19XR 3SS

19XR
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 with soap and water. If liquid refrigerant enters the eyes, IMME-
and reliable service when operated within design speci- DIATELY FLUSH EYES with water and consult a physician.
fications. When operating this equipment, use good judg- NEVER APPLY an open flame or live steam to a refrigerant
ment and safety precautions to avoid damage to equip- cylinder. Dangerous over pressure can result. When it is necessary
ment and property or injury to personnel. to heat 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
safety precautions contained in the chiller instructions to refill them. It is DANGEROUS AND ILLEGAL. When cylinder
as well as those listed in this guide. is emptied, evacuate remaining gas pressure, loosen the collar and
unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to
the chiller. The introduction of the wrong refrigerant can cause dam-
DO NOT VENT refrigerant relief valves within a building. Outlet age or malfunction to this chiller.
from rupture disc or relief valve must be vented outdoors in ac-
cordance 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, Refrig- cited herein should comply with ANSI/ASHRAE15 (latest edi-
eration, and Air Conditioning Engineers). The accumulation of tion). Contact Carrier for further information on use of this chiller
refrigerant in an enclosed space can displace oxygen and cause with other refrigerants.
asphyxiation. DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE is under pressure or while chiller is running. Be sure pressure is at
15, especially for enclosed and low overhead spaces. Inhalation of 0 psig (0 kPa) before breaking any refrigerant connection.
high concentrations of vapor is harmful and may cause heart ir- CAREFULLY INSPECT all relief devices, rupture discs, and other
regularities, unconsciousness, or death. Misuse can be fatal. Vapor relief devices AT LEAST ONCE A YEAR. If chiller operates in a
is heavier than air and reduces the amount of oxygen available for corrosive atmosphere, inspect the devices at more frequent
breathing. Product causes eye and skin irritation. Decomposition intervals.
products are hazardous. DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief
DO NOT USE OXYGEN to purge lines or to pressurize a chiller device when corrosion or build-up of foreign material (rust, dirt,
for any purpose. Oxygen gas reacts violently with oil, grease, and scale, etc.) is found within the valve body or mechanism. Replace
other common substances. the device.
NEVER EXCEED specified test pressures, VERIFY the allowable DO NOT install relief devices in series or backwards.
test pressure by checking the instruction literature and the design USE CARE when working near or in line with a compressed spring.
pressures on the equipment nameplate. Sudden release of the spring can cause it and objects in its path to
DO NOT USE air for leak testing. Use only refrigerant or dry act as projectiles.
nitrogen.
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
functioning before operating any chiller. and 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.
present on motor leads even though the motor is not running when Follow safe practices when using ladders.
a solid-state or inside-delta mechanical starter is used. Open the USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or
power supply disconnect before touching motor leads or terminals. move inspection covers or other heavy components. Even if com-
ponents are light, use mechanical equipment when there is a risk of
slipping or losing your balance.
DO NOT WELD OR FLAMECUT any refrigerant line or vessel BE AWARE that certain automatic start arrangements CAN
until 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 disconnect ahead of the starter, tower fans, or pumps.
the work area should be well ventilated. Refrigerant in contact with USE only repair or replacement parts that meet the code require-
an open flame produces toxic gases. ments of the original equipment.
DO NOT USE eyebolts or eyebolt holes to rig chiller sections or DO NOT VENT OR DRAIN waterboxes containing industrial brines,
the entire assembly. liquid, gases, or semisolids without the permission of your process
DO NOT work on high-voltage equipment unless you are a quali- control group.
fied electrician. DO NOT LOOSEN waterbox cover bolts until the waterbox has
DO NOT WORK ON electrical components, including control pan- been completely drained.
els, switches, starters, or oil heater until you are sure ALL POWER DOUBLE-CHECK that coupling nut wrenches, dial indicators, or
IS OFF and no residual voltage can leak from capacitors or solid- other items have been removed before rotating any shafts.
state components. DO NOT LOOSEN a packing gland nut before checking that the
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK nut has a positive thread engagement.
IS INTERRUPTED, confirm that all circuits are deenergized be- PERIODICALLY INSPECT all valves, fittings, and piping for cor-
fore resuming work. rosion, rust, leaks, or damage.
AVOID SPILLING liquid refrigerant on skin or getting it into PROVIDE A DRAIN connection in the vent line near each pres-
the eyes. USE SAFETY GOGGLES. Wash any spills from the skin sure 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. 531-974 Printed in U.S.A. Form 19XR-3SS Pg 1 6-98 Replaces: New
Tab 5a
CONTENTS
Page Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote Start/Stop Controls . . . . . . . . . . . . . . . . 36
Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . 36
ABBREVIATIONS AND EXPLANATIONS . . . . . . 4 Spare Safety Alarm Contacts . . . . . . . . . . . . . . 36
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . 5-7 Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . 36
Chiller Information Plate . . . . . . . . . . . . . . . . . . . . 5 Condenser Pump Control . . . . . . . . . . . . . . . . . . 36
System Components . . . . . . . . . . . . . . . . . . . . . . . . 5 Condenser Freeze Prevention . . . . . . . . . . . . . . 37
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tower Fan Relay Low and High . . . . . . . . . . . . . 37
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Auto. Restart After Power Failure . . . . . . . . . . . 37
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 • RESET TYPE 1
Factory-Mounted Starter (Optional) . . . . . . . . . . 7 • RESET TYPE 2
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . 7 • RESET TYPE 3
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . 7 Demand Limit Control Option . . . . . . . . . . . . . . . . 38
Surge Prevention Algorithm . . . . . . . . . . . . . . . . 38
MOTOR AND LUBRICATING OIL Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 39
COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 7,8 Lead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . 8 • COMMON POINT SENSOR INSTALLATION
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • CHILLER COMMUNICATION WIRING
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • LEAD/LAG OPERATION
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . 8 • FAULTED CHILLER OPERATION
• PRIMARY OIL RECOVERY MODE • LOAD BALANCING
• SECONDARY OIL RECOVERY METHOD • AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . 41
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 8-10 • ICE BUILD INITIATION
Unit-Mounted Solid-State Starter • START-UP/RECYCLE OPERATION
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • TEMPERATURE CONTROL DURING
Unit-Mounted Wye-Delta Starter ICE BUILD
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 • TERMINATION OF ICE BUILD
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 • RETURN TO NON-ICE BUILD OPERATIONS
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Attach to Network Device Control . . . . . . . . . . 42
• ANALOG SIGNAL • ATTACHING TO OTHER CCN MODULES
• DISCRETE SIGNAL Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . 43
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 • TO ACCESS THE SERVICE SCREENS
PIC II System Components . . . . . . . . . . . . . . . . . 10 • TO LOG OUT OF NETWORK DEVICE
• CHILLER VISUAL CONTROLLER (CVC) • HOLIDAY SCHEDULING
• INTEGRATED STARTER MODULE (ISM) START-UP/SHUTDOWN/RECYCLE
• CHILLER CONTROL MODULE (CCM) SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,45
• OIL HEATER CONTACTOR (1C) Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
• OIL PUMP CONTACTOR (2C) Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . 45
• HOT GAS BYPASS CONTACTOR RELAY (3C) Automatic Soft Stop Amps Threshold . . . . . . . 45
(Optional) Chilled Water Recycle Mode . . . . . . . . . . . . . . . . 45
• CONTROL TRANSFORMERS (T1, T2) Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CVC Operation and Menus . . . . . . . . . . . . . . . . . 14
• GENERAL BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . 46-58
• ALARMS AND ALERTS Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . 46
• CVC MENU ITEMS Equipment Required . . . . . . . . . . . . . . . . . . . . . . . 46
• BASIC CVC OPERATIONS (Using the Softkeys) Using the Optional Storage Tank
• TO VIEW STATUS and Pumpout System . . . . . . . . . . . . . . . . . . . . 46
• OVERRIDE OPERATIONS Remove Shipping Packaging . . . . . . . . . . . . . . . 46
• TIME SCHEDULE OPERATION Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . 46
• TO VIEW AND CHANGE SET POINTS Tighten All Gasketed Joints and
• SERVICE OPERATION Guide Vane Shaft Packing . . . . . . . . . . . . . . . . 46
PIC II System Functions . . . . . . . . . . . . . . . . . . . 32 Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . 46
• CAPACITY CONTROL Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . 46
• ECW CONTROL OPTION Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• CONTROL POINT DEADBAND Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . 48
• DIFFUSER CONTROL Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . 51
• PROPORTIONAL BANDS AND GAIN Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . 51
• DEMAND LIMITING Check Optional Pumpout Compressor
• CHILLER TIMERS Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
• OCCUPANCY SCHEDULE Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . 51
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . 35 Carrier Comfort Network Interface . . . . . . . . . . 52
Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . 35 Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 • MECHANICAL STARTER
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . 35 • BENSHAW, INC. REDISTART MICRO
High Discharge Temperature Control . . . . . . . 35 SOLID-STATE STARTER
Oil Sump Temperature Control . . . . . . . . . . . . . 35 Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2
CONTENTS (cont)
Page Page
Power Up the Controls and After Extended Shutdown . . . . . . . . . . . . . . . . . . 60
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . 53 Cold Weather Operation . . . . . . . . . . . . . . . . . . . 60
• SOFTWARE VERSION Manual Guide Vane Operation . . . . . . . . . . . . . . 60
Software Configuration . . . . . . . . . . . . . . . . . . . . 53 Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Input the Design Set Points . . . . . . . . . . . . . . . . 53 PUMPOUT AND REFRIGERANT TRANSFER
Input the Local Occupied Schedule PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 62-64
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Input Service Configurations . . . . . . . . . . . . . . . 53 Operating the Optional Pumpout Unit . . . . . . 62
• PASSWORD • TO READ REFRIGERANT PRESSURES
• INPUT TIME AND DATE Chillers with Storage Tanks . . . . . . . . . . . . . . . . 63
• CHANGE CVC CONFIGURATION • TRANSFER REFRIGERANT FROM
IF NECESSARY PUMPOUT STORAGE TANK TO CHILLER
• TO CHANGE THE PASSWORD • TRANSFER THE REFRIGERANT FROM
• TO CHANGE THE CVC DISPLAY FROM CHILLER TO PUMPOUT STORAGE TANK
ENGLISH TO METRIC UNITS Chillers with Isolation Valves . . . . . . . . . . . . . . . 64
• MODIFY CONTROLLER IDENTIFICATION • TRANSFER ALL REFRIGERANT TO
IF NECESSARY CHILLER CONDENSER VESSEL
• INPUT EQUIPMENT SERVICE PARAMETERS • TRANSFER ALL REFRIGERANT TO
IF NECESSARY CHILLER COOLER VESSEL
• CONFIGURE DIFFUSER CONTROL IF • RETURN CHILLER TO NORMAL
NECESSARY OPERATING CONDITIONS
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . 65,66
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . 56 Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . 65
Check Optional Pumpout System Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 65
Controls and Compressor . . . . . . . . . . . . . . . . 56 Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . 65
High Altitude Locations . . . . . . . . . . . . . . . . . . . . 56 Adjusting the Refrigerant Charge . . . . . . . . . . . 65
Charge Refrigerant Into Chiller . . . . . . . . . . . . . 56 Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . 65
• CHILLER EQUALIZATION WITHOUT A Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PUMPOUT UNIT Test After Service, Repair, or Major Leak . . . . 65
• CHILLER EQUALIZATION WITH • REFRIGERANT TRACER
PUMPOUT UNIT • TO PRESSURIZE WITH DRY NITROGEN
• TRIMMING REFRIGERANT CHARGE Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . 65
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 58,59 Checking Guide Vane Linkage . . . . . . . . . . . . . . 65
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . 65
Dry Run to Test Start-Up Sequence . . . . . . . . . 58
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . 58 WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . 66
• IF THE MOTOR ROTATION IS CLOCKWISE Check the Lubrication System . . . . . . . . . . . . . . 66
• IF THE MOTOR ROTATION IS NOT SCHEDULED MAINTENANCE . . . . . . . . . . . . . . 66-69
CLOCKWISE Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Oil Pressure and Compressor Inspect the Control Panel . . . . . . . . . . . . . . . . . . 66
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Check Safety and Operating Controls
To Prevent Accidental Start-Up . . . . . . . . . . . . . 59 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check Chiller Operating Condition . . . . . . . . . . 59 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 66
Instruct the Customer Operator . . . . . . . . . . . . 59 Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• COOLER-CONDENSER Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• OPTIONAL PUMPOUT STORAGE TANK AND • TO CHANGE THE OIL
PUMPOUT SYSTEM Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• MOTOR COMPRESSOR ASSEMBLY Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• MOTOR COMPRESSOR LUBRICATION Inspect Refrigerant Float System . . . . . . . . . . . 67
SYSTEM Inspect Relief Valves and Piping . . . . . . . . . . . . 67
• CONTROL SYSTEM Compressor Bearing and Gear
• AUXILIARY EQUIPMENT Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
• DESCRIBE CHILLER CYCLES Inspect the Heat Exchanger Tubes
• REVIEW MAINTENANCE and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . 68
• SAFETY DEVICES AND PROCEDURES • COOLER AND FLOW DEVICES
• CHECK OPERATOR KNOWLEDGE • CONDENSER AND FLOW DEVICES
• REVIEW THE START-UP, OPERATION, AND Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
MAINTENANCE MANUAL Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . 59-61 Inspect the Starting Equipment . . . . . . . . . . . . . 68
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Check Pressure Transducers . . . . . . . . . . . . . . . 68
Prepare the Chiller for Start-Up . . . . . . . . . . . . . 59 Optional Pumpout System Maintenance . . . . . 68
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . 59 • OPTIONAL PUMPOUT COMPRESSOR OIL
Check the Running System . . . . . . . . . . . . . . . . 59 CHARGE
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . 60 • OPTIONAL PUMPOUT SAFETY CONTROL
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . 60 SETTINGS
Preparation for Extended Shutdown . . . . . . . . 60 Ordering Replacement Chiller Parts . . . . . . . . 69
3
CONTENTS (cont)
Page Page
Notes on Module Operation . . . . . . . . . . . . . . . . 80
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . 69-99 Chiller Control Module (CCM) . . . . . . . . . . . . . . . . 81
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 • INPUTS
Checking the Display Messages . . . . . . . . . . . . 69 • OUTPUTS
Checking Temperature Sensors . . . . . . . . . . . . 69 ISM Integrated Starter Module . . . . . . . . . . . . . . 81
• RESISTANCE CHECK • INPUTS
• VOLTAGE DROP • OUTPUTS
• CHECK SENSOR ACCURACY Replacing Defective Processor Modules . . . . 81
• DUAL TEMPERATURE SENSORS • INSTALLATION
Checking Pressure Transducers . . . . . . . . . . . . 70 Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . 81
• COOLER AND CONDENSER PRESSURE • TESTING SILICON CONTROL RECTIFIERS
TRANSDUCER AND WATERSIDE FLOW DEVICE IN BENSHAW, INC. SOLID-STATE STARTERS
CALIBRATION • SCR REMOVAL/INSTALLATION
• TRANSDUCER REPLACEMENT Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Control Algorithms Checkout Procedure . . . . 70
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,101
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 INITIAL START-UP CHECKLIST FOR
• RED LED (Labeled as STAT) 19XR HERMETIC CENTRIFUGAL
• GREEN LED (Labeled as COM) LIQUID CHILLER . . . . . . . . . . . . . . . . . . CL-1 to CL-12
INTRODUCTION ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:
Prior to initial start-up of the 19XR unit, those involved
in the start-up, operation, and maintenance should be thor- CCM — Chiller Control Module
oughly familiar with these instructions and other necessary CCN — Carrier Comfort Network
job data. This book is outlined to familiarize those involved CVC — Chiller Visual Control
CCW — Counterclockwise
in the start-up, operation and maintenance of the unit with CW — Clockwise
the control system before performing start-up procedures. Pro- ECDW — Entering Condenser Water
cedures in this manual are arranged in the sequence required ECW — Entering Chilled Water
for proper chiller start-up and operation. EMS — Energy Management System
HGBP — Hot Gas Bypass
I/O — Input/Output
ISM — Integrated Starter Module
LCD — Liquid Crystal Display
LCDW — Leaving Condenser Water
This unit uses a microprocessor control system. Do not LCW — Leaving Chilled Water
short or jumper between terminations on circuit boards LED — Light-Emitting Diode
or modules; control or board failure may result. OLTA — Overload Trip Amps
PIC II — Product Integrated Control II
Be aware of electrostatic discharge (static electricity) when RLA — Rated Load Amps
handling or making contact with circuit boards or mod- SCR — Silicon Controlled Rectifier
ule connections. Always touch a chassis (grounded) part SI — International System of Units
to dissipate body electrostatic charge before working in- TXV — Thermostatic Expansion Valve
side control center.
Words printed in all capital letters or in italics may be viewed
Use extreme care when handling tools near boards and on the Chiller Visual Control (CVC) (e.g., LOCAL, CCN,
when connecting or disconnecting terminal plugs. Cir- ALARM, etc.).
cuit boards can easily be damaged. Always hold boards
by the edges and avoid touching components and Words printed in both all capital letters and italics can also
connections. be viewed on the CVC and are parameters (e.g., CONTROL
MODE, COMPRESSOR START RELAY, ICE BUILD
This equipment uses, and can radiate, radio frequency OPTION, etc.) with associated values (e.g., modes, tempera-
energy. If not installed and used in accordance with the tures, percentages, pressures, on, off, etc.).
instruction manual, it may cause interference to radio
communications. It has been tested and found to com- Words printed in all capital letters and in a box represent
ply with the limits for a Class A computing device pur- softkeys on the CVC control panel (e.g., ENTER ,
suant to Subpart J of Part 15 of FCC Rules, which are EXIT , INCREASE , QUIT , etc.).
designed to provide reasonable protection against such
interference when operated in a commercial environ- Factory-installed additional components are referred to as
ment. Operation of this equipment in a residential area options in this manual; factory-supplied but field-installed
is likely to cause interference, in which case the user, at additional components are referred to as accessories.
his own expense, will be required to take whatever mea- The chiller software part number of the 19XR unit is lo-
sures may be required to correct the interference. cated on the back of the CVC.
Always store and transport replacement or defective boards
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 Plate — The information plate is
located on the right side of the chiller control panel. Control Panel — The control panel is the user interface
for controlling the chiller. It regulates the chiller’s capacity
System Components — The components include the as required to maintain proper leaving chilled water tem-
cooler and condenser heat exchangers in separate vessels, perature. The control panel:
motor-compressor, lubrication package, control panel, and • registers cooler, condenser, and lubricating system
motor starter. All connections from pressure vessels have ex- pressures
ternal threads to enable each component to be pressure tested • shows chiller operating condition and alarm shutdown
with a threaded pipe cap during factory assembly. conditions
Cooler — This vessel (also known as the evaporator) is • records the total chiller operating hours
located underneath the compressor. The cooler is main- • sequences chiller start, stop, and recycle under micro-
tained at lower temperature/pressure so evaporating refrig- processor control
erant can remove heat from water flowing through its inter- • displays status of motor starter
nal tubes. • provides access to other CCN (Carrier Comfort Network)
devices
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.
MODEL NUMBER NOMENCLATURE
Fig. 1 — 19XR Identification

5
1 LEGEND
2 1 — Guide Vane Actuator
3 2 — Suction Elbow
3 — Chiller Visual Control (CVC)
4 4 — Chiller Identification Nameplate
5 5 — Cooler, Auto Reset Relief Valves
17 6 6 — Cooler Pressure Transducer
7 — Condenser In/Out Temperature
Thermistors
8 — Condenser Waterflow Device
9 — Cooler In/Out Temperature Thermistors
10 — Cooler Waterflow Device
16 11 — Refrigerant Charging Valve
12 — Typical Flange Connection
13 — Oil Drain Charging Valve
14 — Oil Level Sight Glasses
7 15 — Refrigerant Oil Cooler (Hidden)
16 — Auxiliary Power Panel
17 — Motor Housing
15 14
13
12
9
11 10
FRONT VIEW
18 19 20 21 22 LEGEND
18 — Condenser Auto. Reset Relief Valves
19 — Motor Circuit Breaker
20 — Solid-State Starter Control Display
21 — Unit-Mounted Starter (Optional),
34 Solid-State Starter Shown
22 — Motor Sight Glass
23
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
REAR VIEW
Fig. 2 — Typical 19XR Components
6
Factory-Mounted Starter (Optional) — The starter [37 to 40 C]) when it is discharged from the compressor into
allows for the proper start and disconnect of electrical en- the condenser.
ergy for the compressor-motor, oil pump, oil heater, and con- Relatively cool (typically 65 to 90 F [18 to 32 C]) water
trol panel. flowing into the condenser tubes removes heat from the re-
frigerant 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 FLASC
a magnetically-coupled dial-type refrigerant level gage, a (Flash Subcooler) chamber (Fig. 3). Since the FLASC cham-
one-inch FPT drain valve, and a 1⁄2-in. male flare vapor ber is at a lower pressure, part of the liquid refrigerant flashes
connection for the pumpout unit. to vapor, thereby cooling the remaining liquid. The FLASC
vapor is recondensed on the tubes which are cooled by en-
NOTE: If a storage vessel is not used at the jobsite, factory- tering condenser water. The liquid drains into a float cham-
installed isolation valves on the chiller may be used to iso- ber between the FLASC chamber and cooler. Here a float
late the chiller charge in either the cooler or condenser. valve forms a liquid seal to keep FLASC chamber vapor from
An optional pumpout system is used to transfer refrigerant entering the cooler. When liquid refrigerant passes through
from vessel to vessel. the valve, some of it flashes to vapor in the reduced pressure
on the cooler side. In flashing, it removes heat from the re-
REFRIGERATION CYCLE maining liquid. The refrigerant is now at a temperature and
The compressor continuously draws refrigerant vapor from pressure at which the cycle began.
the cooler at a rate set by the amount of guide vane opening.
As the compressor suction reduces the pressure in the cooler, MOTOR AND LUBRICATING OIL
the remaining refrigerant boils at a fairly low temperature COOLING CYCLE
(typically 38 to 42 F [3 to 6 C]). The energy required for The motor and the lubricating oil are cooled by liquid re-
boiling is obtained from the water flowing through the cooler frigerant taken from the bottom of the condenser vessel
tubes. With heat energy removed, the water becomes cold (Fig. 3). Refrigerant flow is maintained by the pressure dif-
enough to use in an air conditioning circuit or for process ferential that exists due to compressor operation. After the
liquid cooling. refrigerant flows past an isolation valve, an in-line
After taking heat from the water, the refrigerant vapor is filter, and a sight glass/moisture indicator, the flow is split
compressed. Compression adds still more heat energy, and between the motor cooling and oil cooling systems.
the refrigerant is quite warm (typically 98 to 102 F
Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles
7
Flow to the motor cooling system passes through an ori- During shutdown, the oil pump will run for 60 seconds to
fice and into the motor. Once past the orifice, the refrigerant post-lubricate after the compressor shuts down. The oil pump
is directed over the motor by a spray nozzle. The refrigerant can also be energized for testing purposes during a Control
collects in the bottom of the motor casing and is then drained Test.
back into the cooler through the motor refrigerant drain line. Ramp loading can slow the rate of guide vane opening to
A back pressure valve or an orifice in this line maintains a minimize oil foaming at start-up. If the guide vanes open
higher pressure in the motor shell than in the cooler/oil sump. quickly, the sudden drop in suction pressure can cause any
The motor is protected by a temperature sensor imbedded in refrigerant in the oil to flash. The resulting oil foam can-
the stator windings. An increase in motor winding tempera- not be pumped efficiently; therefore, oil pressure falls off
ture past the motor override set point overrides the tempera- and lubrication is poor. If oil pressure falls below 15 psid
ture capacity control to hold, and if the motor temperature (103 kPad) differential, the PIC II will shut down the
rises 10° F (5.5° C) above this set point, closes the inlet guide compressor.
vanes. If the temperature rises above the safety limit, the com- If the controls are subject to a power failure that lasts more
pressor shuts down. than 3 hours, the oil pump will be energized periodically when
Refrigerant that flows to the oil cooling system is regu- the power is restored. This helps to eliminate refrigerant that
lated by thermostatic expansion valves (TXVs). The TXVs has migrated to the oil sump during the power failure. The
regulate flow into the oil/refrigerant plate and frame-type heat controls energize the pump for 60 seconds every 30 minutes
exchanger (the oil cooler in Fig. 3). The expansion valve until the chiller is started.
bulbs control oil temperature to the bearings. The refrigerant
leaving the oil cooler heat exchanger then returns to the chiller Oil Reclaim System — The oil reclaim system re-
cooler. turns oil lost from the compressor housing back to the oil
reservoir by recovering the oil from 2 areas on the chiller.
LUBRICATION CYCLE The guide vane housing is the primary area of recovery. Oil
is also recovered by skimming it from the operating refrig-
Summary — The oil pump, oil filter, and oil cooler make erant level in the cooler vessel.
up a package located partially in the transmission casting of
the compressor-motor assembly. The oil is pumped into a PRIMARY OIL RECOVERY MODE — Oil is normally
filter assembly to remove foreign particles and is then forced recovered through the guide vane housing on the chiller. This
into an oil cooler heat exchanger where the oil is cooled to is possible because oil is normally entrained with refrigerant
proper operational temperatures. After the oil cooler, part of in the chiller. As the compressor pulls the refrigerant up from
the flow is directed to the gears and the high speed shaft the cooler into the guide vane housing to be compressed, the
bearings; the remaining flow is directed to the motor shaft oil normally drops out at this point and falls to the bottom
bearings. Oil drains into the transmission oil sump to com- of the guide vane housing where it accumulates. Using dis-
plete the cycle (Fig. 4). charge gas pressure to power an eductor, the oil is drawn
from the housing and is discharged into the oil reservoir.
Details — Oil is charged into the lubrication system through SECONDARY OIL RECOVERY METHOD — The sec-
a hand valve. Two sight glasses in the oil reservoir permit oil ondary method of oil recovery is significant under light load
level observation. Normal oil level is between the middle of conditions, when the refrigerant going up to the compressor
the upper sight glass and the top of the lower sight glass suction does not have enough velocity in which to bring oil
when the compressor is shut down. The oil level should be along. Under these conditions, oil collects in a greater con-
visible in at least one of the 2 sight glasses during operation. centration at the top level of the refrigerant in the cooler.
Oil sump temperature is displayed on the CVC (Chiller This oil and refrigerant mixture is skimmed from the side of
Visual Control) default screen. During compressor opera- the cooler and is then drawn up to the guide vane housing.
tion, the oil sump temperature ranges between 125 to 150 F There is a filter in this line. Because the guide vane housing
(52 to 66 C). pressure is much lower than the cooler pressure, the refrig-
The oil pump suction is fed from the oil reservoir. An erant boils off, leaving the oil behind to be collected by the
oil pressure relief valve maintains 18 to 25 psid (124 to primary oil recovery method.
172 kPad) differential pressure in the system at the pump
discharge. This differential pressure can be read directly from STARTING EQUIPMENT
the CVC default screen. The oil pump discharges oil to the The 19XR requires a motor starter to operate the centrifu-
oil filter assembly. This filter can be closed to permit gal hermetic compressor motor, the oil pump, and various
removal of the filter without draining the entire oil system auxiliary equipment. The starter is the main field wiring in-
(see Maintenance sections, pages 65 to 69, for details). The terface for the contractor.
oil is then piped to the oil cooler heat exchanger. The oil See Carrier Specification Z-415 for specific starter re-
cooler uses refrigerant from the condenser as the coolant. quirements. All starters must meet these specifications in
The refrigerant cools the oil to a temperature between 120 order to properly start and satisfy mechanical safety require-
and 140 F (49 to 60 C). ments. Starters may be supplied as separate, free-standing
As the oil leaves the oil cooler, it passes the oil pressure units or may be mounted directly on the chiller (unit mounted)
transducer and the thermal bulb for the refrigerant expan- for low-voltage units only.
sion valve on the oil cooler. The oil is then divided. Part of Three separate circuit breakers are inside the starter. Cir-
the oil flows to the thrust bearing, forward pinion bearing, cuit breaker CB1 is the compressor motor circuit breaker.
and gear spray. The rest of the oil lubricates the motor shaft The disconnect switch on the starter front cover is connected
bearings and the rear pinion bearing. The oil temperature is to this breaker. Circuit breaker CB1 supplies power to the
measured in the bearing housing as it leaves the thrust and compressor motor.
forward journal bearings. The oil then drains into the oil res-
ervoir at the base of the compressor. The PIC II (Product
Integrated Control II) measures the temperature of the oil in
the sump and maintains the temperature during shutdown The main circuit breaker (CB1) on the front of the starter
(see Oil Sump Temperature Control section, page 35). This disconnects the main motor current only. Power is still
temperature is read on the CVC default screen. energized for the other circuits. Two more circuit break-
During the chiller start-up, the PIC II energizes the oil pump ers inside the starter must be turned off to disconnect
and provides 45 seconds of prelubrication to the bearings power to the oil pump, PIC II controls, and oil heater.
after pressure is verified before starting the compressor.
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
Fig. 4 — Lubrication System
Circuit breaker CB2 supplies power to the control panel, torque required to get the motor moving. The voltage is re-
oil heater, and portions of the starter controls. duced by silicon controlled rectifiers (SCRs). The voltage
Circuit breaker CB3 supplies power to the oil pump. Both and current are then ramped up in a desired period of time.
CB2 and CB3 are wired in parallel with CB1 so that power Once full voltage is reached, a bypass contactor is energized
is supplied to them if the CB1 disconnect is open. to bypass the SCRs.
All starters must include a Carrier control module called
the Integrated Starter Module (ISM), excluding the
Benshaw solid-state starters. This module controls and moni- When voltage is supplied to the solid-state circuitry, the
tors all aspects of the starter. See the Controls section on heat sinks in the starter as well as the wires leading to
page 10 for additional ISM information. All starter replace- the motor and the motor terminal are at line voltage.
ment parts are supplied by the starter manufacturer exclud- Do not touch the heat sinks, power wiring, or motor
ing the ISM (contact Carrier’s Replacement Component terminals while voltage is present or serious injury will
Division [RCD]). result.
Unit-Mounted Solid-State Starter (Optional) There is a display on the front of the Benshaw, Inc., solid-
— The 19XR chiller may be equipped with a solid-state, state starters that is useful for troubleshooting and starter check-
reduced-voltage starter (Fig. 5 and 6). This starter’s primary out. The display indicates:
function is to provide on-off control of the compressor mo- • voltage to the SCRs
tor. This type of starter reduces the peak starting torque, • SCR control voltage
reduces the motor inrush current, and decreases mechanical • power indication
shock. This capability is summed up by the phrase ‘‘soft start- • proper phasing for rotation
ing.’’ The solid-state starter is available as a 19XR option • start circuit energized
(factory supplied and installed). The solid-state starters manu- • over-temperature
facturer name is located inside the starter access door. • ground fault
A solid-state, reduced-voltage starter operates by reduc- • current unbalance
ing the starting voltage. The starting torque of a motor at full • run state
voltage is typically 125% to 175% of the running torque. • software configuration
When the voltage and the current are reduced at start-up, the The starter is further explained in the Check Starter and
starting torque is reduced as well. The object is to reduce the Troubleshooting Guide sections, pages 52 and 66.
starting voltage to just the voltage necessary to develop the
9
Unit-Mounted Wye-Delta Starter (Optional)
— The 19XR chiller may be equipped with a wye-delta starter
mounted on the unit. This starter is intended for use with
low-voltage motors (under 600 v). It reduces the starting
6 current inrush by connecting each phase of the motor
windings into a wye configuration. This occurs during the
starting period when the motor is accelerating up to speed.
1 Once the motor is up to speed, the starter automatically con-
nects the phase windings into a delta configuration. Starter
control, monitoring, and motor protection is provided by
Carrier’s Integrated Starter Module (ISM).
2 CONTROLS
Definitions
3
5 ANALOG SIGNAL — An analog signal varies in propor-
tion to the monitored source. It quantifies values between
operating limits. (Example: A temperature sensor is an ana-
log device because its resistance changes in proportion to
the temperature, generating many values.)
DISCRETE SIGNAL — A discrete signal is a 2-position rep-
4
resentation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value
is above or below a set point or boundary by generating an
on/off, high/low, or open/closed signal.)
LEGEND
General — The 19XR hermetic centrifugal liquid chiller
contains a microprocessor-based control center that moni-
1 — Ready-Start Micro Input/Output Card tors and controls all operations of the chiller (see Fig. 7).
2 — Circuit Breaker 2 (CB2):
Machine Control and Heater Power The microprocessor control system matches the cooling
3 — Circuit Breaker 3 (CB3): Oil Pump Power capacity of the chiller to the cooling load while providing
4 — Ready-Start Micro Central Processing Unit Card (CPU) state-of-the-art chiller protection. The system controls cool-
5 — Restart Micro Power Card (hidden, not depicted) ing load within the set point plus the deadband by sensing
6 — Restart Micro Bypass Card (hidden, not depicted)
the leaving chilled water or brine temperature and regula-
Fig. 5 — Solid-State Starter Box, ting the inlet guide vane via a mechanically-linked actuator
Internal View motor. The guide vane is a variable flow pre-whirl assem-
bly that controls the refrigeration effect in the cooler by
regulating the amount of refrigerant vapor flow into the com-
pressor. An increase in guide vane opening increases capac-
ity. A decrease in guide vane opening decreases capacity. The
microprocessor-based control center protects the chiller by
monitoring the digital and analog inputs and executing
capacity overrides or safety shutdowns, if required.
PIC II System Components — The chiller control
system is called the PIC II (Product Integrated Control II).
See Table 1. The PIC II controls the operation of the chiller
by monitoring all operating conditions. The PIC II can di-
agnose a problem and let the operator know what the prob-
lem is and what to check. It promptly positions the guide
vanes to maintain leaving chilled water temperature. It can
interface with auxiliary equipment such as pumps and cool-
ing tower fans to turn them on when required. It continually
checks all safeties to prevent any unsafe operating condi-
tion. It also regulates the oil heater while the compressor is
off and regulates the hot gas bypass valve, if installed. The
PIC II controls provide critical protection for the compres-
sor motor and controls the motor starter.
Fig. 6 — Typical Starter External View

(Solid-State Starter Shown)
10
COOLER SCHRADER CONTROL GUIDE VANE POWER COMMUNICATION
FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE
WATER
SENSOR
CABLES WATER
SENSOR
CABLES
COOLER
PRESSURE
CONNECTION
CONDENSER CONDENSER CONDENSER COMPRESSOR MOTOR WINDING

PRESSURE SCHRADER PRESSURE DISCHARGE TEMPERATURE
CABLE FITTING (HIDDEN) CONNECTION ELBOW JOINTS CABLE
TRANSDUCER
TOP VIEW
VIEW A — A (COMPRESSOR DETAIL)

Fig. 7 — 19XR Controls and Sensor Locations
11
The PIC II can interface with the Carrier Comfort Net- tower fan, spare alarm contacts, and the shunt trip. The ISM
work (CCN) if desired. It can communicate with other monitors starter inputs such as line voltage, motor current,
PIC I or PIC II equipped chillers and other CCN devices. ground fault, remote start contact, spare safety, condenser
The PIC II consists of 3 modules housed inside 3 major high pressure, oil pump interlock, starter 1M, and run con-
components. The component names and corresponding contacts. The ISM contains logic capable of safety shutdown. It
trol voltages are listed below (also see Table 1): shuts down the chiller if communications with the CVC
are lost.
• control panel
— all extra low-voltage wiring (24 v or less) CHILLER CONTROL MODULE (CCM) — This module
• power panel is located in the control panel. The CCM provides the input
— 230 or 115 v control voltage (per job requirement) and outputs necessary to control the chiller. This module moni-
— up to 600 v for oil pump power tors refrigerant pressure, entering and leaving water tem-
peratures, and outputs control for the guide vane actuator,
• starter cabinet oil heaters, and oil pump. The CCM is the connection point
— chiller power wiring (per job requirement) for optional demand limit, chilled water reset, remote tem-
perature reset, and refrigerant leak sensor.
Table 1 — Major PIC Components and
Panel Locations* OIL HEATER CONTACTOR (1C) — This contactor is lo-
cated in the power panel (Fig. 11) and operates the heater at
PIC II COMPONENT PANEL LOCATION either 115 or 230 v. It is controlled by the PIC II to maintain
Chiller Visual Controller (CVC) and Display Control Panel oil temperature during chiller shutdown.
Integrated Starter Module (ISM) Starter Cabinet OIL PUMP CONTACTOR (2C) — This contactor is located
Chiller Control Module (CCM) Control Panel in the power panel. It operates all 200 to 575-v oil pumps.
Oil Heater Contactor (1C) Power Panel The PIC II energizes the contactor to turn on the oil pump
Oil Pump Contactor (2C) Power Panel as necessary.
Hot Gas Bypass Relay (3C) (Optional) Power Panel HOT GAS BYPASS CONTACTOR RELAY (3C) (Op-
Control Transformers (T1, T2) Power Panel tional) — This relay, located in the power panel, controls the
Temperature Sensors See Fig. 7. opening of the hot gas bypass valve. The PIC II energizes
Pressure Transducers See Fig. 7. the relay during low load, high lift conditions.
*See Fig. 5 and Fig. 7-11.
CONTROL TRANSFORMERS (T1, T2) — These trans-
formers convert incoming control voltage to 24 vac power
for the 3 power panel contactor relays, CCM, and CVC.
CHILLER VISUAL CONTROLLER (CVC) — The CVC is
the ‘‘brain’’ of the PIC II. This module contains all the op-
erating software needed to control the chiller. The CVC is
mounted to the control panel (Fig. 10) and is the input center
for all local chiller set points, schedules, configurable
functions, and options. The CVC has a stop button, an alarm
light, four buttons for logic inputs, and a backlight display.
The backlight will automatically 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 Fig. 8 — Control Sensors (Temperature)
the softkeys.
The viewing angle of the CVC can be adjusted for opti-
mum 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 back-
ward to change the viewing angle. See Fig. 10. To change
the contrast of the display, access the adjustment on the back
of the CVC. See Fig. 10.
INTEGRATED STARTER MODULE (ISM) — This mod-
ule is located in the starter cabinet. This module initiates com- Fig. 9 — Control Sensors
mands from the CVC for starter functions such as starting (Pressure Transducers, Typical)
and stopping the compressor, condenser, chilled water pumps,
12
Fig. 10 — Control Panel
Fig. 11 — Power Panel
13
CVC Operation and Menus (Fig. 12-18) PRIMARY STATUS
MESSAGE
COMPRESSOR
ONTIME
DATE TIME
GENERAL SECONDARY
STATUS RUNNING TEMP CONTROL 01-01-95 11:48
• The CVC display automatically reverts to the default screen MESSAGE LEAVING CHILLED WATER 28.8 HOURS
CHW IN CHW OUT EVAP REF
after 15 minutes if no softkey activity takes place and if ALARM LIGHT
55.1 44.1 40.7
the chiller is not in the pumpdown mode (Fig. 12). (ILLUMINATED CDW IN CDW OUT COND REF
WHEN POWER ON) 85.0 95.0 98.1
• If a screen other than the default screen is displayed on the • BLINKS CONTINUOUSLY
ON FOR AN ALARM
OIL PRESS OIL TEMP AMPS %
CVC, the name of that screen is in the upper right corner 21.8 132.9 93
• CONFIRMONCE
BLINKS TO
A STOP CCN LOCAL RESET MENU
(Fig. 13).
• The CVC may be set to display either English or SI units.
Use the CVC configuration screen (accessed from the Serv-
ice menu) to change the units. See the Service Operation STOP BUTTON
• HOLD FOR ONE
section, page 43. SECOND TO STOP
• Local Operation — The PIC II can be placed in local SOFT KEYS

EACH KEY'S FUNCTION IS MENU
operating mode by pressing the LOCAL softkey. The DEFINED BY THE MENU DESCRIPTION LINE
ON MENU LINE ABOVE
PIC II then accepts commands from the CVC only and
uses the Local Time Schedule to determine chiller start Fig. 12 — CVC Default Screen
and stop times.
• CCN Operation — The PIC II can be placed in the CCN
operating mode by pressing the CCN softkey. The
PIC II then accepts modifications from any CCN interface 19XR_II SERVICE
or module (with the proper authority), as well as from the ALARM HISTORY
CVC. The PIC II uses the CCN time schedule to deter- CONTROL TEST
CONTROL ALGORITHM STATUS
mine start and stop times. EQUIPMENT CONFIGURATION
ISM (STARTER) CONFIGURATION DATA
EQUIPMENT SERVICE
TIME AND DATE
ALARMS AND ALERTS — An alarm shuts down the com- ATTACH TO NETWORK DEVICE
LOG OUT OF DEVICE
pressor. An alert does not shut down the compressor, but it CVC CONFIGURATION
notifies the operator that an unusual condition has occurred.

An alarm (*) or alert (!) is indicated on the STATUS screens
on the far right field of the CVC display screen.
Alarms are indicated when the control center alarm light
(!) flashes. The primary alarm message is displayed on the
default screen. An additional, secondary message and
troubleshooting information are sent to the ALARM HIS-
TORY table. Fig. 13 — CVC Service Screen
When an alarm is detected, the CVC default screen will
freeze (stop updating) at the time of alarm. The freeze en-
ables the operator to view the chiller conditions at the time
of alarm. The STATUS tables will show the updated infor- • The SERVICE menu can be used to view or modify
mation. Once all alarms have been cleared (by pressing the information on the Alarm History, Control Test, Control
RESET softkey), the default CVC screen will return to nor- Algorithm Status, Equipment Configuration, ISM Starter
mal operation. Configuration data, Equipment Service, Time and Date, At-
tach to Network Device, Log Out of Network Device, and
CVC MENU ITEMS — To perform any of the operations CVC Configuration screens.
described below, the PIC II must be powered up and have
successfully completed its self test. The self test takes place For more information on the menu structures, refer to
automatically, after power-up. Fig. 15.
Press the MENU softkey to view the list of menu struc- Press the softkey that corresponds to the menu structure
tures: STATUS , SCHEDULE , SETPOINT , and to be viewed : STATUS , SCHEDULE , SETPOINT , or
SERVICE . SERVICE . To view or change parameters within any of
• The STATUS menu allows viewing and limited calibra- these menu structures, use the NEXT and PREVIOUS soft-
tion or modification of control points and sensors, relays keys to scroll down to the desired item or table. Use the
and contacts, and the options board.
SELECT softkey to select that item. The softkey choices
• The SCHEDULE menu allows viewing and modification
of the local and CCN time schedules and Ice Build time that then appear depend on the selected table or menu. The
schedules. softkey choices and their functions are described below.
• The SETPOINT menu allows set point adjustments, such BASIC CVC OPERATIONS (Using the Softkeys) — To per-
as the entering chilled water and leaving chilled water set form any of the operations described below, the PIC II must
points. be powered up and have successfully completed its self test.
14
• 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 startup of chiller
• COMPRESS — Status of sensors related to the
compressor
• HEAT_EX — Status of sensors related to the heat
• Press ENTER to leave the selected decision or field and exchangers
save changes. • POWER — Status of motor input power
• ISM_STAT — Status of motor starter
• CVC_PSWD — Service menu password forcing ac-
cess screen
• Press NEXT to scroll the cursor bar down in order to

highlight a point or to view more points below the current
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
Active Demand Limit
44.6 F
100%
Average Line Current 0.0%
• Press INCREASE or DECREASE to change the high-

lighted point value.
Fig. 14 — Example of Status Screen
OVERRIDE OPERATIONS
To Override a Value or Status
1. From any point status screen, press NEXT or
PREVIOUS to highlight the desired value.
TO VIEW STATUS (Fig. 14) — The status table shows the
actual value of overall chiller status such as CONTROL MODE,
RUN STATUS, AUTO CHILLED WATER, RESET, and RE-
MOTE 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:
15
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)

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

STOP START 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 RELEASE 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 16
Fig. 15 — 19XR CVC Menu Structure
16
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 YES NO QUIT ENTER (DISCRETE VALUES)

ON NEXT PAGE
Fig. 16 — 19XR Service Menu Structure
17
SERVICE MENU CONTINUED
FROM PREVIOUS PAGE
ISM (STARTER CONFIG DATA)
EQUIPMENT SERVICE
4 4 4 4 (ENTER A 4-DIGIT PASSWORD)
Service Tables:
• OPTIONS Service Tables:
• SETUP1 • ISM (STARTER) CONFIG PASSWORD
• SETUP2 • ISM_CONFIG
• 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)

NO YES 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
List Network Devices
• Local • Device 6
• Device 1 • Device 7
• Device 4
• Device 5
Select a Device
NEXT PREVIOUS SELECT ATTACH
Modify Device Address

• 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
• To Modify — CVC CCN Address • To View — CVC Software Version
— English or S.I. Metric Units (last 2 digits of part number
— Password indicate software version)
LEGEND
CCN — Carrier Comfort Network
CVC — Chiller Visual Control
PIC II — Product Integrated Control II
Fig. 16 — 19XR Service Menu Structure (cont)
18
For Discrete Points — Press START or STOP to se- 2. Press NEXT or PREVIOUS to highlight the de-
lect the desired state. sired schedule.
OCCPC01S — LOCAL Time Schedule
OCCPC02S — ICE BUILD Time Schedule
OCCPC03 — CCN Time Schedule
For Analog Points — Press INCREASE or

DECREASE to select the desired value.
3. Press SELECT to view the desired time schedule.
3. Press ENTER to register the new value.
4. Press NEXT or PREVIOUS to highlight the de-

sired period or override to change.
NOTE: When overriding or changing metric values, it is nec-

essary to hold down the softkey for a few seconds in order
to see a value change, especially on kilopascal values.
To Remove an Override 5. Press SELECT to access the highlighted period or
1. On the point status table press NEXT or override.
PREVIOUS to highlight the desired value.
6. a. Press INCREASE or DECREASE to change the

2. Press SELECT to access the highlighted value. time values. Override values are in one-hour incre-
ments, up to 4 hours.
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. 17)

1. On the Menu screen, press SCHEDULE .
Fig. 17 — Example of Time Schedule

Operation Screen
19
2. There are 5 set points on this screen: BASE DEMAND
b. Press ENABLE to select days in the day-of-week LIMIT, LCW SETPOINT (leaving chilled water set point),
fields. Press DISABLE to eliminate days from the ECW SETPOINT (entering chilled water set point), ICE
period. BUILD SETPOINT, and TOWER FAN HIGH SET-
POINT. Only one of the chilled water set points can be
active at one time. The set point that is active is deter-
mined from the SERVICE menu. See the Service Opera-
tion section, page 43. The ice build (ICE BUILD) func-
tion is also activated and configured from the SERVICE
menu.
7. Press ENTER to register the values and to move
horizontally (left to right) within a period. 3. Press NEXT or PREVIOUS to highlight the desired
set point entry.
8. Press EXIT to leave the period or override.

4. Press SELECT to modify the highlighted set point.
9. Either return to Step 4 to select another period or

override, or press EXIT again to leave the current time
schedule screen and save the changes. 5. Press INCREASE or DECREASE to change the se-
lected set point value.
10. The Holiday Designation (HOLIDEF table) may be found

in the Service Operation section, page 43. The month,
day, and duration for the holiday must be assigned. The 6. Press ENTER to save the changes and return to the
Broadcast function in the BRODEF table also must be previous screen.
enabled for holiday periods to function.
TO VIEW AND CHANGE SET POINTS (Fig. 18)
1. To view the SETPOINT table, from the MENU screen
press SETPOINT .
SERVICE OPERATION — To view the menu-driven pro-

grams available for Service Operation, see Service Opera-
tion section, page 43. For examples of CVC display screens,
see Table 2.
19XR_II SETPOINT SETPOINT SELECT

Base Demand Limit 100%
Control Point
LCW Setpoint 50.0 F
ECW Setpoint 60.0 F
ICE BUILD Setpoint 40.0 F
Tower Fan High Setpoint 85.0 F
Fig. 18 — Example of Set Point Screen
20
Table 2 — CVC Display Data
6. Reference Point Names shown in these tables in all capital letters
IMPORTANT: The following notes apply to all Table 2 can be read by CCN and BS software. Of these capitalized names,
examples.
those preceded by a dagger can also be changed (that is, written
1. Only 12 lines of information appear on the CVC screen at any one to) by the CCN, BS, and the CVC. Capitalized Reference Point
Names preceded by two asterisks can be changed only from the
time. Press the NEXT or PREVIOUS softkey to highlight a
CVC. Reference Point Names in lower case type can be viewed
point or to view items below or above the current screen. Press by CCN or BS only by viewing the whole table.
the NEXT softkey twice to page forward; press the 7. Alarms and Alerts: An asterisk in the far right field of a CVC status
screen indicates that the chiller is in an alarm state; an exclama-
PREVIOUS softkey twice to page back. tion point in the far right field of the CVC screen indicates an alert
2. To access the information shown in Examples 9 through 21, enter state. The asterisk (or exclamation point) indicates that the value
your 4-digit password after pressing the SERVICE softkey. If on that line has exceeded (or is approaching) a limit. For more
information on alarms and alerts, see the Alarms and Alerts
no softkeys are pressed for 15 minutes, the CVC automatically section, page 14.
logs off (to prevent unrestricted access to PIC II controls) and re-
LEGEND
verts to the default screen. If this happens, you must reenter your
password to access the tables shown in Examples 9 through 21. CCN — Carrier Comfort Network
3. Terms in the Description column of these tables are listed as they CHW — Chilled Water
appear on the CVC screen. CHWR — Chilled Water Return
CHWS — Chilled Water Supply
4. The CVC may be configured in English or Metric (SI) units using CVC — Chiller Visual Control
the CVC CONFIGURATION screen. See the Service Operation CT — Current Transformer
section, page 43, for instructions on making this change. ECW — Entering Chilled Water
5. The items in the Reference Point Name column do not appear on HGBP — Hot Gas Bypass
the CVC screen. They are data or variable names used in CCN or ISM — Integrated Starter Module
Building Supervisor (BS) software. They are listed in these tables LCW — Leaving Chilled Water
as a convenience to the operator if it is necessary to cross ref- LRA — Locked Rotor Amps
erence CCN/BS documentation or use CCN/BS programs. For more mA — Milliamps
P — Pressure
information, see the 19XR CCN literature. SS — Solid State
T — Temperature
VFD — Variable Frequency Drive
WSM — Water System Manager
EXAMPLE 1 — CVC DEFAULT SCREEN

The following data is displayed in the CVC Default screen.
DESCRIPTION RANGE UNITS REFERENCE POINT NAME DISPLAY

(ALARM HISTORY)
(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.
21
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 OFF/ON 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 ICR 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
Starter 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.
22
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 DEG F 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
Oil Heater Relay 0/1 OFF/ON OILH
Diffuser Actuator 0-100 % DIFF ACT
**Target VFD Speed 0-110 % VFD OUT
**Actual VFD Speed 0-100 % VFD ACT
Surge Protection Counts 0-5 spc
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
for the CVC only.
23
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
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.
EXAMPLE 7 — ISM STAT 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
ICR Start Complete 0-1 FALSE/TRUE START OK
IM 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 TRIP
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
ICR Stop Complete 0-1 FALSET/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.
24
EXAMPLE 8 — SET POINT DISPLAY SCREEN
1. Press MENU .
2. Press SETPOINT (Base Demand Limit will be highlighted).
3. Press SELECT .
DESCRIPTION STATUS UNITS POINT DEFAULT

Base Demand Limit 40-100 % DLM 100
Control Point
LCW Set Point 10-120 DEG F lcw sp 50.0
ECW Set Point 15-120 DEG F ecw sp 60.0
Ice Build Set Point 15-60 DEG F ice sp 40.0
Tower Fan High Set Point 55-105 DEG F tf2 sp 75
NOTE: All variables are available for CCN read operation; forcing shall not be supported on set point screens.
EXAMPLE 9 — 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 .

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 DEG F cperr
ECW Delta T −99-99 DEG F ecwdt
ECW Reset −99-99 DEG F ecwres
LCW Reset −99-99 DEG F lcwres
Total Error + Resets −99-99 DEG 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 Inhibit Active 0-1 NO/YES DEM INH
Amps/kW Ramp 0-100 % DMD RAMP
NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance
screen.
25
EXAMPLE 10 — OVERRIDE DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight OVERRIDE .

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 DEG F SUPRHEAT
Superheat Required 6-99 ^F SUPR REQ
Condenser Refrig Temp −40-245 ^F CRT
screens.
EXAMPLE 11 — LL MAINT DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight LL MAINT. .

Lead Lag Control
LEAD/LAG: 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 ^ DEG 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
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.
26
EXAMPLE 12 — ISM HIST DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight ISM HIST .

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 13 — WSMDEFME DISPLAY SCREEN

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

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.
27
EXAMPLE 14 — 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 .

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 15 — ISM CONF DISPLAY SCREEN

1. Press MENU .
2. Press SERVICE .
3. Scroll down to highlight ISM (STARTER) CONFIG DATA .
4. Press SELECT .
5. Scroll down to highlight ISM CONF .

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 5
Voltage Imbalance Time 1-10 SEC v time 5
Motor Rated Load Amps 10-5000 AMPS a fs 200
Motor Locked Rotor Trip 100-60000 AMPS motor lr 1000
Locked Rotor Start Delay 1-10 cycles lrdelay 5
Starter LRA Rating 100-60000 AMPS start lr 2000
Motor Current CT Ratio:1 10-1000 ct turns 100
Current % Imbalance 5-40 % c unbal 15
Current Imbalance Time 1-10 SEC c time 5
3 Grnd Fault CT’s? (1 = No) 0-1 NO/YES gf phase YES
Ground Fault CT Ratio:1 150 gf ctr 150
Ground Fault Current 1-20 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
28
EXAMPLE 16 — 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 .

Auto Restart Option 0/1 DSABLE/ENABLE astart DSABLE
Remote Contacts Option 0/1 DSABLE/ENABLE r contact DSABLE
Soft Stop Amps Threshold 40-100 % softstop 100
Surge/Hot Gas Bypass
Surge Limit/HGBP Option 0/1 srg hgbp 0
Select: Surge = 0, HGBP = 1
Min. Load Point (T1/P1)
Surge/HGBP Delta T1 0.5-15 ^F hgb dt1 1.5
Surge/HGBP Delta P1 30-170 PSI hgb dp1 50
Full Load Point (T2/P2)
Surge/HGBP Delta T2 0.5-15 ^F hgb dt2 10
Surge/HGBP Delta P2 50-170 PSI hgb dp2 85
Surge/HGBP Deadband 0.5-3 ^F hgb dp 1
Surge Protection
Surge Delta % Amps 5-15 % 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
EXAMPLE 17 — SETUP1 DISPLAY SCREEN

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

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 Press Verify Time 15-300 SEC oilpr t 40
Recycle control
Recycle Restart Delta T 2.0-10.0 DEG F rcycr dt 5
Recycle Shutdown Delta 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 operation; forcing shall not be supported on service screens.
29
EXAMPLE 18 — SETUP2 DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight SETUP2 .

Capacity Control
Proportional Inc Band 2-10 gv inc 6.5
Proportional DEC Band 2-10 gv dec 6.0
Proportional ECW Gain 1-3 gv ecw 2.0
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 0-100 % df 25 0
Diffuser 50% Load Pt 0-100 % df 50 0
Diffuser 75% Load Pt 0-100 % df 75 0
Diffuser Full Span mA 15-22 mA diff ma 18
VFD Speed Control
VFD Option 0/1 DSABLE/ENABLE vfd opt DSABLE
VFD Gain 0.1-1.5 vfd gain 0.75
VFD Increase Step 1-5 % vfd step 2
VFD Minimum Speed 65-100 % vfd min 70
VFD Maximum speed 90-110 % vfd max 100
NOTE: No variables are available for CCN read operation; forcing shall be supported on service screens.
EXAMPLE 19 − LEADLAG DISPLAY SCREEN

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

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 Percent 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 preflt 5
STANDBY Chiller Option 0/1 DSABLE/ENABLE stndopt DSABLE
STANDBY Percent Capacity 25-57 % stnd per 50
STANDBY Address 1-236 stnd add 93
30
EXAMPLE 20 — RAMP_DEM DISPLAY SCREEN
1. Press MENU .
2. Press SERVICE .
4. Press SELECT .
5. Scroll down to highlight RAMP_DEM .

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
20mA Demand Limit Opt 0/1 DS/ENABLE dem sel DSABLE
Motor Rated Kilowatts 50-9999 kW motor kw 145
Demand Watts Interval 5-60 MIN dw int 15
EXAMPLE 20 — TEMP_CTL DISPLAY SCREEN

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

Control Point
EWB 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
31
PIC II System Functions The Proportional Band — There are two response modes,
one for temperature response above the control point, the
NOTE: Words not part of paragraph headings and printed other for the response below the control point.
in all capital letters can be viewed on the CVC (e.g., LO-
CAL, CCN, RUNNING, ALARM, etc.). Words printed in The temperature response above the control point is called
both in all capital letters and italics can also be viewed on the PROPORTIONAL INC BAND, and it can slow or quicken
the CVC and are parameters (CONTROL MODE, COOL- guide vane response to chilled water/brine temperatures above
ING SET POINT, TARGET GUIDE VANE POS, etc.) with the DEADBAND. The PROPORTIONAL INC BAND can be
associated values (e.g., modes, temperatures, pressures, per- adjusted from a setting of 2 to 10; the default setting is 6.5.
centages, on, off, enable, disable, etc.). Works printed in all The response below the control point is called the
capital letters and in a box represent softkeys on the CVC PROPORTIONAL DEC BAND, and it can slow or quicken
(e.g., ENTER and EXIT ). See Table 2 for examples of the guide vane response to chilled water temperature below
the deadband plus the control point. The PROPORTIONAL
the type of information that can appear on the CVC screens. DEC BAND can be adjusted on the CVC from a setting of
Figures 12-18 give an overview of CVC operations and menus. 2 to 10. The default setting is 6.0.
CAPACITY CONTROL — The PIC II controls the chiller NOTE: Increasing either of these settings causes the guide
capacity by modulating the inlet guide vanes in response to vanes to respond more slowly than they would at a lower
chilled water temperature changes away from the CON- setting.
TROL POINT. The CONTROL POINT may be changed by
a CCN network device or is determined by the PIC II adding The PROPORTIONAL ECW GAIN can be adjusted on the
any active chilled water reset to the SET POINT. The PIC II CVC display for values of 1, 2, or 3; the default setting is 2.
uses the PROPORTIONAL INC (Increase) BAND, PRO- Increase this setting to increase guide vane response to a change
PORTIONAL DEC (Decrease) BAND, and the PROPOR- in entering chilled water temperature.
TIONAL ECW (Entering Chilled Water) GAIN to determine DEMAND LIMITING — The PIC II responds to the
how fast or slow to respond. CONTROL POINT may be viewed ACTIVE DEMAND LIMIT set point by limiting the opening
or overridden from the MAINSTAT screen. of the guide vanes. It compares the ACTIVE DEMAND LIMIT
ECW CONTROL OPTION — If this option is enabled, the set point to the DEMAND LIMIT SOURCE (either the
PIC II uses the ENTERING CHILLED WATER temperature AVERAGE LINE CURRENT or the MOTOR KW). Depend-
to modulate the vanes instead of the LEAVING CHILLED ing on how the control is configured. DEMAND LIMIT
WATER temperature. The ECW CONTROL OPTION may be SOURCE is on the RAMP_DEM screen. The default source
viewed on the TEMP_CTL screen, which is accessed from is the compressor motor current.
the EQUIPMENT SERVICE screen. CHILLER TIMERS — The PIC II maintains 2 runtime clocks,
CONTROL POINT DEADBAND — This is the tolerance known as COMPRESSOR ONTIME and SERVICE ON-
range on the chilled water/brine temperature control point. TIME. COMPRESSOR ONTIME indicates the total life-
If the water temperature goes outside the CHILLED WATER time compressor run hours. This timer can register up to
DEADBAND, the PIC II opens or closes the guide vanes un- 500,000 hours before the clock turns back to zero. The
til the temperature is within tolerance. The PIC II may be SERVICE ONTIME is a reset table timer that can be used to
configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband. CHILLED indicate the hours since the last service visit or any other
WATER DEADBAND may be viewed or modified on the event. The time can be changed from the CVC to whatever
SETUP1 screen, which is accessed from the EQUIPMENT value is desired. This timer can register up to 32,767 hours
SERVICE table. before it rolls over to zero.
For example, a 1° F (0.6° C) deadband setting controls The chiller also maintains a start-to-start timer and a stop-
the water temperature within ±0.5° F (0.3° C) of the control to-start timer. These timers limit how soon the chiller can be
point. This may cause frequent guide vane movement if the started. START INHIBIT TIMER is displayed on the
chilled water load fluctuates frequently. A value of 1° F MAINSTAT screen. See the Start-Up/Shutdown/Recycle Se-
(0.6° C) is the default setting. quence section, page 44, for more information on this topic.
DIFFUSER CONTROL — On 19XR compressors equipped OCCUPANCY SCHEDULE — The chiller schedule, de-
with a variable discharge diffuser, the PIC II adjusts the dif- scribed in the Time Schedule Operation section (page 19),
fuser actuator position (DIFFUSER ACTUATOR on the COM- determines when the chiller can run. Each schedule consists
PRESS screen) to correspond to the actual guide vane po- of from 1 to 8 occupied or unoccupied time periods, set by
sition (ACTUAL GUIDE VANE POS on the COMPRESS the operator. The chiller can be started and run during an
screen). occupied time period (when OCCUPIED ? is set to YES on
the MAINSTAT display screen). It cannot be started or run
The diffuser control can be enabled or disabled from the during an unoccupied time period (when OCCUPIED ? is
SETUP2 screen. See Table 2, Example 18. In addition, the set to NO on the MAINSTAT display screen). These time
diffuser and guide vane load points may be viewed and modi- periods can be set for each day of the week and for holidays.
fied from this screen. These points must be correct for the The day begins with 0000 hours and ends with 2400 hours.
compressor size. The diffuser opening can be incremented The default setting for OCCUPIED ? is YES, unless an un-
from fully open to completely closed. A 0% setting is fully occupied time period is in effect.
open; a 100% setting is completely closed. To obtain the proper
settings for Diffuser Control, contact a Carrier Engineering These schedules can be set up to follow a building’s oc-
representative. cupancy schedule, or the chiller can be set so to run 100%
of the time, if the operator wishes. The schedules also can be
PROPORTIONAL BANDS AND GAIN — Proportional band bypassed by forcing the CHILLER START/STOP parameter
is the rate at which the guide vane position is corrected in on the MAINSTAT screen to START. For more information
proportion to how far the chilled water/brine temperature is on forced starts, see Local Start-Up, page 44.
from the control point. Proportional gain determines how The schedules also can be overridden to keep the chiller
quickly the guide vanes react to how quickly the tempera- in an occupied state for up to 4 hours, on a one time basis.
ture is moving from the CONTROL POINT. The propor- See the Time Schedule Operation section, page 19.
tional bands and gain may be viewed or modified from the
SETUP2 screen, which is accessed from the EQUIPMENT
SERVICE table.
32
Figure 17 shows a schedule for a typical office building • voltage imbalance
with a 3-hour, off-peak, cool-down period from midnight • current imbalance
to 3 a.m., following a weekend shutdown. Holiday periods
are in an unoccupied state 24 hours per day. The building • excessive motor acceleration time
operates Monday through Friday, 7:00 a.m. to 6:00 p.m., and • excessive starter transition time
Saturdays from 6:00 a.m. to 1:00 p.m. This schedule also • lack of motor current signal
includes the Monday midnight to 3:00 a.m. weekend cool- • excessive motor amps
down schedule.
• excessive compressor surge
NOTE: This schedule is for illustration only and is not in-
tended to be a recommended schedule for chiller operation. • temperature and transducer faults
Whenever the chiller is in the LOCAL mode, it uses *Superheat is the difference between saturation temperature
Occupancy Schedule 01 (OCCPC01S). When the chiller is and sensible temperature. The high discharge temperature
in the ICE BUILD mode, it uses Occupancy Schedule 02 safety measures only sensible temperature.
(OCCPC02S). When the chiller is in CCN mode, it uses Starter faults or optional protective devices within the starter
Occupancy Schedule 03 (OCCPC03S). can shut down the chiller. The protective devices you
The CCN SCHEDULE NUMBER is configured on the have for your application depend on what options were
NET_OPT display screen, accessed from the EQUIPMENT purchased.
CONFIGURATION table. See Table 2, Example 14.
SCHEDULE NUMBER can be changed to any value from
03 to 99. If this number is changed on the NET_OPT screen,
the operator must go to the ATTACH TO NETWORK DE- If compressor motor overload occurs, check the motor
VICE screen to upload the new number into the SCHED- for grounded or open phases before attempting a
ULE screen. See Fig. 16. restart.
Safety Controls — The PIC II monitors all safety con- If the PIC II control initiates a safety shutdown, it dis-
trol inputs and, if required, shuts down the chiller or limits plays the reason for the shutdown (the fault) on the CVC
the guide vanes to protect the chiller from possible damage display screen along with a primary and secondary message,
from any of the following conditions: energizes an alarm relay in the starter, and blinks the alarm
• high bearing temperature light on the control panel. The alarm is stored in memory
• high motor winding temperature and can be viewed on the ALARM HISTORY and
ISM_HIST screens on the CVC, along with a message for
• high discharge temperature troubleshooting. If the safety shutdown was also initiated by
• low discharge superheat* a fault detected in the motor starter, the conditions at the
• low oil pressure time of the fault will be stored in ISM_HIST.
• low cooler refrigerant temperature/pressure To give more precise information or warnings on the chill-
er’s operating condition, the operator can define alert limits
• condenser high pressure or low pressure on various monitored inputs. Safety contact and alert limits
• inadequate water/brine cooler and condenser flow are defined in Table 3. Alarm and alert messages are listed
• high, low, or loss of voltage in the Troubleshooting Guide section, page 69.
• ground fault
33
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, configure chilled medium for water
TEMPERATURE (SETUP1 table)
,EVAP REFRIG TRIPPOINT (set point Configure chilled medium for brine (SETUP1
adjustable from 0 to 40 F [–18 to 4 C] for table). Adjust EVAP REFRIG TRIPPOINT for
brine chilling) proper cutout
TRANSDUCER VOLTAGE ,4.5 vdc . 5.5 vdc Preset
CONDENSER PRESSURE — SWITCH .263 ± 7 psig (1813 ± 48 kPa), reset at Preset
180 ± 10 (1241 ± 69 kPa)
— CONTROL 165 psig (1138 kPa) Preset
OIL PRESSURE Cutout ,15 psid (103 kPad) Preset
Alert ,18 psid (124 kPad)
LINE VOLTAGE — HIGH .110% for one minute Preset, based on transformed line voltage to
— LOW ,90% for one minute or <85% for 3 seconds ISM. Also monitored at CVC and CCM power
input.
— SINGLE-CYCLE ,50% for one cycle
COMPRESSOR MOTOR LOAD .110% for 30 seconds Preset
,15% with compressor running Preset
.15% with compressor off Preset
STARTER ACCELERATION TIME .45 seconds For chillers with reduced voltage mechanical
(Determined by inrush current and solid-state starters
going below 100% compressor .10 seconds For chillers with full voltage starters
motor load) (Configured on ISM_CONFIG table)
STARTER TRANSITION .75 seconds Reduced voltage starters only
CONDENSER FREEZE PROTECTION Energizes condenser pump relay if condenser CONDENSER FREEZE POINT configured in
refrigerant temperature or condenser entering SETUP1 table with a default setting of
water temperature is below the configured 34 F (1 C).
condenser freeze point temperature. Deener-
gizes when the temperature is 5 F (3 C)
above condenser freeze point temperature.
DISCHARGE SUPERHEAT Minimum value calculated based on Calculated minimum required superheat and
operating conditions and then compared actual superheat are shown on OVERRIDE
to actual superheat. screen.
VARIABLE DIFFUSER OPERATION Detects discharge pulses caused by incorrect Preset, no calibration needed.
diffuser position.
34
Shunt Trip (Option) — The function of the shunt trip If kilowatts is selected for the DEMAND LIMIT SOURCE,
option on the PIC II is to act as a safety trip. The shunt trip the MOTOR RATED KILOWATTS must be entered (infor-
is wired from an output on the ISM to a shunt trip equipped mation found on the chiller Requisition form).
motor circuit breaker. If the PIC II tries to shut down the The TEMP PULLDOWN DEG/MIN may be viewed or modi-
compressor using a normal shutdown procedure but is un- fied on the TEMP_CTL screen which is accessed from the
successful for 30 seconds, the shunt trip output is energized EQUIPMENT SERVICE screen. PULLDOWN RAMP TYPE,
and causes the circuit breaker to trip off. If ground fault pro- DEMAND LIMIT SOURCE, and MOTOR LOAD RAMP
tection has been applied to the starter, the ground fault trip %/MIN may be viewed or modified on the RAMP_DEM screen.
also energizes the shunt trip to trip the circuit breaker. Pro-
tective devices in the starter can also energize the shunt trip. Capacity Override (Table 4) — Capacity overrides
The shunt trip feature can be tested using the Control Test can prevent some safety shutdowns caused by exceeding the
feature. motor amperage limit, refrigerant low temperature safety limit,
motor high temperature safety limit, and condenser high pres-
Default Screen Freeze — When the chiller is in an sure limit. In all cases there are 2 stages of compressor vane
alarm state, the default CVC display ‘‘freezes,’’ that is, it control.
stops updating. The first line of the CVC default screen dis-
plays a primary alarm message; the second line displays a 1. The vanes are prevented from opening further, and
secondary alarm message. the status line on the CVC indicates the reason for the
override.
The CVC default screen freezes to enable the operator to
see the conditions of the chiller at the time of the alarm. If 2. The vanes are closed until the condition decreases to be-
the value in alarm is one normally displayed on the default low the first step set point. Then the vanes are released to
screen, it flashes between normal and reverse video. The CVC normal capacity control.
default screen remains frozen until the condition that caused Whenever the motor current demand limit set point
the alarm is remedied by the operator. (ACTIVE DEMAND LIMIT) is reached, it activates a capac-
Knowledge of the operating state of the chiller at the time ity override, again, with a 2-step process. Exceeding 110%
an alarm occurs is useful when troubleshooting. Additional of the rated load amps for more than 30 seconds will initiate
chiller information can be viewed on the status screens and a safety shutdown.
the ISM_HIST screen. Troubleshooting information is re- The compressor high lift (surge prevention) set point will
corded in the ALARM HISTORY table, which can be ac- cause a capacity override as well. When the surge preven-
cessed from the SERVICE menu. tion set point is reached, the controller normally will only
To determine what caused the alarm, the operator should prevent the guide vanes from opening. If so equipped, the
read both the primary and secondary default screen mes- hot gas bypass valve will open instead of holding the vanes.
sages, as well as the alarm history. The primary message See the Surge Prevention Algorithm section, page 38.
indicates the most recent alarm condition. The secondary mes-
sage gives more detail on the alarm condition. Since there High Discharge Temperature Control — If the dis-
may be more than one alarm condition, another alarm mes- charge temperature increases above 160 F (71.1 C), the guide
sage may appear after the first condition is cleared. Check vanes are proportionally opened to increase gas flow through
the ALARM HISTORY screen for additional help in deter- the compressor. If the leaving chilled water temperature is
mining the reasons for the alarms. Once all existing alarms then brought 5° F (2.8° C) below the control set point tem-
perature, the PIC II will bring the chiller into the recycle
are cleared (by pressing the RESET softkey), the default mode.
CVC display returns to normal operation.
Oil Sump Temperature Control — The oil sump tem-
Ramp Loading — The ramp loading control slows down perature control is regulated by the PIC II, which uses the
the rate at which the compressor loads up. This control can oil heater relay when the chiller is shut down.
prevent the compressor from loading up during the short pe-
riod of time when the chiller is started and the chilled water As part of the pre-start checks executed by the controls,
loop has to be brought down to CONTROL POINT. This helps the oil sump temperature (OIL SUMP TEMP) is compared
reduce electrical demand charges by slowly bringing the chilled to the cooler refrigerant temperature (EVAPORATOR
water to CONTROL POINT. The total power draw during REFRIG TEMP). If the difference between these 2 tempera-
this period remains almost unchanged. tures is 50 F (27.8 C) or less, the start-up will be delayed
until the oil temperature is 50 F (27.8 C) or more. Once this
There are two methods of ramp loading with the PIC II. temperature is confirmed, the start-up continues.
Ramp loading can be based on chilled water temperature or
on motor load. Either method is selected from the The oil heater relay is energized whenever the chiller com-
RAMP__DEM screen. pressor is off and the oil sump temperature is less than
140 F (60.0 C) or the oil sump temperature is less than
1. Temperature ramp loading (TEMP PULLDOWN DEG/ the cooler refrigerant temperature plus 53° F (11.7° C). The
MIN) limits the degrees per minute rate at which either oil heater is turned off when the oil sump temperature is
leaving chilled water or entering chilled water tempera- either
ture decreases. This rate is configured by the operator on
the TEMP_CTL screen. The lowest temperature ramp rate • more than 152 F (66.7 C), or
will also be used if chiller power has been off for 3 hours • more than 142 F (61.1 C) and more than the cooler
or more (even if the motor ramp load is selected as the refrigerant temperature plus 55° F (12.8° C).
ramp loading method. The oil heater is always off during start-up or when the
2. Motor load ramp loading (LOAD PULLDOWN) limits the compressor is running.
degrees per minute rate at which the compressor motor The oil pump is also energized during the time the oil
current or compressor motor load increases. The LOAD is being heated (for 60 seconds at the end of every
PULLDOWN rate is configured by the operator on the 30 minutes).
RAMP_DEM screen in amps or kilowatts.
35
Table 4 — Capacity Overrides
SECOND STAGE OVERRIDE
FIRST STAGE SET POINT SET POINT TERMINATION
OVERRIDE
CAPACITY CONTROL View/Modify Default Configurable Value Value
on CVC Screen Value Range
HIGH CONDENSER 125 psig 90 to 165 psig .Override ,Override
PRESSURE SETUP1 (862 kPa) (620 to 1138 kPa) Set Point Set Point
+ 2.4 psid (16.5 kPad)
HIGH MOTOR .200 F 150 to 200 F .Override ,Override
SETUP1 Set Point
TEMPERATURE (93.3 C) (66 to 93 C) +10° F (6° C) Set Point
LOW REFRIGERANT
TEMPERATURE <Trippoint .Trippoint
(Refrigerant SETUP1 3° F (1.6° C) 2° to 5° F + Override + Override
Override Delta (1° to 3° C) DT –1° F (0.56° C) DT +2° F (1.2° C)
Temperature)
Min: T1 — 1.5° F 0.5° to 15° F
(0.8° C) (0.3° to 8.3° C)
HIGH COMPRESSOR P1 — 50 psid 30 to 170 psid Within Lift Limits
(345 kPad) (207 to1172 kPad)
LIFT OPTIONS Max: T2 — 10° F 0.5° to 15° F None Plus Surge/HGBP
(Surge Prevention) (5.6° C) (0.3° to 8.3° C) Deadband Setting
P2 — 85 psid 50 to 170 psid
(586 kPad) (348 to 1172 kPad)
MANUAL GUIDE VANE CAPACITY Automatic 0 to 100% None Release of
TARGET Manual Control
MOTOR LOAD — MAINSTAT 100% 40 to 100% >5% of 2% Lower
ACTIVE DEMAND LIMIT Set Point Than Set Point
LOW DISCHARGE Calculated Minimum 2° F (1.1° C) 1° F (0.56° C)
SUPERHEAT OVERRIDE Superheat None Below Calculated Above Calculated
for Conditions Minimum Superheat Minimum Superheat
Oil Cooler — The oil must be cooled when the com- factory-installed jumper. (Wire multiple inputs in series.) The
pressor is running. This is accomplished through a small, opening of any contact will result in a safety shutdown and
plate-type heat exchanger (also called the oil cooler) located a display on the CVC. Refer to the certified drawings for
behind the oil pump. The heat exchanger uses liquid con- safety contact ratings.
denser refrigerant as the cooling liquid. Refrigerant thermo- Analog temperature sensors may also be added to the mod-
static expansion valves (TXVs) regulate refrigerant flow to ule (SPARE TEMP #1 and #2). The analog temperature sen-
control the oil temperature entering the bearings. The bulbs sors may be configured to cause an alert or alarm on the CCN
for the expansion valves are strapped to the oil supply line network. The alert will not shut the chiller down. Config-
leaving the heat exchanger, and the valves are set to main- uring for alarm state will cause the chiller to shut down.
tain 110 F (43 C).
NOTE: The TXVs are not adjustable. The oil sump temper- Spare Safety Alarm Contacts — One set of alarm
ature may be at a lower temperature during compressor contacts is provided in the starter. The contact ratings are
operations. provided in the certified drawings. The contacts are located
on terminal strip JP, terminals 15 and 16.
Remote Start/Stop Controls — A remote device, such
as a timeclock that uses a set of contacts, may be used to Refrigerant Leak Detector — An input is available
start and stop the chiller. However, the device should not be on the CCM module [terminal 15-5 (−) and J5-6 (+)] for a
programmed to start and stop the chiller in excess of 2 or refrigerant leak detector. Enabling REFRIGERANT LEAK
3 times every 12 hours. If more than 8 starts in 12 hours (the OPTION (OPTIONS screen) will allow the PIC II controls
STARTS IN 12 HOURS parameter on the MAINSTAT screen) to go into an alarm state at a user configured level
occur, an excessive starts alarm displays, preventing the chiller (REFRIGERANT LEAK ALARM mA). The input is con-
figured for 4 to 20 mA by setting the DIP switch 1 on SW2
from starting. The operator must press the RESET softkey at the ON position, or configured for 0 to 5 vdc by setting
on the CVC to override the starts counter and start the chiller. switch 1 at the OFF position. The output of the refrigerant
If the chiller records 12 starts (excluding recycle starts) in a leak detector is displayed as REFRIGERANT LEAK SEN-
sliding 12-hour period, it can be restarted only by pressing SOR on the MAINSTAT screen. For a 0 to 5 vcd input, 0 vdc
the RESET softkey followed by the LOCAL or CCN input represents 4 mA displayed and 5 vdc input represents
20 mA displayed.
softkey. This ensures that, if the automatic system is mal-
functioning, the chiller will not repeatedly cycle on and off. Condenser Pump Control — The chiller will moni-
If the automatic restart after a power failure option (AUTO tor the condenser pressure (CONDENSER PRESSURE) and
RESTART OPTION on the OPTIONS screen) is not acti- may turn on the condenser pump if the condenser pressure
vated when a power failure occurs, and if the remote contact becomes too high while the compressor is shut down. The
is closed, the chiller will indicate an alarm because of the condenser pressure override (COND PRESS OVERRIDE)
loss of voltage. parameter is used to determine this pressure point. COND
The contacts for remote start are wired into the starter at PRESS OVERRIDE is found in the SETUP1 display screen,
terminal strip J2, terminals 5 and 6 on the ISM. See the cer- which is accessed from the EQUIPMENT SERVICE table.
tified drawings for further details on contact ratings. The con- The default value is 125 psig (862 kPa).
tacts must have 24 vac rating. If the CONDENSER PRESSURE is greater than or equal
to the COND PRESS OVERRIDE, and the entering con-
Spare Safety Inputs — Normally closed (NC) dis- denser water temperature (ENTERING CONDENSER
crete inputs for additional field-supplied safeties may be wired WATER) is less than 115 F (46 C), the condenser pump will
to the spare protective limits input channel in place of the
36
energize to try to decrease the pressure. The pump will
turn off when the condenser pressure is 3.5 psi (24.1 kPa)
less than the pressure override or when the condenser re-
frigerant temperature (CONDENSER REFRIG TEMP) is within The tower fan relay control is not a substitute for a
3° F (1.7° C) of the entering condenser water temperature condenser water temperature control. When used with
(ENTERING CONDENSER WATER). a water temperature control system, the tower fan relay
control can be used to help prevent low condenser
Condenser Freeze Prevention — This control water temperatures.
algorithm helps prevent condenser tube freeze-up by ener-
gizing the condenser pump relay. The PIC II controls the Auto. Restart After Power Failure — This option
pump and, by starting it, helps to prevent the water in the may be enabled or disabled and may be viewed or modified
condenser from freezing. The PIC II can perform this func- on the OPTIONS screen, which is accessed from the EQUIP-
tion whenever the chiller is not running except when it is MENT CONFIGURATION table. If the AUTO. RESTART
either actively in pumpdown or in pumpdown/lockout with option is enabled, the chiller will start up automatically after
the freeze prevention disabled. a power failure has occurred (after a single cycle dropout;
When the CONDENSER REFRIG TEMP is less than low, high, or loss of voltage; and the power is within ± 10%
or equal to the CONDENSER FREEZE POINT, the of normal). The 15- and 3-minute inhibit timers are ignored
CONDENSER WATER PUMP is energized until the during this type of start-up.
CONDENSER REFRIG TEMP is greater than the CON- When power is restored after the power failure and if the
DENSER FREEZE POINT plus 5° F (2.7° C) and the compressor had been running, the oil pump will energize for
ENTERING CONDENSER WATER TEMPERATURE is less one minute before energizing the cooler pump. AUTO.
than or equal to the CONDENSER FREEZE POINT. An alarm RESTART will then continue like a normal start-up.
is generated if the chiller is in PUMPDOWN mode and the
pump is energized. An alert is generated if the chiller is not If power to the CVC module has been off for more than
in PUMPDOWN mode and the pump is energized. If the 3 hours or the timeclock has been set for the first time, start
chiller is in RECYCLE SHUTDOWN mode, the mode will the compressor with the slowest temperature-based ramp load
transition to a non-recycle shutdown. rate possible in order to minimize oil foaming.
The oil pump is energized occasionally during the time
Tower Fan Relay Low and High — Low condenser the oil is being brought up to proper temperature in order to
water temperature can cause the chiller to shut down when eliminate refrigerant that has migrated to the oil sump dur-
refrigerant temperature is low. The tower fan relays, located ing the power failure. The pump turns on for 60 seconds at
in the starter, are controlled by the PIC II to energize and the end of every 30-minute period until the chiller is started.
deenergize as the pressure differential between cooler and
condenser vessels changes. This prevents low condenser wa- Water/Brine Reset — Three types of chilled water or
ter temperature and maximizes chiller efficiency. The tower brine reset are available and can be viewed or modified on
fan relay can only accomplish this if the relay has been added the TEMP_CTL screen, which is accessed from the EQUIP-
to the cooling tower temperature controller. MENT SERVICE table.
The tower fan relay low is turned on whenever the con- The CVC default screen indicates when the chilled water
denser water pump is running, flow is verified, and the dif- reset is active. RESET TEMPERATURE on the MAIN-
ference between cooler and condenser pressure is more than STAT screen indicates the amount of reset. The CONTROL
30 psid (207 kPad) for entering condenser water tempera- POINT will be determined by adding the RESET
ture greater than 65 F (18.3 C). TEMPERATURE to the SETPOINT.
The tower fan relay low is turned off when the condenser To activate a reset type, access the TEMP_CTL screen and
pump is off, flow is stopped, or the cooler refrigerant tem- input all configuration information for that reset type. Then,
perature is less than the override temperature for ENTER- input the reset type number (1, 2, or 3) in the SELECT/
ING CONDENSER WATER temperature less than 62 F ENABLE RESET TYPE input line.
(16.7 C), or the differential pressure is less than 25 psid
(172.4 kPad) for entering condenser water less than RESET TYPE 1: 4 to 20 mA (0 to 5 vdc) TEMPERATURE
80 F (27 C). RESET — Reset Type 1 is an automatic chilled water tem-
perature reset based on a remote temperature sensor input
The tower fan relay high is turned on whenever the con- configured for either an externally powered 4 to 20 mA or a
denser water pump is running, flow is verified and the dif- 0 to 5 vcd signal. Reset Type 1 permits up to ±30 F (±16 C)
ference between cooler and condenser pressure is more than of automatic reset to the chilled water set point.
35 psid (241.3 kPa) for entering condenser water tempera-
ture greater than the TOWER FAN HIGH SETPOINT (SET- The auto, chilled water reset is hardwired to terminals
POINT menu, default 75 F [23.9 C]). J5-3 (−) and J5-4 (+) on the CCM. Switch setting number 2
on SW2 will determine the type of input signal. With the
The tower fan relay high is turned off when the condenser switch set at the ON position the input is configured for an
pump is off, flow is stopped, or the cooler refrigerant tem- externally powered 4 to 20 mA signal. With the switch in the
perature is less than the override temperature and ENTER- OFF position the input is configured for an external
ING CONDENSER WATER is less than 70 F (21.1 C), or the 0 to 5 vdc signal.
difference between cooler and condenser pressure is less than
28 Psid (193 kPa), or ENTERING CONDENSER WATER tem- RESET TYPE 2: REMOTE TEMPERATURE RESET — Re-
perature is less than TOWER FAN HIGH SETPOINT minus set Type 2 is an automatic chilled water temperature reset
3 F (−16.1 C). based on a remote temperature sensor input signal. Reset Type
2 permits ± 30° F (± 16° C) of automatic reset to the set
The TOWER FAN RELAY LOW and HIGH parameter is point based on a temperature sensor wired to the CCM mod-
accessed from the STARTUP screen. ule (see wiring diagrams or certified drawings). The tem-
IMPORTANT: A field-supplied water temperature con- perature sensor must be wired to terminal J4-13 and J4-14.
trol system for condenser water should be installed. To configure Reset Type 2, enter the temperature of
The system should maintain the leaving condenser the remote sensor at the point where no temperature reset
water temperature at a temperature that is 20° F will occur (REMOTE TEMP [NO RESET]). Next, enter the
(11° C) above the leaving chilled water temperature. temperature at which the full amount of reset will occur
37
(REMOTE TEMP [FULL RESET]). Then, enter the maxi- PREVENTION is on, the point must pass through the dead-
mum amount of reset required to operate the chiller band region before the HOT GAS BYPASS/SURGE PRE-
(DEGREES RESET). Reset Type 2 can now be activated. VENTION is turned off. Information on modifying the de-
fault set points of the minimum and full load points may be
RESET TYPE 3 — Reset Type 3 is an automatic chilled wa- found in the Input Service Configurations section, page 53.
ter temperature reset based on cooler temperature differ-
ence. Reset Type 3 adds ± 30° F (± 16° C) based on the Corrective action can be taken by making one of 2 choices.
temperature difference between the entering and leaving chilled If a hot gas bypass line is present and the hot gas option
water temperature. is selected on the OPTIONS table (SURGE LIMIT/HGBP
To configure Reset Type 3, enter the chilled water tem- OPTION is set to 1), the hot gas bypass valve can be ener-
perature difference (the difference between entering and gized. If the hot gas bypass option is not selected (SURGE
leaving chilled water) at which no temperature reset occurs LIMIT/HGBP OPTION is set to 0), hold the guide vanes.
(CHW DELTA T [NO RESET]). This chilled water temper- See Table 4, Capacity Overrides. Both of these corrective
ature difference is usually the full design load temper- actions try to reduce the lift experienced by the compressor
ature difference. Next, enter the difference in chilled water and help prevent a surge condition.
temperature at which the full amount of reset occurs (CHW
DELTA T [FULL RESET]). Finally, enter the amount of re-
set (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 0 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%
demand set point with an operator-configured minimum de-
mand at a 20 mA set point (DEMAND LIMIT AT 20 mA).
The auto. demand limit is hardwired to terminals J5-5 (−)
and J5-6 (+) 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
powered 4 to 20 mA signal. With the switch in the OFF
position the input is configured for an external 0 to 5 vdc
signal.
LEGEND
Surge Prevention Algorithm — This is an operator-
ECW — Entering Chilled Water
configurable feature that can determine if lift conditions are HGBP — Hot Gas Bypass
too high for the compressor and then take corrective action. LCW — Leaving Chilled Water
Lift is defined as the difference between the pressure at the DP = (Condenser Psi) − (Cooler Psi)
impeller eye and at the impeller discharge. The maximum DT = (ECW) − (LCW)
lift a particular impeller wheel can perform varies with the Fig. 19 — 19XR Hot Gas Bypass/Surge
gas flow across the impeller and the size of the wheel. Prevention with Default English Settings
A surge condition occurs when the lift becomes so
high the gas flow across the impeller reverses. This condi-
tion can eventually cause chiller damage. The surge preven-
tion algorithm notifies the operator that chiller operating
conditions are marginal and to take action to help prevent
chiller damage such as lowering entering condenser water
temperature.
The surge prevention algorithm first determines if cor-
rective action is necessary. The algorithm checks 2 sets of
operator-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. 19 and 20. 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
compressor. When the actual differential pressure between
the cooler and condenser and the temperature difference be-
tween the entering and leaving chilled water are above the
line on the graph (as defined by the minimum and full load
points), the algorithm goes into a corrective action mode. If
the actual values are below the line and outside of the dead-
band region, the algorithm takes no action. When the point LEGEND
defined by the ACTIVE DELTA P and ACTIVE DELTA T, ECW — Entering Chilled Water
moves from the region where the HOT GAS BYPASS/ HGBP — Hot Gas Bypass
SURGE PREVENTION is off, the point must pass through LCW — Leaving Chilled Water
the deadband region to the line determined by the config- DP = (Condenser kPa) − (Cooler kPa)
ured valves before the HOT GAS BYPASS/SURGE DT = (ECW) − (LCW)
PREVENTION will be turned on. As the point moves from Fig. 20 — 19XR Hot Gas Bypass/Surge
the region where the HOT GAS BYPASS/SURGE Prevention with Default Metric Settings
38
Surge Protection — The PIC II monitors surge, which If the entering chilled water control option (ECW CON-
is a fluctuation in compressor motor amperage. Each time TROL OPTION) is enabled (configured in TEMP_CTL screen)
the fluctuation exceeds an operator-specified limit (SURGE and a common point sensor is desired (COMMON SENSOR
DELTA % AMPS), the PIC II counts the surge. If more than OPTION in LEADLAG screen selected as 1) then the sensor
5 surges occur within an operator-specified time (SURGE is wired in Spare Temp #2 position on the CCM.
TIME PERIOD), the PIC II initiates a surge protection shut- When installing chillers in series, a common point sensor
down of the chiller. should be used. If a common point sensor is not used, the
The surge limit can be adjusted from the OPTIONS screen. leaving chilled water sensor of the upstream chiller must be
moved into the leaving chilled water pipe of the downstream
Scroll down to the SURGE DELTA % AMPS parameter, and chiller.
use the INCREASE or DECREASE softkey to adjust the
If return chilled water control is required on chillers piped
percent of surge. The default setting is 10% amps. in series, the common point return chilled water sensor should
The surge time period can also be adjusted from the be installed. If this sensor is not installed, the return chilled
OPTIONS screen. Scroll to the SURGE TIME PERIOD water sensor of the downstream chiller must be relocated to
parameter, and use the INCREASE or DECREASE soft- the return chilled water pipe of the upstream chiller.
key to adjust the amount of time. The default setting is To properly control the common supply point temperature
8 minutes. sensor when chillers are piped in parallel, the water flow through
the shutdown chillers must be isolated so no water bypass
Access the display screen (COMPRESS) to monitor the around the operating chiller occurs. The common point sen-
surge count (SURGE PROTECTION COUNTS). sor option must not be used if water bypass around the
Lead/Lag Control — The lead/lag control system operating chiller is occurring.
automatically starts and stops a lag or second chiller in a CHILLER COMMUNICATION WIRING — Refer to the
2-chiller water system. A third chiller can be added to the chiller’s Installation Instructions, Carrier Comfort Network
lead/lag system as a standby chiller to start up in case Interface section for information on chiller communication
the lead or lag chiller in the system has shut down during wiring.
an alarm condition and additional cooling is required. LEAD/LAG OPERATION — The PIC II not only has the
Refer to Fig. 15 and 16 for menu, table, and screen selection ability to operate 2 chillers in lead/lag, but it can also start
information. a designated standby chiller when either the lead or lag chiller
NOTE: The lead/lag function can be configured on the LEAD- is faulted and capacity requirements are not met. The lead/
LAG screen, which is accessed from the SERVICE menu lag option only operates when the chillers are in CCN mode.
and EQUIPMENT SERVICE table. See Table 2, If any other chiller configured for lead/lag is set to the
Example 19. Lead/lag status during chiller operation can be LOCAL or OFF modes, it will be unavailable for lead/lag
viewed on the LL_MAINT display screen, which is ac- operation.
cessed from the SERVICE menu and CONTROL ALGO-
RITHM STATUS table. See Table 2, Example 11. Lead/Lag Chiller Configuration and Operation
• A chiller is designated the lead chiller when its LEAD/
Lead/Lag System Requirements: LAG CONFIGURATION value on the LEADLAG screen
• all chillers in the system must have software capable of is set to ‘‘1.’’
performing the lead/lag function • A chiller is designated the lag chiller when its LEAD/LAG
• water pumps MUST be energized from the PIC II controls CONFIGURATION value is set to ‘‘2.’’
• water flows should be constant
• the CCN time schedules for all chillers must be identical • A chiller is designated as a standby chiller when its LEAD/
LAG CONFIGURATION value is set to ‘‘3.’’
Operation Features: • A value of ‘‘0’’ disables the lead/lag designation of a chiller.
• 2 chiller lead/lag
• addition of a third chiller for backup To configure the LAG ADDRESS value on the LEAD-
• manual rotation of lead chiller LAG screen, always enter the address of the other chiller on
• load balancing if configured the system. For example, if you are configuring chiller A,
• staggered restart of the chillers after a power failure enter the address for chiller B as the lag address. If you are
• chillers may be piped in parallel or in series chilled water configuring chiller B, enter the address for chiller A as the
flow lag address. This makes it easier to rotate the lead and lag
chillers.
COMMON POINT SENSOR INSTALLATION — Lead/ If the address assignments in the LAG ADDRESS and
lag operation does not require a common chilled water point STANDBY ADDRESS parameters conflict, the lead/lag func-
sensor. Common point sensors (Spare Temp #1 and #2) can tion is disabled and an alert (!) message displays. For
be added to the CCM module, if desired. Spare Temp #1 and example, if the LAG ADDRESS matches the lead chiller’s
#2 are wired to plug J4 terminals 25-26 and 27-28 (J4 lower, address, the lead/lag will be disabled and an alert (!)
respectively). message displayed. The lead/lag maintenance screen
NOTE: If the common point sensor option is chosen on a (LL_MAINT) displays the message ‘INVALID CONFIG’ in
chilled water system, each chiller should have its own com- the LEAD/LAG CONFIGURATION and CURRENT MODE
mon point sensor installed. Each chiller uses its own com- fields.
mon point sensor for control when that chiller is designated The lead chiller responds to normal start/stop controls such
as the lead chiller. The PIC II cannot read the value of com- as the occupancy schedule, a forced start or stop, and remote
mon point sensors installed on the other chillers in the chilled start contact inputs. After completing start-up and ramp load-
water system. ing, the PIC II evaluates the need for additional capacity. If
If leaving chilled water control (ECW CONTROL OP- additional capacity is needed, the PIC II initiates the start-up
TION is set to 0 [DSABLE] TEMP_CTL screen) and a com- of the chiller configured at the LAG ADDRESS. If the lag
mon point sensor is desired (COMMON SENSOR OPTION chiller is faulted (in alarm) or is in the OFF or LOCAL modes,
in LEADLAG screen selected as 1) then the sensor is wired the chiller at the STANDBY ADDRESS (if configured) is
in Spare Temp #1 position on the CCM. requested to start. After the second chiller is started and is
39
running, the lead chiller monitors conditions and eval- start. If the lag chiller fails to start, the standby chiller, if
uates whether the capacity has been reduced enough for the configured is started.
lead chiller to sustain the system alone. If the capacity is Lag Chiller Shutdown Requirements — The following con-
reduced enough for the lead chiller to sustain the CONTROL ditions must be met in order for the lag chiller to be stopped.
POINT temperatures alone, then the operating lag chiller is
stopped. 1. Lead chiller compressor motor average line current or load
value (MOTOR PERCENT KILOWATTS on the MAIN-
If the lead chiller is stopped in CCN mode for any reason STAT screen) is less than the lead chiller percent
other than an alarm (*) condition, the lag and standby chill- capacity.
ers are also stopped. If the configured lead chiller stops for
an alarm condition, the configured lag chiller takes the lead NOTE: Lead chiller percent capacity = 115 – LAG PER-
chiller’s place as the lead chiller, and the standby chiller serves CENT CAPACITY. The LAG PERCENT CAPACITY
as the lag chiller. parameter is on the LEADLAG screen, which is accessed
from the EQUIPMENT SERVICE table on the SERV-
If the configured lead chiller does not complete the start-up ICE menu.
before the PRESTART FAULT TIMER (a user-configured
value) elapses, then the lag chiller starts and the lead chiller 2. The lead chiller chilled water temperature is less than
shuts down. The lead chiller then monitors the start request the CONTROL POINT temperature (see the MAINSTAT
from the acting lead chiller. The PRESTART FAULT TIMER screen) plus 1⁄2 the CHILLED WATER DEADBAND tem-
is initiated at the time of a start request. The PRESTART FAULT perature (see the SETUP1 screen).
TIMER provides a timeout if there is a prestart alert condi- 3. The configured LAG STOP TIME entry has elapsed. The
tion that prevents the chiller from starting in a timely man- LAG STOP TIMER starts when the lead chiller chilled
ner. The PRESTART FAULT TIMER parameter is on the LEAD- water temperature is less than the chilled water
LAG screen, which is accessed from the EQUIPMENT SERV- CONTROL POINT plus 1/2 of the CHILLED WATER
ICE table of the SERVICE menu. DEADBAND and the lead chiller compressor motor load
If the lag chiller does not achieve start-up before the (MOTOR PERCENT KILOWATT or AVERAGE LINE CUR-
PRESTART FAULT TIMER elapses, the lag chiller stops, and RENT on the MAINSTAT screen) is less than the lead
the standby chiller is requested to start, if configured and chiller percent capacity.
ready. NOTE: Lead chiller percent capacity = 115 – LAG PER-
Standby Chiller Configuration and Operation — A chiller is CENT CAPACITY. The LAG PERCENT CAPACITY param-
designated as a standby chiller when its LEAD/LAG eter is on the LEADLAG screen, which is accessed from the
CONFIGURATION value on the LEADLAG screen is set to EQUIPMENT SERVICE table on the SERVICE menu.
‘‘3.’’ The standby chiller can operate as a replacement for FAULTED CHILLER OPERATION — If the lead chiller
the lag chiller only if one of the other two chillers is in an shuts down because of an alarm (*) condition, it stops com-
alarm (*) condition (as shown on the CVC panel). If both municating to the lag and standby chillers. After 30 seconds,
lead and lag chillers are in an alarm (*) condition, the standby the lag chiller becomes the acting lead chiller and starts and
chiller defaults to operate in CCN mode, based on its con- stops the standby chiller, if necessary.
figured occupancy schedule and remote contacts input. If the lag chiller goes into alarm when the lead chiller is
Lag Chiller Start-Up Requirements — Before the lag chiller also in alarm, the standby chiller reverts to a stand-alone CCN
can be started, the following conditions must be met: mode of operation.
1. Lead chiller ramp loading must be complete. If the lead chiller is in an alarm (*) condition (as shown
2. Lead chilled water temperature must be greater than the on the CVC panel), press the RESET softkey to clear the
CONTROL POINT temperature (see the MAINSTAT screen) alarm. The chiller is placed in CCN mode. The lead chiller
plus 1/2 the CHILLED WATER DEADBAND tempera- communicates and monitors the RUN STATUS of the lag
ture (see the SETUP1 screen). and standby chillers. If both the lag and standby chillers are
NOTE: The chilled water temperature sensor may be the running, the lead chiller does not attempt to start and does
leaving chilled water sensor, the return water sensor, the not assume the role of lead chiller until either the lag or standby
common supply water sensor, or the common return wa- chiller shuts down. If only one chiller is running, the lead
ter sensor, depending on which options are configured and chiller waits for a start request from the operating chiller.
enabled. When the configured lead chiller starts, it assumes its role as
3. Lead chiller ACTIVE DEMAND LIMIT (see the lead chiller.
MAINSTAT screen) value must be greater than 95% of If the lag chiller is the only chiller running when the lead
full load amps. chiller assumes its role as a lead chiller then the lag chiller
4. Lead chiller temperature pulldown rate (TEMP PULL- will perform a RECOVERY START REQUEST (LL_MAINT
DOWN DEG/MIN on the TEMP_CTL screen) of the chilled screen). The lead chiller will start up when the following
water temperature is less than 0.5° F (0.27° C) per minute. conditions are met.
5. The lag chiller status indicates it is in CCN mode and is 1. Lag chiller ramp loading must be complete.
not in an alarm condition. If the current lag chiller is in 2. Lag CHILLED WATER TEMP (MAINSTAT screen) is
an alarm condition, the standby chiller becomes the ac- greater than CONTROL POINT plus 1/2 the CHILLED
tive lag chiller, if it is configured and available. WATER DEADBAND temperature.
6. The configured LAG START TIMER entry has elapsed. 3. Lag chiller ACTIVE DEMAND LIMIT value must be greater
The LAG START TIMER starts when the lead chiller than 95% of full load amps.
ramp loading is completed. The LAG START TIMER 4. Lag chiller temperature pulldown rate (TEMP PULL-
entry is on the LEADLAG screen, which is accessed DOWN DEG/MIN) of the chilled water temperature is less
from the EQUIPMENT SERVICE table of the than 0.5 F (0.27 C) per minute.
SERVICE menu.
5. The standby chiller is not running as a lag chiller.
When all the above requirements have been met, the lag
chiller is commanded to a STARTUP mode (SUPVSR flash- 6. The configured LAG START TIMER has elapsed. The LAG
ing next to the point value on the STATUS table). The START TIMER is started when ramp loading is
PIC II control then monitors the lag chiller for a successful completed.
40
LOAD BALANCING — When the LOAD BALANCE • the chilled water temperature is less than the ice build set
OPTION (see LEADLAG screen) is enabled, the lead chiller point and the remote contact inputs from an ice level in-
sets the ACTIVE DEMAND LIMIT in the lag chiller to the dicator are open. In this case, the operator sets the ICE
lead chiller’s compressor motor load value MOTOR PER- BUILD TERMINATION parameter to 2 on the OPTIONS
CENT KILOWATTS or AVERAGE LINE CURRENT on the screen.
MAINSTAT screen). This value has limits of 40% to 100%. • the end of the ice build time schedule has been reached.
When the lag chiller ACTIVE DEMAND LIMIT is set, the
CONTROL POINT must be modified to a value of 3° F ICE BUILD INITIATION — The ice build time schedule
(1.67° C) less than the lead chiller’s CONTROL POINT value. (OCCPC02S) is the means for activating the ice build
If the LOAD BALANCE OPTION is disabled, the ACTIVE option. The ice build option is enabled if:
DEMAND LIMIT and the CONTROL POINT are forced to • a day of the week and a time period on the ice build time
the same value as the lead chiller. schedule are enabled. The SCHEDULE screen shows an
AUTO. RESTART AFTER POWER FAILURE — When an X in the day field and ON/OFF times are designated for
auto. restart condition occurs, each chiller may have a delay the day(s),
added to the start-up sequence, depending on its lead/lag • and the ICE BUILD OPTION is enabled.
configuration. The lead chiller does not have a delay. The The following events take place (unless overridden by a
lag chiller has a 45-second delay. The standby chiller has a higher authority CCN device).
90-second delay. The delay time is added after the chiller 1. CHILLER START/STOP is forced to START.
water flow is verified. The PIC II ensures the guide vanes 2. The CONTROL POINT is forced to the ICE BUILD
are closed. After the guide vane position is confirmed, the SETPOINT.
delay for lag and standby chillers occurs prior to energizing
the oil pump. The normal start-up sequence then continues. 3. Any force (Auto) is removed from the ACTIVE
The auto. restart delay sequence occurs whether the chiller DEMAND LIMIT.
is in CCN or LOCAL mode and is intended to stagger the NOTE: A parameter’s value can be forced, that is, the value
compressor motor starts. Preventing the motors from start- can be manually changed at the CVC by an operator, changed
ing simultaneously helps reduce the inrush demands on the from another CCN device, or changed by other algorithms
building power system. in the PIC II control system.
Ice Build Control — The ice build control option NOTE: Items 1-3 (shown above) do not occur if the chiller
automatically sets the CONTROL POINT of the chiller to a is configured and operating as a lag or standby chiller for
temperature that allows ice building for thermal storage. lead/lag operation and is actively being controlled by a lead
chiller. The lead chiller communicates the ICE BUILD SET
NOTE: For ice build control to operate properly, the PIC II POINT, the desired CHILLER START/STOP state, and the
must be in CCN mode. ACTIVE DEMAND LIMIT to the lag or standby chiller as
NOTE: See Fig. 15 and 16 for more information on ice build- required for 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 SERV- lowing conditions, based on the ICE BUILD TERMINA-
ICE table. From there, select the OPTIONS screen to en- TION value, to avoid starting the compressor unnecessarily:
able or disable the ICE BUILD OPTION. See • if ICE BUILD TERMINATION is set to the TEMP option
Table 2, Example 16. and the ENTERING CHILLED WATER temperature is less
• The ICE BUILD SETPOINT can be configured from the than or equal to the ICE BUILD SETPOINT;
SETPOINT display, which is accessed from the PIC II main • if ICE BUILD TERMINATION is set to the CONTACTS
menu. See Table 2, Example 8. 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 (tem-
the SCHEDULE table. From this table, select the ice build perature and contacts) option and the ENTERING CHILLED
schedule (OCCPC02S) screen. See Fig. 17 and the section WATER temperature is less than or equal to the ICE BUILD
on Time Schedule Operation, page 19, for more informa- SETPOINT and the remote contacts are open.
tion on modifying chiller schedules.
The ICE BUILD RECYCLE on the OPTIONS screen de-
The ice build time schedule defines the period(s) during termines whether or not the chiller will go into an ice build
which ice build is active if the ice build option is RECYCLE mode.
enabled. If the ice build time schedule overlaps other sched-
• If the ICE BUILD RECYCLE is set to DSABLE (disable),
ules, the ice build time schedule takes priority. During the
the PIC II reverts to normal temperature control when the
ice build period, the CONTROL POINT is set to the ICE ice build function terminates.
BUILD SETPOINT for temperature control. The ICE BUILD
RECYCLE and ICE BUILD TERMINATION parameters, ac- • If the ICE BUILD RECYCLE is set to ENABLE, the
cessed from the OPTIONS screen, allow the chiller operator PIC II goes into an ICE BUILD RECYCLE mode and the
to recycle or terminate the ice build cycle. The ice build cycle chilled water pump relay remains energized to keep the
can be configured to terminate if: chilled water flowing when the ice build function termi-
• the ENTERING CHILLED WATER temperature is less than nates. If the temperature of the ENTERING CHILLED
the ICE BUILD SETPOINT. In this case, the operator sets WATER increases above the ICE BUILD SETPOINT plus
the ICE BUILD TERMINATION parameter to 0 on the the RECYCLE RESTART DELTA T value, the compressor
restarts and controls the chilled water/brine temperature to
OPTIONS screen.
the ICE BUILD SETPOINT.
• the REMOTE CONTACT inputs from an ice level indi-
cator are opened. In this case, the operator sets the ICE TEMPERATURE CONTROL DURING ICE BUILD — Dur-
BUILD TERMINATION parameter to 1 on the OPTIONS ing ice build, the capacity control algorithm shall use the
screen. CONTROL POINT minus 5 F (−2.8 C) for control of the
LEAVING CHILLED WATER temperature. See Table 2, ex-
ample 9, the CAPACITY CONTROL parameter on the CA-
PACITY screen.) The ECW CONTROL OPTION and any
41
temperature reset option shall be ignored, if enabled, dur- address of the chiller on which it is mounted. Whenever the
ing ice build. The AUTO DEMAND LIMIT INPUT shall controller identification of the CVC changes, the change is
also be ignored if enabled during ice build. reflected automatically in the BUS and ADDRESS columns
• ECW CONTROL OPTION and any temperature reset for the local device. See Fig. 16. Default address for local
options (configured on TEMP_CTL screen). device is BUS 0 ELEMENT 1.
• 20 mA DEMAND LIMIT OPT (configured on
RAMP_DEM screen).
TERMINATION OF ICE BUILD — The ice build function
terminates under the following conditions:
1. Time Schedule — When the current time on the ice build
time schedule (OCCPC02S) is not set as an ice build time
period.
2. Entering Chilled Water Temperature — Compressor
operation terminates, based on temperature, if the ICE
BUILD TERMINATION parameter is set to 0 (TEMP),
the ENTERING CHILLED WATER temperature is less than
the ICE BUILD SETPOINT, and the ICE BUILD Fig. 21 — Example of Attach to Network
RECYCLE is set to DSABLE. If the ICE BUILD RE- Device Screen
CYCLE OPTION is set to ENABLE, a recycle shutdown
occurs and recycle start-up depends on the LEAVING
CHILLED WATER temperature being greater than the
WATER/BRINE CONTROL POINT plus the RECYCLE When the ATTACH TO NETWORK DEVICE screen is
RESTART DELTA T temperature. accessed, information can not be read from the CVC on any
3. Remote Contacts/Ice Level Input — Compressor opera- device until one of the devices listed on that screen is
tion terminates when the ICE BUILD TERMINATION attached. The CVC erases information about the module to
parameter is set to 1 CONTACTS) and the remote con- which it was attached to make room for information on
tacts are open and the ICE BUILD RECYCLE is set to another device. Therefore, a CCN module must be attached
DSABLE (0). In this case, the contacts provide ice level when this screen is entered.
termination control. The contacts are used to stop the To attach any CCN device, highlight it using the
ice build function when a time period on the ice build SELECT softkey and press the ATTACH softkey. The mes-
schedule (OCCPC02S) is set for ice build operation. The sage ‘‘UPLOADING TABLES, PLEASE WAIT’’ displays.
remote contacts can still be opened and closed to start The CVC then uploads the highlighted device or module. If
and stop the chiller when a specific time period on the ice the module address cannot be found, the message ‘‘COM-
build schedule is not set for ice build. MUNICATION FAILURE’’ appears. The CVC then reverts
4. Entering Chilled Water Temperature and ICE BUILD Con- back to the ATTACH TO DEVICE screen. Try another de-
tacts — Compressor operation terminates when the ICE vice or check the address of the device that would not at-
BUILD TERMINATION parameter is set to 2 (BOTH) tach. The upload process time for each CCN module is dif-
and the conditions described above in items 2 and 3 for ferent. In general, the uploading process takes 1 to 2 minutes.
entering chilled water temperature and remote contacts Before leaving the ATTACH TO NETWORK DEVICE screen,
have occurred. select the local device. Otherwise, the CVC will be unable
NOTE: It is not possible to override the CHILLER START/ to display information on the local chiller.
STOP, CONTROL POINT, and ACTIVE DEMAND LIMIT ATTACHING TO OTHER CCN MODULES — If the chiller
variables from CCN devices (with a priority 4 or greater) CVC has been connected to a CCN Network or other PIC
during the ice build period. However, a CCN device can over- controlled chillers through CCN wiring, the CVC can be used
ride these settings during 2-chiller lead/lag operation. to view or change parameters on the other controllers. Other
RETURN TO NON-ICE BUILD OPERATIONS — The ice PIC II chillers can be viewed and set points changed (if the
build function forces the chiller to start, even if all other sched- other unit is in CCN control), if desired, from this particular
ules indicate that the chiller should stop. When the ice build CVC module.
function terminates, the chiller returns to normal tempera- If the module number is not valid, the ‘‘COMMUNICA-
ture control and start/stop schedule operation. The CHILLER TION FAILURE’’ message will show and a new address num-
START/STOP and CONTROL POINT return to normal op- ber must be entered or the wiring checked. If the module is
eration. If the CHILLER START/STOP or CONTROL POINT communicating properly, the ‘‘UPLOAD IN PROGRESS’’
has been forced (with a device of less than 4 priority) before message will flash and the new module can now be viewed.
the ice build function started, when the ice build function Whenever there is a question regarding which module on
ends, the previous forces (of less than 4 priority) are not au- the CVC is currently being shown, check the device name
tomatically restored. descriptor on the upper left hand corner of the CVC screen.
See Fig. 21.
Attach to Network Device Control — The Service
menu includes the ATTACH TO NETWORK DEVICE screen. When the CCN device has been viewed, the ATTACH TO
From this screen, the operator can: NETWORK DEVICE table should be used to attach to the
PIC that is on the chiller. Move to the ATTACH TO NET-
• enter the time schedule number (if changed) for OCCPC03S, WORK DEVICE table (LOCAL should be highlighted) and
as defined in the NET_OPT screen
• attach the CVC to any CCN device, if the chiller has been press the ATTACH softkey to upload the LOCAL device.
connected to a CCN network. This may include other PIC- The CVC for the 19XR will be uploaded and default screen
controlled chillers. will display.
• upgrade software NOTE: The CVC will not automatically reattach to the local
Figure 21 shows the ATTACH TO NETWORK DEVICE module on the chiller. Press the ATTACH softkey to attach
screen. The LOCAL parameter is always the CVC module to the LOCAL device and view the chiller operation.
42
Service Operation — An overview of the tables and HOLIDAY SCHEDULING (Fig. 22) — The time schedules
screens available for the SERVICE function is shown in may be configured for special operation during a holiday
Fig. 16. period. When modifying a time period, the ‘‘H’’ at the end
of the days of the week field signifies that the period is
TO ACCESS THE SERVICE SCREENS — When the applicable to a holiday. (See Fig. 17.)
SERVICE screens are accessed, a password must be
entered. The broadcast function must be activated for the holidays
configured on the HOLIDEF screen to work properly.
1. From the main MENU screen, press the SERVICE soft- Access the BRODEF screen from the EQUIPMENT CON-
key. The softkeys now correspond to the numerals 1, 2, FIGURATION table and select ENABLE to the activated
3, 4. function. Note that when the chiller is connected to a CCN
2. Press the four digits of the password, one at a time. An Network, only one chiller or CCN device can be configured
asterisk (*) appears as each digit is entered. as the broadcast device. 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. 16.
NOTE: The initial factory-set password is 1 - 1- 1 - 1. If To view or change the holiday periods for up to 18 dif-
the password is incorrect, an error message is displayed. ferent holidays, perform the following operation:
1. At the Menu screen, press SERVICE to access the Serv-
ice menu.
2. If not logged on, follow the instructions for To Log On
or To Log Off. Once logged on, press NEXT until Equip-
ment Configuration is highlighted.
If this occurs, return to Step 1 and try to access the SERV-
ICE screens again. If the password is correct, the softkey 3. Once Equipment Configuration is highlighted, press
labels change to: SELECT to access.
4. Press NEXT until HOLIDAYS is highlighted. This is
the Holiday Definition table.
5. Press SELECT to enter the Data Table Select screen.
This screen lists 18 holiday tables.
NOTE: The SERVICE screen password can be changed 6. Press NEXT to highlight the holiday table that is to be
by entering the CVC CONFIGURATION screen under
SERVICE menu. The password is located at the bottom viewed or changed. Each table is one holiday period,
of the menu. starting on a specific date, and lasting up to 99 days.
The CVC screen displays the following list of available 7. Press SELECT to access the holiday table. The Con-
SERVICE screens: figuration Select table now shows the holiday start month
• Alarm History and day, and how many days the holiday period will last.
• Control Test 8. Press NEXT or PREVIOUS to highlight the
• Control Algorithm Status month, day, or duration.
• Equipment Configuration
• ISM (STARTER) Config Data 9. Press SELECT to modify the month, day, or
• Equipment Service duration.
• Time and Date 10. Press INCREASE or DECREASE to change the
• Attach to Network Device selected value.
• Log Out of Device
• CVC Configuration 11. Press ENTER to save the changes.
See Fig. 16 for additional screens and tables available from 12. Press EXIT to return to the previous menu.
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 ap-
propriate 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 Fig. 22 — Example of Holiday Period Screen
softkey. The CVC default screen will now be displayed.
43
START-UP/SHUTDOWN/RECYCLE WATER FLOW VERIFY TIME (operator-configured, default
SEQUENCE (Fig. 23) 5 minutes) expires to confirm flow. After flow is verified, the
chilled water temperature is compared to CONTROL POINT
Local Start-Up — Local start-up (or a manual start-up) plus 1/2 CHILLED WATER DEADBAND. If the temperature
is initiated by pressing the LOCAL menu softkey on the is less than or equal to this value, the PIC II turns off the
condenser pump relay and goes into a RECYCLE mode.
default CVC screen. Local start-up can proceed when the
chiller schedule indicates that the current time and date have If the water/brine temperature is high enough, the start-up
been established as a run time and date, and after the inter- sequence continues and checks the guide vane position. If
nal 15-minute start-to-start and the 1-minute stop-to-start the guide vanes are more than 4% open, the start-up waits
inhibit timers have expired. These timers are represented in until the PIC II closes the vanes. If the vanes are closed and
the START INHIBIT TIMER and can be viewed on the MAIN- the oil pump pressure is less than 4 psi (28 kPa), the oil
STAT screen and DEFAULT screen. The timer must expire pump relay energizes. The PIC II then waits until the oil pres-
before the chiller will start. If the timers have not expired sure (OIL PRESS VERIFY TIME, operator-configured,
the RUN STATUS parameter on the MAINSTAT screen now default of 40 seconds) reaches a maximum of 18 psi
reads TIMEOUT. (124 kPa). After oil pressure is verified, the PIC II waits
40 seconds, and the compressor start relay (1CR) energizes
NOTE: The time schedule is said to be ‘‘occupied’’ if the to start the compressor.
OCCUPIED ? parameter on the MAINSTAT screen is set to Compressor ontime and service ontime timers start, and
YES. For more information on occupancy schedules, see the the compressor starts in 12 hours counter and the number of
sections on Time Schedule Operation (page 19), Occupancy starts over a 12-hour period counter advance by one.
Schedule (page 32), and To Prevent Accidental Start-Up
(page 59), and Fig. 17. Failure to verify any of the requirements up to this point
will result in the PIC II aborting the start and displaying the
If the OCCUPIED ? parameter on the MAINSTAT screen applicable pre-start mode of failure on the CVC default screen.
is set to NO, the chiller can be forced to start as follows. A pre-start failure does not advance the starts in 12 hours
From the default CVC screen, press the MENU and counter. Any failure after the 1CR relay has energized
STATUS softkeys. Scroll to highlight MAINSTAT. Press results in a safety shutdown, advances the starts in the
12 hours counter by one, and displays the applicable shut-
the SELECT softkey. Scroll to highlight CHILLER START/ down status on the CVC display.
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 sched-
ule. 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- A — START INITIATED — Prestart checks made; evaporator
STAT screen must be CLOSED. From the CVC default screen, pump started.
B — Condenser water pump started (5 seconds after A).
press the MENU and STATUS softkeys. Scroll to high- C — Water flows verified (30 seconds to 5 minutes maximum
after B). Chilled water temperatures checked against con-
light MAINSTAT and press the SELECT softkey. Scroll trol point. Guide vanes checked for closure. Oil pump started;
down the STATUS01 screen to highlight REMOTE CON- tower fan control enabled.
D — Oil pressure verified (15 seconds minimum, 300 seconds
TACTS INPUT and press the SELECT softkey. Then, press maximum after C).
E — Compressor motor starts, compressor ontime and service
the CLOSE softkey. To end the override, select REMOTE ontime start, 15-minute inhibit timer starts (10 seconds
CONTACTS INPUT and press the RELEASE softkey. after D), total compressor starts advances by one, and the
number of starts over a 12-hour period advances by one.
Once local start-up begins, the PIC II performs a series of F — SHUTDOWN INITIATED — Compressor motor stops, com-
pre-start tests to verify that all pre-start alerts and safeties pressor ontime and service ontime stops, and 1-minute
are within the limits shown in Table 3. The RUN STATUS inhibit timer starts.
G — Oil pump and evaporator pumps deenergized (60 seconds
parameter on the MAINSTAT screen line now reads after F). Condenser pump and tower fan control may con-
PRESTART. If a test is not successful, the start-up is de- tinue to operate if condenser pressure is high. Evaporator
layed or aborted. If the tests are successful, the chilled water/ pump may continue if in RECYCLE mode.
brine pump relay energizes, and the MAINSTAT screen line O/A — Restart permitted (both inhibit timers expired: minimum of
15 minutes after E; minimum of 1 minute after F).
now reads STARTUP.
Five seconds later, the condenser pump relay energizes. Fig. 23 — Control Sequence
Thirty seconds later the PIC II monitors the chilled water
and condenser water flow devices and waits until the
44
Shutdown Sequence — Chiller shutdown begins if Chilled Water Recycle Mode — The chiller may cycle
any of the following occurs: off and wait until the load increases to restart when
• the STOP button is pressed for at least one second (the the compressor is running in a lightly loaded condition. This
alarm light blinks once to confirm the stop command) cycling is normal and is known as 9recycle.9 A recycle shut-
• a recycle condition is present (see Chilled Water Recycle down is initiated when any of the following conditions
Mode section) are true:
• the time schedule has gone into unoccupied mode • the chiller is in LCW control, the difference between the
• the chiller protective limit has been reached and chiller is LEAVING CHILLED WATER temperature and ENTER-
in alarm ING CHILLED WATER temperature is less than the
• the start/stop status is overridden to stop from the CCN RECYCLE SHUTDOWN DELTA T (found in the
network or the CVC SETUP1 table) and the LEAVING CHILLED WATER tem-
When a stop signal occurs, the shutdown sequence first perature is below the CONTROL POINT, −5 F (−15.0 C)
stops the compressor by deactivating the start relay (1CR). the CONTROL POINT has not increased in the last 5 min-
A status message of ‘‘SHUTDOWN IN PROGRESS, COM- utes and ICE BUILD is not active.
PRESSOR DEENERGIZED’’ is displayed, and the com- • the ECW CONTROL OPTION is enabled, the difference
pressor ontime and service ontime stop. The guide vanes are between the ENTERING CHILLED WATER temperature
then brought to the closed position. The oil pump relay and and the LEAVING CHILLED WATER temperature is less
the chilled water/brine pump relay shut down 60 seconds than the RECYCLE SHUTDOWN DELTA T (found in the
after the compressor stops. The condenser water pump shuts SETUP1 table), and the ENTERING CHILLED WATER
down at the same time if the ENTERING CONDENSER temperature is below the CONTROL POINT −5 F
WATER temperature is greater than or equal to 115 F (−15.0 C) and the CONTROL POINT has not increased in
(46.1 C) and the CONDENSER REFRIG TEMP is greater the last 5 minutes.
than the CONDENSER FREEZE POINT plus 5 F (−15.0 C). • the LEAVING CHILLED WATER temperature is within
The stop-to-start timer now begins to count down. If the start- 3° F (2° C) of the EVAP REFRIG TRIPPOINT.
to-start timer value is still greater than the value of the start- When the chiller is in RECYCLE mode, the chilled water
to-stop timer, then this time displays on the CVC. pump relay remains energized so the chilled water temper-
Certain conditions that occur during shutdown can change ature can be monitored for increasing load. The recycle
this sequence. control uses RECYCLE RESTART DELTA T to check when
• If the AVERAGE LINE CURRENT is greater than 15% af- the compressor should be restarted. This is an operator-
ter shutdown, or the starter contacts remain energized, the configured function which defaults to 5° F (3° C). This value
oil pump and chilled water pump remain energized and can be viewed or modified on the SETUP1 table. The com-
the alarm is displayed. pressor will restart when the chiller is:
• The condenser pump shuts down when the CONDENSER • in LCW CONTROL and the LEAVING CHILLED
PRESSURE is less than the CONDENSER PRESSURE WATER temperature is greater than the CONTROL POINT
OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the plus the RECYCLE RESTART DELTA T.
CONDENSER REFRIG TEMP is less than or equal to the • in ECW CONTROL and the ENTERING CHILLED
ENTERING CONDENSER WATER temperature plus WATER temperature is greater than the CONTROL POINT
3° F (−1.6° C). plus the RECYCLE RESTART DELTA T.
• If the chiller shuts down due to low refrigerant tempera-
ture, the chilled water pump continues to run until the LEAV- Once these conditions are met, the compressor initiates a
ING CHILLED WATER temperature is greater than the start-up with a normal start-up sequence.
CONTROL POINT temperature, plus 5° F (3° C). An alert condition may be generated if 5 or more recycle
start-ups occur in less than 4 hours. Excessive recycling can
Automatic Soft Stop Amps Threshold — The soft reduce chiller life; therefore, compressor recycling due to
stop amps threshold feature closes the guide vanes of the extremely low loads should be reduced.
compressor automatically if a non-recycle, non-alarm stop To reduce compressor recycling, use the time schedule to
signal occurs before the compressor motor is deenergized. shut the chiller down during known low load operation
If the STOP button is pressed, the guide vanes close to a period, or increase the chiller load by running the fan sys-
preset amperage percent until the guide vane is less than tems. If the hot gas bypass is installed, adjust the values to
4% open or 4 minutes have passed. The compressor then ensure that hot gas is energized during light load condi-
shuts off. tions. Increase the RECYCLE RESTART DELTA T on the
If the chiller enters an alarm state or if the compres- SETUP1 table to lengthen the time between restarts.
sor enters a RECYCLE mode, the compressor deenergizes The chiller should not be operated below design mini-
immediately. mum load without a hot gas bypass installed.
To activate the soft stop amps threshold feature, scroll to
the bottom of OPTIONS screen on the CVC. Use the Safety Shutdown — A safety shutdown is identical to
a manual shutdown with the exception that, during a safety
INCREASE or DECREASE softkey to set the SOFT shutdown, the CVC displays the reason for the shutdown,
STOP AMPS THRESHOLD parameter to the percent of amps the alarm light blinks continuously, and the spare alarm con-
at which the motor will shut down. The default setting is tacts are energized.
100% amps (no 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, a status message, ‘‘SHUTDOWN IN PROGRESS, pressed to clear the alarm. If the alarm condition is still present,
COMPRESSOR UNLOADING’’ displays on the CVC. the alarm light continues to blink. Once the alarm is cleared,
The soft stop amps threshold function can be terminated the operator must press the CCN or LOCAL softkeys to
and the compressor motor deenergized immediately by de- restart the chiller.
pressing the STOP button twice.
45
BEFORE INITIAL START-UP To determine if there are any leaks, the chiller should
be charged with refrigerant. Use an electronic leak detector
Job Data Required to check all flanges and solder joints after the chiller is
• list of applicable design temperatures and pressures (prod- pressurized. If any leaks are detected, follow the leak test
uct data submittal) procedure.
• chiller certified prints If the chiller is spring isolated, keep all springs blocked in
both directions to prevent possible piping stress and dam-
• starting equipment details and wiring diagrams age during the transfer of refrigerant from vessel to vessel
• diagrams and instructions for special controls or options during the leak test process, or any time refrigerant is being
• 19XR Installation Instructions transferred. Adjust the springs when the refrigerant is in
• pumpout unit instructions operating condition and the water circuits are full.
Equipment Required Refrigerant Tracer — Carrier recommends the use of

an environmentally acceptable refrigerant tracer for leak test-
• mechanic’s tools (refrigeration) ing with an electronic detector or halide torch.
• digital volt-ohmmeter (DVM) Ultrasonic leak detectors can also be used if the chiller is
• clamp-on ammeter under pressure.
• electronic leak detector
• absolute pressure manometer or wet-bulb vacuum indica-
tor (Fig. 24) Do not use air or oxygen as a means of pressurizing
• 500-v insulation tester (megohmmeter) for compressor the chiller. Mixtures of HFC-134a and air can undergo
motors with nameplate voltage of 600 v or less, or a combustion.
5000-v insulation tester for compressor motor rated above
600 v
Using the Optional Storage Tank and Pumpout

System — Refer to Chillers with Storage Tanks section,
page 63 for pumpout system preparation, refrigerant trans-
fer, 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
filter 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 gas-
keted joints and the guide vane shaft packing to ensure a
leak-tight chiller.
Fig. 24 — Typical Wet-Bulb Type
Check Chiller Tightness — Figure 25 outlines the Vacuum Indicator
proper sequence and procedures for leak testing.
19XR chillers are shipped with the refrigerant contained
in the condenser shell and the oil charge in the compressor.
The 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.
46
47
Fig. 25 — 19XR Leak Test Procedures

Leak Test Chiller — Due to regulations regarding re- 5. If no leak is found during the initial start-up procedures,
frigerant emissions and the difficulties associated with sepa- complete the transfer of refrigerant gas from the
rating contaminants from the refrigerant, Carrier recommends pumpout storage tank to the chiller (see Transfer Refrig-
the following leak test procedure. See Fig. 25 for an outline erant from Pumpout Storage Tank to Chiller section,
of the leak test procedure. Refer to Fig. 26 and 27 during page 63). Retest for leaks.
pumpout procedures and Tables 5A and 5B for refrigerant 6. If no leak is found after a retest:
pressure/temperature values. a. Transfer the refrigerant to the pumpout storage tank
1. If the pressure readings are normal for the chiller and perform a standing vacuum test as outlined in the
condition: Standing Vacuum Test section, below.
a. Evacuate the holding charge from the vessels, if present. b. If the chiller fails the standing vacuum test, check for
b. Raise the chiller pressure, if necessary, by adding large leaks (Step 2b).
refrigerant until pressure is at the equivalent saturated c. If the chiller passes the standing vacuum test, dehy-
pressure for the surrounding temperature. Follow the drate the chiller. Follow the procedure in the Chiller
pumpout procedures in the Transfer Refrigerant from Dehydration section. Charge the chiller with refriger-
Pumpout Storage Tank to Chiller section, Steps 1a - e, ant (see Transfer Refrigerant from Pumpout Storage
page 63. Tank to Chiller section, page 63).
7. If a leak is found after a retest, pump the refrigerant back
into the pumpout storage tank or, if isolation valves are
Never charge liquid refrigerant into the chiller if present, pump the refrigerant into the non-leaking ves-
the pressure in the chiller is less than 35 psig sel (see Pumpout and Refrigerant Transfer procedures
(241 kPa) for HFC-134a. Charge as a gas only, with section).
the cooler and condenser pumps running, until this 8. Transfer the refrigerant until the chiller pressure is at
pressure is reached, using PUMPDOWN LOCK- 18 in. Hg (40 kPa absolute).
OUT and TERMINATE LOCKOUT mode on
the PIC II. Flashing of liquid refrigerant at low 9. Repair the leak and repeat the procedure, beginning from
pressures can cause tube freeze-up and consider- Step 2h, to ensure a leak-tight repair. (If the chiller is opened
able damage. to the atmosphere for an extended period, evacuate it be-
fore repeating the leak test.)
c. Leak test chiller as outlined in Steps 3 - 9. Standing Vacuum Test — When performing the stand-
ing vacuum test or chiller dehydration, use a manometer or
2. If the pressure readings are abnormal for the chiller a wet bulb indicator. Dial gages cannot indicate the small
condition: amount of acceptable leakage during a short period of time.
a. Prepare to leak test chillers shipped with refrigerant 1. Attach an absolute pressure manometer or wet bulb in-
(Step 2h). dicator to the chiller.
b. Check for large leaks by connecting a nitrogen bottle 2. Evacuate the vessel (see Pumpout and Refrigerant
and raising the pressure to 30 psig (207 kPa). Soap Transfer Procedures section, page 62) to at least 18 in.
test all joints. If the test pressure holds for 30 minutes, Hg vac, ref 30-in. bar (41 kPa), using a vacuum pump or
prepare the test for small leaks (Steps 2g - h). the pumpout unit.
c. Plainly mark any leaks that are found. 3. Valve off the pump to hold the vacuum and record the
d. Release the pressure in the system. manometer or indicator reading.
e. Repair all leaks. 4. a. If the leakage rate is less than 0.05 in. Hg (0.17 kPa)
f. Retest the joints that were repaired. in 24 hours, the chiller is sufficiently tight.
g. After successfully completing the test for large leaks, b. If the leakage rate exceeds 0.05 in. Hg (0.17 kPa)
remove as much nitrogen, air, and moisture as pos-
in 24 hours, repressurize the vessel and test for leaks.
sible, given the fact that small leaks may be present in If refrigerant is available in the other vessel, pres-
the system. This can be accomplished by following surize by following Steps 2-10 of Return Chiller To
the dehydration procedure, outlined in the Chiller Normal Operating Conditions section, page 64. If not,
Dehydration section, page 51. use nitrogen and a refrigerant tracer. Raise the vessel
h. Slowly raise the system pressure to a maximum of pressure in increments until the leak is detected. If
160 psig (1103 kPa) but no less than 35 psig (241 kPa) refrigerant is used, the maximum gas pressure is
for HFC-134a by adding refrigerant. Proceed with the approximately 70 psig (483 kPa) for HFC-134a at nor-
test for small leaks (Steps 3-9). mal ambient temperature. If nitrogen is used, limit the
3. Check the chiller carefully with an electronic leak detec- leak test pressure to 230 psig (1585 kPa) maximum.
tor, halide torch, or soap bubble solution. 5. Repair the leak, retest, and proceed with dehydration.
4. Leak Determination — If an electronic leak detector in-
dicates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
at rates greater than 1 lb/year (0.45 kg/year) for the entire
chiller must be repaired. Note the total chiller leak rate
on the start-up report.
48
Fig. 26 — Typical Optional Pumpout System Piping Schematic with Storage Tank
Fig. 27 — Typical Optional Pumpout System Piping Schematic without Storage Tank
49
Table 5A — HFC-134a Pressure — Table 5B — HFC-134a Pressure —
Temperature (F) Temperature (C)
TEMPERATURE, PRESSURE TEMPERATURE, PRESSURE GAGE
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
50
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. 28 — Dehydration Cold Trap
Inspect Water Piping — Refer to piping diagrams pro-

Inside-delta type starters must be disconnected by an iso- vided in the certified drawings and the piping instructions
lation switch before placing the machine under a vacuum in the 19XR Installation Instructions manual. Inspect the pip-
because one lead of each phase is live with respect to ing to the cooler and condenser. Be sure that the flow
ground even though there is not a complete circuit to directions are correct and that all piping specifications have
run the motor. To be safe, isolate any starter before evacu- been met.
ating the chiller if you are not sure if there are live leads Piping systems must be properly vented with no stress on
to the hermetic motor. waterbox nozzles and covers. Water flows through the cooler
and condenser must meet job requirements. Measure the pres-
sure drop across the cooler and the condenser.
Dehydration can be done at room temperatures. Using a
cold trap (Fig. 28) may substantially reduce the time re-
quired to complete the dehydration. The higher the room tem-
perature, the faster dehydration takes place. At low room Water must be within design limits, clean, and treated
temperatures, a very deep vacuum is required to boil off any to ensure proper chiller performance and to reduce the
moisture. If low ambient temperatures are involved, contact potential of tube damage due to corrosion, scaling, or
a qualified service representative for the dehydration tech- erosion. Carrier assumes no responsibility for chiller
niques required. damage resulting from untreated or improperly treated
Perform dehydration as follows: water.
1. Connect a high capacity vacuum pump (5 cfm [.002 m3/s]
or larger is recommended) to the refrigerant charging valve Check Optional Pumpout Compressor Water
(Fig. 2). Tubing from the pump to the chiller should be Piping — If the optional pumpout storage tank and/or
as short in length and as large in diameter as possible to pumpout system are installed, check to ensure the
provide least resistance to gas flow. pumpout condenser water has been piped in. Check for field-
2. Use an absolute pressure manometer or a wet bulb vacuum supplied shutoff valves and controls as specified in the job
indicator to measure the vacuum. Open the shutoff valve data. Check for refrigerant leaks on field-installed piping.
to the vacuum indicator only when taking a reading. Leave See Fig. 26 and 27.
the valve open for 3 minutes to allow the indicator vacuum Check Relief Valves — Be sure the relief valves have
to equalize with the chiller vacuum. been piped to the outdoors in compliance with the
3. If the entire chiller is to be dehydrated, open all isolation latest edition of ANSI/ASHRAE Standard 15 and applicable
valves (if present). local safety codes. Piping connections must allow for access
4. With the chiller ambient temperature at 60 F (15.6 C) or to the valve mechanism for periodic inspection and leak
higher, operate the vacuum pump until the manometer reads testing.
29.8 in. Hg vac, ref 30 in. bar. (0.1 psia)(–100.61 kPa) or The 19XR relief valves are set to relieve at the 185 psig
a vacuum indicator reads 35 F (1.7 C). Operate the pump (1275 kPa) chiller design pressure.
an additional 2 hours.
Do not apply a greater vacuum than 29.82 in. Hg vac Inspect Wiring
(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 equip-
of evaporation (sublimation) of ice at these low tempera- ment and precautions. Serious injury may result. Fol-
tures and pressures greatly increases dehydration time. low power company recommendations.
5. Valve off the vacuum pump, stop the pump, and record
the instrument reading.
6. After a 2-hour wait, take another instrument reading. If
the reading has not changed, dehydration is complete. If Do not apply any kind of test voltage, even for a rota-
the reading indicates vacuum loss, repeat Steps 4 and 5. tion check, if the chiller is under a dehydration vacuum.
Insulation 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
(1103 kPa) pressure. Locate and repair the leak, and re- 1. Examine the wiring for conformance to the job wiring
peat dehydration. diagrams and all applicable electrical codes.
51
2. On low-voltage compressors (600 v or less) connect a 10. Tighten all wiring connections to the plugs on the ISM
voltmeter across the power wires to the compressor starter and CCM modules.
and measure the voltage. Compare this reading to the 11. On chillers with free-standing starters, inspect the power
voltage rating on the compressor and starter panel to ensure that the contractor has fed the wires into
nameplates. the bottom of the panel. Wiring into the top of the panel
3. Compare the ampere rating on the starter nameplate to can cause debris to fall into the contactors. Clean and
rating on the compressor nameplate. The overload trip inspect the contactors if this has occurred.
amps must be 108% to 120% of the rated load amps.
4. The starter for a centrifugal compressor motor must con- Carrier Comfort Network Interface — The Carrier
tain the components and terminals required for PIC II Comfort Network (CCN) communication bus wiring is sup-
refrigeration control. Check the certified drawings. plied and installed by the electrical contractor. It consists of
shielded, 3-conductor cable with drain wire.
5. Check the voltage to the following components and
compare it to the nameplate values: oil pump contact, The system elements are connected to the communication
pumpout compressor starter, and power panel. bus in a daisy chain arrangement. The positive pin of each
system element communication connector must be wired to
6. Ensure that fused disconnects or circuit breakers have the positive pins of the system element on either side of it.
been supplied for the oil pump, power panel, and The negative pins must be wired to the negative pins. The
pumpout unit. signal ground pins must be wired to the signal ground pins.
7. Ensure all electrical equipment and controls are prop- See installation manual.
erly grounded in accordance with job drawings, certi- NOTE: Conductors and drain wire must be 20 AWG
fied drawings, and all applicable electrical codes. (American Wire Gage) minimum stranded, tinned copper. In-
8. Ensure the customer’s contractor has verified proper op- dividual conductors must be insulated with PVC, PVC/
eration of the pumps, cooling tower fans, and associated nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester
auxiliary equipment. This includes ensuring motors are 100% foil shield and an outer jacket of PVC, PVC/nylon,
properly lubricated and have proper electrical supply and chrome vinyl, or Teflon with a minimum operating tempera-
proper rotation. ture range of −4 F to 140 F (−20 C to 60 C) is required. See
9. For field-installed starters only, test the chiller compres- table below for cables that meet the requirements.
sor motor and its power lead insulation resistance with
a 500-v insulation tester such as a megohmmeter. (Use MANUFACTURER CABLE NO.
a 5000-v tester for motors rated over 600 v.) Factory- Alpha 2413 or 5463
mounted starters do not require a megohm test. American A22503
a. Open the starter main disconnect switch and follow Belden 8772
lockout/tagout rules. Columbia 02525
When connecting the CCN communication bus to a sys-

If the motor starter is a solid-state starter, the tem element, a color code system for the entire network is
motor leads must be disconnected from the starter recommended to simplify installation and checkout. The fol-
before an insulation test is performed. The voltage lowing color code is recommended:
generated from the tester can damage the starter
solid-state components. CCN BUS CONDUCTOR CVC PLUG J1
SIGNAL TYPE INSULATION COLOR PIN NO.
b. With the tester connected to the motor leads, take
+ Red 1
10-second and 60-second megohm readings as
follows: Ground White 2
− Black 3
6-Lead Motor — Tie all 6 leads together and test be-
tween the lead group and ground. Next tie the leads
in pairs: 1 and 4, 2 and 5, and 3 and 6. Test between
Check Starter
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
c. Divide the 60-second resistance reading by the the starter 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 60-second Use the instruction and service manual supplied by the
readings must be at least 50 megohms. starter manufacturer to verify the starter has been installed
If the readings on a field-installed starter are unsat- correctly, to set up and calibrate the starter, and for complete
isfactory, repeat the test at the motor with the power troubleshooting information.
leads disconnected. Satisfactory readings in this sec-
ond test indicate the fault is in the power leads.
NOTE: Unit-mounted starters do not have to be meg- The main disconnect on the starter front panel may not
ohm tested. deenergize all internal circuits. Open all internal and re-
mote disconnects before servicing the starter.
52
MECHANICAL STARTER energizes the oil heater and the control circuit. When first
1. Check all field wiring connections for tightness, clear- powered, the CVC should display the default screen within
ance from moving parts, and correct connection. a short period of time.
2. Check the contactor(s) to ensure they move freely. Check The oil heater is energized by powering the control cir-
the mechanical interlock between contactors to ensure that cuit. This should be done several hours before start-up to
1S and 2M contactors cannot be closed at the same time. minimize oil-refrigerant migration. The oil heater is con-
Check all other electro-mechanical devices, such as trolled by the PIC II and is powered through a contactor in
relays, for free movement. If the devices do not move the power panel. Starters contain a separate circuit breaker
freely, contact the starter manufacturer for replacement to power the heater and the control circuit. This arrangement
components. allows the heater to energize when the main motor circuit
breaker is off for service work or extended shutdowns. The
3. Some dashpot-type magnetic overload relays must be filled oil heater relay status (OIL HEATER RELAY) can be viewed
with oil on the jobsite. If the starter is equipped with de- on the COMPRESS table on the CVC. Oil sump tempera-
vices of this type, remove the fluid cups from these mag- ture can be viewed on the CVC default screen.
netic overload relays. Add the dashpot oil to the cups
according to the instructions supplied with the starter. The SOFTWARE VERSION — The software part number is la-
oil is usually shipped in a small container attached to the beled on the backside of the CVC module. The software ver-
starter frame near the relays. Use only the dashpot oil sup- sion also appears on the CVC configuration screen as the
plied with the starter. Do not substitute. last two digits of the software part number.
Solid-state overload relays do not have oil. Software Configuration
4. Reapply starter control power (not main chiller power) to
check the electrical functions.
Ensure the starter (with relay 1CR closed) goes through Do not operate the chiller before the control configu-
a complete and proper start cycle. rations have been checked and a Control Test has been
BENSHAW, INC. REDISTART MICRO SOLID-STATE satisfactorily completed. Protection by safety controls
STARTER cannot be assumed until all control configurations have
been confirmed.
As the 19XR unit is configured, all configuration settings

This equipment is at line voltage when AC power is should be written down. A log, such as the one shown on
connected. Pressing the STOP button does not remove pages CL-1 to CL-12, provides a convenient list for con-
voltage. figuration 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
and is sufficient size. PIC II can control a set point to either the leaving or entering
3. Verify the motors are properly grounded to the starter. chilled water. This control method is set in the EQUIP-
4. Ensure all of the relays are properly seated in their MENT SERVICE (TEMP_CTL) table.
sockets. Input the Local Occupied Schedule (OCCPC01S)
5. Verify the proper ac input voltage is brought into the starter — Access the schedule OCCPC01S screen on the CVC and
according to the certified drawings. set up the occupied time schedule according to the custom-
6. Apply power to the starter. er’s requirements. If no schedule is available, the default is
factory set for 24 hours occupied, 7 days per week including
Oil Charge — The oil charge for the 19XR compressor holidays.
depends on the compressor Frame size: For more information about how to set up a time sched-
• Frame 2 compressor — 5 gal (18.9 L) ule, see the Controls section, page 10.
• Frame 3 compressor — 8 gal (30 L) The CCN Occupied Schedule (OCCPC03-99S) should be
• Frame 4 compressor — 10 gal (37.8 L) configured if a CCN system is being installed or if a sec-
ondary time schedule is needed.
• Frame 5 compressor — 18 gal (67.8 L)
NOTE: The default CCN Occupied Schedule OCCPC03S is
The chiller is shipped with oil in the compressor. When configured to be unoccupied.
the sump is full, the oil level should be no higher than the
middle of the upper sight glass, and minimum level is the Input Service Configurations — The following con-
bottom of the lower sight glass (Fig. 2). If oil is added, it figurations require the CVC screen to be in the SERVICE
must meet Carrier’s specification for centrifugal compressor portion of the menu.
use as described in the Oil Specification section. Charge the • password
oil through the oil charging valve located near the bottom of • input time and date
the transmission housing (Fig. 2). The oil must be pumped • CVC configuration
from the oil container through the charging valve due to higher • service parameters
refrigerant pressure. The pumping device must be able to lift • equipment configuration
from 0 to 200 psig (0 to 1380 kPa) or above unit pressure. • automated control test
Oil should only be charged or removed when the chiller is
shut down. PASSWORD — When accessing the SERVICE tables, a pass-
word must be entered. All CVC are initially set for a pass-
Power Up the Controls and Check the Oil Heater word of 1-1-1-1.
— Ensure that an oil level is visible in the compressor be-
fore energizing the controls. A circuit breaker in the starter
53
INPUT TIME AND DATE — Access the TIME AND DATE INPUT EQUIPMENT SERVICE PARAMETERS IF NEC-
table on the SERVICE menu. Input the present time of day, ESSARY — The EQUIPMENT SERVICE table has six serv-
date, and day of the week. The HOLIDAY TODAY param- ice tables.
eter should only be configured to YES if the present day is Configure SERVICE Tables — Access the SERVICE tables,
a holiday. depicted on the next page, to modify or view the following
NOTE: Because a schedule is integral to the chiller control to job site parameters:
sequence, the chiller will not start until the time and date
have been set. PARAMETER TABLE
Starter Type ISM_CONF — Select 0 for full voltage,
CHANGE CVC CONFIGURATION IF NECESSARY — 1 for reduced voltage, or 2 for solid state/
From the SERVICE table, access the CVC CONFIGU- variable frequency drive.
RATION screen. From there, view or modify the CVC CCN Motor Rated Line ISM_CONF — Enter actual line voltage
address, change to English or SI units, and change the pass- Voltage from power screen.
word. If there is more than one chiller at the jobsite, change Volt Transformer ISM_CONF — Enter ratio (reduced to a
the CVC address on each chiller so that each chiller has its Ratio ratio to 1) of power transformer wired to
own address. Note and record the new address. Change the terminal J3 of ISM. If no transformer is
used enter 1.
screen to SI units as required, and change the password if
Motor Rated Load ISM_CONF — Per chiller identification
desired. Amps nameplate data.
TO CHANGE THE PASSWORD — The password may be Motor Locked Rotor ISM_CONF — Per chiller identification
changed from the CVC CONFIGURATION screen. Trip nameplate data. Enter locked rotor delta
amps (LR AMPS D-).
1. Press the MENU and SERVICE softkeys. Enter the cur- Starter LRA Rating ISM_CONF — Enter value from name-
rent password and highlight CVC CONFIGURATION. plate in starter cabinet.
Motor Current ISM_CONF — Enter ratio (reduced to a
Press the SELECT softkey. Only the last 5 entries on CT Ratio ratio to 1) of current transformers wired
the CVC CONFIG screen can be changed: BUS #, to terminal J4 of ISM.
ADDRESS #, BAUD RATE, US IMP/METRIC, and Ground Fault ISM_CONF — Enter 0 if three ground
PASSWORD. Current fault CTs are wired to terminal J5 of ISM.
Transformers Enter 1 if one ground fault CT is used.
2. Use the ENTER softkey to scroll to PASSWORD. The Ground Fault CT ISM_CONF — Enter ratio (reduced to a
Ratio ratio to 1) of ground fault CT.
first digit of the password is highlighted on the screen.
Single Cycle ISM_CONF — ENABLE if motor protec-
3. To change the digit, press the INCREASE or Dropout tion required from drop in line voltage
within one cycle.
DECREASE softkey. When the desired digit is seen, press
Line Frequency ISM_CONF — Enter YES for 60 Hz or
the ENTER softkey. NO for 50 Hz.
4. The next digit is highlighted. Change it, and the third and Line Frequency ISM_CONF — ENABLE if motor protec-
Faulting tion required for drop in line frequency.
fourth digits in the same way the first was changed.
Surge LImiting or OPTIONS — Enter 1 if HGBP is
5. After the last digit is changed, the CVC goes to the BUS Hot Gas Byapss installed.
Option
parameter. Press the EXIT softkey to leave that screen
Minimum Load OPTIONS — Per job data — See modify
and return to the SERVICE menu. Points (T1/P1) load points section.
Full (Maximum) OPTIONS — Per job data — See modify
Load Points load points section.
(T2/P2)
Be sure to remember the password. Retain a copy Chilled Medium SEETUP1 — Enter water or brine.
for future reference. Without the password, access Evaporator SETUP1 — Usually 3° F (1.7° C) below
to the SERVICE menu will not be possible unless Refrigerant design refrigerant temperature.
the CVC_PSWD menu on the STATUS screen is Trippoint
accessed by a Carrier representative. Evaporator Flow SETUP1 — Enter 50% of design
Delta P Cutout pressure drop to 0.5 psi (3.4 kPa).*
Condenser Flow SETUP1 — Enter 50% of design
TO CHANGE THE CVC DISPLAY FROM ENGLISH TO Delta P Cutout pressure drop to 0.5 psi (3.4 kPa).*
METRIC UNITS — By default, the CVC displays informa- Diffuser Option SETUP2 — ENABLE for 5 size
tion in English units. To change to metric units, access the compressor only. See model number
CVC CONFIGURATION screen: nomenclature.
Diffuser Full Span SETUP2 — Enter diffuser actuator full
1. Press the MENU and SERVICE softkeys. Enter the mA Rating span mA rating for 5 size compressor
password and highlight CVC CONFIGURATION. Press only. Value is located on label on side of
diffuser actuator motor.
the SELECT softkey. Motor Rated RAMP_DEM — Enter value from chiller
2. Use the ENTER softkey to scroll to US IMP/METRIC. Kilowatts requisition form (product data submittal) if
kilowatt ramp demand is enabled.
3. Press the softkey that corresponds to the units desired for
display on the CVC (e.g., US or METRIC). *With variable flow systems this point may be configured to the lower
end of the range.
MODIFY CONTROLLER IDENTIFICATION IF NECES- NOTE: Other parameters on these screens are normally left at the
SARY — The CVC module address can be changed from default settings; however, they may be changed by the operator as
the CVC CONFIGURATION screen. Change this address required. The time and persistence settings on the ISM_CONF table
for each chiller if there is more than one chiller at the job- can be adjusted to increase or decrease the sensitivity to a fault
site. Write the new address on the CVC module for future condition. Increasing time or persistence decreases sensitivity. De-
creasing time or persistence increases sensitivity to the fault
reference. condition.
54
Modify Minimum and Maximum Load Points (DT1/P1; If surge prevention occurs too soon or too late:
D T2/P2) If Necessary — These pairs of chiller load points,
located on the OPTIONS screen, determine when to limit LOAD SURGE PREVENTION SURGE PREVENTION
guide vane travel or open the hot gas bypass valve when OCCURS TOO SOON OCCURS TOO LATE
surge prevention is needed. These points should be set based At low
loads Increase P1 by 10 psid Decrease P1 by 10 psid
on individual chiller operating conditions. (,50%) (70 kPad) (70 kPad)
If after configuring a value for these points, surge preven- At high Decrease P2 by 10 psid
tion is operating too soon or too late for conditions, these loads Increase P2 by 10 psid (70 kPad)
(.50%) (70 kPad)
parameters should be changed by the operator.
An example of such a configuration is shown below. The differential pressure (DP) and temperature (DT) can
Refrigerant: HCFC-134a be monitored during chiller operation by viewing ACTIVE
Estimated Minimum Load Conditions: DELTA P and ACTIVE DELTA T (HEAT_EX screen). Com-
44 F (6.7 C) LCW paring SURGE/AGBP DELTA T to active DETLA T will de-
45.5 F (7.5 C) ECW termine when the SURGE PREVENTION function will oc-
43 F (6.1 C) Suction Temperature cur. The smaller the difference between the SURGE/AGBP
70 F (21.1 C) Condensing Temperature DELTA T and the ACTIVE DELTA T values, the closer to
surge prevention.
Estimated Maximum Load Conditions:
44 F (6.7 C) LCW CONFIGURE DIFFUSER CONTROL IF NECESSARY —
54 F (12.2 C) ECW If the compressor is equipped with a variable diffuser,
42 F (5.6 C) Suction Temperature (5 size compressor) access the SETUP2 screen. Scroll to DIF-
98 F (36.7 C) Condensing Temperature FUSER CONTROL and press the ENABLE softkey. Enter
Calculate Maximum Load — To calculate the maximum load the correct diffuser and guide vane values (GUIDE VANE
points, use the design load condition data. If the chiller 25% LOAD PT, GUIDE VANE 50 % LOAD PT, GUIDE VANE
full load cooler temperature difference is more than 15 F 75% LOAD PT, DIFFUSER 25% LOAD PT, DIFFUSER 50%
(8.3 C), estimate the refrigerant suction and condensing tem- LOAD PT, DIFFUSER 75% LOAD PT). Default values are
peratures at this difference. Use the proper saturated pres- located on the label inside the control panel. See Fig. 10. To
sure and temperature for the particular refrigerant used. obtain proper settings for diffuser control, contact a Carrier
Engineering representative.
Suction Temperature:
42 F (5.6 C) = 37 psig (255 kPa) saturated Compressors with variable diffuser control have actuators
refrigerant pressure (HFC-134a) tested and stamped with the milliamp (mA) value that
results in 100% actuator rotation. This valve is configured
Condensing Temperature: on the SETUP2 screen. It is labeled DIFFUSER FULL
98 F (36.7 C) = 120 psig (1827 kPa) saturated SPAN mA.
refrigerant pressure (HFC-134a)
MODIFY EQUIPMENT CONFIGURATION IF NECES-
Maximum Load DT2: SARY — The EQUIPMENT SERVICE table has screens to
54 – 44 = 10° F (12.2 – 6.7 = 5.5° C) select, view, or modify parameters. Carrier’s certified draw-
Maximum Load DP2: ings have the configuration values required for the jobsite.
120 – 37 = 83 psid (827 – 255 = 572 kPad) Modify these values only if requested.
To avoid unnecessary surge prevention, add about 10 psid SERVICE Screen Modifications — Change the values on these
(70 kPad) to DP2 from these conditions: screens according to specific job data. See the certified draw-
DT2 = 10° F (5.5° C) ings for the correct values. Modifications can include:
DP2 = 93 psid (642 kPad) • chilled water reset
Calculate Minimum Load — To calculate the minimum load • entering chilled water control (Enable/Disable)
conditions, estimate the temperature difference the cooler will • 4 to 20 mA demand limit
have at 10% load, then estimate what the suction and con- • auto restart option (Enable/Disable)
densing temperatures will be at this point. Use the proper • remote contact option (Enable/Disable)
saturated pressure and temperature for the particular refrig- Owner-Modified CCN Tables— The following EQUIP-
erant used. MENT CONFIGURATION screens are described for refer-
Suction Temperature: ence only.
43 F (6.1 C) = 38 psig (262 kPa) saturated OCCDEFCS — The OCCDEFCS screen contains the Local
refrigerant pressure (HFC-134a) and CCN time schedules, which can be modified here or on
the SCHEDULE screen as described previously.
Condensing Temperature:
70 F (21.1 C) = 71 psig (490 kPa) saturated HOLIDAYS — From the HOLIDAYS screen, the days of the
refrigerant pressure (HFC-134a) year that holidays are in effect can be configured. See the
holiday paragraphs in the Controls section for more
Minimum Load DT1 (at 20% Load): 2 F (1.1 C) details.
Minimum Load DP1: BRODEF — The BRODEF screen defines the start and end
71 – 38 = 33 psid (490 – 262 = 228 kPad) of daylight savings time. Enter the dates for the start and end
Again, to avoid unnecessary surge prevention, add 20 psid of daylight savings if required for your location. BRODEF
(140 kPad) at DP1 from these conditions: also activates the Broadcast function which enables the holi-
DT1 = 2 F (1.1 C) day periods that are defined on the CVC to take effect.
DP1 = 53 psid (368 kPad) Other Tables — The CONSUME, and RUNTIME screens
contain parameters used with a CCN system. See the appli-
cable CCN manual for more information on these screens.
These tables can only be defined from a CCN Building
Supervisor.
55
Perform a Control Test — Check the safety controls Table 6 — Control Test Menu Functions
status by performing an automated control test. Access the
CONTROL TEST table and select a test to be performed TESTS TO BE DEVICES TESTED
PERFORMED
function (Table 6).
1. CCM Thermistors Entering Chilled Water
The Automated Control Test checks all outputs and inputs Leaving Chilled Water
for function. The compressor must be in the OFF mode to Entering Condenser Water
operate the controls test. The compressor can be put in OFF Leaving Condenser Water
Remote Reset Sensor
mode by pressing the STOP push-button on the CVC. Each Comp Discharge Temp
test asks the operator to confirm the operation is occurring Comp Thrust Bearing Temp
and whether or not to continue. If an error occurs, the op- Oil Sump Temp
erator can try to address the problem as the test is being done Comp Motor Winding Temp
Spare Temperature 1
or note the problem and proceed to the next test. Space Temperature 2
NOTE: Enter guide vane calibration to calibrate guide 2. CCM Pressure Evaporator Pressure
input on CCM (Plug J4 upper terminal 9 and 10). Transducers Condenser Pressure
Oil Pump Delta P
NOTE: If during the control test the guide vanes do not open, Spare Pressure Delta P
verify the low pressure alarm is not active. (An active low Condenser Water Delta P
pressure alarm causes the guide vanes to close.) Transducer Voltage Ref
NOTE: The oil pump test will not energize the oil pump if 3. Pumps Oil Pump — Confirm pressure
Chilled Water — Confirm Delta P
cooler pressure is below –5 psig (–35 kPa). Condenser Water — Confirm
Delta P
When the control test is finished or the EXIT softkey is
4. Discrete Outputs Oil Heater Relay
pressed, the test stops, and the CONTROL TEST menu dis- Hot Gas Bypass Relay
plays. If a specific automated test procedure is not com- Tower Fan Relay Low
pleted, access the particular control test to test the function Tower Fan Relay High
Alarm Relay
when ready. The CONTROL TEST menu is described in the Shunt Trip Relay
table below. 5. Guide Vane Actuator Open/Close
6. Diffuser Actuator Open/Close
CCM Pressure Thermistors Check of all thermistors. 7. Pumpdown/Lockout When using pumpdown/lockout,
CCM Pressure Transducers Check of all transducers. observe freeze up precautions when
Pump Checks operation of pump out- removing charge:
puts; pumps are activated. Also Instructs operator which valves to
tests associated inputs such as close and when.
flow or pressure. Starts chilled water and condenser
Discrete ouputs Activation of all on/off outputs water pumps and confirms flows.
individually. Monitors
Guide Vane Check of the guide vane Evaporator pressure
operation. Condenser pressure
Diffuser Actuator* Check of the diffuser actuator. Evaporator temperature during
pumpout procedures
Pumpdown/Lockout Pumpdown prevents the low re-
frigerant alarm during evacuation Turns pumps off after pumpdown.
so refrigerant can be removed Locks out compressor.
form the unit. Also locks the 8. Terminate Lockout Starts pumps and monitors flows.
compressor off and starts the
water pumps. Instructs operator which valves to
open and when.
Terminate Lockout To charge refrigerant and enable
the chiller to run after pumpdown Monitors
lockout. Evaporator pressure
Condenser pressure
Guide Vane Calibration Calibrates guide vane input on Evaporator temperature during
CCM. charging process
*Diffuser tests function only on size 5 compressor with diffuser con- Terminates compressor lockout.
trol enabled.
NOTE: During any of the tests, an out-of-range reading will have an High Altitude Locations — Because the chiller is ini-
asterisk (*) next to the reading and a message will be displayed. tially calibrated at sea level, it is necessary to recalibrate
the pressure transducers if the chiller has been moved to a
Check Optional Pumpout System Controls and high altitude location. See the calibration procedure in the
Compressor — Controls include an on/off switch, a 3-amp Troubleshooting Guide section.
fuse, the compressor overloads, an internal thermostat, a com-
pressor contactor, and a refrigerant high pressure cutout. Charge Refrigerant into Chiller
The high pressure cutout is factory set to open at 161 psig
(1110 kPa) and reset at 130 psig (896 kPa). Ensure the water-
cooled condenser has been connected. Loosen the The transfer, addition, or removal of refrigerant in spring
compressor holddown bolts to allow free spring travel. Open isolated chillers may place severe stress on external pip-
the compressor suction and discharge the service valves. En- ing if springs have not been blocked in both up and down
sure oil is visible in the compressor sight glass. Add oil if directions.
necessary.
See the Pumpout and Refrigerant Transfer Procedures and
Optional Pumpout System Maintenance sections, pages 62
and 68, for details on the transfer of refrigerant, oil speci-
fications, etc.
56
4. Once the pressures have equalized, the discharge isola-
tion valve, cooler isolation valve, optional hot gas bypass
Always operate the condenser and chilled water pumps isolation valve, and the refrigerant isolation valve can be
during charging operations to prevent freeze-ups. opened. Close valves 1a and 1b, and all pumpout unit
valves.
The standard 19XR chiller is shipped with the refrigerant
already charged in the vessels. However, the 19XR may be
ordered with a nitrogen holding charge of 15 psig (103 kPa). Whenever turning the discharge isolation valve, be
Evacuate the nitrogen from the entire chiller, and charge the sure to reattach the valve locking device. This pre-
chiller from refrigerant cylinders. vents the valve from opening or closing during serv-
CHILLER EQUALIZATION WITHOUT A PUMPOUT ice work or during chiller operation.
UNIT
The full refrigerant charge on the 19XR will vary with
chiller components and design conditions, as indicated on
the job data specifications. An approximate charge may be
When equalizing refrigerant pressure on the 19XR chiller determined by adding the condenser charge to the cooler charge
after service work or during the initial chiller start-up, as listed in Table 7.
do not use the discharge isolation valve to equalize.
Either the motor cooling isolation valve or the charging
hose (connected between the pumpout valves on top of Table 7 — Refrigerant (HFC-134a) Charge
the cooler and condenser) should be used as the equal-
ization valve. REFRIGERANT REFRIGERANT
COOLER CHARGE CONDENSER CHARGE
CODE CODE
To equalize the pressure differential on a refrigerant iso- lb kg lb kg
lated 19XR chiller, use the terminate lockout function of the 10 290 132 10 200 91
11 310 141 11 200 91
CONTROL TEST on the SERVICE menu. This helps to turn 12 330 150 12 200 91
on pumps and advises the operator on proper procedures. 15 320 145 15 250 113
The following steps describe how to equalize refrigerant 16 340 154 16 250 113
17 370 168 17 250 113
pressure in an isolated 19XR chiller without a pumpout unit. 20 345 157 20 225 102
1. Access terminate lockout function on the CONTROL TEST 21 385 175 21 225 102
22 435 197 22 225 102
screen. 30 350 159 30 260 118
2. IMPORTANT: Turn on the chilled water and con- 31 420 190 31 260 118
32 490 222 32 260 118
denser water pumps to prevent freezing. 35 400 181 35 310 141
36 480 218 36 310 141
37 550 250 37 310 141
3. Slowly open the refrigerant cooling isolation valve. The 40 560 254 40 280 127
chiller cooler and condenser pressures will gradually equal- 41 630 286 41 280 127
ize. This process takes approximately 15 minutes. 42 690 313 42 280 127
45 640 290 45 330 150
4. Once the pressures have equalized, the cooler isolation 46 720 327 46 330 150
valve, the condenser isolation valve, and the hot gas iso- 47 790 358 47 330 150
lation valve may now be opened. Refer to Fig. 26 and 27, 50 750 340 50 400 181
for the location of the valves. 51 840 381 51 400 181
52 900 408 52 400 181
55 870 395 55 490 222
56 940 426 56 490 222
57 980 445 57 490 222
Whenever turning the discharge isolation valve, be 60 940 426 60 420 190
sure to reattach the valve locking device. This pre- 61 980 445 61 420 190
vents the valve from opening or closing during serv- 62 1020 463 62 420 190
65 1020 463 65 510 231
ice work or during chiller operation. 66 1060 481 66 510 231
67 1090 494 67 510 231
70 1220 553 70 780 354
CHILLER EQUALIZATION WITH PUMPOUT UNIT — 71 1340 608 71 780 354
The following steps describe how to equalize refrigerant pres- 72 1440 653 72 780 354
sure on an isolated 19XR chiller using the pumpout unit. 75 1365 619 75 925 420
76 1505 683 76 925 420
1. Access the terminate lockout function on the CONTROL 77 1625 737 77 925 420
TEST screen. 80 1500 680 80 720 327
81 1620 735 81 720 327
2. IMPORTANT: Turn on the chilled water and con- 82 1730 785 82 720 327
85 1690 766 85 860 390
denser water pumps to prevent possible freezing. 86 1820 825 86 860 390
87 1940 880 87 860 390
3. Open valve 4 on the pumpout unit and open valves 1a
and 1b on the chiller cooler and condenser, Fig. 26 and
27. Slowly open valve 2 on the pumpout unit to equalize
the pressure. This process takes approximately
15 minutes.
57
2. Observe the default screen on the CVC: the Status mes-
sage in the upper left-hand corner reads, ‘‘Manually
Always operate the condenser and chilled water pumps Stopped.’’ Press the CCN or LOCAL softkey to start.
whenever charging, transferring, or removing refrig- If the chiller controls do not go into a start mode, go to
rant from the chiller. the Schedule screen and override the schedule or change
the occupied time. Press the LOCAL softkey to begin
Use the CONTROL TEST terminate lockout function to the start-up sequences.
monitor conditions and start the pumps. 3. Verify the chilled water and condenser water pumps
If the chiller has been shipped with a holding charge, the have energized.
refrigerant is added through the refrigerant charging valve 4. Verify the oil pump has started and is pressurizing the
(Fig. 26 and 27, valve 7) or to the pumpout charging con- lubrication system. After the oil pump has run about
nection. First evacuate the nitrogen holding charge from the 11 seconds, the starter energizes and goes through its start-up
chiller vessels. Charge the refrigerant as a gas until the sys- sequence.
tem pressure exceeds 35 psig (141 kPa) for HFC-134a. After
the chiller is beyond this pressure the refrigerant should be 5. Check the main contactor for proper operation.
charged as a liquid until all the recommended refrigerant charge 6. The PIC II eventually shows an alarm for motor amps
has been added. not sensed. Reset this alarm and continue with the initial
TRIMMING REFRIGERANT CHARGE — The 19XR is start-up.
shipped with the correct charge for the design duty of the Check Motor Rotation
chiller. Trimming the charge can best be accomplished when
the design load is available. To trim the charge, check the 1. Engage the main motor disconnect on the front of the starter
temperature difference between the leaving chilled water tem- panel. The motor is now ready for a rotation check.
perature and cooler refrigerant temperature at full load 2. After the default screen status message states ‘‘Ready
design conditions. If necessary, add or remove refrigerant to for Start’’ press the LOCAL softkey. The PIC II control
bring the temperature difference to design conditions or mini- performs start-up checks.
mum differential.
3. When the starter is energized and the motor begins to turn,
Table 7 lists the 19XR chiller refrigerant charges for each check for clockwise motor rotation (Fig. 29).
cooler and condenser code. Total refrigerant charge is the
sum of the cooler and condenser charge. IF THE MOTOR ROTATION IS CLOCKWISE, allow the
compressor to come up to speed.
IF THE MOTOR ROTATION IS NOT CLOCKWISE
INITIAL START-UP (as viewed through the sight glass), reverse any 2 of the 3
incoming power leads to the starter and recheck the rotation.
Preparation — Before starting the chiller, verify:
NOTE: Solid-state starters have phase protection and do not
1. Power is on to the main starter, oil pump relay, tower fan permit a start if the phase is not correct. If this happens, a
starter, oil heater relay, and the chiller control panel. fault message appears on the CVC.
2. Cooling tower water is at proper level and at-or-below
design entering temperature.
3. Chiller is charged with refrigerant and all refrigerant and Do not check motor rotation during coastdown. Rota-
oil valves are in their proper operating positions. tion may have reversed during equalization of vessel
4. Oil is at the proper level in the reservoir sight glasses. pressures.
5. Oil reservoir temperature is above 140 F (60 C) or re-
frigerant temperature plus 50° F (28° C).
6. Valves in the evaporator and condenser water circuits are
open.
NOTE: If the pumps are not automatic, ensure water is
circulating properly.
Do not permit water or brine that is warmer than

110 F (43 C) to flow through the cooler or con-
denser. Refrigerant overpressure may discharge through
the relief valves and result in the loss of refrigerant
charge.
7. Access the CONTROL TEST screen. Scroll down on the
TERMINATE LOCKOUT option. Press the SELECT (to
enable the chiller to start) and answer YES to restart unit
to operating mode. The chiller is locked out at the factory
in order to prevent accidental start-up.
Dry Run to Test Start-Up Sequence Fig. 29 — Correct Motor Rotation
1. Disengage the main motor disconnect on the starter front
panel. This should only disconnect the motor power. Power
to the controls, oil pump, and starter control circuit should
still be energized.
58
Check Oil Pressure and Compressor Stop REVIEW MAINTENANCE — Scheduled, routine, and
extended shutdowns, importance of a log sheet, importance
1. When the motor is at full speed, note the differential oil of water treatment and tube cleaning, and importance of main-
pressure reading on the CVC default screen. It should be taining a leak-free chiller.
between 18 and 30 psid (124 to 206 kPad).
2. Press the Stop button and listen for any unusual sounds SAFETY DEVICES AND PROCEDURES — Electrical dis-
from the compressor as it coasts to a stop. connects, relief device inspection, and handling refrigerant.
To Prevent Accidental Start-Up — A chiller STOP CHECK OPERATOR KNOWLEDGE — Start, stop, and shut-
override setting may be entered to prevent accidental start-up down procedures, safety and operating controls, refrigerant
and oil charging, and job safety.
during service or whenever necessary. Access the MAIN-
REVIEW THE START-UP, OPERATION, AND MAINTE-
STAT screen and using the NEXT or PREVIOUS soft- NANCE MANUAL.
keys, highlight the CHILLER START/STOP parameter. Override
the current START value by pressing the SELECT softkey.
Press the STOP softkey followed by the ENTER softkey. OPERATING INSTRUCTIONS
The word SUPVSR! displays on the CVC indicating the over-
ride is in place. Operator Duties
To restart the chiller the STOP override setting must be 1. Become familiar with the chiller and related equipment
removed. Access the MAINSTAT screen and using before operating the chiller.
NEXT or PREVIOUS softkeys highlight CHILLER 2. Prepare the system for start-up, start and stop the chiller,
START/STOP. The 3 softkeys that appear represent 3 choices: and place the system in a shutdown condition.
3. Maintain a log of operating conditions and document any
• START — forces the chiller ON abnormal readings.
• STOP — forces the chiller OFF 4. Inspect the equipment, make routine adjustments, and per-
• RELEASE — puts the chiller under remote or schedule form a Control Test. Maintain the proper oil and refrig-
erant levels.
control.
5. Protect the system from damage during shutdown
To return the chiller to normal control, press the periods.
RELEASE softkey followed by the ENTER softkey. For 6. Maintain the set point, time schedules, and other PIC
more information, see Local Start-Up, page 44. functions.
The default LID screen message line indicates which com-
mand is in effect. Prepare the Chiller for Start-Up — Follow the steps
described in the Initial Start-Up section, page 58.
Check Chiller Operating Condition — Check to
be sure that chiller temperatures, pressures, water flows, and To Start the Chiller
oil and refrigerant levels indicate the system is functioning 1. Start the water pumps, if they are not automatic.
properly. 2. On the CVC default screen, press the LOCAL or
Instruct the Customer Operator — Ensure the CCN softkey to start the system. If the chiller is in the
operator(s) understand all operating and maintenance pro- OCCUPIED mode and the start timers have expired, the
cedures. Point out the various chiller parts and explain their start sequence will start. Follow the procedure described
function as part of the complete system. in the Start-Up/Shutdown/Recycle section, page 44.
COOLER-CONDENSER — Float chamber, relief valves, re-
frigerant charging valve, temperature sensor locations, pres- Check the Running System — After the compres-
sure transducer locations, Schrader fittings, waterboxes and sor starts, the operator should monitor the CVC display and
tubes, and vents and drains. observe the parameters for normal operating conditions:
OPTIONAL PUMPOUT STORAGE TANK AND PUMP- 1. The oil reservoir temperature should be above 120 F
OUT SYSTEM — Transfer valves and pumpout system, (49 C) during shutdown and above 125 F (58 C) during
refrigerant charging and pumpdown procedure, and relief compressor operation.
devices. 2. The bearing oil temperature accessed on the COM-
MOTOR COMPRESSOR ASSEMBLY — Guide vane PRESS table should be 120 to 165 F (49 to 74 C). If the
actuator, transmission, motor cooling system, oil cooling bearing temperature reads more than 180 F (83 C) with
system, temperature and pressure sensors, oil sight glasses, the oil pump running, stop the chiller and determine the
integral oil pump, isolatable oil filter, extra oil and motor cause of the high temperature. Do not restart the chiller
temperature sensors, synthetic oil, and compressor until corrected.
serviceability. 3. The oil level should be visible anywhere in one of the
MOTOR COMPRESSOR LUBRICATION SYSTEM — Oil two sight glasses. Foaming oil is acceptable as long as
pump, cooler filter, oil heater, oil charge and specification, the oil pressure and temperature are within limits.
operating and shutdown oil level, temperature and pressure, 4. The oil pressure should be between 18 and 30 psid
and oil charging connections. (124 to 207 kPad) differential, as seen on the CVC de-
CONTROL SYSTEM — CCN and LOCAL start, reset, menu, fault screen. Typically the reading will be 18 to 25 psid
softkey functions, CVC operation, occupancy schedule, set (124 to 172 kPad) at initial start-up.
points, safety controls, and auxiliary and optional controls. 5. The moisture indicator sight glass on the refrigerant
AUXILIARY EQUIPMENT — Starters and disconnects, sepa- motor cooling line should indicate refrigerant flow and a
rate electrical sources, pumps, and cooling tower. dry condition.
DESCRIBE CHILLER CYCLES — Refrigerant, motor cool- 6. The condenser pressure and temperature varies with
ing, lubrication, and oil reclaim. the chiller design conditions. Typically the pressure will
range between 100 and 210 psig (690 to 1450 kPa)
59
with a corresponding temperature range of 60 to 105 F Check the cooler pressure on the CVC default screen and
(15 to 41 C). The condenser entering water temperature compare it to the original holding charge that was left in the
should be controlled below the specified design entering chiller. If (after adjusting for ambient temperature changes)
water temperature to save on compressor kilowatt any loss in pressure is indicated, check for refrigerant leaks.
requirements. See Check Chiller Tightness section, page 46.
7. Cooler pressure and temperature also will vary with the Recharge the chiller by transferring refrigerant from the
design conditions. Typical pressure range will be be- pumpout storage tank (if supplied). Follow the Pumpout and
tween 60 and 80 psig (410 and 550 kPa), with tempera- Refrigerant Transfer Procedures section, this page. Observe
ture ranging between 34 and 45 F (1 and 8 C). freeze-up precautions.
8. The compressor may operate at full capacity for a short Carefully make all regular preliminary and running sys-
time after the pulldown ramping has ended, even though tem checks. Perform a Control Test before start-up. If the
the building load is small. The active electrical demand compressor oil level appears abnormally high, the oil may
setting can be overridden to limit the compressor IkW, or have absorbed refrigerant. Ensure that the oil temperature is
the pulldown rate can be decreased to avoid a high above 140 F (60 C) or above the cooler refrigerant tempera-
demand charge for the short period of high demand ture plus 50° F (27° C).
operation. Pulldown rate can be based on load rate or tem-
perature rate. It is accessed on the Equipment SERVICE Cold Weather Operation — When the entering con-
screen, RAMP_DEM table (Table 2, Example 20). denser water temperature drops very low, the operator should
automatically cycle the cooling tower fans off to keep the
To Stop the Chiller temperature up. Piping may also be arranged to bypass the
1. The occupancy schedule starts and stops the chiller cooling tower. The PIC II controls have a low limit tower
automatically once the time schedule is configured. fan output that can be used to assist in this control (terminal
11 and 12 on ISM).
2. By pressing the STOP button for one second, the alarm
light blinks once to confirm the button has been pressed. Manual Guide Vane Operation — It is possible to
The compressor will then follow the normal shutdown manually operate the guide vanes in order to check con-
sequence as described in the Controls section. The chiller trol operation or to control the guide vanes in an emergency.
will not restart until the CCN or LOCAL softkey is Manual operation is possible by overriding the target guide
pressed. The chiller is now in the OFF control mode. vane position. Access the COMPRESS screen on the CVC
and scroll down to highlight TARGET GUIDE VANE
IMPORTANT: Do not attempt to stop the chiller by POS. To control the position, use the INCREASE or
opening an isolating knife switch. High intensity DECREASE softkey to adjust to the percentage of guide
arcing may occur.
vane opening that is desired. Zero percent is fully closed;
100% is fully open. To release the guide vanes to automatic
Do not restart the chiller until the problem is diagnosed
and corrected. control, press the RELEASE softkey.
NOTE: Manual control increases the guide vane openings
After Limited Shutdown — No special preparations and overrides the pulldown rate during start-up. Motor cur-
should be necessary. Follow the regular preliminary checks rent above the electrical demand setting, capacity overrides,
and starting procedures. and chilled water temperature below the control point over-
Preparation for Extended Shutdown — The ride the manual target and close the guide vanes. For
refrigerant should be transferred into the pumpout storage descriptions of capacity overrides and set points, see the
tank (if supplied; see Pumpout and Refrigerant Transfer Controls section.
Procedures) to reduce chiller pressure and the possibility Refrigeration Log — A refrigeration log (as shown in
of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to Fig. 30), is a convenient checklist for routine inspection and
4.5 kg) of refrigerant or nitrogen to prevent air from leaking maintenance and provides a continuous record of chiller
into the chiller. performance. It is also an aid when scheduling routine main-
If freezing temperatures are likely to occur in the chiller tenance and diagnosing chiller problems.
area, drain the chilled water, condenser water, and the pump- Keep a record of the chiller pressures, temperatures, and
out condenser water circuits to avoid freeze-up. Keep the liquid levels on a sheet similar to the one in Fig. 30. Auto-
waterbox drains open. matic recording of PIC II data is possible by using CCN
Leave the oil charge in the chiller with the oil heater devices such as the Data Collection module and a Build-
and controls energized to maintain the minimum oil reser- ing Supervisor. Contact a Carrier representative for more
voir temperature. information.
After Extended Shutdown — Ensure the water sys-
tem drains are closed. It may be advisable to flush the water
circuits to remove any soft rust which may have formed. This
is a good time to brush the tubes and inspect the Schrader
fittings on the waterside flow devices for fouling, if
necessary.
60
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)
61
REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water
drained from dehydrator. Include amounts.
Fig. 30 — Refrigeration Log
PUMPOUT AND REFRIGERANT 3. Refer to Fig. 26, 27, and 32 for valve locations and
TRANSFER PROCEDURES numbers.
Preparation — The 19XR may come equipped with an
optional pumpout storage tank, pumpout system, or pump-
out compressor. The refrigerant can be pumped for service Transfer, addition, or removal of refrigerant in spring-
work to either the chiller compressor vessel or chiller con- isolated chillers may place severe stress on external pip-
denser vessel by using the optional pumpout system. If a ing if springs have not been blocked in both up and down
pumpout storage tank is supplied, the refrigerant can be iso- directions.
lated in the storage tank. The following procedures describe
how to transfer refrigerant from vessel to vessel and perform
chiller evacuations.
Always run the chiller cooler and condenser water pumps

and always charge or transfer refrigerant as a gas when
the chiller pressure is less than 30 psig (207 kPa). Be-
low these pressures, liquid refrigerant flashes into gas,
resulting in extremely low temperatures in the cooler/
condenser tubes and possibly causing tube freeze-up.
During transfer of refrigerant into and out of the

optional storage tank, carefully monitor the storage LEGEND
tank level gage. Do not fill the tank more than 90% of C — Contactor
capacity to allow for refrigerant expansion. Overfilling FU — Fuse, 3 Amps
HP — High-Pressure Cutout
may result in damage to the tank or personal injury. OL — Compressor Overload
T’STAT — Internal Thermostat
Compressor Terminal
Contactor Terminal
Do not mix refrigerants from chillers that use different Overload Terminal
compressor oils. Compressor damage can result.
Pumpout Unit Terminal
*Bimetal thermal protector imbedded in motor winding.
Operating the Optional Pumpout Unit
Fig. 31 — 19XR Pumpout Unit Wiring Schematic
1. Be sure that the suction and the discharge service valves
on the optional pumpout compressor are open (back-
seated) during operation. Rotate the valve stem fully OIL RETURN
counterclockwise to open. Frontseating the valve closes LINE
the refrigerant line and opens the gage port to compres- CONNECTION
sor pressure.
2. Ensure that the compressor holddown bolts have been loos-
ened to allow free spring travel.
3. Open the refrigerant inlet valve on the pumpout
compressor.
4. Oil should be visible in the pumpout unit compressor sight
glass under all operating conditions and during shut-
down. If oil is low, add oil as described under Optional
Pumpout System Maintenance section, page 68. The pump-
out unit control wiring schematic is detailed in Fig. 31.
TO READ REFRIGERANT PRESSURES during pumpout
or leak testing:
1. The CVC display on the chiller control panel is suitable
for determining refrigerant-side pressures and low (soft)
vacuum. To assure the desired range and accuracy when
measuring evacuation and dehydration, use a quality vacuum CONDENSER REFRIGERANT
WATER
indicator or manometer. This can be placed on the Schrader CONNECTIONS
INLET VALVE
connections on each vessel (Fig. 7) by removing the pres-
sure transducer. Fig. 32 — Optional Pumpout Unit
2. To determine pumpout storage tank pressure, a 30 in.
-0-400 psi (-101-0-2769 kPa) gage is attached to the stor-
age tank.
62
Chillers with Storage Tanks — If the chiller has iso- TRANSFER REFRIGERANT FROM CHILLER TO
lation valves, leave them open for the following procedures. PUMPOUT STORAGE TANK
The letter ‘‘C’’ describes a closed valve. See Fig. 15, 16, 26, 1. Equalize refrigerant pressure.
and 27. a. Valve positions:
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
1. Equalize refrigerant pressure.
a. Use the PIC II terminate lockout function on the PUMP- b. Slowly open valve 5. When the pressures are equal-
DOWN LOCKOUT screen, accessed from the CON- ized, open liquid line valve 7 to allow liquid refrig-
TROL TEST table to turn on the water pumps and erant to drain by gravity into the pumpout storage tank.
monitor pressures. VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
If the chilled water and condenser water pumps are 2. Transfer the remaining liquid.
not controlled by the PIC II, these pumps must be a. Turn off the pumpout condenser water. Place the valves
started and stopped manually at the appropriate times in the following positions:
during the refrigerant transfer procedure. VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
b. Close pumpout unit valves 2, 4, 5, 8, and 10, and close
chiller charging valve 7; open chiller isolation valves b. Run the pumpout compressor for approximately 30 min-
11, 12, 13, and 14 (if present). utes; then close valve 10.
c. Open pumpout unit/storage tank valves 3 and 6, open VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
chiller valves 1a and 1b. CONDITION C C C C
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C
c. Turn off the pumpout compressor.
3. Remove any remaining refrigerant.
d. Slowly open valve 5 to increase chiller pressure to a. Turn on the chiller water pumps using the PUMP-
68 psig 35 psig (141 kPa) for HFC-134a. Feed refrig- DOWN LOCKOUT screen, accessed from the CON-
erant slowly to prevent freeze up. TROL TEST table. Turn on the pumps manually, if
e. Open valve 5 fully after the pressure rises above the they are not controlled by the PIC II.
freeze point of the refrigerant. Open liquid line valves b. Turn on the pumpout condenser water.
7 and 10 until refrigerant pressure equalizes.
c. Place valves in the following positions:
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C
CONDITION C C C C
2. Transfer the remaining refrigerant.
d. Run the pumpout compressor until the chiller pres-
a. Close valve 5 and open valve 4. sure reaches 30 psig (207 kPa) for HFC-134a. Then,
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
shut off the pumpout compressor. Warm condenser
CONDITION C C C
water will boil off any entrapped liquid refrigerant and
the chiller pressure will rise.
b. Turn off the chiller water pumps using the CVC (or e. When the pressure rises to 40 psig (276 kPa) for
manually, if necessary). HFC-134a, turn on the pumpout compressor until the
c. Turn off the pumpout condenser water, and turn on the pressure again reaches 30 psig (207 kPa), and then
pumpout compressor to push liquid out of the storage turn off the pumpout compressor. Repeat this process
tank. until the pressure no longer rises. Then, turn on the
pumpout compressor and pump until the pressure reaches
d. Close liquid line valve 7. 18 in. Hg. (40 kPa absolute).
e. Turn off the pumpout compressor. f. Close valves 1a, 1b, 3, 4, 6, 7, and 10.
f. Close valves 3 and 4.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
g. Open valves 2 and 5.
CONDITION C C C C C C C C C C
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C g. Turn off the pumpout condenser water and continue to
use the PIC II PUMPDOWN LOCKOUT screen func-
h. Turn on the pumpout condenser water. tions, which lock out the chiller compressor for
i. Run the pumpout compressor until the pumpout stor- operation.
age tank pressure reaches 5 psig (34 kPa) (18 in. Hg 4. Establish a vacuum for service.
[40 kPa absolute] if repairing the tank). To conserve refrigerant, operate the pumpout compressor
j. Turn off the pumpout compressor. until the chiller pressure is reduced to 18 in. Hg vac., ref
k. Close valves 1a, 1b, 2, 5, 6, and 10. 30 in. bar. (40 kPa abs.) following Step 3e.
VALVE 1a 1b 2 3 4 5 6 7 8 10 11 12 13 14
CONDITION C C C C C C C C C C
l. Turn off pumpout condenser water.
63
Chillers with Isolation Valves 2. Evacuate the refrigerant gas from the chiller condenser
vessel.
TRANSFER ALL REFRIGERANT TO CHILLER CON- a. Access the PUMPDOWN LOCKOUT function ac-
DENSER VESSEL — For chillers with isolation valves, cessed from the CVC CONTROL TEST table to turn
refrigerant can be stored in one chiller vessel or the other on the chiller water pumps. Turn the chiller water pumps
without the need for an external storage tank. on manually if they are not controlled by the PIC II.
1. Push refrigerant into the chiller condenser. b. Close pumpout unit valves 3 and 4; open valves 2
a. Valve positions: and 5.
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C CONDITION C C C C C C C
b. Using the PIC II controls, turn off the chiller water c. Turn on the pumpout condenser water.
pumps and pumpout condenser water. If the chiller d. Run the pumpout compressor until the chiller con-
water pumps are not controlled through the PIC II, turn denser pressure reaches 18 in. Hg vac (40 kPa abs.).
them off manually. Monitor pressure at the CVC and at refrigerant gages.
c. Turn on the pumpout compressor to push the liquid e. Close valve 1b.
refrigerant out of the chiller cooler vessel.
f. Turn off the pumpout compressor.
d. When all liquid refrigerant has been pushed into
the chiller condenser vessel, close chiller isolation g. Close valves 1a, 2, and 5.
valve 11. VALVE 1a 1b 2 3 4 5 8 11 12 13 14
e. Access the PUMPDOWN LOCKOUT screen on the CONDITION C C C C C C C C C C C
PIC II CONTROL TEST table to turn on the chiller
water pumps. If the chiller water pumps are not con- h. Turn off the pumpout condenser water.
trolled by the PIC II, turn them on manually. i. Proceed to the PUMPDOWN LOCKOUT test from
f. Turn off the pumpout compressor. the CVC CONTROL TEST table to turn off the chill-
er water pumps and lock out the chiller compressor.
2. Evacuate the refrigerant gas from chiller cooler vessel. Turn off the chiller water pumps manually if they are
a. Close pumpout compressor valves 2 and 5, and open not controlled by the PIC II.
valves 3 and 4.
RETURN CHILLER TO NORMAL OPERATING
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 CONDITIONS
CONDITION C C C C C C C
1. Ensure vessel that was opened has been evacuated.
b. Turn on the pumpout condenser water. 2. Access the TERMINATE LOCKOUT function CVC from
c. Run the pumpout compressor until the chiller cooler the CONTROL TEST table to view vessel pressures and
vessel pressure reaches 18 in. Hg vac (40 kPa abs.). turn on chiller water pumps. If the chiller water pumps
Monitor pressures on the CVC and on refrigerant gages. are not controlled by the PIC II, turn them on manually.
d. Close valve 1a. 3. Open valves 1a, 1b, and 3.
e. Turn off the pumpout compressor. VALVE 1a 1b 2 3 4 5 8 11 12 13 14
f. Close valves 1b, 3, and 4. CONDITION C C C C C C C C
VALVE 1a 1b 2 3 4 5 8 11 12 13 14 4. Slowly open valve 5, gradually increasing pressure in

CONDITION C C C C C C C C C C C the evacuated vessel to 35 psig (141 kPa). Feed refrig-
erant slowly to prevent tube freeze up.
g. Turn off the pumpout condenser water.
5. Leak test to ensure vessel integrity.
h. Proceed to the PUMPDOWN/LOCKOUT function
accessed from the CONTROL TEST table to turn off 6. Open valve 5 fully.
the chiller water pumps and lock out the chiller com- VALVE 1a 1b 2 3 4 5 8 11 12 13 14
pressor. Turn off the chiller water pumps manually if CONDITION C C C C C C C
they are not controlled by the PIC II.
7. Open valve 11 to equalize the liquid refrigerant level
TRANSFER ALL REFRIGERANT TO CHILLER COOLER between the vessels.
VESSEL
8. Close valves 1a, 1b, 3, and 5.
1. Push the refrigerant into the chiller cooler vessel.
9. Open isolation valves 12, 13, and 14 (if present).
a. Valve positions:
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
VALVE 1a 1b 2 3 4 5 8 11 12 13 14
CONDITION C C C C C C C
CONDITION C C C C C C
10. Proceed to the TERMINATE LOCKOUT screen (ac-
b. Turn off the chiller water pumps (either through cessed from the CONTROL TEST table) to turn off the
the PIC II controls or manually, if necessary) and the water pumps and enable the chiller compressor for start-
pumpout condenser water. up. If the chiller water pumps are not controlled by the
c. Turn on the pumpout compressor to push the refrig- PIC II, turn them off manually.
erant out of the chiller condenser.
d. When all liquid refrigerant is out of the chiller con-
denser, close the cooler isolation valve 11.
e. Turn off the pumpout compressor.
64
GENERAL MAINTENANCE
Refrigerant Properties — The standard refrigerant for
the 19XR chiller is HFC-134a. At normal atmospheric pres- HFC-134a should not be mixed with air or oxygen and
sure, HFC-134a will boil at –14 F (–25 C) and must, there- pressurized for leak testing. In general, this refrigerant
fore, be kept in pressurized containers or storage tanks. The should not be present with high concentrations of air or
refrigerant is practically odorless when mixed with air oxygen above atmospheric pressures, because the mix-
and is noncombustible at atmospheric pressure. Read the ture can undergo combustion.
Material Safety Data Sheet and the latest ASHRAE Safety
Guide for Mechanical Refrigeration to learn more about safe REFRIGERANT TRACER — Use an environmentally
handling of this refrigerant. acceptable refrigerant as a tracer for leak test procedures.
TO PRESSURIZE WITH DRY NITROGEN — Another
method of leak testing is to pressurize with nitrogen only
HFC-134a will dissolve oil and some nonmetallic ma- and to use a soap bubble solution or an ultrasonic leak
terials, dry the skin, and, in heavy concentrations, may detector to determine if leaks are present.
displace enough oxygen to cause asphyxiation. When NOTE: Pressurizing with dry nitrogen for leak testing should
handling this refrigerant, protect the hands and eyes and only be done if all refrigerant has been evacuated from the
avoid breathing fumes. vessel.
1. Connect a copper tube from the pressure regulator on the
Adding Refrigerant — Follow the procedures de- cylinder to the refrigerant charging valve. Never apply
scribed in Trim Refrigerant Charge section, this page. full cylinder pressure to the pressurizing line. Follow the
listed sequence.
2. Open the charging valve fully.
Always use the compressor pumpdown function in the 3. Slowly open the cylinder regulating valve.
Control Test table to turn on the cooler pump and lock 4. Observe the pressure gage on the chiller and close the
out the compressor when transferring refrigerant. Liq- regulating valve when the pressure reaches test level. Do
uid refrigerant may flash into a gas and cause possible not exceed 140 psig (965 kPa).
freeze-up when the chiller pressure is below
30 psig (207 kPa) for HFC-134a. 5. Close the charging valve on the chiller. Remove the cop-
per tube if it is no longer required.
Removing Refrigerant — If the optional pumpout sys- Repair the Leak, Retest, and Apply Standing
tem is used, the 19XR refrigerant charge may be transferred Vacuum Test — After pressurizing the chiller, test for
to a pumpout storage tank or to the chiller condenser or cooler leaks with an electronic halide leak detector, soap bubble
vessels. Follow the procedures in the Pumpout and Refrig- solution, or an ultrasonic leak detector. Bring the chiller back
erant Transfer Procedures section when transferring refrig- to atmospheric pressure, repair any leaks found, and retest.
erant from one vessel to another. After retesting and finding no leaks, apply a standing vacuum
Adjusting the Refrigerant Charge — If the addi- test. Then dehydrate the chiller. Refer to the Standing Vacuum
tion or removal of refrigerant is required to improve chiller Test and Chiller Dehydration section (pages 48 and 51) in
performance, follow the procedures given under the Trim the Before Initial Start-Up section.
Refrigerant Charge section, this page. Checking Guide Vane Linkage — When the
Refrigerant Leak Testing — Because HFC-134a is chiller is off, the guide vanes are closed and the actuator
above atmospheric pressure at room temperature, leak test- mechanism is in the position shown in Fig. 33. If slack de-
ing can be performed with refrigerant in the chiller. Use an velops in the drive chain, do the following to eliminate
electronic halide leak detector, soap bubble solution, or ultra- backlash:
sonic leak detector. Ensure that the room is well ventilated 1. With the chiller shut down and the actuator fully closed,
and free from concentration of refrigerant to keep false read- remove the chain guard and loosen the actuator bracket
ings to a minimum. Before making any necessary repairs to holddown bolts.
a leak, transfer all refrigerant from the leaking vessel. 2. Loosen guide vane sprocket adjusting bolts.
Leak Rate — It is recommended byASHRAE that chill- 3. Pry bracket upwards to remove slack, then retighten the
ers be taken off line immediately and repaired if the refrig- bracket holddown bolts.
erant leak rate for the entire chiller is more than 10% of the 4. Retighten the guide vane sprocket adjusting bolts. En-
operating refrigerant charge per year. sure that the guide vane shaft is rotated fully in the clock-
In addition, Carrier recommends that leaks totalling less wise direction in order close it fully.
than the above rate but more than a rate of 0.1% of the total Trim Refrigerant Charge — If, to obtain optimal chiller
charge per year should be repaired during annual mainte- performance, it becomes necessary to adjust the refrigerant
nance or whenever the refrigerant is transferred for other serv- charge, operate the chiller at design load and then add or
ice work. remove refrigerant slowly until the difference between the
Test After Service, Repair, or Major Leak — If leaving chilled water temperature and the cooler refrigerant
all the refrigerant has been lost or if the chiller has been opened temperature reaches design conditions or becomes a mini-
for service, the chiller or the affected vessels must be pres- mum. Do not overcharge.
sure tested and leak tested. Refer to the Leak Test Chiller Refrigerant may be added either through the storage tank
section to perform a leak test. or directly into the chiller as described in the Charge
Refrigerant into Chiller section.
To remove any excess refrigerant, follow the procedure in
Transfer Refrigerant from Chiller to Pumpout Storage Tank
section, Steps 1a and b, page 63.
65
Service Ontime — The CVC will display a SERVICE
ONTIME value on the MAINSTAT screen. This value should
be reset to zero by the service person or the operator each
time major service work is completed so that the time be-
tween service can be viewed and tracked.
Inspect the Control Panel — Maintenance consists
of general cleaning and tightening of connections. Vacuum
the cabinet to eliminate dust build-up. If the chiller control
malfunctions, refer to the Troubleshooting Guide section for
control checks and adjustments.
Ensure power to the control center is off when cleaning

and tightening connections inside the control panel.
Check Safety and Operating Controls Monthly

— To ensure chiller protection, the automated Control Test
should be performed at least once per month. See Table 3
for safety control settings. See Table 6 for Control Test
functions.
Changing Oil Filter — Change the oil filter on a yearly
basis or when the chiller is opened for repairs. The 19XR
Fig. 33 — Guide Vane Actuator Linkage has an isolatable oil filter so that the filter may be changed
with the refrigerant remaining in the chiller. Use the follow-
ing procedure:
WEEKLY MAINTENANCE
1. Ensure the compressor is off and the disconnect for the
Check the Lubrication System — Mark the oil level compressor is open.
on the reservoir sight glass, and observe the level each week 2. Disconnect the power to the oil pump.
while the chiller is shut down.
3. Close the oil filter isolation valves located behind power
If the level goes below the lower sight glass, check the oil panel on top of oil pump assembly.
reclaim system for proper operation. If additional oil is re-
quired, add it through the oil drain charging valve (Fig. 2). 4. Connect an oil charging hose from the oil charging valve
A pump is required when adding oil against refrigerant pres- (Fig. 2) and place the other end in a clean container suit-
sure. The oil charge for the 19XR compressor depends on able for used oil. The oil drained from the filter hous-
the compressor Frame size: ing should be used as an oil sample and sent to a labo-
ratory for proper analysis. Do not contaminate this
• Frame 2 compressor — 5 gal (18.9 L) sample.
• Frame 3 compressor — 8 gal (30 L) 5. Slowly open the charging valve to drain the oil from the
• Frame 4 compressor — 10 gal (37.8 L) housing.
• Frame 5 compressor — 18 gal (67.8 L)
The added oil must meet Carrier specifications for the 19XR. The oil filter housing is at a high pressure. Relieve
Refer to Changing Oil Filter and Oil Changes section on this this pressure slowly.
page. Any additional oil that is added should be logged by
noting the amount and date. Any oil that is added due to oil
loss that is not related to service will eventually return to the 6. Once all oil has been drained, place some rags or
sump. It must be removed when the level is high. absorbent material under the oil filter housing to catch
any drips once the filter is opened. Remove the 4 bolts
An oil heater is controlled by the PIC II to maintain oil from the end of the filter housing and remove the filter
temperature (see the Controls section) when the compressor cover.
is off. The CVC COMPRESS screen displays whether the
heater is energized or not. The heater is energized if the OIL 7. Remove the filter retainer by unscrewing the retainer nut.
HEATER RELAY parameter reads ON. If the PIC II shows The filter may now be removed and disposed of
that the heater is energized and if the sump is still not heat- properly.
ing up, the power to the oil heater may be off or the oil level 8. Replace the old filter with a new filter. Install the filter
may be too low. Check the oil level, the oil heater contactor retainer and tighten down the retainer nut. Install the
voltage, and oil heater resistance. filter cover and tighten the 4 bolts.
The PIC II does not permit compressor start-up if the oil 9. Evacuate the filter housing by placing a vacuum pump
temperature is too low. The PIC II continues with start-up on the charging valve. Follow the normal evacuation
only after the temperature is within allowable limits. procedures. Shut the charging valve when done and
reconnect the valve so that new oil can be pumped into
SCHEDULED MAINTENANCE the filter housing. Fill with the same amount that was
removed; then close the charging valve.
Establish a regular maintenance schedule based on your
actual chiller requirements such as chiller load, run hours, 10. Remove the hose from the charging valve, open the iso-
and water quality. The time intervals listed in this section lation valves to the filter housing, and turn on the power
are offered as guides to service only. to the pump and the motor.
66
Oil Specification — If oil is added, it must meet the 3. Clean the chamber and valve assembly thoroughly. Be
following Carrier specifications: sure the valve moves freely. Ensure that all openings are
free of obstructions.
Oil Type for units using R-134a . . . . . . . . . . . . . . Inhibited
polyolester-based synthetic 4. Examine the cover gasket and replace if necessary.
compressor oil formatted for See Fig. 34 for a view of the float valve design. For linear
use with HFC, gear-driven, float valve designs, inspect the orientation of the float slide
hermetic compressors. pin. It must be pointed toward the bubbler tube for proper
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 operation.
The polyolester-based oil (P/N: PP23BZ103) may be

ordered from your local Carrier representative.
Oil Changes — Carrier recommends changing the oil
after the first year of operation and every five years there-
after as a minimum in addition to a yearly oil analysis. How-
ever, if a continuous oil monitoring system is functioning
and a yearly oil analysis is performed, the time between oil
changes can be extended.
TO CHANGE THE OIL
1. Transfer the refrigerant into the chiller condenser vessel
(for isolatable vessels) or to a pumpout storage tank.
2. Mark the existing oil level.
3. Open the control and oil heater circuit breaker.
4. When the chiller pressure is 5 psig (34 kPa) or less, drain
the oil reservoir by opening the oil charging valve
(Fig. 2). Slowly open the valve against refrigerant
pressure.
5. Change the oil filter at this time. See Changing Oil Filter
section.
6. Change the refrigerant filter at this time, see the next sec-
tion, Refrigerant Filter. LEGEND
7. Charge the chiller with oil. Charge until the oil level is 1 — Refrigerant Inlet from FLASC Chamber
equal to the oil level marked in Step 2. Turn on the power 2 — Linear Float Assembly
3 — Float Screen
to the oil heater and let the PIC II warm it up to at least 4 — Bubble Line
140 F (60 C). Operate the oil pump manually, using the 5 — Float Cover
Control Test function, for 2 minutes. For shutdown con- 6 — Bubble Line Connection
ditions, the oil level should be full in the lower sight glass. 7 — Refrigerant Outlet to Cooler
8 — Gasket
If the oil level is above 1⁄2 full in the upper sight glass,
remove the excess oil. The oil level should now be equal Fig. 34 — 19XR Float Valve Design
to the amount shown in Step 2.
Inspect Relief Valves and Piping — The relief valves
Refrigerant Filter — A refrigerant filter/drier, located on this chiller protect the system against the potentially dan-
on the refrigerant cooling line to the motor, should be changed gerous effects of overpressure. To ensure against damage to
once a year or more often if filter condition indicates a need the equipment and possible injury to personnel, these de-
for more frequent replacement. Change the filter by closing vices must be kept in peak operating condition.
the filter isolation valves (Fig. 4) and slowly opening the As a minimum, the following maintenance is required.
flare fittings with a wrench and back-up wrench to relieve
the pressure. A moisture indicator sight glass is located be- 1. At least once a year, disconnect the vent piping at the
yond this filter to indicate the volume and moisture in the valve outlet and carefully inspect the valve body and mecha-
refrigerant. If the moisture indicator indicates moisture, nism for any evidence of internal corrosion or rust, dirt,
locate the source of water immediately by performing a scale, leakage, etc.
thorough leak check. 2. If corrosion or foreign material is found, do not attempt
to repair or recondition. Replace the valve.
Oil Reclaim Filter — The oil reclaim system has a strainer
on the eductor suction line, a strainer on the discharge pres- 3. If the chiller is installed in a corrosive atmosphere or the
sure line, and a filter on the cooler scavenging line. Replace relief valves are vented into a corrosive atmosphere, in-
the filter once per year or more often if filter condition inspect the relief valves at more frequent intervals.
dicates a need for more frequent replacement. Change the Compressor Bearing and Gear Maintenance —
filter by closing the filter isolation valves and slowly open- The key to good bearing and gear maintenance is proper
ing the flare fitting with a wrench and back-up wrench to lubrication. Use the proper grade of oil, maintained at rec-
relieve the pressure. Change the strainers once every 5 years ommended level, temperature, and pressure. Inspect the
or whenever refrigerant is evacuated from the cooler. lubrication system regularly and thoroughly.
Inspect Refrigerant Float System — Perform this To inspect the bearings, a complete compressor teardown
inspection every 5 years or when the condenser is opened is required. Only a trained service technician should remove
for service. and examine the bearings. The cover plate on older com-
1. Transfer the refrigerant into the cooler vessel or into a pressor bases was used for factory-test purposes and is not
pumpout storage tank. usable for bearing or gear inspection. The bearings and gears
should be examined on a scheduled basis for signs of wear.
2. Remove the float access cover. The frequency of examination is determined by the hours of
67
chiller operation, load conditions during operation, and the Inspect the Starting Equipment — Before work-
condition of the oil and the lubrication system. Excessive ing on any starter, shut off the chiller and open all discon-
bearing wear can sometimes be detected through increased nects supplying power to the starter.
vibration or increased bearing temperature. If either symp-
tom appears, contact an experienced and responsible service
organization for assistance.
The disconnect on the starter front panel does not de-
Inspect the Heat Exchanger Tubes and Flow energize all internal circuits. Open all internal and
Devices remote disconnects before servicing the starter.
COOLER AND FLOW DEVICES — Inspect and clean the
cooler tubes at the end of the first operating season. Because
these tubes have internal ridges, a rotary-type tube cleaning Never open isolating knife switches while equipment is
system is needed to fully clean the tubes. Inspect the tubes’ operating. Electrical arcing can cause serious injury.
condition to determine the scheduled frequency for future
cleaning and to determine whether water treatment in the
chilled water/brine circuit is adequate. Inspect the entering Inspect starter contact surfaces for wear or pitting
and leaving chilled water temperature sensors and flow de- on mechanical-type starters. Do not sandpaper or file
vices for signs of corrosion or scale. Replace a sensor or silverplated contacts. Follow the starter manufacturer’s
Schrader fitting if corroded or remove any scale if found. instructions for contact replacement, lubrication, spare parts
ordering, and other maintenance requirements.
CONDENSER AND FLOW DEVICES — Since this water
circuit is usually an open-type system, the tubes may be sub- Periodically vacuum or blow off accumulated debris on
ject to contamination and scale. Clean the condenser tubes the internal parts with a high-velocity, low-pressure blower.
with a rotary tube cleaning system at least once per year and Power connections on newly installed starters may relax
more often if the water is contaminated. Inspect the entering and loosen after a month of operation. Turn power off and
and leaving condenser water sensors and flow devices for retighten. Recheck annually thereafter.
signs of corrosion or scale. Replace the sensor or Schrader
fitting if corroded or remove any scale if found.
Higher than normal condenser pressures, together with the Loose power connections can cause voltage spikes, over-
inability to reach full refrigeration load, usually indicate dirty heating, malfunctioning, or failures.
tubes or air in the chiller. If the refrigeration log indicates a
rise above normal condenser pressures, check the condenser
refrigerant temperature against the leaving condenser water Check Pressure Transducers — Once a year, the
temperature. If this reading is more than what the design dif- pressure transducers should be checked against a pressure
ference is supposed to be, the condenser tubes may be dirty gage reading. Check all eight transducers: the 2 oil differ-
or water flow may be incorrect. Because HFC-134a is a high- ential pressure transducers, the condenser pressure
pressure refrigerant, air usually does not enter the chiller. transducer, the cooler pressure transducer, and the waterside
pressure transducers (consisting of 4 flow devices: 2 cooler,
During the tube cleaning process, use brushes specially 2 condenser).
designed to avoid scraping and scratching the tube wall. Con-
tact your Carrier representative to obtain these brushes. Do Note the evaporator and condenser pressure readings on
not use wire brushes. the HEAT_EX screen on the CVC (EVAPORATOR PRES-
SURE and CONDENSER PRESSURE). Attach an accurate
set of refrigeration gages to the cooler and condenser Schrader
fittings. Compare the two readings. If there is a difference in
Hard scale may require chemical treatment for its pre- readings, the transducer can be calibrated as described in the
vention or removal. Consult a water treatment specialist Troubleshooting Guide section. Oil differential pressure (OIL
for proper treatment. PUMP DELTA P on the COMPRESS screen) should be zero
whenever the compressor is off.
Water Leaks — The refrigerant moisture indicator on Optional Pumpout System Maintenance — For
the refrigerant motor cooling line (Fig. 2) indicates whether pumpout unit compressor maintenance details, refer to the
there is water leakage during chiller operation. Water leaks 06D, 07D Installation, Start-Up, and Service Instructions.
should be repaired immediately.
OPTIONAL PUMPOUT COMPRESSOR OIL CHARGE —
Use oil conforming to Carrier specifications for reciprocat-
ing compressor usage. Oil requirements are as follows:
The chiller must be dehydrated after repair of water leaks. ISO Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
See Chiller Dehydration section, page 51.
Carrier Part Number . . . . . . . . . . . . . . . . . . . . PP23BZ103
Water Treatment — Untreated or improperly treated The total oil charge, 4.5 pints (2.6 L), consists of
water may result in corrosion, scaling, erosion, or algae. The 3.5 pints (2.0 L) for the compressor and one additional pint
services of a qualified water treatment specialist should be (0.6 L) for the oil separator.
obtained to develop and monitor a treatment program. Oil should be visible in one of the compressor sight glasses
during both operation and at shutdown. Always check the
oil level before operating the compressor. Before adding or
changing oil, relieve the refrigerant pressure as follows:
Water must be within design flow limits, clean, and treated
to ensure proper chiller performance and reduce the 1. Attach a pressure gage to the gage port of either com-
potential of tube damage due to corrosion, scaling, ero- pressor service valve (Fig. 33).
sion, and algae. Carrier assumes no responsibility for
chiller damage resulting from untreated or improperly
treated water.
68
2. Close the suction service valve and open the discharge • The CONTROL ALGORITHM STATUS screens (which
line to the storage tank or the chiller. include the CAPACITY, OVERRIDE, LL_MAINT,
3. Operate the compressor until the crankcase pressure drops ISM_HIST, LOADSHED, WSMDEFME, and OCCDEFCM
to 2 psig (13 kPa). screens) display information that helps to diagnose prob-
lems with chilled water temperature control, chilled water
4. Stop the compressor and isolate the system by closing temperature control overrides, hot gas bypass, surge al-
the discharge service valve. gorithm status, and time schedule operation.
5. Slowly remove the oil return line connection (Fig. 32). • The control test feature facilitates the proper operation and
Add oil as required. test of temperature sensors, pressure transducers, the guide
6. Replace the connection and reopen the compressor serv- vane actuator, oil pump, water pumps, tower control, and
ice valves. other on/off outputs while the compressor is stopped. It
OPTIONAL PUMPOUT SAFETY CONTROL SETTINGS also has the ability to lock off the compressor and turn on
(Fig. 35) — The optional pumpout system high-pressure switch water pumps for pumpout operation. The CVC shows the
opens at 161 psig (1110 kPa) and closes at 130 psig temperatures and pressures required during these
(896 kPa). Check the switch setting by operating the pump- operations.
out compressor and slowly throttling the pumpout con- • From other SERVICE tables, the operator/technician can
denser water. access configured items, such as chilled water resets, over-
ride set points, etc.
• If an operating fault is detected, an alarm message is gen-
erated and displayed on the CVC default screen. A more
detailed message — along with a diagnostic message —
is also stored into the ALARM HISTORY table.
Checking Display Messages — The first area to check
when troubleshooting the 19XR is the CVC display. If the
alarm light is flashing, check the primary and secondary mes-
sage lines on the CVC default screen (Fig. 12). These mes-
sages will indicate where the fault is occurring. These mes-
sages contain the alarm message with a specified code. This
code or state appears with each alarm and alert message. The
ALARM HISTORY table on the CVC SERVICE menu also
contains an alarm message to further expand on the alarm.
For a complete list of possible alarm messages, see Table 8.
If the alarm light starts to flash while accessing a menu screen,
press the EXIT softkey to return to the default screen to
read the alarm message. The STATUS screen can also be
accessed to determine where an alarm exists.
Checking Temperature Sensors — All tempera-
ture sensors are thermistor-type sensors. This means that the
resistance of the sensor varies with temperature. All sensors
Fig. 35 — Optional Pumpout System Controls have the same resistance characteristics. If the controls are
on, determine sensor temperature by measuring voltage drop;
if the controls are powered off, determine sensor tempera-
Ordering Replacement Chiller Parts — When ture by measuring resistance. Compare the readings to the
ordering Carrier specified parts, the following information values listed in Table 9A or 9B.
must accompany an order: RESISTANCE CHECK — Turn off the control power and,
• chiller model number and serial number from the module, disconnect the terminal plug of the sensor
• name, quantity, and part number of the part required in question. With a digital ohmmeter, measure sensor resis-
tance between receptacles as designated by the wiring dia-
• delivery address and method of shipment. gram. The resistance and corresponding temperature are listed
in Table 9A or 9B. Check the resistance of both wires to
ground. This resistance should be infinite.
TROUBLESHOOTING GUIDE VOLTAGE DROP — The voltage drop across any ener-
Overview — The PIC II has many features to help the gized sensor can be measured with a digital voltmeter while
operator and technician troubleshoot a 19XR chiller. the control is energized. Table 9A or 9B lists the relation-
ship between temperature and sensor voltage drop (volts dc
• The CVC shows the chiller’s actual operating conditions measured across the energized sensor). Exercise care when
and can be viewed while the unit is running. measuring voltage to prevent damage to the sensor leads,
• The CVC default screen freezes when an alarm occurs. connector plugs, and modules. Sensors should also be checked
The freeze enables the operator to view the chiller con- at the sensor plugs. Check the sensor wire at the sensor for
ditions at the time of alarm. The STATUS screens con- 5 vdc if the control is powered on.
tinue to show current information. Once all alarms have
been cleared (by correcting the problems and pressing the
RESET softkey), the CVC default screen returns to nor- Relieve all refrigerant pressure or drain the water be-
mal operation. fore replacing the temperature sensors.
69
CHECK SENSOR ACCURACY — Place the sensor in a CONDENSER PRESSURE parameter on the HEAT_EX
medium of known temperature and compare that temper- screen). To calibrate oil pressure or waterside flow de-
ature to the measured reading. The thermometer used to vice, view the particular reading (CHILLED WATER DELTA
determine the temperature of the medium should be of P and CONDENSER WATER DELTA P on the HEAT_EX
laboratory quality with 0.5° F (.25° C) graduations. The sen- screen, and OIL PUMP DELTA P on the COMPRESS
sor in question should be accurate to within 2° F (1.2° C). screen). It should read 0 psi (0 kPa). If the reading is not
See Fig. 7 for sensor locations. The sensors are immersed 0 psi
directly in the refrigerant or water circuits. The wiring at each (0 kPa), but within ± 5 psi (35 kPa), the value may be set
sensor is easily disconnected by unlatching the connector. to zero by pressing the SELECT softkey while the ap-
These connectors allow only one-way connection to the sen- propriate transducer parameter is highlighted on the CVC
sor. When installing a new sensor, apply a pipe sealant or
thread sealant to the sensor threads. screen. Then press the ENTER softkey. The value will
now go to zero. No high end calibration is necessary for
DUAL TEMPERATURE SENSORS — For servicing con- OIL PUMP DELTA P or flow devices.
venience, there are 2 sensors each on the bearing and motor
temperature sensors. If one of the sensors is damaged, the If the transducer value is not within the calibration range,
other can be used by simply moving a wire. The number 2 the transducer returns to the original reading. If the pres-
terminal in the sensor terminal box is the common line. To sure is within the allowed range (noted above), check the
use the second sensor, move the wire from the number 1 voltage ratio of the transducer. To obtain the voltage ra-
position to the number 3 position. tio, divide the voltage (dc) input from the transducer by
the supply voltage signal (displayed in CONTROL TEST
Checking Pressure Transducers — There are menu in the CCM PRESSURE TRANSDUCERS screen)
8 pressure transducers on 19XR chillers. They determine or measure across the positive (+ red) and negative
cooler, condenser, oil pressure, and cooler and condenser flow. (− black) leads of the transducer. For example, the con-
The cooler and condenser transducers are also used by the denser transducer voltage input is measured at CCM ter-
PIC II to determine the refrigerant temperatures. The oil sup- minals J2-4 and J2-5. The voltage ratio must be between
ply pressure transducer value and the oil transmission sump 0.80 and 0.11 for the software to allow calibration. Pres-
pressure transducer value difference is calculated by the CCM. surize the transducer until the ratio is within range. Then
The CCM module then displays the differential pressure. In attempt calibration again.
effect, the CCM reads only one input for oil pressure for a 4. A high pressure point can also be calibrated between 25
total of 5 pressure inputs: cooler pressure, condenser pres- and 250 psig (172.4 and 1723.7 kPa) by attaching a regu-
sure, oil differential pressure, cooler waterside differential lated 250 psig (1724 kPa) pressure (usually from
pressure, and condenser waterside differential pressure. See a nitrogen cylinder). The high pressure point can be cali-
the Check Pressure Transducers section (page 68) under Sched- brated by accessing the appropriate transducer parameter
uled Maintenance. on the HEAT_EX screen, highlighting the parameter, press-
These 5 pressure transducers can be calibrated if neces- ing the SELECT softkey, and then using the
sary. It is not usually necessary to calibrate at initial start-up.
However, at high altitude locations, it is necessary to cali- INCREASE or DECREASE softkeys to adjust the
brate the transducers to ensure the proper refrigerant value to the exact pressure on the refrigerant gage. Press
temperature/pressure relationship. Each transducer is sup- the ENTER softkey to finish the calibration. Pressures
plied with 5 vdc power from the CCM. If the power supply
fails, a transducer voltage reference alarm occurs. If the trans- at high altitude locations must be compensated for, so the
ducer reading is suspected of being faulty, check the supply chiller temperature/pressure relationship is correct.
voltage. It should be 5 vdc ± .5 v displayed in CONTROL The PIC II does not allow calibration if the transducer is
TEST under CCM Pressure Transducers. If the supply too far out of calibration. In this case, a new transducer must
voltage is correct, the transducer should be recalibrated or be installed and re-calibrated.
replaced. TRANSDUCER REPLACEMENT — Since the trans-
COOLER CONDENSER PRESSURE TRANSDUCER AND ducers are mounted on Schrader-type fittings, there is no
WATERSIDE FLOW DEVICE CALIBRATION — Cali- need to remove refrigerant from the vessel when replacing
bration can be checked by comparing the pressure readings the transducers. Disconnect the transducer wiring by pulling
from the transducer to an accurate refrigeration gage read- up on the locking tab while pulling up on the weather-tight
ing. These readings can be viewed or calibrated from the connecting plug from the end of the transducer. Do not pull
HEAT_EX screen on the CVC. The transducer can be checked on the transducer wires. Unscrew the transducer from the
and calibrated at 2 pressure points. These calibration points Schrader fitting. When installing a new transducer, do not
are 0 psig (0 kPa) and between 25 and 250 psig (173 and use pipe sealer (which can plug the sensor). Put the plug
1724 kPa). To calibrate these transducers: connector back on the sensor and snap into place. Check for
1. Shut down the compressor, cooler, and condenser pumps. refrigerant leaks.
NOTE: There should be no flow through the heat
exchangers.
2. Disconnect the transducer in question from its Schrader Be sure to use a back-up wrench on the Schrader fitting
fitting for cooler or condenser transducer calibration. For whenever removing a transducer, since the Schrader fit-
oil pressure or flow device calibration keep transducer in ting may back out with the transducer, causing a large
place. leak and possible injury to personnel.
NOTE: If the cooler or condenser vessels are at 0 psig
(0 kPa) or are open to atmospheric pressure, the trans- Control Algorithms Checkout Procedure — One
ducers can be calibrated for zero without removing the of the tables on the CVC SERVICE menu is CONTROL
transducer from the vessel. ALGORITHM STATUS. The maintenance screens may
3. Access the HEAT_EX screen and view the particular be viewed from the CONTROL ALGORITHM STATUS
transducer reading (the EVAPORATOR PRESSURE or table to see how a particular control algorithm is operating.
70
These maintenance screens are very useful in helping to Control Test — The Control Test feature can check all
determine how the control temperature is calculated and guide the thermistor temperature sensors, pressure transducers, pumps
vane positioned and for observing the reactions from load and their associated flow devices, the guide vane actuator,
changes, control point overrides, hot gas bypass, surge pre- and other control outputs such as hot gas bypass. The tests
vention, etc. The tables are: can help to determine whether a switch is defective or a pump
relay is not operating, as well as other useful troubleshoot-
CAPACITY Capacity This table shows all values ing issues. During pumpdown operations, the pumps are en-
Control used to calculate the chilled ergized to prevent freeze-up and the vessel pressures and
water/brine control point. temperatures are displayed. The Pumpdown/Lockout fea-
OVERRIDE Override Details of all chilled water con- ture prevents compressor start-up when there is no refrig-
Status trol override values.
erant in the chiller or if the vessels are isolated. The Termi-
HEAT_EX Surge/ The surge and hot gas bypass nate Lockout feature ends the Pumpdown/Lockout after the
HGBP control algorithm status is
Status viewed from this screen. All pumpdown procedure is reversed and refrigerant is added.
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
Status to help the operator quickly de-
termine whether the schedule LEGEND TO TABLES 8A - 8J
is in the 9occupied9 mode or
not. CCM — Chiller Control Module
CVC — Chiller Visual Control
WSMDEFME Water The water system manager is a CHW — Chilled Water
System CCN module that can turn on ISM — Integrated Starter Module
Manager the chiller and change the PIC II — Product Integrated Control II
Status chilled water control point. This VFD — Variable Frequency Drive
screen indicates the status of
this system.
Table 8 — 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 top stop.
71
Custom Alarm/Alert Messages with Troubleshooting Guides (cont)
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.
D. PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary.
STATE PRIMARY SECONDARY ALARM MESSAGE 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 Check motor cooling line for proper operation, or
limit of [LIMIT]*. restrictions.
Check for excessive starts within a short time span.
103 PRESTART HIGH DISCHARGE 103->Comp Discharge Allow discharge sensor to cool.
ALERT TEMP Temp [VALUE] exceeded Check for sensor wiring and accuracy.
limit of [LIMIT]*. Check for excessive starts.
104 PRESTART LOW REFRIGERANT 104->Evaporator Refrig Check transducer wiring and accuracy.
ALERT TEMP Temp [VALUE] exceeded Check for low chilled fluid supply temperatures.
limit of [LIMIT]*. Check refrigerant charge.
105 PRESTART LOW OIL 105->Oil Sump Temp Check oil heater contactor/relay and power.
ALERT TEMPERATURE [VALUE] exceeded limit of Check oil level and oil pump operation.
[LIMIT]*.
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 MODEChiller 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.
72
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 D 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 surge 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.
G. NORMAL RUN WITH OVERRIDES
STATE PRIMARY SECONDARY ALARM MESSAGE ADDITIONAL

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 Check setting in SETUP1.
[LIMIT]*.
121 RUN CAPACITY HIGH MOTOR 121->Comp Motor Winding Check motor cooling lines.
LIMITED TEMPERATURE Temp [VALUE] exceeded Check for closed valves.
limit of [LIMIT]*. Check setting in SETUP1.
122 RUN CAPACITY LOW EVAP 122->Evaporator Refrig Check refrigerant charge.
LIMITED REFRIG TEMP Temp [VALUE] exceeded Check for low entering cooler temperatures.
limit of [LIMIT]*.
123 RUN CAPACITY HIGH COMPRESSOR 123->Surge Prevention Check for high condenser water temperatures or low
LIMITED LIFT Override: Lift Too High For suction temperature.
Compressor.
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

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
73
I. CHILLER PROTECT LIMIT FAULTS

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
START ACCELERATION Fault — Average Line closed at start-up.
TIME Current [VALUE] Check starter for proper operation.
Reduce unit pressure if possible.
204 FAILURE TO 1M/2M CONTACT 208->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;
LIMIT FAULT Check Optional Starter
Contacts
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.
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
LIMIT RESET Power-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
LIMIT IMBALANCE Imbalance; Check ISM Fault
History to Identify Phase
216 PROTECTIVE LINE VOLTAGE 216->Line Voltage
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
74
I. CHILLER PROTECT LIMIT FAULTS (cont)

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 Flow; Perform pump control test.
LIMIT WATER 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 Temp Check sensor resistance or voltage drop.
LIMIT TEMP [VALUE] exceeded limit of Check for proper wiring.
[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 Temp Check for proper refrigerant charge.
LIMIT TEMP [VALUE] exceeded limit of Check float operation.
[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 limit Check motor cooling line for proper operation,
of [LIMIT]*. or 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 limit Check for low oil level, partially closed oil supply
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,
LIMIT PRESSURE [VALUE] exceeded limit of low water flow, fouled tubes.
[LIMIT]*. Check for division plate/gasket bypass.
Check for noncondensables.
236 PROTECTIVE CCN OVERRIDE 236->CCN Override Stop while CCN has signaled the chiller to stop. Reset and
LIMIT STOP 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 temp Check surge protection configuration.
and flow
239 PROTECTIVE TRANSDUCER 239->Transducer Voltage Ref
LIMIT VOLTAGE FAULT [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 Communication Check wiring to ISM.
COMMUNICATION MODULE With Starter.
242 LOSS OF WITH CCM 242->Loss of Communication Check wiring to CCM.
COMMUNICATION MODULE With CCM.
243 POTENTIAL EVAP PRESS/TEMP 243->Evaporator Refrig Temp Check for proper refrigerant charge.
FREEZE-UP TOO LOW [VALUE] exceeded limit of Check float operation.
[LIMIT]*. Check for proper fluid flow and temperature.
Check for proper inlet guide vane operation.
244 POTENTIAL COND PRESS/TEMP 244->Condenser Refrig Temp
FREEZE-UP TOO LOW [VALUE] exceeded limit of
[LIMIT]*.
245 PROTECTIVE VFD SPEED 245->Actual VFD Speed
LIMIT OUT OF RANGE [VALUE] exceeded limit of
[LIMIT]*.
75
I. CHILLER PROTECT LIMIT FAULTS (cont)

246 PROTECTIVE INVALID DIFFUSER 246->Diffuser Control Invalid Check diffuser/inlet 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 actuator
and inlet guide vane actuator.
Check diffuser coupling.
Check inlet guide vane operation.
Check inlet guide vane calibration.
Check diffuser/inlet guide vane schedule.
Check diffuser mechanical set-up for proper
orientation.
If not using variable diffuser, check that the option
has not been enabled.
248 PROTECTIVE 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]*.
alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.
J. CHILLER ALERTS

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 142->Low Oil Pressure Alert. Check for partially or closed shut-off valves.
ALERT FILTER 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
restart 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-On ISM has detected a hardware fault and has reset.
PENDING RESET Reset When Running Chiller automatically restarting.
148 AUTORESTART POWER LOSS 148->Control Power-Loss Check control power.
PENDING When Running
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 (XR5 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.
76
J. CHILLER ALERTS (cont)

151 CONDENSER PRESSURE PUMP RELAY 151->High Condenser Check sensor wiring and accuracy.
ALERT ENERGIZED Pressure [VALUE]: Pump Check condenser flow and fluid temperature.
Energized to Reduce Check for fouled tubes. This alarm is not
Pressure. 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 reading
FREEZE-UP TOO LOW prevention a pressure that could freeze the condenser
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.
77
Table 9A — Thermistor Temperature (F) vs Resistance/Voltage Drop
TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE
(F) DROP (V) (Ohms) (F) DROP (V) (Ohms) (F) DROP (V) (Ohms)
−25 4.821 98,010 60 3.409 7,665 145 1.211 1,141
−24 4.818 94,707 61 3.382 7,468 146 1.192 1,118
−23 4.814 91,522 62 3.353 7,277 147 1.173 1,095
−22 4.806 88,449 63 3.323 7,091 148 1.155 1,072
−21 4.800 85,486 64 3.295 6,911 149 1.136 1,050
−20 4.793 82,627 65 3.267 6,735 150 1.118 1,029
−19 4.786 79,871 66 3.238 6,564 151 1.100 1,007
−18 4.779 77,212 67 3.210 6,399 152 1.082 986
−17 4.772 74,648 68 3.181 6,238 153 1.064 965
−16 4.764 72,175 69 3.152 6,081 154 1.047 945
−15 4.757 69,790 70 3.123 5,929 155 1.029 925
−14 4.749 67,490 71 3.093 5,781 156 1.012 906
−13 4.740 65,272 72 3.064 5,637 157 0.995 887
−12 4.734 63,133 73 3.034 5,497 158 0.978 868
−11 4.724 61,070 74 3.005 5,361 159 0.962 850
−10 4.715 59,081 75 2.977 5,229 160 0.945 832
−9 4.705 57,162 76 2.947 5,101 161 0.929 815
−8 4.696 55,311 77 2.917 4,976 162 0.914 798
−7 4.688 53,526 78 2.884 4,855 163 0.898 782
−6 4.676 51,804 79 2.857 4,737 164 0.883 765
−5 4.666 50,143 80 2.827 4,622 165 0.868 750
−4 4.657 48,541 81 2.797 4,511 166 0.853 734
−3 4.648 46,996 82 2.766 4,403 167 0.838 719
−2 4.636 45,505 83 2.738 4,298 168 0.824 705
−1 4.624 44,066 84 2.708 4,196 169 0.810 690
0 4.613 42,679 85 2.679 4,096 170 0.797 677
1 4.602 41,339 86 2.650 4,000 171 0.783 663
2 4.592 40,047 87 2.622 3,906 172 0.770 650
3 4.579 38,800 88 2.593 3,814 173 0.758 638
4 4.567 37,596 89 2.563 3,726 174 0.745 626
5 4.554 36,435 90 2.533 3,640 175 0.734 614
6 4.540 35,313 91 2.505 3,556 176 0.722 602
7 4.527 34,231 92 2.476 3,474 177 0.710 591
8 4.514 33,185 93 2.447 3,395 178 0.700 581
9 4.501 32,176 94 2.417 3,318 179 0.689 570
10 4.487 31,202 95 2.388 3,243 180 0.678 561
11 4.472 30,260 96 2.360 3,170 181 0.668 551
12 4.457 29,351 97 2.332 3,099 182 0.659 542
13 4.442 28,473 98 2.305 3,031 183 0.649 533
14 4.427 27,624 99 2.277 2,964 184 0.640 524
15 4.413 26,804 100 2.251 2,898 185 0.632 516
16 4.397 26,011 101 2.217 2,835 186 0.623 508
17 4.381 25,245 102 2.189 2,773 187 0.615 501
18 4.366 24,505 103 2.162 2,713 188 0.607 494
19 4.348 23,789 104 2.136 2,655 189 0.600 487
20 4.330 23,096 105 2.107 2,597 190 0.592 480
21 4.313 22,427 106 2.080 2,542 191 0.585 473
22 4.295 21,779 107 2.053 2,488 192 0.579 467
23 4.278 21,153 108 2.028 2,436 193 0.572 461
24 4.258 20,547 109 2.001 2,385 194 0.566 456
25 4.241 19,960 110 1.973 2,335 195 0.560 450
26 4.223 19,393 111 1.946 2,286 196 0.554 445
27 4.202 18,843 112 1.919 2,239 197 0.548 439
28 4.184 18,311 113 1.897 2,192 198 0.542 434
29 4.165 17,796 114 1.870 2,147 199 0.537 429
30 4.145 17,297 115 1.846 2,103 200 0.531 424
31 4.125 16,814 116 1.822 2,060 201 0.526 419
32 4.103 16,346 117 1.792 2,018 202 0.520 415
33 4.082 15,892 118 1.771 1,977 203 0.515 410
34 4.059 15,453 119 1.748 1,937 204 0.510 405
35 4.037 15,027 120 1.724 1,898 205 0.505 401
36 4.017 14,614 121 1.702 1,860 206 0.499 396
37 3.994 14,214 122 1.676 1,822 207 0.494 391
38 3.968 13,826 123 1.653 1,786 208 0.488 386
39 3.948 13,449 124 1.630 1,750 209 0.483 382
40 3.927 13,084 125 1.607 1,715 210 0.477 377
41 3.902 12,730 126 1.585 1,680 211 0.471 372
42 3.878 12,387 127 1.562 1,647 212 0.465 367
43 3.854 12,053 128 1.538 1,614 213 0.459 361
44 3.828 11,730 129 1.517 1,582 214 0.453 356
45 3.805 11,416 130 1.496 1,550 215 0.446 350
46 3.781 11,112 131 1.474 1,519 216 0.439 344
47 3.757 10,816 132 1.453 1,489 217 0.432 338
48 3.729 10,529 133 1.431 1,459 218 0.425 332
49 3.705 10,250 134 1.408 1,430 219 0.417 325
50 3.679 9,979 135 1.389 1,401 220 0.409 318
51 3.653 9,717 136 1.369 1,373 221 0.401 311
52 3.627 9,461 137 1.348 1,345 222 0.393 304
53 3.600 9,213 138 1.327 1,318 223 0.384 297
54 3.575 8,973 139 1.308 1,291 224 0.375 289
55 3.547 8,739 140 1.291 1,265 225 0.366 282
56 3.520 8,511 141 1.289 1,240
57 3.493 8,291 142 1.269 1,214
58 3.464 8,076 143 1.250 1,190
59 3.437 7,868 144 1.230 1,165
78
Table 9B — Thermistor Temperature (C) vs Resistance/Voltage Drop
TEMPERATURE VOLTAGE RESISTANCE TEMPERATURE VOLTAGE RESISTANCE
(C) DROP (V) (Ohms) (C) DROP (V) (Ohms)
−40 4.896 168 230 45 1.898 2 184
−39 4.889 157 440 46 1.852 2 101
−38 4.882 147 410 47 1.807 2 021
−37 4.874 138 090 48 1.763 1 944
−36 4.866 129 410 49 1.719 1 871
−35 4.857 121 330 50 1.677 1 801
−34 4.848 113 810 51 1.635 1 734
−33 4.838 106 880 52 1.594 1 670
−32 4.828 100 260 53 1.553 1 609
−31 4.817 94 165 54 1.513 1 550
−30 4.806 88 480 55 1.474 1 493
−29 4.794 83 170 56 1.436 1 439
−28 4.782 78 125 57 1.399 1 387
−27 4.769 73 580 58 1.363 1 337
−26 4.755 69 250 59 1.327 1 290
−25 4.740 65 205 60 1.291 1 244
−24 4.725 61 420 61 1.258 1 200
−23 4.710 57 875 62 1.225 1 158
−22 4.693 54 555 63 1.192 1 118
−21 4.676 51 450 64 1.160 1 079
−20 4.657 48 536 65 1.129 1 041
−19 4.639 45 807 66 1.099 1 006
−18 4.619 43 247 67 1.069 971
−17 4.598 40 845 68 1.040 938
−16 4.577 38 592 69 1.012 906
−15 4.554 38 476 70 0.984 876
−14 4.531 34 489 71 0.949 836
−13 4.507 32 621 72 0.920 805
−12 4.482 30 866 73 0.892 775
−11 4.456 29 216 74 0.865 747
−10 4.428 27 633 75 0.838 719
−9 4.400 26 202 76 0.813 693
−8 4.371 24 827 77 0.789 669
−7 4.341 23 532 78 0.765 645
−6 4.310 22 313 79 0.743 623
−5 4.278 21 163 80 0.722 602
−4 4.245 20 079 81 0.702 583
−3 4.211 19 058 82 0.683 564
−2 4.176 18 094 83 0.665 547
−1 4.140 17 184 84 0.648 531
0 4.103 16 325 85 0.632 516
1 4.065 15 515 86 0.617 502
2 4.026 14 749 87 0.603 489
3 3.986 14 026 88 0.590 477
4 3.945 13 342 89 0.577 466
5 3.903 12 696 90 0.566 456
6 3.860 12 085 91 0.555 446
7 3.816 11 506 92 0.545 436
8 3.771 10 959 93 0.535 427
9 3.726 10 441 94 0.525 419
10 3.680 9 949 95 0.515 410
11 3.633 9 485 96 0.506 402
12 3.585 9 044 97 0.496 393
13 3.537 8 627 98 0.486 385
14 3.487 8 231 99 0.476 376
15 3.438 7 855 100 0.466 367
16 3.387 7 499 101 0.454 357
17 3.337 7 161 102 0.442 346
18 3.285 6 840 103 0.429 335
19 3.234 6 536 104 0.416 324
20 3.181 6 246 105 0.401 312
21 3.129 5 971 106 0.386 299
22 3.076 5 710 107 0.370 285
23 3.023 5 461
24 2.970 5 225
25 2.917 5 000
26 2.864 4 786
27 2.810 4 583
28 2.757 4 389
29 2.704 4 204
30 2.651 4 028
31 2.598 3 861
32 2.545 3 701
33 2.493 3 549
34 2.441 3 404
35 2.389 3 266
36 2.337 3 134
37 2.286 3 008
38 2.236 2 888
39 2.186 2 773
40 2.137 2 663
41 2.087 2 559
42 2.039 2 459
43 1.991 2 363
44 1.944 2 272
79
Control Modules Notes on Module Operation
1. The chiller operator monitors and modifies configura-
tions in the microprocessor by using the 4 softkeys and
Turn controller power off before servicing controls. This the CVC. Communications between the CVC and the CCM
ensures safety and prevents damage to the controller. is accomplished through the SIO (Sensor Input/Output)
bus, which is a phone cable. The communication be-
The CVC, CCM, and ISM modules perform continuous tween the CCM and ISM is accomplished through the sen-
diagnostic evaluations of the hardware to determine its con- sor bus, which is a 3-wire cable.
dition. Proper operation of all modules is indicated by LEDs 2. If a green LED is on continuously, check the communi-
(light-emitting diodes) located on the circuit board of the CVC, cation wiring. If a green LED is off, check the red LED
CCM, and ISM. operation. If the red LED is normal, check the module
There is one green LED located on the CCM and ISM address switches (Fig. 36-38).
boards respectively, and one red LED located on the CVC, All system operating intelligence resides in the CVC. Some
CCM, and ISM boards respectively. safety shutdown logic resides in the ISM in case com-
RED LED (Labeled as STAT) — If the red LED: munications are lost between the ISM and CVC. Outputs
• blinks continuously at a 2-second interval, the module is 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 replac- via 24-vac power sources.
ing the module The transformers are located within the power panel, with
• is off continuously, the power should be checked the exception of the ISM, which operates from a 115-vac
• blinks 3 times per second, a software error has been dis- power source and has its own 24-vac transformer located
covered and the module must be replaced in the module.
If there is no input power, check the fuses and circuit breaker. In the power panel, T1 supplies power to the compressor
If the fuse is good, check for a shorted secondary of the oil heater, oil pump, and optional hot gas bypass, and T2
transformer or, if power is present to the module, replace the supplies power to both the CVC and CCM.
module.
Power is connected to Plug J1 on each module.
GREED LED (Labeled as COM) — These LEDs indicate
the communication status between different parts of the con-
troller and the network modules and should blink continu-
ously.
J5 J1 J7 MODULE PART #
KEYPAD POWER/CCN SIO SOFTWARE PART #
STAT
CONTRAST BACK OF CVC J8

(CHILLER VISUAL SERVICE
CONTROLLER)
Fig. 36 — Rear of CVC (Chiller Visual Controller)
80
Chiller Control Module (CCM) (Fig. 37) 8. Access the MAINSTAT table and highlight the TOTAL
COMPRESSOR STARTS parameter. Press the
INPUTS — Each input channel has 2 or 3 terminals. Refer
to individual chiller wiring diagrams for the correct terminal SELECT softkey. Increase or decrease the value to
numbers for your application. match the starts value recorded in Step 3. Press the
OUTPUTS — Output is 24 vac. There are 2 terminals per ENTER softkey when you reach the correct value. Now,
output. Refer to the chiller wiring diagram for your specific move the highlight bar to the COMPRESSOR ONTIME
application for the correct terminal numbers. parameter. Press the SELECT softkey. Increase or de-
crease the run hours value to match the value recorded
Integrated Starter Module (Fig. 38)
in Step 2. Press the ENTER softkey when the correct
INPUTS — Inputs on strips J3-5 and J3 are analog and dis- value is reached.
crete (on/off) inputs. The specific application of the chiller
determines which terminals are used. Refer to the individual 9. Complete the CVC installation. Following the instruc-
chiller wiring diagram for the correct terminal numbers for tions in the Input Service Configurations section,
your application. page 53, input all the proper configurations such as the
time, date, etc. Check the pressure transducer calibra-
OUTPUTS — Outputs are 24 vac and wired to strip J9. There tions. PSIO installation is now complete.
are 2 terminals per output.
Solid-State Starters — Troubleshooting information
Replacing Defective Processor Modules — The pertaining to the Benshaw, Inc., solid-state starter may be
module replacement part number is printed on a small label found in the following paragraphs and in the Carrier RE-
on the rear of the CVC module. The chiller model and DISTART MICRO Instruction Manual supplied by the starter
serial numbers are printed on the chiller nameplate located vendor.
on an exterior corner post. The proper software is factory- Attempt to solve the problem by using the following pre-
installed by Carrier in the replacement module. When liminary checks before consulting the troubleshooting tables
ordering a replacement chiller visual control (CVC) module, found in the Benshaw manual.
specify the complete replacement part number, full chiller
model number, and chiller serial number. The installer must
configure the new module to the original chiller data. Fol-
low the procedures described in the Software Configuration 1. Motor terminals or starter output lugs or wire should
section on page 53. not be touched without disconnecting the incoming
power supply. The silicon control rectifiers (SCRs)
although technically turned off still have AC mains
potential on the output of the starter.
Electrical shock can cause personal injury. Disconnect
all electrical power before servicing. 2. Power is present on all yellow wiring throughout the
system even though the main circuit breaker in the
unit is off.
INSTALLATION
1. Verify the existing CVC module is defective by using With power off:
the procedure described in the Troubleshooting Guide • Inspect for physical damage and signs of arcing, overheat-
section, page 69, and the Control Modules section, ing, etc.
page 80. Do not select the ATTACH TO NETWORK • Verify the wiring to the starter is correct.
DEVICE table if the CVC indicates a communication • Verify all connections in the starter are tight.
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 is suspected of being defective, use the following pro-
procedures described in the Software Configuration cedure as part of a general troubleshooting guide.
section.
1. Verify power is applied.
If a CCN Building Supervisor or Service Tool is avail-
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 NOTE: All LEDs should be lit. If any red or green side
computer. of these LEDs is not lit, the line voltage is not present
Any communication wires from other chillers or CCN or one or more SCRs has failed.
modules should be disconnected to prevent the new CVC 3. Check incoming power. If voltage is not present check
module from uploading incorrect run hours into memory. the incoming line. If voltage is present, proceed to
3. To install this module, record values for the TOTAL COM- Steps 4 through 11.
PRESSOR STARTS and the COMPRESSOR ONTIME NOTE: If after completing Steps 4 - 11 all mea-
from the MAINSTAT screen on the CVC. surements are within specified limits, the SCRs are
4. Power off the controls. functioning normally. If after completing Steps 4 - 11
resistance measurements are outside the specified
5. Remove the old CVC. limits, the motor leads on the starter power lugs T1 through
6. Install the new CVC module. Turn the control power T6 should be removed and the steps repeated. This will
back on. identify if abnormal resistance measurements are being
7. The CVC now automatically attaches to the local net- influenced by the motor windings.
work device. 4. Remove power from the starter unit.
81
J11 J12
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. 37 — Chiller Control Module (CCM)
J9 J8 J7 COM STAT
INTEGRATED STARTER MODULE
J1 FUSE J2 J3-1 J3-2 J3-3 J4 J5 J6
Fig. 38 — Integrated Starter Module (ISM)
82
5. Using an ohmmeter, perform the following resistance
measurements and record the results:
SCR PAIRS
Care must be taken to prevent nut rotation while tight-
MEASURE BEING RECORDED ening the bolts. If the nut rotates while tighting the
BETWEEN CHECKED VALUE bolt, SCR replacement must be started over.
T1 and T6 3 and 6
T2 and T4 2 and 5 6. Reconnect the red (cathode) wire from the SCR and the
T3 and T5 1 and 4 white (anode-gate) wire to the appropriate location on
the firing card (i.e., SCR1 wires to firing card terminal
If all measured values are greater than 5K ohms, pro- G1-white wire, and K1-red wire).
ceed to Step 10. If any values are less than 5K ohms, 7. Reconnect all other wiring and bus work.
one or more of the SCRs in that pair is shorted. 8. Return starter to normal operation.
6. Remove both SCRs in the pair (See SCR Removal/
Installation).
7. Using an ohmmeter, measure the resistance (anode to
cathode) of each SCR to determine which device has
failed.
NOTE: Both SCRs may be defective, but typically, only NUT
LOOSEN
one is shorted. If both SCRs provide acceptable resis- AND
CLAMPING
tance measurements, proceed to Step 10. BOLT TIGHTEN
A BOLTS
8. Replace the defective SCR(s). ALUMINUM FROM
HEATSINK THIS END
9. Retest the ‘‘pair’’ for resistance values indicated above.
10. On the right side of the firing card, measure the resis- ROLL PIN
tance between the red and white gate/cathode leads for
each SCR (1 through 6). A measurement between 5 and SCR
50 ohms is normal. Abnormally high values may indi-
cate a failed gate for that SCR.
If any red or white SCR gate leads are removed SCR PART CLAMP A NO OF BOLT
NUMBER SIZE DIMENSION TURNS LENGTH
from the firing card or an SCR, care must be taken BISCR (in.) (in.)
to ensure the leads are replaced EXACTLY as they 2.75 3.0
were (white wires to gates, and red wires to cath- 6601218 1030 ( 70 mm) 1 ⁄2
1
( 76 mm)
odes on both the firing card and SCR), or damage 2.75 3.0
to the starter and/or motor may result. 6601818 1030 11⁄2
( 70 mm) ( 76 mm)
2.75 3.5
8801230 1035 ( 70 mm) 13⁄4
( 89 mm)
11. Replace the SCRs and retest the pair. 2.75 3.0
8801830 1035 ( 70 mm) 13⁄4
( 89 mm)
SCR REMOVAL/INSTALLATION — Refer to Fig. 39. 4.00 4.0
15001850 2040 23⁄4
1. Remove the SCR by loosening the clamping bolts on each (102 mm) (102 mm)
side of the SCR, 4.00 5.0
15001850 2050 (102 mm) 23⁄4
(127 mm)
2. After the SCR has been removed and the bus work is loose, 220012100 Consult Benshaw Representative
apply a thin coat of either silicon based thermal joint com- 330018500 Consult Benshaw Representative
pound or a joint compound for aluminum or copper wire
connections to the contact surfaces of the replacement SCR. Fig. 39 — SCR Installation
This allows for improved heat dissipation and electrical
conductivity.
3. Place the SCR between the roll pins on the heatsink as-
semblies so the roll pins fit into the small holes in each
side of the SCR.
NOTE: Ensure the SCR is installed so the cathode side is
the side from which the red wire extends. The heatsink is
labeled to show the correct orientation.
4. Hand tighten the bolts until the SCR contacts the
heatsink.
5. Using quarter-turn increments, alternating between clamp-
ing bolts, apply the appropriate number of whole turns
referencing the table in Fig. 39.
83
Physical Data — Tables 10A-17 and Fig. 40-47 pro- and wiring schematics for the operator’s convenience during
vide additional information on component weights, com- troubleshooting.
pressor fits and clearances, physical and electrical data,
Table 10A — Heat Exchanger Data (English)
ENGLISH
NUMBER OF
TUBES Dry (Rigging) Weight Chiller Charge
(lb)
CODE
Refrigerant Water Volume
Cooler Condenser Cooler Condenser Weight (gal)
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
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
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 tubing,
1. Cooler data: based on a cooler with standard wall tubing, 2-pass, 2-pass, 150 psig, nozzle-in-head waterbox with victaulic grooves.
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight Weight includes the float valve, discharge elbow, and distribution
includes suction elbow, control panel, and distribution piping. Weight piping. Weight does not include unit-mounted starter, isolation valves,
does not include compressor. and pumpout unit.
84
Table 10B — Heat Exchanger Data (SI)
SI
NUMBER OF
TUBES Dry (Rigging) Weight Chiller Charge
(kg)
CODE
Refrigerant Water Volume
Cooler Condenser Cooler Condenser Weight (L)
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
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
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 tubing,
1. Cooler data: based on a cooler with standard wall tubing, 2-pass, 2-pass, 1034 kPa, nozzle-in-head waterbox with victaulic grooves.
150 psig, nozzle-in-head waterbox with victaulic grooves. Weight Weight includes the float valve, discharge elbow, and distribution
includes suction elbow, control panel, and distribution piping. Weight piping. Weight does not include unit-mounted starter, isolation valves,
does not include compressor. and pumpout unit.
85
Table 11 — 19XR Additional Data for Marine Waterboxes*
ENGLISH SI
HEAT EXCHANGER
FRAME, PASS Psig Rigging Weight Water Volume kPa Rigging Weight Water Volume
(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 12 — 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.
86
Table 13 — 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.
87
Table 14A — 19XR Waterbox Cover Weights — English (lb)
FRAME 1 FRAME 2 FRAME 3
HEAT WATERBOX
EXCHANGER DESCRIPTION Standard Flanged Standard Flanged Standard 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 Flanged Standard Flanged
Nozzles 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
Nozzles Nozzles
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 10A and 10B.
88
Table 14B — 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 kPa 269 303 347 381 399 434
NIH/MWB End Cover, 2068 kPa 258 258 323 323 378 378

HEAT WATERBOX
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
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 10A and 10B.
89
Table 15 — Optional Pumpout System Table 17 — Motor Voltage Code
Electrical Data
MOTOR VOLTAGE CODE
MOTOR CONDENSER MAX Code Volts Frequency
CODE UNIT VOLTS-PH-Hz RLA LRA
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
50 230 50
Table 16 — Additional Miscellaneous Weights 51 346 50
52 400 50
ITEM Lb Kg
53 3000 50
CONTROL CABINET 30 14
54 3300 50
UNIT-MOUNTED STARTER 500 227
55 6300 50
OPTIONAL ISOLATION VALVES 115 52
90
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. 40 — Compressor Fits and Clearances
91
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. 40 — Compressor Fits and Clearances (cont)
92
93
LEGEND (cont)
FR — Frame
GV — Guide Vane
HT EXCHD — Heat Exchanger
L — Main Supply Power
LVG — Leaving
N.O. — Normally Open
PRESS — Pressure
LEGEND REQM’T — Requirement
TB — Terminal Board
AUX — Auxiliary
BRG — Bearing Denotes Oil Pump Terminal
C — Contactor
CB — Circuit Breaker Denotes Power Panel Terminal
CCM — Chiller Control Module
CCN — Carrier Comfort Network ** Denotes Motor Starter Panel Conn
COMP’R — Compressor
COND — Condenser Denotes Component Terminal
CVC — Chiller Visual Controller
DISCH — Discharge Wire Splice
ENT — Entering
EVAP — Evaporator Denotes Conductor Male/Female Connector
EXT — External Option Wiring
Fig. 41 — Electronic PIC II Control Panel Wiring Schematic (Frame 2, 3, 4 Compressor)

94
LEGEND (cont)
FR — Frame
GV — Guide Vane
HT EXCHD — Heat Exchanger
L — Main Supply Power
LVG — Leaving
PRESS — Pressure
REQM’T — Requirement
LEGEND TB — Terminal Board
AUX — Auxiliary Denotes Oil Pump Terminal
BRG — Bearing
C — Contactor
CB — Circuit Breaker Denotes Power Panel Terminal
CCM — Chiller Control Module
CCN — Carrier Comfort Network ** Denotes Motor Starter Panel Conn
COMP’R — Compressor Denotes Component Terminal
COND — Condenser
CVC — Chiller Visual Controller Wire Splice
DISCH — Discharge
ENT — Entering Denotes Conductor Male/Female Connector
EVAP — Evaporator
EXT — External Option Wiring
Fig. 42 — Electronic PIC II Control Panel Wiring Schematic (Frame 5 Compressor)

95
LEGEND
AUX — Auxiliary T — Transformer

C — Contactor TB — Terminal Board
CB — Circuit Breaker
CCM — Chiller Control Module Denotes Oil Pump Terminal
COMM — Communication
COMPR — Compressor Denotes Power Panel Terminal
DISCH — Discharge
FR — Frame * Denotes Mach. Control Panel Conn.
G — Ground
GRD — Ground ** Denotes Motor Starter Panel Conn.
GVA — Guide Vane Actuator Denotes Component Terminal
HT EXCHD — Heat Exchanger Wire Splice
L — Main Power Supply Denotes Conductor Male/Female Connector
PRESS — Pressure Option Wiring
REQMT — Requirement
Fig. 43 — Power Panel Wiring Schematic

NOTE: Power factor correction capacitors (when required)
are connected ahead of all current transformers for proper
calibration and sensing by the ISM and IQDP4130.
LEGEND
AUX — Auxiliary HPR — Horsepower
C — Contactor ISM — Integrated Starter Module
CB — Circuit Breaker L — Main Supply Power
CR — Control Relay LL — Control Power Supply
CT — Current Transformer M — Contactor
DS — Disconnect Switch RES — Resistor
FU — Fuse S — Contactor
G — Ground TB — Terminal Block
CAUTION: Yellow wires remain energized when unit main disconnect is off.
Optional features are indicated by bold dashed lines.
Dry Contact
Field Connection
For connection diagram refer to 261143 D4.
Fig. 44 — Cutler-Hammer Wye Delta Unit Mounted Starter Wiring Schematic (Low Voltage)
96
97
NOTES: LEGEND
LED status with power applied and prior to run command. AUX — Auxiliary G — Ground Wire Node Symbol
‘‘ON’’ BR — Bridge Rectifier L — Main Supply Power PC Board Terminals
1 may have terminal block
CB — Circuit Breaker LL — Control Power Supply
‘‘OFF’’ COMM — Communication M — Contactor Benshaw supplied Twisted Pair
COND — Condenser O/L — Overload Reset terminal block
Transformer T1 primary fuses FU1/FU2 value dependent on system voltage and model, per Chart 1. CPU — Central Processing Unit S — Contactor Twisted Shielded Pair
2 Transformer connections per transformer nameplate connection diagram. CVC — Chiler Visual Controller SCR — Silicone Controller Rectifier Terminal Strip
CT — Current Transformer ST — Shunt Trip
MOVs are used on power stack assemblies for system voltages of 200 thru 460 vac (as shown). Resistor/ EVAP — Evaporator TB — Terminal Block Shield Wire
3 capacitor networks (DVDTs) are used on power stack assemblies in place of MOVs for a system voltage FU — Fuse Power Connection Field Wiring
of 575 vac (not shown).
K3 relay shown in deenergized state. K3 contact will close when power is applied. K3 contact will open
4 on stop command or system fault.
Fig. 45 — Benshaw, Inc. Solid-State Unit Mounted Starter Wiring Schematic (Low Voltage)
LEGEND
98
AUX — Auxiliary
C — Contactor
COND — Condenser
CPT — Control Power Transformer
CR — Control Relay
CT — Current Transformer
DS — Disconnect Switch
EVAP — Evaporator
FU — Fuse
G — Ground
GFCT — Ground Fault Current Transformer
HPR — Horsepower
ISM — Intergrated Starter Module
L — Main Power Supply
LL — Control Power Supply
LVG — Leaving
M — Contactor
MTR — Motor
PRESS — Pressure
PT — Power Transformer
ST — Shunt Trip
STAT — Status
TB — Terminal Block
TRANS — Transition
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. 46 — Typical Across-the-Line Starter Wiring Schematic (Medium Voltage)

LEGEND
99
AUX — Auxiliary
C — Contactor
COND — Condenser
CPT — Control Power Transformer
CR — Control Relay
CT — Current Transformer
DS — Disconnect Switch
EVAP — Evaporator
FU — Fuse
G — Ground
GFCT — Ground Fault Current Transformer
HPR — Horsepower
ISM — Intergrated Starter Module
L — Main Power Supply
LL — Control Power Supply
LVG — Leaving
M — Contactor
MTR — Motor
PRESS — Pressure
PT — Power Transformer
ST — Shunt Trip
STAT — Status
TB — Terminal Block
TRANS — Transition
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. 47 — Typical Primary Reactor Starter Wiring Schematic (Medium Voltage)

INDEX
Abbreviations and Explanations, 4 Notes on Module Operation, 80
Adding Refrigerant, 65 Oil Changes, 67
Adjusting the Refrigerant Charge, 65 Oil Charge, 53
After Extended Shutdown, 60 Oil Cooler, 36
After Limited Shutdown, 60 Oil Pressure and Compressor Stop (Check), 59
Attach to Network Device Control, 42 Oil Reclaim Filter, 67
Automatic Soft Stop Amps Threshold, 45 Oil Reclaim System, 8
Auto. Restart After Power Failure, 37 Oil Specification, 67
Before Initial Start-Up, 46 Oil Sump Temperature Control, 35
Capacity Override, 35 Open Oil Circuit Valves, 46
Carrier Comfort Network Interface, 52 Operating Instructions, 59
Changing Oil Filter, 66 Operating the Optional Pumpout Unit, 62
Charge Refrigerant Into Chiller, 56 Operator Duties, 59
Chilled Water Recycle Mode, 44 Optional Pumpout Compressor Water Piping (Check), 51
Chiller Control Module (CCM), 81 Optional Pumpout System Controls and
Chiller Dehydration, 51 Compressor (Check), 56
Chiller Familiarization, 5 Optional Pumpout System Maintenance, 68
Chiller Information Plate, 5 Ordering Replacement Chiller Parts, 69
Chiller Operating Condition (Check), 59 Overview (Troubleshooting Guide), 69
Chiller Tightness (Check), 46 Perform a Controls Test, 56
Chillers with Isolation Valves, 64 Physical Data, 84
Chillers with Storage Tanks, 63 PIC II System Components, 10
Cold Weather Operation, 60 PIC II System Functions, 32
Compressor Bearing and Gear Maintenance, 67 Power Up the Controls and Check the Oil Heater, 53
Condenser, 5 Preparation (Initial Start-Up), 58
Condenser Freeze Prevention, 37 Preparation (Pumpout and Refrigerant Transfer
Condenser Pump Control, 36 Procedures), 62
Control Algorithms Checkout Procedure, 70 Prepare the Chiller for Start-Up, 59
Control Panel, 5 Pressure Transducers (Check), 68, 70
Control Modules, 80 Prevent Accidential Start-Up, 59
Control Test, 71 Pumpout and Refrigerant Transfer Procedures, 62
Controls, 10 Ramp Loading, 35
CVC Operation and Menus, 14 Refrigerant Filter, 67
Cooler, 5 Refrigerant Float System (Inpsect), 67
Default Screen Freeze, 35 Refrigerant Leak Detector, 36
Definitions (Controls), 10 Refrigerant Leak Testing, 65
Demand Limit Control Option, 38 Refrigerant Properties, 65
Design Set Points, (Input), 53 Refrigerant (Removing), 65
Details (Lubrication Cycle), 8 Refrigerant Tracer, 46
Display Messages (Check), 69 Refrigeration Cycle, 7
Dry Run to Test Start-Up Sequence, 58 Refrigeration Log, 60
Equipment Required, 46 Relief Valves (Check), 51
Extended Shutdown (Preparation for), 60 Relief Valves and Piping (Inspect), 67
Factory-Mounted Starter, 7 Remote Start/Stop Controls, 36
General (Controls), 10 Repair the Leak, Retest, and
General Maintenance, 65 Apply Standing Vacuum Test, 65
Guide Vane Linkage (Check), 65 Replacing Defective Processor Modules, 81
Heat Exchanger Tubes and Flow Devices (Inspect), 68 Running System (Check), 59
High Altitude Locations, 56 Safety and Operating Controls (Check Monthly), 66
High Discharge Temperature Control, 35 Safety Considerations, 1
Ice Build Control, 41 Safety Controls, 33
Initial Start-Up, 58 Safety Shutdown, 45
Initial Start-Up Checklist for 19XR Hermetic Scheduled Maintenance, 66
Centrifugal Liquid Chiller, CL-1 Service Configurations (Input), 53
Inspect the Control Panel, 66 Service Ontime, 66
Instruct the Customer Operator, 59 Service Operation, 43
Integrated Starter Module (ISM), 81 Shipping Packaging (Remove), 46
Introduction, 4 Shunt Trip (Option), 35
Job Data Required, 46 Shutdown Sequence, 45
Lead/Lag Control, 39 Software Configuration, 53
Leak Rate, 65 Solid-State Starters, 81
Leak Test Chiller, 48 Spare Safety Alarm Contacts, 36
Local Occupied Schedule (Input), 53 Spare Safety Inputs, 36
Local Start-Up, 44 Standing Vacuum Test, 48
Lubrication Cycle, 8 Starter (Check), 52
Lubrication System (Check), 66 Starting Equipment, 8
Manual Guide Vane Operation, 60 Starting Equipment (Inspect), 68
Motor and Oil Refrigeration Cooling Cycle, 7 Start-Up/Shutdown/Recycle Sequence, 44
Motor-Compressor, 5 Start the Chiller, 59
Motor Rotation (Check), 58 Stop the Chiller, 60
100
INDEX (cont)
Storage Vessel, 7 Unit Mounted Solid-State Starter, 9
Summary (Lubrication Cycle), 8 Unit Mounted Wye-Delta Starter, 10
Surge Prevention Algorithm, 38 Using the Optional Storage Tank and Pumpout
Surge Protection, 39 System, 46
System Components, 5 Water/Brine Reset, 37
Temperature Sensors (Check), 69 Water Leaks, 68
Test After Service, Repair, or Major Leak, 65 Water Piping (Inspect), 51
Tighten All Gasketed Joints and Guide Vane Packing, 46 Water Treatment, 68
Tower Fan Relay Low and High, 37 Weekly Maintenance, 66
Trim Refrigerant Charge, 65 Wiring (Inspect), 51
Troubleshooting Guide, 69
101
Copyright 1998 Carrier Corporation
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg 104 6-98 Replaces: New
Tab 5a
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
INITIAL START-UP CHECKLIST FOR
19XR HERMETIC CENTRIFUGAL LIQUID CHILLER
(Remove and use for job file.)
MACHINE INFORMATION:
NAME JOB NO.
ADDRESS MODEL
CITY STATE ZIP S/N
DESIGN CONDITIONS:
TONS BRINE FLOW TEMPERATURE TEMPERATURE PRESSURE PASS SUCTION CONDENSER

RATE IN OUT DROP TEMPERATURE TEMPERATURE
CUT ALONG DOTTED LINE
COOLER ******
CONDENSER ******
COMPRESSOR: Volts RLA OLTA

STARTER: Mfg Type S/N
OIL PUMP: Volts RLA OLTA
CONTROL/OIL HEATER: Volts M 115 M 230

REFRIGERANT: Type: Charge
CARRIER OBLIGATIONS: Assemble . . . . . . . . . . . . . . . Yes M No M

Leak Test . . . . . . . . . . . . . . . Yes M No M
Dehydrate . . . . . . . . . . . . . . . Yes M No M
Charging . . . . . . . . . . . . . . . . Yes M No M
Operating Instructions Hrs.
START-UP TO BE PERFORMED IN ACCORDANCE WITH APPROPRIATE MACHINE START-UP

INSTRUCTIONS
JOB DATA REQUIRED:
1. Machine Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Yes M No M
2. Machine Assembly, Wiring and Piping Diagrams . . . . . . . . . . . . Yes M No M
3. Starting Equipment Details and Wiring Diagrams . . . . . . . . . . . . Yes M No M
4. Applicable Design Data (see above) . . . . . . . . . . . . . . . . . . . . . . Yes M No M
5. Diagrams and Instructions for Special Controls . . . . . . . . . . . . . Yes M No M
INITIAL MACHINE PRESSURE:
YES NO
Was Machine Tight?
If Not, Were Leaks Corrected?
Was Machine Dehydrated After Repairs?
CHECK OIL LEVEL AND RECORD:

ADD OIL: Yes M No M
Amount:
RECORD PRESSURE DROPS: Cooler Condenser
CHARGE REFRIGERANT: Initial Charge Final Charge After Trim
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg CL-1 6-98 Replaces: New
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 M Solid-State M Manufacturer

Serial Number
Motor Load Current Transformer Ratio :

Solid-State Overloads Yes M No M
CONTROLS: SAFETY, OPERATING, ETC.

Perform Controls Test (Yes/No)
PIC II CAUTION Yes

COMPRESSOR MOTOR AND CONTROL PANEL MUST BE PROPERLY AND INDIVIDUALLY CON-
NECTED 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 M No M
Chilled Water Flow Yes M No M
Pump Interlocks Yes M No M
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* M No M
*If yes, determine cause.
START MACHINE AND OPERATE. COMPLETE THE FOLLOWING:

A: Trim Charge and Record Under Charge Refrigerant Section on page 56.
B: Complete Any Remaining Control Calibration and Record Under Controls Section (pages 10-43).
C: Take At Least 2 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
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19XR PIC II SETPOINT TABLE CONFIGURATION SHEET
DESCRIPTION RANGE UNITS DEFAULT VALUE

Base Demand Limit 40 to 100 % 100
LCW Setpoint 10 to 120 DEG F 50.0
ECW Setpoint 15 to 120 DEG F 60.0
Ice Build Setpoint 15 to 60 DEG F 40.0
Tower Fan High Setpoint 55 to 105 DEG F 75
CVC Software Version Number:
CVC Controller Identification: BUS: ADDRESS:

CL-3
19XR 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 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 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 PIC II ISM_CONF TABLE CONFIGURATION SHEET

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 33 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 % 5
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 10 to 1000 100
Current % Imbalance 5 to 40 % 15
Current Imbalance Time 1 to 10 SEC 5
3 Grnd Fault CT’s? (1=No) 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 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 15 ^F 1.5
Surge/HGBP Delta P1 30 to 170 PSI 50
Full Load Point (T2/P2)
Surge/HGBP Delta T2 0.5 to 15 ^F 10
Surge/HGBP Delta P2 50 to 170 PSI 85
Surge/HGBP Deadband 0.5 to 3 ^F 1
Surge Protection
Surge Delta % Amps 5 to 15 % 10
Surge Time Period 7 to 10 MIN 8
Ice Build Control

Ice Build Option 0/1 DSABLE/ENABLE DSABLE
Ice Build Termination 0 to 2 0
0=Temp, 1=Contacts,2=Both
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
CL-6
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19XR 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 ^F 1.0

Evap Refrig Trippoint 0.0 to 40.0 DEG F 33
Refrig Override Delta T 2.0 to 5.0 ^F 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
Recycle Restart Delta T 2.0 to 10.0 DEG F 5
Recycle Shutdown Delta 0.t 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 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 Pt 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 110 % 100
CL-8
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19XR PIC II LEADLAG TABLE CONFIGURATION SHEET
DESDRIPTION RANGE UNITS DEFAULT VALUE

Lead Lag Control
LEAD/LAG Configuration 0 to 3 0
DSABLE=0, LEAD=1,
LAG=2, STANDBY=3
Load Balance Option 0/1 DSABLE/ENABLE DSABLE
Common Sensor Option 0/1 DSABLE/ENABLE DSABLE
LAG Percent 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 Percent Capacity 25 to 75 % 50
STANDBY Address 1 to 236 93
CL-9
19XR 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 PIC II TEMP_CTL TABLE CONFIGURAITON SHEET

Control Point
ECW Control Option 0/1 DSABLE/ENABLE DSABLE
Temp Pulldown Deg/Min 2 to 10 ^F 3
Temperature Reset
RESET TYPE 1
Degrees Reset At 20 mA −30 to 30 ^F 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 ^F 10
RESET TYPE 3
CHW Delta T (No Reset) 0 to 15 ^F 10
CHW Delta T (Full Reset) 0 to 15 ^F 0
Degrees Reset −30 to 30 ^F 5
Select/Enable Reset Type 0 to 3 0
CL-10
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BROADCAST (BRODEF) CONFIGURATION SHEET

Time Broadcast Enable DISABLE/ENABLE DSABLE
Daylight Savings
Start Month 1 to 12 4
Start Day of Week 1 to 7 7
Start Week 1 to 5 3
Start Time 00:00 to 24:00 HH:MM 02:00
Start Advance 0 to 360 MIN 60

Stop Month 1 to 12 10
Stop Day of Week 1 to 7 7
Stop Week 1 to 5 3
Stop Time 00:00 to 24:00 02:00
Stop Back 0 to 360 MIN 60
CL-11
Copyright 1998 Carrier Corporation
Book 2 PC 211 Catalog No. 531-974 Printed in U.S.A. Form 19XR-3SS Pg CL-12 6-98 Replaces: New
Tab 5a

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19XR

Hermetic Centrifugal Liquid Chillers

Start-Up, Operation, and Maintenance Instructions

INTRODUCTION ABBREVIATIONS AND EXPLANATIONS

MODEL NUMBER NOMENCLATURE

Fig. 1 — 19XR Identification

Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles

Fig. 4 — Lubrication System

Fig. 6 — Typical Starter External View

CONDENSER CONDENSER CONDENSER COMPRESSOR MOTOR WINDING

VIEW A — A (COMPRESSOR DETAIL)

Fig. 11 — Power Panel

• Local Operation — The PIC II can be placed in local SOFT KEYS

notifies the operator that an unusual condition has occurred.

• 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)

Display The Setpoint Table

Modify a Discrete Point

Modify an Analog Point

Fig. 15 — 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)

CONTINUED YES NO QUIT ENTER (DISCRETE VALUES)

Fig. 16 — 19XR Service Menu Structure

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

For Analog Points — Press INCREASE or

3. Press SELECT to view the desired time schedule.

3. Press ENTER to register the new value.

4. Press NEXT or PREVIOUS to highlight the de-

NOTE: When overriding or changing metric values, it is nec-

6. a. Press INCREASE or DECREASE to change the

3. Press RELEASE to remove the override and return the

Override Indication — An override value is indicated by

TIME SCHEDULE OPERATION (Fig. 17)

Fig. 17 — Example of Time Schedule

8. Press EXIT to leave the period or override.

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

10. The Holiday Designation (HOLIDEF table) may be found

SERVICE OPERATION — To view the menu-driven pro-

19XR_II SETPOINT SETPOINT SELECT

Fig. 18 — Example of Set Point Screen

EXAMPLE 1 — CVC DEFAULT SCREEN