Page 1: Safety Considerations
Be sure you understand and follow the procedures and safety precautions contained in the machine instructions as well as those listed in this guide. Hermetic Centrifugal Liquid Chillers with HCFC–22 and HFC–134a Form 19XL-3SS Copyright © Carrier Corporation 1994 Safety Considerations 19XL 50/60 Hz Replaces: 19XL-2SS...
Page 2 DANGER DANGER DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
Page 3 WARNING WARNING 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 dis- placed with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.
Page 4 WARNING WARNING 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 machine. The introduction of the wrong refrigerant can cause machine damage or malfunction to this machine.
Page 5 CAUTION CAUTION DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury. DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders. USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components.
Page 6 CAUTION CAUTION PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, 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.
Page 7: Table Of Contents
List of Tables List of Figures Safety Considerations Introduction Abbreviations and Explanations Machine Familiarization Machine Information Plate System Components Cooler Condenser Motor-Compressor Control Center Factory-Mounted Starter (Optional) Storage Vessel (Optional) Contents...
Page 8 Refrigeration Cycle Motor/Oil Refrigeration Cooling Cycle Lubrication Cycle Summary Details Oil Reclaim System During Normal Machine Operation During Light Load Conditions Starting Equipment Unit Mounted Solid-State Starter (Optional) Unit Mounted Wye-Delta Starter (Optional) Controls Definitions Analog Signal Contents...
Page 9 Digital Signal Volatile Memory General PIC System Components Processor Module (PSIO) Starter Management Module (SMM) Local Interface Device (LID) 6-Pack Relay Board 8-Input Modules Oil Heater Contactor (1C) Oil Pump Contactor (2C) Hot Gas Bypass Contactor Relay (3C) (Optional) Control Transformers (T1-T4) Control and Oil Heater Voltage Selector (S1) LID Operation and Menus General...
Page 10 Menu Structure To View Point Status Override Operations Time Schedule Operation To View and Change Set Points Service Operation PIC System Functions Capacity Control Entering Chilled Water Control Deadband Proportional Bands and Gain Demand Limiting Machine Timers Occupancy Schedule Safety Controls Shunt Trip Contents...
Page 11 Default Screen Freeze Motor Cooling Control Ramp Loading Control Capacity Override High Discharge Temperature Control Oil Sump Temperature Control PSIO Software Versions 08 and Lower PSIO Software Versions 09 and Higher Oil Cooler Remote Start/Stop Controls Spare Safety Inputs Spare Alarm Contacts Condenser Pump Control Condenser Freeze Protection Contents...
Page 12 Tower Fan Relay Auto. Restart After Power Failure Water/Brine Reset Demand Limit Control, Option (Requires Optional 8-Input Module) Surge Prevention Algorithm Surge Protection Lead/Lag Control Common Point Sensor Installation Machine Communication Wiring Lead/Lag Operation Faulted Chiller Operation Load Balancing Auto Restart After Power Failure Ice Build Control Ice Build Initiation Contents...
Page 13 Start-Up/Recycle Operation Temperature Control During Ice Build Termination of Ice Build Return to Non-ice Build Operations Attach to Network Device Control Changing Refrigerant Types Attaching to Other CCN Modules Service Operation To Log On To Log Off Holiday Scheduling Start-Up/Shutdown/Recycle Sequence Local Start-Up Shutdown Sequence Automatic Soft-Stop Amps Threshold (PSIO Software Version 09 and...
Page 14 Contents Chilled Water Recycle Mode Safety Shutdown Before Initial Start-Up Job Data Required Equipment Required Using the Optional Storage Tank and Pumpout System Remove Shipping Packaging Open Oil Circuit Valves Torque All Gasketed Joints Check Machine Tightness Refrigerant Tracer Leak Test Machine Standing Vacuum Test...
Page 15 Machine Dehydration Inspect Water Piping Check Optional Pumpout Compressor Water Piping Check Relief Devices Inspect Wiring Carrier Comfort Network Interface Check Starter Mechanical-Type Starters Benshaw, Inc. Solid-State Starter Cutler-Hammer® Solid-State Starters Oil Charge Power Up the Controls and Check the Oil Heater...
Page 16 Input the Local Occupied Schedule (OCCPC01S) Selecting Refrigerant Type To Confirm Refrigerant Type To Change Refrigerant Type Input Service Configurations Password Input Time and Date Change LID Configuration If Necessary Modify Controller Identification If Necessary Input Equipment Service Parameters If Necessary Modify Equipment Configuration If Necessary Check Voltage Supply Perform an Automated Control Test...
Page 17 Charge Refrigerant into Machine 19XL Machine Equalization without Pumpout Unit 19XL Machine Equalization with Pumpout Unit Trimming Refrigerant Charge Initial Start-Up Preparation Manual Operation of the Guide Vanes Dry Run to Test Start-Up Sequence Check Rotation If Rotation Is Proper If the Motor Rotation Is Not Clockwise Notes on Solid-State Starters (Benshaw, Inc.) Check Oil Pressure and Compressor Stop...
Page 18: Motor-Compressor
Check Machine Operating Condition Instruct the Customer Operator Cooler-Condenser Optional Storage Tank and Pumpout System Motor Compressor Assembly Motor Compressor Lubrication System Control System Auxiliary Equipment Describe Machine Cycles Review Maintenance Safety Devices and Procedures Check Operator Knowledge Review the Start-Up, Operation, and Maintenance Manual Operating Instructions Operator Duties Contents...
Page 19 Contents Prepare the Machine for Start-Up To Start the Machine Check the Running System To Stop the Machine After Limited Shutdown Extended Shutdown After Extended Shutdown Cold Weather Operation Manual Guide Vane Operation Refrigeration Log Pumpout and Refrigerant Transfer Procedures Preparation Operating the Optional Pumpout Compressor To Read Refrigerant Pressures...
Page 20 Machines with Storage Tanks Transfer Refrigerant from Storage Tank to Machine Transfer the Refrigerant from Machine to Storage Tank Machines with Isolation Valves Transfer All Refrigerant to Condenser Vessel Transfer All Refrigerant to Cooler/Compressor Vessel Return Refrigerant to Normal Operating Conditions General Maintenance Refrigerant Properties Adding Refrigerant...
Page 21 Test After Service, Repair, or Major Leak Refrigerant Tracer To Pressurize with Dry Nitrogen Repair the Leak, Retest, and Apply Standing Vacuum Test Checking Guide Vane Linkage Checking the Auxiliary Switch on Guide Vane Actuator Trim Refrigerant Charge Weekly Maintenance Check the Lubrication System Scheduled Maintenance Service Ontime...
Page 22 Oil Changes To Change the Oil Refrigerant Filter Oil Reclaim Filters Inspect Refrigerant Float System Inspect Relief Valves and Piping Compressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes Cooler Condenser Water Leaks Water Treatment Inspect the Starting Equipment Check Pressure Transducers Contents...
Page 23 Optional Pumpout System Maintenance Optional Pumpout Compressor Oil Charge Optional Pumpout Safety Control Settings Ordering Replacement Chiller Parts Troubleshooting Guide Overview Checking the Display Messages Checking Temperature Sensors Resistance Check Voltage Drop Check Sensor Accuracy Dual Temperature Sensors Checking Pressure Transducers Transducer Replacement Control Algorithms Checkout Procedure Contents...
Page 24 Control Test Control Modules Red LED Green LEDs Notes on Module Operation Processor Module (PSIO) Inputs Outputs Starter Management Module (SMM) Inputs Outputs Options Modules (8-Input) Replacing Defective Processor Modules Installation Contents...
Page 25 Solid-State Starters Testing Silicon Control Rectifiers in Benshaw, Inc. Solid-State Starters Testing Silicon Control Rectifiers (SCRs) in Cutler-Hammer® Solid-State Starters Electronic Protection Relay (EPR) Physical Data Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller Contents...
Page 26 List of Tables Table 1 — Major PIC Components and Panel Locations Table 2 — LID Screens Example 1 — Status01 Display Screen Example 2 — Status02 Display Screen Example 3 — Status03 Display Screen Example 4 — Setpoint Display Screen Example 5 —...
Page 27 Table 3 — Protective Safety Limits and Control Settings Table 4 — Capacity Overrides Table 5A — HCFC-22 Pressure — Temperature (F) Table 5B — HCFC-22 Pressure — Temperature (C) Table 5C — HFC-134a Pressure Table 5D — HFC-134a Pressure Table 6 —...
Page 28 Table 10 — LID Primary and Secondary Messages and Custom Alarm/ Alert Messages with Troubleshooting Guides (Continued) D. Pre-Start Alerts E. Normal or Auto.-Restart F. Start-Up Failures G. Compressor Jumpstart and Refrigerant Protection H. Normal Run with Reset, Temperature, or Demand I.
Page 29 Contents Table 13 — Cutler-Hammer® Solid-State Starter Troubleshooting Guide Table 14 — Heat Exchanger Data Table 15 — Additional Data for Marine Waterboxes Table 16 — Compressor Weights Table 17 — Compressor/Motor Weights Table 18 — Waterbox Cover Weights Table 19 — Optional Pumpout System Electrical Data...
Page 30 Contents List of Figures Figure 1 — 19XL Identification Figure 2A— Typical 19XL Components — Design I Figure 2B— Typical 19XL Components — Design II Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles Figure 4 — Lubrication System Figure 5 —...
Page 31 Contents 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 —...
Page 32 Figure 27 — Typical Optional Pumpout System Piping Schematic with Storage Tank Figure 28 — Typical Optional Pumpout System Piping Schematic with- out Storage Tank Figure 29 — Dehydration Cold Trap Figure 30 — Benshaw, Inc. Solid-State Starter Power Stack Figure 31 —...
Page 33 Figure 40 — Optional Pumpout System Controls 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) Figure 45 —...
Page 34 Figure 52 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical) Figure 53 — Compressor Fits and Clearances Figure 54 — Compressor Fits and Clearances (Continued) Figure 55 — Compressor Fits and Clearances (Continued) Figure 56 — Electronic PIC Controls Wiring Schematic Figure 57 —...
Page 35 Introduction Prior to initial start-up of the 19XL 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 so that you may become familiar with the control system before performing start-up procedures.
Page 36 WARNING WARNING 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 dissipate body electrostatic charge before working inside control center.
Page 37: Abbreviations And Explanations
Abbreviations and Explanations Frequently used abbreviations in this manual include: — Carrier Comfort Network — Counterclockwise — Clockwise — Entering Chilled Water ECDW — Entering Condenser Water — Energy Management System HGBP — Hot Gas Bypass — Input/Output — Liquid Crystal Display LCDW —...
Page 38: Machine Familiarization
Figure 1 , Figure 2A (Front Machine Information Plate The information plate is located on the right side of the machine control center panel. Click here for Figure 1 — 19XL Identification System Components The components include the cooler and condenser heat exchangers in separate vessels, motor-compressor, lubrication package, control center, and motor starter.
Page 39: Control Center
• sequences machine start, stop, and recycle under microprocessor control • provides access to other CCN (Carrier Comfort Network) devices Factory-Mounted Starter (Optional) The starter allows for the proper starting and disconnecting of the electrical energy for the compressor-motor, oil pump, oil heater, and control panels.
Page 40: Refrigeration Cycle
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 to isolate the machine charge in either the cooler or condenser. An optional pumpout compressor system is used to transfer refrigerant from vessel to ves- sel.
Page 41 (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 FLASC vapor is recondensed on the tubes which are cooled by entering condenser water. The liquid drains into a float chamber between the FLASC chamber and cooler.
Page 42 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 temperatures (above 125 F [51 C]) energize a solenoid to provide additional motor cooling. A further increase in temperature past the motor override set point will override the temperature capacity control to hold, and if the motor temperature rises 10°...
Page 43: Lubrication Cycle
Click here for Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles Summary The oil pump, oil filter, and oil cooler make up a package located partially in the transmission casting 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.
Page 44 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 the system at the pump discharge. This differential pressure can be read directly from the Local Interface Device (LID) default screen. The oil pump discharges oil to the oil filter assembly.
Page 45: Oil Reclaim System
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 to minimize oil foaming at start-up. If the guide vanes open quickly, the sudden drop in suction pressure can cause any refrigerant in the oil to flash.
Page 46 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 refrigerant are also recovered from the top of the cooler refrigerant level and are discharged into the guide vane housing. The oil will drop to the bottom of the guide vane housing and be recovered by the eductor system.
Page 47: Starting Equipment
The starter serves as the main field wiring interface for the contractor. Three types of starters are available from Carrier Corporation: solid-state, wye-delta, and across-the-line starters. See Carrier Specification Z-375 for specific starter requirements. All starters must meet these specifications in order to properly start and satisfy mechanical safety requirements.
Page 48 CB1 so that power is supplied to them if the CB1 disconnect is open. All starters are shipped with a Carrier control module called the Starter Management Module (SMM). This module controls and monitors all aspects of the starter. See the for additional SMM information.
Page 49 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 required to get the motor moving. The voltage and current are then ramped up in a desired period of time. The voltage is reduced through the use of silicon controlled rectifiers (SCR).
Page 50 • current unbalance • run state These LEDs are further explained in the Unit-Mounted Wye-Delta Starter (Optional) The 19XL machine may be equipped with a wye-delta starter mounted on the unit. This starter is intended for use with low-voltage motors (under 600 v). It reduces the starting current inrush by connecting each phase of the motor windings into a wye configuration.
Page 51 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 because its resistance changes in proportion to the temperature, generating many values.) Digital Signal A digital (discrete) signal is a 2-position representation of the value of a monitored source.
Page 52: Pic System Components
General The 19XL hermetic centrifugal liquid chiller contains a microprocessor-based control center that monitors and controls all operations of the machine. The microprocessor control system matches the cooling capacity of the machine to the cooling load while providing state-of-the-art machine 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.
Page 53 The PIC can be interfaced with the Carrier Comfort Network (CCN) if desired. It can communicate with other PIC-equipped chillers and other CCN devices.
Page 54 to control the machine. The 19XL uses 3 pressure transducers and 8 thermistors to sense pressures and temperatures. These are connected to the PSIO module. The PSIO also provides outputs to the: guide vane actuator; oil pump; oil heater; hot gas bypass (optional); motor cooling solenoid;...
Page 55 6-Pack Relay Board This 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, alarm, optional hot gas bypass relay, and motor cooling solenoid. 8-Input Modules One optional module is factory installed in the control center panel when ordered.
Page 56 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 energizes the relay during low load, high lift conditions. Control Transformers (T1-T4) These transformers convert incoming control voltage to either 21 vac power for the PSIO module and options modules, or 24 vac power for 3 power panel contactor relays, 3 control solenoid valves, and the guide vane actuator.
Page 57 Click here for Figure 12 — Power Panel with Options 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 to the voltage used at the job site. LID Operation and Menus ( Figure 18 Figure 19...
Page 58 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 CCN time sched- ule to determine start and stop times. Alarms and Alerts Alarm (*) and alert (!) status are indicated on the Status tables.
Page 59 Menu Structure To perform any of the operations described below, the PIC must be powered up and have successfully completed its self test. • Press QUIT to leave the selected decision or field without saving any changes. INCREASE DECREASE • Press ENTER to leave the selected decision or field and save changes.
Page 60 • Press NEXT to scroll the cursor bar down in order to highlight a point or to view more points below the current screen. NEXT PREVIOUS • Press PREVIOUS to scroll the cursor bar up in order to highlight a point or to view points above the current screen.
Page 61 • Press EXIT to return to the previous screen level. NEXT • Press INCREASE or DECREASE to change the highlighted point value. INCREASE Figure 15 To View Point Status ( Point Status is the actual value of all of the temperatures, pressures, relays, and actuators sensed and controlled by the PIC.
Page 62 2. Press NEXT or PREVIOUS to highlight the desired status table. The list of tables is: • Status01 — Status of control points and sensors • Status02 — Status of relays and contacts • Status03 — Status of both optional 8-input modules and sensors NEXT 3.
Page 63 Override Operations To Override a Value or Status 1. On the Point Status table press NEXT or PREVIOUS to highlight the desired point. NEXT 2. Press SELECT to select the highlighted point. Then: NEXT Click here for Figure 15 — Example of Point Status Screen (Status 01) Click here for Figure 16 —...
Page 64 Click here for Figure 17 — 19XL Service Menu Structure For Discrete Points — Press START or STOP to select the desired state. START For Analog Points — Press INCREASE or DECREASE to select the desired value. INCREASE 3. Press ENTER to register new value. NEXT Note: When overriding or changing metric values, it is necessary to hold the softkey down for a STOP...
Page 65 few seconds in order to see a value change, especially on kilopascal values. To Remove an Override 1. On the Point Status table press NEXT or PREVIOUS to highlight the desired point. NEXT 2. Press SELECT to access the highlighted point. NEXT 3.
Page 66 Time Schedule Operation 1. On the Menu screen, press SCHEDULE. STATUS 2. Press NEXT or PREVIOUS to highlight the desired schedule. PSIO Software Version 08 and lower: OCCPC01S — LOCAL Time Schedule OCCPC02S — CCN Time Schedule PSIO Software Version 09 and higher: OCCPC01S —...
Page 67 3. Press SELECT to access and view the time schedule. NEXT 4. Press NEXT or PREVIOUS to highlight the desired period or override that you wish to change. NEXT 5. Press SELECT to access the highlighted period or override. NEXT PREVIOUS SELECT PREVIOUS...
Page 68 a. Press INCREASE or DECREASE to change the time values. Override values are in one- hour increments, up to 4 hours. INCREASE DECREASE b. Press ENABLE to select days in the day-of-week fields. Press DISABLE to eliminate days from the period. ENABLE 7.
Page 69 8. Press EXIT to leave the period or override. NEXT 9. Either return to Step 4 to select another period or override, or press EXIT again to leave the current time schedule screen and save the changes. NEXT Click here for Figure 18 — Example of Time Schedule Operation Screen 10.
Page 70 To View and Change Set Points 1. To view the Set Point table, at the Menu screen press SETPOINT. STATUS 2. There are 4 set points on this screen: Base Demand Limit; LCW Set Point (leaving chilled water set point); ECW Set Point (entering chilled water set point); and ICE BUILD set point (PSIO Software Version 09 and higher only).
Page 71 4. Press SELECT to modify the highlighted set point. NEXT 5. Press INCREASE or DECREASE to change the selected set point value. INCREASE 6. Press ENTER to save the changes and return to the previous screen. INCREASE Click here for Figure 19 — Example of Set Point Screen PREVIOUS SELECT DECREASE...
Page 72 Service Operation To view the menu-driven programs available for Service Operation, see section. For examples of LID display screens, see Table 2 (begins on this page). Table 2 — LID Screens Note: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen.
Page 73 Table 2 — LID Screens (Continued) Click on an example to view: Example 6 — Lead/Lag Configuration Display Screen Example 7 — Service1 Display Screen Example 8 — Service2 Display Screen Example 9 — Service3 Display Screen Example 10 — Maintenance (Maint01) Display Screen Example 11 —...
Page 74: Pic System Functions
PIC System Functions Note: Throughout this manual, words printed in capital letters and italics are values that may be viewed on the LID. See the Description column. An overview of LID operation and menus is given in Figure Figure Figure 16, Figure Capacity Control The PIC controls the machine capacity by modulating the inlet guide vanes in response to chilled water temperature changes away from the CONTROL POINT .
Page 75 Deadband This is the tolerance on the chilled water/ brine temperature CONTROL POINT . If the water temperature goes outside of the DEADBAND , the PIC opens or closes the guide vanes in response until it is within tolerance. The PIC may be configured with a 0.5 to 2 F (0.3 to 1.1 C) deadband.
Page 76 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 setting is 6.0. Increasing either of these settings will cause the vanes to respond slower than a lower setting. The PROPORTIONAL ECW GAIN can be adjusted at the LID display from a setting of 1.0 to 3.0, with a default setting of 2.0.
Page 77 register up to 32,767 hours before it rolls over to zero. The chiller also maintains a start-to-start timer and a stop-to-start timer. These timers limit how soon the machine can be started. See the for operational information. Occupancy Schedule This schedule determines when the chiller is either occupied or unoccupied. Each schedule consists of from one to 8 occupied/unoccupied time periods, set by the operator.
Page 78 midnight to 3:00 a.m. weekend cool-down schedule. Note: This schedule is for illustration only, and is not intended to be a recommended schedule for chiller operation. PSIO Software Version 08 and Lower Whenever the chiller is in the LOCAL mode, the machine will start when the Occupancy Schedule 01 indicates OCCUPIED.
Page 79: Safety Controls
Safety Controls The PIC monitors all safety control inputs, and if required, shuts down the machine or limits the guide vanes to protect the machine from possible damage from any of the following conditions: • high bearing temperature • high motor winding temperature •...
Page 80 CAUTION If compressor motor overload occurs, check the motor for grounded or open phases before attempting a restart. 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 relay in the starter and blinks the alarm light on the control center.
Page 81: Default Screen Freeze
Shunt Trip The 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 PIC tries to shut down the compressor through normal shutdown procedure but is unsuccessful for 30 seconds, the shunt trip output is energized and causes the circuit breaker to trip off.
Page 82: Ramp Loading Control
Ramp Loading Control The ramp loading control slows down the rate at which the compressor loads up. This control can prevent the compressor from loading up during the short period of time when the machine is started, and the chilled water loop has to be brought down to normal design conditions. This helps reduce electrical demand charges by slowly bringing the chilled water to control point.
Page 83 Capacity Override (Table These can prevent some safety shutdowns caused by exceeding motor amperage limit, refrigerant low temperature safety limit, motor high temperature safety limit, and condenser high pressure limit. In all cases there are 2 stages of compressor vane control. 1.
Page 84: High Discharge Temperature Control
High Discharge Temperature Control If the discharge temperature increases above 160 F (71.1 C) (PSIO Software Version 09 and higher) or 180 F (82 C) (PSIO Software Version 08 or lower), the guide vanes are proportionally opened to increase gas flow through the compressor. If the leaving chilled water temperature is then brought 5°...
Page 85: Oil Cooler
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 150 F (65.6 C) or the oil sump temperature is less than the cooler refrigerant temperature plus 70°...
Page 86: Spare Safety Inputs
regulates refrigerant flow to control oil temperature entering the bearings. There is always a flow of refrigerant bypassing the thermal expansion valve (TXV). The bulb for the expansion valve is strapped to the oil supply line leaving the heat exchanger and the valve is set to maintain 110 F (43 C).
Page 87: Condenser Pump Control
spare protective limits input channel in place of the factory-installed jumper. (Wire multiple inputs in series.) The opening of any contact will result in a safety shutdown and LID display. Refer to the certified drawings for safety contact ratings. Analog temperature sensors may also be added to the options modules, if installed. These may be programmed to cause an alert on the CCN network, but will not shut the machine down.
Page 88: Condenser Freeze Prevention
Condenser Freeze Prevention This control algorithm helps prevent condenser tube freeze-up by energizing the condenser pump relay. If the pump is controlled by the PIC, starting the pump will help prevent the water in the condenser from freezing. Condenser freeze prevention can occur whenever the machine is not running except when it is either actively in pumpdown or in Pumpdown Lockout with the freeze prevention disabled (refer to Control Test table, Pumpdown/Terminate Lockout tables).
Page 89 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 CONDENSER WATER PUMP is running, flow is verified, and the difference between cooler and condenser pressure is more than 45 psid (310 kPad) (30 psid [207 kPad] for HFC-134a) or entering condenser water temperature is greater than 85 F (29 C).
Page 90 Auto. Restart After Power Failure This option may be enabled or disabled, and may be viewed/modified in the Config table of Equipment Configuration. If enabled, the chiller will start up automatically after a single cycle dropout, low, high, or loss of voltage has occurred, and the power is within ±10% of normal. The 15- and 3-minute inhibit timers are ignored during this type of start-up.
Page 91 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/ENABLE RESET TYPE input line. 1. Reset Type 1 (Requires optional 8-input module) — Automatic chilled water temperature reset based on a 4 to 20 mA input signal.
Page 92 Reset Type 2 can now be activated. 3. Reset Type 3 — Automatic chilled water temperature reset based on cooler temperature difference. This type of reset will add ±30° F (±16° C) based on the temperature difference between entering and leaving chilled water temperature. This is the only type of reset available without the need of the number one 8-input module.
Page 93: Surge Prevention Algorithm
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 management system (EMS). The option is set up on the Config table. When enabled, the control is set for 100% demand with 4 mA and an operator configured minimum demand set point at 20 mA.
Page 94 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 Table 4. These settings and the algorithm function are graphically displayed in Figure 20. The two sets of load points on this graph (default settings are shown) describe a line which the algorithm uses to determine the maximum lift of the compressor.
Page 95: Surge Protection
Surge Protection Surging of the compressor can be determined by the PIC through operator configured settings. Surge will cause amperage fluctuations of the compressor motor. The PIC monitors these amperage swings, and if the swing is greater than the configurable setting in one second, then one surge count has occurred.
Page 96 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 automatically starts and stops a lag or second chiller in a 2-chiller water system. Refer to selection information.
Page 97 Operation Features: • 2 chiller lead/lag • addition of a third chiller for backup • manual rotation of lead chiller • load balancing if configured • staggered restart of the chillers after a power failure • chillers may be piped in parallel or in series chilled water flow Common Point Sensor Installation Lead/lag operation does not require a common chilled water point sensor.
Page 98 Note: Lead/lag configuration is viewed and edited in Lead/Lag, under the Equipment Configu- ration table of the Service menu. Lead/lag status during machine operation is viewed in the MAINT04 table in the Control Algorithm Status table. Carrier Comfort Network Interface section for...
Page 99 Lead/Lag Chiller Configuration and Operation The configured lead chiller is identified when the LEAD/LAG SELECT value for that chiller is configured to the value of ‘‘1.’’ The configured lag chiller is identified when the LEAD/LAG SELECT for that chiller is configured to the value of ‘‘2.’’ The standby chiller is configured to a value of ‘‘3.’’...
Page 100 requested to start. After the second chiller is started and is running, the lead chiller shall monitor conditions and evaluate whether the capacity has reduced enough for the lead chiller to sustain the system alone. If the capacity is reduced enough for the lead chiller to sustain the CONTROL POINT temperatures alone, then the operating lag chiller is stopped.
Page 101 Standby Chiller Configuration and Operation The configured standby chiller is identified as such by having the LEAD/LAG SELECT configured to the value of ‘‘3.’’ The standby chiller can only operate as a replacement for the lag chiller if one of the other two chillers is in an alarm (*) condition (as shown on the LID panel). If both lead and lag chillers are in an alarm (*) condition, the standby chiller shall default to operate in CCN mode based on its configured Occupancy Schedule and remote contacts input.
Page 102 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 START TIMER entry is accessed by selecting Lead/Lag from the Equipment Configuration table of the Service menu.
Page 103 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 (1.67° C) below the CONTROL POINT and the lead chiller COMPRESSOR MOTOR LOAD value is less than the lead chiller percent capacity plus 15%.
Page 104 Load Balancing When the LOAD BALANCE OPTION is enabled, the lead chiller will set the ACTIVE DEMAND LIMIT in the lag chiller to the lead chiller’s COMPRESSOR MOTOR LOAD value. This value has limits of 40% to 100%. When setting the lag chiller ACTIVE DEMAND LIMIT, the CONTROL POINT shall be modified to a value of 3°...
Page 105: Ice Build Control
Ice Build Control IMPORTANT: The Ice Build control option is only available on machines with PSIO Software Version 09 and higher. Ice build control automatically sets the chilled WATER/ BRINE CONTROL POINT of the machine to a temperature where an ice building operation for thermal storage can be accomplished.
Page 106 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 Build Time Schedule. Ice Build Initiation The Ice Build Time Schedule provides the means for activating ice build. The ice build time table is named OCCPC02S.
Page 107 Start-Up/Recycle Operation If the machine is not running when ice build activates, then the PIC checks the following parameters, based on the ICE BUILD TERMINATION value, to avoid starting the compressor unnecessarily: • if ICE BUILD TERMINATION is set to the TEMPERATURE ONLY OPTION and the ENTERING CHILLED WATER temperature is less than or equal to the ICE BUILD SETPOINT;...
Page 108 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 the LEAVING CHILLED WATER temperature. The ECW OPTION and any temperature reset option are ignored during ice build. The 20 mA DEMAND LIMIT OPTION is also ignored during ice build.
Page 109 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 Contacts — Termination of compressor operation shall occur when ICE BUILD TERMINATION is set to BOTH (temperature and contacts) option and the previously described conditions for ECW TEMPERATURE and remote contacts have occurred.
Page 110: Attach To Network Device Control
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 upload new parameters when switching the controller to HFC-134a refrigerant. • to upload the Occupancy Schedule Number (if changed) for OCCPC03S, as defined in the Service01 table •...
Page 111 various CCN modules is different for each module. In general, the uploading process will take 3 to 5 minutes. Changing Refrigerant Types To select refrigerant type, go to the Control Test table. Whenever the refrigerant type is changed, the ATTACH TO NETWORK DEVICE table must be used. After changing the refrigerant type in the Control Test table, move to the ATTACH TO NETWORK DEVICE table.
Page 112 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 a question regarding which module on the LID is currently being shown, check the device name descriptor on the upper left hand corner of the LID screen. See Figure When the CCN device has been viewed, the ATTACH TO NETWORK DEVICE table should now be used to attach to the PIC that is on the machine.
Page 113: Service Operation
Service Operation An overview of the menu-driven programs available for Service Operation is shown in Figure To Log On 1. On the Menu screen, press SERVICE. The keys now correspond to the numerals 1, 2, 3, 4. 2. Press the four digits of your password, one at a time. An asterisk (*) appears as you enter each digit.
Page 114 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 order to password-protect the Service menu. The LID will automatically sign off and password-protect itself if a key is not pressed for 15 minutes.
Page 115 that is configured to be the broadcaster is the device responsible for transmitting holiday, time, and daylight-savings dates throughout the network. To view or change the holiday periods for up to 18 different holidays, perform the following operation: 1. At the Menu screen, press SERVICE to access the Service menu. STATUS 2.
Page 116 4. Press NEXT until Holidef is highlighted. This is the Holiday Definition table. NEXT 5. Press SELECT to enter the Data Table Select screen. This screen lists 18 holiday tables. NEXT 6. Press NEXT to highlight the holiday table that you wish to view or change. Each table is one holiday period, starting on a specific date, and lasting up to 99 days.
Page 117 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 period will last. NEXT 8. Press NEXT or PREVIOUS to highlight the month, day, or duration. NEXT 9.
Page 118 10. Press INCREASE or DECREASE to change the selected value. INCREASE DECREASE 11. Press ENTER to save the changes. INCREASE DECREASE 12. Press EXIT to return to the previous menu. NEXT Click here for Figure 23 — Example of Holiday Period Screen QUIT QUIT PREVIOUS...
Page 119 Start-Up/Shutdown/Recycle Sequence Local Start-Up Local start-up (or a manual start-up) is initiated by pressing the LOCAL menu softkey which is on the default LID screen. Local start-up can proceed when Time Schedule 01 is in OCCUPIED mode, and after the internal 15 minute start-to-start and the 3 minute stop-to-start inhibit timers have expired (on PSIO software Version 08 and lower or a 1 minute stop-to-start timer on PSIO Software Version 09 and higher).
Page 120: Shutdown Sequence
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, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes.
Page 121 confirm stop command) • recycle condition is present (see • time schedule has gone into UNOCCUPIED mode (machine protective limit has been reached and machine is in alarm) • the start/stop status is overridden to stop from the CCN network or the LID When a stop signal occurs, the shutdown sequence first stops the compressor by deactivating the start relay.
Page 122: Chilled Water Recycle Mode
• if the machine shuts down due to low refrigerant temperature, the chilled water pump will stay running until the LEAVING CHILLED WATER is greater than CONTROL POINT , plus 5° F (3° C) Automatic Soft Stop Amps Threshold (PSIO Software Version 09 and Higher) The SOFT STOP AMPS THRESHOLD closes the guide vanes of the compressor automatically when a non-recycle, non-alarm stop signal occurs before the compressor motor is...
Page 123 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 when any of the following conditions are true: when in LCW control, the LEAVING CHILLED WATER temperature is more than 5° F •...
Page 124: Safety Shutdown
hours. This excessive recycling can reduce machine life. Compressor recycling due to extremely low loads should be reduced. To reduce compressor recycling, use the time schedule to shut the machine down during low load operation or increase the machine load by running the fan systems.
Page 125 CAUTION Do not reset starter loads or any other starter safety for 30 seconds after the compressor has stopped. Voltage output to the compressor start signal is main- tained for 10 seconds to determine starter fault. Job Data Required • list of applicable design temperatures and pressures (product data submittal) •...
Page 126 • absolute pressure manometer or wet-bulb vacuum indicator • 500 v insulation tester (megohmmeter) for compressor motors with nameplate volt- age of 600 v or less, or a 5000-v insulation tester for compressor motor rated above 600 v Using the Optional Storage Tank and Pumpout System Refer to Pumpout and Refrigerant Transfer Procedures preparation, refrigerant transfer, and machine evacuation.
Page 127: Refrigerant Tracer
Refrigerant Tracer Carrier recommends the use of an environmentally acceptable refrigerant tracer for leak testing with an electronic detector or halide torch. Ultrasonic leak detectors also can be used if the machine is under pressure.
Page 128 Click here for Figure 26 — 19XL Leak Test Procedures Leak Test Machine Due to regulations regarding refrigerant emissions and the difficulties associated with separating contaminants from refrigerant, Carrier recommends the following leak test procedures. See Figure 26 for an outline of the leak test procedures. Refer to...
Page 129 WARNING Never charge liquid refrigerant into the machine if the pressure in the machine is less than 68 psig (469 kPa) for HCFC-22 and 35 psig (241 kPa) for HFC-134a. Charge as a gas only, with the cooler and condenser pumps running, until this pressure is reached, using PUMPDOWN LOCKOUT and TERMINATE LOCKOUT mode on the PIC.
Page 130 g. After successfully completing the test for large leaks, remove as much nitrogen, air, and moisture as possible, given the fact that small leaks may be present in the system. This can be accomplished by following the dehydration procedure, outlined in the Dehydration section.
Page 131: Standing Vacuum Test
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 procedure in the Machine Dehydration section. Charge machine with refrigerant (see Pumpout and Refrigerant Transfer Procedures, 7.
Page 132 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. Hg (.17 kPa) in 24 hours, repressurize the vessel and test for leaks.
Page 133 Click here for Table 5A — HCFC-22 Pressure — Temperature (F) Click here for Table 5B — HCFC-22 Pressure — Temperature (C) Click here for Table 5C — HFC-134a Pressure — Temperature (F) Click here for Table 5D — HFC-134a Pressure — Temperature (C) Machine Dehydration Dehydration is recommended if the machine has been open for a considerable period of time, if the machine is known to contain moisture, or if there has been a complete loss of...
Page 134 WARNING Do not start or megohm test the compressor motor or oil pump motor, even for a rotation check, if the machine is under dehydration vacuum. Insulation break- down and severe damage may result. Dehydration is readily accomplished at room temperatures. Use of a cold trap may substantially reduce the time required to complete the dehydration.
Page 135 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 higher, operate the vacuum pump until the manometer reads 29.8 in. Hg vac, ref 30 in. bar. (0.1 psia) (–100.61 kPa) or a vacuum indicator reads 35 F (1.7 C).
Page 136 Water must be within design limits, clean, and treated to ensure proper machine performance and reduce the potential of tubing damage due to corrosion, scal- ing, or erosion. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
Page 137 Check Relief Devices Be sure that relief devices have been piped to the outdoors in compliance with the latest edition of ANSI/ASHRAE Standard 15 and applicable local safety codes. Piping connections must allow for access to the valve mechanism for periodic inspection and leak testing. 19XL relief valves are set to relieve at the 300 psig (2068 kPa) machine design pressure.
Page 138 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 reading with the voltage rating on the compressor and starter nameplates. 3. Compare the ampere rating on the starter nameplate with the compressor nameplate. The overload trip amps must be 108% to 120% of the rated load amps.
Page 139 a. Open the starter main disconnect switch and follow lockout/tagout rules. CAUTION If the motor starter is a solid-state starter, the motor leads must be disconnected from the starter before an insulation test is performed. The voltage generated from the tester can damage the starter solid-state components. b.
Page 140: Carrier Comfort Network Interface
Carrier Comfort Network Interface The Carrier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire. The system elements are connected to the communication bus in a daisy chain arrangement.
Page 141 tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl or Teflon with a minimum operating temperature range of –20 C to 60 C is required. See table below for cables that meet the requirements. Manufacturer Alpha American...
Page 142 Check Starter CAUTION BE AWARE that certain automatic start arrangements can engage the starter . Open the disconnect ahead of the starter in addition to shutting off the machine or pump. Use the instruction and service manual supplied by the starter manufacturer to verify that the starter has been installed correctly.
Page 143 Mechanical-Type Starters 1. Check all field wiring connections for tightness, clearance from moving parts, and correct connection. 2. Check the contactor(s) to be sure they move freely. Check the mechanical interlock between contactors to ensure that 1S and 2M contactors cannot be closed at the same time.
Page 144 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, goes through a complete and proper start cycle. Benshaw, Inc. Solid-State Starter WARNING This equipment is at line voltage when AC power is connected.
Page 145 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 dial position for a 60 Hz motor is approximately the 11:30 position. The nominal dial position for a 50 Hz motor is approxi- mately in the 9:30 position because the board is turned on its side, so that the 9:00 o’clock position is located where the 6:00 o’clock position would normally be located.
Page 146 Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller Click here for Initial Start-Up Checklist for 19XL Hermetic Centrifugal Liquid Chiller Cutler-Hammer® Solid-State Starters WARNING This equipment is at line voltage when ac power is connected. Pressing the STOP button does not remove voltage. Use caution when adjusting the potentiometers on the equipment.
Page 147 important because of the interdependency of these functions. See be made in the following sequence: Potentiometer Adjustment Note: All potentiometers are factory set. The following information is provided for reference. Adjustment potentiometers are nearly linear. To make an initial setting, determine the percentage of the potentiometer rotation.
Page 148 CAUTION Do not adjust any potentiometer beyond its stops. This type of adjustment will result in damage to the potentiometer. Starting Current The torque required to start a machine (initial torque) varies from one application to another. Starting current may be adjusted to match the initial motor torque of the application. The starting current value is adjustable from 100% to 400% FLA and is factory set at 100%.
Page 149 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 potentiometer (adjustable from 2 to 30 seconds at 400% current limit setting). The 19XL is factory set at 15 seconds. However, based on jobsite conditions, a range of ±5 seconds is acceptable.
Page 150: Oil Charge
When the sump is full, the oil level should be no higher than the middle of the upper sight glass and minimum level is the bottom of the lower sight glass Figure 2B). If oil is added, it must meet Carrier’s specification for centrifugal compressor usage as described in the Oil Changes section.
Page 151 located near the bottom of the transmission housing pumped from the oil container through the charging valve due to higher refrigerant pressure. The pumping device must be able to lift from 0 to 200 psig (0 to 1380 kPa) or above unit pressure.
Page 152 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 Version The software version will always be labeled on the PSIO module, and on the back side of the LID module.
Page 153: Input The Design Set Points
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 set point. The PIC can control a set point to either the leaving or entering chilled water.
Page 154: Input Service Configurations
refrigerant setting. Press EXIT softkey to leave the screen without changes. To Change Refrigerant Type Enter the Controls Test tables on the Service Menu. See TYPE. The screen will display the current refrigerant setting. Press YES softkey to change the current setting.
Page 155 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’’ should only be configured to ‘‘Yes’’ if the present day is a holiday.
Page 156 Configure SERVICE1 Table Access Service1 table to modify/view the following to jobsite parameters: Chilled Medium Brine Refrigerant Trippoint Surge Limiting or Hot Gas Bypass Option Minimum Load Points (T1/P1) Maximum Load Points (T2/P2) Amps Correction Factor Motor Rated Load Amps Motor Rated Line Voltage Motor Rated Line kW Line Frequency...
Page 157 If, after configuring a value for these points, surge prevention is operating too soon or too late for conditions, these parameters should be changed by the operator. Example of configuration: Machine operating parameters Refrigerant used: HCFC-22 Estimated Minimum Load Conditions: 44 F (6.7 C) LCW 45.5 F (7.5 C) EWC 43 F (6.1 C) Suction Temperature...
Page 158 Calculate Maximum Load To calculate maximum load points, use design load condition data. If the machine full load cooler temperature difference is more than 15° F (8.3 C), estimate the refrigerant suction and condensing temperatures at this difference. Use the proper saturated pressure and temperature for the particular refrigerant used.
Page 159 Calculate Minimum Load To calculate minimum load conditions, estimate the temperature difference that the cooler will have at 10% load, then estimate what the suction and condensing temperatures will be at this point. Use the proper saturated pressure and temperature for the particular refrigerant used.
Page 160 Click here for Table 7 — Amps Correction Factors for 19XL Motors Modify Equipment Configuration If Necessary The Equipment Configuration table has tables to select and view or modify. Carrier’s certified drawings will have the configuration values required for the jobsite. Modify these tables only if requested.
Page 161 Config Table Modifications Change the values in this table per job data. See certified drawings for values. Modifications include: • chilled water reset • entering chilled water control (Enable/Disable) • 4-20 mA demand limit • auto restart option (Enable/Disable) • remote contact option (Enable/Disable) Owner-Modified CCN Tables The following tables are described for reference only.
Page 162 system. See the applicable CCN manual for more information on these tables. These tables can only be defined through a CCN Building Supervisor. Check Voltage Supply Access the Status 01 screen and read the actual line voltage. This reading should be equal to the incoming power to the starter.
Page 163 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 pressed, the test will be stopped and the Control Test menu will be displayed. If a specific automated test procedure is not completed, access the particular control test to test the function when ready.
Page 164 Check Optional Pumpout System Controls and Compressor Controls include an on/off switch, a 3-amp fuse, the compressor overloads, an internal thermostat, a compressor contactor, and a refrigerant high pressure cutout. The high pressure cutout is factory set to open at 220 ± 5 psig (1250 ± 34 kPa), and automatically reset at 185 +0,–7 (1280 +0,–48 kPa) with HCFC-22.
Page 165 Charge Refrigerant into Machine CAUTION The transfer, addition, or removal of refrigerant in spring isolated machines may place severe stress on external piping if springs have not been blocked in both up and down directions. The standard 19XL machine will have the refrigerant already charged in the vessels. The 19XL may be ordered with a nitrogen holding charge of 15 psig (103 kPa).
Page 166 To equalize the pressure differential on a refrigerant isolated 19XL machine, use the TERMINATE LOCKOUT function of the Control Test in the SERVICE menu. This will help to turn on pumps and advise the proper procedure. The following procedure describes how to equalize refrigerant pressure on an isolated 19XL machine without a pumpout unit: 1.
Page 167 19XL Machine Equalization with Pumpout Unit The following procedure describes how to equalize refrigerant pressure on an isolated 19XL machine using the pumpout unit: 1. Access the TERMINATE LOCKOUT mode in the Control Test. 2. Turn on the chilled water and condenser water pumps to prevent possible freezing. 3.
Page 168 adding the condenser charge to the cooler charge listed in Always operate the condenser and chilled water pumps during charging operations to prevent freeze-ups. Use the Control Test Terminate Lockout to monitor conditions and start the pumps. If the machine has been shipped with a holding charge, the refrigerant will be added through the refrigerant charging valve connection.
Page 169 Trimming Refrigerant Charge The 19XL is shipped with the correct charge for the design duty of the machine. Trimming the charge can be best accomplished when design load is available. To trim, check the temperature difference between leaving chilled water temperature and cooler refrigerant temperature at full load design conditions.
Page 170 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 circuits are open. Note: If pumps are not automatic, make sure water is circulating properly. 7.
Page 171: Manual Operation Of The Guide Vanes
Manual Operation of the Guide Vanes Manual operation of the guide vanes is helpful to establish a steady motor current for calibration of the motor amps value. In order to manually operate the guide vanes, it is necessary to override the TARGET GUIDE VANE POSITION value which is accessed on the Status01 table.
Page 172: Check Rotation
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 Local to start. If not, go to the Schedule screen and override the schedule or change the occupied time. Press the LOCAL softkey to begin the start-up sequences.
Page 173 If the Motor Rotation Is Not Clockwise 2 of the 3 incoming power leads to the starter and recheck rotation. Note: Solid-state starters have phase protection and will not allow a start if the phase is not cor- rect. Instead, a Starter Fault message will occur if this happens. CAUTION Do not check motor rotation during coastdown.
Page 174: Check Oil Pressure And Compressor Stop
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 counterclockwise for a shorter time, clockwise for a longer time. (See Figure 6 Check Oil Pressure and Compressor Stop 1.
Page 175 To Prevent Accidental Start-Up The PIC can be set up so that start-up of the unit is more difficult than just pressing the LOCAL or CCN softkeys during machine service or when necessary. By accessing the Status01 table, and highlighting the chiller Start/Stop line, the value can be overridden to stop by pressing SELECT and then the STOP and ENTER softkeys.
Page 176 Optional Storage Tank and Pumpout System Transfer valves and pumpout system, refrigerant charging and pumpdown procedure, and relief devices. Motor Compressor Assembly Guide vane actuator, transmission, motor cooling system, oil cooling system, temperature and pressure sensors, oil sight glasses, integral oil pump, isolatable oil filter, extra oil and motor temperature sensors, synthetic oil, and compressor serviceability.
Page 177: Operating Instructions
Review Maintenance Scheduled, routine, and extended shutdowns, importance of a log sheet, importance of water treatment and tube cleaning, and importance of maintaining a leak-free machine. Safety Devices and Procedures Electrical disconnects, relief device inspection, and handling refrigerant. Check Operator Knowledge Start, stop, and shutdown procedures, safety and operating controls, refrigerant and oil charging, and job safety.
Page 178: Check The Running System
5. Protect the system from damage during shutdown periods. 6. Maintain the set point, time schedules, and other PIC functions. Prepare the Machine for Start-Up Follow the steps described in the To Start the Machine 1. Start the water pumps, if they are not automatic. 2.
Page 179 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 temperature are within limits. 4. The oil pressure should be between 18 and 30 psid (124 to 207 kPad) differential, as seen on the LID default screen.
Page 180: After Limited Shutdown
based on load rate or temperature rate. It is accessed on the Equipment Configuration, Config table (Table 2, Example To Stop the Machine 1. The occupancy schedule will start and stop the machine automatically once the time schedule is set up. 2.
Page 181: Extended Shutdown
Extended Shutdown The refrigerant should be transferred into the storage vessel (if supplied; see Refrigerant Transfer Procedures) in order to reduce machine pressure and possibility of leaks. Maintain a holding charge of 5 to 10 lbs (2.27 to 4.5 kg) of refrigerant to prevent air from leaking into the machine.
Page 182: Cold Weather Operation
Carefully make all regular preliminary and running system checks. Perform a Control Test before start-up. If the compressor oil level appears abnormally high, the oil may have absorbed refrigerant. Make sure that the oil temperature is above 140 F (60 C) or cooler refrigerant temperature plus 50°...
Page 183 Keep a record of the machine pressures, temperatures, and liquid levels on a sheet similar to that shown. Automatic recording of PIC data is possible through the use of CCN devices such as the Data Collection module and a Building Supervisor. Contact your Carrier representative for more information.
Page 184 Pumpout and Refrigerant Transfer Procedures Preparation The 19XL may come equipped with an optional storage tank or pumpout system, or a pumpout compressor. The refrigerant can be pumped for service work to either the cooler/ compressor vessel, or the condenser vessel by using the optional pumpout system. If a storage tank is supplied, the refrigerant can be isolated in the external tank.
Page 185 To Read Refrigerant Pressures 1. The LID display on the machine control center is suitable for determining refrigerant-side pressures and low (soft) vacuum. For evacuation or dehydration measurement, use a quality vacuum indicator or manometer to ensure the desired range and accuracy. This can be placed on the Schrader connections on each vessel transducer.
Page 186 Transfer Refrigerant from Storage Tank to Machine 1. Equalize refrigerant pressure. a. Use the Control Test Terminate Lockout to turn on water pumps and monitor pressures. b. Close pumpout/storage tank valves 2, 4, 5, and 8, and close machine charging valve 7; open machine isolation valves 11, 12, 13, and 14 (if present).
Page 187 e. Open valve 5 fully after the pressure rises above the freeze point of the refrigerant. Open liquid line valve 7 until refrigerant pressure equalizes. Valve Condition 2. Transfer remaining refrigerant. a. Close valve 5 and open valve 4. Valve Condition b.
Page 188 g. Open valves 2 and 5. Valve Condition h. Turn on pumpout condenser water. i. Run the pumpout compressor until the storage tank pressure reaches 5 psig (34 kPa) (18 in. Hg [40 kPa absolute] if repairing the tank). j. Turn off the pumpout compressor. k.
Page 189 Transfer the Refrigerant from Machine to Storage Tank 1. Equalize refrigerant pressure. a. Valve positions: Valve Condition b. Slowly open valve 5 and liquid line valve 7 to allow liquid refrigerant to drain by gravity into the storage tank. Valve Condition 2.
Page 190 b. Run the pumpout compressor for 30 minutes then close valve 7. c. Turn off the pumpout compressor. Valve Condition 3. Remove any remaining refrigerant. a. Turn on water pumps through the use of the Control Test Pumpdown. b. Turn on pumpout condenser water. c.
Page 191 (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 turn on the pumpout compressor and pumpout until the pressure reaches 18 in. Hg. (40 kPa absolute).
Page 192 Machines with Isolation Valves Transfer All Refrigerant to Condenser Vessel 1. Push refrigerant into condenser. a. Valve positions: Valve Condition b. Turn off machine water pumps and pumpout condenser water. c. Turn on pumpout compressor to push liquid out of the cooler/compressor. d.
Page 193 2. Evacuate gas from cooler/compressor vessel. a. Close pumpout valves 2 and 5, and open valves 3 and 4. Valve Condition b. Turn on pumpout condenser water. c. Run pumpout until the compressor reaches 18 in. Hg vac (40 kPa abs.). Monitor pressures on the LID and on refrigerant gages.
Page 194 Transfer All Refrigerant to Cooler/Compressor Vessel 1. Push refrigerant into the cooler vessel. a. Valve positions: Valve Condition b. Turn off machine water pumps and pumpout condenser water. c. Turn on pumpout compressor to push refrigerant out of the condenser. d.
Page 195 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 refrigerant gages. e. Close valve 1b. f. Turn off pumpout compressor. g. Close valves 1a, 2, and 5. Valve Condition h.
Page 196 Return Refrigerant to Normal Operating Conditions 1. Be sure that the vessel that was opened has been evacuated. 2. Access the Control Test Terminate Lockout table to view vessel pressures and turn on machine water pumps. 3. Open valves 1a, 1b, and 3. Valve Condition 4.
Page 197 8. Close valves 1a, 1b, 3, and 5. 9. Open isolation valves 12, 13, and 14 (if present). Valve Condition 10. Proceed to Terminate Pumpdown Lockout test to turn off water pumps and enable the machine compressor for start-up.
Page 198: General Maintenance
Refrigerant Properties HCFC-22 or HFC-134a is the standard refrigerant in the 19XL. At normal atmospheric pressure, HCFC-22 will boil at –41 F (–40 C) and HFC-134a will boil at –14 F (–25 C) and must, therefore, be kept in pressurized containers or storage tanks. The refrigerants are practically odorless when mixed with air.
Page 199 Adding Refrigerant Follow the procedures described in WARNING Always use the compressor Pumpdown function in the Control Test table to turn on the evaporator pump and lock out the compressor when transferring refriger- ant. Liquid refrigerant may flash into a gas and cause possible freeze-up when the machine pressure is below 65 psig (448 kPa), for HCFC-22, 30 psig (207 kPa) for HFC-134a.
Page 200: Refrigerant Leak Testing
10% of the operating refrigerant charge per year. Additionally, Carrier recommends that leaks totalling less than the above rate but more than a rate of 1 lb (0.5 kg) per year should be repaired during annual maintenance or whenever the refrigerant is pumped over for other service work.
Page 201 WARNING HCFC-22 and HFC-134a should not be mixed with air or oxygen and pressurized for leak testing. In general, neither refrigerant should not be allowed to be present with high concentrations of air or oxygen above atmospheric pressures, as the mixture can undergo combustion.
Page 202: Checking Guide Vane Linkage
5. Close the charging valve on the machine. Remove the copper tube if no longer required. Repair the Leak, Retest, and Apply Standing Vacuum Test After pressurizing the machine, test for leaks with an electronic, halide leak detector, soap bubble solution, or an ultrasonic leak detector. Bring the machine back to atmospheric pressure, repair any leaks found, and retest.
Page 203 Checking the Auxiliary Switch on Guide Vane Actuator The auxiliary switch used to activate the oil reclaim system solenoids should move to the OPEN position when the actuator is 70 degrees open. (At this point the guide vanes should be 30 degrees open.) Click here for Figure 38 —...
Page 204: Weekly Maintenance
(Figure 2A Figure 2B). A pump is required for adding oil against refrigerant pressure. The oil charge is approximately 8 gallons (30 L). The added oil must meet Carrier specifications for the 19XL. Refer to Changing Oil Filter should be logged by noting the amount and date. Any oil that is added due to oil loss that is not related to service will eventually return to the sump.
Page 205: Scheduled Maintenance
Establish a regular maintenance schedule based on the actual machine requirements such as machine load, run hours, and water quality. The time intervals listed in this section are offered as guides to service only. Service Ontime The LID will display a SERVICE ONTIME value on the Status01 table. This value should be reset to zero by the service person or the operator each time major service work is completed so that time between service can be viewed.
Page 206: Changing Oil Filter
Check Safety and Operating Controls Monthly To ensure machine protection, the Control Test Automated Test should be done at least once per month. See Table 3 Changing Oil Filter Change the oil filter on a yearly basis or when the machine is opened for repairs. The 19XL has an isolatable oil filter so that the filter may be changed with the refrigerant remaining in the machine.
Page 207 CAUTION The oil filter housing is at a high pressure. Relieve this pressure slowly. 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. Remove the 4 bolts from the end of the filter housing and remove the filter cover.
Page 208 PP23BZ103) may be ordered from your local Carrier representative. Oil Changes Carrier recommends changing the oil after the first year of operation and every three years thereafter as a minimum in addition to a yearly oil analysis. However, if a continuous oil monitoring system is functioning and a yearly oil analysis is performed, time between oil changes can be extended.
Page 209: Refrigerant Filter
4. When the machine pressure is 5 psi (34 kPa) or less, drain the oil reservoir by opening the oil charging valve (Figure 2A pressure. 5. Change the oil filter at this time. See 6. Change the refrigerant filter at this time, see the next section, 7.
Page 210: Oil Reclaim Filters
Oil Reclaim Filters The oil reclaim system has a strainer on the eductor suction line and a filter on the cooler scavaging line. Replace these filters once per year, or more often if filter condition indicates a need for more frequent replacement. Change these filters by transferring the refrigerant charge to a storage vessel or the condenser.
Page 211 As a minimum, the following maintenance is required. 1. At least once a year, disconnect the vent piping at the valve outlet and carefully inspect the valve body and mechanism for any evidence of internal corrosion or rust, dirt, scale, leakage, etc.
Page 212: Inspect The Heat Exchanger Tubes
symptom appears, contact an experienced and responsible service organization for assistance. Inspect the Heat Exchanger Tubes Cooler Inspect and clean the cooler tubes at the end of the first operating season. Because these tubes have internal ridges, a rotary-type tube cleaning system is necessary to fully clean the tubes.
Page 213 Because HCFC-22 and HFC134-a are high-pressure refrigerants, air usually does not enter the machine, rather, the refrigerant leaks out. During the tube cleaning process, use brushes especially designed to avoid scraping and scratching the tube wall. Contact your Carrier representative to obtain these brushes. Do not use wire brushes. CAUTION Hard scale may require chemical treatment for its prevention or removal.
Page 214 Water must be within design flow limits, clean, and treated to ensure proper machine performance and reduce the potential of tubing damage due to corro- sion, scaling, erosion, and algae. Carrier assumes no responsibility for chiller damage resulting from untreated or improperly treated water.
Page 215 Inspect the Starting Equipment Before working on any starter, shut off the machine, and open all disconnects supplying power to the starter. WARNING The disconnect on the starter front panel does not deenergize all internal circuits. Open all internal and remote disconnects before servicing the starter. WARNING Never open isolating knife switches while equipment is operating.
Page 216 CAUTION Loose power connections can cause voltage spikes, overheating, malfunction- ing, or failures. Check Pressure Transducers Once a year, the pressure transducers should be checked against a pressure gage reading. Check all three transducers: oil pressure, condenser pressure, cooler pressure. Note the evaporator and condenser pressure readings on the Status01 table on the LID.
Page 217 Optional Pumpout Compressor Oil Charge Use oil conforming to Carrier specifications for reciprocating compressor usage. Oil requirements are as follows: ISO Viscosity...68 Carrier Part Number ... PP23BZ103 The total oil charge, 4.5 pints (2.6 L), consists of 3.5 pints (2.0 L) for the compressor and one additional pint (0.6 L) for the oil separator.
Page 218 Click here for Figure 40 — Optional Pumpout System Controls Ordering Replacement Chiller Parts When ordering Carrier specified parts, the following information must accompany an order: • machine model number and serial number •...
Page 219: Troubleshooting Guide
Overview The PIC has many features to aid the operator and the technician in troubleshooting a 19XL machine. • By using the LID display, the chiller actual operating conditions can be viewed while the unit is running. • When an alarm occurs, the default LID screen will freeze at the time of alarm. The freeze enables the operator to view the machine conditions at the time of alarm.
Page 220 Checking the Display Messages The first area to check when troubleshooting the 19XL is the LID display. If the alarm light is flashing, check the primary and secondary message lines on the LID default screen These messages will indicate where the fault is occurring. The Alarm History table on the LID Service menu will also carry an alarm message to further expand on this alarm.
Page 221 a digital ohmmeter. The resistance and corresponding temperature is listed in Table 11B. Check the resistance of both wires to ground. This resistance should be infinite. Voltage Drop Using a digital voltmeter, the voltage drop across any energized sensor can be measured while the control is energized.
Page 222 Figure 8 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconnected by unlatching the connector. These connectors allow only one-way connection to the sensor. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads.
Page 223 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. IMPORTANT: Whenever the oil pressure or the cooler pressure transducer is cali- brated, the other sensor should be calibrated to prevent problems with oil differential pressure readings.
Page 224 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 the allowed range (noted above), check the voltage ratio of the transducer. To obtain the voltage ratio, divide the voltage (dc) input from the transducer by the supply voltage signal, measured at the PSIO terminals J7-J34 and J7-J35.
Page 225 The PIC will not allow calibration if the transducer is too far out of calibration. A new transducer must be installed and recalibrated. Transducer Replacement Since the transducers are mounted on Schrader-type fittings, there is no need to remove refrigerant from the vessel. Disconnect the transducer wiring by pulling up on the locking tab while pulling up on the weather-tight connecting plug from the end of the transducer.
Page 226: Control Algorithms Checkout Procedure
Control Algorithms Checkout Procedure In the LID Service menu, one of the tables is Control Algorithm Status. This table contains 4 maintenance tables which may be viewed in order to see how the particular control algorithm is operating. The 4 tables are: MAINT01 Capacity Control Override Status...
Page 227 Control Test The Control Test feature can check all of the thermistor temperature sensors, including those on the Options modules, pressure transducers, pumps and their associated flow switches, the guide vane actuator, and other control outputs, such as hot gas bypass. The tests can help to determine whether a switch is defective, or a pump relay is not operating, among other useful troubleshooting tests.
Page 228 Click here for Table 10C — In Recycle Shutdown Click here for Table 10D — Pre-Start Alerts Click here for Table 10E — Normal or Auto.-Restart Click here for Table 10F — Start-Up Failures Click here for Table 10G — Compressor Jumpstart and Refrigerant Protection Click here for Table 10H —...
Page 229 Click here for Table 10I — Normal Run Overrides Active (Alerts) Click here for Table 10J — Out-of-Range Sensor Failures Click here for Table 10K — Machine Protect Limit Faults Click here for Table 10L — Machine Alerts Click here for Table 10M — Spare Sensor Alert Messages Click here for Table 10N —...
Page 230 Click here for Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop Click here for Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop Control Modules CAUTION Turn controller power off before servicing controls. This ensures safety and pre- vents damage to controller. The Processor module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous diagnostic evaluations of the hardware to determine its condition.
Page 231 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 requiring replacement of the module. Off continuously indicates that the power should be checked. If the red LED blinks 3 times per second, a software error has been discovered and the module must be replaced.
Page 232 PSIO Module Green LED closest to communications connection — Communication with SMM and 8-input module; must blink continuously. Other Green LED — Communication with LID; must blink every 3 to 5 seconds. 8-Input Modules and SMM Green LED — Communication with PSIO module; will blink continuously.
Page 233: Notes On Module Operation
Notes on Module Operation 1. The machine operator monitors and modifies configurations in the microprocessor through the 4 softkeys and the LID. Communication with the LID and the PSIO is accomplished through the CCN bus. The communication between the PSIO, SMM, and both 8-input modules is accomplished through the sensor bus, which is a 3-wire cable.
Page 234 If all modules indicate communications failure, check communications plug on the PSIO module for proper seating. Also check the wiring (CCN bus — 1:red, 2:wht, 3:blk; Sensor bus — 1:red, 2:blk, 3:clr/wht). If a good connection is assured and the condition persists, replace the PSIO module.
Page 235 Click here for Figure 41 — PSIO Module Address Selector Switch Locations and LED Locations Click here for Figure 42 — LID Module (Rear View) and LED Locations Processor Module (PSIO) ( Inputs Each input channel has 3 terminals; only 2 of the terminals are used. Application of machine determines which terminals are normally used.
Page 236 Starter Management Module (SMM) ( Inputs Inputs on strips J2 and J3 are a mix of analog and discrete (on/off) inputs. Application of the machine determines which terminals are used. Always refer to the individual unit wiring diagram for terminal numbers. Outputs Outputs are 24 vdc and wired to strip J1.
Page 237 Options Modules (8-Input) The options modules are optional additions to the PIC, and are used to add temperature reset inputs, spare sensor inputs, and demand limit inputs. Each option module contains 8 inputs, each input meant for a specific duty. See the wiring diagram for exact module wire terminations.
Page 238: Replacing Defective Processor Modules
The proper software is factory-installed by Carrier in the replacement module. When ordering a replacement processor module (PSIO), specify complete replacement part number, full unit model number, and serial number.
Page 239 Save the screw for later use. The green ground wire is held in place with the module mounting screw. 5. Package the defective module in the carton of the new module for return to Carrier. Control Modules section.
Page 240 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 grounding wire is reinstalled along with the mounting screw. 7. Connect the LID communication wires (CCN bus) and the power wires. If CCN wiring has been attached to the CCN bus, disconnect the wires.
Page 241 14. Restore chiller to normal operation, calibrate motor amps. Solid-State Starters Troubleshooting guides and information pertaining to the operation of the solid-state starter may be found in Figure Figure Table 12, and Table Attempt to solve the problem by using the following preliminary checks before consulting the troubleshooting tables.
Page 242 IMPORTANT: Before performing the SCR check below, remove power from the starter and disconnect the motor terminals T1, T2, and T3. 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 connecting bus heatsink between SCR3 and SCR6 and check anode to cathode of SCR3 and SCR6 separately to determine which device is defective.
Page 243 CAUTION Damage to the starter may result if wires are reversed. If problem is still not resolved, consult the starter manufacturer for servicing. Testing Silicon Control Rectifiers (SCRs) in Cutler-Hammer® Solid-State Starters To check for a shorted SCR refer to Steps 1-3 and Note: Do not megger (high voltage insulation test) the starter.
Page 244 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 wire is disconnected to prevent the shorted SCR detection from operating the disconnect device while this test is being performed.
Page 245 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 limit. If the voltage is higher than 2 v on only 1 or 2 power poles, not all SCRs are firing properly. Make sure the gate lead connections are tight.
Page 246 System Ready (SYST RDY) — This light-emitting diode (LED) provides a visual indication that the EPR is functioning. Trip Time Potentiometer — The Trip Time potentiometer has 50 selectable overload trip classes ranging from 1 to 50 seconds. Reset Time Potentiometer — The Reset Time potentiometer has 5 to 120 minutes of motor cooling reset.
Page 247 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 SYST RDY LED is a flashing green light, a motor overload trip has occurred. When the FLT LED is a solid red light and the SYST RDY LED is a solid green light, the overload has tripped because of a phase unbalance.
Page 248 Click here for Table 13 — Cutler-Hammer® Solid-State Starter Troubleshooting Guide Physical Data Table Table Table Figure Figure 57, and Figure 58 and clearances, physical and electrical data, and wiring schematics for operator convenience during troubleshooting. Click here for Table 14 — Heat Exchanger Data Click here for Table 15 —...
Page 249 Click here for Table 17 — Compressor/Motor Weights Click here for Table 18 — Waterbox Cover Weights Click here for Table 19 — Optional Pumpout System Electrical Data Click here for Figure 53 — Compressor Fits and Clearances Click here for Figure 54 — Compressor Fits and Clearances (continued) Click here for Figure 55 —...
Page 250 Click here for Figure 56 — Electronic PIC Controls Wiring Schematic Click here for Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic Click here for Figure 58 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic...
Page 251 Table 1 — Major PIC Components and Panel Locations* Pic Component Processor Sensor Input/Output Module (PSIO) Starter Management Module (SMM) Local Interface Device (LID) 6-Pack Relay Board 8-Input Modules (Optional) Oil Heater Contactor (1C) Oil Pump Contactor (2C) Hot Gas Bypass Relay (3C) (Optional) Control Transformers (T1-T4) Control and Oil Heater Voltage Selector (S1) Temperature Sensors...
Page 252 Table 2 — LID Screens Notes: 1. Only 12 lines of information appear on the LID screen at any given time. Press NEXT or PREVIOUS to highlight a point or to view points below or above the current screen. 2. The LID may be configured in English or SI units, as required, through the LID configuration screen. 3.
Page 253 Table 2, Example 1 — Status01 Display Screen (Continued) Description Entering Chilled Water Leaving Chilled Water Entering Condenser Water Leaving Condenser Water Evaporator Refrig Temp Evaporator Pressure Condenser Refrig Temp Condenser Pressure Discharge Temperature Bearing Temperature Motor Winding Temp Oil Sump Temperature Oil Pressure Transducer Oil Pressure Line Voltage: Percent...
Page 254 Example 2 — Status02 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press STATUS. 3. Scroll down to highlight STATUS02. 4. Press SELECT. Table 2, Example 2 — Status02 Display Screen Description Hot Gas Bypass Relay *Chilled Water Pump Chilled Water Flow *Condenser Water Pump...
Page 255 Example 3 — Status03 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press STATUS. 3. Scroll down to highlight STATUS03. 4. Press SELECT. Table 2, Example 3 — Status03 Display Screen Description OPTIONS BOARD 1 *Demand Limit 4-20 mA *Temp Reset 4-20 mA *Common CHWS Sensor...
Page 256 Example 4 — Setpoint Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SETPOINT. Table 2, Example 4 — Setpoint Display Screen Configurable Description Range Base Demand Limit 40-100 20-120 (–6.7-48.9) LCW Setpoint ECW Setpoint 20-120 (–6.7-48.9) 20- 60 (–6.7-15.6)
Page 257 Example 5 — Configuration (Config) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT CONFIGURATION. 4. Press SELECT. 5. Scroll down to highlight CONFIG. 6. Press SELECT. Table 2, Example 5 —...
Page 258 Example 6 — Lead/Lag Configuration Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT CONFIGURATION. 4. Press SELECT. 5. Scroll down to highlight Lead/Lag. 6. Press SELECT. Table 2, Example 6 —...
Page 259 Example 7 — Service1 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT. 5. Scroll down to highlight SERVICE1. 6. Press SELECT. Table 2, Example 7 —...
Page 260 Table 2, Example 7 — Service1 Display Screen (Continued) Description Surge/HGBP Delta P2 Full Load Points (T2/P2) Surge/HGBP Deadband Surge Delta Percent Amps Surge Time Period Demand Limit Source Select: Amps=0, Load=1 Amps Correction Factor Motor Rated Load Amps Motor Rated Line Voltage Meter Rated Line KW Line Frequency Select: 0=60 Hz, 1=50 Hz...
Page 261 Example 8 — Service2 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT. 5. Scroll down to highlight SERVICE2. 6. Press SELECT. Table 2, Example 8 —...
Page 262 Table 2, Example 8 — Service2 Display Screen (Continued) Description OPTIONS BOARD 2 20 mA POWER CONFIGURA- TION External = 0, Internal = 1 SPARE 1 20 mA Power Source SPARE 2 20 mA Power Source SPARE ALERT ENABLE Disable = 0, Low = 1, High = 2 Temp = Alert Threshold Spare Temp 4 Enable Spare Temp 4 Alert...
Page 263 Example 9 — Service3 Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight EQUIPMENT SERVICE. 4. Press SELECT. 5. Scroll down to highlight SERVICE3. Table 2, Example 9 — Service3 Display Screen Description Proportional Inc Band Proportional Dec Band...
Page 264 Example 10 — Maintenance (Maint01) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT01. Table 2, Example 10 — Maintenance (Maint01) Display Screen Description CAPACITY CONTROL Control Point...
Page 265 Example 11 — Maintenance (Maint02) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT02. 6. Press SELECT. Table 2, Example 11 —...
Page 266 Example 12 — Maintenance (Maint03) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT03. 6. Press SELECT. Table 2, Example 12 —...
Page 267 Example 13 — Maintenance (Maint04) Display Screen To access this display from the LID default screen: 1. Press MENU. 2. Press SERVICE. 3. Scroll down to highlight CONTROL ALGORITHM STATUS. 4. Press SELECT. 5. Scroll down to highlight MAINT04. 6. Press SELECT. Table 2, Example 13 —...
Page 268 Table 3 — Protective Safety Limits and Control Settings Monitored Parameter Temperature Sensors Out Of Range Pressure Transducers Out Of Range Compressor Discharge Tem- perature Motor Winding Temperature Bearing Temperature Evaporator Refrigerant Temperature Transducer Voltage Condenser Pressure — Switch — Control Oil Pressure —...
Page 269 Table 3 — Protective Safety Limits and Control Settings (Continued) Monitored Parameter Starter Acceleration Time (Determined by inrush current going below 100% compres- sor motor load) Starter Transition Condenser Freeze Protection Flow Switches (Field Supplied) Operate water pumps with machine off. Manually reduce water flow and observe switch for proper cutout. Safety shutdown occurs when cutout time exceeds 3 seconds.
Page 270 Table 4 — Capacity Overrides First Stage Setpoint Override Capacity View/ Control Modify Default Value on LID Screen HCFC-22 High Equip- 195 psig Condenser ment (1345 kPa) Pressure Service1 Equip- 200 F High Motor ment (93.3 C) Temperature Service1 Equip- 3°...
Page 271 Table 4 — Capacity Overrides (Continued) First Stage Setpoint Override Capacity View/ Control Modify Default Value on LID Screen 100% Motor Load Status01 — Active Demand Limit Configurable Range 40 to 100% Second Override Stage Termination Setpoint Value Value >5% of 2% Lower Set Point Than Set...
Page 272 Table 5A — HCFC-22 Pressure – Temperature (F) Pressure (psi) Temper- ature (F) Absolute Gage 11.67 6.154* 12.34 4.829* 13.00 3.445* 13.71 2.002* 14.45 0.498* 15.22 0.526 16.02 1.328 16.86 2.163 17.73 3.032 18.63 3.937 19.57 4.877 20.55 5.853 21.56 6.868 22.62 7.921...
Page 273 Table 5B — HCFC-22 Pressure – Temperature (C) Pressure (kPa) Temper- ature (C) Absolute Gage Pressure (kPa) Temper- ature (C) Absolute Gage 1020 1040 1070 1100 1000 1130 1030 1160 1060 1190 1090 1220 1120 1260 1160 1290 1190 1320 1220 1360 1260...
Page 274 Table 5C — HFC-134a Pressure – Temperature (F) Temperature, F Pressure (psig) 6.50 7.52 8.60 9.66 10.79 11.96 13.17 14.42 15.72 17.06 18.45 19.88 21.37 22.90 24.48 26.11 27.80 29.53 31.32 33.17 35.08 37.04 39.06 41.14 43.28 45.48 47.74 50.07 52.47 54.93 57.46...
Page 275 Table 5C — HFC-134a Pressure – Temperature (F) (Continued) Temperature, F Pressure (psig) 71.18 74.14 77.18 80.30 83.49 86.17 90.13 93.57 97.09 100.70 104.40 108.18 112.06 116.02 120.08 124.23 128.47 132.81 137.25 141.79 146.43 151.17 156.01 160.96 166.01 171.17 176.45 181.83 187.32 192.93...
Page 276 Table 5D — HFC-134a Pressure – Temperature (C) Temperature, C -18.0 -16.7 -15.6 -14.4 -13.3 -12.2 -11.1 -10.0 -8.9 -7.8 -6.7 -5.6 -4.4 -3.3 -2.2 -1.1 10.0 11.1 12.2 13.3 14.4 Pressure Gage (kPa) 44.8 51.9 59.3 66.6 74.4 82.5 90.8 99.4 108.0...
Page 277 Table 5D — HFC-134a Pressure – Temperature (C) (Continued) Temperature, C 15.6 16.7 17.8 18.9 20.0 21.1 22.2 23.3 24.4 25.6 26.7 27.8 28.9 30.0 31.1 32.2 33.3 34.4 35.6 36.7 37.8 38.9 40.0 41.1 42.2 43.3 44.4 45.6 46.7 47.8 48.9 50.0...
Page 278 Table 6 — Potentiometer Adjustment Adjustment Range Dial Minimum (CCW) Starting Current 100% Ramp Time (Adjust- 2 seconds able Current Ramp) Current Limit 100% Pulse Start 0 (Off) Current Trip Power Saver — CCW — Counterclockwise CW — Clockwise Function Maximum (CW) 400%...
Page 279 Table 7 — Amps Correction Factors for 19XL Motors Motor Code Volt/ Hz 200/60 208/60 220/60 230/60 240/60 360/60 380/60 400/60 440/60 460/60 480/60 550/60 575/60 600/60 3300/60 2400/60 4160/60 220/50 230/50 240/50 320/50 346/50 360/50 380/50 400/50 415/50 3000/50 3300/50...
Page 280 Table 8 — Control Test Menu Functions Tests To Be Performed 1. Automated Tests* 2. PSIO Thermistors 3. Options Thermistors 4. Transducers 5. Guide Vane Actuator 6. Pumps Devices Tested Operates the second through seventh tests Entering chilled water Leaving chilled water Entering condenser water Leaving condenser water Discharge temperature...
Page 281 Table 8 — Control Test Menu Functions (Continued) Tests To Be Performed 7. Discrete Outputs 8. Pumpdown/Lockout 9. Terminate Lockout 10. Refrigerant Type * 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 displayed.
Page 282 Table 9 — Refrigerant (HCFC-22 or HFC-134a) Charges 19XL Total Refrigerant Charge Cooler Size Design I Machine 1420 1490 1550 1600 1850 1900 1980 2050 — — — — Notes: 1. The size of the cooler determines refrigerant charge for the entire machine. 2.
Page 283 Legend For Table 10, A - N 1CR AUX — Compressor Start Contact CA P — Compressor Current CDFL — Condenser Water Flow CHIL S S — Chiller Start/Stop CMPD — Discharge Temperature — Condenser Pressure — Evaporator Refrigerant Temperature EVFL —...
Page 284 Table 10B — Timing Out or Timed Out Primary Message Secondary Message Ready To Start In XX Min Unoccupied Mode Ready To Start In XX Min Remote Contacts Open Ready To Start In XX Min Stop Command In Effect Ready To Start In XX Min Recycle Restart Pend- Ready To Start Unoccupied Mode...
Page 285 Table 10C — In Recycle Shutdown Primary Message Recycle Restart Pending Recycle Restart Pending Recycle Restart Pending Recycle Restart Pending Secondary Message Probable Cause/Remedy Occupied Mode Unit in recycle mode, chilled water temperature is not high enough to start. Remote Contact Closed Unit in recycle mode, chilled water temperature is not high enough to start.
Page 286 Table 10D — Prestart Alerts: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary. Primary Message Secondary Message Prestart Alert Starts Limit Exceeded High Motor Tempera- Prestart Alert ture High Bearing Tempera- Prestart Alert ture Prestart Alert...
Page 287 Table 10E — Normal or Auto.-Restart Primary Message Startup in Progress Startup in Progress Startup in Progress AutoRestart in Progress AutoRestart in Progress AutoRestart in Progress Secondary Message Probable Cause/Remedy Occupied Mode Machine starting. Time schedule is occupied. Remote Contact Closed Machine starting.
Page 288 Table 10F — Start-Up Failures: This is an alarm condition. A manual reset is required to clear. Primary Secondary Message Message Low Oil Pressure Failure To Start Oil Press Sensor Fault Failure To Start Low Chilled Failure To Water Flow Start Low Condenser Failure To...
Page 289 Table 10F — Start-Up Failures: This is an alarm condition. A manual reset is required to clear. (Continued) Primary Secondary Message Message Starter Transi- Failure To tion Fault Start 1CR AUX Con- Failure To tact Fault Start Motor Amps Not Failure To Sensed Start...
Page 290 Table 10G — Compressor Jumpstart and Refrigerant Protection Secondary Primary Message Message Unit Should Be Stopped Unauthorized Operation Evap Press/Temp Potential Freeze- Too Low Disconnect Power Failure To Stop With Starter Loss Of Communciation Abnormal 1CR or Run Starter Contact Fault Cond Press/Temp Too Low...
Page 291 Table 10H — Normal Run with Reset, Temperature, or Demand Primary Message Running — Reset Active Running — Reset Active Running — Reset Active Running — Temp Control Running — Temp Control Running — Temp Control Running — Demand Limited Running —...
Page 292 Table 10I — Normal Run Overrides Active (Alerts) Primary Message Secondary Message Run Capacity Lim- High Condenser Pres- ited sure Run Capacity Lim- High Motor Temperature ited Run Capacity Lim- Low Evap Refrig Temp ited Run Capacity Lim- High Compressor Lift ited Run Capacity Lim- Manual Guide Vane Tar-...
Page 293 Table 10J — Out-of-Range Sensor Failures Primary Message Secondary Message Leaving CHW Temperature Sensor Fault: Check leaving CHW Sensor Fault Entering CHW Temperature Sensor Fault: Check entering CHW Sensor Fault Condenser Pressure Sensor Fault Evaporator Pressure Sensor Fault Bearing Temperature Sensor Fault Motor Winding Temp Sensor Fault...
Page 294 Table 10K — Machine Protect Limit Faults WARNING Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise. Primary Secondary Message Message High Discharge Temp Protective Limit Low Refrigerant Protective Temp Limit High Motor Temper- ature Protective Limit...
Page 295 Table 10K — Machine Protect Limit Faults (Continued) WARNING Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise. Primary Secondary Message Message Power Loss Protective Limit Low Line Voltage Protective Limit High Line Voltage Protective Limit Low Chilled Water...
Page 296 Table 10K — Machine Protect Limit Faults (Continued) WARNING Excessive numbers of the same fault can lead to severe machine damage. Seek service expertise. Primary Secondary Message Message CCN Override Stop Protective Limit Spare Safety Device Protective Limit Excessive Motor Protective Amps Limit...
Page 297 Table 10L — Machine Alerts Primary Secondary Message Message High Amps at Shut- Recycle Alert down Leaving Cond Water Sensor Fault Temp Alert Entering Cond Water Sensor Fault Temp Alert Check Oil Filter Low Oil Pressure Alert Power Loss AutoRestart Pending Low Line Voltage AutoRestart...
Page 298 Table 10M — Spare Sensor Alert Messages Secondary Primary Message Message Common CHWS Sen- Spare Sensor Alert Common CHWR Sen- Spare Sensor Alert Remote Reset Sensor Spare Sensor Alert Temp Sensor — Spare Sensor Spare 1 Alert Temp Sensor — Spare Sensor Spare 2 Alert...
Page 299 Table 10N — Other Problems/Malfunctions Description/ Probable Cause/Remedy Malfunction Chilled water set point set too high. Access set point on LID and verify. Capacity override or excessive cooling load (machine at design capacity). Check LID status messages. Check for outside air infiltration into conditioned space. Condenser temperature too high.
Page 300 Table 10N — Other Problems/Malfunctions (Continued) Description/ Probable Cause/Remedy Malfunction Check that PSIO communication plugs are connected correctly. Check SMM com- munication plug. Check for proper SMM power supply. See Communications tion. Failure Check for proper oil level (too much oil). Check that TXV valve is operating prop- High Oil erly.
Page 301 Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop Voltage Temperature Resistance Drop (Ohms) -25.0 4.821 98,010 -24.0 4.818 94,707 -23.0 4.814 91,522 -22.0 4.806 88,449 -21.0 4.800 85,486 -20.0 4.793 82,627 -19.0 4.786 79,871 -18.0 4.779 77,212 -17.0 4.772 74,648 -16.0 4.764...
Page 302 Table 11A — Thermistor Temperature (F) vs Resistance/Voltage Drop (Continued) Voltage Temperature Resistance Drop (Ohms) 1.822 2,060 1.792 2,018 1.771 1,977 1.748 1,937 1.724 1,898 1.702 1,860 1.676 1,822 1.653 1,786 1.630 1,750 1.607 1,715 1.585 1,680 1.562 1,647 1.538 1,614 1.517 1,582...
Page 303 Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop Voltage Temperature (C) Drop (V) 4.896 4.889 4.882 4.874 4.866 4.857 4.848 4.838 4.828 4.817 4.806 4.794 4.782 4.769 4.755 4.740 4.725 4.710 4.693 4.676 4.657 4.639 4.619 4.598 4.577 4.554 4.531 4.507 4.482...
Page 304 Table 11B — Thermistor Temperature (C) vs Resistance/Voltage Drop (Continued) Voltage Temperature (C) Drop (V) 1.594 1.553 1.513 1.474 1.436 1.399 1.363 1.327 1.291 1.258 1.225 1.192 1.160 1.129 1.099 1.069 1.040 1.012 0.984 0.949 0.920 0.892 0.865 0.838 0.813 0.789 0.765 0.743...
Page 305 Table 12 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide Problem Probable Causes AK board phase cor- L1 and L3 switch phases reversed. rect not on. Missing phase voltage. Improper line voltage. AK board relay not on. Ribbon cable not properly seated.
Page 306 Table 12 — Benshaw, Inc. Solid-State Starter Troubleshooting Guide (Continued) Problem Probable Causes AK board power AK board not functioning applied, run command properly. given, starter at full voltage, but aux LED not lit. 1L boards LEDs lit. Motor terminal voltage phase imbalance exists.
Page 307 Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide Problem Probable Cause CB trips (electrically Motor is not connected. operated disconnecting Incorrect phase sequence to the starter, 3- means opens) as it is phase power not connected, or terminal closed. loose. Shorted SCR.
Page 308 Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide (Continued) Problem Probable Cause Motor accelerates too Current limit is too high. quickly. Improper current feedback. Pulse start setting is too long. Broken current feedback transformer wire. Current limit adjustment Improper current feedback. has no effect during acceleration.
Page 309 Table 13 — Cutler-Hammer Solid-State Starter Troubleshooting Guide (Continued) Problem Probable Cause Overload relay trips Incorrect heater coils (melting allow). when starting. Loose heater coil. Long starting time (high inertia applications may require slow trip overload and oversize starter). Mechanical problems. Single phasing.
Page 310 Table 14 — Heat Exchanger Data Heat Vessel Exchanger Code Cooler Condenser Rigging Weights Number Dry Wt. Design I Design II Tubes 5000 2275 5340 5150 2350 5485 5325 2425 5655 5500 2500 5845 6625 3000 7020 6850 3100 7255 7100 3225 7510...
Page 311 Table 15 — Additional Data for Marine Waterboxes* English Heat Exchanger Rigging Wt (lb) Frame, Pass Cooler Condenser 1115 1660 Frame 4, 2 Pass 2030 1160 Frame 4, 1 & 3 Pass 1220 1935 Frame 5, 2 Pass 2240 1705 Frame 5, 1 &...
Page 312 Table 16 — Compressor Weights Component Suction Elbow Discharge Elbow Transmission Suction Housing Impeller Shroud Compressor Base Diffuser Oil Pump Miscellaneous Total Weight (Less Motor) Weight 1155 1125 1150 1123 1730 1331 1350 1159 1180 1136 1050 1476 1170 1132 1150 1168 1135...
Page 313 Table 17 — Compressor/Motor Weights English Stator Motor Weight Compressor Size (lb) Weight (lb) 2660 1153 2660 1162 2660 1202 2660 1225 2660 1276 2660 1289 2660 1306 2660 1335 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.
Page 314 Table 18 — Waterbox Cover Weights* (English (lb)) Heat Waterbox Description Exchanger NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover Coolers NIH, Plain End Cover MWB Cover Plain End Cover NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover Condensers NIH, Plain End Cover...
Page 315 Table 18 — Waterbox Cover Weights* (SI (kg)) (Continued) Heat Waterbox Description Exchanger NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover Coolers NIH, Plain End Cover MWB Cover Plain End Cover NIH, 1 Pass Cover NIH, 2 Pass Cover NIH, 3 Pass Cover Condensers NIH, Plain End Cover...
Page 316 Table 19 — Optional Pumpout System Electrical Data Motor Code Condenser Unit 19EA47-748 19EA42-748 19EA44-748 19EA46-748 Legend LRA — Locked Rotor Amps RLA — Rated Load Amps Volts-PH-HZ Max RLA 575-3-60 13.8 200/208-3-60 10.9 230-3-60 19.5 400/460-3-50/60 14.7 23.0 63.5 57.5 28.8...
Page 317 Figure 1 — 19XL Identification...
Page 318 Figure 2A (Front View) — Typical 19XL Components — Design I (See next page for Rear View)
Page 319 Figure 2A (Rear View) — Typical 19XL Components — Design I...
Page 320 Figure 2B (Front View) — Typical 19XL Components — Design II (See next page for Rear View)
Page 321 Figure 2B (Rear View) — Typical 19XL Components — Design II...
Page 322 Figure 3 — Refrigerant Motor Cooling and Oil Cooling Cycles...
Page 323 Figure 4 — Lubrication System...
Page 324 Figure 5 — Cutler-Hammer Solid-State Starter, Internal View...
Page 325 Figure 6 — Benshaw, Inc. Solid-State Starter, Internal View...
Page 326 Figure 7 — Typical Starter Front View (Solid-State Starter Shown)
Page 327 Figure 8 — 19XL Controls and Sensor Locations...
Page 328 Figure 9 — Control Sensors (Temperature)
Page 329 Figure 10 — Control Sensors (Pressure Transducer, Typical)
Page 330 Figure 11 — Control Panel (Front View), with Options Module...
Page 331 Figure 12 — Power Panel with Options...
Page 332 Figure 13 — LID Default Screen...
Page 333 Figure 14 — LID Service Screen...
Page 334 Figure 15 — Example of Point Status Screen (Status01)
Page 335 Figure 16 — 19XL Menu Structure...
Page 336 Figure 17 — 19XL Service Menu Structure...
Page 337 Figure 18 — Example of Time Schedule Operation Screen...
Page 338 Figure 19 — Example of Set Point Screen...
Page 339 Figure 20 — 19XL Hot Gas Bypass/Surge Prevention...
Page 340 Figure 21 — 19XL with Default Metric Settings...
Page 341 Figure 22 — Example of Attach to Network Device Screen...
Page 342 Figure 23 — Example of Holiday Period Screen...
Page 343 — START INITIATED — Prestart checks made; evaporator pump started — Condenser water pump started (5 seconds after A) — Water flows verified (30 seconds to 5 minutes maximum after B). Chilled water temperatures checked against control point. Guide vanes checked for closure. Oil pump started; tower fan control enabled. —...
Page 344 Figure 25 — Typical Wet-Bulb Type Vacuum Indicator...
Page 345 Figure 26 — 19XL Leak Test Procedures...
Page 346 Figure 27 — Typical Optional Pumpout System Piping Schematic with Storage Tank...
Page 347 Figure 28 — Typical Optional Pumpout System Piping Schematic without Storage Tank...
Page 348 Figure 29 — Dehydration Cold Trap...
Page 349 Figure 30 — Benshaw, Inc. Solid-State Starter Power Stack...
Page 350 Figure 31 — Ramp Up and Starting Torque Potentiometers...
Page 351 Figure 32 — Typical Potentiometer Adjustment...
Page 352 Figure 33 — Typical Cutler-Hammer Solid-State Starter ®...
Page 353 Figure 34 — Correct Motor Rotation...
Page 354 REFRIGERATION LOG CARRIER 19XL HERMETIC CENTRIFUGAL REFRIGERATION MACHINE Plant ______________ MACHINE MODEL NO. ______________ DATE ______ COOLER Refrigerant Water Pressure Temp TIME Press. Temp REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, air exhausted and water drained from dehydrator. Include amounts.
Page 355 C — Contactor Fu — Fuse, 3 Amps HP — High-Pressure Cutout OL — Compressor Overload T’stat — Internal Thermostat Figure 36 — 19XL Pumpout Unit Wiring Schematic Compressor Terminal Contactor Terminal Overload Terminal Pumpout Unit Terminal...
Page 356 Figure 37 — Optional Pumpout System...
Page 357 Figure 38 — Guide Vane Actuator Linkage...
Page 358 Figure 39 — 19XL Float Valve Designs...
Page 359 Figure 40 — Optional Pumpout System Controls...
Page 360 Figure 41 — PSIO Module Address Selector Switch Locations and LED Locations...
Page 361 Figure 42 — LID Module (Rear View) and LED Locations...
Page 362 Figure 43 — Processor (PSIO) Module...
Page 363 Figure 44 — Starter Management Module (SSM)
Page 364 Switch Setting Option Module 1 Figure 45 — Options Module Option Module 2...
Page 365 Figure 46 — Typical Benshaw, Inc. Solid-State Starter (Internal View)
Page 366 Figure 47 — Resistance Check...
Page 367 Figure 48 — SCR and Power Poles...
Page 368 Figure 49 — Typical Cutler-Hammer Solid-State Starter ® (Internal View)
Page 369 Figure 50 — Cutler-Hammer Terminal Functions ®...
Page 370 Figure 51 — Solid-State Starter, General Operation Troubleshooting Guide (Typical)
Page 371 Figure 52 — Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide (Typical)
Page 372 Compressor Assembly Torques Item Description Oil Heater Grommet Nut Impeller Retaining Bolt Bull Gear Retaining Bolt Motor Terminals (Low Voltage) Demister Bolts Guide Vane Shaft Seal Nut Motor Terminals (High Voltage) Figure 53 — Compressor Fits and Clearances Torque ft-lb 44-46 80-85 15-19...
Page 373 Figure 54 — Compressor Fits and Clearances (Continued)
Page 374 Figure 55 — Compressor Fits and Clearances (Continued)
Page 375 Legend Carrier Factory Wiring Optional (Factory or Field-Installed) Wiring Figure 56 — Electronic PIC Controls Wiring Schematic (page 1 of 2)
Page 376 Legend Carrier Factory Wiring Optional (Factory or Field-Installed) Wiring Figure 56 — Electronic PIC Controls Wiring Schematic (page 2 of 2)
Page 377 Legend Starter Cabinet Wiring Field Wiring Carrier Factory Wiring Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic (page 1 of 2)
Page 378 Legend Starter Cabinet Wiring Field Wiring Carrier Factory Wiring Figure 57 — Machine Power Panel, Starter Assembly, and Motor Wiring Schematic (page 2 of 2)
Page 379 Optional features are indicated by bold dotted boxes. Caution: Yellow wires remain energized when main disconnect is off. = Dry Contact Figure 58 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic (page 1 of 2)
Page 380 Optional features are indicated by bold dotted boxes. Caution: Yellow wires remain energized when main disconnect is off. = Dry contact Figure 58 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic (page 2 of 2)
Page 381 M 115 REFRIGERANT: Type: CARRIER OBLIGATIONS: Assemble ....Yes M Leak Test ....Yes M Dehydrate .
Page 382 C: Take At Least 2 Sets of Operational Log Readings and Record. E: After Machine Has Been Successfully Run and Set Up, Shut Down and Mark Shutdown Oil and Refrigerant Levels. F: Give Operating Instructions to Owner’s Operating Personnel. G: Call your Carrier factory representative to report chiller start-up. SIGNATURES: CARRIER...
Page 383 HERMETIC CENTRIFUGAL LIQUID CHILLER 19XL SET POINT TABLE CONFIGURATION SHEET DESCRIPTION Base Demand Limit LCW Setpoint ECW Setpoint ICE BUILD Setpoint PSIO Software Version Number: LID Software Version Number: PSIO Controller Identiﬁcation: BUS LID Identiﬁcation: 19XL CONFIGURATION SETTINGS LOG (Remove and use for job ﬁle.) RANGE UNITS 40 to 100...
Page 384 19XL PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC01S Period 1: Period 2: Period 3: Period 4: Period 5: Period 6: Period 7: Period 8: NOTE: Default setting is OCCUPIED 24 hours/day. ICE BUILD 19XL PIC TIME SCHEDULE CONFIGURATION SHEET OCCPC02S Period 1: Period 2: Period 3: Period 4:...
Page 385 19XL PIC CONFIG TABLE CONFIGURATION SHEET DESCRIPTION RESET TYPE 1 Degrees Reset at 20 mA RESET TYPE 2 Remote Temp (No Reset) Remote Temp (Full Reset) Degrees Reset RESET TYPE 3 CHW Temp (No Reset) CHW Temp (Full Reset) Degrees Reset Select/Enable Reset Type ECW Control Option Demand Limit at 20 mA...
Page 386 19XL PIC LEAD/LAG TABLE CONFIGURATION SHEET DESCRIPTION LEAD/LAG SELECT DISABLE =0, LEAD =1, LAG =2, STANDBY =3 Load Balance Option Common Sensor Option LAG Percent Capacity LAG Address LAG START Timer LAG STOP Timer PRESTART FAULT Timer STANDBY Chiller Option STANDBY Percent Capacity STANDBY Address RANGE...
Page 387 19XL PIC SERVICE1 TABLE CONFIGURATION SHEET DESCRIPTION Motor Temp Override Cond Pressure Override Refrig Override Delta T Chilled Medium Brine Refrig Trippoint Compr Discharg Alert Bearing Temp Alert Water Flow Verify Time Oil Press Verify Time Water/Brine Deadband Recycle Restart Delta T Surge Limit/HGBP Option Surge=0/HGBP=1 Surge/HGBP Delta T1...
Page 388 19XL PIC SERVICE1 TABLE CONFIGURATION SHEET DESCRIPTION Motor Rated Load Amps Motor Rated Line Voltage Meter Rated Line kW Line Frequency 0=60 Hz/1=50 Hz Compressor Starter Type Condenser Freeze Point Soft Stop Amps Threshold RANGE UNITS 1 to 9999 AMPS 1 to 9999 VOLTS 1 to 9999...
Page 389 19XL PIC SERVICE2 TABLE CONFIGURATION SHEET DESCRIPTION RESET 20 mA Power Source DEMAND 20 mA Power Source CHWS Temp Enable 0 to 2 –40 to 245 CHWS Temp Alert (–40 to 118) CHWR Temp Enable 0 to 2 –40 to 245 CHWR Temp Alert (–40 to 118) Reset Temp Enable...
Page 390 19XL PIC SERVICE3 TABLE CONFIGURATION SHEET DESCRIPTION Proportional Inc Band Proportional Dec Band Proportional ECW Gain Guide Vane Travel Limit RANGE UNITS 2 to 10 2 to 10 1 to 3 30 to 100 CL-10 DEFAULT VALUE...
Page 391 HOLIDAY (HOLIDEF) CONFIGURATION SHEET HOLIDEF DESCRIPTION Holiday Start Month Start Day Duration HOLIDAY (HOLIDEF) CONFIGURATION SHEET DESCRIPTION Holiday Start Month Start Day Duration HOLIDAY (HOLIDEF) CONFIGURATION SHEET DESCRIPTION Holiday Start Month Start Day Duration NOTE: There are no HOLIDAYS deﬁned on the default menu. HOLIDAY dates must be updated yearly if they are used. RANGE UNITS 1 to 12...
Page 392 BROADCAST (BRODEFS) CONFIGURATION SHEET DESCRIPTION Activate Yes/No OAT Broadcast Controller Name 8 characters Bus Number 0 to 239 Element Number 0 to 239 OARH Broadcast Controller Name 8 characters Bus Number 0 to 239 Element Number 0 to 239 Daylight Savings Start Month 1 to 12 1 to 31...

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