cooler with standard wall tubing, 2-pass, ing, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight grooves. Weight includes the float valve, discharge elbow, and
includes suction elbow, control panel, and distribution piping. distribution piping. Weight does not include unit-mounted starter,
Weight does not include compressor. isolation valves, and pumpout unit.
91
Table 13B — Heat Exchanger Data (SI)
SI
NUMBER OF TUBES
Dry (Rigging) Weight (kg) Chiller Charge
CODE
Cooler Condenser Refrigerant Weight (kg) Water Volume (L)
Cooler Condenser
Only Only 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
NOTES: 2. Condenser data: based on a condenser with standard wall tub-
1. Cooler data: based on a cooler with standard wall tubing, 2-pass, ing, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight grooves. Weight includes the float valve, discharge elbow, and
includes suction elbow, control panel, and distribution piping. distribution piping. Weight does not include unit-mounted starter,
Weight does not include compressor. isolation valves, and pumpout unit.
92
Table 14 — 19XR Additional Data for Marine Waterboxes*
ENGLISH SI
HEAT EXCHANGER
FRAME, PASS Rigging Weight Water Volume Rigging Weight Water Volume
Psig kPa
(lb) (gal) (kg) (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
*Add to heat exchanger data for total weights or volumes.
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame size.
2. For the total weight of a vessel with a marine waterbox, add these values to the heat
exchanger weights (or volumes).
Table 15 — Compressor Weights

FRAME 2 FRAME 3 FRAME 4 FRAME 5
COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR
COMPONENT WEIGHT WEIGHT WEIGHT WEIGHT
lb kg lb kg lb kg lb kg
SUCTION ELBOW 50 23 54 24 175 79 400 181
DISCHARGE ELBOW 60 27 46 21 157 71 325 147
TRANSMISSION* 320 145 730 331 656 298 1000 454
SUCTION HOUSING 300 136 350 159 446 202 1200 544
IMPELLER SHROUD 35 16 80 36 126 57 250 113
COMPRESSOR BASE 1260 571 1050 476 1589 721 3695 1676
DIFFUSER 35 16 70 32 130 59 300 136
OIL PUMP 125 57 150 68 150 68 185 84
MISCELLANEOUS 100 45 135 61 144 65 220 100
TOTAL WEIGHT 2300 1043 2660 1207 3712 1684 6850 3107
(Less Motor and Elbows)
*Transmission weight does not include rotor, shaft, and gear.
93
Table 16 — 19XR Motor Weights Standard and High Efficiency Motors
ENGLISH SI
MOTOR Stator Weight* Rotor Weight End Bell Stator Weight* Rotor Weight End Bell
SIZE (lb) (lb) Cover (kg) (kg) Cover
60 Hz 50 Hz 60 Hz 50 Hz (lb) 60 Hz 50 Hz 60 Hz 50 Hz (kg)
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
*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.
94
Table 17A — 19XR Waterbox Cover Weights — English (lb)
FRAME 1 FRAME 2 FRAME 3
HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Standard Standard
Flanged Flanged Flanged
Nozzles Nozzles Nozzles
NIH, 1 Pass Cover, 150 psig 177 204 320 350 320 350
COOLER/ NIH/MWB End Cover, 150 psig 136 136 300 300 300 300
CONDENSER NIH, 1 Pass Cover, 300 psig 248 301 411 486 411 486
NIH/MWB End Cover, 300 psig 175 175 400 400 400 400

HEAT WATERBOX
COOLER/ NIH/MWB End Cover, 150 psig 379 379 428 428 583 583
CONDENSER NIH, 1 Pass Cover, 300 psig 593 668 764 839 880 956
NIH/MWB End Cover, 300 psig 569 569 713 713 833 833
FRAME 7 COOLER FRAME 7 CONDENSER

HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Standard
Nozzles Flanged Flanged
Nozzles
NIH, 1 Pass Cover, 150 psig 1392 1469 1205 1282
COOLER/ NIH/MWB End Cover, 150 psig 1022 1022 920 920
CONDENSER NIH, 1 Pass Cover, 300 psig 1985 2150 1690 1851
NIH/MWB End Cover, 300 psig 1567 1567 1440 1440

HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Standard
Nozzles Flanged Nozzles Flanged
COOLER/ NIH/MWB End Cover, 150 psig 1480 1480 1228 1228
CONDENSER NIH, 1 Pass Cover, 300 psig 2690 2854 2394 2549
NIH/MWB End Cover, 300 psig 1923 1923 1767 1767
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-Pass Cover, 150 psig is included in the heat exchanger weights shown in Tables 13A and 13B.
95
Table 17B — 19XR Waterbox Cover Weights — SI (kg)
HEAT WATERBOX
NIH, 1 Pass Cover, 1034 kPa 80 93 145 159 145 159
COOLER/ NIH/MWB End Cover, 1034 kPa 62 62 136 136 136 136
CONDENSER NIH, 1 Pass Cover, 2068 kPa 112 137 186 220 186 220
NIH/MWB End Cover, 2068 kPa 79 79 181 181 181 181

HEAT WATERBOX
COOLER/ NIH/MWB End Cover, 1034 kPa 172 172 194 194 264 264
CONDENSER NIH, 1 Pass Cover, 2068 kPag 269 303 347 381 399 434
NIH/MWB End Cover, 2068 kPa 258 258 323 323 378 378

HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Flanged Standard Flanged
Nozzles Nozzles
NIH, 1 Pass Cover, 1034 kPa 631 666 547 581
COOLER/ NIH/MWB End Cover, 1034 kPa 464 464 417 417
CONDENSER NIH, 1 Pass Cover, 2068 kPa 900 975 767 839
NIH/MWB End Cover, 2068 kPa 711 711 653 653

HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Flanged Standard Flanged
Nozzles Nozzles
COOLER/ NIH/MWB End Cover, 1034 kPa 671 671 557 557
CONDENSER NIH, 1 Pass Cover, 2068 kPa 1220 1295 1085 1156
NIH/MWB End Cover, 2068 kPa 872 872 801 801
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
NOTE: Weight for NIH 2-Pass Cover, 1034 kPa is included in the heat exchanger weights shown in Tables 13A and 13B.
96
Table 18 — Optional Pumpout System Table 20 — Motor Voltage Code
Electrical Data
MOTOR VOLTAGE CODE
MOTOR CONDENSER MAX Code Volts Frequency
VOLTS-PH-Hz LRA
CODE UNIT RLA 60 200 60
1 19EA47-748 575-3-60 3.8 23.0
61 230 60
4 19EA42-748 200/208-3-60 10.9 63.5
62 380 60
5 19EA44-748 230-3-60 9.5 57.5
63 416 60
6 19EA46-748 400/460-3-50/60 4.7 28.8
64 460 60
LEGEND 65 575 60
LRA — Locked Rotor Amps 66 2400 60
RLA — Rated Load Amps
67 3300 60
68 4160 60
69 6900 60
Table 19 — Additional Miscellaneous Weights 50 230 50
ITEM Lb Kg 51 346 50
CONTROL CABINET 30 14 52 400 50
UNIT-MOUNTED STARTER 500 227 53 3000 50
OPTIONAL ISOLATION VALVES 115 52 54 3300 50
UNIT MOUNTED VFD 1000 454 55 6300 50
97
COMPRESSOR, TRANSMISSION AREA
Compressor Assembly Torques

TORQUE
ITEM DESCRIPTION
ft-lb N•m
1* Oil Heater Retaining Nut 20 28
2 Bull Gear Retaining Bolt 80-85 108-115
3 Demister Bolts 15-19 20-26
4 Impeller 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
LEGEND
N•m — Newton meters
*Not shown.
NOTES:
1. All clearances for cylindrical surfaces are diametrical.
2. Dimensions are with rotor in thrust position.
3. Dimensions shown are in inches.
4. Impeller spacing should be performed in accordance with most
recent Carrier Service Bulletin on impeller spacing.
VIEW A
LOW SPEED SHAFT THRUST DISK
Fig. 44 — Compressor Fits and Clearances
98
VIEW B — HIGH SPEED SHAFT
19XR COMPRESSOR CLEARANCES

COMPRESSOR CODE
ITEM
221-299 321-389 421-489 521-599
.0050 .0050 .0055 .0069
A
.0040 .0040 .0043 .0059
.0050 .0050 .0053 .0065
B
.0040 .0040 .0043 .0055
.0115 .0115 .0100 .0010
C
.0055 .0080 .0050 .0060
.0190 .022 .027 .0350
D
.0040 .012 .017 .0250
–.002 –.0020 –.0029 –.0019
E
–.0005 –.0005 –.0014 –.0005
.0050 .0050 .0048 .0062
F
.0040 .0040 .0038 .0052
.157 .157 .0340 .0530
G
.0257 .0257 .0240 .0430
NOTE: All clearances for cylindrical surfaces are diametrical.
Fig. 44 — Compressor Fits and Clearances (cont)
99
100
LEGEND (cont)
LEGEND L — Main Supply Power
AUX — Auxiliary LVG — Leaving
BRG — Bearing N.O. — Normally Open
C — Contactor PRESS — Pressure
CB — Circuit Breaker REQM’T — Requirement
CCM — Chiller Control Module TEMP — Temperature
CCN — Carrier Comfort Network TB — Terminal Board
COMP’R — Compressor
COND — Condenser Denotes Control Panel Terminal
DISCH — Discharge Denotes Oil Pump Terminal
DL/DP — Datalink or Dataport Denotes Power Panel Terminal
ENT — Entering
EVAP — Evaporator ** Denotes Motor Starter Panel Conn.
EXT — External
FR — Frame Denotes Component Terminal
GND — Ground Wire Splice
G.V. — Guide Vane Denotes Conductor
HGBP — Hot Gas Bypass Male/Female Connector
HT EXCH — Heat Exchanger Option Wiring
Fig. 45 — Electronic PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor)

101
LEGEND (cont)
L — Main Supply Power
LEGEND LVG — Leaving
AUX — Auxiliary N.O. — Normally Open
BRG — Bearing PRESS — Pressure
C — Contactor REQM’T — Requirement
CB — Circuit Breaker TEMP — Temperature
CCM — Chiller Control Module TB — Terminal Board
CCN — Carrier Comfort Network
COMP’R — Compressor Denotes Control Panel Terminal
COND — Condenser
CVC — Chiller Visual Controller Denotes Oil Pump Terminal
DISCH — Discharge
DL/DP — Datalink or Dataport Denotes Power Panel Terminal
ENT — Entering
EVAP — Evaporator ** Denotes Motor Starter Panel Conn.
EXT — External Denotes Component Terminal
FR — Frame
GND — Ground Wire Splice
G.V. — Guide Vane Denotes Conductor Male/Female Connector
HT EXCH — Heat Exchanger Option Wiring
Fig. 46 — Electronic PIC II Control Panel Wiring Schematic (Frame 5 Compressor)

102
LEGEND
AUX — Auxiliary FR — Frame L — Main Supply Power Denotes Oil Pump Terminal
C — Contactor G — Ground N.O. — Normally Open Denotes Component Terminal
CB — Circuit Breaker GRD — Ground PRESS — Pressure Denotes Power Panel Terminal
REQM’T — Requirement Wire Splice
CCM — Chiller Control Module GVA — Guide Vane Actuator
COMM — Communication HGBP — Hot Gas Bypass T — Transformer * Denotes Mach. Control Panel Conn. Denotes Conductor Male/Female Connector
COMPR — Compressor HT EXCH — Heat Exchanger TB — Terminal Board ** Denotes Motor Starter Panel Conn.
DISCH — Discharge ISM — Integrated Starter Module Option Wiring
Fig. 47 — Power Panel Wiring Schematic

LEGEND NOTES:
1. Power factor correction capacitors (when required) are connected ahead of all current
HPR — High Pressure Relay transformers for proper calibration and sensing by the ISM and IQDP4130.
AUX — Auxiliary 2. For phase to phase ground fault protection refer to Fig. 50.
C — Contactor ISM — Integrated Starter Module
L — Main Supply Power 3. For metering information refer to Fig. 51.
CB — Circuit Breaker
CT — Current Transformer LL — Control Power Supply
DS — Disconnect Switch M — Contactor
FU — Fuse RES — Resistor
G — Ground S — Contactor
TB — Terminal Block
Fig. 48 — Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP
103
LEGEND NOTES:
1. Power factor correction capacitors (when required) are connected ahead of all current
HPR — High Pressure Relay transformers for proper calibration and sensing by the ISM and IQDP4130.
AUX — Auxiliary 2. For metering option see Fig. 51.
C — Contactor ISM — Integrated Starter Module
CB — Circuit Breaker L — Main Supply Power
CT — Current Transformer LL — Control Power Supply
DS — Disconnect Switch M — Contactor
FU — Fuse RES — Resistor
G — Ground S — Contactor
Fig. 49 — Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP
104
LEGEND
AM — Ammeter
LL — Control Power Supply
VM — Voltmeter
Represents Twisted Wire
To Door
Fig. 50 — Ground Fault Phase Current Option
LEGEND
AM — Ammeter
VM — Voltmeter
Represents Twisted Wire
To Door
Fig. 51 — Separate Metering Option
105
Fig. 52 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)
106
LEGEND
AUX — Auxiliary L — Main Supply Power Wire Node Symbol PC Board Terminals
BR — Bridge Rectifier LL — Control Power Supply may have terminal block
CB — Circuit Breaker M — Contactor Twisted Pair
COND — Condenser O/L — Overload Reset Benshaw supplied
CPU — Central Processing Unit PFCC — Power Factor terminal block Twisted Shielded Pair
CVC — Chiller Visual Controller Correction Capacitor
CT — Current Transformer Terminal Strip Shield Wire
RLA — Rated Load Amps
EVAP — Evaporator SCR — Silicone Controller Rectifier Power Connection Field Wiring
FU — Fuse ST — Shunt Trip
GND — Ground TB — Terminal Block
NOTES:
1 LED status with power applied and prior to run command. "ON"
"OFF"
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1.
2
Transformer connections per transformer nameplate connection diagram.
MOVs are used on power stack assemblies for system voltages of 200 through 460 vac (as shown).
3 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
4 on stop command or system fault.
5 CT1-CT3 are sized per Chart 2.
6 Optional.
Fig. 52 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage) (cont)
107
LEGEND
AUX — Auxiliary
C — Contactor
COMM — Communication
COND — Condenser
CPT — Control Power
Transformer
CR — Control Relay
DS — Disconnect Switch
EVAP — Evaporator
FU — Fuse
G — Ground
GFCT — Ground Fault Current
108
Transformer
HPR — Horsepower
ISM — Integrated Starter
Module
L — Main Power Supply
LVG — Leaving
M — Contactor
MTR — Motor
PRESS — Pressure
PT — Power Transformer
ST — Shunt Trip
STAT — Status
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
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
Fig. 53 — Typical Across-the-Line Starter Wiring Schematic (Medium Voltage)

LEGEND
AUX — Auxiliary
C — Contactor
COND — Condenser
Transformer
EVAP — Evaporator
FU — Fuse
G — Ground
109
Transformer
HPR — Horsepower
Module
LVG — Leaving
M — Contactor
MTR — Motor
PRESS — Pressure
ST — Shunt Trip
STAT — Status
Drive
VL — Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
Field Installed
Control Wiring
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
Fig. 54 — Typical Primary Reactor Starter Wiring Schematic (Medium Voltage)

LEGEND
AUX — Auxiliary
C — Contactor
COND — Condenser
Transformer
DISCH — Discharge
EVAP — Evaporator
110
FU — Fuse
Transformer
HPR — Horsepower
Module
MTR — Motor
PRESS — Pressure
ST — Shunt Trip
STAT — Status
TC — Transition Clear
Drive
VL — Wire Label
Starter Vendor
Power Wiring
Starter Vendor
Control Wiring
Field Installed
Power Wiring
Field Installed
Control Wiring
Option — Starter
Vendor Wiring
Twisted Pair Wiring
by Starter Vendor
Customer Terminal
Connection
Fig. 55 — Typical Autotransformer Starter Wiring Schematic (Medium Voltage)

111
Fig. 56 — Typical Variable Frequency Drive (VFD) Wiring Schematic
112
Fig. 56 — Typical Variable Frequency Drive (VFD) Wiring Schematic (cont)
113
114
115
116
LEGEND FOR FIG. 56
AUX — Auxiliary VFD — Variable Frequency Drive Pressure Switch
CB — Circuit Breaker 1C — Compressor Oil Heater Contactor
CCM — Chiller Control Module 1M — Start Contactor Compr Oil Pump Terminal
CCN — Carrier Comfort Network 2C — Oil Pump Contactor
COMM — Communications 3C — Hot Gas Bypass Relay Cartridge Fuse
CT — Currrent Transformer Field Control Wiring Earth Ground
CVC — Chiller Visual Controller Field Power Wiring
DP/DL — Data Port/Data Link Factory Wiring Resistor
FD — Fused Disconnect Shielded Cable Chassis Ground
FR — Fan Relay Light
FU — Fuse Twisted Pair Wiring
G — Chassis Ground Temperature Switch
GV — Guide Vane Male/Female Connector Common Potential
HPR — High Discharge Pressure Relay Terminal Block Connection
Dry Contact
HPS — High Pressure Switch
HX — Heat Exchanger Wire Splice or Junction
VFD Terminal
IGBT — Insulated Gate Bipolar Transitor Cam Switch
IGV — Inlet Guide Vane Current Transformer, Polarized
ISM — Integrated Starter Module (Direction Determined by •)
J — Junction Component Terminal
LEM — Current Detector Transformer
Thermistor
MAB — Module Adapter Board
-
RC — Regulator Controller Transducer IGBT
RMI — Remote Metering Interface +
ST — Shunt Trip Diode

T — Transformer Fusible Link
TB — Terminal Block Potentiometer Silicone Control Rectifier
117
INDEX
Abbreviations and Explanations, 4 Motor Rotation (Check), 65
Adding Refrigerant, 71 Notes on Module Operation, 87
Adjusting the Refrigerant Charge, 72 Oil Changes, 73
After Extended Shutdown, 67 Oil Charge, 55
After Limited Shutdown, 66 Oil Cooler, 36
Attach to Network Device Control, 44 Oil Pressure and Compressor Stop (Check), 65
Automatic Soft Stop Amps Threshold, 47 Oil Reclaim Filter, 73
Auto. Restart After Power Failure, 38 Oil Reclaim System, 8
Before Initial Start-Up, 48 Oil Specification, 73
Capacity Override, 36 Oil Sump Temperature Control, 36
Carrier Comfort Network Interface, 54 Open Oil Circuit Valves, 48
Changing Oil Filter, 73 Operating Instructions, 66
Charge Refrigerant Into Chiller, 63 Operating the Optional Pumpout Unit, 67
Chilled Water Recycle Mode, 47 Operator Duties, 66
Chiller Control Module (CCM), 88 Optional Pumpout Compressor Water Piping (Check), 53
Chiller Dehydration, 53 Optional Pumpout System Controls and
Chiller Familiarization, 5 Compressor (Check), 63
Chiller Information Nameplate, 5 Optional Pumpout System Maintenance, 75
Chiller Operating Condition (Check), 65 Ordering Replacement Chiller Parts, 75
Chiller Tightness (Check), 48 Overview (Troubleshooting Guide), 76
Chillers with Isolation Valves, 70 Perform a Control Test, 62
Chillers with Storage Tanks, 69 Physical Data, 90
Cold Weather Operation, 67 PIC II System Components, 11
Compressor Bearing and Gear Maintenance, 74 PIC II System Functions, 33
Condenser, 5 Power Up the Controls and Check the Oil Heater, 55
Condenser Freeze Prevention, 38 Preparation (Initial Start-Up), 64
Condenser Pump Control, 37 Preparation (Pumpout and Refrigerant Transfer
Control Algorithms Checkout Procedure, 77 Procedures), 67
Control Panel, 5 Prepare the Chiller for Start-Up, 66
Control Modules, 87 Pressure Transducers (Check), 75, 76
Control Test, 77 Prevent Accidential Start-Up, 65
Controls, 10 Pumpout and Refrigerant Transfer Procedures, 67
CVC Operation and Menus, 15 Ramp Loading, 36
Cooler, 5 Refrigerant Filter, 73
Default Screen Freeze, 35 Refrigerant Float System (Inpsect), 74
Definitions (Controls), 10 Refrigerant Leak Detector, 37
Demand Limit Control Option, 39 Refrigerant Leak Testing, 71
Design Set Points, (Input), 55 Refrigerant Properties, 71
Details (Lubrication Cycle), 8 Refrigerant (Removing), 71
Display Messages (Check), 76 Refrigerant Tracer, 48
Dry Run to Test Start-Up Sequence, 64 Refrigeration Cycle, 7
Equipment Required, 48 Refrigeration Log, 67
Extended Shutdown (Preparation for), 66 Relief Valves (Check), 53
Factory-Mounted Starter or Variable Frequency Drive, 7 Relief Valves and Piping (Inspect), 74
General (Controls), 11 Remote Reset of Alarms, 37
General Maintenance, 71 Remote Start/Stop Controls, 36
Guide Vane Linkage (Check), 72 Repair the Leak, Retest, and
Heat Exchanger Tubes and Flow Devices (Inspect), 74 Apply Standing Vacuum Test, 72
High Altitude Locations, 63 Replacing Defective Processor Modules, 88
High Discharge Temperature Control, 36 Running System (Check), 66
Ice Build Control, 43 Safety and Operating Controls (Check Monthly), 73
Initial Start-Up, 64 Safety Considerations, 1
Initial Start-Up Checklist for 19XR Hermetic Safety Controls, 34
Centrifugal Liquid Chiller, CL-1 Safety Shutdown, 47
Inspect the Control Panel, 73 Scheduled Maintenance, 73
Instruct the Customer Operator, 65 Service Configurations (Input), 55
Integrated Starter Module (ISM), 88 Service Ontime, 73
Introduction, 4 Service Operation, 45
Job Data Required, 48 Shipping Packaging (Remove), 48
Kilowatt Output, 37 Shunt Trip (Option), 35
Lead/Lag Control, 41 Shutdown Sequence, 47
Leak Rate, 71 Software Configuration, 55
Leak Test Chiller, 50 Solid-State Starters, 88
Local Occupied Schedule (Input), 55 Spare Safety Alarm Contacts, 37
Local Start-Up, 46 Spare Safety Inputs, 36
Lubrication Cycle, 8 Standing Vacuum Test, 50
Lubrication System (Check), 72 Starter (Check), 54
Manual Guide Vane Operation, 67 Starting Equipment, 9
Motor and Lubricating Oil Cooling Cycle, 7 Starting Equipment (Inspect), 75
Motor-Compressor, 5 Start-Up/Shutdown/Recycle Sequence, 46
118
INDEX (cont)
Start the Chiller, 66 Trim Refrigerant Charge, 72
Stop the Chiller, 66 Troubleshooting Guide, 76
Storage Vessel, 7 Unit Mounted Solid-State Starter, 9
Summary (Lubrication Cycle), 8 Unit Mounted VFD, 10
Surge Prevention Algorithm (Fixed Speed Chiller), 39 Unit Mounted Wye-Delta Starter, 10
Surge Prevention Algorithm with VFD, 40 Using the Optional Storage Tank and Pumpout
Surge Protection (Fixed Speed Chillers), 40 System, 48
Surge Protection VFD Units, 40 VFD Cooling Cycle, 8
System Components, 5 Water/Brine Reset, 38
Temperature Sensors (Check), 76 Water Leaks, 74
Test After Service, Repair, or Major Leak, 71 Water Piping (Inspect), 53
Tighten All Gasketed Joints and Guide Vane Packing, 48 Water Treatment, 75
Tower Fan Relay Low and High, 38 Weekly Maintenance, 72
119
Copyright 2000 Carrier Corporation
Book 2 PC 211 Catalog No. 531-980 Printed in U.S.A. Form 19XR-4SS Pg 122 1-00 Replaces: 19XR-3SS
Tab 5a
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -
INITIAL START-UP CHECKLIST
FOR 19XR, XRV HERMETIC CENTRIFUGAL LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME JOB NO.

ADDRESS MODEL
CITY STATE ZIP S/N
DESIGN CONDITIONS:
FLOW TEMPERATURE TEMPERATURE PRESSURE SUCTION CONDENSER
TONS BRINE PASS
RATE IN OUT DROP TEMPERATURE TEMPERATURE
COOLER ******
CONDENSER ******
COMPRESSOR: Volts RLA OLTA

CUT ALONG DOTTED LINE
STARTER: Mfg Type S/N

OIL PUMP: Volts RLA OLTA
CONTROL/OIL HEATER: Volts 115 230

REFRIGERANT: Type: Charge
CARRIER OBLIGATIONS: Assemble . . . . . . . . . . . . . . . . . . . Yes No
Leak Test . . . . . . . . . . . . . . . . . . . Yes No
Dehydrate . . . . . . . . . . . . . . . . . . Yes No
Charging . . . . . . . . . . . . . . . . . . . Yes No
Operating Instructions Hrs.
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:
YES NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD: 3/4

1/2 Top sight glass
ADD OIL: Yes No
1/4 Amount:
3/4
1/2 Bottom sight glass
1/4
RECORD PRESSURE DROPS: Cooler Condenser
CHARGE REFRIGERANT: Initial Charge Final Charge After Trim
Book 2 PC 211 Catalog No. 531-980 Printed in U.S.A. Form 19XR-4SS Pg CL-1 1-00 Replaces: 19XR-3SS
Tab 5a
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.
“PHASE TO PHASE” “PHASE TO GROUND”
MEGGER MOTOR
T1-T2 T1-T3 T2-T3 T1-G T2-G T3-G
10-Second Readings:
60-Second Readings:
Polarization Ratio:
STARTER: Electro-Mechanical Solid-State Manufacturer

Serial Number
Motor Load Current Transformer Ratio :
Solid-State Overloads Yes
No
CONTROLS: SAFETY, OPERATING, ETC.
Perform Controls Test (Yes/No)
PIC II CAUTION
COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY Yes
CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH
CERTIFIED DRAWINGS).
RUN MACHINE: Do these safeties shut down machine?

Condenser Water Flow Yes No
Chilled Water Flow Yes No
Pump Interlocks 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 CUSTOMER
TECHNICIAN REPRESENTATIVE
DATE DATE
CL-2
CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - -
ECW Setpoint
LCW Setpoint
Ice Build Setpoint

Base Demand Limit
DESCRIPTION
CVC Software Version Number:

Tower Fan High Setpoint
CVC Controller Identification: BUS:

15 to 60
15 to 120
10 to 120
55 to 105
40 to 100
RANGE
CL-3
%
DEG F
DEG F
DEG F
DEG F
UNITS
ADDRESS:
75
100
40.0
60.0
50.0
DEFAULT
19XR, XRV PIC II SETPOINT TABLE CONFIGURATION SHEET
VALUE
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC01S
Day Flag Occupied Unoccupied

M T W T F S S H Time Time
Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
ICE BUILD 19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC02S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is UNOCCUPIED 24 hours/day.
19XR, XRV PIC II TIME SCHEDULE CONFIGURATION SHEET OCCPC03S

Period 1:
Period 2:
Period 3:
Period 4:
Period 5:
Period 6:
Period 7:
Period 8:
NOTE: Default setting is OCCUPIED 24 hours/day.
CL-4
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19XR, XRV PIC II ISM_CONF TABLE CONFIGURATION SHEET

DESCRIPTION RANGE UNITS DEFAULT VALUE
Starter Type
0 to 2 1
(0=Full, 1=Red, 2=SS/VFD)
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-5
19XR, XRV PIC II OPTIONS TABLE CONFIGURATION SHEET
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
0/1 0
Select: Surge=0, HGBP=1
Min. Load Point (T1, P1)
Surge/HGBP Delta T1 0.5 to 20 ˆF 1.5
Surge/HGBP Delta P1 30 to 170 PSI 50
Full Load Point (T2, P2)
Surge/HGBP Delta T2 0.5 to 20 ˆF 10
Surge/HGBP Delta P2 50 to 170 PSI 85
Surge/HGBP Deadband 0.5 to 3 ˆF 1
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 30 psi 25
Delta P at 100% (20 mA) 35 to 50 psi 35
Minimum Output 0 to 10 % 0
CL-6
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19XR, XRV PIC II SETUP1 TABLE CONFIGURATION SHEET

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 ˆF 1.0
Evap Refrig Trippoint 0.0 to 40.0 DEG F 33
Refrig Override Delta T 2.0 to 5.0 ˆF 3
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-7
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
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-8
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19XR, XRV PIC II LEADLAG TABLE CONFIGURATION SHEET

Lead Lag Control
LEAD/LAG: Configuration
DSABLE=0, LEAD=1, 0 to 3 0
LAG=2, STANDBY=3
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-9
19XR, XRV PIC II RAMP_DEM TABLE CONFIGURATION SHEET
Pulldown Ramp Type:
0/1 1
Select: Temp=0, Load=1
Demand Limit + kW Ramp
Demand Limit Source 0/1 0
Select: Amps=0, kW=1
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 156
Demand Watts Interval 5 to 60 MIN 15
19XR, XRV PIC II TEMP_CTL TABLE CONFIGURATION SHEET

Control Point
ECW Control Option 0/1 DSABLE/ENABLE DSABLE
Temp Pulldown Deg/Min 2 to 10 ˆF 3
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA –30 to 30 ˆF 10
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 ˆF 10
RESET TYPE 3
CHW Delta T -> No Reset 0 to 15 ˆF 10
CHW Delta T -> Full Reset 0 to 15 ˆF 0
Degrees Reset –30 to 30 ˆF 5
Select/Enable Reset Type 0 to 3 0
CL-10
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Stop Back
Stop Time
Stop Week
Start Time
Start Week
Stop Month
Start Month
Start Advance
Daylight Savings
Stop Day of Week

Start Day of Week
Time Broadcast Enable
DESCRIPTION
1 to 5
1 to 7
1 to 5
1 to 7
1 to 12
1 to 12
0 to 360
0 to 360
00:00 to 24:00
00:00 to 24:00
RANGE
DSABLE/ENABLE
CL-11
MIN
MIN
HH:MM
UNITS
BROADCAST (BRODEF) CONFIGURATION SHEET
3
7
3
7
4
60
10
60
02:00
02:00
DSABLE
DEFAULT
VALUE
UNIT-MOUNTED VFD CONFIGURATION SHEET
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
*Variable by job — refer to component nameplates and labels.
CL-12
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CCN
PRIMARY MESSAGE:
SECONDARY MESSAGE:
CHW IN
CDW IN
OILPRESS
COMMUNICATION MESSAGE
LOCAL
CL-13
OIL TEMP
CDW OUT
CHW OUT
RESET
DATE:
CVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
COMPRESSOR ONTIME:
TIME:
MENU
AMPS %
EVAP REF
COND REF
CVC DISPLAY AND ALARM SHUTDOWN STATE RECORD SHEET
PRIMARY MESSAGE: DATE: TIME:

SECONDARY MESSAGE: COMPRESSOR ONTIME:
CHW IN CHW OUT EVAP REF
CDW IN CDW OUT COND REF
OILPRESS OIL TEMP AMPS %
COMMUNICATION MESSAGE
CCN LOCAL RESET MENU
Copyright 2000 Carrier Corporation
Book 2 PC 211 Catalog No. 531-980 Printed in U.S.A. Form 19XR-4SS Pg CL-14 1-00 Replaces: 19XR-3SS
Tab 5a

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19XR,XRV

Hermetic Centrifugal Liquid Chillers

Start-Up, Operation, and Maintenance Instructions

INTRODUCTION ABBREVIATIONS AND EXPLANATIONS

19XR- — High Efficiency Hermetic

Motor Voltage Code

MODEL NUMBER NOMENCLATURE

Week of Year Unique Number

Year of Manufacture Place of Manufacture

SERIAL NUMBER BREAKDOWN

Fig. 1 — 19XR Identification

Fig. 2 — Typical 19XR Components

Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles

OIL SKIMMER LINE

Fig. 4 — Lubrication System

Fig. 7 — Variable Frequency Drive (VFD)

OIL PUMP + DANGER -

AND OIL LINE

CONDENSER SCHRADER CONDENSER DISCHARGE COMPRESSOR MOTOR WINDING

CHILLER VISUAL CONTROLLER (CVC) — The CVC is

Fig. 13 — Power Panel

corner (Fig. 15). 21.8 132.9 93

units. Use the CVC configuration screen (accessed from

When an alarm is detected, the CVC default screen will

• Press NEXT to scroll the cursor bar down in order to

• Press PREVIOUS to scroll the cursor bar up in order to

• Press SELECT to view the next screen level (high-

• Press INCREASE or DECREASE to change the high-

Start Chiller In CCN Control

Start Chiller in Local Control

Clear Alarms Access Main Menu

STATUS SCHEDULE SETPOINT SERVICE

1 1 1 1 (ENTER A 4-DIGIT PASSWORD) (VALUES SHOWN AT FACTORY DEFAULT)

Display The Setpoint Table

Modify a Discrete Point

Modify an Analog Point

Fig. 17 — 19XR CVC Menu Structure

Display Alarm History

CONTROL TEST List the Control Tests

OCCDEFM (Time Schedule Status)

OCCPC01S (Local Status)

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)

Fig. 18 — 19XR Service Menu Structure

Select a Service Table

Modify a Service Table Parameter

ENABLE DISABLE QUIT ENTER (DISCRETE VALUES)

TIME AND DATE

Display Time and Date Table:

Modify Device Address

LOG OUT OF DEVICE

Fig. 18 — 19XR Service Menu Structure (cont)

4. Press NEXT or PREVIOUS to highlight the desired

2. Press SELECT to access the highlighted value.

b. Press ENABLE to select days in the day-of-week

Override Indication — An override value is indicated by

2. Press NEXT or PREVIOUS to highlight the desired

9. Either return to Step 4 to select another period or over-

10. The Holiday Designation (HOLIDEF table) may be