19XL Centrifugal Chiller Control System with Product Integrated Controls (PIC) Service Training

Familiarization User Operations Start-up Shutdown Troubleshooting

The contents of the 19XL-01 Packaged Training Program, Catalog No. 021-901 are: one VHS video, 138 35mm slides and this workbook, Catalog No. 021-900. This program covers:

"MANUFACTURER RESERVES THE RIGHT TO DISCONTINUE, MODIFY, OR CHANGE SPECIFICATIONS AND/OR DESIGNS AT ANY TIME WITHOUT NOTICE OR INCURRING OBLIGATION. THIS PROGRAM IS INTENDED FOR FAMILIARIZATION AND/OR TRAINING PURPOSES ONLY AND SHOULD NOT BE CONSIDERED OR TREATED AS COMPLETE INSTALLATION, SERVICE, OR TROUBLESHOOTING REFERENCES FOR SUBJECT OR OTHER PRODUCTS. CURRENT PRODUCT SPECIFIC INSTALLATION AND SERVICE LITERATURE SHOULD BE CONSULTED BEFORE ATTEMPTING THE PROCEDURES, PROCESSES, OR TECHNIQUES DESCRIBED HEREIN." Copyright Carrier Corporation 1993

Contents
Machine Familiarization PIC Components PIC Components & Circuitry Inputs and Outputs LID Screens PIC User Operations
Status Function Schedule Function Setpoint Function Service Function Equipment Configuration Equipment Service Controls Test

Operating System Control Machine Start-Up and Shutdown

Contents
Troubleshooting Quiz Quiz Key Wiring Diagram A Wiring Diagram B

Objectives:
Upon completion of this training program, you will be familiar with the 19XL Centrifugal Chiller with PIC Control and understand the operating sequences.

Presentation Instructions:
1. Obtain necessary audio visual equipment, training aids, handout materials and program workbooks for each participant. 2. View the video. A break is provided for review purposes. Use the slides to reinforce important topics. 3. Distribute and review materials (see suggested list of additional materials below). 4. Administer quiz, then review using Slide/Page references noted in the Quiz Key. 5. Distributors may obtain Certificates of Achievement through Literature Distribution.

Additional Training Materials:

1. 19XL Start-Up, Operation and Maintenance Instructions. 2. This 19XL book, Catalog No. 021-900.

Self Instruction:
When using this program for self instruction, review the video tape, read the workbook in its entirety, and complete the quiz. Quiz answers with paragraph references are located in the Quiz Key.

Introduction
Click here for Figure 1 19XL Centrifugal Chiller

1. The primary purpose of this program is to familiarize you with the new 19XL centrifugal liquid chiller controls. We will be covering the following subjects: Machine familiarization PIC controls features and functions PIC Components Inputs and outputs LID screens PIC user operations Operating system control Machine start-up and shutdown At the conclusion of the program you should understand the operation of the controls, and how to conduct a machine start-up.

Machine Familiarization
But first we want to introduce the unit features in this latest Carrier-designed chiller. This centrifugal chiller will be introduced with a single-frame size of 300 to 600 tons. The 19XL is available with either HCFC-22 or HFC-134A refrigerants.

Click here for Figure 2 19XL Heat Exchanger

2. This 19XL Heat Exchanger is made for ease of service. Overall, the 19XL machine is designed for the replacement or retrofit market. It can be broken down into three pieces; cooler, condenser, and compressor. The cooler and condenser are bolted together and can be separated to fit into tight places.

Click here for Figure 3 19XL Compressor

3. The compressor is mounted on the cooler section and has lifting lugs for rigging, one on the motor and one on the compressor base. It also can be removed to make rigging into small spaces easier. Gasketted flanges and "O" rings make disassembly and reassembly easy, eliminating any cutting and welding.

Click here for Figure 4 Compressor (Flanged Elbows)

4. The compressor has flanged elbows on both the suction and discharge for easy servicing. The 19XL is equipped with isolation valves; one valve between the condenser and the discharge elbow and another valve under the cooler. A third valve is located in the motor cooling refrigerant line. These valves are used to isolate the refrigerant charge for service work. You can close the valve located at the discharge elbow and the refrigerant cooling isolation valve.

Click here for Figure 5 Liquid Transfer

5. Then push the liquid refrigerant out of the cooler and into the condenser using the optional pumpout unit. When all the liquid refrigerant is transferred, the isolation valve under the cooler is closed, and the pumpout unit is used to evacuate the gas from the cooler and compressor. To speed up the transfer use the PIC controls. Go to the controls test function and use the pumpout feature. This starts the condenser water pump and the cooler pump. It also directs you through the entire pumpdown process and locks out the low pressure alarm and the

compressor from being started. Run the pumpout unit until it reaches as low a vacuum as possible. Use the PIC display and the gauges to monitor the pressures. It is also possible to use the pumpout unit to transfer the charge into the cooler/compressor to service the condenser.

Click here for Figure 6 19XL High Side Float

6. A high-side float is used for refrigerant control. It is similar to a 19FA-style refrigerant float that uncovers an orifice to maintain the proper liquid level. This is also flanged for easy service. New-style machines will be equipped with a linear-style float valve.

Click here for Figure 7 Hot Gas By-pass Option

7. An optional hot gas bypass is located on the bottom of the cooler. Hot condenser gas enters the cooler through a solenoid valve which is piped up into the condenser. This valve is controlled by the temperature difference or T between the entering and leaving chilled water and the pressure differential or P between the cooler and condenser.

Click here for Figure 8 19XL Cooler Tubes

8. Each vessel, cooler and condenser are ASME approved with relief valves, so that the refrigerant may be safely isolated in either side of the machine. A pressure gauge is mounted on the condenser along side the relief valves. The cooler and condenser are available in 2 or 3 pass configurations. Inside the heat exchangers, the tubes are supported by two tube sheets and three support sheets. The standard cooler tubes are high efficiency type with external nucleate boiling surface. The internal surface is spiral fin for maximum heat transfer. Standard condenser tubes are Spikefin, also with internal rifling.

Spikefin Tube: This tube derives from the conventional integral-finned tube where circumferential integral fins are notched to provide spikes. Surface tension controlled condensation occurs on these spikes and provides higher heat transfer coefficients. These tubes show lesser condensate retention and thus provide higher heat transfer coefficients when compared to integral-finned tubes. The condenser has a baffle plate located under the compressor discharge ell to distribute the refrigerant over the condenser tubes. Remember, with R-22 we only have to move 20% as much refrigerant vapor CFM to get the same refrigerant effect as R-11. It also has a flash subcooler, similar to the 19DK machine, which subcools the refrigerant prior to entering the float chamber.

Diffuser
Click here for Figure 9 Diffuser

9. Next is the conical diffuser. The technology for this diffuser was derived from aerospace technology used on Pratt & Whitney's jet aircraft engines. This diffuser is designed for high efficiency and to operate in a very stable manner over a wide range of conditions. This diffuser has built in surge protection and practically eliminates any need for a moveable diffuser wall or hot gas bypass. Notice this area on the diffuser wall. This is machined into a scalloped shape with a shallow angle. The refrigerant leaving the impeller is channeled through this scalloped shape into the conical diffuser. The refrigerant then follows Bernoulli's basic law of physics where the refrigerant enters the conical channel at high velocity, low static and leaves at low velocity, high static. Just the right conditions for a centrifugal chiller.

Impeller
Click here for Figure 10 19XL Impeller

10. Now let's look at the impeller. This is an entirely new design. The 19XL machine uses a single aluminum impeller. It is an open type impeller and the running speed is 16,000 RPM. Notice how the fins sweep back to increase stability and raise efficiency. And, notice the splitter blades; they make for more efficient compression with less chance of surge.

Click here for Figure 11 19XL Impeller (Drilled Holes)

11. There are four drilled holes through the impeller that are used to reduce thrust. These venting holes equalize the pressure on both sides of the impeller. Located in the back of the impeller is a Labyrinth seal. This is used to counteract the thrust with suction pressure.

Controls
Click here for Figure 12 Controls

12. As for controls, the 19XL machine is equipped with a product integrated control or a PIC and will interface with the Carrier Comfort Network. Notice there are two boxes on this side of the machine. On the back side, on the condenser, is a mounting for an optional starter, either electromechanical or solid state.

Click here for Figure 13 19XL Power Panel

13. The box in front of the oil pump is called the Power Panel. Part of the circuitry is high voltage and contains contactors for the oil pump and oil heater. Also in the Power Panel are step-down transformers to supply the low voltage needed for the PIC control box.

Click here for Figure 14 19XL PIC Control Center

14. Here is the PIC control center. On the front we have a stop button, an alarm light, an LID and four function switches or softkeys. Inside the box we find a processor module known as the PSIO (Processor Sensor Input Output). There is room enough to add four optional modules for future requirements. To the left is a relay module. This entire box is low voltage and gets its power from the Power Panel. The LID displays information both while the machine is running and during shutdown. Near the top, there are two system messages displaying the operation mode. To the top right is the time and date display and the compressor run time indicator. Under that we have nine blocks of information which concern: Entering chilled water temperature Leaving chilled water temperature Evaporator refrigerant temperature Condenser water inlet temperature Condenser water leaving temperature Condenser refrigerant temperature Oil pressure

 Oil sump temperature Percent motor current Below, on the monitor, we find a display for each of the four softkeys. As we use these menu functions, the nomenclatures and function of these four keys will change. Sensors feed information to the PIC controls. These sensors are new and have a quick release plug at the sensor for easy servicing. There is one in the oil sump to monitor sump temperature, and also to control the oil heater. There is one dual-element bearing sensor (one element is a spare). The terminal plate for the high speed bearing sensor is located on the compressor base near the oil pump. There are two sensors for motor temperature embedded in the stator windings (one is a spare). The motor sensor terminal plate is located on the side of the stator near the motor terminal box.

Click here for Figure 15 19XL Sensors (Compressor Discharge)

15. There are two sensors in the compressor discharge. One is a pressure switch that opens on high pressure. The other measures discharge gas temperature.

Click here for Figure 16 19XL Sensors

16. Sensors measure both entering and leaving chilled water. The condenser water circuit also has sensors on both the entering and leaving water connections. A temperature switch is embedded in the oil pump motor winding. Its terminals are on the oil pump motor terminal plate. To measure oil pressure, there is a transducer in the oil pump discharge. There is a transducer on top of the evaporator to measure evaporator refrigerant pressure. There is another transducer on top of the condenser measuring condenser refrigerant pressure there. The combination of all these thermistors and transducers relay information to the PIC controls.

Click here for Figure 17 19XL Optional Starters

17. This unit is available with one of two types of factory-mounted optional starters.

Click here for Figure 18 Electro-mechanical Style Starter

18. One option is an electro-mechanical style starter. The controls on this starter include a Starter Management Module or SMM to communicate with the PSIO in the PIC control box. The control panel is hinged and swings out of the way to service the starter contacts.

Click here for Figure 19 19XL Solid State Starter

19. The second type of starter available is solid state. The solid state starter is new to Carrier centrifugals. This starter also uses a Starter Management Module, or SMM, to communicate with the PSIO in the PIC control box. Amperage, voltage and operating information are relayed between the PSIO and the SMM. This operating information can be displayed on the LID by pushing the status function softkey.

Compressor
Click here for Figure 20 19XL Compressor

20. The 19XL compressor is a new design which utilizes the best of older designs and new technology. The suction guide vanes, used to control capacity, are chain driven, using a vane actuator motor.

Click here for Figure 21 19XL Motor Cooling

21. Motor cooling is accomplished by piping liquid refrigerant from the bottom of the condenser through a valve, a filter-dryer and a sight glass to the motor end bell. To control the motor cooling process, there is a bypass line with a solenoid valve which will open to allow extra refrigerant into the motor during high load conditions. From there the refrigerant travels to a spray nozzle and is sprayed into the rotor and stator where it flashes and cools the motor. The refrigerant level is maintained in the motor shell and overflows through a drain on the side of the motor shell to a back pressure valve located at the flanged drain connection. This back pressure valve is a spring check type and maintains a 5 to 7 lb. differential between the motor cavity and the cooler.

Click here for Figure 22 19XL Oil Recovery System

22. To recover oil an eductor system is used which is similar to the one used on the 19D Series machines. High pressure gas piped from the compressor discharge is directed across an eductor. This creates a low pressure area at the eductor which, in turn, is connected to the suction housing. Oil is normally carried with the refrigerant into the suction housing. However, an additional line from the cooler to the suction housing ensures that oil travels into the housing. The refrigerant and oil are then transferred through a line and filter into the oil reservoir. The refrigerant flashes to a gas and returns to the system through the demister and vent line located between the transmission housing and suction elbow. This keeps the transmission at suction pressure. The vent at the transmission housing uses a demister pad similar to the 19D Series. The oil then drops into the oil reservoir. A check valve prevents the oil from flowing backward during shutdown. During light load conditions, the guide vane actuator closes a switch which energizes two solenoids. Because of the low suction pressure, the eductor will now take suction directly from the cooler shell in order to return the oil.

Click here for Figure 23 Oil Pump/Transmission Housing

23. Notice how the oil pump is located in the transmission housing -- not directly under the motor, but offset to one side. The oil pump motor is 3 phase and the pump is a positive displacement vane type. The 19XL machine has a 10 gallon oil capacity and uses a new synthetic oil. The oil cooler is located outside of the oil pump housing and uses liquid refrigerant to cool the oil. A thermostatic expansion valve controls the refrigerant flow and maintains the oil temperature. The compressor housing is both the oil reservoir and sump. There are two sight glasses for the oil, and the operating oil level should be maintained between the two. The shutdown level should be somewhere between the top of the bottom glass and the middle of the upper glass. Typical oil pressure is 20 to 25 lbs differential pressure.

Click here for Figure 24 19XL Lubrication System

24. Pressurized oil is supplied to compressor bearings and gears by an internally mounted, electric motor driven, vane type pump, which is submerged in the oil reservoir. Oil from the pump discharge passes through the oil pump motor and serves as a coolant. Oil pressure is regulated by a relief valve that is located internally. The valve relieves the pump discharge back into the oil sump, maintaining proper oil system pressure. Pressurized oil then passes from the pump motor housing and into the filter chamber via some external piping. After being filtered, the oil is piped to the external oil cooler. Notice the valving on the oil filter. These two valves enable the service technician to isolate the oil filter and change it without draining the entire oil sump or having to pull the refrigerant charge. A charging valve is located on the filter housing to drain the oil in the filter chamber and also to evacuate and recharge new oil. The pressurized oil flows to the transmission assembly where it feeds two lines. The lower line supplies oil to the high speed thrust bearing assembly and lubricates the gears. The upper line supplies the low speed shaft bearings. From there the oil is channeled to the high speed shaft bearing nearest the pinion. The oil then drains to a sump at the base of the compressor housing.

Click here for Figure 25 19XL Oil Heater

25. The oil heater is a new design with 1200 Watts. The oil heater has a flanged terminal plate with a flat washer-type gasket. The oil heater is controlled by a thermistor with its sensor immersed in the oil sump. The oil temperature in the sump is maintained between 140 and 160F depending upon what the evaporator refrigerant temperature is.

PIC Components
Click here for Figure 26 19XL Local Interface Device (LID)

26. Now, let's identify the components. At the top of the control panel is the Local Interface Device (LID), which contains a Liquid Crystal Display (LCD). Input and output information appears on this screen. To the left of the LID is the alarm light and the Stop button. Immediately below the screen are four "softkeys," whose functions vary with the particular screen being displayed. In every display, the bottom line on the screen will identify the function of the softkeys.

Click here for Figure 27 19XL Processor Module

27. Inside the panel we have the processor module (PSIO), a six-pack relay module, a power supply, and four circuit breakers. One or two additional 8-input modules can be installed for reset options, spare temperature sensors, or applications with a CCN network. The controls are powered by two of the transformers we saw earlier in the power panel.

Click here for Figure 28 19XL Local Interface Device

28. The local interface device displays information both while the machine is running and during shutdown. These controls will: Control start-up and shutdown of the chiller. Modulate the compressor guide vanes to maintain desired chilled water temperature, and to protect against abnormal compressor conditions. Generate alarm and alert messages for abnormal conditions, and shut down the machine when system safety requires. Control unit operation per the programmed occupied/unoccupied schedules. Provide testing of all inputs and outputs. Display all input and output data. Provide compatibility with CCN systems.

Click here for Figure 29 19XL Product Integrated Control (PIC)

29. The starter management module (SMM), the power panel and the control panel make up the Product Integrated Control (PIC). These are microprocessor based devices that control machine operation and perform diagnostic functions, using inputs from the machine and the operator. The remainder of this program will be spent learning how these devices function and how to use them.

Click here for Figure 30 32MP System

30. Before we get into detail on the PIC controls, it might be helpful to compare the PIC system with the 32MP system that you may be familiar with. To begin with, both systems provide startup and operational control, a controls test, and considerable diagnostics. Both control the same basic and optional unit functions, and both systems use similar 5K ohm thermistors.

Click here for Figure 31 32MP vs. PIC

31. The advantage of PIC is that it is a system with modified keypad entry and display screen, simplifying inputs and enabling messages rather than codes to be displayed to the user. Gone are the potentiometer calibration inputs of the 32MP, replaced by precise keypad inputs in PIC. And the dip switches are no longer required, thanks to the keypad inputs. PIC can also read transducer inputs, so system pressures can be monitored. And, of course, PIC can interface with the Carrier CCN network and the Building Supervisor, well beyond the scope of the 32MP.

PIC Components and Circuitry

Click here for Figure 32 PIC Components and Circuitry

32. The PIC consists of three panels which contain the major control components. The three individual panels mentioned are the control panel, power panel, and Starter Management Module (SMM). Located within the control panel are the processor module (PSIO), local interface device (LID), 6-pack relay board, and options module.

Click here for Figure 33 PSIO Module

33. The PSIO contains all of the operating software needed to control the machine. Connected to the PSIO module are three pressure transducers and eight temperature thermistors. There are also outputs to the guide vane actuator, and the 6-pack relay board for control of: oil pump, oil heater, hot gas bypass, motor cooling solenoid valve, and spare alarm contact. The PSIO communicates with the LID and SMM for user interface and starter management.

Click here for Figure 34 LID Mount

34. The LID is mounted on the front panel of the control center and is used by the operator to interface with PIC. It is the input center for all machine setpoints, operating schedules, setup functions and options. The lid has a large display screen, an alarm light, a stop button and four buttons for logic input. The function of the four buttons or "soft keys" is always shown on the bottom or menu line of the display screen.

Click here for Figure 35 6-pack Relay Board

35. The 6-pack relay is located within the control panel and is used as a pilot relay, when energized by the PSIO, to operate the oil pump, oil heater, spare alarm, optional HGBP valve, and motor cooling solenoid valve.

Click here for Figure 36 Option Modules

36. The option modules, when present, are factory or field installed in the control panel. There could be one or two of these modules installed, each with up to eight spare inputs available. It is used whenever chilled water reset, demand reset, or for reading any spare temperature sensor. The sensors are field installed.

Click here for Figure 37 Power Panel

37. The power panel contains the HGBP relay, control transformers, oil pump terminal block, voltage selection switch and contactors for the oil heater and oil pump.

Click here for Figure 38 Oil Pump Contactor

38. The oil pump contactor operates the oil pump at rated voltage per the job requirement. The PIC energizes the contactor to operate the oil pump as necessary during machine start-up, operation and shutdown. The oil heater contactor is controlled by the PSIO and 6-pack relay board to maintain proper oil temperatures during machine shutdown.

Click here for Figure 39 Hot Gas Bypass Relay

39. The hot gas bypass relay controls the opening of the hot gas bypass valve. The PIC energizes the relay during low load, high lift operating conditions.

Click here for Figure 40 Control Transformers

40. The control transformers convert incoming control voltage to either 21V or 24V supply power for the PSIO module, the three power panel contactor relays, the guide vane actuator, and the options module.

Click here for Figure 41 Control Circuit Voltage Selector

41. It is possible to utilize either 115 or 230 volt incoming control power in the power panel. The voltage selector switch is set for a particular application.

Click here for Figure 42 Starter Management Module

42. The Starter Management Module (SMM) is always located within the starter panel. The starter can be unit mounted or remotely located.

Click here for Figure 43 Starter Management Module (PSIO)

43. This SMM initiates PSIO commands for starter functions such as starting/stopping the: compressor, condenser and chilled water pumps, tower fans, spare alarm contacts, and the shunt trip. The SMM monitors starter inputs such as flow switches, remote start contact, spare safety, condenser high pressure, oil pump interlock, motor current signal, starter 1CR and RUN contacts, and KW transducer input. The SMM also contains programming to safely stop the machine if communications from the PSIO are lost.

Click here for Figure 44 Transformer (T1)

44. Main 115V or 230V single-phase power for the controls is fed from the starter panel to the power panel transformers through the voltage selection switch. This power also feeds the oil heater when the 1C contacts are closed. Transformer T1 provides 21-volt power to the 5-volt transformer, in the control panel, used to power the condenser, evaporator and oil pressure transducers. T1 also powers the PSIO module and the LID.

Click here for Figure 45 Transformer (T2)

45. Transformer T2 provides 24V control power to the oil heat contactor (1C), oil pump contactor (2C), and HGBP relay (3C) and oil recovery solenoids. Of course, these items are powered only when the PSIO sends the proper signals to the 6-pack relay board pilot relays K1, K2, K4 and K5. Note also that the oil pump contactor cannot function unless the oil pump motor winding temperature safeties are closed.

Click here for Figure 46 Transformer (T3)

46. Transformer T3 powers the compressor guide vane actuator to open and close the guide vanes as signals are received from the PSIO. The actuator operates on 24 volts.

Click here for Figure 47 Transformer (T4)

47. Transformer T4 supplies 21 volts to the 8 input options module. Option modules are always required if the machine has Auto Demand Reset Option or Auto Chill Water Reset Option. It may also be required if a Chillervisor Lead/Lag system is installed. It also has optional inputs for five additional temperature inputs. All of the inputs to the module must be field installed. These inputs are communicated to the PSIO and the LID.

Click here for Figure 48 Starter Panel

48. As mentioned, the Starter Panel contains the Starter Management Module (SMM). The SMM receives its power from a 115V to 24 VAC transformer. Inputs monitored by the SMM include contact closures for remote start, evaporator and condenser water flows, and a spare safety contact. It also checks the closure of the IM auxiliary contact, motor run, condenser high pressure and oil pump auxiliary contacts.

Click here for Figure 49 Starter Fault Contacts

49. Tied in series with the condenser high pressure safety and oil pump auxiliary contacts are the starter fault contacts and 1CR control coil. Motor output is measured by a current transformer input to indicate motor amperage. Available as an option is a 4-20mA kilowatt transducer to measure motor power. Also measured is motor voltage which uses a 24-volt transformer with a trim potentiometer. The voltage measured to the motor should equal the voltage read on the STATUS01 screen. Adjust the trim POT to set the voltage on the LID screen.

Click here for Figure 50 Starter Management Module

50. The SMM also outputs signals to the chilled water pump, condenser water pump, tower fans, shunt trip and alarm pilot relay control coils through communication with the PIC.

Inputs and Outputs

Click here for Figure 51 Inputs Supply System

51. Inputs supply system information to the controls so that proper control decisions can be made. The input devices may be thermistors for measuring temperature, transducers for measuring pressure, contacts that supply or interrupt voltage, or dry contacts whose condition will be sensed by the controls. The PSIO has several inputs, located at the J7 terminals. The three pressure inputs are: Condenser refrigerant pressure Evaporator refrigerant pressure, and Oil pressure. Temperature inputs include: Entering chilled water temperature Leaving chilled water temperature Compressor discharge temperature Thrust bearing temperature

Oil sump temperature Compressor motor winding temperature Condenser entering water temperature Condenser leaving water temperature Stop push button/Voltage reference

Click here for Figure 52 Outputs

52. Outputs are signals to report information or cause system controls to operate. The PSIO outputs are at the J6 terminals and provide signals to the 6-pack relay board. Some examples of outputs are: Guide vane operation Oil heater relay Motor cooling solenoid Oil pump relay Hot gas bypass relay Alarm relay

Click here for Figure 53 8-Input Module

53. Each 8-input module has two 4-20 mA inputs and six spare temperature inputs. The 4-20 milliampere inputs can be internally or externally powered. The number 1 8-input module has the following inputs: Auto demand reset Auto chilled water reset Common chilled water supply temperature Common chilled water return temperature Remote temperature reset Remaining 3 input are spare temperatures The number 2 8-input module has two spare 4-20 mA inputs and 6 spare temperature inputs.

Click here for Figure 54 Starter Management Module (SMM)

54. The Starter Management Module (SMM) also has inputs and outputs, for control of system start-up and shutdown. These inputs might include:

Chilled water flow switch Condenser water flow switch Compressor start auxiliary contacts Compressor run auxiliary contact Spare protection contacts Starter fault Remote Contacts Compressor motor amps Line voltage monitor

Click here for Figure 55 SMM Outputs Control

55. The SMM outputs control pilot relays in the starter for the 1CR compressor start relay Chilled water pump relay Condenser water pump relay Tower fan relay Shunt trip relay Alarm relay

Click here for Figure 56 PIC Controls

56. Let's briefly discuss what the PIC controls can do. These controls: Start-up and shutdown the chiller including controlling some timing functions associated with the starter. Modulate the compressor inlet guide vanes to maintain the leaving chilled water temperature and limit the power consumed by the motor.

Click here for Figure 57 Guide Vane Position Control

57.

Override the guide vane position control in response to low refrigerant temperature, high motor temperature, high motor current, manual guide vane control, high compressor lift, or condenser high pressure. Generate alerts, such as high bearing temperature, or high discharge temperature. Provide surge protection by shutting the compressor off based on a number of specific changes in motor current over a time period. This can be configured in the equipment service function. Provide protection against high compressor discharge temperature.

Click here for Figure 58 PIC Controls

58.

Protect the chiller from damage by monitoring certain control inputs and executing a safety shutdown if required. Provide full compatibility with the ChillervisorTM system manager and other CCN devices. Allows readability of all PIC points and provides the capability of "Writing" to certain points with a CCN network. Will display via the LID all input and output data.

LID Screens
Click here for Figure 59 Local Interface Device (LID)

59. The LID (Local Interface Device) is used by the operator to access operating, service, and maintenance data for the chiller. With the LID, you can perform operations such as viewing and adjusting setpoints and schedules, viewing and modifying configuration and service data, viewing alarm history, or checking chiller status.

Click here for Figure 60 Default Screen

60. A variety of displays (screens) are available at the LID. If no other specific display has been called for, then the default screen is displayed. This provides basic information on machine operation, such as chilled water and condenser water temperatures, refrigerant saturated temperatures, oil pressure and temperature, etc.

Click here for Figure 61 Function of the Soft Keys

61. Notice the bottom line of data. Every screen uses the bottom line to identify the function of the softkeys. In this case, the left key puts the machine under CCN control, the next is for LOCAL control, the next for RESET of alarms, and the last is for the MENU.

Click here for Figure 62 Depressing Menu Soft Key

62. Depressing the MENU softkey brings up a new screen, whose bottom line identifies the softkey functions of STATUS, SCHEDULE, SETPOINT, and SERVICE. Each of these is a section of the software devoted to those specific functions, and is accessed by depressing the appropriate softkey. The STATUS function provides information on the status of the machine, and provides capability for changing certain points or conditions. The SCHEDULE function is for entering or viewing the on/off schedule. The SETPOINT function is for entering or viewing the system setpoints, and the SERVICE function deals with configuration data, service, and controls testing.

Click here for Figure 63 STATUS Function

63. The STATUS function has three screens. The first displays status of control points and sensors. The second STATUS screen displays status of relays and contacts. The third STATUS screen displays the status of options module sensors.

Click here for Figure 64 SCHEDULE Function

64. Likewise, the SCHEDULE function has several screens relating to the machine start/stop schedule, and the SETPOINT function has one screen displaying the system setpoints. The SERVICE function has a variety of screens relating to equipment configuration, alarm history, controls test, system maintenance, and so on.

PIC User Operations

Click here for Figure 65 Control Circuit Power

65. Now that we have seen what the controls consist of, and reviewed their basic functions, it is time to see what happens as we operate them. First we will make sure that we have control circuit power to the transformers, and all the circuit breakers are closed, which will power up the controls.

Click here for Figure 66 Default Screen Display (Diagnostics)

66. When the controls power up, the LID performs several diagnostic tests to insure that it is functioning properly, and that it is correctly connected to the chiller. If the diagnostics are successful, the default screen will then be displayed.

Click here for Figure 67 Default Screen

67. The default screen provides basic information on the chiller operation, as well as alert and alarm messages. This screen appears whenever you exit any of the PIC operations, or whenever the LID has been left on another display for 15 minutes. In the upper left hand corner, the primary and secondary chiller messages are shown. In this example, the machine is running under normal temperature and in the occupied mode. In the right hand corner are the date, time, and length of time the machine has been running. The default screen data is updated every 2 to 5 seconds.

Click here for Figure 68 Default Screen Displays

68. The center of the default screen displays the status of the following points:

CHW IN CHW OUT EVAP REF

Entering chilled water temp Leaving chilled water temp Evaporator refrigerant temp

CDW IN CDW OUT COND REF OIL PRESS OIL TEMP MTR AMPS

Entering condenser water temp Leaving condenser water temp Condenser pressure Oil pressure Oil sump temperature Percent of compressor motor current

Throughout this program, you will hear the terms "point" or "points." Points are pieces of information which are part of the controls data base. It can be an input or output; for example: pressure or temperature, or a derived value such as motor current.

Click here for Figure 69 Prestart Display

69. There are two other terms we would like to define: Alert and Alarm. An ALERT is an abnormal condition that generates a warning message. It may delay start-up, but is not serious enough to cause shutdown of an operating machine. Let's pick an example where the machine fails to start. In the upper left hand corner the primary message is PRESTART ALERT, and below this the secondary message stating the reason - LOW OIL TEMPERATURE. A point in

alert will be blinking about once a second, and in our example, the display OIL TEMPERATURE will be blinking. As soon as the oil temperature rises above setpoint, the start-up process will resume automatically.

Click here for Figure 70 Alarm and Reset Key

70. An ALARM is an abnormal condition serious enough to prevent start-up or to cause automatic shutdown of an operating machine. If a point is in alarm, its value switches back and forth between the normal condition and the actual abnormal condition. Let's say COND REF (condenser pressure) is in alarm. First, notice the message in the upper left corner of the screen. Here we see protective limits and the reason is HIGH CONDENSER PRESSURE. And at the right side of the screen the point COND REF will be alternating between the normal value and the highlighted actual value. The cause of the high condenser pressure must be corrected, and the RESET key must be pressed to remove the alarm in order for the machine to start.

Status Function
Click here for Figure 71 STATUS, SCHEDULE, SETPOINT, and SERVICE

71. Now we will leave the default screen by depressing the MENU key, which brings up the choices of STATUS, SCHEDULE, SETPOINT, and SERVICE. We will press the STATUS key, and a list of the three status screens is displayed - STATUS01, 02 and 03. Note that the softkey functions are now NEXT, PREVIOUS, SELECT, and EXIT. The top line, STATUS01, is highlighted. If we wanted to look at that screen, we would simply press SELECT. If we wanted to look at STATUS03, we would press NEXT until STATUS03 is highlighted. After highlighting STATUS03, if we wanted to go back to STATUS02, we could press PREVIOUS.

Click here for Figure 72 Status Screens

72. The three status screens display specific types of information: STATUS01 shows the status of the pressure and temperature sensors and control settings STATUS02 shows the status of the relays and contacts (either on or off) STATUS03 shows the status of the option modules sensors

Click here for Figure 73 Status Table Select Screen

73. When you select one of the tables on the Status Table Select screen, the Point Status Screen appears. Remember, points are pieces of information which are part of the controls data base. This screen displays the current value of the points in the selected table. Shown here is a typical point status screen for STATUS01. Each status line consists of four pieces of information: the point's name, its value, its units, and its status.

Click here for Figure 74 Status Line

74. The last position of the status line tells you the point's status. If an asterisk (*) appears, the point is in alarm. In this example, condenser refrigerant temperature is in alarm. If a "C" appears in the status position, a communication failure has occurred, as in this example of remote contact input. A blank in the status position indicates that the point is normal and an exclamation point (!) indicates the value is in an alert condition.

On some screens like the Point Status Screen, all of the items will not fit on one screen at a time. By pressing the NEXT or PREVIOUS keys the highlight will scroll downward or upward to highlight the various points.

Click here for Figure 75 Point Override

75. Some points are allowed to be changed or modified by the operator, and this is called an "override". To do this, first select the point to be modified by using the NEXT or PREVIOUS keys on the Point Status screen to highlight the desired point. Then press the SELECT key and two things will occur. MODIFY POINT will appear in the upper right corner of the screen, and the bottom line will show new names for the softkeys. The INCREASE and DECREASE keys are used to raise or lower the point value. Each time either of these keys is pressed, the value of the last digit of the point will change by one increment. If the INCREASE or DECREASE key is held for more than five seconds, the value of the second digit changes by one for each second the key is held.

Click here for Figure 76 START/STOP/RELEASE and ENTER

76. If the selected point is start/stop or release, the softkey functions will be renamed to START/ STOP/RELEASE and ENTER.

Click here for Figure 77 ON, OFF, RELEASE and ENTER

77. If the point is an On or Off type, then the softkeys are renamed ON, OFF, RELEASE and ENTER. The control will not permit a point to be overridden to an OFF state. After you change the value or state of a point, the ENTER key must be pressed to register the new value. Then you can select another point to be modified, or press EXIT twice to return to the default screen. Each press of the exit key will back you up a screen.

Click here for Figure 78 SUPVSR, BEST or SERVICE

78. Points that have been overridden will display the type of override next to the point's value. SUPVSR, BEST, or SERVICE will appear to indicate there is an override. To remove an override, select the point as before, and press the RELEASE key.

Click here for Figure 79 Points Unable to be Overridden

79. What happens if you try to change a point that is not allowed to be overridden? Fortunately, you cannot "crash" the system that easily. The controls simply will not let the point change. For example, if we tried to change Leaving Condenser Water, which is not allowed to be overridden, we would highlight the point on the STATUS01 screen, and as soon as we pressed the SELECT key we would get a message CANNOT CONTROL SELECTED POINT. You then get to EXIT gracefully, without embarrassment!

Click here for Figure 80 Target Guide Vane Position

80. If we highlight Target Guide Vane Position and press the select key, its value can be raised or lowered using the INCREASE/DECREASE keys as required to obtain the new value. Remember to press the ENTER key after the new value is set to save this value. To release the override when finished, press RELEASE.

Click here for Figure 81 Status Table Select Screen

81. Press the EXIT key to bring up the Status Table Select Screen and highlight the STATUS02 line using the NEXT key. Press the SELECT key, and STATUS02 screen appears. The items on this screen are discrete points. For example: highlight Tower Fan Relay press SELECT, and turn it on using the ON key. Be sure to press the ENTER key to save the required point value. The RELEASE key will bring the point back to automatic control. Because the tower fan is an important machine control point, the controls will not allow the fan to be overridden "OFF". It can only be ON or in the automatic mode.

Click here for Figure 82 STATUS03 Screen

82. If we were to proceed to the STATUS03 screen, you would find it contains all of the 19XL 8input module points. All of the items on this screen are able to be overridden.

Click here for Figure 83 Status Function Keystrokes

83. Now let's recap the STATUS function keystrokes. At the default screen, press MENU. At the menu screen, press STATUS. Select the proper status screen by using NEXT or PREVIOUS to highlight the desired screen, and press SELECT. View the desired point by using NEXT or PREVIOUS to highlight the point. Press SELECT to choose the desired point to override Use the softkey functions to change the point's value or state. Press ENTER to register the new value or state. Press EXIT until you return to the default screen.

Schedule Function
Click here for Figure 84 Schedule Function

84. The schedule function defines the occupied (on) and unoccupied (off) periods for the system, and is accessed in the same way as the status function. At the default screen, press MENU and at the menu screen press SCHEDULE. This brings up a schedule select screen containing two choices: OCCPC01S and OCCPC02S. OCCPC01S is used whenever the unit is started in the local mode, and OCCPC02S is used whenever the unit is used in CCN mode. Press SELECT to bring up the period select screen, which lists all of the periods. Scroll to highlight the desired period and press SELECT to modify the period.

Click here for Figure 85 Period Definition

85. Up to eight periods may be configured for our machine. Often only two are necessary; one for weekdays and one for weekends. We will be defining each period by selecting a start time and stop time, and then assigning the desired days of the week to each period. The start and stop times must be entered in 24-hour military time.

Click here for Figure 86 Example (Period Selection)

86. Now let's work through an example. Suppose we want to set up an occupied schedule for 6:15 a.m. to 6:30 p.m. on Mondays through Fridays. On the period select screen we will highlight PERIOD 1 and press the SELECT key. Notice that the hour portion of the ON time is highlighted. We will use the INCREASE/DECREASE keys to set the ON hours to 06. Pressing ENTER will register the new value and move the highlight to the minutes. We will set the ON minutes by using the INCREASE key to display 15, and press ENTER to register the value and the highlight will move to the OFF hours. We will use the INCREASE/ DECREASE keys as before to set the OFF hours to 18 and the OFF minutes to 30. Then, pressing ENTER will register the values and highlight the first day of the week.

Click here for Figure 87 ENABLE, DISABLE, ENTER and EXIT

87. When the highlight moved to the days of the week, the softkey identification changed to ENABLE, DISABLE, ENTER, and EXIT. Days of the week with an X are selected; days of the week with a blank are disabled. Pressing ENABLE places an X under the highlighted day of the

week, which will cause the system to start at the ON time and shutdown at the OFF time on that day. Pressing DISABLE will cause the ON and OFF times to be ignored on the highlighted day. Since we want period 1 to apply to Monday through Friday, but not the weekend, we will press ENABLE for Monday and then press ENTER to register the condition and move the highlight to Tuesday. We will move through the weekdays in the same manner. When finished with period 1, we can EXIT to the period select screen and set up any additional periods required. Scheduling for holiday periods will be covered later in the SERVICE Function.

Click here for Figure 88 Temporary Override

88. A temporary override of the operating schedule can be imposed at any time, using the Schedule function. At the Period Select screen, highlight Override and press SELECT. An override of one to four hours can be selected, using the INCREASE/DECREASE keys. The selected override hours will be displayed near the bottom of the screen, and pressing ENTER will initiate the override. If the override is entered during an occupied period, then that period will be extended by the amount of the override. If the override is entered during an unoccupied period, the system will start and run for the specified override period. Press EXIT until you get back to the default screen.

Setpoint Function
Click here for Figure 89 SETPOINT Function

89. SETPOINT is used to view or modify the system setpoints. There are only three setpoints: Base demand limit, Leaving chilled water, and Entering chilled water. Only one of the chilled water setpoints can be active, and this choice is configured in the SERVICE function. The controls are factory configured with the leaving chilled water setpoint active.

Click here for Figure 90 SETPOINT Function Access

90. The SETPOINT function is accessed from the default screen in the same manner as STATUS and SCHEDULE. At the default screen press MENU, then press SETPOINT, and you can view the three points. If you wish to modify a point, press NEXT or PREVIOUS to highlight the desired setpoint, and press SELECT to activate the override screen.

Click here for Figure 91 Modifying a Setpoint

91. Modifying a setpoint uses the same techniques we have already learned. When we went to the override screen, the softkey labels became INCREASE, DECREASE, QUIT and ENTER. Simply press the INCREASE or DECREASE keys to raise or lower the value, and then press ENTER to register the value. This will also return you to the previous screen, where you can EXIT to the default screen. As before, holding the INCREASE or DECREASE keys down increases the rate at which the value changes.

Click here for Figure 92 Example

92. Let's run through an example. Suppose we wish to change the leaving chilled water setpoint to 58 F. Starting at the default screen, we press MENU, then SETPOINT, then use NEXT to highlight Leaving Chilled Water, then press SELECT. The displayed value is 55.0 F. To change it to 58.0 F, we depress the INCREASE key until 58.0 is displayed. When 58 is reached, we press ENTER to register the value.

Click here for Figure 93 QUIT/Escape Key

93. QUIT is an escape key. If you increase or decrease a setpoint value and then decide not to change it, pressing QUIT will leave the setpoint at its original value and return you to the previous screen. There are limits established for each setpoint, and if you should attempt to change a setpoint beyond its allowed limit, you will get a message LIMIT EXCEEDED at the bottom of the screen. Then press QUIT, then EXIT to return to the default screen.

Service Function
Now we will look at some of the SERVICE function operations. Some of the things you can do in the service function are: Check the alarm history file Perform controls tests Check current state of various control algorithms View and modify equipment configuration data Set equipment service variables Set time and date Communicate with other CCN devices Log out of device View and modify the controller ID table Configure the LID We will cover only five of the items, which may be needed for initial system setup or routine servicing.

Click here for Figure 94 Service/Function Password

94. The SERVICE function is password protected to prevent unauthorized changes. At the default screen, press MENU and at the menu screen press SERVICE. This brings up the password screen, and you must enter the 4 digit password in order to access the service screen. The softkeys represent the numbers 1, 2, 3, and 4, and when pressed in the proper sequence, the service screen will appear. If a specific password has not already been programmed, then the default password of 1111 will apply.

Click here for Figure 95 Time and Date Selection

95. At the service screen, we see a variety of choices available. Using the NEXT or PREVIOUS keys, we will move the highlight to TIME AND DATE and press SELECT, which brings up a new screen. We can now use the INCREASE OR DECREASE keys to set the correct time and date, pressing ENTER to register the values, and then EXIT to the service screen.

Click here for Figure 96 Service Function Example

96. As an example, let's say it is now 3:30 p.m. on Wednesday, January 13, 1993, and we want to enter that into the controls. Highlight TIME AND DATE, and press SELECT to bring time and date up on the screen. The highlight is on HOURS, and we will set the time as we did in the schedule example, using INCREASE to advance the hours display to 15. Then we will press enter to register the value and highlight minutes. Now we will use INCREASE to advance the minutes display to 30, press ENTER, and the highlight moves to date. Now we will use the increase and decrease keys to select the DATE, 1 for January, then press ENTER, 13, ENTER, 93, ENTER, and the date is registered. Once the date is entered, use the increase and decrease keys to change to the correct day of the week, WEDNESDAY. The last line of data shows whether the present date has been programmed as a holiday. Holiday scheduling will be covered shortly. Now we will complete the example by pressing EXIT to return to the service screen.

Click here for Figure 97 Alarm History

97. Now let's look at ALARM HISTORY, which will let us view up to 25 alarms and alerts. At the service screen we will highlight ALARM HISTORY, and press SELECT, which will bring up the alarm history screen. Wait 6 seconds for the alarm table to update, then the most recent alarm or alert will be at the top of the screen with a time and date stamp to identify them, and the NEXT or PREVIOUS key can be used to scroll to any alarms that are off screen. The EXIT key will return us to the service screen.

Equipment Configuration
Next we will look at EQUIPMENT CONFIGURATION. This is where various options are enabled or disabled, and setpoints entered to define the operation of each option. The configuration table contains the following options, which are accessed from the configuration table select screen: Chilled water reset (3 types) Return/Leaving water control Pulldown rate Auto restart Remote contacts option Demand limit

Click here for Figure 98 Equipment Configuration

98. As an example, suppose we wanted to change the chilled water control from leaving water to return water. Starting at the service screen, we use the NEXT or PREVIOUS keys to highlight EQUIPMENT CONFIGURATION. Pressing the SELECT key brings up the configuration table select screen, and we will use the NEXT or PREVIOUS keys to highlight Entering Chilled Water Control, also known as the Return Chilled Water Control. The controls are factory supplied with

the return water control disabled, which by default causes the machine to control from leaving water. So if we want to change to return water control, we press the SELECT key, and enable the function by pressing the ENABLE key. If we change our mind and then want to disable it, we can do that by pressing the DISABLE key. Then we can return to the service screen using the EXIT key.

Click here for Figure 99 Holiday Scheduling

99. Another function you may need to know about is Holiday Scheduling, which allows an operating schedule (defined in the SCHEDULE function) to be applied to up to 18 holiday periods. Starting at the equipment configuration screen, scroll to highlight HOLIDEF, and press SELECT to bring up the data table select screen. Then we will use the NEXT key to highlight the desired holiday table. Each table is one holiday period, starting on a specific date, and lasting up to 99 days.

Click here for Figure 100 Holiday Table

100. Now we will press SELECT to access the first holiday table, and the screen now shows the holiday start month and day, and the number of days the first holiday period will last. There are no factory-programmed holidays, so they will have to be done as part of an initial start-up. Now press SELECT, then we will use the INCREASE or DECREASE keys to change the value of each line of data, pressing ENTER to register each new value. The numbers 1 through 12 represent the months. For example, if we entered the value 1 in each of the three lines, that would define January 1 as a one day holiday. Now we can return to the default screen by using the EXIT keys. And back at the SCHEDULE function, the particular schedule to be applied to the holiday periods is identified by entering an "H" at the end of the Days-of-the-Week field, then press ENABLE and then press ENTER to add the holiday.

Equipment Service
Click here for Figure 101 Equipment Service Function

101. Another area that may require field input is in the Equipment SERVICE function. This is used to view or modify the configuration of the chiller service tables. Starting at the SERVICE screen, scroll to highlight EQUIPMENT SERVICE, and press SELECT to bring up the Table Select screen. There are three choices on this screen: SERVICE1 contains the basic operating configuration points and defines alert and override conditions, SERVICE2 defines alert conditions for the optional 8-input modules, and SERVICE3 contains the guide vane's algorithm proportional and gain values.

Click here for Figure 102 SERVICE1 Variables

102. We are interested mainly in screen 1, so press SELECT to bring up the list of configuration points. We want to make sure that all items are correct for our application. Changes can be made as previously described, if necessary. Some examples of the variables you will find in the SERVICE1 screen are: Motor temperature override with default of (200 F). Condenser pressure override (195 psi). Refrigerant override T (2 F), and so on.

Controls Test
Click here for Figure 103 Controls Test

103. Now we will cover one of the most useful functions, the Controls Test. This can be done in a variety of ways by making selections from the Controls Test menu. The Automated Test is a comprehensive test of all inputs and outputs for proper values and/or operation. The chiller must be off to run this test press the stop button to put the chiller in the off mode. Each part of the test will ask the operator to confirm that the specific operation is happening and whether or not to continue to the next function. If an error occurs, the operator can either fix the problem before continuing or proceed with the test. When the final test is complete, pressing the EXIT key will return the screen to the Controls Test menu. By selecting other items from the menu, you can accomplish the following: PSIO Thermistor - Check of all PSIO thermistors. Options Thermistors - Check of all option board thermistors. Transducers - Check of all transducers. Guide Vane Actuator - Check of the actuator and guide vane operation. Pumps - Check output of pumps. The pumps can be activated all together or individually. This test confirms associated input, such as flows or pressures. Discrete Outputs - Checks all ON/OFF outputs, together or individually.

Pumpdown - To pumpdown refrigerant from unit. It shows the proper sequence to follow, locks compressor off and starts water pumps during the evacuation. Terminate Lockout - Enables chiller to run after pumpdown lockout. It instructs the operator as to the proper sequence to follow.

If a bad reading should occur during any tests that are not automated, an asterisk will appear next to that reading.

Click here for Figure 104 Running Controls Test

104. To run the controls tests, start at the SERVICE screen and scroll to highlight CONTROL TEST. Press SELECT to bring up the controls test menu, and scroll to highlight the desired test. Press SELECT and the selected test will begin.

Click here for Figure 105 Pump Check

105. For example, if we wanted to check our pumps, we would scroll down to PUMPS on the controls test screen. Press SELECT, then decide all or individual. We will select all. Now the test begins and the screen displays the message PUMPS TEST IN PROGRESS. And when each pump is found to be OK, the message FLOW CONFIRMED appears. If a pump was found

each pump is found to be OK, the message FLOW CONFIRMED appears. If a pump was found to be bad, the message FLOW NOT CONFIRMED would appear. There will be a question, DEACTIVATE ALL PUMPS NOW? Press YES. It then displays PUMPS TEST COMPLETE. When finished, the EXIT key will return us to the Control Test Select screen, and pressing it again returns us to the SERVICE screen.

Click here for Figure 106 Maintenance Table Select

106. Returning to the SERVICE SCREEN highlight and select CONTROL ALGORITHM STATUS. When this item is chosen, a MAINTENANCE TABLE SELECT screen with menu appears. Selecting any of the MAINT01, 02 or 03 tables provides a MAINTENANCE SELECT screen where you can view the values of items listed. MAINT01 is the capacity control algorithm. MAINT02 presents override status and MAINT03 shows surge and hot gas bypass status. Also listed on the MAINTENANCE TABLE SELECT is the OCCDEFM or time schedule status for LOCAL and CCN control.

Click here for Figure 107 Data Table Select

107. When you select this item for viewing a DATA TABLE SELECT screen presents a menu from which you would select topic items to view or change. The SELECT soft key would provide a MAINTENANCE SELECT screen with the appropriate information available for viewing.

Click here for Figure 108 LID Configuration

108. Now, let's exit back to the SERVICE SCREEN and select LID CONFIGURATION. This menu item when selected presents a LID CONFIGURATION screen. From this screen we can elect to modify the LID CCN address, pick US or metric units of measure, and change the LOGON to SERVICE password. Now exit back to the SERVICE screen.

Click here for Figure 109 LOG OUT OF DEVICE

109. To password protect the SERVICE function, log off from the SERVICE function. Simply use the EXIT key to return to the service menu, then highlight LOG OUT OF DEVICE, press

SELECT, and the default screen will come up. An alternative to logging out is to simply do nothing. If the controls sense no activity for 15 minutes, they will automatically log you off and return to the default screen. Once this procedure is performed, the password menu will appear the next time the SERVICE menu is accessed. That concludes the fundamentals of user operation. Before we go through a typical start-up and shutdown procedure, let's make sure we understand what the controls are doing during machine operation. Remember that we earlier said that the controls generate alarms and alerts, and control chilled water temperature. They also provide diagnostic data and controls testing capability, and tell the unit when to run, and how to start up and shut down.

Operating System Control

Click here for Figure 110 Operating System Control

110. Now let's look at how the chilled water temperature is controlled. The PSIO receives inputs from both the entering and leaving chilled water thermistors, and as we saw earlier, one of these will have been selected as the control point. As long as the actual chilled water temperature is stabilized above the setpoint (desired) temperature, the machine will load up and operate continuously during the occupied condition.

Click here for Figure 111 Compressor Guide Vanes

111. When the chilled water temperature starts to drop, the controls will cause the compressor guide vanes to move toward the closed position, which reduces the amount of refrigerant pumped by the compressor. The rate at which the compressor is unloaded depends on how far we are from the setpoint, and how fast the water temperature is dropping.

Click here for Figure 112 Capacity Control

112. The guide vanes vary the compressor capacity. When the vanes are in the fully unloaded position, the compressor is at approximately 10% of its full load capacity. And in the fully loaded position, of course, the compressor is at 100% capacity.

Click here for Figure 113 Compressor Capacity

113. The PSIO will keep adjusting the guide vanes position until the capacity of the compressor causes the chilled water temperature to equal the setpoint. The guide vanes are driven from the actuator motor.

Click here for Figure 114 Recycle Mode

114. If the guide vanes are at the unloaded or closed position and the chilled water temperature still goes 5 F. below setpoint, the machine will go into a Recycle mode. In Recycle, the controls will cycle the machine through automatic shutdowns and start-ups to maintain the chilled water

temperature. Of course, if hot gas bypass has been specified, that will be activated as the load drops below the minimum configured conditions, reducing the probability of having to go into Recycle.

Click here for Figure 115 Capacity Overrides

115. Capacity overrides can prevent some safety shutdowns caused by: exceeding motor amperage limit, refrigerant low temperature safety limit, motor high temperature safety limit, compressor high lift (surge protection), and condenser high pressure limit. In all cases there are two stages of compressor vane control. The vanes are held from opening further, and the status line on the LID indicates the reason for the override. The vanes are closed until condition decreases below the first step setpoint, and then the vanes are released to normal capacity control. Whenever the motor current demand limit setpoint is reached, it activates a capacity override, again with a two-step process. Exceeding 110% of the rated load amps for more than 30 seconds will initiate the safety shutdown. The surge prevention setpoint will cause a capacity override, as well. When the surge prevention setpoint is reached, the controller normally will CLOSE the guide vanes. If so

equipped, the hot gas bypass valve will open instead of closing the vanes. High discharge temperature override takes effect if the discharge temperature increases above 180 F. The guide vanes are proportionally opened to increase gas flow through the compressor. If the leaving chilled water temperature is then brought 5 F below the Leaving Chilled Water control temperature, the controls will bring the machine into the recycle mode.

Click here for Figure 116 Temperature Reset

116. There are two operating modes that should be mentioned. The first is Temperature Reset, which temporarily raises or lowers the chilled water control point. This is a means of saving energy by not producing water that is any cooler than necessary. Temperature reset can be triggered by a remote temperature, a remote 4-20 mA input, or by the water temperature differential across the cooler. Temperature reset is configured in the Equipment Configuration portion of the SERVICE function. The machine's chilled water control is the same as for normal running, except the control point is temporarily increased or decreased.

Click here for Figure 117 Automatic Demand Limit

117. The other operating mode we should be aware of is Automatic Demand Limit. This is simply a means to limit the power drawn by the compressor, to avoid excessive electrical service charges during high use periods. Demand limit is initiated by a schedule that activates during the high cost time periods. The controls reduce the compressor load to a preset level, using the guide vanes and monitoring motor current. Automatic demand limit is configured in the Equipment Configuration portion of the SERVICE function. Control of the chilled water temperature may be temporarily lost when demand limit is active, due to the limit imposed on the compressor power.

Click here for Figure 118 ALERT/ALARM Function

118. One of the important functions of the PIC controls is to protect the machine from damage when abnormal conditions occur. Typically, an ALERT is issued when a protective limit is approached, and an ALARM and machine shutdown occurs if the protective limit is exceeded. The following limits are a few examples of those monitored during machine operation:

 High or low line voltage. High discharge temperature. High motor winding temperature. Low evaporator refrigerant temperature, and so on. In general, the values assigned to these protective limits are preset, and are not field adjustable. Limits related to compressor motor amps and low temperature brine operation can be field modified.

Click here for Figure 119 Step Override

119. The controls will attempt to avoid alarm conditions due to high motor temperature, high discharge temperature, low evaporator refrigerant temperature, and high condenser pressure. They do this by initiating a two step override on the compressor guide vanes, as the protective limits are approached. The first step is a "hold", which simply prevents the guide vanes from loading up any further. If the condition continues to worsen, then the second step causes the guide vanes to unload until the condition improves past the point where the first step was initiated. At that time the guide vanes are released from the override and will respond to normal capacity signals.

Machine Start-Up and Shutdown

Now let's see what happens during an actual start-up and shutdown. We will assume that all the required field-supplied control data has been entered, and that an occupied schedule has been set up for the present time. Further, there is a very important and comprehensive pre-start checklist that must be executed before doing an initial start-up, and we will assume that has been completed. We will also assume that we have a stand-alone unit, not connected to a CCN network.

Click here for Figure 120 Local Start-up

120. A local or manual start-up is initiated by pressing the LOCAL key at the default screen. In order for the start-up to proceed, an occupied mode must be specified for present time (or unoccupied mode overridden), at least 3 minutes must have elapsed since the last shutdown, and at least 15 minutes must have elapsed since the last start-up. And there cannot have been more than eight starts in the last 12 hours. If remote contacts are enabled, then the contact status determines if the start-up process continues. When those conditions are met, the controls will perform a series of pre-start checks to verify that all safeties are within limits.

Click here for Figure 121 Control Sequence Chart

121. It is easier to visualize the start-up and shutdown sequences if we look at the control sequence chart. Point A is when the LOCAL key is pressed and the safeties check performed.

Click here for Figure 122 Chilled Water Pump Started (Point B)

122. If the safeties are OK, then the chilled water pump is started, and 5 seconds later (Point B) the condenser water pump is started.

Click here for Figure 123 Monitoring Flow Switches

123. One minute later (Point C) the controls monitor the chilled water and condenser water flow switches, and will wait up to 5 minutes if necessary to confirm the flow. The 5-minute wait time can be modified, if desired, in the equipment service function. After the water flow is verified, the tower fans are started, if the condenser pressure is high enough, and then the chilled water temperature is compared to both the setpoint and deadband. If the water temperature is lower

than both, the condenser pump will be shut off and the machine will go into recycle mode. If the chilled water temperature is high enough, the start-up sequence continues on to check the guide vane position. If the guide vanes are more than 6% open, the start-up waits until the PIC closes the vanes. If the vanes are closed, and the oil pump pressure is less than 3 psi, the oil pump relay will then be energized.

Click here for Figure 124 PIC (Oil Pressure Verification)

124. Then (Point D), the PIC waits until the oil pressure is verified with minimum pressure of 15 psi.

Click here for Figure 125 Compressor Start Relay

125. After oil pressure is verified, the PIC waits 15 seconds and then the compressor start relay (1CR) is energized to start the compressor (Point E.) At this point, the 15-minute start-to-start timer is activated.

Click here for Figure 126 Ramp Loading Function

126. Once the system is up and running, the Ramp Loading function takes over. This is simply a means to limit the electrical demand and possible motor overloading by controlling the rate at which the chilled water temperature is pulled down, or the rate at which the motor amps build up. Temperature pulldown is accomplished by temporarily modifying the chilled water setpoint upward, and gradually decreasing it while the compressor capacity control adjusts accordingly. Once the chilled water temperature reaches its normal setpoint, Ramp Loading is terminated. During normal running or start-up, there are many status messages that can appear at the LID. Some of these are: TIMEOUT Waiting for timers to time out. READY Timeouts completed, machine off for other reasons. RECYCLE Shut down due to low load. START-UP Normal start-up in progress. RAMPING Pulldown limits in effect. RUNNING Normal run mode. OVERRIDE Running with an override active. DEMAND Demand limit active.

 ABNORMAL Emergency run mode. TRIPOUT Shutdown due to fault condition. Shutdown of the machine can occur for a variety of reasons: The STOP button has been pressed. Machine is RECYCLING to maintain chilled water temperature. Time schedule has moved to unoccupied mode. A protective limit has been reached and the machine is in ALARM. The start/stop status has been overridden at the LID or CCN network. Power failure. Remote contacts have opened.

Click here for Figure 127 Stop Signal Occurrence

127. When a stop signal occurs (Point F) the shutdown sequence first stops the compressor by de-activating the start relay (1CR). At this point, the 3-minute stop-to-start timer is activated.

Click here for Figure 128 Compressor Shutdown

128. Sixty seconds after the compressor shuts down (Point G,) the tower fans, oil pump and chilled water and condenser water pumps are shut down. However, if the condenser pressure or temperature is high, the condenser water pump and the tower fan may continue to run.

Click here for Figure 129 Recycle Shutdown

129. A RECYCLE shutdown is an automatic shutdown when the compressor is already at minimum capacity, and the chilled water temperature has dropped 5o F. below setpoint and deadband. It is the same sequence as the manual shutdown just described, except the chilled water pump remains running so the chilled water temperature can be monitored. When the chilled water temperature rises, in this example, to setpoint plus 5 F, the machine will automatically initiate a normal start-up, as described earlier.

Click here for Figure 130 Safety Shutdown

130. A safety shutdown is identical to a manual shutdown, except the LID will display the reason for shutdown, the alarm light will blink continuously, and the spare alarm contacts will be energized. A safety shutdown requires that the RESET key be pressed in order to clear the alarm and allow a machine start-up. Once the alarm is cleared, the LOCAL key must be pressed to initiate start-up.

Click here for Figure 131 Auto Restart

131. If it is desired that a machine automatically restart when power is restored after a power interruption, AUTO RESTART in the Equipment Configuration function should be enabled. Then, when the line voltage returns to within 10% of nominal, the guide vanes have closed and an oil pump pre-lube has occurred, and all other start conditions are met, the machine will automatically go through the normal start-up process.

Troubleshooting
Click here for Figure 132 Troubleshooting (LID Display)

132. The first thing to check when troubleshooting is the LID display. If the alarm light is flashing, check the primary and secondary message lines on the LID default screen. These messages will tell where the fault is occurring. The Alarm History table on the LID SERVICE menu will also carry an alarm message to further expand on this alarm. For a complete listing of messages, see the Start-Up, Operation and Maintenance Instructions.

Click here for Figure 133 Control Test

133. The Control Test we mentioned earlier is another troubleshooting feature that can check out all of the thermistor temperature sensors, including those on the Options modules, pressure transducers, pumps and their associated flow switches, guide vane actuator, and other control outputs, such as hot gas bypass. The tests can help to determine whether a switch is defective, or a pump relay is not operating, among other useful troubleshooting tests. During pumpdown operations, the pumps are energized to prevent a freeze-up and the vessel pressures and temperatures are displayed. The lockout feature will prevent start-up of the compressor when no refrigerant is in the machine, or the vessels are isolated.

Click here for Figure 134 PSIO, SMM, LID (Self Diagnostics)

134. The Processor module (PSIO), 8-input (Options) modules, Starter Management Module (SMM), and the Local Interface Device (LID) module perform continuous self diagnostic evaluations. Proper operation of all modules is indicated by LEDs (Light Emitting Diodes) located on the side of the LID, and on the top horizontal surface of the PSIO, SMM, and 8-input modules.

Click here for Figure 135 Red LEDs (Proper Operation)

135. Red LEDs blinking continuously at 1-second intervals indicates proper operation. If it is lit continuously, a problem exists which requires replacement of the module. If the light is off, the power supply should be checked. Lack of input power could be caused by a blown fuse as a result of either a shorted transformer or a bad module.

Click here for Figure 136 Green LEDs (Power On)

136. Green LEDs should always be blinking when the power is on. This indicates intercommunications between modules and proper operation. If the green LED is not blinking, check the red LED. If a green LED is on solid and not blinking, check the communication wiring. If a green LED is off, check the red LED. If the red LED is normal, check the module's communications wiring.

Click here for Figure 137 Communications Plug

137. If a communications failure is indicated by all the modules, check the communication plug (COMM) on the PSIO module. If properly seated and a good connection is assured but the condition persists, replace the PSIO module. When a SMM or the LID indicates a communications malfunction, again, check the COMM plug at the module. If the problem continues, change the module. Now a word of caution, if you are replacing a PSIO module, make sure the new PSIO has the correct software to match your machine. The service replacement part number can be found on the PSIO module label.

If replacing a SMM or an 8-input module, check the address switches. The module address switch information can be found in the Service Instructions. None of the modules can be field repaired. Whenever a module is non-functional, it must be replaced. If a PSIO is to be replaced, the new PSIO must be reconfigured to the original machine data. A CCN Building Supervisor or a Service Tool can be used to download the machine's configuration into the new PSIO, unless the software has been upgraded from the previous module. The configuration can always be manually modified.

Click here for Figure 138 Transformers

138. Now we will talk about the transformers. If the power plugs are in place, secure and in good condition, but the modules are not working, we would check the transformers. First check the primary to see if power is available, then check the secondary. The transformer output voltage can be checked at the module power plug terminal screws. We are looking for 21 volts on everything but the SMM, which is 24 volts. The transformers are located within the power panel, with the exception of the SMM, which has its own transformer located within the starter. If everything appears OK, perform normal troubleshooting procedures which would include checking the relays and the thermistor sensor circuits.

This concludes the PIC controls familiarization program for the 19XL centrifugal chillers. You should now have a good grasp of what the controls are, how they function, and how to use them. Because of their extreme complexity and versatility, there are many controls functions and details that we have not dealt with in this program. Further information will be found in the machine Installation, Start-up and Service Instructions, and in the CCN Application Manual.

19XL PIC Chiller Quiz

1. True or False? The video monitor (LID) displays information only when the machine is running. 2. The four keys below the LID are called _______________ keys. 3. True or False? The starter management module (SMM) is used with both the solid state starter and the electro-mechanical starter. 4. Liquid refrigerant is used to cool both the _______________ and _______________. 5. Normal lube oil pressure is _______________ differential. a. 15 - 20 b. 20 - 25 c. 40 - 45 6. Normal lube oil temperature is ______________ F. a. 120 - 140 b. 140 - 160 c. 160 - 180 7. The _______________ contains all the operating software needed to control the machine. 8. Operator access to the PIC controls is provided by the _______________.

9. On/off control of the motor cooling solenoid, oil heater, oil pump, alarm contact and hot gas bypass valve is provided by the _______________ _______________. 10. The chilled water pump relay and condenser water pump relay are controlled by the _______________. 11. The LID screen that appears when no other screen has been specified is called the _______________ screen. a. primary b. functional c. default 12. True or False? The function of the four keys below the LID varies depending on the screen displayed. 13. A displayed point that is blinking on the default screen indicates that the point is in _______________. a. alert b. alarm c. override

14. If an asterisk follows a point on the status screen, it indicates that the point is _______________. a. in alert b. in alarm c. a setpoint d. overridden 15. The _______________ key is used to release alarms and allow normal operation of the machine after the alarm conditions have been corrected. 16. The _______________ key is used to remove a forced or override condition. 17. The only software function that requires a password is the _______________ function. a. STATUS b. SCHEDULE c. SETPOINT d. SERVICE 18. True or False? The controls test can be conducted whenever the compressor is running. 19. In order for the machine to start, at least _______________ minutes must have elapsed since the last shutdown, and at least _______________ minutes must have elapsed since the last start-up.

20. True or False? Ramp loading is a means for limiting electrical demand by limiting the rate at which the chilled water temperature is pulled down. 21. Normal operation of the PIC modules would be indicated when the red LEDs are _______________. a. on continuously b. off c. blinking 22. True or False? If the green LED on a PIC module is on continuously, it indicates a fault in the communications circuit.

Quiz Key
Answer
1. False 2. soft 3. True 4. motor, lube oil 5. b 6. b 7. PSIO processor module 8. LID (Local Interface Device) 9. six pack relay 10. SMM (Starter Management Module) 11. c 12. True 13. a 14. b 15. RESET 16. RELEASE

Paragraph No.
28 26 18, 19 21, 23 23 25 33 59 35, 52 43, 55 60 26 69 74 70 80

Answer
17. d 18. False 19. 3, 15 20. True 21. c 22. True

Paragraph No.
94 103 120 126 135 136

Wiring Diagram A

Wiring Diagram B

Figure 1 19XL Centrifugal Chiller

Figure 2 19XL Heat Exchanger

Figure 3 19XL Compressor

Figure 4 Compressor (Flanged Elbows)

Figure 5 Liquid Transfer

Figure 6 19XL High Side Float

Figure 7 Hot Gas By-Pass Option

Figure 8 19XL Cooler Tubes

Figure 9 Diffuser

Figure 10 19XL Impeller

Figure 11 19XL Impeller (Drilled Holes)

Figure 12 Controls

Figure 13 19XL Power Panel

Figure 14 19XL PIC Control Center

Figure 15 19XL Sensors (Compressor Discharge)

Figure 16 19XL Sensors

Figure 17 19XL Optional Starters

Figure 18 Electro-mechanical Style Starter

Figure 19 19XL Solid State Starter

Figure 20 19XL Compressor

Figure 21 19XL Motor Cooling

Figure 22 19XL Oil Recovery System

Figure 23 Oil Pump/Transmission Housing

Figure 24 19XL Lubrication System

Figure 25 19XL Oil Heater

Figure 26 19XL Local Interface Device (LID)

Figure 27 19XL Processor Module

Figure 28 19XL Local Interface Device

Figure 29 19XL Product Integrated Control (PIC)

Figure 30 32MP System

Figure 31 32MP vs. PIC

Figure 32 PIC Components and Circuitry

Figure 33 PSIO Module

Figure 34 LID Mount

Figure 35 6-pack Relay Board

Figure 36 Option Modules

Figure 37 Power Panel

Figure 38 Oil Pump Contactor

Figure 39 Hot Gas Bypass Relay

Figure 40 Control Transformers

Figure 41 Control Circuit Voltage Selector

Figure 42 Starter Mangement Module

Figure 43 Starter Management Module (PSIO)

Figure 44 Transformer (T1)

Figure 45 Transformer (T2)

Figure 46 Transformer (T3)

Figure 47 Transformer (T4)

Figure 48 Starter Panel

Figure 49 Starter Fault Contacts

Figure 50 Starter Management Module

Figure 51 Inputs Supply System

Figure 52 Outputs

Figure 53 8-Input Module

Figure 54 Starter Management Module (SMM)

Figure 55 SMM Outputs Control

Figure 56 PIC Controls

Figure 57 Guide Vane Position Control

Figure 58 PIC Controls

Figure 59 Local Interface Device (LID)

Figure 60 Default Screen

Figure 61 Function of the Soft Keys

Figure 62 Depressing Menu Soft Key

Figure 63 STATUS Function

Figure 64 SCHEDULE Function

Figure 65 Control Circuit Power

Figure 66 Default Screen Display (Diagnostics)

Figure 67 Default Screen

Figure 68 Default Screen Displays

Figure 69 Prestart Display

Figure 70 Alarm and Reset Key

Figure 71 STATUS, SCHEDULE, SETPOINT and SERVICE

Figure 72 Status Screens

Figure 73 Status Table Select Screen

Figure 74 Status Line

Figure 75 Point Override

Figure 76 START/STOP/RELEASE and ENTER

Figure 77 ON, OFF, RELEASE and ENTER

Figure 78 SUPVSR, BEST or SERVICE

Figure 79 Points Unable to be Overridden

Figure 80 Target Guide Vane Position

Figure 81 Status Table Select Screen

Figure 82 STATUS03 Screen

Figure 83 Status Function Keystrokes

Figure 84 Schedule Function

Figure 85 Period Definition

Figure 86 Example (Period Selection)

Figure 87 Enable, Disable, Enter and Exit

Figure 88 Temporary Override

Figure 89 Setpoint Function

Figure 90 SETPOINT Function Access

Figure 91 Modifying a Setpoint

Figure 92 Example

Figure 93 QUIT/Escape Key

Figure 94 Service/Function Password

Figure 95 Time and Date Selection

Figure 96 Service Function Example

Figure 97 Alarm History

Figure 98 Equipment Configuration

Figure 99 Holiday Scheduling

Figure 100 Holiday Table

Figure 101 Equipment Service Function

Figure 102 SERVICE1 Variables

Figure 103 Controls Test

Figure 104 Running Controls Test

Figure 105 Pump Check

Figure 106 Maintenance Table Select

Figure 107 Data Table Select

Figure 108 LID Configuration

Figure 109 LOG OUT OF DEVICE

Figure 110 Operating System Control

Figure 111 Compressor Guide Vanes

Figure 112 Capacity Control

Figure 113 Compressor Capacity

Figure 114 Recycle Mode

Figure 115 Capacity Overrides

Figure 116 Temperature Reset

Figure 117 Automatic Demand Limit

Figure 118 ALERT/ALARM Function

Figure 119 Step Override

Figure 120 Local Start-up

Figure 121 Control Sequence Chart

Figure 122 Chilled Water Pump Started (Point B)

Figure 123 Monitoring Flow Switches

Figure 124 PIC (Oil Pressure Verification)

Figure 125 Compressor Start Relay

Figure 126 Ramp Loading Function

Figure 127 Stop Signal Occurrence

Figure 128 Compressor Shutdown

Figure 129 Recycle Shutdown

Figure 130 Safety Shutdown

Figure 131 Auto Restart

Figure 132 Troubleshooting (LID Display)

Figure 133 Control Test

Figure 134 PSIO, SMM, LID (Self Diagnostics)

Figure 135 Red LEDs (Proper Operation)

Figure 136 Green LEDs (Power On)

Figure 137 Communications Plug

Figure 138 Transformers