36C24819Q1357-001.pdf

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 211 Catalog No. 531-982 Printed in U.S.A. Form 19XR-5SS Pg 1 6-01 Replaces: 19XR-4SSBook 2

Tab 5a

Start-Up, Operation, and Maintenance Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifica-tions. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.

Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outlet from rupture disc or relief valve must be vented outdoors in accor-dance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigera-tion, and Air Conditioning Engineers). The accumulation of refriger-ant in an enclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregular-ities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing.

Product causes eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

NEVER EXCEED specified test pressures, VERIFY the allowable test pressure by checking the instruction literature and the design pres-sures on the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed and functioning before operating any chiller.

RISK OF INJURY OR DEATH by electrocution. High voltage is present on motor leads even though the motor is not running when a solid-state or inside-delta mechanical starter is used. Open the power supply disconnect before touching motor leads or terminals.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller.

Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig chiller sections or the entire assembly.

DO NOT work on high-voltage equipment unless you are a qualified electrician.

DO NOT WORK ON electrical components, including control pan-els, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.

NEVER APPLY an open flame or live steam to a refrigerant cylinder.

Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller. The introduction of the wrong refrigerant can cause dam-age or malfunction to this chiller.

Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE 15 (latest edition).

Contact Carrier for further information on use of this chiller with other refrigerants.

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If chiller operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.

DO NOT install relief devices in series or backwards.

USE CARE when working near or in line with a compressed spring.

Sudden release of the spring can cause it and objects in its path to act as projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or staging. Fol-low safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if compo-nents are light, use mechanical equipment when there is a risk of slip-ping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fans, or pumps.

USE only repair or replacement parts that meet the code requirements of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, fittings, and piping for corro-sion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.

19XR,XRV

Hermetic Centrifugal Liquid Chillers

50/60 Hz With PIC II Controls and HFC-134a

CONTENTS

Page

SAFETY CONSIDERATIONS

INTRODUCTION

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . 4,5

CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . . 5-7

Chiller Information Nameplate System Components Cooler Condenser Motor-Compressor Control Panel Factory-Mounted Starter or Variable

Frequency Drive (Optional) Storage Vessel (Optional)

REFRIGERATION CYCLE

MOTOR AND LUBRICATING OIL

COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,8

VFD COOLING CYCLE

LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 8,9

Summary Details Oil Reclaim System

• PRIMARY OIL RECOVERY MODE

• SECONDARY OIL RECOVERY METHOD

STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 9,10

Unit-Mounted Solid-State Starter

(Optional) Unit-Mounted Wye-Delta Starter

(Optional) Unit-Mounted VFD (Optional) CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 Definitions

• ANALOG SIGNAL

• DISCRETE SIGNAL

General PIC II System Components

• CHILLER VISUAL CONTROLLER (CVC)

• INTERNATIONAL CHILLER VISUAL

CONTROLLER (ICVC)

• INTEGRATED STARTER MODULE (ISM)

• CHILLER CONTROL MODULE (CCM)

• OIL HEATER CONTACTOR (1C)

• OIL PUMP CONTACTOR (2C)

• HOT GAS BYPASS CONTACTOR RELAY (3C)

(Optional)

• CONTROL TRANSFORMERS (T1, T2)

• OPTIONAL TRANSFORMER (T3)

CVC/ICVC Operation and Menus

• GENERAL

• ALARMS AND ALERTS

• CVC/ICVC MENU ITEMS

• BASIC CVC/ICVC OPERATIONS (Using the Softkeys)

• TO VIEW STATUS

• OVERRIDE OPERATIONS

• TIME SCHEDULE OPERATION

• TO VIEW AND CHANGE SET POINTS

• SERVICE OPERATION

PIC II System Functions

• CAPACITY CONTROL FIXED SPEED

• CAPACITY CONTROL VFD

• ECW CONTROL OPTION

• CONTROL POINT DEADBAND

• DIFFUSER CONTROL

• PROPORTIONAL BANDS AND GAIN

• DEMAND LIMITING

• CHILLER TIMERS

• OCCUPANCY SCHEDULE

Safety Controls

Page Shunt Trip (Option) Default Screen Freeze Ramp Loading Capacity Override High Discharge Temperature Control Oil Sump Temperature Control Oil Cooler Remote Start/Stop Controls Spare Safety Inputs Alarm (Trip) Output Contacts Refrigerant Leak Detector Kilowatt Output Remote Reset of Alarms Condenser Pump Control Condenser Freeze Prevention Evaporator Freeze Protection (ICVC Only) Tower Fan Relay Low and High Auto. Restart After Power Failure Water/Brine Reset

• RESET TYPE 1

• RESET TYPE 2

• RESET TYPE 3

Demand Limit Control Option Surge Prevention Algorithm

(Fixed Speed Chiller) Surge Prevention Algorithm with VFD Surge Protection VFD Units Surge Protection (Fixed Speed Chiller)

• HEAD PRESSURE REFERENCE OUTPUT

Lead/Lag Control

• COMMON POINT SENSOR INSTALLATION

• CHILLER COMMUNICATION WIRING

• LEAD/LAG OPERATION

• FAULTED CHILLER OPERATION

• LOAD BALANCING

• AUTO. RESTART AFTER POWER FAILURE

Ice Build Control

• ICE BUILD INITIATION

• START-UP/RECYCLE OPERATION

• TEMPERATURE CONTROL DURING ICE BUILD

• TERMINATION OF ICE BUILD

• RETURN TO NON-ICE BUILD OPERATIONS

Attach to Network Device Control

• ATTACHING TO OTHER CCN MODULES

Service Operation

• TO ACCESS THE SERVICE SCREENS

• TO LOG OUT OF NETWORK DEVICE

• HOLIDAY SCHEDULING

START-UP/SHUTDOWN/RECYCLE

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47

Local Start-Up Shutdown Sequence Automatic Soft Stop Amps Threshold Chilled Water Recycle Mode Safety Shutdown

BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 48-64

Job Data Required Equipment Required Using the Optional Storage Tank and Pumpout System Remove Shipping Packaging Open Oil Circuit Valves Tighten All Gasketed Joints and

Guide Vane Shaft Packing Check Chiller Tightness Refrigerant Tracer Leak Test Chiller Standing Vacuum Test

CONTENTS (cont) Page

Chiller Dehydration Inspect Water Piping Check Optional Pumpout Compressor

Water Piping Check Relief Valves Inspect Wiring Carrier Comfort Network Interface Check Starter

• MECHANICAL STARTER

• BENSHAW, INC. RediStart MICRO™

SOLID-STATE STARTER

• VFD STARTER

Oil Charge Power Up the Controls and

Check the Oil Heater

• SOFTWARE VERSION

Software Configuration Input the Design Set Points Input the Local Occupied Schedule

(OCCPC01S)

Input Service Configurations

• PASSWORD

• INPUT TIME AND DATE

• CHANGE CVC/ICVC CONFIGURATION

IF NECESSARY

• TO CHANGE THE PASSWORD

• TO CHANGE THE CVC/ICVC DISPLAY FROM

ENGLISH TO METRIC UNITS

• CHANGE LANGUAGE (ICVC ONLY)

• MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY

• INPUT EQUIPMENT SERVICE PARAMETERS

IF NECESSARY

• CHANGE THE BENSHAW, INC., RediStart

MICRO SOFTWARE CONFIGURATION

IF NECESSARY

• VERIFY VFD CONFIGURATION AND CHANGE

PARAMETERS IF NECESSARY

• VFD CHILLER FIELD SET UP AND VERIFICATION

• VFD CONTROL VERIFICATION (Non-Running)

• VFD CONTROL VERIFICATION (Running)

• CONFIGURE DIFFUSER CONTROL IF

NECESSARY

• MODIFY EQUIPMENT CONFIGURATION

IF NECESSARY

Perform a Control Test

• COOLER CONDENSER PRESSURE TRANSDUCER

AND WATERSIDE FLOW DEVICE CALIBRATION

Check Optional Pumpout System

Controls and Compressor High Altitude Locations Charge Refrigerant Into Chiller

• CHILLER EQUALIZATION WITHOUT A

PUMPOUT UNIT

• CHILLER EQUALIZATION WITH

PUMPOUT UNIT

• TRIMMING REFRIGERANT CHARGE

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66

Preparation Dry Run to Test Start-Up Sequence Check Motor Rotation Check Oil Pressure and Compressor Stop To Prevent Accidental Start-Up Check Chiller Operating Condition Instruct the Customer Operator

• COOLER-CONDENSER

• OPTIONAL PUMPOUT STORAGE TANK AND

PUMPOUT SYSTEM

• MOTOR COMPRESSOR ASSEMBLY

Page

• MOTOR COMPRESSOR LUBRICATION

SYSTEM

• CONTROL SYSTEM

• AUXILIARY EQUIPMENT

• DESCRIBE CHILLER CYCLES

• REVIEW MAINTENANCE

• SAFETY DEVICES AND PROCEDURES

• CHECK OPERATOR KNOWLEDGE

• REVIEW THE START-UP, OPERATION, AND

MAINTENANCE MANUAL

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . .66,67

Operator Duties Prepare the Chiller for Start-Up To Start the Chiller Check the Running System To Stop the Chiller After Limited Shutdown Preparation for Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation Refrigeration Log

PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-71

Preparation Operating the Optional Pumpout Unit

• TO READ REFRIGERANT PRESSURES

Chillers with Storage Tanks

• TRANSFER REFRIGERANT FROM

PUMPOUT STORAGE TANK TO CHILLER

• TRANSFER REFRIGERANT FROM

CHILLER TO PUMPOUT STORAGE TANK

Chillers with Isolation Valves

• TRANSFER ALL REFRIGERANT TO

CHILLER CONDENSER VESSEL

• TRANSFER ALL REFRIGERANT TO

CHILLER COOLER VESSEL

• RETURN CHILLER TO NORMAL

OPERATING CONDITIONS

GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . .71,72

Refrigerant Properties Adding Refrigerant Removing Refrigerant Adjusting the Refrigerant Charge Refrigerant Leak Testing Leak Rate Test After Service, Repair, or Major Leak

• TESTING WITH REFRIGERANT TRACER

• TESTING WITHOUT REFRIGERANT TRACER

• TO PRESSURIZE WITH DRY NITROGEN

Repair the Leak, Retest, and Apply

Standing Vacuum Test Checking Guide Vane Linkage Trim Refrigerant Charge

WEEKLY MAINTENANCE

Check the Lubrication System

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-75

Service Ontime Inspect the Control Panel Check Safety and Operating Controls

Monthly Changing Oil Filter Oil Specification Oil Changes

• TO CHANGE THE OIL

Refrigerant Filter Oil Reclaim Filter Inspect Refrigerant Float System

CONTENTS (cont)

Page Inspect Relief Valves and Piping Compressor Bearing and Gear

Maintenance Inspect the Heat Exchanger Tubes and Flow Devices

• COOLER AND FLOW DEVICES

• CONDENSER AND FLOW DEVICES

Water Leaks Water Treatment Inspect the Starting Equipment Check Pressure Transducers Optional Pumpout System Maintenance

• OPTIONAL PUMPOUT COMPRESSOR OIL

CHARGE

• OPTIONAL PUMPOUT SAFETY CONTROL

SETTINGS

Ordering Replacement Chiller Parts

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-122

Overview Checking Display Messages Checking Temperature Sensors

• RESISTANCE CHECK

• VOLTAGE DROP

• CHECK SENSOR ACCURACY

• DUAL TEMPERATURE SENSORS

Checking Pressure Transducers

• UNITS EQUIPPED WITH CVC

• UNITS EQUIPPED WITH ICVC

• TRANSDUCER REPLACEMENT

Control Algorithms Checkout Procedure Control Test Control Modules

• RED LED (Labeled as STAT)

• GREEN LED (Labeled as COM) Notes on Module Operation Chiller Control Module (CCM)

• INPUTS

• OUTPUTS

Integrated Starter Module

• INPUTS

• OUTPUTS

Replacing Defective Processor Modules

• INSTALLATION

Solid-State Starters

• TESTING SILICON CONTROL RECTIFIERS IN

BENSHAW, INC. SOLID-STATE STARTERS

• SCR REMOVAL/INSTALLATION

Physical Data INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,124

INITIAL START-UP CHECKLIST FOR

19XR, XRV HERMETIC CENTRIFUGAL

LIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-16

INTRODUCTION

Prior to initial start-up of the 19XR unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with these instructions and other necessary job data.

This book is outlined to familiarize those involved in the start-up, operation and maintenance of the unit with the control sys-tem before performing start-up procedures. Procedures in this manual are arranged in the sequence required for proper chiller start-up and operation.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

Words printed in all capital letters or in italics may be viewed on the Chiller Visual Controller/International Chiller Visual Controller (CVC/ICVC) (e.g., LOCAL, CCN, ALARM, etc.).

Words printed in both all capital letters and italics can also be viewed on the CVC/ICVC and are parameters (e.g., CON-

TROL MODE, COMPRESSOR START RELAY, ICE BUILD

OPTION, etc.) with associated values (e.g., modes, tempera-tures, percentages, pressures, on, off, etc.).

Words printed in all capital letters and in a box represent softkeys on the CVC/ICVC control panel (e.g., , , , , etc.).

This unit uses a microprocessor control system. Do not short or jumper between terminations on circuit boards or modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) when handling or making contact with circuit boards or module connections. Always touch a chassis (grounded) part to dis-sipate body electrostatic charge before working inside con-trol center.

Use extreme care when handling tools near boards and when connecting or disconnecting terminal plugs. Circuit boards can easily be damaged. Always hold boards by the edges and avoid touching components and connections.

This equipment uses, and can radiate, radio frequency energy. If not installed and used in accordance with the instruction manual, it may cause interference to radio com-munications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Sub-part J of Part 15 of FCC Rules, which are designed to pro-vide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interfer-ence, in which case the user, at his own expense, will be required to take whatever measures may be required to cor-rect the interference.

Always store and transport replacement or defective boards in anti-static shipping bag.

CCM — Chiller Control Module CCN — Carrier Comfort Network CCW — Counterclockwise CVC — Chiller Visual Controller CW — Clockwise ECDW — Entering Condenser Water ECW — Entering Chilled Water EMS — Energy Management System HGBP — Hot Gas Bypass I/O — Input/Output ICVC — International Chiller Visual Controller ISM — Integrated Starter Module LCD — Liquid Crystal Display LCDW — Leaving Condenser Water LCW — Leaving Chilled Water LED — Light-Emitting Diode OLTA — Overload Trip Amps PIC II — Product Integrated Controls II RLA — Rated Load Amps SCR — Silicon Controlled Rectifier SI — International System of Units TXV — Thermostatic Expansion Valve VFD — Variable Frequency Drive

ENTER

EXIT INCREASE QUIT

Factory-installed additional components are referred to as options in this manual; factory-supplied but field-installed ad-ditional components are referred to as accessories.

The chiller software part number of the 19XR unit is located on the back of the CVC/ICVC.

CHILLER FAMILIARIZATION

(Fig. 1 and 2)

Chiller Information Nameplate — The information nameplate is located on the right side of the chiller control panel.

System Components — The components include the cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control panel, and mo-tor starter. All connections from pressure vessels have external threads to enable each component to be pressure tested with a threaded pipe cap during factory assembly.

Cooler — This vessel (also known as the evaporator) is lo-cated underneath the compressor. The cooler is maintained at lower temperature/pressure so evaporating refrigerant can re-move heat from water flowing through its internal tubes.

Condenser — The condenser operates at a higher temperature/pressure than the cooler and has water flowing through its internal tubes in order to remove heat from the refrigerant.

Motor-Compressor — This component maintains sys-tem temperature and pressure differences and moves the heat-carrying refrigerant from the cooler to the condenser.

Control Panel — The control panel is the user interface for controlling the chiller. It regulates the chiller’s capacity as required to maintain proper leaving chilled water temperature.

The control panel:

• registers cooler, condenser, and lubricating system pressures

• shows chiller operating condition and alarm shutdown conditions

• records the total chiller operating hours

• sequences chiller start, stop, and recycle under micropro-cessor control

• displays status of motor starter

• provides access to other CCN (Carrier Comfort Net-work) devices and energy management systems

• Languages pre-installed at factory include: English, Chi-nese, Japanese, and Korean (ICVC only).

• International language translator (ILT) is available for conversion of extended ASCII characters (ICVC only).

19XRV 52 51 473 DG H 64 –

19XR- — High Efficiency Hermetic Centrifugal Liquid Chiller

19XRV — High Efficiency Hermetic Centrifugal Liquid Chiller with Variable Frequency Drive Unit-Mounted

Condenser Size 10-12 (Frame 1 XR) 15-17 (Frame 1 XR) 20-22 (Frame 2 XR) 30-32 (Frame 3 XR) 35-37 (Frame 3 XR) 40-42 (Frame 4 XR) 45-47 (Frame 4 XR) 50-52 (Frame 5 XR) 55-57 (Frame 5 XR) 60-62 (Frame 6 XR) 65-67 (Frame 6 XR) 70-72 (Frame 7 XR) 75-77 (Frame 7 XR) 80-82 (Frame 8 XR) 85-87 (Frame 8 XR)

Special Order Indicator

– — Standard S — Special Order

Motor Voltage Code Code Volts-Phase-Hertz

60 — 200-3-60 61 — 230-3-60 62 — 380-3-60 63 — 416-3-60 64 — 460-3-60 65 — 575-3-60 66 — 2400-3-60 67 — 3300-3-60 68 — 4160-3-60 69 — 6900-3-60 50 — 230-3-50 51 — 346-3-50 52 — 400-3-50 53 — 3000-3-50 54 — 3300-3-50 55 — 6300-3-50

Compressor Code (First Digit Indicates Compressor Frame Size)*

Motor Efficiency Code H — High Efficiency S — Standard Efficiency

Motor Code

BD CD DB EH

BE CE DC EJ

BF CL DD EK

BG CM DE EL

BH CN DF EM

CP DG EN

CQ DH EP

DJ

27 99 Q 59843

Week of Year

Year of Manufacture

Unique Number

Place of Manufacture

MODEL NUMBER NOMENCLATURE

SERIAL NUMBER BREAKDOWN

Cooler Size 10-12 (Frame 1 XR) 15-17 (Frame 1 XR) 20-22 (Frame 2 XR) 30-32 (Frame 3 XR) 35-37 (Frame 3 XR) 40-42 (Frame 4 XR) 45-47 (Frame 4 XR) 50-52 (Frame 5 XR) 5A (Frame 5 XR) 5B (Frame 5 XR) 5C (Frame 5 XR)

55-57 (Frame 5 XR) 5F (Frame 5 XR) 5G (Frame 5 XR) 5H (Frame 5 XR) 60-62 (Frame 6 XR) 65-67 (Frame 6 XR) 70-72 (Frame 7 XR) 75-77 (Frame 7 XR) 80-82 (Frame 8 XR) 85-87 (Frame 8 XR)

*Second digit will be a letter (example 4G3) on units equipped with split ring diffuser.

Fig. 1 — 19XR Identification

18 19 20 21 22

31 30 29 28 27 26 25 24

33 24

15 14

Fig. 2 — Typical 19XR Components

LEGEND

1 — Guide Vane Actuator 2 — Suction Elbow 3 — Chiller Visual Controller/ International Chiller

Visual Control (CVC/ICVC) 4 — Chiller Identification Nameplate 5 — Cooler, Auto Reset Relief Valves 6 — Cooler Pressure Transducer 7 — Condenser In/Out Temperature Thermistors 8 — Condenser Waterflow Device (ICVC Inputs available) 9 — Cooler In/Out Temperature Thermistors

10 — Cooler Waterflow Device (ICVC Inputs avail-able)

11 — Refrigerant Charging Valve 12 — Typical Flange Connection 13 — Oil Drain Charging Valve 14 — Oil Level Sight Glasses 15 — Refrigerant Oil Cooler (Hidden) 16 — Auxiliary Power Panel 17 — Compressor Motor Housing

LEGEND

18 — Condenser Auto. Reset Relief Valves 19 — Compressor Motor Circuit Breaker 20 — Solid-State Starter Control Display 21 — Unit-Mounted Starter (Optional)

Solid-State Starter Shown 22 — Motor Sight Glass 23 — Cooler Return-End Waterbox Cover 24 — ASME Nameplate (One Hidden) 25 — Typical Waterbox Drain Port 26 — Condenser Return-End Waterbox Cover 27 — Refrigerant Moisture/Flow Indicator 28 — Refrigerant Filter/Drier 29 — Liquid Line Isolation Valve (Optional) 30 — Linear Float Valve Chamber 31 — Vessel Take-Apart Connector 32 — Discharge Isolation Valve (Optional) 33 — Pumpout Valve 34 — Condenser Pressure Transducer

REAR VIEW

FRONT VIEW

Factory-Mounted Starter or Variable Fre-quency Drive (Optional) — The starter allows for the proper start and disconnect of electrical energy for the com-pressor-motor, oil pump, oil heater, and control panel.

Storage Vessel (Optional) — There are 2 sizes of storage vessels available. The vessels have double relief valves, a magnetically-coupled dial-type refrigerant level gage, a one-inch FPT drain valve, and a 1/2-in. male flare vapor con-nection for the pumpout unit.

NOTE: If a storage vessel is not used at the jobsite, factory-installed isolation valves on the chiller may be used to isolate the chiller charge in either the cooler or condenser. An optional pumpout system is used to transfer refrigerant from vessel to vessel.

REFRIGERATION CYCLE

The compressor continuously draws refrigerant vapor from the cooler at a rate set by the amount of guide vane opening or compressor speed (19XRV only). As the compressor suction reduces the pressure in the cooler, the remaining refrigerant boils at a fairly low temperature (typically 38 to 42 F [3 to 6 C]). The energy required for boiling is obtained from the wa-ter flowing through the cooler tubes. With heat energy re-moved, the water becomes cold enough to use in an air condi-tioning circuit or for process liquid cooling.

After taking heat from the water, the refrigerant vapor is compressed. Compression adds still more heat energy, and the refrigerant is quite warm (typically 98 to 102 F [37 to 40 C]) when it is discharged from the compressor into the condenser.

Relatively cool (typically 65 to 90 F [18 to 32 C]) water flowing into the condenser tubes removes heat from the refrig-erant and the vapor condenses to liquid.

The liquid refrigerant passes through orifices into the FLASC (Flash Subcooler) chamber (Fig. 3). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid drains into a float cham-ber between the FLASC chamber and cooler. Here a float valve forms a liquid seal to keep FLASC chamber vapor from enter-ing the cooler. When liquid refrigerant passes through the valve, some of it flashes to vapor in the reduced pressure on the cooler side. In flashing, it removes heat from the remaining liq-uid. The refrigerant is now at a temperature and pressure at which the cycle began.

MOTOR AND LUBRICATING OIL

COOLING CYCLE

The motor and the lubricating oil are cooled by liquid re-frigerant taken from the bottom of the condenser vessel (Fig. 3). Refrigerant flow is maintained by the pressure differ-ential that exists due to compressor operation. After the refrig-erant flows past an isolation valve, an in-line filter, and a sight glass/moisture indicator, the flow is split between the motor cooling and oil cooling systems.

Fig. 3 — Refrigerant Motor Cooling and Oil Cooling Cycles

Flow to the motor cooling system passes through an orifice and into the motor. Once past the orifice, the refrigerant is directed over the motor by a spray nozzle. The refrigerant collects in the bottom of the motor casing and is then drained back into the cooler through the motor refrigerant drain line.

An orifice (in the motor shell) maintains a higher pressure in the motor shell than in the cooler. The motor is protected by a temperature sensor imbedded in the stator windings. An increase in motor winding temperature past the motor override set point overrides the temperature capacity control to hold, and if the motor temperature rises 10° F (5.5° C) above this set point, closes the inlet guide vanes. If the temperature rises above the safety limit, the compressor shuts down.

Refrigerant that flows to the oil cooling system is regulated by thermostatic expansion valves (TXVs). The TXVs regulate flow into the oil/refrigerant plate and frame-type heat exchang-er (the oil cooler in Fig. 3). The expansion valve bulbs control oil temperature to the bearings. The refrigerant leaving the oil cooler heat exchanger returns to the chiller cooler.

VFD COOLING CYCLE

The unit-mounted variable frequency drive (VFD) is cooled in a manner similar to the motor and lubricating oil cooling cycle (Fig. 3).

If equipped with a unit-mounted VFD, the refrigerant line that feeds the motor cooling and oil cooler also feeds the heat exchanger on the unit-mounted VFD. Refrigerant is metered through a thermostatic expansion valve (TXV). To maintain proper operating temperature in the VFD, the TXV bulb is mounted to the heat exchanger to regulate the flow of refriger-ant. The refrigerant leaving the heat exchanger returns to the cooler.

LUBRICATION CYCLE

Summary — The oil pump, oil filter, and oil cooler make up a package located partially in the transmission casing of the compressor-motor assembly. The oil is pumped into a filter assembly to remove foreign particles and is then forced into an oil cooler heat exchanger where the oil is cooled to proper operational temperatures. After the oil cooler, part of the flow is directed to the gears and the high speed shaft bearings; the remaining flow is directed to the motor shaft bearings. Oil drains into the transmission oil sump to complete the cycle (Fig. 4).

Details — Oil is charged into the lubrication system through a hand valve. Two sight glasses in the oil reservoir permit oil level observation. Normal oil level is between the middle of the upper sight glass and the top of the lower sight glass when the compressor is shut down. The oil level should be visible in at least one of the 2 sight glasses during operation. Oil sump tem-perature is displayed on the CVC/ICVC (Chiller Visual Con-troller/International Chiller Visual Controller) default screen.

During compressor operation, the oil sump temperature ranges between 125 to 150 F (52 to 66 C).

The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to172 kPad) differential pressure in the system at the pump discharge. This differential pressure can be read directly from the CVC/ICVC default screen. The oil pump discharges oil to the oil filter as-sembly. This filter can be closed to permit removal of the filter without draining the entire oil system (see Maintenance sec-tions, pages 71 to 75, for details). The oil is then piped to the oil cooler heat exchanger. The oil cooler uses refrigerant from the condenser as the coolant. The refrigerant cools the oil to a tem-perature between 120 and 140 F (49 to 60 C).

As the oil leaves the oil cooler, it passes the oil pressure transducer and the thermal bulb for the refrigerant expansion valve on the oil cooler. The oil is then divided. Part of the oil flows to the thrust bearing, forward pinion bearing, and gear spray. The rest of the oil lubricates the motor shaft bearings and the rear pinion bearing. The oil temperature is measured in the bearing housing as it leaves the thrust and forward journal bearings. The oil then drains into the oil reservoir at the base of the compressor. The PIC II (Product Integrated Control II) measures the temperature of the oil in the sump and maintains the temperature during shutdown (see Oil Sump Temperature Control section, page 36). This temperature is read on the CVC/ICVC default screen.

During the chiller start-up, the PIC II energizes the oil pump and provides 45 seconds of pre-lubrication to the bearings after pressure is verified before starting the compressor. During shutdown, the oil pump will run for 60 seconds to post-lubricate after the compressor shuts down. The oil pump can also be energized for testing purposes during a Control Test.

Ramp loading can slow the rate of guide vane opening to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any re-frigerant in the oil to flash. The resulting oil foam cannot be pumped efficiently; therefore, oil pressure falls off and lubrica-tion is poor. If oil pressure falls below 15 psid (103 kPad) dif-ferential, the PIC II will shut down the compressor.

If the controls are subject to a power failure that lasts more than 3 hours, the oil pump will be energized periodically when the power is restored. This helps to eliminate refrigerant that has migrated to the oil sump during the power failure. The con-trols energize the pump for 60 seconds every 30 minutes until the chiller is started.

Oil Reclaim System — The oil reclaim system returns oil lost from the compressor housing back to the oil reservoir by recovering the oil from 2 areas on the chiller. The guide vane housing is the primary area of recovery. Oil is also recov-ered by skimming it from the operating refrigerant level in the cooler vessel.

PRIMARY OIL RECOVERY MODE — Oil is normally re-covered through the guide vane housing on the chiller. This is possible because oil is normally entrained with refrigerant in the chiller. As the compressor pulls the refrigerant up from the cooler into the guide vane housing to be compressed, the oil normally drops out at this point and falls to the bottom of the guide vane housing where it accumulates. Using discharge gas pressure to power an eductor, the oil is drawn from the housing and is discharged into the oil reservoir.

SECONDARY OIL RECOVERY METHOD — The sec-ondary method of oil recovery is significant under light load conditions, when the refrigerant going up to the compressor suction does not have enough velocity to bring oil along. Under these conditions, oil collects in a greater concentration at the top level of the refrigerant in the cooler. This oil and refrigerant mixture is skimmed from the side of the cooler and is then drawn up to the guide vane housing. There is a filter in this line.

Because the guide vane housing pressure is much lower than the cooler pressure, the refrigerant boils off, leaving the oil be-hind to be collected by the primary oil recovery method.

STARTING EQUIPMENT

The 19XR requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxilia-ry equipment. The starter is the main field wiring interface for the contractor.

See Carrier Specification Z-415 for specific starter require-ments, Z-416 for free-standing VFD requirements and Z-417 for unit-mounted VFD requirements. All starters must meet these specifications in order to properly start and satisfy me-chanical safety requirements. Starters may be supplied as sepa-rate, free-standing units or may be mounted directly on the chiller (unit mounted) for low voltage units only.

Three separate circuit breakers are inside the starter. Circuit breaker CB1 is the compressor motor circuit breaker. The dis-connect switch on the starter front cover is connected to this breaker. Circuit breaker CB1 supplies power to the compressor motor.

Circuit breaker CB2 supplies power to the control panel, oil heater, and portions of the starter controls.

Circuit breaker CB3 supplies power to the oil pump. Both CB2 and CB3 are wired in parallel with CB1 so that power is supplied to them if the CB1 disconnect is open.

All starters must include a Carrier control module called the Integrated Starter Module (ISM), excluding the Benshaw solid-state starters. This module controls and monitors all as-pects of the starter. See the Controls section on page 10 for ad-ditional ISM information. All starter replacement parts are sup-plied by the starter manufacturer excluding the ISM (contact Carrier’s Replacement Component Division [RCD]).

Unit-Mounted Solid-State Starter (Optional) — The 19XR chiller may be equipped with a solid-state, reduced-voltage starter (Fig. 5 and 6). This starter’s primary function is to provide on-off control of the compressor motor. This type of starter reduces the peak starting torque, reduces the motor in-rush current, and decreases mechanical shock. This capability is summed up by the phrase “soft starting.” The solid-state starter is available as a 19XR option (factory supplied and in-stalled). The solid-state starters manufacturer name is located inside the starter access door.

A solid-state, reduced-voltage starter operates by reducing the starting voltage. The starting torque of a motor at full volt-age is typically 125% to 175% of the running torque. When the voltage and the current are reduced at start-up, the starting torque is reduced as well. The object is to reduce the starting voltage to just the voltage necessary to develop the torque re-quired to get the motor moving. The voltage is reduced by sili-con controlled rectifiers (SCRs). The voltage and current are then ramped up in a desired period of time. Once full voltage is reached, a bypass contactor is energized to bypass the SCRs.

The main circuit breaker (CB1) on the front of the starter disconnects the main motor current only. Power is still energized for the other circuits. Two more circuit breakers inside the starter must be turned off to disconnect power to the oil pump, PIC II controls, and oil heater.

When voltage is supplied to the solid-state circuitry (CB1 is closed), the heat sinks in the starter as well as the wires leading to the motor and the motor terminal are at line volt-age. Do not touch the heat sinks, power wiring, or motor terminals while voltage is present or serious injury will result.

REAR MOTOR

BEARING

ISOLATION

VALVE

SIGHT

GLASS

FILTER

ISOLATION

VALVE

FILTEREDUCTOR

OIL

PUMPTXV BULB PRESSURE

TRANSDUCER

ISOLATION

VALVE

OIL

COOLER OIL PUMP

MOTOR

OIL

HEATER

MOTOR

COOLING LINE

LABYRINTH

GAS LINE

FWD MOTOR

BEARING

OIL SUPPLY TO

FORWARD HIGH

SPEED BEARING

SIGHT GLASS

OIL SKIMMER LINE

Fig. 4 — Lubrication System

There is a display on the front of the Benshaw, Inc., solid-state starters that is useful for troubleshooting and starter checkout. The display indicates:

• voltage to the SCRs

• SCR control voltage

• power indication

• proper phasing for rotation

• start circuit energized

• over-temperature

• ground fault

• current unbalance

• run state

• software configuration

The starter is further explained in the Check Starter and Troubleshooting Guide sections, pages 54 and 76.

Unit-Mounted Wye-Delta Starter (Optional) — The 19XR chiller may be equipped with a wye-delta starter mounted on the unit. This starter is used with low-voltage mo-tors (under 600 v). It reduces the starting current inrush by con-necting each phase of the motor windings into a wye configu-ration. This occurs during the starting period when the motor is accelerating up to speed. Once the motor is up to speed, the starter automatically connects the phase windings into a delta configuration. Starter control, monitoring, and motor protec-tion is provided by Carrier’s Integrated Starter Module (ISM).

Unit-Mounted VFD (Optional) — The 19XRV unit will be equipped with a variable frequency drive motor control-ler mounted on the unit. See Fig. 7 and 8. This VFD is used with low voltage motors between 380 and 480 VAC. It reduces the starting current inrush by controlling the voltage and fre-quency to the compressor motor. Once the motor has accelerat-ed to minimum speed the PIC II modulates the compressor speed and guide vane position to control chilled water tempera-ture. The VFD is further explained in the Controls section and Troubleshooting Guide section, pages 10 and 76.

There is a separate display located on the unit-mounted VFD. Operational parameters and fault codes are displayed rel-ative to the drive. Refer to specific drive literature along with troubleshooting sections. The display is also the interface for entering specific chiller operational parameters. These parame-ters have been preprogrammed at the factory. An adhesive backed label on the inside of the drive has been provided for verification of the specific job parameters. See Initial Start-Up Checklist section for details.

CONTROLS

Definitions ANALOG SIGNAL — An analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Example: A temperature sensor is an analog device be-cause its resistance changes in proportion to the temperature, generating many values.)

DISCRETE SIGNAL — A discrete signal is a 2-position rep-resentation of the value of a monitored source. (Example: A switch produces a discrete signal indicating whether a value is above or below a set point or boundary by generating an on/off, high/low, or open/closed signal.)

LEGEND

Fig. 5 — Solid-State Starter Box, Internal View

1 — RediStart MICRO™ Input/Output Card 2 — Fuses 1-4 (Hidden, not depicted) 3 — Circuit Breaker 2 (CB2): Machine Control and Heater Power 4 — Circuit Breaker 3 (CB3): Oil Pump Power 5 — RediStart MICRO Central Processing Unit Card (CPU) 6 — RediStart MICRO Power Card (hidden, not depicted) 7 — RediStart MICRO Bypass Card (hidden, not depicted)

Fig. 6 — Typical Starter External View (Solid-State Starter Shown)

General — The 19XR hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the chiller (see Fig. 9). The microprocessor control system matches the cooling capacity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling load within the set point plus the deadband by sensing the leaving chilled water or brine temperature and regulating the inlet guide vane via a mechanically linked actuator motor. The guide vane is a vari-able flow pre-whirl assembly that controls the refrigeration ef-fect in the cooler by regulating the amount of refrigerant vapor flow into the compressor. An increase in guide vane opening increases capacity. A decrease in guide vane opening decreases capacity. The microprocessor-based control center protects the chiller by monitoring the digital and analog inputs and execut-ing capacity overrides or safety shutdowns, if required.

PIC II System Components — The chiller control system is called the PIC II (Product Integrated Control II). See Table 1. The PIC II controls the operation of the chiller by monitoring all operating conditions. The PIC II can diagnose a problem and let the operator know what the problem is and what to check. It promptly positions the guide vanes to main-tain leaving chilled water temperature. It can interface with auxiliary equipment such as pumps and cooling tower fans to turn them on when required. It continually checks all safeties to prevent any unsafe operating condition. It also regulates the oil heater while the compressor is off and regulates the hot gas by-pass valve, if installed. The PIC II controls provide critical pro-tection for the compressor motor and controls the motor starter.

SPEED

VOLTS

AMPS

Hz

Kw

TORQUE

Password

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

PROGRAM

PRO-

GRAM

Forward Reverse

ENTER

RUN

JOB

AUTO

MAN

SPEED

VOLTS

AMPS

Hz

Kw

TORQUE

Password

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

PROGRAM

PROGRAM

Forward Reverse

ENTER

RUN

JOB

AUTO

MAN

MANUAL RESET

OPTIONAL

METER

PACKAGE

SPEED

VOLTS

AMPS

Hz

Kw

TORQUE

Password

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

PROGRAM

PROGRAM

Forward Reverse

ENTER

RUN

JOB

AUTO

MAN

DANGER

HIGH VOLTAGE

INITIAL DC BUS

MEASUREMENT

POINT

DC BUS BAR

MEASUREMENT

POINT

VFD

MODULE

COOLING LINES

COMPRESSOR

MOTOR

DISCONNECT

TXV

CONTROL

AND OIL

HEATER

DISCONNECT

OIL PUMP

DISCONNECT

INTEGRATED

STARTER

MODULE

(ISM)

LINE

LOAD

Fig. 7 — Variable Frequency Drive (VFD)

Fig. 8 — Variable Frequency Drive (VFD) Starter Internal View

FITTING (HIDDEN) PANEL ACTUATOR CABLE PANEL CABLE

WATER

SENSOR

CABLES

WATER

SENSOR

CABLES

COOLER

PRESSURE

TRANSDUCER

CONNECTION

CONDENSER

PRESSURE

CABLE

SCHRADER

FITTING (HIDDEN)

CONDENSER

PRESSURE

TRANSDUCER

CONNECTION

CONDENSER

SERVICE

VALVE

COMPRESSOR

DISCHARGE

ELBOW JOINTS

MOTOR WINDING

TEMPERATURE

CABLE

DISCHARGE

ISOLATION

VALVE

(OPTIONAL)

TOP VIEW

COMPRESSOR DETAIL

Fig. 9 — 19XR Controls and Sensor Locations

The PIC II can interface with the Carrier Comfort Network (CCN) if desired. It can communicate with other PIC I or PIC II equipped chillers and other CCN devices.

The PIC II consists of 3 modules housed inside 3 major components. The component names and corresponding control voltages are listed below (also see Table 1):

• control panel

— all extra low-voltage wiring (24 v or less)

• power panel

— 230 or 115 v control voltage (per job requirement)

— up to 600 v for oil pump power

• starter cabinet

— chiller power wiring (per job requirement)

Table 1 — Major PIC II Components and Panel Locations*

*See Fig. 8-13.

CHILLER VISUAL CONTROLLER (CVC) — The CVC is the “brain” of the PIC II. This module contains all the operating software needed to control the chiller. The CVC is mounted to the control panel (Fig. 12) and is the input center for all local chiller set points, schedules, configurable functions, and op-tions. The CVC has a stop button, an alarm light, four buttons for logic inputs, and a backlight display. The backlight will au-tomatically turn off after 15 minutes of non-use. The functions of the four buttons or “softkeys” are menu driven and are shown on the display directly above the softkeys.

The viewing angle of the CVC can be adjusted for optimum viewing. Remove the 2 bolts connecting the control panel to the brackets attached to the cooler. Place them in one of the holes to pivot the control panel forward to backward to change the viewing angle. See Fig. 12. To change the contrast of the display, access the adjustment on the back of the CVC. See Fig. 12.

INTERNATIONAL CHILLER VISUAL CONTROLLER

(ICVC) — Incorporates all of the functions and operating soft-ware of the CVC with the added feature of 4 factory pro-grammed languages:

English (default) Chinese Japanese Korean

NOTE: Pressing any one of the four softkey buttons will acti-vate the backlight display without implementing a softkey function.

INTEGRATED STARTER MODULE (ISM) — This mod-ule is located in the starter cabinet. This module initiates com-mands from the CVC/ICVC for starter functions such as start-ing and stopping the compressor, condenser, chilled water pumps, tower fan, spare alarm contacts, and the shunt trip. The ISM monitors starter inputs such as line voltage, motor current, ground fault, remote start contact, spare safety, condenser high pressure, oil pump interlock, starter 1M, and run contacts. The ISM contains logic capable of safety shutdown. It shuts down the chiller if communications with the CVC/ICVC are lost.

The ISM can also act as the interface for PIC II to the VFD controller.

CHILLER CONTROL MODULE (CCM) — This module is located in the control panel. The CCM provides the input and outputs necessary to control the chiller. This module monitors refrigerant pressure, entering and leaving water temperatures, and outputs control for the guide vane actuator, oil heaters, and oil pump. The CCM is the connection point for optional de-mand limit, chilled water reset, remote temperature reset, re-frigerant leak sensor and motor kilowatt output.

OIL HEATER CONTACTOR (1C) — This contactor is lo-cated in the power panel (Fig. 13) and operates the heater at either 115 or 230 v. It is controlled by the PIC II to maintain oil temperature during chiller shutdown. The XR4 with split ring diffuser has a line voltage oil heater. Refer to the control panel wiring schematic.

OIL PUMP CONTACTOR (2C) — This contactor is located in the power panel. It operates all 200 to 575-v oil pumps.

The PIC II energizes the contactor to turn on the oil pump as necessary.

HOT GAS BYPASS CONTACTOR RELAY (3C)

(Optional) — This relay, located in the power panel, controls the opening of the hot gas bypass valve. The PIC II energizes the relay during low load, high lift conditions.

CONTROL TRANSFORMERS (T1, T2) — These transform-ers convert incoming control voltage to 24 vac power for the 3 power panel contactor relays, CCM, and CVC/ICVC.

OPTIONAL TRANSFORMER (T3) — This transformer pro-vides control power to Dataport™/DataLINK™ modules.

PIC II COMPONENT PANEL LOCATION

Chiller Visual Controller (CVC/ICVC) and Display

Control Panel

Integrated Starter Module (ISM) Starter Cabinet Chiller Control Module (CCM) Control Panel Oil Heater Contactor (1C) Power Panel Oil Pump Contactor (2C) Power Panel Hot Gas Bypass Relay (3C) (Optional) Power Panel Control Transformers (T1, T2) Power Panel Temperature Sensors See Fig. 9.

Pressure Transducers See Fig. 9.

Fig. 10 — Control Sensors (Temperature)

Fig. 11 — Control Sensors (Pressure Transducers, Typical)

Fig. 12 — Control Panel

Fig. 13 — Power Panel

CVC/ICVC Operation and Menus (Fig. 14-20)

GENERAL

• The CVC/ICVC display automatically reverts to the default screen after 15 minutes if no softkey activity takes place and if the chiller is not in the pumpdown mode (Fig. 14).

• If a screen other than the default screen is displayed on the CVC/ICVC, the name of that screen is in the upper right corner (Fig. 15).

• The CVC/ICVC may be set to display either English or SI units. Use the CVC/ICVC configuration screen (accessed from the Service menu) to change the units.

See the Service Operation section, page 45.

• Local Operation — The PIC II can be placed in local operating mode by pressing the softkey. The PIC II then accepts commands from the CVC/ICVC only and uses the Local Time Schedule to determine chiller start and stop times.

• CCN Operation — The PIC II can be placed in the CCN operating mode by pressing the softkey. The PIC II then accepts modifications from any CCN interface or module (with the proper authority), as well as from the CVC/ICVC. The PIC II uses the CCN time schedule to determine start and stop times.

ALARMS AND ALERTS — An alarm shuts down the com-pressor. An alert does not shut down the compressor, but it no-tifies the operator that an unusual condition has occurred. An alarm (*) or alert (!) is indicated on the STATUS screens on the far right field of the CVC/ICVC display screen.

Alarms are indicated when the control center alarm light (!)

flashes. The primary alarm message is displayed on the default screen. An additional, secondary message and troubleshooting information are sent to the ALARM HISTORY table.

When an alarm is detected, the CVC/ICVC default screen will freeze (stop updating) at the time of alarm. The freeze en-ables the operator to view the chiller conditions at the time of alarm. The STATUS tables will show the updated information.

Once all alarms have been cleared (by pressing the softkey), the default CVC/ICVC screen will return to normal operation.

CVC/ICVC MENU ITEMS — To perform any of the opera-tions described below, the PIC II must be powered up and have successfully completed its self test. The self test takes place au-tomatically, after power-up.

Press the softkey to view the list of menu struc-tures: , , , and

• The STATUS menu allows viewing and limited calibra-tion or modification of control points and sensors, relays and contacts, and the options board.

• The SCHEDULE menu allows viewing and modification of the local and CCN time schedules and Ice Build time schedules.

• The SETPOINT…