Carrier AquaEdge 19XR series User guide

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190045-01 Printed in U.S.A. Form 19XR,XRV-CLT-10SS Pg 1 12-16 Replaces: 19XR,XRV-CLT-9SS
Start-Up, Operation, and Maintenance Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe
and reliable service when operated within design specifi-
cations. When operating this equipment, use good judg-
ment and safety precautions to avoid damage to
equipment and property or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions
as well as those listed in this guide.
DANGER
Failure to follow these procedures will result in severe per-
sonal injury or death.
DO NOT VENT refrigerant relief valves within a building.
Outlet from rupture disc or relief valve must be vented out-
doors in accordance with the latest edition of ANSI/
ASHRAE 15 (American National Standards Institute/
American Society of Heating, Refrigerating, and Air-
Conditioning Engineers). The accumulation of refrigerant
in an enclosed space can displace oxygen and cause
asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead
spaces. Inhalation of high concentrations of vapor is harm-
ful and may cause heart irregularities, unconsciousness, or
death. Misuse can be fatal. Vapor is heavier than air and
reduces the amount of oxygen available for breathing.
Product causes eye and skin irritation. Decomposition
products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
chiller for any purpose. Oxygen gas reacts violently with
oil, grease, and other common substances.
NEVER EXCEED specified test pressures. VERIFY the
allowable test pressure by checking the instruction litera-
ture and the design pressures on the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or
dry nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly
installed and functioning before operating any chiller.
RISK OF INJURY OR DEATH by electrocution. High
voltage is present on motor leads even though the motor is
not running when a solid-state or wye-delta mechanical
starter is used. Open the power supply disconnect before
touching motor leads or terminals.
WARNING
Failure to follow these procedures may result in personal
injury or death.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig-
erant in contact with an open flame produces toxic
gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
DO NOT USE eyebolts or eyebolt holes to rig chiller sec-
tions or the entire assembly.
DO NOT work on high-voltage equipment unless you are a
qualified electrician.
DO NOT WORK ON electrical components, including
control panels, switches, starters, or oil heater until you are
sure ALL POWER IS OFF and no residual voltage can
leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servic-
ing. IF WORK IS INTERRUPTED, confirm that all cir-
cuits are deenergized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it
into the eyes. USE SAFETY GOGGLES. Wash any spills
from the skin with soap and water. If liquid refrigerant
enters the eyes, IMMEDIATELY FLUSH EYES with
water and consult a physician.
NEVER APPLY an open flame or live steam to a refriger-
ant cylinder. Dangerous overpressure can result. When it is
necessary to heat refrigerant, use only warm (110 F [43 C])
water.
DO NOT REUSE disposable (nonreturnable) cylinders or
attempt to refill them. It is DANGEROUS AND ILLE-
GAL. When cylinder is emptied, evacuate remaining gas
pressure, loosen the collar, and unscrew and discard the
valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding
refrigerant to the chiller. The introduction of the wrong
refrigerant can cause damage or malfunction to this chiller.
(Warnings continued on next page.)
AquaEdge®
19XR,XRV
Single-Stage or Two-Stage
Semi-Hermetic Centrifugal Liquid Chillers
with PIC II Controls and HFC-134a
50/60 Hz

2
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1,2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABBREVIATIONS AND EXPLANATIONS. . . . . . . . . . 5
CHILLER FAMILIARIZATION . . . . . . . . . . . . . . . . . . . 5-9
Chiller Information Nameplate. . . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Economizer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factory-Mounted Starter or Variable
Frequency Drive (Optional). . . . . . . . . . . . . . . . . . . . . 7
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERATION CYCLE. . . . . . . . . . . . . . . . . . . . . 10,11
MOTOR AND OIL COOLING CYCLE . . . . . . . . . . 11,12
VFD COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION CYCLE. . . . . . . . . . . . . . . . . . . . . . . . 12-15
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
• PRIMARY OIL RECOVERY MODE
• SECONDARY OIL RECOVERY METHOD
STARTING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 15-17
Unit-Mounted Solid-State Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Unit-Mounted Wye-Delta Starter
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit-Mounted VFD (Optional). . . . . . . . . . . . . . . . . . . . 16
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-64
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• ANALOG SIGNAL
• DISCRETE SIGNAL
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PIC II System Components . . . . . . . . . . . . . . . . . . . . . . 17
• INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
• INTEGRATED STARTER MODULE (ISM)
• CHILLER CONTROL MODULE (CCM)
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• CONTROL TRANSFORMERS (T1, T2)
•SENSORS
ICVC Operation and Menus. . . . . . . . . . . . . . . . . . . . . . 21
• GENERAL
•MODES
• ALARMS AND ALERTS
• ICVC MENU ITEMS
• BASIC ICVC OPERATIONS
• TO VIEW STATUS
• OVERRIDE OPERATIONS
• TIME SCHEDULE OPERATION
• TO VIEW AND CHANGE SET POINTS
• SERVICE OPERATION
PIC II System Functions . . . . . . . . . . . . . . . . . . . . . . . . . 43
• ALARMS AND ALERTS
• ICVC MENU ITEMS
• BASIC ICVC OPERATIONS
• FLOW DETECTION
• CAPACITY CONTROL
• FIXED SPEED APPLICATIONS
• VARIABLE SPEED (VFD) APPLICATIONS
• ECW CONTROL OPTION
• CONTROL POINT DEADBAND
WARNING
Operation of this equipment with refrigerants other than
those cited herein should comply with ANSI/ASHRAE 15
(latest edition). Contact Carrier for further information on
use of this chiller with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc.,
while chiller is under pressure or while chiller is running.
Be sure pressure is at 0 psig (0 kPa) before breaking any
refrigerant connection.
CAREFULLY INSPECT all relief devices, rupture discs,
and other relief devices AT LEAST ONCE A YEAR. If
chiller operates in a corrosive atmosphere, inspect the
devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION
any relief device when corrosion or build-up of foreign
material (rust, dirt, scale, etc.) is found within the valve
body or mechanism. Replace the device.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a com-
pressed spring. Sudden release of the spring can cause it
and objects in its path to act as projectiles.
CAUTION
Failure to follow these procedures may result in personal
injury or damage to equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip
about and release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or
staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to
lift or move inspection covers or other heavy components.
Even if components are light, use mechanical equipment
when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements
CAN ENGAGE THE STARTER, TOWER FAN, OR
PUMPS. Open the disconnect ahead of the starter, tower
fans, or pumps.
USE only repair or replacement parts that meet the code
requirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing
industrial brines, liquid, gases, or semisolids without the
permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the water-
box has been completely drained.
DO NOT LOOSEN a packing gland nut before checking
that the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping
for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate
or rain water.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations.
DO NOT leave refrigerant system open to air any longer
than the actual time required to service the equipment. Seal
circuits being serviced and charge with dry nitrogen to pre-
vent oil contamination when timely repairs cannot be
completed.

3
CONTENTS (cont)
Page
• PROPORTIONAL BANDS
• DIFFUSER CONTROL
• DEMAND LIMITING
• CHILLER TIMERS AND STARTS COUNTER
• OCCUPANCY SCHEDULE
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pump and Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shunt Trip (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Function Loss Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Default Screen Freeze. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ramp Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rampdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Capacity Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
High Discharge Temperature Control . . . . . . . . . . . 52
Compressor Bearing Temperature . . . . . . . . . . . . . . 52
Oil Sump Temperature and Pump Control. . . . . . . 52
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remote Start/Stop Controls . . . . . . . . . . . . . . . . . . . . . 54
Spare Safety and Spare Temperature Inputs . . . . 54
Alarm (Trip) Output Contacts . . . . . . . . . . . . . . . . . . . 54
Refrigerant Leak Detector . . . . . . . . . . . . . . . . . . . . . . . 54
Kilowatt Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remote Reset of Alarms . . . . . . . . . . . . . . . . . . . . . . . . 54
Condenser Pump Control . . . . . . . . . . . . . . . . . . . . . . . 54
Condenser Freeze Prevention. . . . . . . . . . . . . . . . . . . 55
Evaporator Freeze Protection . . . . . . . . . . . . . . . . . . . 55
Tower Fan Relay Low and High . . . . . . . . . . . . . . . . . 55
Auto. Restart After Power Failure . . . . . . . . . . . . . . . 55
Fast Power Source Transfers . . . . . . . . . . . . . . . . . . . 56
Water/Brine Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
• RESET TYPE 1
• RESET TYPE 2
• RESET TYPE 3
Demand Limit Control Option . . . . . . . . . . . . . . . . . . . 56
Surge Prevention — Constant Flow and
Variable Primary Flow (VPF) . . . . . . . . . . . . . . . . . . 56
Hot Gas Bypass (Optional) Algorithm . . . . . . . . . . . 56
Surge Protection (Fixed Speed Chiller). . . . . . . . . . 57
Surge Prevention Algorithm with VFD. . . . . . . . . . . 57
Surge Protection (VFD Chiller) . . . . . . . . . . . . . . . . . . 58
VFD Start-Up Speed Control . . . . . . . . . . . . . . . . . . . . 58
Head Pressure Reference Output . . . . . . . . . . . . . . . 58
Lead/Lag Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
• COMMON POINT SENSOR USAGE AND
INSTALLATION
• CHILLER COMMUNICATION WIRING
• LEAD/LAG OPERATION
• FAULTED CHILLER OPERATION
• LOAD BALANCING
• AUTO. RESTART AFTER POWER FAILURE
Ice Build Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
• ICE BUILD INITIATION
• START-UP/RECYCLE OPERATION
• TEMPERATURE CONTROL DURING ICE BUILD
• TERMINATION OF ICE BUILD
• RETURN TO NON-ICE BUILD OPERATIONS
Attach to Network Device Control . . . . . . . . . . . . . . . 62
• ATTACHING TO OTHER CCN MODULES
Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
• TO ACCESS THE SERVICE SCREENS
• TO LOG OUT OF NETWORK DEVICE
• TIME BROADCAST ENABLE
• HOLIDAY SCHEDULING
• DAYLIGHT SAVING TIME CONFIGURATION
START-UP/SHUTDOWN/RECYCLE
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-67
Local Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Automatic Soft Stop Amps Threshold. . . . . . . . . . . 66
Page
Chilled Water Recycle Mode . . . . . . . . . . . . . . . . . . . . 66
Safety Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
BEFORE INITIAL START-UP. . . . . . . . . . . . . . . . . . 67-86
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Using the Optional Storage Tank
and Pumpout System . . . . . . . . . . . . . . . . . . . . . . . . . 67
Remove Shipping Packaging. . . . . . . . . . . . . . . . . . . . 67
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . . . 67
Tighten All Gasketed Joints and
Guide Vane Shaft Packing . . . . . . . . . . . . . . . . . . . . 67
Check Chiller Tightness. . . . . . . . . . . . . . . . . . . . . . . . . 67
Refrigerant Tracer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspect Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Check Optional Pumpout Compressor
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Carrier Comfort Network®Interface . . . . . . . . . . . . . 72
Check Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
• MECHANICAL STARTER
• BENSHAW, INC. RediStart MX3™
SOLID-STATE STARTER
•VFDSTARTER
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Power Up the Controls and
Check the Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 73
• SOFTWARE VERSION
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 74
Input the Design Set Points . . . . . . . . . . . . . . . . . . . . . 74
Input the Local Occupied Schedule
(OCCPC01S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Input Service Configurations. . . . . . . . . . . . . . . . . . . . 74
•PASSWORD
• INPUT TIME AND DATE
• CHANGE ICVC CONFIGURATION
IF NECESSARY
• TO CHANGE THE PASSWORD
• TO CHANGE THE ICVC DISPLAY FROM
ENGLISH TO METRIC UNITS
• CHANGE LANGUAGE
• MODIFY CONTROLLER IDENTIFICATION
IF NECESSARY
• INPUT EQUIPMENT SERVICE PARAMETERS
IF NECESSARY
• CHANGE THE BENSHAW, INC., RediStart
MX3 SOFTWARE CONFIGURATION
IF NECESSARY
VFD Field Set Up and Verification . . . . . . . . . . . . . . . 75
• LABEL LOCATIONS
• DRIVE PROTECTION AND OTHER INCOMING
WIRING
• VFD CONTROL VERIFICATION (Non-Running)
• VFD CONTROL VERIFICATION (Running)
• HAND CALCULATE SURGE PREVENTION
CONFIGURATIONS
• CONFIGURE DIFFUSER CONTROL IF
NECESSARY
• MODIFY EQUIPMENT CONFIGURATION
IF NECESSARY
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . 82
• GUIDE VANE ACTUATOR CALIBRATION
• COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND WATERSIDE FLOW DEVICE
CALIBRATION

4
CONTENTS (cont)
Page
• OPTIONAL THERMAL DISPERSION FLOW
SWITCH CALIBRATION
Check Optional Pumpout System
Controls and Compressor. . . . . . . . . . . . . . . . . . . . . 84
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . . . . 84
Charge Refrigerant Into Chiller . . . . . . . . . . . . . . . . . . 84
• CHILLER EQUALIZATION WITHOUT A
PUMPOUT UNIT
• CHILLER EQUALIZATION WITH
PUMPOUT UNIT
• TRIMMING REFRIGERANT CHARGE
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 86,87
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dry Run to Test Start-Up Sequence . . . . . . . . . . . . . 86
Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Check Oil Pressure and Compressor Stop . . . . . . 86
To Prevent Accidental Start-Up. . . . . . . . . . . . . . . . . . 87
Check Chiller Operating Condition . . . . . . . . . . . . . . 87
Instruct the Customer Operator . . . . . . . . . . . . . . . . . 87
• 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 MANUAL
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . 87,88
Operator Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Prepare the Chiller for Start-Up. . . . . . . . . . . . . . . . . . 87
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Running System . . . . . . . . . . . . . . . . . . . . . 87
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 88
Preparation for Extended Shutdown. . . . . . . . . . . . . 88
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . 88
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . 88
Manual Guide Vane Operation. . . . . . . . . . . . . . . . . . . 88
Refrigeration Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PUMPOUT AND REFRIGERANT TRANSFER
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-93
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Operating the Optional Pumpout Unit . . . . . . . . . . . 90
• TO READ REFRIGERANT PRESSURES
• POSITIVE PRESSURE CHILLERS WITH STORAGE
TANKS
• CHILLERS WITH ISOLATION VALVES
• DISTILLING THE REFRIGERANT
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . 93-95
Refrigerant Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . . 93
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . 93
Leak Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Test After Service, Repair, or Major Leak . . . . . . . . 94
• TESTING WITH REFRIGERANT TRACER
• TESTING WITHOUT REFRIGERANT TRACER
• TO PRESSURIZE WITH DRY NITROGEN
Repair the Leak, Retest, and Apply
Standing Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . 94
Checking Guide Vane Linkage . . . . . . . . . . . . . . . . . . 94
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . 95
Page
WEEKLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 95
Check the Lubrication System . . . . . . . . . . . . . . . . . . 95
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . 95-98
Service Ontime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Inspect the Control Panel . . . . . . . . . . . . . . . . . . . . . . . 95
Check Safety and Operating Controls
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Oil Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Oil Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
• TO CHANGE THE OIL
Refrigerant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Oil Reclaim Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Inspect Refrigerant Float System. . . . . . . . . . . . . . . . 96
• ECONOMIZER FLOAT SYSTEM
• ECONOMIZER DAMPER VALVE
Inspect Relief Valves and Piping . . . . . . . . . . . . . . . . 96
Compressor Bearing and Gear
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect the Heat Exchanger Tubes
and Flow Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
• COOLER AND OPTIONAL FLOW DEVICES
• CONDENSER AND OPTIONAL FLOW DEVICES
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect the Starting Equipment . . . . . . . . . . . . . . . . . 98
Recalibrate Pressure Transducers . . . . . . . . . . . . . . 98
Optional Pumpout System Maintenance. . . . . . . . . 98
• OPTIONAL PUMPOUT COMPRESSOR OIL
CHARGE
• OPTIONAL PUMPOUT SAFETY CONTROL
SETTINGS
Ordering Replacement Chiller Parts . . . . . . . . . . . . . 98
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . 99-178
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Checking Display Messages . . . . . . . . . . . . . . . . . . . . 99
Checking Temperature Sensors . . . . . . . . . . . . . . . . . 99
• RESISTANCE CHECK
• VOLTAGE DROP
• CHECK SENSOR ACCURACY
• DUAL TEMPERATURE SENSORS
Checking Pressure Transducers . . . . . . . . . . . . . . . 116
• TRANSDUCER REPLACEMENT
• COOLER AND CONDENSER PRESSURE TRANS-
DUCER AND OPTIONAL WATERSIDE FLOW
DEVICE CALIBRATION
Control Algorithms Checkout Procedure . . . . . . . 117
Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
• RED LED (Labeled as STAT)
• GREEN LED (Labeled as COM)
Notes on Module Operation . . . . . . . . . . . . . . . . . . . . 117
Chiller Control Module (CCM) . . . . . . . . . . . . . . . . . . 117
• INPUTS
•OUTPUTS
Integrated Starter Module . . . . . . . . . . . . . . . . . . . . . . 117
• INPUTS
•OUTPUTS
Replacing Defective Processor Modules . . . . . . . 120
• INSTALLATION
Solid-State Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
• TESTING SILICON CONTROL RECTIFIERS IN
BENSHAW, INC. SOLID-STATE STARTERS
• SCR REMOVAL/INSTALLATION
End of Life and Equipment Disposal . . . . . . . . . . . 121
Physical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
APPENDIX A — ICVC PARAMETER INDEX . .179-185

5
CONTENTS (CONT)
Page
APPENDIX B — LEAD/LAG WIRING . . . . . . . . 186,187
APPENDIX C — MAINTENANCE SUMMARY
AND LOG SHEETS . . . . . . . . . . . . . . . . . . . . . . . 188-190
APPENDIX D — BACNET COMMUNICATION
OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191-197
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
INITIAL START-UP CHECKLIST FOR
19XR, XRV HERMETIC CENTRIFUGAL
LIQUID CHILLER . . . . . . . . . . . . . . . . . . . . CL-1 to CL-14
INTRODUCTION
Prior to initial start-up of the 19XR unit, those involved in
the start-up, operation, and maintenance should be thoroughly
familiar with these instructions and other necessary job data.
This book is outlined to familiarize those involved in the start-
up, operation and maintenance of the unit with the control sys-
tem before performing start-up procedures. Procedures in this
manual are arranged in the sequence required for proper chiller
start-up and operation.
ABBREVIATIONS AND EXPLANATIONS
Frequently used abbreviations in this manual include:
Words printed in all capital letters or in italics may be
viewed on the International Chiller Visual Controller (ICVC)
(e.g., LOCAL, CCN, ALARM, etc.).
Words printed in both all capital letters and italics can also
be viewed on the ICVC and are parameters (e.g., CONTROL
MODE, COMPRESSOR START RELAY, ICE BUILD
OPTION, etc.) with associated values (e.g., modes, tempera-
tures, percentages, pressures, on, off, etc.).
Words printed in all capital letters and in a box represent
softkeys on the ICVC control panel (e.g., , ,
, , etc.).
Factory-installed additional components are referred to as
options in this manual; factory-supplied but field-installed ad-
ditional components are referred to as accessories.
The chiller software part number of the 19XR unit is located
on the back of the ICVC.
CHILLER FAMILIARIZATION (FIG. 1-3)
Chiller Information Nameplate — The information
nameplate is located on the right side of the chiller control
panel.
System Components — The components include the
cooler and condenser heat exchangers in separate vessels,
motor-compressor, lubrication package, control panel, econo-
mizer (optional) and motor starter. All connections from pres-
sure vessels have external threads to enable each component to
be pressure tested with a threaded pipe cap during factory as-
sembly.
CAUTION
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dis-
sipate body electrostatic charge before working inside con-
trol center.
Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may cause interference to radio com-
munications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Inter-
national Standard in North America EN 61000-2/3 which
are designed to provide reasonable protection against such
interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to
cause interference, in which case the user, at his own
expense, will be required to take whatever measures may
be required to correct the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
CAUTION
Do NOT punch holes or drill into the top surface of the
VFD (variable frequency drive) enclosure for field wiring.
Knockouts are provided on the side of the VFD enclosure
for field wiring connections. The top panel of the enclosure
must be removable for servicing the power module.
CAUTION
PROVIDE MACHINE PROTECTION. Store machine
and starter indoors, protected from construction dirt and
moisture. Inspect under shipping tarps, bags or crates to be
sure water has not collected during transit. Keep protective
shipping covers in place until machine is ready for
installation.
CAUTION
WHEN FLUSHING THE WATER SYSTEMS isolate the
chiller from the water circuits to prevent damage to the heat
exchanger tubes.
CCM — Chiller Control Module
CCN — Carrier Comfort Network®
CCW — Counterclockwise
CW — Clockwise
ECDW — Entering Condenser Water
ECW — Entering Chilled Water
EMS — Energy Management System
HGBP — Hot Gas Bypass
I/O — Input/Output
ICVC — International Chiller Visual Controller
ISM — Integrated Starter Module
LCD — Liquid Crystal Display
LCDW — Leaving Condenser Water
LCW — Leaving Chilled Water
LED — Light-Emitting Diode
OLTA — Overload Trip Amps
PIC II — Product Integrated Controls II
RLA — Rated Load Amps
SCR — Silicon Controlled Rectifier
SI — International System of Units
TXV — Thermostatic Expansion Valve
VFD — Variable Frequency Drive
ENTER
EXIT
INCREASE
QUIT

6
27 10 Q 19843
Week of Year
Year of Manufacture
Unique Number
Place of Manufacture
MODEL NUMBER NOMENCLATURE
SERIAL NUMBER BREAKDOWN
Fig. 1 — 19XR,XRV Identification
a19-1969
8H
Cooler Size†
10-12 (Frame 1)
15-17 (Frame 1)
20-22 (Frame 2)
30-32 (Frame 3)
35-37 (Frame 3)
40-42 (Frame 4)
45-47 (Frame 4)
50-54 (Frame 5)
5A-5C (Frame 5)**
55-59 (Frame 5)
5F-5H (Frame 5)**
5K-5R (Frame 5)††
5T-5Z (Frame 5)††
60-64 (Frame 6)
6K-6R (Frame 6)††
65-69 (Frame 6)
6T-6Z (Frame 6)††
70-74 (Frame 7)
7K-7R (Frame 7)††
75-79 (Frame 7)
7T-7Z (Frame 7)††
80-84 (Frame 8)
8K-8R (Frame 8)††
85-89 (Frame 8)
8T-8Z (Frame 8)††
Condenser Size†
10-12 (Frame 1)
15-17 (Frame 1)
20-22 (Frame 2)
30-32 (Frame 3)
35-37 (Frame 3)
40-42 (Frame 4)
45-47 (Frame 4)
50-54 (Frame 5)
55-59 (Frame 5)
60-64 (Frame 6)
65-69 (Frame 6)
70-74 (Frame 7)
75-79 (Frame 7)
80-84 (Frame 8)
85-89 (Frame 8) Compressor Frame
2, 3, 4, 5 — Single-Stage
E — Two-Stage
Motor Code***
Motor Voltage Code
Code Volts-Phase-Hertz
60 — 200-3-60
61 — 230-3-60
62 — 380-3-60
63 — 416-3-60
64 — 460-3-60
65 — 575-3-60
66 — 2400-3-60
67 — 3300-3-60
68 — 4160-3-60
69 — 6900-3-60
50 — 230-3-50
52 — 400-3-50
53 — 3000-3-50
54 — 3300-3-50
55 — 6300-3-50
5A
5B
6A
6B
6C
—
—
—
—
—
10000-3-50
11000-3-50
11000-3-60
11000-3-60
13800-3-60
Special Order Indicator
– — Standard
S — Special Order
Description
19XR– — High Efficiency Semi-Hermetic
Centrifugal Liquid Chiller
19XRV — High Efficiency Semi-Hermetic
Centrifugal Liquid Chiller with
Unit-Mounted VFD
Impeller Diameter
UG T* 64
19XR
–
52 51 3
Impeller Shroud
Motor Efficiency Code
Compressor Frame 2, 3, 4, 5
H — High Efficiency
S — Standard Efficiency
Gear Code
Compressor Frame E
A,B,C,D,E— A-E Gear Ratio
Compressor Frame 3, UMotor
R,S,T,U,V,W— R-W Gear Ratio
* Digit 15 will refer to the Gear Code for the following models:
1. Digit 10 (Compressor Frame) is E
2. Digit 10 (Compressor Frame) is 3 and Digit 13 of the Motor Code is U.
† Frame sizes 1 through 6 available on single-stage units only.
** Refer to 19XR,XRV Computer Selection Program for details on these sizes.
†† Frame sizes with K-R and T-Z are with 1 in. OD evaporator tubing.
*** Refer to the 19XR,XRV Computer Selection Program for motor size details.
a19-2026

7
Cooler — This vessel (also known as the evaporator) is lo-
cated underneath the compressor. The cooler is maintained at
lower temperature/pressure so evaporating refrigerant can re-
move heat from water flowing through its internal tubes.
Condenser — The condenser operates at a higher tem-
perature/pressure than the cooler and has water flowing
through its internal tubes in order to remove heat from the re-
frigerant.
Motor-Compressor — This component maintains sys-
tem temperature and pressure differences and moves the heat-
carrying refrigerant from the cooler to the condenser. Compres-
sor Frames 2-5 are single-stage compressors with one impeller.
Frame E compressors are two-stage compressors with two
impellers.
Control Panel — The control panel is the user interface
for controlling the chiller. It regulates the chiller’s capacity as
required to maintain proper leaving chilled water temperature.
The control panel:
• registers cooler, condenser, and lubricating system
pressures
• shows chiller operating condition and alarm shutdown
conditions
• records the total chiller operating hours
• sequences chiller start, stop, and recycle under micropro-
cessor control
• displays status of motor starter
• provides access to other CCN (Carrier Comfort Net-
work®) devices and energy management systems
• Languages that may be pre-installed at factory include:
English, Chinese, Japanese, and Korean.
• International language translator (ILT) is available for
conversion of extended ASCII characters.
Economizer (Optional) — An economizer, along
with a two-stage compressor, allows for higher lift applica-
tions. The economizer is a separate vessel in the flow path after
the condenser that improves the refrigerant cycle by allowing a
small amount of refrigerant to flash into vapor. This phase
change decreases the temperature of the remaining liquid re-
frigerant. The vapor is drawn into the second stage of the com-
pressor, which saves energy because the refrigerant does not
have to be compressed by both stages.
Factory-Mounted Starter or Variable Fre-
quency Drive (Optional) — The starter allows for the
proper start and disconnect of electrical energy for the com-
pressor-motor, oil pump, oil heater, and control panel.
Storage Vessel (Optional) — There are 2 sizes of
storage vessels available. The vessels have double relief valves,
a magnetically-coupled dial-type refrigerant level gage, a 1-in.
FPT drain valve, and a 1/2-in. male flare vapor connection for
the pumpout unit.
NOTE: If a storage vessel is not used at the jobsite, factory-
installed isolation valves on the chiller may be used to isolate
the chiller charge in either the cooler or condenser. An optional
pumpout system is used to transfer refrigerant from vessel to
vessel.

8
Fig. 2 — 19XR,XRV Single-Stage Compressor
REAR VIEW
FRONT VIEW
LEGEND
1— Guide Vane Actuator
2— Suction Elbow
3— International Chiller Visual Control (ICVC)
4— Chiller Identification Nameplate
5— Cooler Auto Reset Relief Valves
6— Cooler Pressure Transducer
7— Condenser In/Out Temperature Thermistors
8— Cooler In/Out Temperature Thermistors
9— Refrigerant Storage Tank Connection Valve
10 — Typical Flange Connection
11 — Oil Drain Valve
12 — Oil Level Sight Glasses
13 — Refrigerant Oil Cooler (Hidden)
14 — Auxiliary Power Panel
15 — Motor Housing
LEGEND
16 — Condenser Auto. Reset Relief Valves
17 — Motor Circuit Breaker
18 — Solid-State Starter Control Display
19 — Unit-Mounted Starter or VFD (Optional)
Solid-State Starter Shown
20 — Motor Sight Glass
21 — Cooler Return-End Waterbox Cover
22 — ASME Nameplate (One Hidden)
23 — Typical Waterbox Drain Port
24 — Condenser Return-End Waterbox Cover
25 — Refrigerant Moisture/Flow Indicator
26 — Refrigerant Filter/Drier
27 — Liquid Line Isolation Valve (Optional)
28 — Liquid Float Valve Chamber
29 — Refrigerant Charging Valve (Hidden)
30 — Vessel Take-Apart Connector
31 — Discharge Isolation Valve (Optional)
32 — Condenser Pressure Transducer
33 — Refrigerant Charging Valve/Pumpout
Connection
1
2
3
5
6
4
11
12
13
15
14
7
9
10
8
a19-2425
1819 20
21
22
23
31
30
29
2827 26 25 24
3222
22
16 17
33

9
Fig. 3 — 19XR,XRV Two-Stage Compressor
REAR VIEW
FRONT VIEW
LEGEND
1—Guide Vane Actuator
2—Suction Elbow
3—Chiller Identification Nameplate
4—Condenser Auto Reset Relief Valves
5—Condenser In/Out Temperature Thermistors
6—Cooler In/Out Temperature Thermistors
7—Cooler Pressure Transducer
8—Refrigerant Storage Tank Connection Valve
9—Refrigerant Isolation Valve
10 — Chiller Visual Controller/ International Chiller
Visual Control (ICVC)
11 — Typical Flange Connection
12 — Oil Level Sight Glasses
13 — Oil Drain Charging Valve
14 — Auxiliary Power Panel
15 — Refrigerant Oil Cooler (Hidden)
16 — Compressor Motor Housing
LEGEND
17 — Damper Valve
18 — Cooler Auto. Reset Relief Valves
19 — Solid-State Starter Control Display (Optional)
20 — Unit-Mounted Starter (Optional)
21 — Motor Sight Glass
22 — Cooler Return-End Waterbox Cover
23 — ASME Nameplate
24 — Vessel Take-Apart Connector
25 — Typical Waterbox Drain Port
26 — Condenser Return-End Waterbox Cover
27 — Refrigerant Moisture/Flow Indicator
28 — Refrigerant Filter/Drier
29 — Liquid Line Isolation Valve (Optional)
30 — Linear Float Valve Chamber
31 — Refrigerant Charging Valve (Hidden)
32 — Economizer Float Ball Valve Assembly (Inside)
33 — Economizer Assembly
34 — Discharge Isolation Valve (Optional)
35 — Condenser Pressure Transducer
36 — Refrigerant Charging Valve/Pumpout
Connection
16
12
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
19 20
21
22
23
24
2325
26
27
28
29
30
31
32
33
34
35
36
a19-2426

10
REFRIGERATION CYCLE
The compressor continuously draws refrigerant vapor from
the cooler at a rate set by the amount of guide vane opening. As
the compressor suction reduces the pressure in the cooler, the
remaining refrigerant boils at a fairly low temperature (typical-
ly 38 to 42 F [3 to 6 C]). The energy required for boiling is ob-
tained from the water flowing through the cooler tubes. With
heat energy removed, the water becomes cold enough to use in
an air conditioning circuit or for process liquid cooling.
After taking heat from the water, the refrigerant vapor is
compressed. Compression adds still more heat energy, and the
refrigerant is quite warm (typically 98 to 102 F [37 to 40 C])
when it is discharged from the compressor into the condenser.
Relatively cool (typically 65 to 90 F [18 to 32 C]) water
flowing into the condenser tubes removes heat from the refrig-
erant and the vapor condenses to liquid.
The liquid refrigerant passes through orifices into the
FLASC (Flash Subcooler) chamber (Fig. 4). Since the FLASC
chamber is at a lower pressure, part of the liquid refrigerant
flashes to vapor, thereby cooling the remaining liquid. The
FLASC vapor is recondensed on the tubes which are cooled by
entering condenser water. The liquid drains into a float cham-
ber between the FLASC chamber and cooler. Here the Accu-
Meter™ float valve forms a liquid seal to keep FLASC
chamber vapor from entering the cooler. When liquid refriger-
ant passes through the valve, some of it flashes to vapor in the
reduced pressure on the cooler side. In flashing, it removes heat
from the remaining liquid. The refrigerant is now at a tempera-
ture and pressure at which the cycle began. Refrigerant from
the condenser also cools the oil and optional variable speed
drive.
The refrigeration cycle for a 19XR,XRV chiller with two-
stage compressor is similar to the one described above, with
the following exception: Liquid refrigerant from the condenser
FLASC chamber linear float valve flows into an economizer at
intermediate pressure (see Fig. 5). As liquid enters the cham-
ber, due to the lower pressure in the economizer, some liquid
flashes into a vapor and cools the remaining liquid. The sepa-
rated vapor flows to the second stage of the compressor for
greater cycle efficiency. A damper valve located on the econo-
mizer line to the compressor acts as a pressure regulating de-
vice to stabilize low load, low condensing pressure operating
conditions. The damper will back up gas flow and thereby rais-
es the economizer pressure to permit proper refrigerant flow
through the economizer valve during those conditions. The
damper also is closed during start-up conditions to allow the
second stage impeller to start unloaded.
The subcooled liquid remaining in the economizer flows
through a float valve and then into the cooler.
Fig. 4 — Refrigeration Cycle — 19XR,XRV Single-Stage Compressor
a19-
1550tf

11
MOTOR AND OIL COOLING CYCLE
The motor and the lubricating oil are cooled by liquid refriger-
ant taken from the bottom of the condenser vessel (Fig. 4 and
5). Refrigerant flow is maintained by the pressure differential
that exists due to compressor operation. After the refrigerant
flows past an isolation valve, an in-line filter, and a sight glass/
moisture indicator, the flow is split between the motor cooling
and oil cooling systems.
COOLER
ISOLATION
VALVE
(OPTION)
CHILLED
WATER
COMPRESSOR
BACK PRESSURE
ORIFICE (INTEGRAL
TO MOTOR SHELL)
IMPELLERS
OIL COOLER
ORIFICE
OPTIONAL UNIT
MOUNTED VFD
(VARIABLE
FREQUENCY
DRIVE) HEAT
EXCHANGER
THERMOSTATIC
EXPANSION
VALVE (TXV)
FLOAT BALL VALVE
HGBP VALVE
ORIFICE
FITTING
MOISTURE/
FLOW
INDICATOR
FILTER
DRIER
REFRIGERANT
COOLING
ISOLATION
VALVE
ROTOR TRANSMISSION
ORIFICE
FITTING
DAMPER
VALVE
REFRIGERANT
ISOLATION VALVE
HOT GAS BYPASS (OPTIONAL)
FLOAT
VALVE
CHAMBER
CONDENSER
WATER
FLASC CHAMBER
ISOLATION
VALVE
REFRIGERANT
LIQUID
REFRIGERANT
VAPOR
REFRIGERANT
LIQUID/VAPOR
MOTOR
Fig. 5 — Refrigeration Cycle — 19XR,XRV Two-Stage Compressor
IMPORTANT: To avoid adverse effects on chiller opera-
tion, considerations must be made to condenser water tem-
perature control. For steady state operation, the minimum
operating refrigerant pressure differential between cooler
and condenser is approximately 20 psi (138 kPa) with a
maximum evaporator refrigerant temperature of 65 F
(18 C). Consult Chiller Builder for required steady state
operational limits. Inverted start conditions are acceptable
for short durations of time, but for periods exceeding 5
minutes, a special control solution strategy should be used
to allow the chiller to establish a minimum refrigerant pres-
sure differential (and thereby adequate equipment cooling).

12
Flow to the motor cooling system passes through an orifice
and into the motor. Once past the orifice, the refrigerant is di-
rected over the motor by a spray nozzle. The refrigerant col-
lects in the bottom of the motor casing and is then drained back
into the cooler through the motor refrigerant drain line. An ori-
fice (in the motor shell) maintains a higher pressure in the
motor shell than in the cooler. The motor is protected by a tem-
perature sensor imbedded in the stator windings. An increase in
motor winding temperature past the motor override set point
overrides the temperature capacity control to hold, and if the
motor temperature rises 10F (5.5C) above this set point, the
Product Integrated Control II (PIC II) controls close the inlet
guide vanes. If the temperature rises above the safety limit, the
compressor shuts down.
Refrigerant that flows to the oil cooling system is regulated
by thermostatic expansion valves (TXVs). The TXVs regulate
flow into the oil/refrigerant plate and frame-type heat exchang-
er (the oil cooler in Fig. 4 and 5). The expansion valve bulbs
control oil temperature to the bearings. The refrigerant leaving
the oil cooler heat exchanger returns to the chiller cooler.
VFD COOLING CYCLE
The unit-mounted variable frequency drive (VFD) typically
has PIC III controls. The only unit-mounted drive available
with PIC II controls is the 575-v input drive.
The 575-v unit-mounted variable frequency drive (VFD) is
cooled in a manner similar to the motor and oil cooling cycle
(Fig. 4 and 5).
If equipped with a unit-mounted VFD, the refrigerant line
that feeds the motor cooling and oil cooler also feeds the heat
exchanger on the unit-mounted VFD. Refrigerant is metered
through an orifice. The refrigerant leaving the heat exchanger
returns to the cooler.
LUBRICATION CYCLE
Summary — The oil pump, oil filter, and oil cooler make
up a package located partially in the transmission casing of the
compressor-motor assembly. The oil is pumped into a filter as-
sembly to remove foreign particles and is then forced into an
oil cooler heat exchanger where the oil is cooled to proper op-
erational temperatures. After the oil cooler, part of the flow is
directed to the gears and the high speed shaft bearings; the re-
maining flow is directed to the motor shaft bearings. Oil drains
into the transmission oil sump to complete the cycle (Fig. 6 and
7).
Details — Oil is charged into the lubrication system through
a hand valve. Two sight glasses in the oil reservoir permit oil
level observation. Normal oil level is between the middle of the
upper sight glass and the top of the lower sight glass when the
compressor is shut down. The oil level should be visible in at
least one of the 2 sight glasses during operation. Oil sump tem-
perature is displayed on the ICVC (International Chiller Visual
Controller) default screen. During compressor operation, the
oil sump temperature ranges between 125 and 150 F (52 and
66 C).
The oil pump suction is fed from the oil reservoir. An oil
pressure relief valve maintains 18 to 25 psid (124 to 172 kPad)
differential pressure in the system at the pump discharge. For
compressors equipped with rolling element bearings, a range of
18 to 40 psid (124 to 172 kPad) is normal. This differential
pressure can be read directly from the ICVC default screen.
The oil pump discharges oil to the oil filter assembly. This filter
can be closed to permit removal of the filter without draining
the entire oil system (see Maintenance sections, pages 93-98,
for details). The oil is then piped to the oil cooler heat exchang-
er. The oil cooler uses refrigerant from the condenser as the
coolant. The refrigerant cools the oil to a temperature between
120 and 140 F (49 to 60 C).
As the oil leaves the oil cooler, it passes the oil pressure
transducer and the thermal bulb for the refrigerant expansion
valve on the oil cooler. The oil is then divided. Part of the oil
flows to the thrust bearing, forward pinion bearing, and gear
spray. The rest of the oil lubricates the motor shaft bearings and
the rear pinion bearing. The oil temperature is measured in the
bearing housing as it leaves the thrust and forward journal
bearings or on the bearing race if the compressor is equipped
with rolling element bearings. The oil then drains into the oil
reservoir at the base of the compressor. The PIC II (Product In-
tegrated Control II) measures the temperature of the oil in the
sump and maintains the temperature during shutdown (see Oil
Sump Temperature and Pump Control section, page 52). This
temperature is read on the ICVC default screen.

13
ISOLATION
VALVE
SIGHT
GLASS
FILTER
ISOLATION
VALVE
OIL SKIMMER
LINE
FILTEREDUCTOR
OIL
PUMP
TXV BULB PRESSURE
TRANSDUCER ISOLATION VALVES
OIL
COOLER OIL PUMP
MOTOR
OIL
HEATER
MOTOR
COOLING LINE
LABYRINTH
GASLINE
FWD MOTOR
BEARING OIL SUPPLY TO FORWARD HIGH
SPEED BEARING
SIGHT
GLASS
FLOW
OIL
FILTER
REAR MOTOR
BEARING
STRAINER
Fig. 6 — Single-Stage Lubrication System
a19-1965
OIL PUMP
AND MOTOR
OIL
HEATER
OIL PRESS
REGULATOR
OIL COOLER
ISOLATION
VALVES
PRESSURE
TRANSDUCER
TXV BULB
MOTOR
COOLING LINE
REAR HIGH
SPD BRG
OIL FILTER
FLOW
EDUCTORS
SIGHT GLASS
STRAINERS
FILTER
SIGHT
GLASS
OIL SKIMMER
LINE
COOLER
LABYRINTH
GAS LINE
OIL SUPPLY TO
FORWARD HIGH
SPEED BEARING
FWD MOTOR
BEARING
REAR MOTOR
BEARING
Fig. 7 — Two-Stage Lubrication System

14
During the chiller start-up, the oil pump is energized and
provides 40 seconds of lubrication to the bearings after pres-
sure is verified before starting the compressor. During shut-
down, the oil pump runs for 60 seconds to ensure lubrication as
the compressor coasts to a stop. The oil pump can also be ener-
gized for testing purposes by using the Controls Test.
Ramp loading can be adjusted to help to slow the rate of
guide vane opening to minimize oil foaming at start-up. If the
guide vanes open quickly, the sudden drop in suction pressure
can cause any refrigerant in the oil to flash. The resulting oil
foam cannot be pumped efficiently; therefore, oil pressure falls
off and lubrication is poor. If oil pressure falls below 15 psid
(103 kPad) differential, the PIC II controls will shut down the
compressor.
When the oil pump is not running and the oil heater remains
energized for 30 minutes, the oil pump will be started and will
run for 30 seconds to evenly distribute the heat in the oil
system.
There are three pump-filter configurations. The original
vane pump, in which the oil filter is contained in the pump
housing, followed by the vane pump with the oil filter being
external in the oil piping between the oil pump and the oil cool-
er. The third configuration is the gerotor pump, also with the
external oil filter.
A gerotor pump has two rotors, one is inside the other and
their center points are offset with respect to each other. This
type of pump provides a smooth continuous flow. It is also qui-
eter than other designs.
The gerotor pump can be most easily identified by the exter-
nal location of the oil pressure regulator. The regulator is
located on the bottom of the pump pointing horizontally to the
left. See Fig. 8.
Bearings — The 19XR compressor assemblies include
four radial bearings and four thrust bearings. The low speed
shaft assembly is supported by two journal bearings located be-
tween the motor rotor and the bull gear. The bearing closer to
the rotor includes a babbitted thrust face which opposes the
normal axial forces which tend to pull the assembly towards
the transmission. The bearing closer to the bull gear includes a
smaller babbitted thrust face, designed to handle counterthrust
forces.
For compressors equipped with hydrodynamic bearings, the
high speed shaft assembly is supported by two journal bearings
located at the transmission end and mid-span, behind the laby-
rinth seal. The transmission side of the midspan bearing also
contains a tilting shoe type thrust bearing which opposes the
main axial forces tending to pull the impeller towards the suc-
tion end. The impeller side face of the midspan bearing in-
cludes a babbitted thrust face, designed to handle counterthrust
forces.
For compressors equipped with rolling element bearings,
the high speed shaft assembly has been redesigned to utilize
rolling element bearings (radial and thrust). Machines employ-
ing the rolling element bearings can be expected to have higher
oil pressure and thrust bearing temperatures than those com-
pressors using the alternate bearing design.
Oil Reclaim System — The oil reclaim system returns
oil lost from the compressor housing back to the oil reservoir
by recovering the oil from 2 areas on the chiller. The guide
vane housing is the primary area of recovery. Oil is also recov-
ered by skimming it from the operating refrigerant level in the
cooler vessel.
PRIMARY OIL RECOVERY MODE — Oil is normally re-
covered through the guide vane housing on the chiller. This is
possible because oil is normally entrained with refrigerant in
the chiller. As the compressor pulls the refrigerant up from the
cooler into the guide vane housing to be compressed, the oil
normally drops out at this point and falls to the bottom of the
guide vane housing where it accumulates. Using discharge gas
pressure to power an eductor, the oil is drawn from the housing
and is discharged into the oil reservoir.
1. GERATOR OIL PUMP
2. ISOLATION VALVE
3. OIL PRESSURE REGULATOR VALVE
4. OIL SUMP PRESSURE TRANSDUCER
5. OIL SUMP DRAIN
6. BEARING TEMPERATURE SENSOR TERMINAL BLOCK
7. OIL HEATER
2
1
3
5
7
6
4
Fig. 8 — Gerotor Oil Pump a19-1852

15
SECONDARY OIL RECOVERY METHOD — The sec-
ondary method of oil recovery is significant under light load
conditions, when the refrigerant going up to the compressor
suction does not have enough velocity to bring oil along. Under
these conditions, oil collects in a greater concentration at the
top level of the refrigerant in the cooler. This oil and refrigerant
mixture is skimmed from the side of the cooler and is then
drawn up to the guide vane housing using discharge gas pres-
sure to power an eductor. There is a filter in this line. Because
the guide vane housing pressure is much lower than the cooler
pressure, the refrigerant boils off, leaving the oil behind to be
collected by the primary oil recovery method.
STARTING EQUIPMENT
The 19XR chiller requires a motor starter to operate the cen-
trifugal hermetic compressor motor, the oil pump, and various
auxiliary equipment. The starter is the main field wiring inter-
face for the contractor.
See Carrier Specification Z-415 for specific starter require-
ments, Z-416 for free-standing VFD requirements and Z-417
for unit-mounted VFD requirements. All starters must meet
these specifications in order to properly start and satisfy me-
chanical safety requirements. Starters may be supplied as sepa-
rate, free-standing units or may be mounted directly on the
chiller (unit mounted) for low voltage units only.
Typically three separate circuit breakers are inside the start-
er. This includes (1) the main compressor motor circuit breaker,
(2) a circuit breaker which provides power to chiller controls
and the oil heater (provided at 115 vac), and (3) a circuit break-
er which provides power at line voltage to the oil pump. The
latter two are typically wired in parallel with the first so that
power is provided to those services when the main breaker is
open. The disconnect switch on the starter front cover is con-
nected to the main breaker.
All starters and freestanding VFDs must include a Carrier
control module called the Integrated Starter Module (ISM), ex-
cluding the Benshaw solid-state and wye-delta MX3™ starters.
This module controls and monitors all aspects of the starter.
See the Controls section (following) for additional ISM infor-
mation. Contact Carrier’s Replacement Component Division
(RCD) for replacement parts.
Unit-Mounted Solid-State Starter (Optional) —
The 19XR chiller may be equipped with a solid-state, reduced-
voltage starter (Fig. 9 and 10). This starter’s primary function is
to provide on-off control of the compressor motor. This type of
starter reduces the peak starting torque, controls the motor in-
rush current, and decreases mechanical shock. This capability
is summed up by the phrase “soft starting.” The solid-state
starter is available as a 19XR option (factory supplied and in-
stalled). The solid-state starters manufacturer name is located
inside the starter access door.
A solid-state, reduced-voltage starter operates by reducing
the starting voltage. The starting torque of a motor at full volt-
age is typically 125% to 175% of the running torque. When the
voltage and the current are reduced at start-up, the starting
torque is reduced as well. The object is to reduce the starting
voltage to adjust the voltage necessary to develop the torque re-
quired to get the motor moving. The voltage is reduced by sili-
con controlled rectifiers (SCRs). The voltage and current are
then ramped up in a desired period of time. Once full voltage is
reached, a bypass contactor is energized to bypass the SCRs.
WARNING
The main circuit breaker on the front of the starter discon-
nects the main motor power only. Power is still energized
for two other circuits. Two additional circuit breakers
inside of the starter must be turned off to disconnect power
to the oil pump, PIC II controls and the oil heater. Failure to
disconnect power will result in personal injury.
MAIN CIRCUIT
BREAKER
TERMINAL
STRIP
MX
BOARD
METERS
SWITCHES
OPTIONAL
VOLT AND AMP
METERSAND
SELECTOR
SWITCHES
METERS
ME
S
WIT
C
HE
S
KEYPAD/
DISPLAY
Fig. 9 — Benshaw Solid-State Starter, Internal View a19-1896

16
There is a display on the front of the Benshaw, Inc., solid-
state and wye-delta starters that is useful for troubleshooting
and starter checkout. The display indicates:
• line voltage
• control voltage status
• power indication
• proper phasing for rotation
• start circuit energized
• ground fault
• current unbalance
•runstate
The starter is further explained in the Check Starter and
Troubleshooting Guide sections, pages 73 and 99.
Unit-Mounted Wye-Delta Starter (Optional) —
The 19XR chiller may be equipped with a wye-delta starter
mounted on the unit. This starter is used with low-voltage mo-
tors (under 600 v). It reduces the starting current inrush by con-
necting each phase of the motor windings into a wye configu-
ration. This occurs during the starting period when the motor is
accelerating up to speed. Once the motor is up to speed, the
starter automatically connects the phase windings into a delta
configuration. Starter control, monitoring, and motor
protection is provided by Carrier’s Integrated Starter Module
(ISM) except for Benshaw MX3™ wye-delta starters which do
not use an ISM.
Unit-Mounted VFD (Optional for 575 v
Only) — The 19XRV unit can be equipped with a variable
frequency drive motor controller mounted on the unit. See
Fig. 11. This VFD is used with low voltage motors at 575 v on-
ly. All other unit-mounted VFDs use PIC III controls. A VFD
reduces the starting current inrush by controlling the voltage
and frequency to the compressor motor. Once the motor has ac-
celerated to start-up speed the PIC II modulates the compressor
speed and guide vane position to control chilled water tempera-
ture. The VFD is further explained in the Controls section and
Troubleshooting Guide sections, pages 17 and 99.
Typically, three separate circuit breakers are inside the start-
er. This includes (1) the VFD circuit breaker, (2) a circuit
breaker which provides power to the chiller controls and the
the oil heater (provided at 115 vac), and (3) a circuit breaker
that provides power at the line voltage to the oil pump. The
controls, oil heater and oil pump circuit breakers are wired in
parallel with the VFD circuit breaker so that power can be pro-
vided to those services when the VFD circuit breaker is open.
The circuit breaker that supplies power to the oil pump and
the circuit breaker that supplies power to the oil heater and
chiller controls are wired in parallel with the main VFD circuit
breaker so that power is supplied to them if the disconnect is
open. Refer to wiring schematic in Physical data section.
SIDE SERVICE
ACCESS PANEL
AIR INTAKE
LOUVERS
OPTIONAL ANALOG 3-PHASE
VOLTMETER AND AMMETER
STARTER CONTROL
DISPLAY INTERFACE
VOLTMETER/
AMMETER
SELECTOR
SWITCHES
STARTER
ACCESS
DOOR
MOTOR
POWER
DISCONNECT
HANDLE
LOW VOLTAGE
ACCESS
DOOR
Fig. 10 — Typical Starter External View (Solid-State Starter Shown) a19-1854
WARNING
When voltage is supplied to the solid-state circuitry (CB1
is closed), the heat sinks in the starter as well as the wires
leading to the motor and the motor terminal are at line volt-
age. Do not touch the heat sinks, power wiring, or motor
terminals while voltage is present or serious injury will
result.
WARNING
The optional main VFD circuit breaker on the front of the
VFD enclosure disconnects the VFD only. Power is still
energized for the other circuits. Two more circuit breakers
inside the starter must be turned off to disconnect power to
the oil pump, PIC II controls, and oil heater. Failure to dis-
connect power will result in personal injury.

17
Other than the unit-mounted starter or drive options dis-
cussed above, 19XR chillers may be provided with other alter-
natives such as free-standing low voltage or medium voltage
starters, or free-standing variable frequency drives. These are
usually specified in the original sales requisition. Features and
functionality included with these alternative starters are defined
in Carrier specifications such that operation with PIC II con-
trols remains consistent.
CONTROLS
Definitions
ANALOG SIGNAL — An analog signal varies in proportion
to the monitored source. It quantifies values between operating
limits. (Example: A temperature sensor is an analog device be-
cause its resistance changes in proportion to the temperature,
generating many values.)
DISCRETE SIGNAL — A discrete signal is a 2-position rep-
resentation of the value of a monitored source. (Example: A
switch produces a discrete signal indicating whether a value is
above or below a set point or boundary by generating an on/off,
high/low, or open/closed signal.)
General — The 19XR hermetic centrifugal liquid chiller
contains a microprocessor-based control center that monitors
and controls all operations of the chiller (see Fig. 12). The mi-
croprocessor control system matches the cooling capacity of
the chiller to the cooling load while providing state-of-the-art
chiller protection. The system controls cooling load within the
set point plus the deadband by sensing the leaving chilled water
or brine temperature and regulating the inlet guide vane via a
mechanically linked actuator motor. The guide vane is a
variable flow pre-whirl assembly that controls the refrigeration
effect in the cooler by regulating the amount of refrigerant va-
por flow into the compressor. An increase in guide vane
opening increases capacity. A decrease in guide vane opening
decreases capacity. The microprocessor-based control center
protects the chiller by monitoring the digital and analog inputs
and executing capacity overrides or safety shutdowns, if re-
quired.
PIC II System Components — The chiller control
system is called the PIC II (Product Integrated Control II). See
Table 1. The PIC II controls the operation of the chiller by
monitoring all operating conditions. The PIC II can diagnose a
problem and let the operator know what the problem is and
what to check. It promptly positions the guide vanes to main-
tain leaving chilled water temperature. It can interface with
auxiliary equipment such as pumps and cooling tower fans to
turn them on when required. It continually checks all safeties to
prevent any unsafe operating condition. It also regulates the oil
heater while the compressor is off and regulates the hot gas by-
pass valve, if installed. The PIC II controls provide critical pro-
tection for the compressor motor and controls the motor starter.
The PIC II can interface with the Carrier Comfort Net-
work®(CCN) if desired. It can communicate with other PIC I,
PIC II or PIC III equipped chillers and other CCN devices.
The PIC II consists of 3 modules housed inside 3 major
components. The component names and corresponding control
voltages are listed below (also see Table 1):
• control panel
— all extra low-voltage wiring (24 v or less)
• power panel
— 115 v control voltage transformer primaries (may be
rewired to accomodate 230 vac)
— 115 vac power for oil heater and actuators (oil heaters
may be rewired to accomodate 230 vac)
— up to 575 v for oil pump power
• starter cabinet
— chiller power wiring (per job requirement)
57.17
54.54
60.00
INPUT INDUCTOR
BEHIND CAP
ASSEMBLY
12
15
14
13
6
8
7
9
1
2
3
4
5
11 10
3KVA X-FORMER
BEHIND
THE 15AMP CB
Fig. 11 — PIC II Unit-Mounted 575-v Variable Frequency Drive (VFD) Internal View
LEGEND
1 — Main Power Circuit Breaker (CB)
2 — Electric Surge Protector
3 — Control Transformer
4 — Contr Power CB
5 — Control Power Fuse
6 — Oil Pump CB
7 — Pre-Charge Resistors
8 — Pre-Charge Fuses
9 — Pre-Charge Contactors
10 — Input line Reactor
11 — Capacitor Filter Bank
12 — Input Current Transformers
13 — Interface Relays
14 — ISM
15 — VFD Power Module

18
Table 1 — Major PIC II Components and
Panel Locations
INTERNATIONAL CHILLER VISUAL CONTROLLER
(ICVC) — The ICVC (International Chiller Visual Controller)
is a display/processor module that comes preprogrammed to
display all tables in the following optional character sets (lan-
guages): English, Mandarin Chinese, Korean, and Japanese.
The language selection appears at the bottom of the Service/
ICVC Configuration screen. Other languages can be translated
and downloaded in place of the Chinese, Korean and Japanese
languages in the field using the ILT (International Language
Translator) utility software. English cannot be overwritten and
will always be resident in the ICVC.
The ICVC may be identified by viewing the back of the
plate on which the display is mounted. (Open up the control
panel door to view.)
*This manual covers ICVC software version 14. Obtain obsolete
manuals and service bulletins for information on previous software
versions.
The ICVC has a stop button, an alarm light, four buttons for
logic inputs, and a backlight display. The backlight will auto-
matically turn off after 15 minutes of non-use. The functions of
the four buttons or “softkeys” are menu driven and are shown
on the display directly above the softkeys.
The viewing angle of the ICVC can be adjusted for opti-
mum viewing. Remove the 2 bolts connecting the control panel
to the brackets attached to the cooler. Place them in one of the
holes to pivot the control panel forward to backward to change
the viewing angle. See Fig. 13. To change the contrast of the
display, access the adjustment on the back of the ICVC. See
Fig. 13.
English is the default language.
Three other programmed languages are available as options:
Chinese
Japanese
Korean
NOTE: Pressing any one of the four softkey buttons will acti-
vate the backlight display without implementing a softkey
function.
INTEGRATED STARTER MODULE (ISM) — This mod-
ule is located in the starter cabinet. This module initiates com-
mands from the ICVC for starter functions such as starting and
stopping the compressor, condenser, chilled water pumps, tow-
er fan, spare alarm contacts, and the shunt trip. The ISM
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV)
OIL COOLER THERMOSTATIC
EXPANSION VALVE (TXV) BULB
OIL HEATER TERMINAL
BOX
HIGH PRESSURE
SWITCH LOCATION
COMPRESSOR DISCHARGE
TEMPERATURE SENSOR
CABLE
GUIDE VALVE
ACTUATOR CABLE
DIFFUSER PRESSURE
AND DIFFUSER ACTUATOR
CABLE (FRAME 4 & 5
COMPRESSOR ONLY)
OIL RECLAIM
SIGHT GLASS
CABLE FROM
CONTROL PANEL
COMPRESSOR OIL SUMP
TEMPERATURE CABLE
COMPRESSOR OIL SUMP
PRESSURE CABLE
BEARING TEMPERATURE
SENSOR CABLE
COMPRESSOR OIL DISCHARGE
PRESSURE CABLE
MOTOR TEMPERATURE
SENSOR CABLE
Fig. 12 — 19XR,XRV Compressor Controls and Sensor Locations
a19-1606
PIC II COMPONENT PANEL
LOCATION
Chiller Visual Controller (ICVC) and
Display Control Panel
Integrated Starter Module (ISM) Starter Cabinet
Chiller Control Module (CCM) Control Panel
Oil Heater Contactor (1C) Power Panel
Oil Pump Contactor (2C) Power Panel
Hot Gas Bypass Relay (3C) (Optional) Power Panel
Control Transformers (T1, T2) Power Panel
Temperature Sensors See Fig. 2, Fig. 12,
and Table 2
Pressure Transducers See Fig. 2, Fig. 12,
and Table 2
CONTROLLER COLOR
OF PLATE CEPL NO. (HARDWARE) SOFTWARE NO.* OTHER MARKINGS
ICVC Metallic
CEPL
130445-03-R
or
130445-04-R
CESR
131294-14
“PIC II”
marking on
back of
green cir-
cuit board

19
monitors starter inputs such as line voltage, motor current,
ground fault, remote start contact, spare safety, condenser high
pressure, oil pump interlock, starter 1M, and run contacts. It
shuts down the chiller if communications with the ICVC are
lost. The ISM can also act as the interface for PIC II to the VFD
controller.
The ISM module directly measures current and voltage for
each phase. Calculation of power factor, power in kilowatts,
and energy in kilowatt hours is performed by software in the
ISM for constant speed starters only. All of these values are
transmitted to the ICVC on the SIO (sensor input/output) com-
munications bus. The ISM software also defines conditions for
transition for different starter types, and it integrates I2t in mon-
itoring motor overload.
CHILLER CONTROL MODULE (CCM) — This module is
located in the control panel. The CCM provides the input and
outputs necessary to control the chiller. This module monitors
refrigerant pressure, entering and leaving water temperatures,
and outputs control for the guide vane actuator, oil heaters, and
oil pump. The CCM is the connection point for optional de-
mand limit, chilled water reset, remote temperature reset, re-
frigerant leak sensor and motor kilowatt output.
OIL HEATER CONTACTOR (1C) — This contactor is lo-
cated in the power panel (Fig. 14) and operates the heater at ei-
ther 115 or 230 v. It is controlled by the PIC II to maintain oil
temperature during chiller shutdown. Refer to the control panel
wiring schematic.
OIL PUMP CONTACTOR (2C) — This contactor is locat-
ed in the power panel. It operates all 200 to 575-v oil pumps.
The PIC II energizes the contactor to turn on the oil pump as
necessary.
HOT GAS BYPASS CONTACTOR RELAY (3C)
(OPTIONAL) — This relay, located in the power panel, con-
trols the opening of the hot gas bypass valve. The PIC II ener-
gizes the relay during low load, high lift conditions.
CONTROL TRANSFORMERS (T1, T2) — These trans-
formers convert incoming control voltage to 24 vac power for
the 3 power panel contactor relays, CCM, and ICVC.
SENSORS — Three types of temperature sensors are used.
Figure 15 shows a typical temperature sensor for which
sensor wells are not used, in systems having an ICVC control-
ler. For this type, the sensor cable can be easily disconnected
from the sensor, which is in direct contact with the fluid.
The other typical temperature sensor has sensor wells. See
Fig. 16. For this type, the sensor cable cannot be separated
from the sensor itself, but the sensor can be easily removed
from the well without breaking into the fluid boundry.
The third type of temperature sensor is a thermistor, which
is installed either in the motor windings or at the thrust bearing
within the compressor. Both of these have redundant sensors
such that if one fails, the other can be connected external to the
machine. See Table 2 for a list of standard instrumentation sen-
sors.
The PIC II control determines refrigerant temperature in the
condenser and evaporator from pressure in those vessels, read
from the corresponding pressure transducers. See Fig. 14. The
pressure values are converted to the equivalent saturation tem-
peratures for R-134a refrigerant. When the chiller is running, if
the computed value for EVAPORATOR REFRIG TEMP is
greater than, or within 0.6° F (0.33° C) of the LEAVING
CHILLED WATER temperature, its value is displayed as 0.6° F
(0.33° C) below LEAVING CHILLED WATER temperature.
When the chiller is running, if the computed value for CON-
DENSER REFRIG TEMP is less than, or within 1.2° F
(0.67° C) of the LEAVING COND WATER temperature, its val-
ue is displayed as 1.2° F (0.67° C) above LEAVING COND
WATER temperature.

20
DIFFUSER
SCHEDULE
SETTINGS
(FRAME 5
COMPRESSOR
AND FRAME 4
WITH SPLIT RING
DIFFUSER ONLY)
CARRIER COMFORT
NETWORK (CCN)
INTERFACE
CONTROL POWER
CIRCUIT BREAKERS
(CB1,CB2)
SURGE/HGBP
PARAMETER
LABEL
CHILLER CONTROL
MODULE (CCM)
CONTROL PANEL INTERNAL VIEW
CHILLER
VISUAL
CONTROLLER
(ICVC)
FRONT VIEW
CONTROL PANEL
DISPLAY
(FRONT VIEW)
Fig. 13 — Control Panel
a19-1855
a19-1897
a19-1956
OIL HEATER CONDUIT CONTROL PANEL
POWER CONDUIT
OPTIONAL HOT GAS
BYPASS CONDUIT
3C HOT GASBYPASS
RELAY (OPTIONAL)
T2-24 VAC POWER TRANSFORMER
FOR ICVC AND CCM
T1-24 VAC POWER TRANSFORMER
FOR HOT GASBYPASS RELAY,
OIL PUMP CONTACTOR, AND
OIL HEATER CONTACTOR
T1 T2
OIL HEATER
CONTACTOR
11 12 13
21 22 23
11 12 13
21 22 23
3
1
6
5
4
2
51
50
43
17
C
B
A
OIL PUMP
CONTACTOR
Fig. 14 — Power Panel
a19-1856