-
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
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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
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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.
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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
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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
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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
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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
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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
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10
LEG
EN
D
Fig
. 3 —
Ref
riger
ant O
il F
low
Sch
emat
ic (
TC
Fra
me
1 an
d 2
Chi
llers
)
HG
BP
—H
ot G
as B
ypas
sR
efrig
era
nt L
iqui
d F
low
Ref
rige
rant
Vap
or F
low
Oil
and
Ref
riger
ant L
iqui
d F
low
Oil
and
Ref
riger
ant V
apor
Flo
wO
il F
low
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11
LEG
EN
D
Fig
. 4 —
Ref
riger
ant O
il F
low
Sch
emat
ic (
TD
Fra
me
4 C
hille
rs)
HG
BP
—H
ot G
as B
ypas
sR
efrig
eran
t Liq
uid
Flo
wR
efrig
eran
t Vap
or F
low
Oil
and
Ref
riger
ant V
apor
Flo
wO
il F
low
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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
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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)
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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