Carrier 19XL Especificações

19XL 50/60 HzHermetic Centrifugal Liquid Chillerswith HCFC–22 and HFC–134aStart-Up, Operation, and Maintenance Instruction

ContentsMenu StructureTo View Point Status Override Operations Time Schedule Operation To View and Change Set PointsService Operation PIC System Funct

requested to start. After the second chiller is started and is running, the lead chiller shall monitor conditions and evaluate whether the capacity ha

Standby Chiller Configuration and Operation The configured standby chiller is identified as such by having the LEAD/LAG SELECT configured to the value

6. The configured LAG START TIMER entry has elapsed. The LAG START TIMER shall be started when the lead chiller ramp loading is completed. The LAG STA

COMPRESSOR MOTOR LOAD is less than the lead chiller percent capacity plus 15%. The timer is ignored if the chilled water temperature reaches 3° F (1.6

Load BalancingWhen the LOAD BALANCE OPTION is enabled, the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s COMP

Ice Build ControlIce build control automatically sets the chilled WATER/ BRINE CONTROL POINT of the machine to a temperature where an ice building ope

temperature being less than the ICE BUILD SETPOINT, opening of the REMOTE CONTACT inputs from an ice level indicator, or reaching the end of the Ice B

Start-Up/Recycle OperationIf the machine is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD

Temperature Control During Ice Build During ice build, the capacity control algorithm uses the WATER/BRINE CONTROL POINT minus 5 F (2.7 C) to control

Schedule is UNOCCUPIED. The contacts are used to stop the ICE BUILD mode when the Ice Build Time Schedule is OCCUPIED. 4. ECW TEMPERATURE and Remote C

ContentsDefault Screen Freeze Motor Cooling ControlRamp Loading ControlCapacity Override High Discharge Temperature ControlOil Sump Temperature Contro

Attach to Network Device Control On the Service menu, one of the selections is ATTACH TO NETWORK DEVICE. This table serves the following purposes:• to

various CCN modules is different for each module. In general, the uploading process will take 3 to 5 minutes.Changing Refrigerant TypesTo select refri

checked. If the model is communicating properly, the ‘‘UPLOAD IN PROGRESS’’ message will flash and the new module can now be viewed. Whenever there is

Service Operation An overview of the menu-driven programs available for Service Operation is shown in Figure 17.To Log On 1.On the Menu screen, pr

Step 1 and try logging on again.Note: The initial factory set password is 1-1-1-1.To Log Off Access the Log Out of Device table of the Service menu in

that is configured to be the broadcaster is the device responsible for transmitting holiday, time, and daylight-savings dates throughout the network.

4. Press NEXT until Holidef is highlighted. This is the Holiday Definition table.5. Press SELECT to enter the Data Table Select screen. This screen li

7. Press SELECT to access the holiday table. The Configuration Select table now shows the holiday start month and day, and how many days the holiday p

10. Press INCREASE or DECREASE to change the selected value.11. Press ENTER to save the changes.12. Press EXIT to return to the previous menu. INCREA

Start-Up/Shutdown/Recycle Sequence (Figure 24)Local Start-Up Local start-up (or a manual start-up) is initiated by pressing the LOCAL menu softkey whi

ContentsTower Fan Relay Auto. Restart After Power FailureWater/Brine Reset Demand Limit Control, Option (Requires Optional 8-Input Module)Surge Preven

than or equal to this value, the PIC will turn off the condenser pump relay and go into a RECYCLE mode. If the water/brine temperature is high enough,

confirm stop command) • recycle condition is present (see Chilled Water Recycle Mode section) • time schedule has gone into UNOCCUPIED mode (machine p

• if the machine shuts down due to low refrigerant temperature, the chilled water pump will stay running until the LEAVING CHILLED WATER is greater th

compressor is running in a lightly loaded condition. This cycling of the chiller is normal and is known as recycle. A recycle shutdown is initiated wh

hours. This excessive recycling can reduce machine life. Compressor recycling due to extremely low loads should be reduced. To reduce compressor recyc

Before Initial Start-UpJob Data Required• list of applicable design temperatures and pressures (product data submittal) • machine certified prints • s

• absolute pressure manometer or wet-bulb vacuum indicator (Figure 25)• 500 v insulation tester (megohmmeter) for compressor motors with nameplate vol

Check Machine Tightness Figure 26 outlines the proper sequence and procedures for leak testing. 19XL chillers are shipped with the refrigerant contain

Leak Test Machine Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant, Ca

c. Leak test machine as outlined in Steps 3 - 9. 2. If the pressure readings are abnormal for machine condition:a. Prepare to leak test machines shipp

ContentsStart-Up/Recycle OperationTemperature Control During Ice BuildTermination of Ice BuildReturn to Non-ice Build Operations Attach to Network Dev

g. After successfully completing the test for large leaks, remove as much nitrogen, air, and moisture as possible, given the fact that small leaks may

b. If the machine fails this test, check for large leaks (Step 2b). c. Dehydrate the machine if it passes the standing vacuum test. Follow the procedu

4.a. If the leakage rate is less than 0.05 in. Hg (.17 kPa) in 24 hours, the machine is suffi-ciently tight. b. If the leakage rate exceeds 0.05 in. H

Machine DehydrationDehydration is recommended if the machine has been open for a considerable period of time, if the machine is known to contain moist

Dehydration is readily accomplished at room temperatures. Use of a cold trap (Figure 29) may substantially reduce the time required to complete the de

3. Open all isolation valves (if present), if the entire machine is to be dehydrated. 4. With the machine ambient temperature at 60 F (15.6 C) or high

Inspect Water Piping Refer to piping diagrams provided in the certified drawings, and the piping instructions in the 19XL Installation Instructions ma

Check Relief DevicesBe sure that relief devices have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and a

2. On low-voltage compressors (600 v or less) connect voltmeter across the power wires to the compressor starter and measure the voltage. Compare this

a. Open the starter main disconnect switch and follow lockout/tagout rules.b. With the tester connected to the motor leads, take 10-second and 60-seco

ContentsChilled Water Recycle ModeSafety Shutdown Before Initial Start-UpJob Data Required Equipment Required Using the Optional Storage Tank and Pump

Note: Unit-mounted starters do not have to be megohm tested. 10. Tighten up all wiring connections to the plugs on the SMM, 8-input, and PSIO modules.

tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and

Check StarterUse the instruction and service manual supplied by the starter manufacturer to verify that the starter has been installed correctly.Whene

Mechanical-Type Starters 1.Check all field wiring connections for tightness, clearance from moving parts, and correct connection. 2.Check the contacto

seconds may be chosen as needed (typically 20 to 30 seconds are used). When the timer has been set, check that the starter, (with relay 1CR closed, go

The starting torque potentiometer should be set so that when the PIC calls for the motor to start, the rotor should just start to turn. The nominal di

Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller(Print and use for job file)Cutler-Hammer® Solid-State Starters1.Check that all

important because of the interdependency of these functions. See Table 6. The settings should be made in the following sequence: Potentiometer Adjustm

Starting Current The torque required to start a machine (initial torque) varies from one application to another. Starting current may be adjusted to m

Ramp Time (Adjustable Current Ramp) The motor current is ramped up from the starting current value over a timed period set by the ramp time potentiome

ContentsMachine Dehydration Inspect Water Piping Check Optional Pumpout Compressor Water Piping Check Relief DevicesInspect WiringCarrier Comfort Netw

Voltage MeasurementsConsider the following when checking voltage measurements: • Before energizing the starter, check the incoming lines for properly

located near the bottom of the transmission housing (Figure 2A or Figure 2B). The oil must be pumped from the oil container through the charging valve

normal operating temperature. A LOW OIL TEMPERATURE alert will show on the default LID screen if the operator has the controls set to start.Software V

Input the Design Set Points Access the LID set point screen and view/modify the base demand limit set point, and either the LCW set point or the ECW s

refrigerant setting. Press EXIT softkey to leave the screen without changes. To Change Refrigerant TypeEnter the Controls Test tables on the Service M

Input Time and Date Access the Time and Date table on the Service menu. Input the present time of day, date, and day of the week. ‘‘Holiday Today’’ sh

Configure SERVICE1 Table Access Service1 table to modify/view the following to jobsite parameters:Note: Other values are left at the default values. T

If, after configuring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed

Calculate Maximum Load To calculate maximum load points, use design load condition data. If the machine full load cooler temperature difference is mor

Calculate Minimum Load To calculate minimum load conditions, estimate the temperature difference that the cooler will have at 10% load, then estimate

ContentsInput the Local Occupied Schedule (OCCPC01S)Selecting Refrigerant TypeTo Confirm Refrigerant TypeTo Change Refrigerant Type Input Service Conf

If surge prevention occurs too soon or too late:Modify Amp Correction FactorsTo modify the amp correction factor, use the values listed in Table 7. En

Config Table ModificationsChange the values in this table per job data. See certified drawings for values. Modifications include: • chilled water rese

system. See the applicable CCN manual for more information on these tables. These tables can only be defined through a CCN Building Supervisor.Check V

Note: The oil pump test will not energize the oil pump if cooler pressure is below –5 psig (–35 kPa).When the test is finished, or the EXIT softkey is

Check Optional Pumpout System Controls and CompressorControls include an on/off switch, a 3-amp fuse, the compressor overloads, an internal thermostat

Charge Refrigerant into MachineThe standard 19XL machine will have the refrigerant already charged in the vessels. The 19XL may be ordered with a nitr

To equalize the pressure differential on a refrigerant isolated 19XL machine, use the TERMINATE LOCKOUT function of the Control Test in the SERVICE me

19XL Machine Equalization with Pumpout Unit The following procedure describes how to equalize refrigerant pressure on an isolated 19XL machine using t

adding the condenser charge to the cooler charge listed in Table 9. Always operate the condenser and chilled water pumps during charging operations to

Trimming Refrigerant ChargeThe 19XL is shipped with the correct charge for the design duty of the machine. Trimming the charge can be best accomplishe

ContentsCharge Refrigerant into Machine 19XL Machine Equalization without Pumpout Unit 19XL Machine Equalization with Pumpout Unit Trimming Refrigeran

5. Oil reservoir temperature is above 140 F (60 C) or refrigerant temperature plus 50° F (28° C). 6. Valves in the evaporator and condenser water circ

Manual Operation of the Guide VanesManual operation of the guide vanes is helpful to establish a steady motor current for calibration of the motor amp

2. Look at the default screen on the LID: the Status message in the upper left-hand corner will show a ‘‘Manually Stopped’’ message. Press CCN or Loca

If the Motor Rotation Is Not Clockwise (as viewed through the sight glass), reverse any 2 of the 3 incoming power leads to the starter and recheck rot

3. The factory setting should bring the motor to full voltage in 15 to 30 seconds. If the setting is not correct, adjust the ramp potentiometer counte

To Prevent Accidental Start-UpThe PIC can be set up so that start-up of the unit is more difficult than just pressing the LOCAL or CCN softkeys during

Optional Storage Tank and Pumpout System Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices. Motor Co

Review MaintenanceScheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importan

5. Protect the system from damage during shutdown periods. 6. Maintain the set point, time schedules, and other PIC functions.Prepare the Machine for

3. The oil level should be visible anywhere in one of the two sight glasses. Foaming of the oil is acceptable as long as the oil pressure and temperat

ContentsCheck Machine Operating Condition Instruct the Customer OperatorCooler-CondenserOptional Storage Tank and Pumpout SystemMotor Compressor Assem

based on load rate or temperature rate. It is accessed on the Equipment Configuration, Config table (Table 2, Example 5).To Stop the Machine 1.The occ

Extended Shutdown The refrigerant should be transferred into the storage vessel (if supplied; see Pumpout and Refrigerant Transfer Procedures) in orde

Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the compressor oil level appears abnormal

Refrigeration Log A refrigeration log, such as the one shown in Figure 35, provides a convenient checklist for routine inspection and maintenance and

Pumpout and Refrigerant Transfer ProceduresPreparationThe 19XL may come equipped with an optional storage tank or pumpout system, or a pumpout compres

To Read Refrigerant Pressures during pumpout or leak testing: 1.The LID display on the machine control center is suitable for determining refrigerant-

Transfer Refrigerant from Storage Tank to Machine 1.Equalize refrigerant pressure.a.Use the Control Test Terminate Lockout to turn on water pumps and

e. Open valve 5 fully after the pressure rises above the freeze point of the refrigerant. Open liquid line valve 7 until refrigerant pressure equalize

g. Open valves 2 and 5.h. Turn on pumpout condenser water. i. Run the pumpout compressor until the storage tank pressure reaches 5 psig (34 kPa) (18 i

Transfer the Refrigerant from Machine to Storage Tank 1.Equalize refrigerant pressure. a.Valve positions:b.Slowly open valve 5 and liquid line valve 7

ContentsPrepare the Machine for Start-UpTo Start the MachineCheck the Running SystemTo Stop the Machine After Limited Shutdown Extended ShutdownAfter

b. Run the pumpout compressor for 30 minutes then close valve 7. c. Turn off the pumpout compressor.3. Remove any remaining refrigerant. a. Turn on wa

(448 kPa) for HCFC-22, 30 psig (207 kPa) for HFC-134a, and then turn off the compressor. Repeat this process until the pressure no longer rises, then

Machines with Isolation Valves Transfer All Refrigerant to Condenser Vessel 1.Push refrigerant into condenser. a.Valve positions:b.Turn off machine wa

2. Evacuate gas from cooler/compressor vessel. a. Close pumpout valves 2 and 5, and open valves 3 and 4.b. Turn on pumpout condenser water. c. Run pum

Transfer All Refrigerant to Cooler/Compressor Vessel 1.Push refrigerant into the cooler vessel. a.Valve positions:b.Turn off machine water pumps and p

c. Turn on pumpout condenser water. d. Run the pumpout until the compressor reaches 18 in. Hg vac (40 kPa abs.). Monitor pressure at the LID and refri

Return Refrigerant to Normal Operating Conditions 1.Be sure that the vessel that was opened has been evacuated. 2.Access the Control Test Terminate Lo

8. Close valves 1a, 1b, 3, and 5. 9. Open isolation valves 12, 13, and 14 (if present).10. Proceed to Terminate Pumpdown Lockout test to turn off wate

General Maintenance Refrigerant Properties HCFC-22 or HFC-134a is the standard refrigerant in the 19XL. At normal atmospheric pressure, HCFC-22 will b

Adding Refrigerant Follow the procedures described in Trimming Refrigerant Charge section.Removing Refrigerant If the optional pumpout system is used,

DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the late

ContentsMachines with Storage Tanks Transfer Refrigerant from Storage Tank to Machine Transfer the Refrigerant from Machine to Storage Tank Machines w

Refrigerant Leak TestingBecause HCFC-22 and HFC-134a are above atmospheric pressure at room temperature, leak testing can be performed with refrigeran

Refrigerant Tracer Use an environmentally acceptable refrigerant as a tracer for leak test procedures.To Pressurize with Dry NitrogenAnother method of

5. Close the charging valve on the machine. Remove the copper tube if no longer required.Repair the Leak, Retest, and Apply Standing Vacuum TestAfter

Checking the Auxiliary Switch on Guide Vane ActuatorThe auxiliary switch used to activate the oil reclaim system solenoids should move to the OPEN pos

Weekly MaintenanceCheck the Lubrication System Mark the oil level on the reservoir sight glass, and observe the level each week while the machine is s

Scheduled Maintenance Establish a regular maintenance schedule based on the actual machine requirements such as machine load, run hours, and water qua

Check Safety and Operating Controls Monthly To ensure machine protection, the Control Test Automated Test should be done at least once per month. See

6. Once all oil has been drained, place some rags or absorbent material under the oil filter housing to catch any drips once the filter is opened. Rem

Oil Specification If oil is to be added, it must meet the following Carrier specifications: • Oil type for HCFC-22 Machines only... Alkyl-benzene-base

4. When the machine pressure is 5 psi (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Figure 2A or Figure 2B). Slowly ope

ContentsTest After Service, Repair, or Major Leak Refrigerant Tracer To Pressurize with Dry Nitrogen Repair the Leak, Retest, and Apply Standing Vacuu

Oil Reclaim FiltersThe oil reclaim system has a strainer on the eductor suction line and a filter on the cooler scavaging line. Replace these filters

As a minimum, the following maintenance is required. 1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the

symptom appears, contact an experienced and responsible service organization for assistance.Inspect the Heat Exchanger Tubes CoolerInspect and clean t

leaving condenser water temperature. If this reading is more than what the design difference is supposed to be, then the condenser tubes may be dirty,

Water Treatment Untreated or improperly treated water may result in corrosion, scaling, erosion, or algae. The services of a qualified water treatment

Inspect the Starting Equipment Before working on any starter, shut off the machine, and open all disconnects supplying power to the starter.Inspect st

Check Pressure Transducers Once a year, the pressure transducers should be checked against a pressure gage reading. Check all three transducers: oil p

Optional Pumpout Compressor Oil Charge Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follow

Optional Pumpout Safety Control Settings (Figure 40) The optional pumpout system high-pressure switch should open at 220 ± 5 psig (1517 ± 34 kPa) and

Troubleshooting GuideOverview The PIC has many features to aid the operator and the technician in troubleshooting a 19XL machine. • By using the LID d

ContentsOil ChangesTo Change the Oil Refrigerant Filter Oil Reclaim Filters Inspect Refrigerant Float SystemInspect Relief Valves and Piping Compresso

Checking the Display MessagesThe first area to check when troubleshooting the 19XL is the LID display. If the alarm light is flashing, check the prima

a digital ohmmeter. The resistance and corresponding temperature is listed in Table 11A or Table 11B. Check the resistance of both wires to ground. Th

See Figure 8 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconn

faulty, check the supply voltage. It should be 5 vdc ± .5 v. If the supply voltage is correct, the transducer should be recalibrated or replaced.Calib

If the transducer value is not within the calibration range, the transducer will return to the original reading. If the LID pressure value is within t

The PIC will not allow calibration if the transducer is too far out of calibration. A new transducer must be installed and recalibrated.Transducer Rep

Control Algorithms Checkout ProcedureIn the LID Service menu, one of the tables is Control Algorithm Status. This table contains 4 maintenance tables

Control Test The Control Test feature can check all of the thermistor temperature sensors, including those on the Options modules, pressure transducer

Click here for Table 10C — In Recycle ShutdownClick here for Table 10D — Pre-Start AlertsClick here for Table 10E — Normal or Auto.-RestartClick here

Click here for Table 10I — Normal Run Overrides Active (Alerts)Click here for Table 10J — Out-of-Range Sensor FailuresClick here for Table 10K — Machi

ContentsOptional Pumpout System MaintenanceOptional Pumpout Compressor Oil ChargeOptional Pumpout Safety Control SettingsOrdering Replacement Chiller

Control ModulesThe Processor module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), and the Local Interface Device (LID) module pe

Red Led If the LED is blinking continuously at a 2-second rate, it is indicating proper operation. If it is lit continuously it indicates a problem re

PSIO Module Green LED closest to communications connection — Communication with SMM and 8-input module; must blink continuously.Other Green LED — Comm

Notes on Module Operation 1.The machine operator monitors and modifies configurations in the microprocessor through the 4 softkeys and the LID. Commun

If all modules indicate communications failure, check communications plug on the PSIO module for proper seating. Also check the wiring (CCN bus — 1:re

Processor Module (PSIO) (Figure 43) Inputs Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines whi

Starter Management Module (SMM) (Figure 44)Inputs Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. Application of the mach

Options Modules (8-Input) The options modules are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, an

Terminal block connections are provided on the options modules. All sensor inputs are field wired and installed. Options module number 1 can be factor

Installation1.Verify if the existing PSIO module is defective, by using the procedure described in the Troubleshooting Guide section, and Control Modu

ContentsControl TestControl Modules Red LEDGreen LEDs Notes on Module Operation Processor Module (PSIO) InputsOutputs Starter Management Module (SMM)

6. Mount the new module in the unit control box using a long-shaft Phillips screwdriver and the screw saved in Step 4 above. Make sure that the green

14. Restore chiller to normal operation, calibrate motor amps.Solid-State StartersTroubleshooting guides and information pertaining to the operation o

1. Connect ohmmeter across terminals L1 and T1. Resistance reading should be greater than 50,000 ohms. 2. If reading is less than 50,000 ohms, remove

If problem is still not resolved, consult the starter manufacturer for servicing.Testing Silicon Control Rectifiers (SCRs) in Cutler-Hammer® Solid-Sta

4. Connect the T1, T2, and T3 terminals on the starter to the motor. 5. Disconnect one of the wires to the shunt trip contact on the starter. This wir

If one of the voltages is higher than 2 v, but the voltages of the 3 power poles are approximately equal, the starter is probably still in current lim

System Ready (SYST RDY) — This light-emitting diode (LED) provides a visual indication that the EPR is functioning. Trip Time Potentiometer — The Trip

light and the fault indicator (FLT) is a flashing red light, the a motor overload trip is approaching. When the FLT LED is a solid red light and the S

Physical DataTable 14, Table 15, Table 16, Table 17, Table 18, Table 19, Figure 53, Figure 54, Figure 55, Figure 56, Figure 57, and Figure 58 provide

Click here for Table 17 — Compressor/Motor WeightsClick here for Table 18 — Waterbox Cover WeightsClick here for Table 19 — Optional Pumpout System El

ContentsSolid-State StartersTesting Silicon Control Rectifiers in Benshaw, Inc. Solid-State StartersTesting Silicon Control Rectifiers (SCRs) in Cutle

Click here for Figure 56 — Electronic PIC Controls Wiring SchematicClick here for Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring

*See Figure 5, Figure 6, Figure 8, Figure 9, Figure 10, Figure 11, and Figure 12.Table 1 — Major PIC Components and Panel Locations*Pic Component Pan

Table 2 — LID ScreensNotes:1.Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or t

Note: All values are variables available for read operation to a CCN. Descriptions shown with (*) support write operations for BEST programming langua

Example 2 — Status02 Display ScreenTo access this display from the LID default screen:1. Press MENU.2. Press STATUS.3. Scroll down to highlight STATUS

Example 3 — Status03 Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press STATUS.3. Scroll down to highlight STATU

Example 4 — Setpoint Display ScreenTo access this display from the LID default screen:1. Press MENU.2. Press SETPOINT.Table 2, Example 4 — Setpoint Di

Example 5 — Configuration (Config) Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to

Example 6 — Lead/Lag Configuration Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to

Example 7 — Service1 Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to highlight EQUI

ContentsList of TablesTable 1 — Major PIC Components and Panel LocationsTable 2 — LID ScreensExample 1 — Status01 Display ScreenExample 2 — Status02 D

Note:1. Condenser Freeze Point and Softstop Amps Threshold are only selectable/readable on PSIO Software Versions 09 and higher. 2. Values in [ ] indi

Example 8 — Service2 Display ScreenTo access this display from the LID default screen:1. Press MENU.2. Press SERVICE.3. Scroll down to highlight EQUIP

Note: This screen provides the means to generate alert messages based on exceeding the ‘‘Temp Alert’’ threshold for each point listed. If the ‘‘Enable

Example 9 — Service3 Display ScreenTo access this display from the LID default screen:1. Press MENU.2. Press SERVICE.3. Scroll down to highlight EQUIP

Example 10 — Maintenance (Maint01) Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to

Example 11 — Maintenance (Maint02) Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to

Example 12 — Maintenance (Maint03) Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to

Example 13 — Maintenance (Maint04) Display ScreenTo access this display from the LID default screen: 1. Press MENU.2. Press SERVICE.3. Scroll down to

Table 3 — Protective Safety Limits and Control Settings Monitored Parameter Limit Applicable CommentsTemperature Sensors Out Of Range –40 to 245 F (–

Flow Switches (Field Supplied) Operate water pumps with machine off. Manually reduce water flow and observe switch for proper cutout. Safety shutdown

ContentsTable 3 —Protective Safety Limits and Control SettingsTable 4 — Capacity OverridesTable 5A — HCFC-22 Pressure — Temperature (F)Table 5B — HCFC

Table 4 — Capacity Overrides Override Capacity ControlFirst Stage SetpointSecond Stage SetpointOverride TerminationView/Modify on LID ScreenDefault V

Motor Load — Active Demand Limit Status01100% 40 to 100% >5% of Set Point2% Lower Than Set PointTable 4 — Capacity Overrides (Continued)Overri

* Inches of mercury below one atmosphere.Table 5A — HCFC-22 Pressure – Temperature (F) Temper-ature (F)Pressure (psi)Temper-ature (F)Pressur

Table 5B — HCFC-22 Pressure – Temperature (C) Temper-ature (C)Pressure (kPa)Temper-ature (C)Pressure (kPa)Temper-ature (C)Pressure (kPa)Absolute Gage

Table 5C — HFC-134a Pressure – Temperature (F) Temperature, F Pressure (psig)024686.507.528.609.6610.79101214161811.9613.1714.4215.7217.0620222426281

707274767871.1874.1477.1880.3083.49808284868886.1790.1393.5797.09100.709092949698104.40108.18112.06116.02120.08100102104106108124.23128.47132.81137.25

Table 5D — HFC-134a Pressure – Temperature (C) Temperature, C Pressure Gage (kPa)-18.0-16.7-15.6-14.4-13.344.851.959.366.674.4-12.2-11.1-10.0-8.9-7.8

15.616.717.818.920.0396.0414.0433.0451.0471.021.122.223.324.425.6491.0511.0532.0554.0576.026.727.828.930.031.1598.0621.0645.0669.0694.032.233.334.435.

CCW — Counterclockwise CW — ClockwiseTable 6 — Potentiometer Adjustment DialAdjustment Range Function Factory SettingMinimum (CCW)Maximum (CW)Starting

Table 7 — Amps Correction Factors for 19XL Motors Volt/ Hz Motor CodeCD CE CL CM CN CP CQ CR200/60208/60220/60230/60352468243423223534122212221222122

ContentsTable 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messages with Troubleshooting Guides (Continued)D. Pre-Start AlertsE. Nor

Table 8 — Control Test Menu Functions Tests To Be Performed Devices Tested1. Automated Tests*2. PSIO Thermistors3. Options Thermistors4. Transducers5

* During any of the tests that are not automated, an out-of-range reading will have an asterisk (*) next to the reading and a message will be displaye

Notes:1. The size of the cooler determines refrigerant charge for the entire machine.2. Design I machines have float chambers.3. Design II machines ha

Legend For Table 10, A - N1CR AUX — Compressor Start Contact OILPD — Oil PressureCA P — Compressor Current OILT — Oil Sump TemperatureCDFL — Cond

Table 10B — Timing Out or Timed Out Primary Message Secondary Message Probable Cause/RemedyReady To Start In XX Min Unoccupied Mode Time schedule

Table 10C — In Recycle Shutdown Primary Message Secondary Message Probable Cause/RemedyRecycle Restart PendingOccupied Mode Unit in recycle mode

* [LIMIT] is shown on the LID as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert.Table 10D — P

Table 10E — Normal or Auto.-RestartPrimary Message Secondary Message Probable Cause/RemedyStartup in ProgressOccupied Mode Machine starting. Time sc

Table 10F — Start-Up Failures: This is an alarm condition. A manual reset is required to clear. Primary Message Secondary Message Alarm Message/Prima

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

ContentsTable 13 — Cutler-Hammer® Solid-State Starter Troubleshooting GuideTable 14 — Heat Exchanger DataTable 15 — Additional Data for Marine Waterbo

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

Table 10H — Normal Run with Reset, Temperature, or Demand Primary Message Secondary Message Probable Cause/RemedyRunning — Reset Active4-20MA Signa

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

Table 10J — Out-of-Range Sensor Failures Primary Message Secondary Message Alarm Message/Primary CauseAdditional Cause/RemedySensor FaultLeaving CHW

Table 10K — Machine Protect Limit Faults Primary Message Secondary MessageAlarm Message/Primary CauseAdditional Cause/RemedyProtective LimitHigh Disc

Protective LimitPower Loss V P Power Loss: Check voltage supply.Check 24-vdc input sensor on the SMM; adjust potentiometer if necessary. Check trans

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

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

Table 10M — Spare Sensor Alert Messages Primary Message Secondary Message Alarm Message/Primary CauseAdditional Cause/RemedySpare Sensor Alert Common

Table 10N — Other Problems/Malfunctions Description/MalfunctionProbable Cause/RemedyChilled Water/Brine Temperature Too High (Machine Running)Chilled

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

ContentsList of FiguresFigure 1 — 19XL IdentificationFigure 2A— Typical 19XL Components — Design IFigure 2B— Typical 19XL Components — Design IIFigure

SMM Communications FailureCheck that PSIO communication plugs are connected correctly. Check SMM com-munication plug. Check for proper SMM power suppl

Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop Temperature (F)VoltageDrop (V)Resistance(Ohms)Temperature(F)VoltageDrop (V)Resistanc

1161171181191201211221231241251261271281291301311321331341351361371381391401411421431441451461471481491501511521531541551561571581591.8221.7921.7711.7

Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop Temperature (C)Voltage Drop (V)Resistance (Ohms)Temperature (C)Voltage Drop (V)Resis

52535455565758596061626364656667686970717273747576777879808182831.5941.5531.5131.4741.4361.3991.3631.3271.2911.2581.2251.1921.1601.1291.0991.0691.0401

Table 12 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide Problem Probable Causes Area of CorrectionAK board phase cor-rect not on.1.L1 and L

LegendLED — Light-Emitting Diode SCR — Silicon Control Rectifier SMM — Starter Management ModuleAK board power applied, run command given, starter at

Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide Problem Probable Cause Area of CorrectionCB trips (electrically operated disconnec

Motor accelerates too quickly. Current limit is too high. Decrease current limit setting counter-clockwise.Improper current feedback. Check current c

LegendCCW — Counter Clockwise CFR — Current Feedback Resistor STR — Shunt Trip RelayOverload relay trips when starting.Incorrect heater coils (melt

ContentsFigure 13 — LID Default ScreenFigure 14 — LID Service ScreenFigure 15 — Example of Point Status Screen (Status01)Figure 16 — 19XL Menu Structu

Table 14 — Heat Exchanger Data VesselHeat ExchangerCodeNumberof TubesRigging Weights Vessel ChargeDry Wt. RefrigerantVolume of WaterDesign I Design I

* Add to heat exchanger weights and volumes for total weight or volume.Table 15 — Additional Data for Marine Waterboxes*Heat ExchangerFrame, PassEngli

Table 16 — Compressor Weights ComponentWeightLb KgSuction Elbow1155 1125Discharge Elbow1150 1123Transmission1730 1331Suction Housing1350 1159Impeller

Note: For medium voltage motors add 85 lbs (39 kg) to above for 60 Hz motors and 145 lbs (66 kg) for 50 Hz motors. Total compressor/motor weight is th

LegendNIH — Nozzle-in-Head MWB — Marine Waterbox CS — Contact Syracuse * These weights are for reference only.Note: The 150 psig (1034 kPa) standa

LegendNIH — Nozzle-in-Head MWB — Marine Waterbox CS — Contact Syracuse * These weights are for reference only.Note:The 150 psig (1034 kPa) standard

Legend LRA — Locked Rotor Amps RLA — Rated Load AmpsTable 19 — Optional Pumpout System Electrical Data Motor Code Condenser Unit Volts-PH-HZ Max RLA L

Figure 1 — 19XL Identification

Figure 2A (Front View) — Typical 19XL Components — Design I (See next page for Rear View)

Figure 2A (Rear View) — Typical 19XL Components — Design I

ContentsFigure 27 — Typical Optional Pumpout System Piping Schematic with Storage TankFigure 28 — Typical Optional Pumpout System Piping Schematic wit

Figure 2B (Front View) — Typical 19XL Components — Design II (See next page for Rear View)

Figure 2B (Rear View) — Typical 19XL Components — Design II

Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles

Figure 4 — Lubrication System

Figure 5 — Cutler-Hammer Solid-State Starter, Internal View

Figure 6 — Benshaw, Inc. Solid-State Starter, Internal View

Figure 7 — Typical Starter Front View (Solid-State Starter Shown)

Figure 8 — 19XL Controls and Sensor Locations

Figure 9 — Control Sensors (Temperature)

Figure 10 — Control Sensors (Pressure Transducer, Typical)

ContentsFigure 40 — Optional Pumpout System ControlsFigure 41 — PSIO Module Address Selector Switch Locations and LED LocationsFigure 42 — LID Module

Figure 11 — Control Panel (Front View), with Options Module

Figure 12 — Power Panel with Options

Figure 13 — LID Default Screen

Figure 14 — LID Service Screen

Figure 15 — Example of Point Status Screen (Status01)

Figure 16 — 19XL Menu Structure

Figure 17 — 19XL Service Menu Structure

Figure 18 — Example of Time Schedule Operation Screen

Figure 19 — Example of Set Point Screen

Figure 20 — 19XL Hot Gas Bypass/Surge Prevention

ContentsFigure 52 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical)Figure 53 — Compressor Fits and Clearance

Figure 21 — 19XL with Default Metric Settings

Figure 22 — Example of Attach to Network Device Screen

Figure 23 — Example of Holiday Period Screen

A — START INITIATED — Prestart checks made; evaporator pump startedB — Condenser water pump started (5 seconds after A)C — Water flows verified (30 se

Figure 25 — Typical Wet-Bulb Type Vacuum Indicator

Figure 26 — 19XL Leak Test Procedures

Figure 27 — Typical Optional Pumpout System Piping Schematic with Storage Tank

Figure 28 — Typical Optional Pumpout System Piping Schematic without Storage Tank

Figure 29 — Dehydration Cold Trap

Figure 30 — Benshaw, Inc. Solid-State Starter Power Stack

IntroductionPrior to initial start-up of the 19XL unit, those involved in the start-up, operation, and maintenance should be thoroughly familiar with

Figure 31 — Ramp Up and Starting Torque Potentiometers

Figure 32 — Typical Potentiometer Adjustment

Figure 33 — Typical Cutler-Hammer® Solid-State Starter

Figure 34 — Correct Motor Rotation

Date _______________REFRIGERATION LOG CARRIER 19XL HERMETIC CENTRIFUGAL REFRIGERATION MACHINEPlant ______________ MACHINE MODEL NO. ______________ MAC

Figure 36 — 19XL Pumpout Unit Wiring SchematicCompressor TerminalContactor TerminalOverload TerminalPumpout Unit TerminalC — ContactorFu — Fuse, 3 Amp

Figure 37 — Optional Pumpout System

Figure 38 — Guide Vane Actuator Linkage

Figure 39 — 19XL Float Valve Designs

Figure 40 — Optional Pumpout System Controls

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

Figure 41 — PSIO Module Address Selector Switch Locations and LED Locations

Figure 42 — LID Module (Rear View) and LED Locations

Figure 43 — Processor (PSIO) Module

Figure 44 — Starter Management Module (SSM)

Switch Setting Option Module 1 Option Module 2S1S26472Figure 45 — Options Module

Figure 46 — Typical Benshaw, Inc. Solid-State Starter (Internal View)

Figure 47 — Resistance Check

Figure 48 — SCR and Power Poles

Figure 49 — Typical Cutler-Hammer® Solid-State Starter (Internal View)

Figure 50 — Cutler-Hammer® Terminal Functions

Abbreviations and Explanations The 19XL machines use HCFC-22 and HFC-134a refrigerant. When referencing refrigerant charges in this manual, the HCFC-2

Figure 51 — Solid-State Starter, General Operation Troubleshooting Guide (Typical)

Figure 52 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical)

Compressor Assembly TorquesItem DescriptionTorqueft-lb N•m1*23456*7*Oil Heater Grommet NutImpeller Retaining BoltBull Gear Retaining BoltMotor Termina

Figure 54 — Compressor Fits and Clearances (Continued)

Figure 55 — Compressor Fits and Clearances (Continued)

Figure 56 — Electronic PIC Controls Wiring Schematic (page 1 of 2)LegendCarrier Factory WiringOptional (Factory orField-Installed) Wiring

LegendCarrier Factory WiringOptional (Factory orField-Installed) WiringFigure 56 — Electronic PIC Controls Wiring Schematic (page 2 of 2)

LegendStarter Cabinet WiringField WiringCarrier Factory WiringFigure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic (page 1 of

LegendStarter Cabinet WiringField WiringCarrier Factory WiringFigure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic (page 2 of

Optional features are indicatedby bold dotted boxes.Caution: Yellow wires remainenergized when maindisconnect is off.= Dry ContactFigure 58 — Typical

Machine Familiarization (Figure 1, Figure 2A (Front View) (Rear View), and Figure 2B (Front View) (Rear View) Machine Information Plate The informatio

Figure 58 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic (page 2 of 2)Optional features are indicated by bold dotted boxes.Caution: Yellow

INITIAL START-UP CHECKLIST FOR19XL HERMETIC CENTRIFUGAL LIQUID CHILLER(Remove and use for job file.)MACHINE INFORMATION:NAME JOB NO.ADDRESS MODELCITY S

INSPECT WIRING AND RECORD ELECTRICAL DATA:RATINGS:Motor VoltageMotor(s) Amps Oil Pump Voltage Starter AmpsLine Voltages: Motor Oil Pump Controls/Oil H

19XLHERMETIC CENTRIFUGAL LIQUID CHILLERCONFIGURATION SETTINGS LOG(Remove and use for job file.)19XL SET POINT TABLE CONFIGURATION SHEETDESCRIPTION RANG

19XL PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC01SDay Flag Occupied UnoccupiedMTWTFSSH Time TimePeriod 1:Period 2:Period 3:Period 4:Period 5:Period 6

19XL PIC CONFIG TABLE CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUERESET TYPE 1Degrees Reset at 20 mA–30 to 30(–17 to 17)DEG F(DEG C)10(6)R

19XL PIC LEAD/LAG TABLE CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUELEAD/LAG SELECTDISABLE =0, LEAD =1,LAG =2, STANDBY =30, 1, 2, 3 0Load

19XL PIC SERVICE1 TABLE CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUEMotor Temp Override150 to 200(66 to 93)DEG F(DEG C)200(93)Cond Pressur

19XL PIC SERVICE1 TABLE CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUEMotor Rated Load Amps 1 to 9999 AMPS 200Motor Rated Line Voltage 1 to

19XL PIC SERVICE2 TABLE CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUERESET 20 mA Power Source 0/1 0 =EXTERNAL, 1 =INTERNAL 0DEMAND 20 mA Po

flowing through its internal tubes in order to remove heat from the refrigerant.Motor-CompressorThis component maintains system temperature/pressure d

19XL PIC SERVICE3 TABLE CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUEProportional Inc Band 2to10 6.5Proportional Dec Band 2to10 6.0Proporti

HOLIDAY (HOLIDEF) CONFIGURATION SHEET HOLIDEF SDESCRIPTION RANGE UNITS VALUEHoliday Start Month 1to12Start Day 1to31Duration 0to99 DAYSHOLIDAY (HOLIDE

BROADCAST (BRODEFS) CONFIGURATION SHEETDESCRIPTION RANGE UNITS DEFAULT VALUEActivate Yes/No NoOAT BroadcastController Name 8 characters TextBus Number

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining

also is supplied with each unit. Note: If a storage vessel is not used at the jobsite, factory-installed isolation valves on the chiller may be used t

(Figure 3). Since the FLASC chamber is at a lower pressure, part of the liquid refrigerant flashes to vapor, thereby cooling the remaining liquid. The

in the motor shell than in the cooler/oil sump. The motor is protected by a temperature sensor imbedded in the stator windings. Higher motor temperatu

Lubrication Cycle SummaryThe oil pump, oil filter, and oil cooler make up a package located partially in the transmission casting of the compressor-mo

The oil pump suction is fed from the oil reservoir. An oil pressure relief valve maintains 18 to 25 psid (124 to 172 kPad) differential pressure in th

of post-lubrication. The oil pump can also be energized for testing purposes in the Control Test. Ramp loading can slow the rate of guide vane opening

discharge gas pressure to power an eductor, the oil is vacuumed from the housing by the eductor and is discharged into the oil reservoir. Oil and refr

Starting Equipment The 19XL requires a motor starter to operate the centrifugal hermetic compressor motor, the oil pump, and various auxiliary equipme

Circuit breaker CB2 supplies power to the control center, oil heater, and portions of the starter controls. Circuit breaker CB3 supplies power to oil

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

CAUTIONCAUTION!DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury. DO NOT climb over a mac

• current unbalance• run state These LEDs are further explained in the Check Starter and Troubleshooting Guide sections.Unit-Mounted Wye-Delta Starter

ControlsDefinitions Analog SignalAn analog signal varies in proportion to the monitored source. It quantifies values between operating limits. (Exampl

GeneralThe 19XL hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the ma

also regulates the oil heater while the compressor is off, and the hot gas bypass valve, if installed. The PIC can be interfaced with the Carrier Comf

to control the machine. The 19XL uses 3 pressure transducers and 8 thermistors to sense pressures and temperatures. These are connected to the PSIO mo

6-Pack Relay BoardThis device is a cluster of 6 pilot relays located in the control center. It is energized by the PSIO for the oil pump, oil heater,

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 energi

Control and Oil Heater Voltage Selector (S1)It is possible to use either 115 v or 230 v incoming control power in the power panel. The switch is set t

mode, and the control will accept modifications from any CCN interface or module (with the proper authority), as well as the LID. The PIC will use the

Menu StructureTo perform any of the operations described below, the PIC must be powered up and have successfully completed its self test.• Press QUIT

CAUTIONCAUTION!PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage. PROVIDE A DRAIN connection in the vent lin

• Press NEXT to scroll the cursor bar down in order to highlight a point or to view more points below the current screen.• Press PREVIOUS to scroll th

• Press EXIT to return to the previous screen level.• Press INCREASE or DECREASE to change the highlighted point value.To View Point Status (Figure 15

2. Press NEXT or PREVIOUS to highlight the desired status table. The list of tables is:• Status01 — Status of control points and sensors• Status02 — S

Override Operations To Override a Value or Status1.On the Point Status table press NEXT or PREVIOUS to highlight the desired point.2.Press SELECT to s

For Discrete Points — Press START or STOP to select the desired state.For Analog Points — Press INCREASE or DECREASE to select the desired value.3. Pr

few seconds in order to see a value change, especially on kilopascal values.To Remove an Override1. On the Point Status table press NEXT or PREVIOUS t

Time Schedule Operation (Figure 18)1.On the Menu screen, press SCHEDULE.2.Press NEXT or PREVIOUS to highlight the desired schedule.PSIO Software Versi

3. Press SELECT to access and view the time schedule.4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change.5.

6.a. Press INCREASE or DECREASE to change the time values. Override values are in one-hour increments, up to 4 hours.b. Press ENABLE to select days in

8. Press EXIT to leave the period or override.9. Either return to Step 4 to select another period or override, or press EXIT again to leave the curren

ContentsList of TablesList of FiguresSafety Considerations IntroductionAbbreviations and ExplanationsMachine Familiarization Machine Information Plate

To View and Change Set Points (Figure 19)1.To view the Set Point table, at the Menu screen press SETPOINT.2.There are 4 set points on this screen: Bas

4. Press SELECT to modify the highlighted set point.5. Press INCREASE or DECREASE to change the selected set point value.6. Press ENTER to save the ch

Service OperationTo view the menu-driven programs available for Service Operation, see Service Operation section. For examples of LID display screens,

Table 2 — LID Screens (Continued)Click on an example to view:Example 6 — Lead/Lag Configuration Display ScreenExample 7 — Service1 Display ScreenExamp

PIC System Functions Note:Throughout this manual, words printed in capital letters and italics are values that may be viewed on the LID. See Table 2 f

DeadbandThis is the tolerance on the chilled water/ brine temperature CONTROL POINT. If the water temperature goes outside of the DEADBAND, the PIC op

vane response to chilled water temperature below deadband plus control point. It can be adjusted on the LID from a setting of 2 to 10, and the default

register up to 32,767 hours before it rolls over to zero. The chiller also maintains a start-to-start timer and a stop-to-start timer. These timers li

midnight to 3:00 a.m. weekend cool-down schedule. Note: This schedule is for illustration only, and is not intended to be a recommended schedule for c

Safety ControlsThe PIC monitors all safety control inputs, and if required, shuts down the machine or limits the guide vanes to protect the machine fr

ContentsRefrigeration Cycle Motor/Oil Refrigeration Cooling Cycle Lubrication Cycle SummaryDetailsOil Reclaim System During Normal Machine OperationDu

If the controller initiates a safety shutdown, it displays the fault on the LID display with a primary and a secondary message, and energizes an alarm

Shunt TripThe shunt trip function of the PIC is a safety trip. The shunt trip is wired from an output on the SMM to the motor circuit breaker. If the

Ramp Loading Control The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loadi

Capacity Override (Table 4)These can prevent some safety shutdowns caused by exceeding motor amperage limit, refrigerant low temperature safety limit,

High Discharge Temperature ControlIf the discharge temperature increases above 160 F (71.1 C) (PSIO Software Version 09 and higher) or 180 F (82 C) (P

PSIO Software Version 09 and Higher The oil heater relay is energized whenever the chiller compressor is off and the oil sump temperature is less than

regulates refrigerant flow to control oil temperature entering the bearings. There is always a flow of refrigerant bypassing the thermal expansion val

spare protective limits input channel in place of the factory-installed jumper. (Wire multiple inputs in series.) The opening of any contact will resu

Condenser Freeze PreventionThis control algorithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. If the pump is contro

relay can only accomplish this if the relay has been added to the cooling tower temperature controller. The TOWER FAN RELAY is turned on whenever the

ContentsDigital SignalVolatile Memory GeneralPIC System ComponentsProcessor Module (PSIO)Starter Management Module (SMM)Local Interface Device (LID)6-

Auto. Restart After Power Failure This option may be enabled or disabled, and may be viewed/modified in the Config table of Equipment Configuration. I

To activate a reset type, input all configuration information for that reset type in the Config table. Then input the reset type number in the SELECT/

Reset Type 2 can now be activated. 3. Reset Type 3 — Automatic chilled water temperature reset based on cooler temperature difference. This type of re

Demand Limit Control, Option — (Requires Optional 8-Input Module)The demand limit may be externally controlled with a 4 to 20 mA signal from an energy

Points, (T1/P1;T2/P2). These points have default settings for each type of refrigerant, HCFC-22 or HFC-134a, as defined on the Service1 table, or on T

Surge Protection Surging of the compressor can be determined by the PIC through operator configured settings. Surge will cause amperage fluctuations o

Lead/Lag Control Note:Lead/lag control is only available on machines with PSIO Software Version 09 or higher.Lead/lag is a control system process that

Operation Features:• 2 chiller lead/lag• addition of a third chiller for backup • manual rotation of lead chiller • load balancing if configured• stag

chilled water sensor should be installed. If this sensor is not installed, the return chilled water sensor of the downstream chiller must be relocated

Lead/Lag Chiller Configuration and OperationThe configured lead chiller is identified when the LEAD/LAG SELECT value for that chiller is configured to