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

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

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