Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without inc urring obligations.PC 211 Catalog No. 532-306 Printed in U.S.A. Form 23XL-3SS Pg 1 7-99 Replaces: NewBook 2

Tab 5e

Start-Up, Operation and MaintenanceInstructions

SAFETY CONSIDERATIONSScrew liquid chillers are designed to provide safe and

reliable service when operated within design specifica-tions. When operating this equipment, use good judgmentand safety precautions to avoid damage to equipment andproperty or injury to personnel.

Be sure you understand and follow the procedures andsafety precautions contained in the chiller instructions, aswell as those listed in this guide.

DO NOT VENT refrigerant relief valves within a building. Outletfrom rupture disc or relief valve must be vented outdoors in accor-dance with the latest edition of ANSI/ASHRAE 15 (AmericanNational Standards Institute, American Society of Heating, Refrigera-tion, and Air Conditioning Engineers), latest edition. The accumula-tion of refrigerant in an enclosed space can displace oxygen and causeasphyxiation.PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially for enclosed and low overhead spaces. Inha-lation of high concentrations of vapor is harmful and may cause heartirregularities, unconsciousness, or death. Misuse can be fatal. Vapor isheavier than air and reduces the amount of oxygen available forbreathing. Product causes eye and skin irritation. Decompositionproducts are hazardous.DO NOT USE OXYGEN to purge lines or to pressurize a chiller forany purpose. Oxygen gas reacts violently with oil, grease, and othercommon substances.NEVER EXCEED specified test pressures. VERIFY the allowabletest pressure by checking the instruction literature and the design pres-sures on the equipment nameplate.DO NOT USE air for leak testing. Use only refrigerant or drynitrogen.DO NOT VALVE OFF any safety device.BE SURE that all pressure relief devices are properly installed andfunctioning before operating any chiller.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel untilall refrigerant (liquid and vapor) has been removed from chiller.Traces of vapor should be displaced with dry air or nitrogen and thework area should be well ventilated. Refrigerant in contact with anopen flame produces toxic gases.DO NOT USE eyebolts or eyebolt holes to rig chiller sections or theentire assembly.DO NOT work on high-voltage equipment unless you are a qualifiedelectrician.DO NOT WORK ON electrical components, including control cen-ters, switches, starters, or oil heater (if applicable) until you are sureALL POWER IS OFF and no residual voltage can leak from capaci-tors or solid-state components.LOCK OPEN AND TAG electrical circuits during servicing. IFWORK IS INTERRUPTED, confirm that all circuits are deenergizedbefore resuming work.DO NOT syphon refrigerant.AVOID SPILLING liquid refrigerant on skin or getting it into theeyes. USE SAFETY GOGGLES. Wash any spills from the skin withsoap and water. If liquid refrigerant enters the eyes, IMMEDIATELYFLUSH EYES with water and consult a physician.

NEVER APPLY an open flame or live steam to a refrigerant cylinder.Dangerous over pressure can result. When it is necessary to heatrefrigerant, use only warm (110 F [43 C]) water.DO NOT REUSE disposable (nonreturnable) cylinders or attempt torefill them. It is DANGEROUS AND ILLEGAL. When cylinder isemptied, evacuate remaining gas pressure, loosen the collar, andunscrew and discard the valve stem. DO NOT INCINERATE.CHECK THE REFRIGERANT TYPE before adding refrigerant tothe chiller. The introduction of the wrong refrigerant can cause dam-age or malfunction to this chiller.Operation of this equipment with refrigerants other than those citedherein should comply with ANSI/ASHRAE 15 (latest edition). Con-tact Carrier for further information on use of this chiller with otherrefrigerants.DO NOT ATTEMPT TO REMOVE fittings, covers, etc., whilechiller is under pressure or while chiller is running. Be sure pressure isat 0 psig (0 kPa) before breaking any refrigerant connection.CAREFULLY INSPECT all relief devices, rupture discs, and otherrelief devices AT LEAST ONCE A YEAR. If chiller operates in acorrosive atmosphere, inspect the devices at more frequent intervals.DO NOT ATTEMPT TO REPAIR OR RECONDITION any reliefdevice when corrosion or build-up of foreign material (rust, dirt, scale,etc.) is found within the valve body or mechanism. Replace thedevice.DO NOT install relief devices in series or backwards.USE CARE when working near or in line with a compressed spring.Sudden release of the spring can cause it and objects in its path to actas projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about andrelease refrigerant, causing personal injury.DO NOT climb over a chiller. Use platform, catwalk, or staging. Fol-low safe practices when using ladders.USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift ormove inspection covers or other heavy components. Even if compo-nents are light, use mechanical equipment when there is a risk of slip-ping or losing your balance.BE AWARE that certain automatic start arrangements CANENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open thedisconnect ahead of the starter, tower fan, or pumps. Shut off thechiller or pump before servicing equipment.USE only repair or replacement parts that meet the code requirementsof the original equipment.DO NOT VENT OR DRAIN waterboxes containing industrial brines,liquid, gases, or semisolids without the permission of your processcontrol group.DO NOT LOOSEN waterbox cover bolts until the waterbox has beencompletely drained.DOUBLE-CHECK that coupling nut wrenches, dial indicators, orother items have been removed before rotating any shafts.DO NOT LOOSEN a packing gland nut before checking that the nuthas a positive thread engagement.PERIODICALLY INSPECT all valves, fittings, and piping for corro-sion, rust, leaks, or damage.PROVIDE A DRAIN connection in the vent line near each pressurerelief device to prevent a build-up of condensate or rain water.

23XLHermetic Screw Liquid Chillers with HCFC-22

and HFC-134a, 50/60 HertzPIC II Controls

2

CONTENTS

PageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 523XL CHILLER FAMILIARIZATION . . . . . . . . . . . . . . 5-8Chiller Identification Nameplate . . . . . . . . . . . . . . . . . . 5System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Muffler-Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Factory-Mounted Starter (Optional Accessory) . . . 8Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 8REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 8MOTOR COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 8LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . 8-12Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8• TC FRAME 1 AND 2 CHILLERS• TD FRAME 4 CHILLERSOil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9• TC FRAME 1 AND 2 CHILLERS• TD FRAME 4 CHILLERSOil Loss Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Slide Valve Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 12,13Unit Mounted Solid-State Starter (Optional) . . . . . 13Unit Mounted Wye-Delta Starter (Optional) . . . . . . 13CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14• ANALOG SIGNAL• DIGITAL SIGNALGeneral Controls Overview . . . . . . . . . . . . . . . . . . . . . . 14PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 14• CHILLER VISUAL CONTROLLER (CVC)• INTEGRATED STARTER MODULE (ISM)• CHILLER CONTROL MODULE (CCM)• OIL HEATER CONTACTOR (1C)• HOT GAS BYPASS CONTACTOR RELAY (3C)

(Optional)• CONTROL TRANSFORMERS (T1, T2)CVC Operation and Menus . . . . . . . . . . . . . . . . . . . . . . 19• GENERAL• ALARMS AND ALERTS• CVC MENU ITEMS• BASIC CVC OPERATIONS (Using the Softkeys)• TO VIEW STATUS• OVERRIDE OPERATIONS• TIME SCHEDULE OPERATION• TO VIEW AND CHANGE SET POINTS• SERVICE OPERATIONPIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 37• CAPACITY CONTROL• ECW CONTROL OPTION• CONTROL POINT DEADBAND• PROPORTIONAL BANDS AND GAIN• DEMAND LIMITING • CHILLER TIMERS• OCCUPANCY SCHEDULESafety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Default Screen Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Low Discharge Temperature Control . . . . . . . . . . . . 39

PageOil Sump Temperature Control TC

(Frame 1 and 2) Chillers Only . . . . . . . . . . . . . . . . . 39Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 40Spare Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Spare Safety Alarm Contacts . . . . . . . . . . . . . . . . . . . . 40Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 40Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 40Condenser Freeze Protection . . . . . . . . . . . . . . . . . . . . 40Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . . 40Auto. Restart After Power Failure . . . . . . . . . . . . . . . . 41Water/Brine Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41• RESET TYPE 1• RESET TYPE 2• RESET TYPE 3Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 41Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 41• HEAD PRESSURE OUTPUT REFERENCELead/Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42• COMMON POINT SENSOR INSTALLATION• CHILLER COMMUNICATION WIRING• LEAD/LAG OPERATION• FAULTED CHILLER OPERATION• LOAD BALANCING • AUTO. RESTART AFTER POWER FAILUREIce Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44• ICE BUILD INITIATION• START-UP/RECYCLE OPERATION• TEMPERATURE CONTROL DURING ICE BUILD• TERMINATION OF ICE BUILD• RETURN TO NON-ICE BUILD OPERATIONSAttach to Network Device Control . . . . . . . . . . . . . . . 45• ATTACHING TO OTHER CCN MODULESService Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46• TO ACCESS THE SERVICE SCREENS• TO LOG OUT OF NETWORK DEVICE• HOLIDAY SCHEDULINGSTART-UP/SHUTDOWN/RECYCLE

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-49Local Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Automatic Soft Stop Amps Threshold . . . . . . . . . . . 48Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . . 49Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . 49-65Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Using the Optional Storage Tank

and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 49Remove Shipping Packaging . . . . . . . . . . . . . . . . . . . . 49Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 49Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . . . 49Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . . . . 49Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Check Optional Pumpout Compressor

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Carrier Comfort Network Interface . . . . . . . . . . . . . . . 59Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59• MECHANICAL STARTER• BENSHAW, INC. REDISTART MICRO

SOLID-STATE STARTEROil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3

CONTENTS (cont)Page

Power Up the Controls andCheck the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 60

• SOFTWARE VERSIONSoftware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 60Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 60Input the Local Occupied Schedule

(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Input Service Configurations . . . . . . . . . . . . . . . . . . . . 60• PASSWORD• INPUT TIME AND DATE• CHANGE CVC CONFIGURATION IF NECESSARY• TO CHANGE THE PASSWORD• TO CHANGE THE CVC DISPLAY FROM ENGLISH

TO METRIC UNITS• MODIFY CONTROLLER IDENTIFICATION

IF NECESSARY• INPUT EQUIPMENT SERVICE PARAMETERS

IF NECESSARY• MODIFY EQUIPMENT CONFIGURATION

IF NECESSARYPerform A Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 63• COOLER AND CONDENSER PRESSURE TRANS-

DUCER AND WATERSIDE FLOW DEVICE CALI-BRATION

Check Optional Pumpout SystemControls and Compressor . . . . . . . . . . . . . . . . . . . . . 63

High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 63Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 64• CHILLER EQUALIZATION WITHOUT

PUMPOUT UNIT• CHILLER EQUALIZATION WITH PUMPOUT UNIT• TRIMMING REFRIGERANT CHARGEINITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65,66Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 65Check Oil Pressure and Compressor Stop . . . . . . 65To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . . . 66Check Chiller Operating Condition . . . . . . . . . . . . . . 66Instruct the Customer Operator . . . . . . . . . . . . . . . . . 66• COOLER-CONDENSER• OPTIONAL PUMPOUT STORAGE TANK AND

PUMPOUT SYSTEM• MOTOR COMPRESSOR ASSEMBLY• MOTOR COMPRESSOR LUBRICATION SYSTEM• CONTROL SYSTEM• AUXILIARY EQUIPMENT• DESCRIBE CHILLER CYCLES• REVIEW MAINTENANCE• SAFETY DEVICES AND PROCEDURES• CHECK OPERATOR KNOWLEDGE• REVIEW THE START-UP OPERATION,

AND MAINTENANCE MANUALOPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 66-68Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . . 66To Start The Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Check the Running System . . . . . . . . . . . . . . . . . . . . . 66To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 67Preparation for Extended Shutdown . . . . . . . . . . . . 67After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 67Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 67Slide Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67PUMPOUT AND REFRIGERANT TRANSFER

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-71Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

PageOperating the Optional Pumpout Unit . . . . . . . . . . . 69• TO READ REFRIGERANT PRESSURESChillers with Isolation Valves . . . . . . . . . . . . . . . . . . . . 70• TRANSFER ALL REFRIGERANT TO CHILLER

CONDENSER VESSEL• TRANSFER ALL REFRIGERANT TO CHILLER

COOLER VESSEL• RETURN CHILLER TO NORMAL OPERATING

CONDITIONSChillers With Storage Tanks . . . . . . . . . . . . . . . . . . . . . 71• TRANSFER REFRIGERNT FROM PUMPOUT

STORAGE TANK TO CHILLER• TRANSFER REFRIGERANT FROM CHILLER TO

PUMPOUT STORAGE TANKGENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 72Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 72Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 72Refrigerant Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Test After Service, Repair, or Major Leak . . . . . . . . 72• REFRIGERANT TRACER• TO PRESSURIZE WITH DRY NITROGENRepair the Leak, Retest, and Apply

Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 72Trim Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 72WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 73Check the Lubrication System . . . . . . . . . . . . . . . . . . 73SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 73-76Service Ontime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 73Check Safety and Operating Controls

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . 73Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Oil Separator Coalescer . . . . . . . . . . . . . . . . . . . . . . . . . 74Refrigerant Filter/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . 74Refrigerant Strainers (TC Frame 1 and

2 Chillers Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Inspect Refrigerant Float System . . . . . . . . . . . . . . . 74Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 74Compressor Bearing Maintenance . . . . . . . . . . . . . . 75Compressor Rotor Check . . . . . . . . . . . . . . . . . . . . . . . 75Inspect the Heat Exchanger Tubes . . . . . . . . . . . . . . 75• COOLER• CONDENSERWater Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Inspect the Starting Equipment . . . . . . . . . . . . . . . . . 75Check Pressure Transducers . . . . . . . . . . . . . . . . . . . . 76Optional Pumpout System Maintenance . . . . . . . . . 76• OPTIONAL PUMPOUT COMPRESSOR

OIL CHARGE• OPTIONAL PUMPOUT SAFETY

CONTROL SETTINGSOrdering Replacement Chiller Parts . . . . . . . . . . . . . 76TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 76-103Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Checking the Display Messages . . . . . . . . . . . . . . . . . 77Checking Temperature Sensors . . . . . . . . . . . . . . . . . 77• RESISTANCE CHECK• VOLTAGE DROP• CHECK SENSOR ACCURACY• DUAL TEMPERATURE SENSORS

4

CONTENTS (cont)

PageChecking Pressure Transducers . . . . . . . . . . . . . . . . . 77• COOLER CONDENSER PRESSURE TRANSDUCER

AND WATERSIDE FLOW DEVICE CALIBRATION• TRANSDUCER REPLACEMENTControl Algorithms Checkout Procedure . . . . . . . . 78Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88• RED LED (Labeled as STAT)• GREEN LED (Labeled as COM)Notes on Module Operation . . . . . . . . . . . . . . . . . . . . . 88Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . . 89• INPUTS• OUTPUTSIntegrated Starter Module (ISM) . . . . . . . . . . . . . . . . . 89• INPUTS• OUTPUTSReplacing Defective Processor Modules . . . . . . . . 89• INSTALLATIONSolid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89• TESTING SILICON CONTROL RECTIFIERS IN

BENSHAW, INC., SOLID-STATE STARTERS• SCR REMOVAL/INSTALLATIONPhysical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104INITIAL START-UP CHECKLIST FOR

23XL HERMETIC SCREWLIQUID CHILLER . . . . . . . . . . . . . . . . . . . .CL-1 to CL-12

INTRODUCTION

Prior to initial start-up of the 23XL chiller, those involved inthe start-up, operation, and maintenance should be thoroughlyfamiliar with these instructions and other necessary job data.This book is outlined to familiarize those involved in the start-up, operation and maintenance of the unit with the control sys-tem before performing start-up procedures. Procedures in thismanual are arranged in the sequence required for proper chillerstart-up and operation.

This unit uses a microprocessor control system. Do notshort or jumper between terminations on circuit boards ormodules. Control or board failure may result.Be aware of electrostatic discharge (static electricity) whenhandling or making contact with circuit boards or moduleconnections. Always touch a chassis (grounded) part to dis-sipate body electrostatic charge before working inside con-trol center.Use extreme care when handling tools near circuit boardsand when connecting or disconnecting terminal plugs.Circuit boards can be damaged easily. Always hold boardsby the edges, and avoid touching components andconnections.This equipment uses, and can radiate, radio frequencyenergy. If not installed and used in accordance with theinstruction manual, it may interfere with radio communica-tions. This equipment has been tested and found to complywith the limits for a Class A computing device pursuant toSubpart J of Part 15 of FCC Rules, which are designed toprovide reasonable protection against such interferencewhen operated in a commercial environment. Operation ofthis equipment in a residential area is likely to cause inter-ference, in which case the user, at his own expense, will berequired to take whatever measures may be required to cor-rect the interference.Always store and transport replacement or defective boardsin an anti-static shipping bag.

5

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

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

Words printed in both all capital letters and italics can alsobe viewed on the CVC and are parameters (e.g., CONTROLMODE, COMPRESSOR START RELAY, ICE BUILDOPTION, etc.) with associated values (e.g., modes, tempera-tures, percentages, pressures, on, off, etc.).

Words printed in all capital letters and in a box representsoftkeys on the CVC control panel (e.g., , ,

, , etc.).

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

The chiller software part number of the 23XL unit is locatedon the back of the CVC.

23XL CHILLER FAMILIARIZATION(Fig. 1, 2A, and 2B)

Chiller Identification Nameplate — The chilleridentification nameplate is located on the right side of thechiller control panel center.

System Components — The components includecooler and condenser, heat exchangers in separate vessels,motor-compressor, lubrication system, control panel, andoptional motor starter. All connections from pressure vesselshave external threads to enable each component to be pressuretested with a threaded pipe cap during factory assembly.

CCM — Chiller Control ModuleCCN — Carrier Comfort NetworkCVC — Chiller Visual ControllerCCW — CounterclockwiseCW — ClockwiseECDW — Entering Condenser WaterECW — Entering Chilled WaterEMS — Energy Management SystemHGBP — Hot Gas BypassI/O — Input/OutputISM — Integrated Starter ModuleLCD — Liquid Crystal DisplayLCDW — Leaving Condenser WaterLCW — Leaving Chilled WaterLED — Light-Emitting DiodeOLTA — Overload Trip AmpsPIC II — Product Integrated Control IIRLA — Rated Load AmpsSCR — Silicon Controlled RectifierSI — International System of Units

ENTER EXITINCREASE QUIT

LEGENDVI — Volumetric Index

SERIAL NUMBER BREAKDOWN

Fig. 1 — 23XL Identification

23XL 21 21 E C6 0Model DescriptionHermetic ScrewLiquid Chiller

Cooler Size10,11 — TC Frame 120, 21 — TC Frame 240,41,42,43 — TD Frame 4

Condenser Size10,11 — TC Frame 120,21 — TC Frame 240,41,42,43 — TD Frame 4

1 — Variable V I0 — Fixed V I

Compressor SizeC2 — 1260 Tons

(560 kW)C4 — 200 Tons

(700 kW)C6 — 250 Tons

(880 kW)D4 — 300 Tons

(1055 kW)D6 — 350 Tons

(1230 kW)

E — EconomizerN — No Economizer

99 28 J 59743Year of ManufactureWeek of Year

Unique NumberPlace of Manufacture

6

13

14

15

16

17

18

5 24 23 22 21 20 1911

9

7

25

26

5

10

27

12 1

2

37 6 5 4

11

10

9

8

Fig. 2A — Typical 23XL Installation (TC Frame 1 and 2 Chillers)

1 — Power Panel2 — Chiller Visual Controller (CVC)3 — Cooler Refrigerant Isolation Valve4 — ASME Nameplate, Economizer (Hidden)5 — Service Valve6 — Take-Apart Rabbet Fit Connector (Lower)7 — Cooler Temperature Sensor8 — ASME Nameplate, Condenser/Cooler9 — Typical Waterbox Drain Port

10 — Cooler Supply/Return End Waterbox Cover11 — Condenser Supply/Return End Waterbox Cover12 — Compressor Nameplate (Hidden)

REAR VIEW

13 — Oil Separator14 — ASME Nameplate, Muffler (Hidden)15 — ASME Nameplate, Oil Separator16 — Cooler Relief Valves (Hidden)17 — Oil Sump Filter Assembly18 — Oil Charging Valve19 — Vessel Separation Feet20 — Float Chamber21 — Condenser Isolation Valve

(Option or Accessory)22 — Refrigerant Charging Valve23 — Condenser24 — Condenser Relief Valves (Hidden)25 — Take-Apart Rabbet Fit Connector

(Upper)26 — Unit Mounted Starter (Option)27 — Machine Identification Nameplate

FRONT VIEW

7

1 2

3

4

5

12 11 10 9 8 76

18

17

16

15

14

13

19 20 21 22

23

24

25

31 30 29 28 8 2627

35

34

33

32

12

Fig. 2B — Typical 23XL Installation (TD Frame 4 Chiller)

1 — Compressor Nameplate (Hidden)2 — Power Panel3 — Chiller Visual Controller (CVC)4 — ASME Nameplate, Cooler5 — Cooler6 — Vessel Separation Feet7 — Economizer Float Valve Access Cover

(Hidden)8 — Refrigerant Charging Valve9 — Economizer

10 — Oil Filter Assembly (Hidden)11 — ASME Nameplate, Economizer12 — Typical Waterbox Drain Port13 — Take-Apart Rabbet Fit Connector14 — ASME Nameplate, Condenser/Cooler15 — Cooler Supply/Return End Waterbox

Cover16 — Condenser Temperature Sensors17 — Condenser Water Pressure Sensors18 — Cooler Relief Valve

19 — Unit Mounted Starter (option)20 — ASME Nameplate, Oil Separator21 — Oil Separator Relief Valves22 — Oil Separator23 — Oil Charging Valve24 — Condenser Isolation Valve (Option or

Accessory)25 — Service Valve26 — Cooler Refrigerant Isolation Valve27 — Condenser Relief Valves and Oil Filter28 — Float Chamber29 — Poppet Valve Assembly30 — Motor Cooling Isolation Valve31 — Condenser32 — Condenser Supply/Return End

Waterbox Cover33 — Cooler Temperature Sensors34 — Cooler Water Pressure Sensors35 — Machine Identification Nameplate

FRONT VIEW

REAR VIEW

8

Cooler — This vessel (also known as the evaporator) islocated underneath the compressor. The cooler is maintained atlow temperature/pressure so that evaporating refrigerant canremove heat from water/brine flowing through its internaltubes.

Condenser — The condenser operates at a highertemperature/pressure than the cooler and has water flowingthrough its internal tubes to remove heat from the refrigerant.

Motor-Compressor — The motor-compressor main-tains system temperature/pressure differences and moves theheat carrying refrigerant from the cooler to the condenser.

Muffler-Oil Separator — The muffler provides acousti-cal attenuation.

Refrigerant/oil separation is accomplished by the oil separa-tor. Discharge gas enters near the midsection and leaves nearthe top, while the separated oil drains out through the bottomand flows through a horizontal oil sump/filter assembly (TCframe 1 and 2 chillers).

TC frame 1 and 2 chillers have an oil separator and a muf-fler assembly. On TD frame 4 chiller, the muffler is located in-side the oil separator.

Control Panel — The control panel is the user interfacefor controlling the chiller and regulating the chiller’s capacityto maintain the proper chilled water temperature. The controlpanel:• registers cooler, condenser, and lubricating system

pressures• shows chiller operating condition and alarm shutdown

conditions• records the total chiller operating hours, starts, and the

number of hours the chiller has been currently running• sequences chiller start, stop, and recycle under micro-

processor control• provides access to other Carrier Comfort Network

devices

Factory-Mounted Starter (Optional Acces-sory) — The starter allows for the proper starting and dis-connecting of electrical energy for the compressor-motor, oilheater (TC frame 1 and 2 chillers), and control panel.

Storage Vessel (Optional) — Two sizes of storagevessels are available. The vessels have double relief valves,a magnetically coupled dial-type refrigerant level gage, a1-in. FPT drain valve, and a 1/2-in. male flare vapor connectionfor the pumpout unit. A 30-in.-0-400 psi (–101-0-2750 kPa)gage is also supplied with each unit.NOTE: If a storage vessel is not used at the jobsite, factory-installed optional isolation valves may be used to isolate thechiller charge in either the cooler or condenser. An optionalpumpout compressor system is used to transfer refrigerantfrom vessel to vessel.

REFRIGERATION CYCLE

The compressor continuously draws refrigerant vapor fromthe cooler. As the compressor suction reduces the pressure inthe cooler, the remaining refrigerant boils at a fairly low tem-perature (typically 38 to 42 F [3 to 6 C]). The energy requiredfor boiling is obtained from the water flowing through the cool-er tubes. With heat energy removed, the water becomes coldenough for use in an air-conditioning circuit or process liquidcooling.

After taking heat from the water, the refrigerant vapor iscompressed. Compression adds still more energy, and the re-frigerant is quite warm (typically 130 to 160 F [54 to 71 C])when it is discharged from compressor into condenser.

Relatively cool (typically 65 to 85 F [18 to 29 C]) waterflowing into the condenser tubes removes heat from the refrig-erant and the vapor condenses to liquid.

The liquid refrigerant passes through orifices into theFLASC (Flash Subcooler) chamber (Fig. 3 and 4). Since theFLASC chamber is at a lower pressure, part of the liquid refrig-erant flashes to vapor, thereby cooling the remaining liquid.The FLASC vapor is recondensed on the tubes which arecooled by entering condenser water. The liquid then passesthrough a float valve assembly which forms a liquid seal tokeep FLASC chamber vapor from entering the cooler.

An optional economizer can be installed between the con-denser and cooler. In this case, the float valve meters the refrig-erant liquid into the economizer. Pressure in this chamber is in-termediate between condenser and cooler pressures. At thislower pressure, some of the liquid refrigerant flashes to gas,cooling the remaining liquid. The flash gas, having absorbedheat, is returned directly to the compressor at a point after suc-tion cutoff (Fig. 5). Here it is mixed with gas from the suctioncut-off point to produce an increase in the mass flow of refrig-erant transported and compressed without either an increase insuction volume or a change in suction temperature. Rather thanproviding the same capacity with less power, the compressorprovides substantially increased capacity with only a slight in-crease in power requirements.

The cooled liquid refrigerant in the economizer is meteredthrough a linear float valve into the cooler. Because pressure inthe cooler is lower than economizer pressure, some of the liq-uid flashes and cools the remainder to evaporator (cooler) tem-perature. The cycle is now complete.

MOTOR COOLING CYCLE

The motor is cooled by liquid refrigerant taken from thebottom of the condenser vessel. The flow of refrigerant ismaintained by the pressure differential that exists due to com-pressor operation. The refrigerant flows through an isolationvalve, in-line filter/drier, and a sight glass/moisture indicator(dry-eye), into the motor through the motor spray nozzle. SeeFig. 3 and 4.

The motor spray nozzle is orificed to control refrigerantflow through the gaps in the rotor and axial vent holes. The re-frigerant collects in the bottom of the motor casing and thendrains into the cooler through the motor cooling drain line.

The motor is protected by a temperature sensor imbeddedin the stator windings. Motor temperatures above the MOTORWINDING TEMPERATURE OVERRIDE THRESHOLD(see Capacity Override section, page 38) will override thechilled water temperature capacity control to hold. If the motortemperature rises 10 F (5.5 C) above this threshold, the slidevalve will unload. If the motor temperature rises above thesafety limit, the compressor will shut down.

LUBRICATION CYCLE

Summary — The 23XL does not require an oil pump. Oilflow is driven by differential pressure between condenser andevaporator. This system pressure difference holds the potentialto push the oil through the oil separator and filter into the com-pressor rotors, bearings, and slide valve. The cycle is referredto as a “high side” oil system. See Fig. 3, 4, and 5.

Details — The oil system:• lubricates the roller bearings which support the male

and female rotors, and the ball bearings of the 23XLcompressor.

• positions the slide valve for capacity control. The slidevalve is connected to a piston via a rod. The position ofthe piston, which rides in a cylinder, is determined byenergizing one of two solenoids which function to

9

supply and equalize oil pressure to and around the pis-ton. This allows the slide valve to unload and load.

• seals the gap between the male and female rotors. Theoil hydrodynamically seals this space to allow the refrig-erant vapor to be compressed. A specific flow rate of oilis injected into the compressor rotor housing at the pointwhere the compression process is initiated.

• cools the compressed refrigerant vapor. The oil that isinjected into the compressor for sealing also acts as aheat sink by absorbing a portion of the heat from com-pression. Thus, constant and cool compressor dischargegas temperature, relative to an oil-less screw compres-sor, is maintained.Oil is charged into the system through a hand valve located

on the bottom of the oil sump (TC frame 1 and 2 chillers) orseparator (TD frame 4 chillers). Sight glasses on the oil sump(TC frame 1 and 2 chillers) and/or oil separator (TD frame 4chillers) permit oil level observation. When the compressor isshut down, an oil level should be visible in the oil sump (TCframe 1 and 2 chillers) or the lower oil separator sight glass(TD frame 4 chillers). During operation, the oil level shouldrise and be visible in the oil separator sight glass (TC frame 1and 2 chillers) or the upper oil separator sight glass (TD frame4 chillers). Approximately 4.2 gal. (15.9 L) of an oil and refrig-erant mixture accumulates in the sump of TC frame 1 and 2chillers. Approximately 10 gal (38 L) of oil accumulates in theseparator and 2 gal. (7.6 L) accumulates on the cooler of TDframe 4 chillers.

Oil is driven from the oil separator through an oil filter toremove foreign particles. The oil filter has a replaceable car-tridge. The filter housing is capable of being valved off to per-mit removal of the filter (see Maintenance sections, pages 72-76, for details). The oil then travels through a shutdown sole-noid and past a pressure transducer to three separate inlets onthe compressor. The oil pressure measured by the transducer isused to determine the oil pressure differential and pressure dropacross the oil filter. The oil pressure differential is equal to thedifference between the oil pressure transducer reading and theevaporator pressure transducer reading. It is read directly fromthe Chiller Visual Controller (CVC) default screen.

Part of the oil flow to the compressor is directed to the slidevalve and is used for capacity control positioning. The remain-ing oil flow is divided between the rotors and bearings. A spe-cific quantity is sent to the rotors and injected at the start ofcompression to seal the clearances between the rotors. Anotherportion is sent to the bearings and used for lubrication.

Oil leaves the compressor mixed with the compressed dis-charge refrigerant vapor. The mixture then enters the oil sepa-rator, where oil is removed from the refrigerant and collected atthe bottom to complete the cycle.TC FRAME 1 AND 2 CHILLERS — The oil and refrigerantvapor mixture enters the oil separator through a nearly tangen-tial nozzle, giving a rotational flow pattern. Oil is thrown to thesides of the oil separator and runs down the walls to a chamberin the bottom where it drains to the sump. A baffle separatesthis chamber from the vortex flow to prevent re-entrainment.Gas flows up through a vortex funnel to a removable coalesc-ing element where the rest of the oil collects. This oil runsdown the element surface to a scavenge line which is piped tothe first closed lobe port.TD FRAME 4 CHILLERS — The oil and refrigerant vapormixture is directed against the rear wall of the oil separator as itenters the side of the oil separator. This action causes the bulkof the oil to drop from the refrigerant and collect at the bottomof the oil separator. A mesh screen is provided near the oil sep-arator outlet to remove any additional oil which may still be en-trained in the refrigerant vapor.

The oil sump (TC frame 1 and 2 chillers) contains a com-bined level switch and temperature sensor, 500-watt oil heater

(TC frame 1 and 2 chillers), and oil filter. Oil temperature ismeasured and displayed on the CVC default screen. Duringshutdown, oil temperature is maintained by the Product Inte-grated Control II (PIC) II). See Oil Sump Temperature Controlsection on page 39.NOTE: TD frame 4 chillers do not have an oil heater.

Operating oil pressure must be at least 20 psi (138 kPa) forHCFC-22 [7 psi (48.3 kPa) for HFC-134a] and is dependentupon system pressure differential (lift). The oil pressure trans-ducer is located downstream of the filter, so the value displayedon the CVC will be slightly less than the lift value. Under nor-mal full load conditions, oil pressure is approximately 120 psi(827 kPa) [76 psi (517 kPa)]. If sufficient system differentialpressure is not established or maintained, oil pressure will notbe established (or will be lost) and chiller shutdown will result.

The compressor provides a pressure differential, but the sys-tem pressure differential is constrained by the temperatures ofthe chilled and tower water circuits. Cold tower water, rapidtower water temperature swings, and high return chilled watertemperature are among the factors which could contribute tofrequent low oil pressure alarms. To help ensure that suitableoil pressure is established at start-up, sufficient tower watercontrol should exist. Increasing the chiller ramp loading ratewill allow faster compressor load up. This will quickly estab-lish the refrigerant and, therefore, oil pressure differential.

Conversely, rapid loading of the compressor could causeany refrigerant in the oil to flash due to the sudden drop in suc-tion pressure. During initial start-up, the 23XL PIC II controlfollows a ramped oil pressure requirement algorithm for thefirst 160 seconds. Therefore, the PIC II control follows and in-ternal oil pressure ramp loading schedule during initial start-up.See The Troubleshooting Guide section on page 76 for furtherinformation.

If the start-up oil pressure falls below the values specified inTable 1, the PIC II control will shut down the chiller.

Table 1 — Oil Pressure Ramp-Up Rate

Oil Reclaim System — The oil reclaim system operatesto return oil from the cooler back to the compressor.TC FRAME 1 AND 2 CHILLERS — The oil reclaim sys-tem returns oil to the compressor using discharge gas pressureto power an ejector. The oil and refrigerant mixture is vacu-umed from the top of the cooler liquid refrigerant level and dis-charged into the compressor suction port.TD FRAME 4 CHILLERS — TD frame 4 chillers do not re-quire an external oil reclaim system.

Oil Loss Prevention — The suction pan is located ontop of the cooler, where oil collects during low-load operation.The cooler is designed so that when oil drains into the coolerfrom the compressor during low loads, it will be re-entrainedwith the suction gas flow.

In addition, the PIC II Controls minimize oil loss to thecooler once the rotor inlet temperature sensor detects hot oildraining down the suction pipe.

If the rotor inlet temperature increases 4 F (2.2 C) in TC(frame 1 and 2) chillers or TD (frame 4) chillers above theleaving chilled water temperature, the slide valve is proportion-ately moved in the load direction to increase suction gas veloc-ity. The chiller will continue to load until the rotor inlet temper-ature is equal to LCWT+1° F or the chiller recycles.

TIME(SEC)

MINIMUM START-UP OIL PRESSURE REQUIREMENT

HCFC-22 HFC-134apsi kPa psi kPa

40 1.4 9.7 1.4 9.780 4 27.6 4 27.6

120 7 48.3 7 48.3

10

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12

Slide Valve Principle — Oil flow to the slide piston iscontrolled by two solenoid valves. Each solenoid is operatedby load and unload signals from the PIC II control.

To unload the compressor, the unload solenoid valve is en-ergized and the load solenoid valve is deenergized. This con-ducts high pressure oil to the cylinder, retracting the capacityrod, and modulating the slide valve toward the open position.See Fig. 6. The slide valve opening vents compressed gas backto the suction port on the compressor, retarding the start of thecompression process.

To load the compressor, the unload solenoid valve is deener-gized and the load solenoid valve is energized. This bleeds oilfrom the cylinder to the suction pressure area within the com-pressor housing. Forces resulting from the discharge-to-suctionpressure differential are then allowed to push the slide valve to-ward the closed (fully loaded) position. See Fig. 7. When theslide valve is closed, the compressor pumps the maximum gasflow.

Extension and retraction of the piston/capacity rod positionthe slide valve along the bottom of the rotors. The valve posi-tion controls the gas flow rate delivered by the compressor.

STARTING EQUIPMENTThe 23XL requires a motor starter to operate the centrifugal

hermetic compressor motor and various auxiliary equipment.The starter is the main field wiring interface for the contractor.

See Carrier Specification Z-415 for specific starter require-ments. All starters must meet these specifications in order toproperly start and satisfy mechanical safety requirements.Starters may be supplied as separate, free-standing units or maybe mounted directly on the chiller (unit mounted) for low-volt-age units only.

Multiple separate circuit breakers are inside the starter. Cir-cuit breaker CB1 is the compressor motor circuit breaker. Thedisconnect switch on the starter front cover is connected to thisbreaker. Circuit breaker CB1 supplies power to the compressormotor.

Circuit breaker CB2 supplies power to the control panel, TCframe 1 and 2 chillers, oil heater, and portions of the startercontrols.

An optional circuit breaker is available when required for apumpout unit.

All starters must include a Carrier control module called theIntegrated Starter Module (ISM), excluding the Benshaw solid-state starters. This module controls and monitors all aspects ofthe starter. See the Controls section on page 14 for additionalISM information. All starter replacement parts are supplied bythe starter manufacturer excluding the ISM (contact Carrier’sReplacement Component Division [RCD]).

The main circuit breaker (CB1) on the front of the starterdisconnects the main motor current only. Power is stillenergized for the other circuits. Two more circuit breakersinside the starter must be turned off to disconnect power tothe PIC II controls, and TC frame 1 and 2 chillers oilheater.

Pumpout compressor voltage must be the same as the com-pressor motor voltage.

Fig. 5 — Screw Compressor Principle

HIGHPRESSURE

OILROTOR

UNLOADSOLENOID

VALVE

LOADSOLENOID

VALVE

PISTON

TO SUCTION PORT

SLIDE VALVE

Fig. 6 — Slide Valve Position at Unload

Fig. 7 — Slide Valve Position at Full Load

13

Unit-Mounted Solid-State Starter (Optional) —The 23XL chiller may be equipped with a solid-state, reduced-voltage starter (Fig. 8 and 9). This starter’s primary function isto provide on-off control of the compressor motor. This type ofstarter reduces the peak starting torque, reduces the motorinrush current, and decreases mechanical shock. This capabil-ity is summed up by the phrase “soft starting.” The solid-statestarter is available as a 23XL option (factory supplied andinstalled). The solid-state starters manufacturer name is locatedinside the starter access door.

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

There is a display on the front of the Benshaw, Inc., solid-state starters that is useful for troubleshooting and startercheckout. The display indicates:• voltage to the SCRs• power indication• proper phasing for rotation• start circuit energized• run state• software configuration

The starter is further explained in the Check Starter andTroubleshooting Guide sections, pages 59 and 76.

Unit-Mounted W ye-Delta Starter (Opt ional) —The 23XL chiller may be equipped with a wye-delta startermounted on the unit. This starter is intended for use with low-voltage motors (under 600 v). It reduces the starting currentinrush by connecting each phase of the motor windings into awye configuration. This occurs during the starting period whenthe motor is accelerating up to speed. Once the motor is up tospeed, the starter automatically connects the phase windingsinto a delta configuration. Starter control, monitoring, andmotor protection is provided by Carrier’s Integrated StarterModule (ISM).

When voltage is supplied to the solid-state circuitry, theheat sinks in the starter as well as the wires leading to themotor and the motor terminal are at line voltage. Do nottouch the heat sinks, power wiring, or motor terminalswhile voltage is present or serious injury will result.

5

1

2

3

4

6

LEGEND

Fig. 8 — Solid-State Starter Box,Internal View

1 — REDISTART™Micro Input/Output Card2 — Circuit Breaker 2 (CB2):

Machine Control and Heater Power3 — Circuit Breaker 3 (CB3): Pumpout Unit4 — REDISTART Micro Central Processing Unit Card (CPU)5 — Restart Micro Power Card (hidden, not depicted)6 — Restart Micro Bypass Card (hidden, not depicted)

Fig. 9 — Typical Starter External View(Solid-State Starter Shown)

14

CONTROLS

DefinitionsANALOG SIGNAL — An analog signal varies in proportionto the monitored source. It quantifies values between operatinglimits. (Example: A temperature sensor is an analog device be-cause its resistance changes in proportion to the temperature,generating many values.)DISCRETE SIGNAL — A discrete signal is a 2-position rep-resentation of the value of a monitored source. (Example: Aswitch produces a discrete signal indicating whether a value isabove or below a set point or boundary by generating an on/off,high/low, or open/closed signal.)

General Controls Overview — The 23XL hermeticscrew liquid chiller contains a microprocessor-based controlcenter that monitors and controls all operations of the chiller.The microprocessor control system matches the cooling capac-ity of the chiller to the cooling load while providing state-of-the-art chiller protection. The system controls cooling capacitywithin the set point plus the deadband by sensing the leavingchilled water or brine temperature and regulating the slidevalve via a mechanically linked, hydraulically actuated piston.Movement of the slide valve alters the point during rotor travelat which compression begins and reduces the effective lengthof the compression cavities. This permits internal gas recircula-tion and reduces suction volume. Thus, smooth, stepless capac-ity regulation is provided in the load direction. Moving of theslide valve increases capacity. Moving of the slide valve in theunload direction decreases capacity. See Fig. 10. Chiller pro-tection is provided by the processor, which monitors the digitaland analog inputs and executes capacity overrides or safetyshutdowns, if required.

PIC II System Components — The chiller controlsystem is called PIC II (Product Integrated Control II). See Ta-ble 2. The PIC II controls the operation of the chiller by moni-toring all operating conditions. The PIC II can diagnose a prob-lem and let the operator know what the problem is and what tocheck. It promptly positions the slide valve to maintain leavingchilled water temperature. It can interface with auxiliary equip-ment such as pumps and cooling tower fans to turn them onwhen required. It continually checks all safeties to prevent anyunsafe operating condition. It also regulates the oil heater whilethe compressor is off and regulates the hot gas bypass valve, ifinstalled. The PIC II controls provide critical protection for thecompressor motor and controls the motor starter.

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

The PIC II consists of 3 modules housed inside 3 majorcomponents. The component names and corresponding controlvoltages are listed below (also see Table 2 and Fig. 11-16):• control panel

all extra low-voltage wiring (24 v or less)• power panel

230 or 115 v control voltage (per job requirement)• starter cabinet

chiller power wiring (per job requirement)

Table 2 — Major PIC II Components andPanel Locations*

*See Fig. 8 and Fig. 11-16.

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

The angle of the control panel can be adjusted for optimumviewing. Remove the 2 bolts connecting the control panel tothe brackets attached to the cooler. Place them in one of theholes to pivot the control panel forward to backward to changethe viewing angle. See Fig. 15. To change the contrast of thedisplay, access the adjustment on the back of the CVC. SeeFig. 15.

PIC II COMPONENT PANEL LOCATIONChiller Visual Controller (CVC) and Display

Control Panel

Integrated Starter Module (ISM) Starter CabinetChiller Control Module (CCM) Control PanelOil Heater Contactor (1C) Power PanelHot Gas Bypass Relay (3C) (Optional) Power PanelControl Transformers (T1, T2) Power PanelTemperature Sensors See Fig. 11 and 12.Pressure Transducers See Fig. 11 and 12.

Fig. 10 — Slide-Valve Capacity Control

15

*Some 23XL chillers will have both an oil temperature sensor and an oil level safety switch (two separate components).

Fig. 11 — 23XL Control and Sensor Locations (TC Frame 1 and 2 Chillers)

16

*Some 23XL chillers will have both an oil temperature sensor and an oil level safety switch (two separate components).

Fig. 12 — 23XL Control and Sensor Locations (TD Frame 4 Chillers)

17

INTEGRATED STARTER MODULE (ISM) — This mod-ule is located in the starter cabinet. This module initiates com-mands from the CVC for starter functions such as starting andstopping the compressor, condenser, chilled water pumps, tow-er fan, spare alarm contacts, 4 to 20 mA Head Pressure Refer-ence output, and the shunt trip. The ISM monitors starter inputssuch as line voltage, motor current, ground fault, remote startcontact, spare safety, condenser high pressure, starter 1M, andrun contacts. The ISM contains logic capable of safety shut-down. It shuts down the chiller if communications with theCVC are lost.CHILLER CONTROL MODULE (CCM) — This module islocated in the control panel. The CCM provides the input andoutputs necessary to control the chiller. This module monitorsrefrigerant pressure, entering and leaving water temperaturesand pressures, and outputs control for the slide valve oil heat-ers, and oil pump. The CCM is the connection point for option-al demand limit, chilled water reset, 4 to 20 mA kW output, re-mote temperature reset, and refrigerant leak sensor.OIL HEATER CONTACTOR (1C) — This contactor is lo-cated in the power panel (Fig. 16) and operates the heater at ei-ther 115 or 230 v. It is controlled by the PIC II to maintain oiltemperature during chiller shutdown.HOT GAS BYPASS CONTACTOR RELAY (3C)(Optional) — This relay, located in the power panel, controlsthe opening of the hot gas bypass valve. The PIC II energizesthe relay during low load, high lift conditions.

CONTROL TRANSFORMERS (T1, T2) — These trans-formers convert incoming control voltage to 24 vac power forthe 3 power panel contactor relays, CCM, and CVC.

Fig. 13 — Control Sensors (Temperature)

Fig. 14 — Control Sensors(Pressure Transducers, Typical)

18

Fig. 15 — Control Panel

Fig. 16 — Power Panel

19

CVC Operation and Menus (Fig. 17-23)GENERAL• The CVC display automatically reverts to the default

screen after 15 minutes if no softkey activity takes place(Fig. 17).

• If a screen other than the default screen is displayed onthe CVC, the name of that screen is in the upper rightcorner (Fig. 18).

• The CVC may be set to display either English or SIunits. Use the CVC configuration screen (accessed fromthe Service menu) to change the units. See the ServiceOperation section, page 46.

• Local Operation — The PIC II can be placed in localoperating mode by pressing the softkey. ThePIC II then accepts commands from the CVC only anduses the Local Time Schedule to determine chiller startand stop times.

• CCN Operation — The PIC II can be placed in the CCNoperating mode by pressing the softkey. The PICII then accepts modifications from any CCN interface ormodule (with the proper authority), as well as from theCVC. The PIC II uses the CCN time schedule to deter-mine start and stop times.

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

Alarms are indicated when the control center alarm light (!)flashes. The primary alarm message is displayed on the defaultscreen. An additional, secondary message and troubleshootinginformation are sent to the ALARM HISTORY table.

When an alarm is detected, the CVC default screen willfreeze (stop updating) at the time of alarm. The freeze enablesthe operator to view the chiller conditions at the time of alarm.The STATUS tables will show the updated information. Onceall alarms have been cleared (by pressing the soft-key), the default CVC screen will return to normal operation.

CVC MENU ITEMS — To perform any of the operationsdescribed below, the PIC II must be powered up and have suc-cessfully completed its self test. The self test takes place auto-matically, after power-up.

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

.

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

• The SCHEDULE menu allows viewing and modifica-tion of the local and CCN time schedules and Ice Buildtime schedules.

• The SETPOINT menu allows set point adjustments,such as the entering chilled water and leaving chilledwater set points.

• The SERVICE menu can be used to view or modifyinformation on the Alarm History, Control Test, ControlAlgorithm Status, Equipment Configuration, ISMStarter Configuration data, Equipment Service, Timeand Date, Attach to Network Device, Log Out of Net-work Device, and CVC Configuration screens.For more information on the menu structures, refer to

Fig. 20. Press the softkey that corresponds to the menu structure to

be viewed: , , , or . To view or change parameters within any of

these menu structures, use the and soft-keys to scroll to the desired item or table. Use the softkey to select that item. The softkey choices that then appeardepend on the selected table or menu. The softkey choices andtheir functions are described below.

BASIC CVC OPERATIONS (Using the Softkeys) — Toperform any of the operations described below, the PIC II mustbe powered up and have successfully completed its self test.

LOCAL

CCN

RESET

MENUSTATUS SCHEDULE SETPOINT

SERVICESTATUS SCHEDULE SETPOINT

SERVICENEXT PREVIOUS

SELECT

CONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONISM (STARTER) CONFIGURATION DATAEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICECVC CONFIGURATION

ALARM HISTORY

23XL_II SERVICE

RUNNING TEMP CONTROLLEAVING CHILLED WATER

01-01-95 11:4828.8 HOURS

CHW IN CHW OUT EVAP REF

CDW IN CDW OUT COND REF

OIL PRESS OIL TEMP AMPS %

CCN LOCAL RESET MENU

55.1 44.1 40.7

85.0 95.0 98.1

21.8 132.9 93

PRIMARY STATUSMESSAGE

COMPRESSORON TIME

DATE TIME

SOFT KEYSMENULINE

EACH KEY'S FUNCTION ISDEFINED BY THE MENU DESCRIPTIONON MENU LINE ABOVE

ALARM LIGHT(ILLUMINATEDWHEN POWER ON)

STOP BUTTON• HOLD FOR ONE

SECOND TO STOP

••

BLINKS CONTINUOUSLYON FOR AN ALARMBLINKS ONCE TOCONFIRM A STOP

SECONDARYSTATUSMESSAGE

Fig. 17 — CVC Default Screen

Fig. 18 — CVC Service Screen

20

• Press to leave the selected decision or field with-out saving any changes.

• Press to leave the selected decision or field andsave changes.

• Press to scroll the cursor bar down in order tohighlight a point or to view more points below the cur-rent screen.

• Press to scroll the cursor bar up in order tohighlight a point or to view points above the currentscreen.

• Press to view the next screen level (high-lighted with the cursor bar), or to override (if allowable)the highlighted point value.

• Press to return to the previous screen level.

• Press or to change the high-lighted point value.

TO VIEW STATUS (Fig. 19) — The status table shows theactual value of overall chiller status such as CONTROLMODE, RUN STATUS, AUTO CHILLED WATER, RESET,and REMOTE RESET SENSOR.

1. On the menu screen, press to view the listof point status tables.

2. Press or to highlight the desiredstatus table. The list of tables is:

• MAINSTAT — Overall chiller status• STARTUP — Status required to perform start-up of

chiller• COMPRESS — Status of sensors related to the

compressor• HEAT_EX — Status of sensors related to the heat

exchangers• POWER — Status of motor input power• ISM_STAT — Status of motor starter• CVC_PSWD — Service menu password forcing

access screen

3. Press to view the desired point status table.

4. On the point status table, press or until the desired point is displayed on the

screen.

OVERRIDE OPERATIONS

To Override a Value or Status

1. From any point status screen, press or to highlight the desired value.

QUIT

ENTER

NEXT

PREVIOUS

SELECT

EXIT

INCREASE DECREASE

STATUS

NEXT PREVIOUS

SELECT

NEXTPREVIOUS

NEXTPREVIOUS

23XL_II MAINSTAT POINT STATUSControl ModeRun StatusStart Inhibit TimerOccupied?System Alert/AlarmChiller Start/StopRemote Start ContactTemperature ResetControl PointChilled Water TempActive Demand LimitAverage Line Current

OFFReady

0.0 MinNO

NORMALSTOPOpen0.0 F

44.0 F44.6 F100%0.0%

Fig. 19 — Example of Status Screen

21

CCN LOCAL RESET MENU

DEFAULT SCREEN

Start Chiller In CCN Control

Start Chiller in Local Control

Clear Alarms

STATUS SCHEDULE SETPOINT SERVICE

(SOFTKEYS)

Access Main Menu

List theStatus Tables

Display The Setpoint Table

List the Service Tables

• OCCPC01S – LOCAL TIME SCHEDULE• OCCPC02S – ICE BUILD TIME SCHEDULE• OCCPC03S – CCN TIME SCHEDULE

List the Schedules

NEXT PREVIOUS SELECT EXIT

ALARM HISTORYCONTROL TESTCONTROL ALGORITHM STATUSEQUIPMENT CONFIGURATIONISM (STARTER) CONFIG DATAEQUIPMENT SERVICETIME AND DATEATTACH TO NETWORK DEVICELOG OUT OF DEVICECVC CONFIGURATION

SEE FIGURE 21

Base Demand Limit • LCW Setpoint • ECW Setpoint • Ice Build Setpoint • Tower Fan High Setpoint

EXITSELECTPREVIOUSNEXTSelect a Schedule

12345678

Override

ENABLE DISABLE

EXITSELECTPREVIOUSNEXTSelect a Time Period/Override

Modify a Schedule Time

ENTER EXIT

INCREASE DECREASE ENTER EXIT (ANALOG VALUES)

(DISCRETE VALUES)Add/Eliminate a Day

1

Select a Status TableNEXT PREVIOUS SELECT EXIT

STARTON

STOPOFF

RELEASE ENTER

EXITNEXT PREVIOUS SELECT

ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERRELEASE

Select a Modification Point

Modify a Discrete Point

Modify an Analog Point

Modify Control Options

• MAINSTAT• STARTUP• COMPRESS• HEAT_EX• POWER• ISM_STAT• CVC_PSWD

Modify the SetpointDECREASEINCREASE QUIT ENTER

NEXT PREVIOUS SELECT EXITSelect the Setpoint

•

(ENTER A 4-DIGIT PASSWORD)1 1 1

Fig. 20 — 23XL CVC Menu Structure

22

NEXT PREVIOUS SELECT EXIT

SERVICE TABLE

Display Alarm History(The table holds up to 25 alarms and alerts with the most recent alarm at the top of the screen.)

• CCM Thermistors• CCM Pressure Transducers• Pumps• Discrete Outputs• Slide Valve Control• Head Pressure Output• VFD Speed Control• Pumpdown/Lockout• Terminate Lockout• Refrigerant Type

CONTINUEDON NEXT PAGE

CONTROL ALGORITHM STATUS

CONTROL TEST

ALARM HISTORY

List the Control Tests

List the Control Algorithm Status Tables• CAPACITY (Capacity Control)• OVERRIDE (Override Status)• LL_MAINT (Lead Lag Status)• ISM_HIST (ISM Alarm History)• LOADSHED• WSMCHLRE (Water System Manager)• OCCDEFCM (Time Schedule Status)

NEXT PREVIOUS SELECT EXITSelect a Table

• NET_OPT• BRODEF• OCCEFCS• HOLIDAYS• CONSUME• RUNTIME

(ANALOG VALUES)

(DISCRETE VALUES)

Select a ParameterNEXT PREVIOUS SELECT EXIT

Modify a Parameter

ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERQUIT

NEXT PREVIOUS SELECT EXITSelect a Table

EQUIPMENT CONFIGURATION List the Equipment Configuration Tables

• CAPACITY (Capacity Control Algorithm)• OVERRIDE (Override Status)• LL_MAINT (LEADLAG Status)• WSMDEFM2 (Water System Manager Control Status)

Maintenance Table Data

NEXT PREVIOUS SELECT EXITData Select Table

OCCPC01S (Local Status)OCCPC02S (CCN, ICE BUILD Status)OCCPC03S (CCN Status)

OCCDEFM (Time Schedule Status)

NEXT PREVIOUS SELECT EXITSelect a Test

Fig. 21 — 23XL Service Menu Structure

23

NEXT PREVIOUS SELECT EXIT

SERVICE MENU CONTINUEDFROM PREVIOUS PAGE

Select a Service Table

Select a Service Table ParameterNEXT PREVIOUS SELECT EXIT

Modify a Service Table Parameter(ANALOG VALUES)

(DISCRETE VALUES)

TIME AND DATE

Display Time and Date Table:• To Modify — Current Time — Day of Week

— Current Date — Holiday TodayATTACH TO NETWORK DEVICEDECREASEINCREASE

ENTERENABLE DISABLE QUIT

DECREASEINCREASE ENTERQUIT

Select a DeviceATTACHNEXT PREVIOUS SELECT

Modify Device AddressEXITINCREASE DECREASE ENTER

• Use to attach CVC to another CCN network or device• Attach to "LOCAL" to enter this machine• To upload new tables

Default ScreenMENURESETCCN LOCAL

LOG OUT OF DEVICE

List Network Devices• Local• Device 1• Device 2• Device 3• Device 4 •• Device 5

• Device 6• Device 7• Device 8• Device 9

Service Tables:• OPTIONS• SETUP1• SETUP2• LEADLAG• RAMP_DEM• TEMP_CTL

EQUIPMENT SERVICE

ISM (STARTER) CONFIG DATA

Service Tables:• ISM (STARTER) CONFIG PASSWORD• ISM_CONF

(ENTER A 4-DIGIT PASSWORD)4 4 4 4

CVC CONFIGURATION

EXITINCREASE DECREASE ENTERCVC Configuration Table

• To Modify — CVC CCN Address— English (US IMP) or S.I. Metric Units— Password

• To View — CVC Software Version (last 2 digits of part number

indicate software version)

Attach To Any Device

(ANALOG VALUES)ENTER EXIT

ENTER EXITNOYES (DISCRETE VALUES)

Fig. 21 — 23XL Service Menu Structure (cont)

LEGENDCCN — Carrier Comfort NetworkCVC — Chiller Visual ControllerIMP — ImperialISM — Integrated Starter ModulePIC II — Product Integrated Control II

24

2. Press to select the highlighted value. Then:

For Discrete Points — Press or toselect the desired state.

For Analog Points — Press or to select the desired value.

3. Press to register the new value.

NOTE: When overriding or changing metric values, it is nec-essary to hold down the softkey for a few seconds in order tosee a value change, especially on kilopascal values.

To Remove an Override

1. On the point status table press or to highlight the desired value.

2. Press to access the highlighted value.

3. Press to remove the override and returnthe point to the PIC II’s automatic control.

Override Indication — An override value is indicated by“SUPVSR,” “SERVC,” or “BEST” flashing next to the pointvalue on the STATUS table.

TIME SCHEDULE OPERATION (Fig. 22)1. On the Menu screen, press .

2. Press or to highlight the de-sired schedule.

OCCPC01S — LOCAL Time ScheduleOCCPC02S — ICE BUILD Time ScheduleOCCPC03S — CCN Time Schedule

3. Press to view the desired time schedule.

4. Press or to highlight the de-sired period or override to change.

5. Press to access the highlighted period oroverride.

6. a Press or to change thetime values. Override values are in one-hourincrements, up to 4 hours.

SELECT

YES NO

YES NO

INCREASEDECREASE

ENTER

NEXTPREVIOUS

SELECT

RELEASE

SCHEDULE

NEXT PREVIOUS

SELECT

NEXT PREVIOUS

SELECT

INCREASE DECREASE

23XL

Fig. 22 — Example of Time ScheduleOperation Screen

25

b. Press to select days in the day-of-weekfields. Press to eliminate days from theperiod.

7. Press to register the values and to move hori-zontally (left to right) within a period.

8. Press to leave the period or override.

9. Either return to Step 4 to select another period or over-ride, or press again to leave the current timeschedule screen and save the changes.

10. The Holiday Designation (HOLIDEF table) may befound in the Service Operation section, page 46. Themonth, day, and duration for the holiday must beassigned. The Broadcast function in the BRODEFtable also must be enabled for holiday periods to func-tion.

TO VIEW AND CHANGE SET POINTS (Fig. 23)1. To view the SETPOINT table, from the MENU screen

press .

2. There are 5 set points on this screen: BASE DEMANDLIMIT, LCW SETPOINT (leaving chilled water setpoint), ECW SETPOINT (entering chilled water setpoint), ICE BUILD SETPOINT, and TOWER FANHIGH SETPOINT. Only one of the chilled water setpoints can be active at one time. The set point that isactive is determined from the SERVICE menu. See theService Operation section, page 46. The ice build (ICEBUILD) function is also activated and configured fromthe SERVICE menu.

3. Press or to highlight the desiredset point entry.

4. Press to modify the highlighted set point.

5. Press or to change the se-lected set point value.

6. Press to save the changes and return to theprevious screen.

SERVICE OPERATION — To view the menu-driven pro-grams available for Service Operation, see Service Operationsection, page 46. For examples of CVC display screens, seeTable 3.

ENABLEDISABLE

ENTER

EXIT

EXIT

SETPOINT

NEXT PREVIOUS

SELECT

INCREASE DECREASE

ENTER

23XL_II SETPOINT SELECTSETPOINT

Base Demand LimitControl PointLCW SetpointECW SetpointICE BUILD SetpointTower Fan High Setpoint

100%

50.0 F60.0 F40.0 F85.0 F

Fig. 23 — Example of Set Point Screen

26

Table 3 — CVC Display Data

1. Only 12 lines of information appear on the CVC screen at anyone time. Press the or softkey to highlighta point or to view items below or above the current screen.Double-click the softkey to page forward; double-clickthe softkey to page back.

2. To access the information shown in Examples 9 through 21,enter your 4-digit password after pressing the soft-key. If no softkeys are pressed for 15 minutes, the CVC automat-ically logs off (to prevent unrestricted access to PIC II controls)and reverts to the default screen. If this happens, you must re-enter your password to access the tables shown in Examples 9through 21.

3. Terms in the Description column of these tables are listed asthey appear on the CVC screen.

4. The CVC may be configured in English or Metric (SI) units usingthe CVC CONFIGURATION screen. See the Service Operationsection, page 46, for instructions on making this change.

5. The items in the Reference Point Name column do not appear onthe CVC screen. They are data or variable names used in CCNor Building Supervisor (BS) software. They are listed in thesetables as a convenience to the operator if it is necessary to crossreference CCN/BS documentation or use CCN/BS programs. Formore information, see the 23XL CCN literature.

6. Reference Point Names shown in these tables in all capital let-ters can be read by CCN and BS software. Of these capitalizednames, those preceded by a dagger can also be changed (thatis, written to) by the CCN, BS, and the CVC. Capitalized Refer-ence Point Names preceded by two asterisks can be changedonly from the CVC. Reference Point Names in lower case typecan be viewed by CCN or BS only by viewing the whole table.

7. Alarms and Alerts: An asterisk in the far right field of a CVC sta-tus screen indicates that the chiller is in an alarm state; an excla-mation point in the far right field of the CVC screen indicates analert state. The asterisk (or exclamation point) indicates that thevalue on that line has exceeded (or is approaching) a limit. Formore information on alarms and alerts, see the Alarms andAlerts section, page 19.

LEGEND

EXAMPLE 1 — CVC DEFAULT SCREENThe following data is displayed in the CVC Default screen.

NOTE: The last three entries are used to indicate operating mode to the PIC II. These values may be forced by the CVC only.

IMPORTANT: The following notes apply to all Table 3examples.

NEXT PREVIOUS

NEXTPREVIOUS

SERVICE

12T — Motor Overload1CR — Control RelayCCN — Carrier Comfort NetworkCHW — Chilled WaterCR — Control RelayCT — Current TransformerCVC — Chiller Visual ControllerECW — Entering Chilled WaterHGBP — Hot Gas BypassISM — Integrated Starter ModuleLCW — Leaving Chilled WaterLRA — Locked Rotor AmpsmA — MilliampsP — PressureSS — Solid StateT — TemperatureSV — Slide ValveVFD — Variable Frequency DriveWSM — Water System Manager

DESCRIPTION RANGE UNITS REFERENCE POINT NAME(ALARM HISTORY) DISPLAY

(PRIMARY MESSAGE)(SECONDARY MESSAGE)(DATE AND TIME)Compressor Ontime 0-500000.0 HOURS C_HRSEntering Chilled Water –40-245 DEG F ECW CHW INLeaving Chilled Water –40-245 DEG F LCW CHW OUTEvaporator Temperature –40-245 DEG F ERT EVAP REFEntering Condenser Water –40-245 DEG F ECDW CDW INLeaving Condenser Water –40-245 DEG F LCD WCDW OUTCondenser Temperature –40-245 DEG F CRT COND REFOil Pressure 0-420 PSI OILPD OILPRESSOil Sump Temp 40-245 DEG F OILT OIL TEMPAverage Line Current 0-999 % AMPS_% AMPS %

0-1 CCN0-1 LOCAL0-1 RESET

27

Table 3 — CVC Display Data (cont)

EXAMPLE 2 — MAINTSTAT DISPLAY SCREENTo access this display from the CVC default screen:1. Press .

2. Press ( will be highlighted).

3. Press .

NOTES:1. Reset, Off, Local, CCN2. Timeout, Ready, Recycle, Prestart, Start-up, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout3. Normal, Alert, Alarm4. All variables with capital letter point names are available for CCN read operation.

Those shown with (*) support write operations for all CCN devices.

EXAMPLE 3 — STARTUP DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .

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

DESCRIPTION STATUS UNITS POINTControl Mode NOTE 1 NOTE 1 CMODERun Status NOTE 2 NOTE 2 RUNSTATStart Inhibit Timer 0-15 min T_STARTOccupied ? 0/1 NO/YES OCCSystem Alert/Alarm 0-2 NOTE 3 SYS_ALM

*Chiller Start/Stop 0/1 STOP/START CHIL_S_S*Remote Start Contact 0/1 OFF/ON REMCONTemperature Reset –30-30 DEG F T_RESET

*Control Point 10-120 DEG F LCW_STPTChilled Water Temp –40-245 DEG F CHW_TMP

*Active Demand Limit 40-100 % DEM_LIMAverage Line Current 0-999 % AMPS_%Motor Percent Kilowatts 0-999 % KW_PAuto Demand Limit Input 4-20 mA AUTODEMAuto Chilled Water Reset 4-20 mA AUTORESRemote Reset Sensor –40-245 DEG F R_RESETTotal Compressor Starts 0-99999 C_STARTSStarts in 12 Hours 0-8 STARTSCompressor Ontime 0-500000.0 HOURS C_HRS

*Service Ontime 0-32767 HOURS S_HRSIce Build Contact 0-1 OPEN/CLOSE ICE_CONRefrigerant Leak Sensor 0-20 mA REF_LEAK

DESCRIPTION STATUS UNITS POINTSlide Valve Unload Timer 0-2 MIN SV_TIMER

**Chilled Water Pump 0-1 OFF/ON CHWPChilled Water Flow 0-1 NO/YES CHW_FLOW

**Condenser Water Pump 0-1 OFF/ON CDPCondenser Water Flow 0-1 NO/YES CDW_FLOWOil Pump Relay 0-1 OFF/ON OILR

**Oil Delta P –67-2009 ^PSI OILPDCompressor Start Relay 0-1 OFF/ON CMPRCompressor Start Contact 0-1 OPEN/CLOSED 1CR_AUXStarter Trans Relay 0-1 OFF/ON CMPTRANSCompressor Run Contact 0-1 OPEN/CLOSED RUN_AUX

**Tower Fan Relay Low 0-1 OFF/ON TFR_LOW**Tower Fan Relay High 0-1 OFF/ON TFR_HIGH

Starter Fault 0-1 ALARM/NORMAL STR_FLTSpare Safety Input 0-1 ALARM/NORMAL SAFETYShunt Trip Relay 0-1 OFF/ON TRIPROil Level Sensor 0-1 OPEN/CLOSED OIL_LEVISM Fault Status 0-255 STRSTAT

MENU

STATUS MAINSTAT

SELECT

MENUSTATUS

STARTUPSELECT

28

Table 3 — CVC Display Data (cont)

EXAMPLE 4 — COMPRESS DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;those with (**) shall support write operations for CVC only.

EXAMPLE 5 — HEAT_EX DISPLAY SCREENTo access this display from the CVC default screen:

1. Press .

2. Press .

3. Scroll down to highlight .

4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;those with (**) shall support write operations for CVC only.

DESCRIPTION STATUS UNITS POINT Slide Valve Load 0-5 SEC SV_LDSlide Valve Unload 0-5 SEC SV_UNLDManual SV Load/Unload –10-10 SEC SV_MAN Slide Valve Duty Cycle –100-100 % SV_DUTY

**Oil Delta P –6.7-200 PSI OILPD Oil Pressure Required 0-20 PSI OILP__REQ Oil Filter Data 0-120 PSI OILF_PDOil Sump Temperature –40-245 DEG F OILT Oil Heater Relay 0/1 OFF/ON OILHComp Motor Winding Temp –40-245 DEG F MTRW Rotor Inlet Temperature –40-245 DEG F ROTOR _ T Discharge Temperature –40-245 DEG F CMPD Discharge Superheat –40-245 ^F SUPRHEAT Variable Index Relay 0/1 OFF/ON VAR_INDX Target VFD Speed 1-100 % VFD_OUTActual VFD Speed 0-110 % VFD_ACT Stall Protection Counts 0-5 spc Spare Temperature 1 –40-245 DEG F SPARE1Spare Temperature 2 –40-245 DEG F SPARE2

DESCRIPTION STATUS UNITS POINT **Chilled Water Delta P –6.7-420 PSI CHW_PD

Entering Chilled Water –40-245 DEG F ECWLeaving Chilled Water –40-245 DEG G LCWChilled Water Delta T –40-245 ^F CHW_DETChil Water Pulldown/Min –20-20 ^F CHW_PULLEvaporator Refrig Temp –40-245 DEG F ERT

**Evaporator Pressure –6.7-420 PSI ERPEvaporator Approach 0-99 ^F EVAP_APP

**Condenser Water Delta P –6.7-420 PSI COND_PDEntering Condenser Water –40-245 DEG F ECDWLeaving Condenser Water –40-245 DEG F LCDWCondenser Refrig Temp –40-245 DEG F CRT

**Condenser Pressure –6.7-420 PSI CRPCondenser Approach 0-99 ^F COND_APPHot Gas Bypass Relay 0/1 OFF/ON HGBRStall/HGBP Active? 0/1 NO/YES SHG_ACTActive Delta P 0-200 PSI dp_aActive Delta T 0-200 ^F dt_cStall/HGBP Delta T 0-200 ^F dt_cHead Pressure Reference 0-100 % hpr

MENUSTATUS

COMPRESSSELECT

MENU

STATUS

HEAT_EX

SELECT

29

Table 3 — CVC Display Data (cont)

EXAMPLE 6 — POWER DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.Those with (**) shall support write operations for CVC only.

EXAMPLE 7 — ISM_STAT SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation.

DESCRIPTION STATUS UNITS POINTAverage Line Current 0-999 % %_AMPSActual Line Current 0-99999 AMPS AMP_A Average Line Voltage 0-999 % VOLT_P Actual Line Voltage 0-99999 VOLTS VOLT_A Power Factor 0.0-1.0 PFMotor Kilowatts 0-99999 KW KW_A

**Motor Kilowatt-Hours 0-999999 KWH KWH Demand Kilowatts 0-99999 KW DEM_KW Line Current Phase 1 0-99999 AMPS AMPS_1 Line Current Phase 2 0-99999 AMPS AMPS_2Line Current Phase 3 0-99999 AMPS AMPS_3 Line Voltage Phase 1 0-99999 VOLTS VOLTS_1 Line Voltage Phase 2 0-99999 VOLTS VOLTS_2Line Voltage Phase 3 0-99999 VOLTS VOLTS_3 Ground Fault Phase 1 0-999 AMPS GF_1 Ground Fault Phase 2 0-999 AMPS GF_2 Ground Fault Phase 4 0-999 AMPS GF_3Frequency 0-99 HZ FREQ12T Sum Heat-Phase 1 0-200 % HEAT1SUM 12T Sum Heat-Phase 2 0-200 % HEAT2SUM 12T Sum Heat-Phase 3 0-200 % HEAT3SUM

DESCRIPTION STATUS UNITS POINTISM Fault Status 0-223 ISMFLTSingle Cycle Dropout 0-1 NORMAL/ALARM CYCLE_1Phase Loss 0-1 NORMAL/ALARM PH_LOSSOvervoltage 0-1 NORMAL/ALARM OV_VOLTUndervoltage 0-1 NORMAL/ALARM UN_VOLTCurrent Imbalance 0-1 NORMAL/ALARM AMP_UNBVoltage Imbalance 0-1 NORMAL/ALARM VOLT_UNBOverload Trip 0-1 NORMAL/ALARM OVERLOADLocked Rotor Trip 0-1 NORMAL/ALARM LRATRIPStarter LRA Trip 0-1 NORMAL/ALARM SLRATRIPGround Fault 0-1 NORMAL/ALARM GRND_FLTPhase Reversal 0-1 NORMAL/ALARM PH_REVFrequency Out of Range 0-1 NORMAL/ALARM FREQFLTISM Power on Reset 0-1 NORMAL/ALARM ISM_PORPhase 1 Fault 0-1 NORMAL/ALARM PHASE_1Phase 2 Fault 0-1 NORMAL/ALARM PHASE_2Phase 3 Fault 0-1 NORMAL/ALARM PHASE_3ICR Start Complete 0-1 FALSE/TRUE START_OK1M Start/Run Fault 0-1 NORMAL/ALARM 1M_FLT2M Start/Run Fault 0-1 NORMAL/ALARM 2M_FLTPressure Trip Contact 0-1 NORMAL/ALARM PRS_RIPStarter Fault 0-1 NORMAL/ALARM STRT_FLTMotor Amps Not Sensed 0-1 NORMAL/ALARM NO_AMPSStarter Acceleration Fault 0-1 NORMAL/ALARM ACCELFLTHigh Motor Amps 0-1 NORMAL/ALARM HIGHAMPS1CR Stop Complete 0-1 FALSE/TRUE STOP_OK1M/2M Stop Fault 0-1 NORMAL/ALARM 1M2MSTOPMotor Amps When Stopped 0-1 NORMAL/ALARM AMPSTOPHardware Failure 0-1 NORMAL/ALARM HARDWARE

MENUSTATUS

POWERSELECT

MENUSTATUS

ISM_STATSELECT

30

Table 3 — CVC Display Data (cont)

EXAMPLE 8 — SETPOINT DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press (Base Demand Limit will be highlighted) .3. Press .

NOTE: No variables are available for CCN read operation; forcing shall not be supported on setpoint screens.

EXAMPLE 9 — CAPACITY DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .5. Scroll down to highlight .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation;forcing shall not be supported on maintenance screens.

DESCRIPTION STATUS UNITS POINT DEFAULTBase Demand Limit 40-100 % DLM 100Control PointLCW Setpoint 10-120 DEG F lcw_sp 50.0ECW Setpoint 15-120 DEG F ecw_sp 60.0Ice Build Setpoint 15-60 DEG F ice_sp 40.0Tower Fan High Setpoint 55-105 DEG F tf2_sp 75

DESCRIPTION STATUS UNITS POINTEntering Chilled Water –40-245 DEG F ECW Leaving Chilled Water –40-245 DEG F LCWCapacity Control Control Point 7-120 DEG F ctrlpt Control Point Error –99-99 ^F cperr ECW Delta T –99-99 ^F ecwdt ECW Reset –99-99 ^F ecwres LCW Reset –99-99 ^F lcwres Total Error + Resets –99-99 ^F error Slide Valve Delta –2-2 % svd Slide Valve Load 0-5 SEC SV_LD Slide Valve Unload 0-5 SEC SV_UNLD Variable Index Relay 0-1 OFF/ON VARINDEX Target VFD Speed 0-100 % VFD_IN Actual VFD Speed 0-100 % VFD_ACT VFD Gain 0.1-1.5 vfd_gain Demand Limit Inhibit 0-1 % DEM_INH Amps/kW Ramp 0-100 % DEMLIM

MENUSETPOINTSELECT

MENUSERVICE

CONTROL ALGORITHM STATUSSELECT

CAPACITY

31

Table 3 — CVC Display Data (cont)

EXAMPLE 10 — OVERRIDE DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .5. Scroll down to highlight .

NOTE: All variables with CAPITAL LETTER point names are available for CCN read operation; forcing shall not be supported on maintenance screens.

EXAMPLE 11 — LL_MAINT DISPLAY SCREENTo access this display from the CVC default screen:1. Press .2. Press .3. Scroll down to highlight .4. Press .5. Scroll down to highlight .

NOTES:1. DISABLE, LEAD, LAG, STANDBY, INVALID2. DISABLE, LEAD, LAG, STANDBY, RECOVERY, CONFIG3. Reset, Off, Local, CCN4. Timeout, Ready, Recycle, Prestart, Startup, Ramping, Running, Demand, Override, Shutdown, Trippout, Pumpdown, Lockout5. Stop, Start, Retain6. All variables with CAPITAL LETTER point names are available for CCN read operation;

forcing shall not be supported on maintenance screens.

DESCRIPTION STATUS UNITS POINT Comp Motor Winding Temp –40-245 DEG F MTRW Comp Motor Temp Override 150-200 DEG F MT_OVER Condenser Pressure 0-420 PSI CRPCond Press Override 150-260 PSI CP_OVER Evaporator Refrig Temp –40-245 DEG F ERT Evap Ref Override Temp 2-245 DEG F RT_OVER Comp Discharge Temp –40-245 DEG F CMPD Comp Discharge Alert 125-200 DEG F CD_ALERT Oil Filter Delta P 0-245 PSI OILF_PD Discharge Superheat –20-999 ^F SUPRHEAT Rotor Inlet Temperature –40-245 DEG F ROTOR_T Condenser Refrig Temp –40-245 DEG F CRT

DESCRIPTION STATUS UNITS POINT Lead Lag Control NOTE 1 leadlag

LEADLAG: Configuration NOTE 2 leadlagCurrent Mode NOTE 3 llmode

Load Balance Option 0/1 DSABLE/ENABLE loadbalLAG Start Time 2-60 MIN lagstartLAG Stop Time 2-60 MIN lagstopPrestart Fault Time 2-30 MIN prefltPulldown: Delta T/Min x.xx ^F pull_dt

Satisfied ? 0/1 NO/YES pull_satLEAD CHILLER in Control 0/1 NO/YES leadctrlLAG CHILLER: Mode NOTE 3 lagmode

Run Status NOTE 4 lagstatStart/Stop NOTE 5 lag_s_sRecovery Start Request 0/1 NO/YES lag_rec

STANDBY CHILLER: Mode NOTE 3 stdmodeRun Status NOTE 4 stdstatStart/Stop NOTE 5 std_s_sRecovery Start Request 0/1 NO/YES std_rec

Spare Temperature 1 –40-245 DEG F SPARE_T1Spar