Carrier PC211 User guide

19XL
50/60 Hz
Hermetic Centrifugal Liquid Chillers
with HCFC–22 and HFC–134a
Start-Up, Operation, and Maintenance Instructions
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and
without incurring obligations.
PC 211 Catalog No. 531-94512-94 Form 19XL-3SS Replaces: 19XL-2SS
Copyright © Carrier Corporation 1994
Safety Considerations
Centrifugal liquid chillers are designed to provide safe and reliable service when
operated within design specifications. When operating this equipment, use good
judgement 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 machine instructions as well as those listed in this guide.
®

DO NOT VENT refrigerant relief devices within a building. Outlet from rupture
disc or relief valve must be vented outdoors in accordance with the latest edition
of ANSI/ASHRAE 15 (American National Standards Institute/American Society of
Heating, Refrigeration, and Air Conditioning Engineers). The accumulation of
refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15, especially
for enclosed and low overhead spaces. Inhalation of high concentrations of
vapor is harmful 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 machine 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 literature 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 machine.
DANGER !DANGER

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant
(
liquid and vapor
) has been removed from chiller. Traces of vapor should be dis-
placed with dry air or nitrogen and the work area should be well ventilated.
Refrigerant in contact with an open flame produces toxic gases.
DO NOT USE eyebolts or eyebolt holes to rig machine sections 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 volt-
age can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTER-
RUPTED, confirm that all circuits are deenergized before resuming work.
DO NOT siphon refrigerant.
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 refrigerant cylinder. Dangerous
over pressure can result. When it is necessary to heat refrigerant, use only
warm (110 F [43 C]) water.
WARNING !WARNING

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It
is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining
gas pressure, loosen the collar, and unscrew and discard the valve stem. DO
NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The
introduction of the wrong refrigerant can cause machine damage or malfunction
to this machine. Operation of this equipment with refrigerants other than those
cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Car-
rier for further information on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under
pressure or while machine 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 machine operates in a corrosive atmosphere,
inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief device when corro-
sion 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 compressed spring. Sudden
release of the spring can cause it and objects in its path to act as projectiles.
WARNING !WARNING

CAUTION CAUTION
!
DO NOT STEP on refrigerant lines. Broken lines can whip about and release
refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe
practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection
covers or other heavy components. Even if components are light, use mechani-
cal 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 fan, and 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 waterbox has been completely
drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items
have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut has a posi-
tive thread engagement.

CAUTION CAUTION
!
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust,
leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure relief device
to prevent a build-up of condensate or rain water.

Contents
List of Tables
List of Figures
Safety Considerations
Introduction
Abbreviations and Explanations
Machine Familiarization
Machine Information Plate
System Components
Cooler
Condenser
Motor-Compressor
Control Center
Factory-Mounted Starter (Optional)
Storage Vessel (Optional)

Contents
Refrigeration Cycle
Motor/Oil Refrigeration Cooling Cycle
Lubrication Cycle
Summary
Details
Oil Reclaim System
During Normal Machine Operation
During Light Load Conditions
Starting Equipment
Unit Mounted Solid-State Starter (Optional)
Unit Mounted Wye-Delta Starter (Optional)
Controls
Definitions
Analog Signal

Contents
Digital Signal
Volatile Memory
General
PIC System Components
Processor Module (PSIO)
Starter Management Module (SMM)
Local Interface Device (LID)
6-Pack Relay Board
8-Input Modules
Oil Heater Contactor (1C)
Oil Pump Contactor (2C)
Hot Gas Bypass Contactor Relay (3C) (Optional)
Control Transformers (T1-T4)
Control and Oil Heater Voltage Selector (S1)
LID Operation and Menus
General
Alarm and Alerts

Contents
Menu Structure
To View Point Status
Override Operations
Time Schedule Operation
To View and Change Set Points
Service Operation
PIC System Functions
Capacity Control
Entering Chilled Water Control
Deadband
Proportional Bands and Gain
Demand Limiting
Machine Timers
Occupancy Schedule
Safety Controls
Shunt Trip